Toro Groundsmaster 3500-D User manual

Operator’s Manual
English (EN, GB)
Form No. 3354–406 Rev C
Groundsmaster)3500-D
Groundsmaster Traction Unit
Model No. 30839—Serial No. 260000001 and Up

2
All Rights Reserved
Printed in the USA
W2005 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
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.
Warning
Contents
Page
Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .
Toro Mower Safety 5. . . . . . . . . . . . . . . . . . . . . . . .
Sound Power Level 7. . . . . . . . . . . . . . . . . . . . . . . .
Sound Pressure Level 7. . . . . . . . . . . . . . . . . . . . . . .
Vibration Level 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 7. . . . . . . . . . . . . . . . .
Specifications 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 11. . . . . . . . . . . . . . . . . . . . .
Optional Equipment 11. . . . . . . . . . . . . . . . . . . . . . . .
Setup 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Activating, Charging, and Connecting the Battery 13
Checking the Angle Indicator 14. . . . . . . . . . . . . . . .
Installing the Hood Latch (CE) 14. . . . . . . . . . . . . . .
Installing the Exhaust Guard (CE) 14. . . . . . . . . . . . .
Adjusting the Lift Arms 15. . . . . . . . . . . . . . . . . . . . .
Rear Ballast 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Operating 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Crankcase Oil 16. . . . . . . . . . . . . . . . . .
Filling the Fuel Tank 16. . . . . . . . . . . . . . . . . . . . . . .
Checking the Cooling System 17. . . . . . . . . . . . . . . .
Checking the Hydraulic System 18. . . . . . . . . . . . . . .
Checking the Tire Pressure 18. . . . . . . . . . . . . . . . . .
Checking the Torque of the Wheel Nuts 19. . . . . . . .
Operation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping the Engine 22. . . . . . . . . . . . . .
Bleeding the Fuel System 22. . . . . . . . . . . . . . . . . . . .
Checking the Interlock System 23. . . . . . . . . . . . . . .
Towing the Traction Unit 23. . . . . . . . . . . . . . . . . . . .
Standard Control Module (SCM) 24. . . . . . . . . . . . . .
Operating Characteristics 26. . . . . . . . . . . . . . . . . . . .
Maintenance 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 28. . . . . . . . .
Daily Maintenance Checklist 29. . . . . . . . . . . . . . . . .
Greasing the Bearings and Bushings 30. . . . . . . . . . .
Service Interval Chart 33. . . . . . . . . . . . . . . . . . . . . .
Removing the Hood 34. . . . . . . . . . . . . . . . . . . . . . . .
General Air Cleaner Maintenance 34. . . . . . . . . . . . .
Servicing the Air Cleaner 34. . . . . . . . . . . . . . . . . . . .
Servicing the Engine Oil and Filter 35. . . . . . . . . . . .
Servicing the Fuel System 35. . . . . . . . . . . . . . . . . . .
Bleeding Air from the Injectors 36. . . . . . . . . . . . . . .
Cleaning the Engine Cooling System 36. . . . . . . . . .
Servicing the Engine Belts 37. . . . . . . . . . . . . . . . . . .
Adjusting the Throttle 38. . . . . . . . . . . . . . . . . . . . . .
Changing the Hydraulic Fluid 38. . . . . . . . . . . . . . . .
Replacing the Hydraulic Filter 39. . . . . . . . . . . . . . . .
Checking the Hydraulic Lines and Hoses 39
. . . . . . .
Adjusting the Traction Drive for Neutral 39. . . . . . . .
Adjusting the Parking Brake 40. . . . . . . . . . . . . . . . .
Caring for the Battery 40. . . . . . . . . . . . . . . . . . . . . .
Storing the Battery 41. . . . . . . . . . . . . . . . . . . . . . . . .
Fuses 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic 42. . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic 43. . . . . . . . . . . . . . . . . . . . . . .
Preparation for Seasonal Storage 44. . . . . . . . . . . . . .
The Toro General Commercial Products Warranty 48. . .

