Form No. 3426-701 Rev A Groundsmaster® 3500-G Rotary Mower Model No. 30809—Serial No. 402700001 and Up Register at www.Toro.com.
Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided.
Contents Inspecting the Fuel Lines and Connections.................................................. 40 Electrical System Maintenance ........................... 41 Electrical System Safety ................................... 41 Servicing the Battery......................................... 41 Servicing the Fuses .......................................... 41 Drive System Maintenance .................................. 42 Checking the Tire Pressure...............................
Safety This machine has been designed in accordance with ANSI B71.4-2017 and meets these standards when the appropriate ballast is added. 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. • 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 99-3444 93-6681 1. Cutting/dismemberment—hazard, fan-stay away from moving parts. decal99-3444 99-3444 1. Transport speed—fast 2. Mowing speed—slow decal93-7276 93-7276 1. Explosion hazard—wear eye protection. 2. Caustic liquid/chemical burn hazard—to perform first aid, flush with water. 3.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. decal117-4764 117-4764 1. Explosion hazard 6. Keep bystanders 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. 1.
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.
decal121-3620 121-3620 1. PTO—Disengage 7. Lock 2. PTO—Engage 8. Engine—Shut off 3. Move the cutting units right. 9. Engine—Run 4. Move the cutting units left. 10. Engine—Start 5. Lower the cutting units. 11. Fast 6. Raise the cutting units. 12. Slow decal138-6977 138-6977 1. Read the Operator’s Manual.
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 Use Qty. No parts required – Activate, charge, and connect the battery. No parts required – Add the rear wheel ballast. Inclinometer 1 Check the angle indicator. No parts required – Adjust the lift arms. No parts required – Adjust the carrier frame. No parts required – Adjust the height of cut. No parts required – Adjust the roller scraper (optional).
WARNING Incorrect battery cable routing could damage the tractor and cables, causing sparks. Sparks can cause the battery gases to explode, resulting in personal injury. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. g031567 • Always connect the positive (red) battery cable before connecting the negative (black) cable. Figure 3 1. Battery cover 2.
2 Adding the Rear Wheel Ballast No Parts Required Procedure g031569 Figure 5 Add 22.6 kg (50 lb) of calcium-chloride ballast to the rear wheel. 1. Angle indicator Important: If a puncture occurs in a tire containing calcium chloride, remove the machine from the turf as quickly as possible. Immediately soak the affected area with water to prevent possible damage to the turf. 3. Note: The angle indicator, mounted on the machine, should now read 0° also. 3 4.
B. 4 Back off the jam nut on the cylinder (Figure 8). 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 6. g031573 Figure 8 1. Jam nut 2. Front cylinder C. Remove the pin from the rod end and rotate the clevis. D. Install the pin and check the clearance. Note: Repeat the procedure if required. E. 2.
g031575 Figure 10 1. Rear cylinder 2. Adjusting nut B. Grasp the cylinder rod close to the nut with a pliers and rag, and rotate the rod. C. Raise the cutting units and check the clearance. g031576 Figure 11 1. Upper, front cutting unit mounting hole Note: Repeat the procedure if required. D. 3. Rear cutting unit mounting hole 2. Lower, front cutting unit mounting hole Tighten the clevis jam nut. Important: Lack of clearance at the front stops or rear wear bar could damage the lift arms. 2.
bench set 6 mm (1/4 inch) above that of the reels cutting in the same area. 8. Repeat steps 4 to 7 for each side adjustment. 9. Tighten the 3 bolts to 41 N∙m (30 ft-lb). Important: Access to the rear cutting units is Note: Tighten the front bolt first. 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.
Product Overview 8 Controls Installing the Mulching Baffle Optional No Parts Required Procedure Contact your authorized Toro distributor for the correct mulching baffle. 1. Thoroughly clean debris from the mounting holes on the rear wall and left wall of the chamber. 2. Install the mulching baffle in the rear opening and secure it with 5 flange-head bolts (Figure 15). g031595 Figure 16 1. Tilt-steering lever 4. Forward traction pedal 2. Angle indicator 5. Mow/transport slide 3.
Traction Pedals Press the forward traction pedal to move forward. Press reverse traction pedal to move backward or to assist in stopping when moving forward (Figure 16). 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 16).
Lift-Lock Lever Note: The cutting units do not drop unless the engine is running. Use the lift-lock lever to secure the lift switch (Figure 17) to the RAISE-DECK position when performing maintenance on the cutting unit or when transporting between mowing locations. Move the lever to the right or left to move the cutting units in the same direction. Note: Do this only when the cutting units are raised or if they are on the ground and the machine is moving.
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. 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.Toro.
performance problems and/or engine damage which may not be covered under warranty. DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. – Do not use gasoline containing methanol. – Do not store fuel either in the fuel tank or fuel containers over the winter unless a fuel stabilizer is used. • Before removing the fuel-tank cap, make sure that the vehicle is positioned on a level surface.
