Form No. 3389-404 Rev B Groundsmaster® 3500-D and 3505-D Rotary Mower Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 30807—Serial No. 30839—Serial No. 30843—Serial No. 30849—Serial No.
This product complies with all relevant European directives; for details please see the separate product specific Declaration of Conformity (DOC) sheet. You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product.
Contents Servicing the Fuel Tank..................................... 49 Inspecting the Fuel Lines and Connections.................................................. 49 Draining the Water Separator ........................... 49 Changing the Fuel Filter Canister...................... 49 Bleeding Air from the Injectors .......................... 49 Electrical System Maintenance ........................... 50 Servicing the Battery......................................... 50 Servicing the Fuses ...............
Safety ◊ Incorrect hitching and load distribution Preparation This machine has been designed in accordance with EN ISO 5395:2013 and ANSI B71.4-2012 specifications in effect at the time of production when equipped with required weight as listed in Rear Ballast section. • While mowing, always wear substantial footwear, long trousers, hard hat, safety glasses, and hearing protection. Long hair, loose clothing, or jewelry may get tangled in moving parts.
• Keep the nozzle in contact with the rim of the fuel • • – Stop on level ground. tank or container opening at all times until fueling is complete. Do not use a nozzle lock open device. If fuel is spilled on clothing, change clothing immediately. Never overfill fuel tank. Replace fuel cap and tighten securely. – Disengage the power take-off and lower the attachments. – Change into neutral and set the parking brake. – Stop the engine and remove the key.
Maintenance and Storage • Use full width ramps for loading machine into • Keep all nuts, bolts and screws tight to be sure the • equipment is in safe working condition. • Never store the equipment with fuel in the tank inside a building where fumes may reach an open flame or spark. • Allow the engine to cool before storing in any trailer or truck. Tie the machine down securely using straps, chains, cable, or ropes.
• Do not touch the engine, muffler, exhaust pipe, or • Keep hands, feet, and clothing away from moving • • • • • • • • • • • • • • hydraulic tank while the engine is running or soon after it has stopped because these areas could be hot enough to cause burns. parts and the mower discharge area. Fill the fuel tank until level is 12 mm (1/2 inch) below the bottom of the filler neck. Do not overfill. Check the safety interlock switches daily for proper operation.
Sound Power Level Vibration Level This unit has a guaranteed sound power level of 104 dBA, which includes an Uncertainty Value (K) of 1 dBA. Hand-Arm Measured vibration level for right hand = 0.5 m/s2 Measured vibration level for left hand = 0.7 m/s2 Sound power level was determined according to the procedures outlined in ISO 11094. Uncertainty Value (K) = 0.5 m/s2 Measured values were determined according to the procedures outlined in EN ISO 5395:2013.
decal100-4837 decal93-7818 100-4837 93-7818 1. Warning—read the Operator's Manual for instructions on torquing the blade bolt/nut to 115-149 N-m (85-110 ft-lb). decal93-7276 decal107-7801 93-7276 107-7801 *This safety decal includes a slope warning required on the machine for compliance to 1. Explosion hazard—wear eye protection. the European Lawn Mower Safety Standard EN836:1997. The conservative maximum 2. Caustic liquid/chemical burn hazard—to perform first aid, flush with water. 3.
decal106-6755 106-6755 1. Engine coolant under pressure. 3. Warning—do not touch the hot surface. 2. Explosion hazard—read the Operator's Manual. 4. Warning—read the Operator's Manual.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. decal104-5181 104-5181 (CE only) 1.
decal106-9290 106-9290 1. Inputs 5. In seat 9. Outputs 2. Reels—active 6. PTO 3. High temperature shutdown 7. Parking brake—Off 10. PTO 11. Engine—Start 4. High temperature warning 12. Engine—Run 8. Neutral 13. Engine—Start 14.
decal121-3532 121–3532 (Model 30807) 1. Read the Operator’s Manual. 4. Optional ligh—15A 2. SCM-2A 5. System gauges—10A 3. Main—15A 6.
decal121-3580 121–3580 (Models 30807, 30839 and 30843) 8. Engine—stop 1. Push down to disengage PTO. 9. Engine—run 2. Pull up to engage PTO. 3. Lower the deck. 10. Engine—run 4. Raise the deck. 11. For more information on starting the engine, read the Operator’s Manual—1) Sit in the operator’s position; 2) Turn the ignition key to the engine run position; 3) Wait for the engine preheat light to turn off; 4) Turn the ignition key to the engine start position; 5) Disengage the parking brake. 5.