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Introduction
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
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. The two numbers are
stamped into a plate located on the frame of the mower.
Write the product model and serial numbers in the space
below:
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.
Safety
This machine meets or exceeds CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI
B71.4-1999 specifications in effect at the time of
production when 50 lb. of calcium chloride ballast is
added to the rear wheels.
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert symbol, which means
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
Safe Operating Practices
The following instructions are from the CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI standard
B71.4-1999.
Training
•Read the Operator’s Manual and other training material
carefully. Be familiar with the controls, safety signs,
and the proper use of the equipment.
•Never allow children or people unfamiliar with these
instructions to use the mower. Local regulations may
restrict the age of the operator.
•Never mow while people, especially children, or pets
are nearby.
•Keep in mind that the operator or user is responsible for
accidents or hazards occurring to himself or herself,
other people, or property.
•Do not carry passengers.
•All drivers and mechanics should seek and obtain
professional and practical instruction. The owner is
responsible for training the users. Such instruction
should emphasize:
– the need for care and concentration when working
with ride-on machines;
– control of a ride-on machine sliding on a slope will
not be regained by the application of the brake. The
main reasons for loss of control are:
•insufficient wheel grip;
•being drive too fast;
•inadequate braking;
•the type of machine is unsuitable for its task;
•lack of awareness of the effect of ground
conditions, especially slopes;
•incorrect hitching and load distribution.
Preparation
•While mowing, always wear substantial footwear, long
trousers, hard hat, safety glasses, and ear protection.
Long hair, loose clothing or jewelry may get tangled in
moving parts. Do not operate the equipment when
barefoot or wearing open sandals.

4
•Thoroughly inspect the area where the equipment is to
be used and remove all objects which may be thrown by
the machine.
•Warning—fuel is highly flammable. Take the
following precautions:
– Store fuel in containers specifically designed for this
purpose.
– Refuel outdoors only and do not smoke while
refuelling.
– Add fuel before starting the engine. Never remove
the cap of the fuel tank or add fuel while the engine
is running or when the engine is hot.
– If fuel is spilled, do not attempt to start the engine
but move the machine away from the area of
spillage and avoid creating any source of ignition
until fuel vapors have dissipated.
– Replace all fuel tank and container caps securely.
•Replace faulty silencers/mufflers.
•Before using, always visually inspect to see that the
blades, blade bolts, and cutting assembly are not worn
or damaged. Replace worn or damaged blades and bolts
in sets to preserve balance.
•On multi-bladed machines, take care as rotating one
blade can cause other blades to rotate.
•Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments approved
by the manufacturer.
•Check that operator’s presence controls, safety
switches, and shields are attached and functioning
properly. Do not operate unless they are functioning
properly.
Operation
•Do not operate the engine in a confined space where
dangerous carbon monoxide fumes can collect.
•Mow only in daylight or in good artificial light.
•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. Use seat belts, if provided.
•Remember there is no such thing as a safe slope. Travel
on grass slopes requires particular care. To guard
against overturning:
– Do not stop or start suddenly when going up or
downhill.
– Engage the clutch slowly, always keep the machine
in gear, especially when travelling downhill.
– The machine speed should be kept low on slopes
and during tight turns.
– Stay alert for humps and hollows and other hidden
hazards.
– Never mow across the face of the slope, unless the
machine is designed for that purpose.
•Stay alert for holes in the terrain and other hidden
hazards.
•Watch out for traffic when crossing or near roadways.
•Stop the blades rotating before crossing surfaces other
than grass.
•When using any attachments, never direct discharge of
material toward bystanders nor allow anyone near the
machine while in operation.
•Never operate the machine with damaged guards,
shields, or without safety protective devices in place. Be
sure all interlocks are attached, adjusted properly, and
functioning properly.
•Do not change the engine governor settings or
overspeed the engine. Operating the engine at excessive
speed may increase the hazard of personal injury.
•Before leaving the operator’s position:
– Stop on level ground.
– Disengage the power take-off and lower the
attachments.
– Change into neutral and set the parking brake.
– Stop the engine and remove the key.
•Disengage drive to attachments, stop the engine, and
disconnect the spark plug wire(s) or remove the ignition
key:
– before clearing blockages;
– before checking, cleaning, or working on the
machine;
– after striking a foreign object. Inspect the machine
for damage and make repairs before restarting and
operating the equipment;
– if the machine starts to vibrate abnormally (check
immediately).
•Disengage drive to attachments when transporting or
not is use.
•Stop the engine and disengage drive to attachment:
– before refueling;
– before making height adjustment unless adjustment
can be made from the operator’s position.

