Form No. 3424-110 Rev B Groundsmaster® 3505-D Rotary Mower Model No. 30849—Serial No. 403207001 and Up Register at www.Toro.com.
Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet.
Contents Bleeding the Fuel System ................................. 43 Bleeding Air from the Injectors .......................... 43 Electrical System Maintenance ........................... 44 Electrical System Safety ................................... 44 Servicing the Battery......................................... 44 Servicing the Fuses .......................................... 44 Drive System Maintenance .................................. 45 Checking the Tire Pressure...............................
Safety This machine has been designed in accordance with EN ISO 5395:2013 and ANSI B71.4-2017. General Safety This product is capable of amputating hands and feet and of throwing objects. Always follow all safety instructions to avoid serious personal injury. Using this product for purposes other than its intended use could prove dangerous to you and bystanders. • Read and understand the contents of this Operator’s Manual before starting the engine. • Use your full attention while operating the machine.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing. decal93-6681 93-6681 1. Cutting/dismemberment—hazard, fan-stay away from moving parts. 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. decal93-7276 93-7276 1.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance away 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. decal117-4764 117-4764 1.
decal106-9290 106-9290 1. Inputs 5. In seat 2. Not active 6. Power take-off (PTO) 10. Power take-off (PTO) 3. High-temperature shutdown 4. High-temperature warning 7. Parking brake off 11. Start 8. Neutral 12. Energize to run (ETR) 9. Outputs decal121-3598 121-3598 This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal.
decal121-3627 121–3627 1. Height-of-cut settings decal121-3623 121-3623 1. Warning—read the Operator's Manual; do not operate the machine unless you have received training. 5. Thrown object hazard—keep bystanders away. 2. Warning—read the Operator's Manual before towing the machine. 3. Tipping hazard—slow the machine before turning; when driving on slopes, keep the cutting units lowered and your seatbelt fastened. 4.
decal121-3619 121-3619 1. PTO—Disengage 6. Engine—Shut off 2. PTO—Engage 7. Engine—Run 3. Lower the cutting units. 8. Engine—Start 9. Fast 4. Raise the cutting units. 5. Lock 10.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 3 4 5 6 7 8 9 Use Qty. No parts required – Activate, charge, and connect the battery. Decal (121-3598) 1 Install the CE decals (if required). Hood-latch 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 – Adjust the carrier frame.
WARNING 1 Charging the battery produces gasses that can explode. Activating, Charging, and Connecting the Battery • Keep sparks and flames away from battery. • Never smoke near the battery. No Parts Required Procedure Note: If the battery is not filled with electrolyte or activated, purchase bulk electrolyte with 1.26 specific gravity from a local battery-supply outlet and add it to the battery. 4. When the battery is charged, disconnect the charger from the electrical outlet and battery posts. 5.
3 Installing the Hood Latch CE Machines Only Parts needed for this procedure: g031568 Figure 4 1. Negative (–) battery cable 2. Positive (+) battery cable Important: If you ever remove the battery, install the battery-clamp bolts 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. 9. Coat both battery connections with Grafo 112X (skin over) grease (Toro Part No.
g012631 Figure 8 g012629 1. Bolt 2. Nut Figure 6 1. CE lock bracket 3. Arm of hood-latch bracket 2. Bolt and nut 5. Align the washers with the holes on the inside of the hood. 6. Rivet the brackets and the washers to the hood (Figure 6). 7. Hook the latch onto the hood-latch bracket (Figure 7). 4 Installing the Exhaust Guard CE Models Only Parts needed for this procedure: 1 Exhaust guard 4 Self-tapping screw Procedure g012630 1. Figure 7 1. Hood latch 8.
5 Adjusting the Lift Arms No Parts Required Procedure 1. Start the engine, raise the cutting units, and ensure that the clearance between each lift arm and the floor-plate bracket is 5 to 8 mm (0.18 to 0.32 inch) as shown in Figure 10. g008875 Figure 9 1. Exhaust guard 2. Secure the exhaust guard to the frame with 4 self-tapping screws (Figure 9). g031571 Figure 10 Cutting units removed for clarity 1. Floor-plate bracket 3. Lift arm 2.