decal121-3581 121–3581 (Model 30849) 1. Push down to disengage PTO. 7. Engine—run 2. Pull up to engage PTO. 8. Engine—run 3. Lower the deck. 9. For more information on starting the engine, read the Operator’s Manual—1) Sit in the operator’s position; 2) Turn the ignition key to the engine run position; 3) Wait for the engine preheat light to turn off; 4) Turn the ignition key to the engine start position; 5) Disengage the parking brake. 4. Raise the deck. 10.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Use Qty. 1 No parts required – Activate, charge, and connect the battery. 2 Inclinometer 1 Check the angle indicator (Models 30839, 30843, and 30807 only). Warning decal (104–5181) Warning decal (99–3558) Warning decal (107–1972) Lock bracket Rivet Washer Screw, 1/4 x 2 inches Locknut, 1/4 inch Exhaust guard Self-tapping screw 1 1 3 1 2 1 1 1 1 4 No parts required – Adjust the lift arms.
1 Activating, Charging, and Connecting the Battery No Parts Required g008874 Figure 3 Procedure 1. Battery cover WARNING CALIFORNIA Proposition 65 Warning Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. 2. Remove the filler caps from the battery and slowly fill each cell until electrolyte is just above the plates. 3.
WARNING 2 Incorrect battery cable routing could damage the tractor and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Checking the Angle Indicator (Models 30839, 30843, and 30807 only) • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Always connect the positive (red) battery cable before connecting the negative (black) cable.
the indicator to obtain a zero degree reading, and tighten the bolts. 3 Installing the CE Decals Parts needed for this procedure: 1 Warning decal (104–5181) 1 Warning decal (99–3558) 3 Warning decal (107–1972) g012628 Figure 6 1. Hood latch bracket Procedure 3. If this machine will be used for CE, affix the CE warning decals over the corresponding English warning decals. 2. Rivets While aligning the mounting holes, position the CE lock bracket and the hood latch bracket onto the hood.
g012630 Figure 8 1. Hood latch 7. Screw the bolt into the other arm of hood lock bracket to lock the latch in position (Figure 9). Note: Tighten bolt securely but do not tighten nut. g008875 Figure 10 1. Exhaust guard 2. 6 g012631 Figure 9 1. Bolt 2. Nut Secure the exhaust guard to the frame with 4 self-tapping screws (Figure 10). Adjusting the Lift Arms 3. Arm of hood lock bracket No Parts Required Procedure 5 1.
g008876 Figure 11 cutting units removed for clarity 1. Lift arm 2. Floor plate bracket D. Install the pin and check the clearance. Repeat the procedure if required. E. Tighten the clevis jam nut. 2. Check to make sure that the clearance between each lift arm and stop bolt is 0.13 to 1.02 mm (0.005 to 0.040 inches) (Figure 12). If the clearance is not in this range, adjust the stop bolts to attain clearance. 3.
mounting position for proper alignment with the sidewinder under frame. 7 For all heights of cut, mount the rear cutting deck in the rear mounting holes (Figure 16). Adjusting the Carrier Frame 8 No Parts Required Adjusting the Front Cutting Decks Adjusting the Height-of-Cut The front and rear cutting decks require different mounting positions. The front cutting deck has two mounting positions depending on what height-of-cut and degree of deck rotation you desire. 1.
4. While supporting the chamber, remove the spacer (Figure 17). 5. Move the chamber to the desired height-of-cut and install a spacer into the designated height-of-cut hole and slot (Figure 18). g011346 Figure 19 1. Roller scraper 3. Grease fitting 2. Mounting screw g026184 Figure 18 6. Position the tapped plate in line with the spacer. 7. Install the bolt finger tight. 8. Repeat steps 4-7 for each side adjustment. 9. Tighten all three bolts to 41 N-m (30 ft-lb).
3. Product Overview Verify that mulching baffle does not interfere with the tip of the blade and does not protrude inside the surface of the rear chamber wall. Controls WARNING Do not use the high lift blade with the mulching baffle. The blade could break, resulting in personal injury or death. g008887 Figure 21 1. Forward traction pedal 4. Tilt steering lever 2. Reverse traction pedal 5. Indicator slot 3. Mow/transport slide 6.
Tilt Steering Lever Throttle Pull the tilt steering lever (Figure 21) back to tilt the steering wheel to the desired position. Then push the lever forward to tighten. Move the throttle (Figure 23) forward to increase the engine speed and rearward to decrease the engine speed. Indicator Slot Cutting Unit Drive Switch Models 30839, 30849 & 30807 only The slot in the operator platform (Figure 21) indicates when the cutting units are in the center position.