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•Reduce the throttle setting during engine shut down
and, if the engine is provided with a fuel shut-off valve,
turn the valve off at the conclusion of mowing.
•Never raise deck with the blades running.
•Keep hands and feet away from the cutting units.
•Look behind and down before backing up to be sure of
a clear path.
•Slow down and use caution when making turns and
crossing roads and sidewalks.
•Do not operate the mower under the influence of
alcohol or drugs.
•Use care when loading or unloading the machine into a
trailer or truck.
•The operator shall turn on flashing warning lights, if
provided, whenever traveling on a public road, except
where such use is prohibited by law.
Maintenance and Storage
•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 enclosure
and do not store near flame.
•To reduce the fire hazard, keep the engine,
silencer/muffler, battery compartment, cutting units,
drives, and fuel storage area free of grass, leaves, or
excessive grease. Clean up oil or fuel spillage.
•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, move traction
pedal to Neutral, set parking brake, stop engine and
remove key. Wait for all movement to stop before
adjusting, cleaning or repairing.
•Shut off fuel while storing or transporting. Do not store
fuel near flames.
•Park machine on level ground. Never allow untrained
personnel to service machine.
•Use jack stands to support components when required.
•Carefully release pressure from components with stored
energy.
•Disconnect battery or remove spark plug wire before
making any repairs. Disconnect the negative terminal
first and the positive last. Reconnect positive first and
negative last.
•Use care when checking blades. Wrap the blades or
wear gloves, and use caution when servicing them.
Only replace blades. Never straighten or weld them.
•Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
•Charge batteries in an open well ventilated area, away
from spark and flames. Unplug charger before
connecting or disconnecting from battery. Wear
protective clothing and use insulated tools.
Toro Mower Safety
The following list contains safety information specific to
Toro products or other safety information that you must
know that is not included in the CEN, ISO, or ANSI
standards.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
Use of this product for purposes other than its intended use
could prove dangerous to user and bystanders.
Engine exhaust contains carbon monoxide, which
is an odorless, deadly poison that can kill you.
Do not run engine indoors or in an enclosed area.
Warning
Preparation
•Be sure to establish your own special procedures and
work rules for unusual operating conditions (E.G.
slopes too steep for operation). Survey the complete
mowing site to determine which hills can be safely
operated on. When performing this site survey, always
use common sense and take into consideration the turf
condition and the rollover risk. To determine which hills
or slopes may be safely operated on, use the
inclinometer provided with each machine. To perform a
site survey, follow the procedure outlined in the
Operation section of the this manual. The maximum
side hill angle should not be greater than 25 degrees.

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Training
•The operator must be skilled and trained in how to drive
on hillsides. Failure to use caution on slopes or hills
may cause the vehicle to tip or roll, possibly resulting in
personal injury or death.
Operation
•Know how to stop the machine and engine quickly.
•Do not operate the machine while wearing tennis shoes
or sneakers.
•Wearing safety shoes and long pants is advisable and
required by some local ordinances and insurance
regulations.
•Keep hands, feet, and clothing away from moving parts
and the mower discharge area.
•Fill fuel tank until level is 1 in. (25 mm) below the
bottom of the filler neck. Do not overfill.
•Check the safety interlock switches daily for proper
operation. If a switch should fail, replace the switch
before operating the machine. After every two years,
replace all interlock switches in the safety system,
regardless if they are working properly or not.
•When starting the engine, engage the parking brake, put
the traction pedal in neutral, and disengage the blade
drive. After the engine starts, release the parking brake
and keep your foot off of the traction pedal. The
machine must not move. If movement is evident, refer
to the Maintenance section of this manual to adjust the
traction drive.
•Use extreme caution when operating close to sand traps,
ditches, creeks, steep hillsides, or other hazards.
•Reduce speed when making sharp turns.
•Do not turn on hills.
•Do not operate on a side hill that is too steep. A rollover
may occur before losing traction.
•The slope angle at which the machine will tip is
dependent on many factors. Among these are mowing
conditions such as wet or undulating turn, speed
(especially in turns), position of the cutting units (with
the Sidewinder), tire pressure, and operator experience.
At side hill angles of 20 degrees or less, the risk of a
rollover is low. As the slope angle increases to a
recommended maximum limit of 25 degrees, the risk of
a rollover increases to a moderate level. Do not exceed
a 25 degree side hill slope angle because the risk of a
rollover and serious injury or death is very high. The
machine is equipped with an angle indicator mounted
on the steering tube. This indicates the side hill angle
the machine is on and identifies the recommended
maximum limit of 25 degrees.
•For steering control, the cutting units must be lowered
when going down slopes.
•Avoid sudden stops and starts.
•Use the reverse pedal for braking.
•Watch for traffic when near or crossing roads. Always
yield the right-of-way.
•Raise the cutting units when driving from one work
area to another.
•Do not touch the engine, muffler, exhaust pipe, or
hydraulic tank while the engine is running or soon after
it has stopped because these areas could be hot enough
to cause burns.
Maintenance and Storage
•Before servicing or making adjustments, stop the engine
and remove the ignition key.
•Ensure that the entire machine is properly maintained
and in good operating condition. Frequently check all
nuts, bolts, screws, and hydraulic fittings.
•Make sure all hydraulic line connectors are tight and all
hydraulic hoses and lines are in good condition before
applying pressure to the system.
•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.
•Before disconnecting or performing any work on the
hydraulic system, all pressure in the system must be
relieved by stopping the engine and lowering the cutting
units to the ground.
•If the engine must be running to perform a maintenance
adjustment, keep hands, feet, clothing, and any parts of
the body away from the cutting units, attachments, and
any moving parts. Keep everyone away.
•Do not overspeed the engine by changing governor
settings. To ensure safety and accuracy, have an
Authorized Toro Distributor check the maximum engine
speed with a tachometer.
•The engine must be shut off before checking the oil or
adding oil to the crankcase.
•If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.
•To make sure of optimum performance and continued
safety certification of the machine, use only genuine
Toro replacement parts and accessories. Replacement