B. Back off the jam nut on the cylinder (Figure 12). g031575 Figure 14 1. Rear cylinder 2. Adjusting nut g031573 Figure 12 1. Jam nut C. Remove the pin from the rod end and rotate the clevis. D. Install the pin and check the clearance. 2. C. Raise the cutting units and check the clearance. D. Tighten the clevis jam nut. Important: Lack of clearance at the front stops or Tighten the clevis jam nut. rear wear bar could damage the lift arms.
bench set 6 mm (1/4 inch) above that of the reels cutting in the same area. Important: Access to the rear cutting units is greatly improved by removing the cutting unit from the machine. If the machine is equipped with a Sidewinder unit, side-wind the cutting units to the right, remove the rear cutting unit, and slide it out to the right side. 1. Lower the cutting deck to the ground, shut off the engine, and remove the ignition key. 2.
8. Repeat steps 4 to 7 for each side adjustment. 9. Tighten the 3 bolts to 41 N∙m (30 ft-lb). 9 Note: Tighten the front bolt first. Installing the Mulching Baffle Note: Adjustments of more than 3.8 cm (1-1/2 inches) may require temporary assembly to an intermediate height to prevent binding (e.g., changing from 3.1 to 7 cm (1-1/4 to 2-3/4 inches) height of cut). Optional 8 No Parts Required Procedure Adjusting the Roller Scraper 1.
Traction Pedals Product Overview Press the forward traction pedal to move forward. Press reverse traction pedal to move backward or to assist in stopping when moving forward (Figure 20). Controls Note: Allow the pedal to move or move it to the NEUTRAL position to stop the machine. Tilt-Steering Lever Pull the tilt-steering lever back to tilt the steering wheel to the desired position, then push the lever forward to tighten (Figure 20).
Mow/Transport Slide Using your heel, move the mow/transport slide to the left to transport, and to the right to mow (Figure 20). Note: The cutting units operate only in the mow position. Important: The mow speed is set at the factory to 9.7 km/h (6 mph). You can increase or decrease the mow speed by adjusting the speed-stop screw (Figure 23). g031598 Figure 22 1. Fuel gauge g031596 Figure 23 2. Seat-adjustment lever 1.
Note: The lever does not need to be held in the forward position while you are lowering the cutting units. Alternator Light The alternator light should be off when the engine is running (Figure 21). Note: If it is on, the charging system should be checked and repaired as necessary.
Specifications Note: Specifications and design are subject to change without notice.
Overall length in mowing position F 295 cm (116 inches) Overall length in transport position G 295 cm (116 inches) Ground clearance 15 cm (6 inches) Weight 963 kg (2,124 lb) Note: Specifications and design are subject to change without notice. Operation Attachments/Accessories A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or authorized Toro distributor or go to www.
• Fuel filter plugging may occur for a time after you • Do not store the machine or fuel container where convert to biodiesel blends. there is an open flame, spark, or pilot light, such as on a water heater or other appliance. • For more information on biodiesel, contact your • If you spill fuel, do not attempt to start the engine; authorized Toro distributor. avoid creating any source of ignition until the fuel vapors have dissipated.
Filling the Fuel Tank Selecting a Blade 1. Clean the area around the fuel-tank cap (Figure 25). 2. Remove the fuel-tank cap. 3. Fill the tank to the bottom of the filler neck. Do not overfill. Install the cap. 4. To prevent a fire hazard, wipe up any spilled fuel. Using a Standard Combination Sail This blade provides excellent lift and dispersion in almost any condition. If you require more or less lift and discharge velocity, consider a different blade.
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 (3/4 to 1-3/4 inches) height of cut Recommended in most applications May work well in light or sparse turf Grass Cutting: 5 to 6.