Selecting a Blade DANGER In certain conditions during fueling, static electricity can be released causing a spark which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. 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.
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 • Never leave a running machine unattended. • Before you leave the operator’s position, do the During Operation Safety following: General Safety – Disengage the power takeoff and lower the attachments. • The owner/operator can prevent and is responsible – Engage the parking brake. • • • • • • • • • • • • • • • – Park the machine on a level surface. for accidents that may cause personal injury or property damage.
Important: To prevent overheating of the starter motor, do not engage the starter for longer than 15 seconds. After 10 seconds of continuous cranking, wait 60 seconds before engaging the starter motor again. operation. Operating the machine on any slope requires extra caution. • Evaluate the site conditions to determine if the slope is safe for machine operation, including surveying the site. Always use common sense and good judgment when performing this survey. 5.
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.
Operating Tips Changing Mowing Patterns Creating a Site Survey Change mowing patterns often to minimize a poor after-cut appearance from repeatedly mowing in the same direction. To perform a site survey, lay a 1.25 m plank (4 ft long 2 x 4) on the slope surface and measure the angle of the slope with the inclinometer provided with the machine. The plank (2 x 4) will average the slope but will not take into consideration dips or holes which can cause a sudden change in side hill angle.
the operator’s position, Allow the machine to cool before adjusting, servicing, cleaning, or storing it. with the mulching baffles installed, the after-cut appearance may deteriorate and the observed power to cut the turf increases. The mulching baffles also perform well for shredding leaves in the fall. • Clean grass and debris from the cutting units, mufflers, and engine compartment to help prevent fires. Clean up oil or fuel spills.
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.
Maintenance • Allow machine components to cool before Note: Determine the left and right sides of the • If the cutting units are in the transport position, use performing maintenance. the positive mechanical lock (if equipped) before you leave the machine unattended. machine from the normal operating position. Note: Download a free copy of the electrical or • If possible, do not perform maintenance while the hydraulic schematic by visiting www.Toro.
Maintenance Service Interval Maintenance Procedure Every 500 hours • Grease the bearings in the rear axle. Every 800 hours • If you are not using the recommended hydraulic fluid or have ever filled the reservoir with an alternative fluid, change the hydraulic fluid. • If you are not using the recommended hydraulic fluid or have ever filled the reservoir with an alternative fluid, replace the hydraulic filter (sooner if the service interval indicator is in the red zone).
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. Check the air filter, dust cup, and burp valve. Check for unusual engine noises. Check the radiator and screen for debris Check for unusual operating noises. Check the hydraulic-systemoil level.
Pre-Maintenance Procedures Using the Cutting Unit Service Latch When servicing the cutting units, use the service latch to prevent injury. Removing the Hood 1. Unlatch and raise the hood. 2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 25). 1. Center the cutting unit sidewinder with the traction unit. 2. Raise the cutting unit to the transport position. 3. Engage the parking brake and shut off the machine. 4.
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 34 • Mow/transport slide (Figure 35) g008898 Figure 31 • 2 left, front lift-arm pivots and lift cylinder (Figure 32) g008902 Figure 35 • Belt-tension pivot (Figure 36) g008899 Figure 32 • 2 right, front lift-arm pivots and lift cylinder (Figure 33) g008903 Figure 36 • Steering cylinder (Figure 37) g008900 Figure 33 • Neutral-adjustment mechanism (Figure 34) 35
Important: Do not lubricate the Sidewinder cross tube. The bearing blocks are self-lubricated. g008904 Figure 37 • 2 (per cutting unit) cutting unit spindle-shaft bearings (Figure 38) Note: You can use either fitting, whichever is more accessible. Pump grease into the fitting until a small amount appears at the bottom of the spindle housing (under the cutting unit).
Engine Maintenance Note: Cleaning of the used element is not recommended due to the possibility of damage to the filter media. Engine Safety 4. • Shut off the engine and remove the key before checking the oil or adding oil to the crankcase. Important: Do not use a damaged filter. • Do not change the governor speed or overspeed the engine. Servicing the Air Cleaner 5. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister. 6.
g016095 Figure 41 1. Position the machine on a level surface and open the hood. 2. Remove the dipstick (Figure 42) and wipe it with a clean rag. Insert the dipstick into the tube and make sure that it is seated fully. Remove the dipstick and check the level-of-the-oil. g002373 Figure 43 1. Note clearance 4. Install the dipstick firmly in place. 5. Install the oil-fill cap and close the hood. Changing the Engine Oil and Filter Service Interval: After the first 50 hours Every 200 hours g008881 1.
g005588 Figure 46 1. Air gap at 0.81 mm (0.032 inch) 4. Set the air gap on each plug between the center and side electrodes to 0.81 mm (0.032 inch). 5. Install the correctly-gapped spark plugs and tighten them to 24.5 to 29 N-m (18 to 22 ft-lb). If you cannot use a torque wrench, tighten the plugs firmly. 6. Install the spark-plug wires. g021414 Figure 45 1. Engine oil filter 3. Add oil to the crankcase; refer to Checking the Engine-Oil Level (page 37).
