Form No. 3371-276 Rev A Groundsmaster® 3500-D and 3505-D Traction Units Model No. 30849—Serial No. 312000001 and Up Model No. 30839—Serial No. 312000001 and Up Model No. 30843—Serial No. 312000001 and Up Model No. 30807—Serial No. 312000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet. WARNING CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Figure 1 1. Model and serial number location Important: This engine is not equipped with a spark arrester muffler.
Contents Draining the Water Separator.............................. 40 Changing the Fuel Filter Canister ........................ 40 Bleeding Air from the Injectors........................... 40 Electrical System Maintenance................................ 41 Caring for the Battery ......................................... 41 Fuses.................................................................. 41 Drive System Maintenance ..................................... 42 Adjusting the Traction Drive for Neutral .
Safety ◊ Inadequate braking ◊ The type of machine is unsuitable for the task ◊ Lack of awareness of the effect of ground conditions, especially slopes ◊ Incorrect hitching and load distribution This machine meets or exceeds CEN standard EN 836:1997 (when appropriate decals applied), and ANSI B71.4-2004 specifications in effect at the time of production when equipped with required weight as listed in Rear Ballast section.
• Before attempting to start the engine, disengage all blade attachment clutches, shift into neutral, and engage the parking brake. Only start the engine from the operator’s position. Never remove the ROPS and always wear the seat belts during operation. • Do not put hands or feet near or under rotating parts. Keep clear of the discharge opening at all times. • Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care.
Preparation • Replace worn or damaged parts for safety. • If the fuel tank has to be drained, do this outdoors. • On multi-bladed machines, take care as rotating one blade can cause other blades to rotate. • When machine is to be parked, stored, or left unattended, lower the cutting units unless a positive mechanical lock is provided. • Disengage drives, lower the cutting units, set parking brake, stop engine and remove key. Wait for all movement to stop before adjusting, cleaning or repairing.
• • • • • • • • • Keep your body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not your hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.
Measured vibration level for right hand = 0.5 m/s2 Whole Body Measured vibration level for left hand = 0.7 m/s2 Measured vibration level = 0.44 m/s2 Uncertainty Value (K) = 0.5 m/s2 Uncertainty Value (K) = 0.5 m/s2 Measured values were determined according to the procedures outlined in EN 836. Measured values were determined according to the procedures outlined in EN 836.
3-6681 1. Cutting/dismemberment—hazard, fan-stay away from moving parts. 107-7801 (CE only) This safety decal includes a slope warning required on the machine for compliance to the European Lawn Mower Safety Standard EN836:1997. The conservative maximum slope angles indicated for operation of this machine are prescribed by and required by this standard. 1. Tipping hazard—do not drive on slopes greater than 15 degrees. 104-1086 Models 30849 & 30843 only 1. Height of cut 106-6753 104-0484 1.
Battery Symbols Some or all of these symbols are on your battery 104-5181 CE only 1. Explosion hazard 6. Keep bystandersa 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. 1. Warning—read the Operator’s Manual. 2.
104-5191 Models 30839, 30849 and 30807 1. Engage the power take off (PTO). 5. Raise the cutting units. 2. Disengage the power take off (PTO). 6. Move the cutting units to the left. 3. Lower the cutting units. 7. Move rear ward to lock the 11. Fast lift lever. 8. Engine—stop 12. Continuous variable setting 4. Move the cutting units to the right. 9. Engine—run 10. Engine—start 11 13.
108-9006 Models 30843 1. Engage the power take off (PTO). 4. Raise the cutting units. 7. Engine—run 10. Continuous variable setting 2. Disengage the power take off (PTO). 5. Move rear ward to lock the lift lever. 8. Engine—start 11. Slow 3. Lower the cutting units. 6. Engine—stop 9. Fast 106-9290 1. Inputs 2. Not active 5. In seat 6. Power Take-off (PTO) 9. Outputs 10. Power Take Off (PTO) 3. High temperature shutdown 7. Parking brake Off 11. Start 4. High temperature warning 12.
117-5103 13
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 2 3 4 5 6 7 Use Qty. Inclinometer 1 Check the angle indicator (Models 30839, 30843 and 30807 only) Warning decal (104–5181) 1 Install CE decals, if required. Lock bracket Rivet Washer Screw, 1/4 x 2 inches Locknut, 1/4 inch Exhaust guard Self-tapping screw 1 2 1 1 1 1 4 No parts required – Adjust the lift arms. No parts required – Rear ballast. Install the Hood Latch (CE).