During Operation • Before leaving the operating position (including to empty the catchers or to unclog the chute), do the following: During Operation Safety – Park the machine on level ground. General Safety – Disengage the power takeoff and lower the attachments. • The owner/operator can prevent and is responsible – Engage the parking brake. for accidents that may cause personal injury or property damage. – Shut off the engine and remove the key. – Wait for all moving parts to stop.
• Avoid starting, stopping, or turning the machine on Note: The key automatically moves to the slopes. Avoid making sudden changes in speed or direction. Make turns slowly and gradually. ON/RUN position. 6. • Do not operate a machine under any conditions where traction, steering, or stability is in question. • Remove or mark obstructions such as ditches, holes, ruts, bumps, rocks, or other hidden hazards. Tall grass can hide obstructions. Uneven terrain could overturn the machine.
Standard-Control Module (SCM) The Standard-Control Module (SCM) is a potted electronic device produced in a 1-size-fits-all configuration. The module uses solid state and mechanical components to monitor and control standard, electrical features required for safe product operation. The module-monitor input includes neutral, parking brake, PTO, start, backlap, and high temperature. The module energizes outputs including PTO, Starter, and ETR (energize to run) solenoid.
Each row (across) in the logic chart below identifies input and output requirements for each specific product function. Product functions are listed in the left column. Symbols identify specific circuit condition, including energized to voltage, closed to ground, and open to ground.
Understanding Counterbalance Operating Tips The counterbalance system maintains hydraulic back pressure on the deck-lift cylinders. This pressure improves traction by transferring the mower-deck weight to the mower-drive wheels. The counterbalance pressure has been set at the factory to an optimal balance of after-cut appearance and traction capability in most turf conditions. Operating the Machine • Start the engine and run it at HALF IDLE until it warms up.
• Allow the engine to cool before storing the machine baffles also perform well for shredding leaves in the fall. • Selecting the Proper Height-of-Cut Setting to Suit Conditions • Remove no more than approximately 25 mm (1 inch), or 1/3 of the grass blade when cutting. In exceptionally lush and dense grass, you may need to raise your height-of-cut setting. • Mowing with Sharp Blades • • A sharp blade cuts cleanly and without tearing or shredding the grass blades like a dull blade.
Pushing or Towing the Machine In an emergency, you can move the machine a very short distance by actuating the bypass valve in the hydraulic pump and pushing or towing the machine. Important: Do not push or tow the machine faster than 3 to 4.8 km/h (2 to 3 mph). If you push or tow at a faster speed, internal transmission damage may occur. If you must move the machine a considerable distance, transport it on a truck or trailer. Important: The bypass valve must be open whenever you push or tow the machine.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval After the first hour Maintenance Procedure • Torque the wheel-lug nuts. After the first 10 hours • Torque the wheel-lug nuts. • Check the condition and tension of all belts. • Change the hydraulic filter. After the first 50 hours • Change the engine oil and engine-oil filter.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Monday Tuesday Wednesday Thursday Friday Saturday 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.
Pre-Maintenance Procedures Preparing the Machine for Maintenance 1. Ensure that the PTO is disengaged. Maintenance Safety 2. Park the machine on a level surface. • Before adjusting, cleaning, repairing, or leaving 3. Engage the parking brake. the machine, do the following: 4. Lower the cutting unit(s) if necessary. – Park the machine on a level surface. 5. Shut off the engine and wait for all moving parts to stop. 6. Turn the ignition key to the STOP position and remove it. 7.
Using the Cutting Deck Service Latch When servicing the cutting decks, use the service latch to prevent injury. 1. Center the cutting deck sidewinder with the traction unit. 2. Raise the cutting decks to the transport position. 3. Engage the parking brake and turn off the machine. 4. Release the latch rod from the front carrier-frame retainer (Figure 30). g031614 Figure 30 1. Service-latch hook 5.