Alternator Light Specifications The alternator light (Figure 23) should be off when the engine is running. If it is on, the charging system should be checked and repaired as necessary. Note: Specifications and design are subject to change without notice. Traction Unit Glow Plug Indicator Overall Width - 68 inch width of cut 182 cm (71.8 inches) The glow plug indicator light (Figure 23) will glow when the glow plugs are operating. Overall Width - 72 inch width of cut 193 cm (75.
Operation 3. Note: Determine the left and right sides of the machine from the normal operating position. Push the dipstick down into the dipstick tube and make sure that it is seated fully. Pull the dipstick out and check the oil level. 4. If the oil level is low, remove the oil fill cap (Figure 26) and gradually add small quantities of oil, checking the level frequently, until the level reaches the Full mark on the dipstick.
• Painted surfaces may be damaged by biodiesel DANGER blends. Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. • Do not fill the fuel tank completely full.
Check the coolant level at the beginning of each day before starting the engine. fluid is Toro Premium All Season Hydraulic Fluid (Available in 19 liter (5 gallon) pails or 55 gallon drums. See parts catalog or Toro distributor for part numbers.) The capacity of the cooling system is approximately 5.7 liters (6 quarts). Alternate fluids: If the Toro fluid is not available, other fluids may be used provided they meet all the following material properties and industry specifications.
Starting and Stopping the Engine You may need to bleed the fuel system if any of the following situations have occurred (refer to Bleeding the Fuel System): • Initial start up of a new engine • The engine has ceased running due to lack of fuel. • Maintenance has been performed upon the fuel system components; i.e. filter replaced, etc. g008886 Starting the Engine Figure 30 1. Hydraulic tank cap 3. Remove the dipstick from the filler neck and wipe it with a clean rag.
Bleeding the Fuel System 1. Park the machine on a level surface. Make sure that the fuel tank is at least half full. 2. Unlatch and raise the hood. until a solid stream of fuel flows out around the screw. 5. Note: Normally the engine should start after the above bleeding procedures are followed. However, if the engine does not start, air may be trapped between the injection pump and injectors; refer to Bleeding Air from the Injectors.
The module energizes outputs including PTO, Starter, and ETR (energize to run) solenoid. moved a considerable distance, transport it on a truck or trailer. 1. Locate the bypass valve on the pump (Figure 32) and rotate it 90°. The module is divided into inputs and outputs. Inputs and outputs are identified by green LED indicators mounted on the printed circuit board. The start circuit input is energized by 12 VDC. All other inputs are energized when the circuit is closed to ground.
2. Move key switch to the On position and ensure that the red power LED is illuminated. 6. If specific output LED is not illuminated, check both fuses. 3. Move all input switches to ensure all LED’s change state. 7. 4. Position input devices at appropriate position to achieve the appropriate output. Use the following logic chart to determine the appropriate input condition.
Selecting a Blade Using a Standard Combination Sail This blade was designed to provide excellent lift and dispersion in almost any condition. If more or less lift and discharge velocity is required, consider a different blade. Attributes: Excellent lift and dispersion in most conditions. Using an Angled Sail The blade generally performs best in lower heights of cut - 1.9 to 6.4 cm (3/4 to 2–1/2 inch). Attributes: • Discharge remains more even at lower heights of cut.
Choosing Accessories Optional Equipment Configurations Angle Sail Blade High Lift Parallel Sail Blade (Do not use with the mulching baffle) Mulching Baffle Roller Scraper Grass Cutting: 1.9 to 4.4 cm (0.75 to 1.75 inch) Height-of-Cut Recommended in most applications May work well in light or sparse turf Grass Cutting: 5 to 6.4 cm (2.00 to 2.50 inch) Height-of-Cut Recommended for thick or lush turf Recommended for light or sparse turf Grass Cutting: 7 to 10 cm (2.75 to 4.
Operating Tips the cutting units, disengage the parking brake, press the forward traction pedal, and carefully drive to an open area. Models 30839, 30843 and 30807 • Practice moving forward and reverse, and starting and stopping the machine. To stop, take your foot off of the traction pedal and let it return to neutral or press down on the reverse pedal to stop. Going down a hill, you may need to use the reverse pedal to stop.
Model 30849 • If an obstacle is in the way, shift the cutting units to easily mow around it. DANGER • When transporting the machine from one work area to another, raise the cutting units to the fully up position, move the mow/transport slide to the left to transport, and place the throttle in the Fast position. The slope angle at which the machine will tip is dependent on many factors.