3. Remove the filler caps from the battery and slowly fill each cell until electrolyte is just above the plates. 1 4. Install the filler caps and connect a 3 to 4 amp battery charger to the battery posts. Charge the battery at a rate of 3 to 4 amperes for 4 to 8 hours. Activating, Charging, and Connecting the Battery WARNING No Parts Required Charging the battery produces gasses that can explode. Procedure • Keep sparks and flames away from battery. • Never smoke near the battery. WARNING 5.
the frame cross rail, by the fuel tank (Figure 5). The inclinometer should read zero degrees when viewed from the operator’s position. Figure 4 1. Positive (+) battery cable 2. Negative (–) battery cable Figure 5 Important: If the battery is ever removed, make sure that the battery clamp bolts are installed with the bolt heads positioned on the bottom side and the nuts on the top side. If the clamp bolts are reversed, they may interfere with the hydraulic tubes when shifting the cutting units. 1.
1 4 2 Installing the Hood Latch (CE Only) Parts needed for this procedure: 1 Lock bracket 2 Rivet 1 Washer 1 Screw, 1/4 x 2 inches 1 Locknut, 1/4 inch G012629 Figure 7 2. Bolt and nut assembly 1. CE lock bracket 4. Align the washers with the holes on the inside of the hood. 5. Rivet the brackets and the washers to the hood (Figure 7). 6. Hook the latch onto the hood latch bracket (Figure 8). Procedure 1. Unhook the hood latch from the hood latch bracket. 2.
5 6 Installing the Exhaust Guard (CE Only) Adjusting the Lift Arms No Parts Required Parts needed for this procedure: 1 Exhaust guard 4 Self-tapping screw Procedure 1. Start the engine, raise the cutting units, and check to ensure that the clearance between each lift arm and the floor plate bracket is 0.18 to 0.32 inches (5 to 8 mm) (Figure 11). Procedure 1. Position the exhaust guard around the muffler while aligning the mounting holes with the holes in the frame (Figure 10).
Figure 15 1. Rear cylinder Figure 13 1. Front cylinder 2. Jam nut 2. Adjusting nut B. Grasp the cylinder rod close to the nut with a pliers and rag and rotate the rod. C. Remove the pin from the rod end and rotate the clevis. C. Raise the cutting units and check the clearance. Repeat the procedure if required. D. Install the pin and check the clearance. Repeat the procedure if required. D. Tighten the clevis jam nut.
Product Overview Tilt Steering Lever Controls Pull the tilt steering lever (Figure 16) back to tilt the steering wheel to the desired position. Then push the lever forward to tighten. Indicator Slot Models 30839, 30849 & 30807 only The slot in the operator platform (Figure 16) indicates when the cutting units are in the center position. Angle Indicator Models 30839, 30843 & 30807 only The angle indicator (Figure 16) indicates the side hill angle of the machine in degrees. Figure 16 1.
Throttle Alternator Light Move the throttle (Figure 18) forward to increase the engine speed and rearward to decrease the engine speed. The alternator light (Figure 18) should be off when the engine is running. If it is on, the charging system should be checked and repaired as necessary. Cutting Unit Drive Switch Glow Plug Indicator The cutting unit drive switch (Figure 18) has two positions: Engage and Disengage. The rocker switch operates a solenoid valve on the valve bank to drive the cutting units.
Specifications Operation Note: Specifications and design are subject to change without notice. Overall Width - 68 inch width of cut 71.8 inches (182 cm) Overall Width - 72 inch width of cut 75.8 inches (193 cm) Length Service Interval: Before each use or daily 70.8 inches (180 cm) Wheel Base 58.
3. 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 21) 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 blends.
Checking the Cooling System Service Interval: Before each use or daily Clean debris off of the radiator and oil cooler daily (Figure 23). Clean the radiator hourly if conditions are extremely dusty and dirty; refer to Cleaning the Engine Cooling System. Figure 24 1. Expansion tank Checking the Hydraulic System Figure 23 1. Access panel Service Interval: Before each use or daily—Check the hydraulic fluid level. 3. Oil cooler 2.
The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure. The correct air pressure in the tires is 14 to 18 psi (97 to 124 kPa). bottles. One bottle is sufficient for 4-6 U.S. gallons (15-22 1) of hydraulic oil. Order part no. 44-2500 from your authorized Toro distributor. Biodegradable Hydraulic Fluid—Mobil 224H Note: Maintain the recommended pressure in all tires to ensure a good quality of cut and proper machine performance.
motor. Release the key when the engine starts. The key will move automatically to the On/Run position. DANGER 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. Important: To prevent overheating of the starter motor, do not engage the starter longer than 15 seconds. After 10 seconds of continuous cranking, wait 60 seconds before engaging the starter motor again.
Checking the Interlock System Service Interval: Before each use or daily CAUTION If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. Figure 27 • Do not tamper with the interlock switches. 1. Bypass valve • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine. 2. Before starting the engine, close the bypass valve by rotating it 90° (1/4 turn).
The decal on the SCM only includes symbols. Three LED output symbols are shown in the output box. All other LED’s are inputs. The chart below identifies the symbols. Figure 28 Here are the logical troubleshooting steps for the SCM device. 5. If specific output LED is illuminated without appropriate output function, check output harness, connections, and component. Repair as required. 1. Determine the output fault you are trying to resolve (PTO, START, or ETR). 6.