Lubrication Greasing the Bearings and Bushings Service Interval: Every 50 hours—Lubricate all of the bearings and bushings. Every 500 hours/Yearly (whichever comes first) The machine has grease fittings that you must lubricate regularly with No. 2 lithium grease. Also, lubricate the machine immediately after every washing.
g008901 Figure 38 • Mow/transport slide (Figure 39) g008898 Figure 35 • 2 left, front lift-arm pivots and lift cylinder (Figure 36) g008902 Figure 39 • Belt-tension pivot (Figure 40) g008899 Figure 36 • 2 right, front lift-arm pivots and lift cylinder (Figure 37) g008903 Figure 40 • 2 (per cutting unit) cutting unit spindle-shaft bearings (Figure 41) Note: You can use either fitting, whichever is more accessible.
Engine Maintenance Engine Safety • Shut off the engine and remove the key before checking the oil or adding oil to the crankcase. • Do not change the governor speed or overspeed the engine. g008906 Servicing the Air Cleaner Figure 41 Check the air-cleaner body for damage that could cause an air leak and replace it if it is damaged. Check the entire intake system for leaks, damage, or loose hose clamps.
g032050 Figure 44 1. Rubber outlet valve 4. Air-cleaner body 2. Air-cleaner latch 5. Air-cleaner-restriction sending unit 3. Air cleaner primary filter 6. Rubber intake hose g031340 Figure 43 Servicing the Air-Cleaner Filter Service Interval: Every 200 hours (More frequently in extreme dusty or dirty conditions) 1.
Servicing the Engine Oil Checking the Engine-Oil Level Service Interval: Before each use or daily The engine is shipped with oil in the crankcase; however, check the oil level before and after you start the engine for the first time. The crankcase capacity is approximately 2.8 L (4 US qt) with the filter. Use high-quality engine oil that meets the following specifications: • API Classification Level Required: CH-4, CI-4, or higher.
4. Fuel System Maintenance Change the engine-oil filter as shown in Figure 48. Draining the Fuel Tank Service Interval: Every 1,000 hours—Drain and clean the fuel tank. Every 2 years—Drain and clean the fuel tank. Drain and clean the tank also if the fuel system becomes contaminated or if you are storing the machine for an extended period of time. Use clean fuel to flush out the tank.
Replacing the Fuel Filter Note: The electric fuel pump will operate, 1. Clean the area where the filter mounts (Figure 49). 2. Remove the filter and clean the mounting surface. 3. Lubricate the gasket on the filter with clean oil. 4. Install the filter by hand until the gasket contacts the mounting surface; then rotate an additional 1/2 turn. forcing air out around the air-bleed screw. Leave the key in the ON position until a solid stream of fuel flows out around the screw. 6.
Electrical System Maintenance WARNING Incorrectly routing the battery cable could damage the tractor and cables, causing sparks. Sparks can cause the battery gases to explode, resulting in personal injury. Electrical System Safety • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last.
Adjusting the Traction Drive for Neutral Drive System Maintenance If the machine moves when the traction pedal is in the NEUTRAL position, adjust the traction cam. Checking the Tire Pressure Service Interval: Before each use or daily 1. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key from the ignition switch. 2. Chock or block the front and rear wheels on one side. 3.
Cooling System Maintenance 5. Start the engine and rotate the cam hex in both directions to determine the mid position of the neutral span. 6. Tighten the locknut securing the adjustment. 7. Shut off the engine. Cooling System Safety 8. Remove the support blocks and lower the machine to the shop floor. Test drive the machine to ensure that it does not move when the traction pedal is in neutral. • Swallowing engine coolant can cause poisoning; • • • • keep out of reach from children and pets.
Cleaning the Cooling System The capacity of the cooling system is approximately 5.7 L (6 US qt). CAUTION Service Interval: Before each use or daily If the engine has been running, the pressurized, hot coolant can escape and cause burns. 1. Raise the hood. 2. Clean the engine area thoroughly of all debris. • Do not open the radiator cap when the engine is running. 3. With compressed air, start from the front of the radiator and blow the debris out toward the back.
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. Service Interval: Every 200 hours—Check the parking-brake adjustment. 1. Every 100 hours—Check the condition and tension of all belts. Loosen the set screw securing the knob to the parking-brake lever (Figure 57). Checking the Alternator-Belt Tension 1. Open the hood. 2.