7
parts and accessories made by other manufacturers
could be dangerous, and such use could void the
product warranty.
Sound Power Level
This unit has a guaranteed sound power level of 105 dBA,
based on measurements of identical machines per Directive
2000/14/EC and amendments.
Sound Pressure Level
This unit has an equivalent continuous A-weighted sound
pressure level at the operator ear of 89 dBA based on
measurements of identical machines per Directive
98/37/EC and amendments
Vibration Level
This unit does not exceed a vibration level of 2.5 m/s2at
the hands based on measurements of identical machines per
ISO 5349 procedures.
This unit does not exceed a vibration level of 0.5 m/s2at
the posterior based on measurements of identical machines
per ISO 2631 procedures.
Safety and Instruction 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 lost.
94-3353
1. Crushing hazard of fingers and hands—keep hands away.
99-3558 (for CE)
1. Warning—read the operator’s manual.
2. To start the engine, sit on the seat and rotate the ignition key to
On/Preheat until the glow plug indicator light goes out. Rotate
the key to start and disengage the parking brake. Read the
operator’s manual for further instructions.
3. To stop the engine, disengage the cutting units, rotate the
ignition key to Off, and remove the key. Engage the parking
brake. Read the operator’s manual for further instructions.
100-4837
93-7276
1. Explosion hazard—wear
eye protection.
2. Caustic liquid
hazard—flush with water
and get medical help fast.
3. Fire hazard—fire, open
light, and smoking
prohibited.
4. Toxic hazard—keep
children away from the
battery.

8
93-7818
1. Warning—read the operator’s manual for blade torque
instructions.
107-7801 (for CE)
1. Tipping hazard—do not drive on slopes greater than 15
degrees.
104-0484
43-8480
93-6681
1. Cutting/dismemberment hazard—stay away from moving parts.
99-3444
1. Reel speed—fast 2. Reel speed—slow
104-1086
1. Height of cut

9
104-5181 (for CE)
1. Warning—read the Operator’s Manual.
2. Tipping hazard—do not drive on slopes greater than 15
degrees and, if the roll bar is installed, wear the seat belt.
3. Thrown object hazard—keep bystanders a safe distance from
the machine.
4. Cutting hazard of hand or foot—stay away from moving parts.
5. Warning—lock the parking brake, stop the engine, and remove
the ignition key before leaving the machine.
Battery Symbols
Some or all of these symbols are on your battery.
1. Explosion hazard
2. No fire, open flames, or
smoking.
3. Caustic liquid/chemical
burn hazard
4. Wear eye protection
5. Read the Operator’s
Manual.
6. Keep bystanders a safe
distance from the battery.
7. Wear eye protection;
explosive gases can
cause blindness and
other injuries
8. Battery acid can cause
blindness or severe
burns.
9. Flush eyes immediately
with water and get
medical help fast.
10. Contains lead; do not
discard.
106-6753 (for CE)
1. Thrown object
hazard—keep bystanders
a safe distance from the
machine.
2. Cutting/dismemberment
hazard of hand or foot,
mower blade—stay away
from moving parts.
106-6754
1. Warning—do not touch the hot surface.
2. Cutting/dismemberment hazard, fan and entanglement hazard,
belt—stay away from moving parts

10
104–5191
1. Engage the power take off
(PTO).
2. Disengage the power take
off (PTO).
3. Lower the cutting units.
4. Move the cutting units to the
right.
5. Raise the cutting units.
6. Move the cutting units to the
left.
7. Move rear ward to lock the
lift lever.
8. Engine—stop
9. Engine—run
10. Engine=start
11. Fast
12. Continuous variable setting
13. Slow
107-7800