Operating Tips To troubleshoot, turn on the key without starting the engine. Identify the specific function that does not work and work across the logic chart. Inspect the condition of each input LED’s to ensure it matches the logic chart. General Tips for Models 30839, 30843 and 30807 If the input LED’s are correct, check the output LED.
the forward traction pedal, and carefully drive to an open area. while at the same time keeping the tractor tires as far away from the edge of traps or water hazards as possible. • 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.
General Tips for Model 30849 • 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. DANGER The slope angle at which the machine will tip is dependent on many factors. Among these are: mowing conditions such as wet of undulating turf, speed (especially in turns), tire pressure, and operator experience.
Check Condition of cutting unit a tree or other object in the distance and drive straight toward it. Make sure cutting chambers are in good condition. Straighten any bends in chamber components to assure correct blade tip/chamber clearance. • As soon as the front cutting units reach the edge of the mowing area, lift the cutting units and perform a tear drop shaped turn to quickly line you up for your next pass.
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. 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.
Service Interval Chart Figure 29 Premaintenance Procedures Removing the Hood The hood may be easily removed to ease maintenance procedures in the engine area of the machine. 1. Unlatch and raise the hood. Figure 30 2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 30). 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.
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 36) Figure 39 • Belt tension pivot (Figure 40) Figure 36 • Right front lift arm pivot and lift cylinder (2) (Figure 37) Figure 40 • Steering cylinder (Figure 41). Figure 37 • Neutral adjust mechanism (Figure 38) Figure 41 Note: If desired, an additional grease fitting may be installed in the other end of the steering cylinder. Remove the tire, install the fitting, grease the fitting, remove the fitting, and install the plug (Figure 42).
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. Figure 42 • Service at the recommended service interval or earlier if engine performance suffers due to extremely dusty, dirty conditions.
Figure 47 1. Engine oil drain plug Figure 46 1. Primary filter 2. Remove the oil filter (Figure 48). Apply a light coat of clean oil to the new filter seal before screwing it on. Do not overtighten. 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.
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 49). Service Interval: Every 2 years—Drain and clean the fuel tank. 2. Remove the filter canister and clean the mounting surface. Drain and clean the tank if the fuel system becomes contaminated or if the machine will be stored for an extended period of time. Use clean fuel to flush out the tank. 3.
Electrical System Maintenance terminals separately. Reconnect the cables, positive (+) cable first, and coat the terminals with petroleum jelly. WARNING Caring for the Battery 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. Service Interval: Every 25 hours—Check the electrolyte level.
Drive System Maintenance Cooling System Maintenance Adjusting the Traction Drive for Neutral Cleaning the Engine Cooling System If the machine moves when the traction pedal is in the neutral position, the traction cam must be adjusted. 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.
Brake Maintenance Belt Maintenance Adjusting the Parking Brake Servicing the Engine Belts Service Interval: Every 200 hours—Check the parking brake adjustment. 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. 1. Loosen the set screw securing the knob to the parking brake lever (Figure 54). 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 57). Figure 56 1. Hydrostat drive belt 2. Spring end 3. Replace the belt. 4. Reverse the procedure to tension the spring. Figure 57 1. Injection pump lever arm 3. Hold the injection pump lever arm against the low idle stop and tighten the cable connector. 4.
Hydraulic System Maintenance Contaminated fluid looks milky or black when compared to clean oil. 1. Turn the engine off and raise the hood. 2. Disconnect the hydraulic line (Figure 59) or remove the hydraulic filter (Figure 58) and let the hydraulic fluid flow into a drain pan. Install the hydraulic line when hydraulic fluid stops draining. Changing the Hydraulic Filter Service Interval: After the first 10 hours Every 200 hours/Yearly (whichever comes first) Use a genuine Toro replacement filter, Part No.
Checking the Hydraulic Lines and Hoses Storage Storing the Battery Service Interval: Before each use or daily If the machine will be stored more than 30 days, remove the battery and charge it fullyStore 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.
Engine 1. Drain the engine oil from the oil pan and replace the drain plug. 2. Remove and discard the oil filter. Install a new oil filter. 3. Refill the oil pan with approximately 4 qt (3.8 l) of SAE15W-40 motor oil. 4. Start the engine and run it at idle speed for approximately two minutes. 5. Stop the engine. 6. Thoroughly drain all fuel from the fuel tank, fuel lines, fuel filter, and water separator assembly. 7. Flush the fuel tank with fresh, clean diesel fuel. 8. Secure all fuel system fittings. 9.
Schematics G008924 Electrical Schematic (Rev.
G008925 Hydraulic Schematic (Rev.
Notes: 50
Notes: 51
The Toro Total Coverage Guarantee A 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).