Replacing the Hydrostat-Drive Belt 1. Controls System Maintenance Insert a nut driver or small piece of tubing onto the end of the belt-tensioning spring. CAUTION Adjusting the Throttle The spring that tensions the belt is under a heavy load, and releasing the tension of the spring improperly may cause injury. Use care when de-tensioning the spring and replacing the belt. 2. 1. Position the throttle lever rearward so that it stops against the control-panel slot. 2.
Hydraulic System Maintenance is sufficient for 15 to 22 L (4 to 6 US gallons) of hydraulic fluid. Order Part No. 44-2500 from your authorized Toro distributor. The reservoir is filled at the factory with approximately 13.2 L (3.5 US gallons) of high-quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter. The recommended replacement fluid is Toro Premium All-Season Hydraulic Fluid (Available in 19 L (5 US gallons) pails or 55-gallon drums.
5. 6. 7. Changing the Hydraulic Fluid Insert the dipstick into the filler neck, then remove it and check the fluid level. Note: The fluid level should be within 6 mm (1/4 inch) of the mark on the dipstick. If the level is low, add the appropriate fluid to raise the level to the FULL mark. Install the dipstick and cap onto the filler neck. Service Interval: Every 400 hours If the fluid becomes contaminated, contact your local Toro distributor to flush the system. Contaminated fluid looks milky or black.
Cutting Unit Maintenance Separating the Mower Decks from the Traction Unit 1. Perform the pre-maintenance procedure; refer to Preparing the Machine for Maintenance (page 35). 2. Remove the hydraulic-motor-mounting screws and disconnect and remove the hydraulic motor from the deck (Figure 65). g031641 Important: Cover the top of the spindle to prevent contamination. Figure 64 1. Hydraulic-tank cap 5. Install the reservoir cap. 6. Start the engine. 7.
3. Mounting the Mower Decks to the Traction Unit Remove the lynch pin or retaining nut securing the deck carrier frame to the lift-arm-pivot pin (Figure 66). 1. Perform the pre-maintenance procedure; refer to Preparing the Machine for Maintenance (page 35). 2. Move the cutting deck into position in front of the traction unit. 3. Slide the deck-carrier frame onto the lift-arm-pivot pin and secure it with the lynch pin or retaining nut (Figure 66). 4.
2. Adjust the 1.5 mm (0.06 inch) shims and/or 0.7 mm (0.03 inch) shim between the deck frame and bracket to achieve the desired height of cut (Figure 68). 3. Install the height-of-cut bracket to the deck frame with the remaining shims assembled below the height-of-cut bracket (Figure 68). 4. Secure the socket-head bolt and spacer and flange nut. Note: The socket-head bolt and spacer are held together with Loctite to prevent the spacer from falling inside the deck frame. g011353 Figure 67 4. 5.
2. Blade Maintenance Insert a punch through the end of the roller housing and drive the opposite bearing out by alternating taps to the opposite side of inner-bearing race. Blade Safety Note: There should be a 1.5 mm (0.06 inch) lip 3. Push the second bearing out in the press. A worn or damaged blade can break, and a piece of the blade could be thrown toward you or bystanders, resulting in serious personal injury or death. 4.
5. Torque the blade bolt to 115 to 149 N∙m (85 to 110 ft-lb). 5. Inspecting and Sharpening the Blade Lay the blade on a level surface and check its ends to ensure that the blade is straight and parallel. Note: The blade ends must be slightly lower than the center, and the cutting edge must be lower than the heel of the blade. These characteristics produce a good quality of cut and require less power from the engine. Note: Check the blade before using the machine.
Preparing the Engine Storage Follow these procedures whenever you store the machine for more than 30 days. Storing the Battery If you are storing the machine for 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 that it is fully charged. The specific gravity of a fully charged battery is 1.265 to 1.299. Preparing the Traction Unit 1. 2. 1.
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California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
The Toro 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).