11
Specifications
General Specifications
Engine
Kubota three-cylinder, 4-cycle liquid-cooled diesel engine. 32 hp @ 2800 RPM,
governed to 3050 RPM. 68.5 cu. in. (1124 cc) displacement. Heavy-duty, 2-stage,
remote mounted air cleaner. High water temperature shutdown switch.
Cooling system Radiator capacity is approximately 6 qt. of 50/50 mixture of ethylene glycol
anti-freeze. Remote mounted 1 qt. expansion tank.
Electrical
12 volt Group 55, 585 cold cranking amps at 0°F (–18°C), 95 minute reserve
capacity at 80°F (27°C). 40 amp alternator with regulator/rectifier. Seat switch,
PTO, parking brake and traction interlock switches.
Fuel capacity 11 gallons
Traction drive High torque hydraulic wheel motors, 3-wheel drive, oil cooler and shuttle valve
provide positive closed-loop cooling.
Hydraulic oil capacity/filter Remote mounted, 3.5 gallon oil reservoir. 10 micron remote mounted spin on filter.
Ground speed
Infinitely variable speed selection in forward and reverse
Mowing speed: 0–6 MPH (adjustable)
Transport speed: 0–9 MPH
Reverse speed: 0–3.5 MPH
Tires/wheels Front tires are 20 x 12-10 and rear tires are 20 x 10-10 tubeless, 4-ply rating with
demountable rims. Recommended tire pressure: 14–18 psi front and rear tires.
Frame Tricycle vehicle with 3-wheel traction drive and rear wheel steering. Frame consists
of formed steel, welded steel, and steel tubing components.
Steering Power steering
Brakes
Service braking accomplished through dynamic characteristics of Hydrostat.
Parking or emergency brake is actuated by over-center hand lever on the
operator’s right-hand side.
Controls
Foot operated forward and reverse traction pedals and mow/transport slide. Hand
operated throttle, ignition switch, blade engagement switch, cutting unit lift, and shift
lever, parking brake, and seat adjustment.
Gauges and protective
systems
Hour meter, 4 light warning cluster gauge: oil pressure, water temperature, amps,
glow plug, and side hill angle indicator.
Seat Standard
Cutting unit lift Hydraulic lift
Note: Specifications and design subject to change without notice.

12
Setup
Note: Determine the left and right sides of the machine from the normal operating position.
Loose Parts
Note: Use this chart as a checklist to ensure that all parts necessary for assembly have been received. Without these parts,
total setup cannot be completed. Some parts may have already been assembled at the factory.
Description Qty. Use
Hood lock bracket
Screw, 1/4 x 1-1/2 in.
Flat washer, 1/4 in.
Locknut, 1/4 in.
1
1
1
1
Mount to the hood for European compliance.
Exhaust guard
Self-tapping screw
1
4Mount to machine for European compliance.
Inclinometer 1 For site survey before operating the machine
EEC Decal 6Affix to machine for European compliance.
Key
EEC certificate
Parts Catalog
2
1
1
Operator’s Manual
Engine manual
2
1Read before operating the machine.
Operator video 1View before operating the machine.
Pre-delivery check list 1Fill out before delivering to the customer.

13
Activating, Charging, and
Connecting 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.
Warning
Note: If the battery is not filled with electrolyte or
activated, bulk electrolyte with 1.260 specific gravity must
be purchased from a local battery supply outlet and added
to the battery.
Danger
Battery electrolyte contains sulfuric acid which is a
deadly poison and causes severe burns.
•Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to
shield your eyes and rubber gloves to protect
your hands.
•Fill the battery where clean water is always
available for flushing the skin.
1. Open the hood.
2. Remove the battery cover (Fig. 1).
1
Figure 1
1. Battery cover
3. Remove the filler caps from the battery and slowly fill
each cell until electrolyte is just above the plates.
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.
Charging the battery produces gasses that can
explode.
Never smoke near the battery and keep sparks and
flames away from battery.
Warning
5. When the battery is charged, disconnect the charger
from the electrical outlet and battery posts.
6. Remove the filler caps. Slowly add electrolyte to each
cell until the level is up to the fill ring. Install the filler
caps.
Important Do not overfill the battery. Electrolyte will
overflow onto other parts of the machine and severe
corrosion and deterioration will result.
7. Install the positive cable (red) to the positive (+)
terminal and the negative cable (black) to the negative
(–) terminal of the battery and secure them with
capscrews and nuts (Fig. 2). Make sure that the positive
(+) terminal is all of the way onto the post and the cable
is positioned snug to the battery. The cable must not
contact the battery cover. Slide the rubber boot over the
positive terminal to prevent a possible short from
occurring.
Incorrect battery cable routing could damage the
tractor and cables causing sparks. Sparks can
cause the battery gasses to explode, resulting in
personal injury.
•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.
Warning
1
2
Figure 2
1. Positive (+) battery cable 2. Negative (–) battery cable