• To mow around bunkers, ponds, or other contours • Practice driving around obstacles with the cutting • • • • • • • • units up and down. Be careful when driving between narrow objects so you do not damage the machine or cutting units. On the Sidewinder unit, get a feel for the reach of the cutting units so you do not hang them up or damage them in any way.
bearings. Make sure that the radiator and oil cooler are kept free of dirt or grass clippings. After cleaning, it is recommended that the machine be inspected for possible hydraulic fluid leaks, damage or wear to the hydraulic and mechanical components, and the cutting unit blades checked for sharpness. Important: After washing the machine, move the Sidewinder mechanism from left to right several times to remove water between the bearing blocks and cross tube.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first hour • Torque the wheel nuts. After the first 10 hours • Torque the wheel nuts. • Check the condition and tension of all belts. • Change the hydraulic filter. After the first 50 hours • Change the oil and oil filter. Before each use or daily • • • • • • • • • Check the engine oil level.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. Fri. Sat. Sun. Check the safety interlock operation. Check the brake operation. Check the engine oil level. Check the cooling system fluid level. Drain the water/fuel separator. Check the air filter, dust cup, and burp valve. Check for unusual engine noises.2 Check the radiator and screen for debris Check for unusual operating noises. Check the hydraulic system oil level.
Notation for Areas of Concern Inspection performed by: Item Date 42 Information
Service Interval Chart decal117-5103 Figure 34 Pre-Maintenance Procedures Removing the Hood The hood may be easily removed to ease maintenance procedures in the engine area of the machine. 1. 2. Unlatch and raise the hood. g008908 Figure 35 Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 35). 1. Hairpin cotter 3. Slide the hood to the right side, lift the other side, and pull it out of the brackets. Note: Reverse the procedure to install the hood.
1. Center the cutting deck sidewinder with the traction unit. 2. Raise the cutting decks to the transport position. 3. Set the parking brake and turn off the machine. 4. Release the latch rod (Figure 36) from front carrier frame retainer. g011350 Figure 36 1. Service latch hook 5. Lift the outside of the front cutting decks and place the latch over the frame pin mounted on the front of the operator's platform (Figure 36). 6. Sit on the operator seat and start the traction unit. 7.
Lubrication Greasing the Bearings and Bushings Service Interval: Every 50 hours (Lubricate all bearings and bushings daily when conditions are dusty and dirty.) Every 500 hours/Yearly (whichever comes first) The machine has grease fittings that must be lubricated regularly with No. 2 General-purpose, lithium base grease. Bearings and bushings must be lubricated daily when operating conditions are extremely dusty and dirty.
• Left front lift arm pivot and lift cylinder (2) (Figure 42) g008902 Figure 45 • Belt tension pivot (Figure 46) g008899 Figure 42 • Right front lift arm pivot and lift cylinder (2) (Figure 43) g008903 Figure 46 • Steering cylinder (Figure 47). g008900 Figure 43 • Neutral adjust mechanism (Figure 44) g008904 Figure 47 g008901 Note: If desired, an additional grease fitting Figure 44 may be installed in the other end of the steering cylinder.
Engine Maintenance Servicing the Air Cleaner Service Interval: Every 200 hours (More frequently in extreme dusty or dirty conditions) • Check the air cleaner body for damage which could cause an air leak. Replace if damaged. Check the whole intake system for leaks, damage, or loose hose clamps. g008905 Figure 48 • Service at the recommended service interval or earlier if engine performance suffers due to extremely dusty, dirty conditions.
g008911 Figure 53 1. Engine oil drain plug g008910 Figure 52 2. 1. Primary filter 5. Inspect the new filter for shipping damage, checking the sealing end of the filter and the body. Do not use a damaged element. 6. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister. Do not apply pressure to the flexible center of the filter. 7. Clean the dirt ejection port located in the removable cover.
Changing the Fuel Filter Canister Fuel System Maintenance Service Interval: Every 400 hours Servicing the Fuel Tank 1. Clean the area where the filter canister mounts (Figure 55). Service Interval: Every 2 years—Drain and clean the fuel tank. 2. Remove the filter canister and clean the mounting surface. 3. Lubricate the gasket on the filter canister with clean oil. 4. Install the filter canister by hand until the gasket contacts the mounting surface; then rotate an additional 1/2 turn.
Electrical System Maintenance If corrosion occurs at the terminals, disconnect the cables, negative (–) cable first, and scrape the clamps and terminals separately. Reconnect the cables, positive (+) cable first, and coat the terminals with petroleum jelly. Servicing the Battery WARNING Service Interval: Every 25 hours—Check the electrolyte level. (If the machine is in storage, check it every 30 days.