Fuel System Maintenance Replacing the Fuel-Pump Filter Service Interval: Every 400 hours DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property g021236 Figure 48 1. Fuel pump • Drain fuel from the fuel tank when the engine is cold. Do this outdoors, in an open area. Wipe up any fuel that spills.
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. 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. Raise a front wheel and a rear wheel off the floor and place support blocks under the frame.
5. Tighten the locknut securing the adjustment. 6. Shut off the engine. 7. 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. Cooling System Maintenance Cooling System Safety • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets. • Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns.
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 54). 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 Servicing the Hydraulic Fluid Hydraulic System Safety Hydraulic Fluid Specifications The reservoir is filled at the factory with high-quality hydraulic fluid. Check the level of the hydraulic fluid before you first start the engine and daily thereafter; refer to Checking the Hydraulic Fluid Level (page 48). • Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor.
Hydraulic Fluid Capacity: 13.2 L (3.5 US gallons) maximum biodegradability and performance, the hydraulic system should be thoroughly flushed of conventional fluid. The oil is available in 19 L (5 US gallons) pails or 208 L (55 US gallons) drums from your authorized Toro distributor. If the fluid becomes contaminated, contact your local Toro distributor to flush the system. Contaminated fluid looks milky or black. Checking the Hydraulic Fluid Level 1. Turn the engine off and raise the hood. 2.
5. Install the reservoir cap. 6. Start the engine. 7. Use all the hydraulic controls to distribute the hydraulic fluid throughout the system, check for leaks, then shut off the engine. Check the fluid level and add enough to raise the level to the FULL mark on the dipstick. 8. Note: Do not overfill. Ensure that the filter mounting area is clean and screw the filter on until the gasket contacts the mounting plate; then tighten the filter 1/2 turn. 6. Release the hose to the filter-mounting plate.
Cutting Unit Maintenance 3. Remove the lynch pin or retaining nut securing the cutting unit carrier frame to the lift-arm-pivot pin (Figure 63). Separating the Cutting Units from the Traction Unit 1. Perform the pre-maintenance procedure; refer to Maintenance Safety (page 30). 2. Remove the hydraulic-motor-mounting screws and disconnect and remove the hydraulic motor from the cutting unit (Figure 62). Important: Cover the top of the spindle to prevent contamination. g031645 Figure 63 1.
Inspecting the Blade Plane 1. Remove the hydraulic motor from the cutting unit and remove the cutting unit from the traction unit. Note: Use a hoist (or a minimum of 2 people) and place the cutting unit on a flat table. 2. Mark an end of the blade with a paint pen or marker. Note: Use this end of the blade to check all heights. 3.
Removing the Front Roller 1. Note: If there is a gap over 1.5 mm (0.06 inch), install enough 5/8-inch diameter washers to take up the slop. Remove the roller-mounting bolt (Figure 66). 6. g031649 Figure 66 1. Bearing 3. Front roller 2. Mounting bolt 4. Bearing spacer 2. 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. Note: There should be a 1.5 mm (0.06 inch) lip of inner race exposed. 3.
Blade Maintenance Inspecting and Sharpening the Blade Blade Safety Note: Check the blade before using the machine. Sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade. If you notice wear, replace the blade; refer to Inspecting and Sharpening the Blade (page 53). • Inspect the blade periodically for wear or damage. • Use care when checking the blades. Wrap the blades or wear gloves, and use caution when servicing the blades.
Note: Position the ends of the blade slightly lower than the center, and the cutting edge lower than the heel of the blade. This blade produces a good quality of cut and requires minimal power from the engine. By contrast a blade that is higher at the ends than the center, or if cutting edge is higher than the heel, the blade is bent or warped and must be replaced.
Storage E. Coat the cable terminals and battery posts with Grafo 112X skin-over grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion. F. Store the battery on the shelf or on the machine in a cool area. Leave the cables disconnected if you store it on the machine. Storage Safety • Shut off the engine, remove the key (if equipped), and wait for all movement to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it.
Preparing the Engine 12. Secure all fuel system fittings. 1. Drain the engine oil from the oil pan and replace the drain plug. 13. Thoroughly clean and service the air cleaner assembly. 2. Remove and discard the oil filter. Install a new oil filter. 14. Seal the air cleaner inlet and the exhaust outlet with weatherproof tape. 3. Refill the oil pan with designated quantity of motor oil. 4. Start the engine and run it at idle speed for approximately 2 minutes. 5. Stop the engine. 6.
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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 Two-Year or 1,500 Hours Limited Warranty Conditions and Products Covered Parts 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 2 years or 1,500 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).