14
Important If the battery is ever removed, make sure
that battery clamp bolts are reinstalled 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.
8. Coat both battery connections with Grafo 112X (skin
over) grease, Toro Part No. 505-47, petroleum jelly, or
light grease to prevent corrosion. Slide the rubber boot
over the positive terminal.
9. Install the battery cover.
Checking the Angle Indicator
Danger
To reduce risk of injury or death due to rollover,
do not operate the machine on side hills steeper
than 255.
1. Park the machine on a flat, level surface.
2. Verify that the machine is level by placing a hand held
inclinometer (supplied with the machine) on the frame
cross rail, by the fuel tank (Fig. 3). The inclinometer
should read zero degrees when viewed from the
operator’s position.
1
Figure 3
1. Angle indicator
3. If the inclinometer does not read zero degrees, move the
machine to a location where a zero degree reading is
obtained. The angle indicator, mounted on the machine,
should now read zero degrees as well.
4. If the angle indicator does not read zero degrees, loosen
the two screws and nuts securing the angle indicator to
the mounting bracket, adjust the indicator to obtain a
zero degree reading, and tighten the capscrews.
Installing the Hood Latch (CE)
1. Unhook the hood latch from the hood latch bracket
(Fig. 4).
2. Slide the hood lock bracket onto the latch (Fig. 4).
3. Hook the latch onto the hood latch bracket (Fig. 4).
4. Insert a bolt (1/4 x 1-1/2 in.) through the hood lock
bracket and secure it with a flat washer and locknut
(Fig. 4).
1
2
3
Figure 4
1. Hood latch
2. Hood latch bracket
3. Hood lock bracket
Installing the Exhaust Guard
(CE)
1. Position the exhaust guard around the muffler while
aligning the mounting holes with the holes in the frame
(Fig. 5).
2. Secure the exhaust guard to the frame with 4
self-tapping screws (Fig. 5).
1
Figure 5
1. Exhaust guard

15
Adjusting the Lift Arms
1. Start the engine, raise the decks, and check to make sure
that the clearance between each lift arm and the floor
plate bracket is .18–.32 in. (5–8 mm) (Fig. 6). If the
clearance is not in this range, back off the stop bolts
(Fig. 7) and adjust the cylinder to attain clearance. To
adjust the cylinder, back off the jam nut on the cylinder
(Fig. 8), remove the pin from the rod end, and rotate the
clevis. Install the pin and check the clearance. Repeat
the procedure if required. Tighten the clevis jam nut.
1
2
3
Figure 6
Decks removed for clarity
1. Lift arm
2. Floor plate bracket
3. Clearance
2. Check to make sure that the clearance between each lift
arm and stop bolt is 0.005–0.040 in. (0.13–1.02 mm)
(Fig. 7). If the clearance is not in this range, adjust the
stop bolts to attain clearance.
1
2
3
Figure 7
1. Stop bolt
2. Lift arm
3. Clearance
1
2
Figure 8
1. Front cylinder 2. Jam nut
3. Start the engine, raise the decks, and check to make sure
that the clearance between the wear strap on the top of
the rear cutting unit wear bar and the bumper strap is
0.02–0.10 in. (0.51–2.54 mm) (Fig. 9). If the clearance
is not in this range, adjust the rear cylinder to attain
clearance. To adjust the cylinder, lower the cutting units
and back off the jam nut on the cylinder (Fig. 10).
Grasp the cylinder rod close to the nut with a pliers and
rag and rotate the rod. Raise the cutting units and check
the clearance. Repeat the procedure if required. Tighten
the clevis jam nut.
Note: If the rear lift arm “clunks” during transport,
clearance can be reduced.
1
2
Figure 9
1. Wear bar 2. Bumper strap
12
Figure 10
1. Rear cylinder 2. Adjusting nut
Important Lack of clearance at the front stops or rear
wear bar could damage the lift arms.