Drive System Maintenance WARNING The engine must be running so that you can make a final adjustment of the traction adjustment cam. Contact with hot or moving parts can result in personal injury. Adjusting the Traction Drive for Neutral Keep your hands, feet, face, and other body parts away from the muffler, other hot parts of the engine, and rotating parts. If the machine moves when the traction pedal is in the NEUTRAL position, adjust the traction cam. 1.
Cooling System Maintenance 4. Cleaning the Engine Cooling System Service Interval: Before each use or daily Remove debris from the oil cooler and radiator daily. Clean them more frequently in dirty conditions. 1. Turn the engine off and raise the hood. Clean the engine area thoroughly of all debris. 2. Remove the access panel (Figure 58). g008914 Figure 58 1. Access panel 3. Radiator 2. Oil cooler 3. Unlatch the oil cooler and pivot it rearward (Figure 59).
Brake Maintenance Belt Maintenance Adjusting the Parking Brake Servicing the Engine Belts Service Interval: After the first 10 hours—Check the condition and tension of all belts. Every 100 hours—Check the condition and tension of all belts. Service Interval: Every 200 hours—Check the parking brake adjustment. 1. Loosen the set screw securing the knob to the parking brake lever (Figure 60). Tensioning the Alternator/Fan Belt 1. Open the hood. 2.
Controls System Maintenance Adjusting the Throttle 1. Position the throttle lever rearward so it stops against the control panel slot. 2. Loosen the throttle cable connector on the injection pump lever arm (Figure 63). g008917 Figure 62 1. Hydrostat drive belt 2. Spring end 3. Replace the belt. 4. Reverse the procedure to tension the spring. g008918 Figure 63 1. Injection pump lever arm 54 3. Hold the injection pump lever arm against the low idle stop and tighten the cable connector. 4.
Hydraulic System Maintenance If the fluid becomes contaminated, contact your local Toro distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil. Changing the Hydraulic Filter 1. Turn the engine off and raise the hood. 2. Disconnect the hydraulic line (Figure 65) or remove the hydraulic filter (Figure 64) and let the hydraulic fluid flow into a drain pan. Install the hydraulic line when hydraulic fluid stops draining.
5. Checking the Hydraulic Lines and Hoses Check the fluid level and add enough to raise the level to Full mark on the dipstick. Do not overfill. Service Interval: Before each use or daily Check hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating. WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
Mounting the Cutting Decks to the Traction Unit Cutting Deck Maintenance 1. Position machine on a level surface and shut engine off. 2. Move cutting deck into position in front of traction unit. 3. Position the machine on a level surface, lower the cutting decks to the floor, shut the engine off, and engage the parking brake. Slide deck carrier frame onto lift arm pivot pin. Secure with lynch pin or retaining nut (Figure 68). 4. Disconnect and remove the hydraulic motor from the deck (Figure 67).
3. Install the height-of-cut bracket to the deck frame with the remaining shims assembled below the height-of-cut bracket. 4. Secure the socket head bolt/spacer and flange nut. Note: Socket head bolt/spacer are held together with Loctite to prevent the spacer from falling inside the deck frame. g011353 5. Verify the 12 o’clock height and adjust if needed. 6. Determine if only one or both (right-hand and left-hand) height-of-cut brackets need to be adjusted. If the 3 or 9 o’clock side is 3.8±2.
Inspecting and Sharpening the Blade Servicing the Cutter Blade Removing the Cutter Blade 1. The blade must be replaced if a solid object is hit, the blade is out of balance, or if the blade is bent. Always use genuine Toro replacement blades to be sure of safety and optimum performance. Never use replacement blades made by other manufacturers because they could be dangerous. Raise the cutting deck to the highest position, shut the engine off, and engage the parking brake.
bearing race. There should be a 1.5 mm (0.060 inch) lip of inner race exposed. g006926 Figure 73 1. Sharpen at this angle only 4. 5. To check the blade for being straight and parallel, lay the blade on a level surface and check its ends. The ends of the blade must be slightly lower than the center, and the cutting edge must be lower than the heel of the blade. This blade will produce good quality of cut and require minimal power from the engine.
Preparing the Engine Storage Storing the Battery If the machine will be stored more than 30 days, remove the battery and charge it fully. Store the battery in a cool atmosphere to avoid quick deterioration of the charge in the battery. To prevent the battery from freezing, make sure it is fully charged. The specific gravity of a fully charged battery is 1.265–1.299. Preparation for Seasonal Storage Follow these procedures anytime you will be storing the machine for more than 30 days.
Notes:
Notes:
Toro General Commercial Product Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