16
Rear Ballast
The Groundsmaster 3500 Traction unit with 27” Rotary
Cutting decks conforms to the B71.4-1999 standard when
50 lb. of calcium chloride ballast is added to the rear
wheels.
Important If a puncture occurs in a tire with calcium
chloride, remove the machine from the turf as quickly as
possible. To prevent possible damage to the turf,
immediately soak the affected area with water.
Before Operating
If you leave the key in the ignition switch, someone
could accidently start the engine and seriously
injure you or other bystanders.
Remove the key from the ignition before you do
any maintenance.
Caution
Checking the Crankcase Oil
The engine is shipped with oil in the crankcase; however,
the oil level must be checked before and after the engine is
first started.
Crankcase capacity is approximately 4 qt. (2.8 l) with the
filter.
Use high-quality engine oil that meets the following
specifications:
API Classification Level Required: CH–4, CI–4 or
higher.
Preferred oil: SAE 15W–40 (above 0_F)
Alternate oil: SAE 10W–30 or 5W–30
(all temperatures)
Toro Premium Engine oil is available from your distributor
in either 15W–40 or 10W–30 viscosity. See the parts
catalog for part numbers.
1. Position the machine on a level surface.
2. Remove the dipstick (Fig. 11) and wipe it with a clean
rag. 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. If the oil level is low, add
enough oil to raise the level to the FULL mark on the
dipstick.
1
Figure 11
1. Dipstick
3. If the oil level is low, remove the oil fill cap (Fig. 12)
and gradually add small quantities of oil, checking the
level frequently, until the level reaches the FULL mark
on the dipstick.
1
Figure 12
1. Oil fill cap
4. Install the oil fill cap and close the hood.
Important Check the oil level every 5 operating hours
or daily. Change the oil and filter initially after the first 50
hours of operation; thereafter change the oil and filter every
150 hours.
Filling the Fuel Tank
The engine runs on No. 2 diesel fuel.
Fuel tank capacity is approximately 11 gallons.
1. Clean the area around the fuel tank cap (Fig. 13).
2. Remove the fuel tank cap.
3. Fill the tank to the bottom of the filler neck. Do not
overfill. Install the cap.

17
4. To prevent a fire hazard, wipe up any fuel that may
have spilled.
1
Figure 13
1. Fuel tank cap
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.
•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. Add fuel
to the fuel tank until the level is 1/4 to 1/2 in. (6
to 13 mm) below the bottom of the filler neck.
This empty space in the tank allows the fuel to
expand.
•Never smoke when handling fuel, and stay away
from an open flame or where fuel fumes may be
ignited by a spark.
•Store fuel in a clean, safety-approved container
and keep the cap in place.
Checking the Cooling System
Clean debris off of the radiator and oil cooler daily
(Fig. 14). Clean the radiator hourly if conditions are
extremely dusty and dirty; refer to Cleaning the Engine
Cooling System, page 36.
1
2
3
Figure 14
1. Access panel
2. Radiator
3. Oil cooler
The cooling system is filled with a 50/50 solution of water
and permanent ethylene glycol anti-freeze. Check the
coolant level at the beginning of each day before starting
the engine.
The capacity of the cooling system is approximately 6 U.S.
quarts (5.7 l).
If the engine has been running, the pressurized,
hot coolant can escape and cause burns.
•Do not open the radiator cap when the engine is
running.
•Use a rag when opening the radiator cap, and
open the cap slowly to allow steam to escape.
Caution
1. Check the coolant level in the expansion tank (Fig. 15).
With a cold engine, the coolant level should be
approximately midway between the marks on the side
of the tank.
2. If the coolant level is low, remove the expansion tank
cap and replenish the system. Do not overfill.
3. Install the expansion tank cap.

18
1
Figure 15
1. Expansion tank
Checking the Hydraulic System
The machines reservoir is filled at the factory with
approximately 3.5 U.S. gallons (13.2 l) 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 5 gallon pails or 55 gallon drums. See
parts catalog or Toro distributor for part numbers.)
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. We do not
recommend the use of synthetic fluid. Consult with your
lubricant distributor to identify a satisfactory product Note:
Toro will not assume responsibility for damage caused by
improper substitutions, so use only products from reputable
manufacturers who will stand behind their
recommendation.
High Viscosity Index/Low Pour Point Antiwear
Hydraulic Fluid, ISO VG 46
Material Properties:
Viscosity, ASTM D445 cSt @ 40_C 44 to 48
cSt @ 100_C 7.9 to 8.5
Viscosity Index ASTM D2270 140 to 160
Pour Point, ASTM D97 –34_F to –49_F
Industry Specifications:
Vickers I–286–S (Quality Level), Vickers M–2950–S
(Quality Level), Denison HF–0
Note: Many hydraulic fluids are almost colorless, making it
difficult to spot leaks. A red dye additive for the hydraulic
system oil is available in 2/3 oz. (20 ml) bottles. One bottle
is sufficient for 4–6 gal (15–22 1) of hydraulic oil. Order
part no.44–2500 from your authorized Toro distributor.
Biodegradable Hydraulic Fluid – Mobil 224H
Toro Biodegradable Hydraulic Fluid
(Available in 5 gallon pails or 55 gallon drums. See
parts catalog or Toro distributor for part numbers.)
Alternate fluid: Mobil EAL 224H
This is vegetable–oil based biodegradable oil tested and
approved by Toro for this model. This fluid is not as
resistant to to high temperatures as standard fluid, so install
an oil cooler if required by the operator manual and follow
recommended fluid change intervals with this fluid.
Contamination by mineral–based hydraulic fluids will
change the biodegradability and toxicity of this oil. When
changing from standard fluid to the biodegradable type, be
certain to follow the approved flushing procedure. Contact
your local Toro Distributor for details.
1. Position the machine on a level surface, lower the
cutting units, and stop the engine.
2. Clean the area around the filler neck and cap of the
hydraulic tank (Fig. 16). Remove the cap.
1
Figure 16
1. Hydraulic tank cap
3. Remove the dipstick from the filler neck and wipe it
with a clean rag. Insert the dipstick into the filler neck;
then remove it and check the fluid level. The fluid level
should be within 1/4 inch (6 mm) of the mark on the
dipstick.
4. If the level is low, add the appropriate fluid to raise the
level to the full mark.
5. Install the dipstick and cap onto the filler neck.
Checking the Tire Pressure
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 14–18 psi (97–124 kPa).
Important Maintain the recommended pressure in all
tires to ensure a good quality of cut and proper machine
performance.

19
Danger
Low tire pressure decreases machine side hill
stability. This could cause a rollover, which may
result in personal injury or death.
Do not under-inflate the tires.
Checking the Torque of the
Wheel Nuts
Failure to maintain proper torque of the wheel
nuts could result in personal injury.
Torque the wheel nuts to 45–65 ft.-lb. (61–88 NVm)
after 1–4 hours of operation and again after 10
hours of operation. Torque every 200 hours
thereafter.
Warning

20
Operation
Note: Determine the left and right sides of the machine
from the normal operating position.
This machine produces sound levels in excess of
85 dBA at the operators ear and can cause hearing
loss through extended periods of exposure.
Wear hearing protection when operating this
machine.
Caution
Controls
Traction Pedals
Depress the traction forward pedal (Fig. 17) to move
forward. Depress traction reverse pedal (Fig. 17) to move
backward or to assist in stopping when moving forward.
Also, allow the pedal to move or move it to the neutral
position to stop the machine.
Mow/Transport Slide
Using your heel, move the mow/transport slide (Fig. 17) to
the left to transport and to the right to mow. The cutting
units will only operate in the mow position.
Note: Mow speed is set at the factory to 6 MPH (9.7 km/h).
It can be increased or decreased by adjusting the speed stop
screw (Fig. 18).
1
2
3
4
5
6
Figure 17
1. Forward traction pedal
2. Reverse traction pedal
3. Mow/transport slide
4. Tilt steering lever
5. Indicator slot
6. Angle indicator
1
Figure 18
1. Speed stop screw
Tilt Steering Lever
Pull the tilt steering lever (Fig. 17) back to tilt the steering
wheel to the desired position. Then push the lever forward
to tighten.
Indicator Slot
The slot in the operator platform (Fig. 17) indicates when
the cutting units are in the center position.
Angle Indicator
The angle indicator (Fig. 17) indicates the side hill angle of
the machine in degrees.
Ignition Switch
The ignition switch (Fig. 19), used to start, stop and preheat
the engine, has three positions: Off, On/Preheat, and Start.
Rotate the key to the On/Preheat position until the glow
plug indicator light goes out (approximately 7 seconds);
then rotate the key to the Start position to engage the starter
motor. Release the key when the engine starts. The key will
move automatically to the On/Run position. To shut the
engine off, rotate the key to the Off position. Remove the
key from the switch to prevent accidental starting.
Throttle
Moving the throttle (Fig. 19) forward increases the engine
speed; rearward decreases the engine speed.
Cutting Unit Drive Switch
The cutting unit drive switch (Fig. 19) has two positions:
Engage and Disengage. The rocker switch operates a
solenoid valve on the valve bank to drive the cutting units.