Groundsmaster® 3500-D/3505-D Rotary Mower

The front and rear cutting decks require different mounting positions. The front cutting deck has 2 mounting positions depending on what height of cut and degree of deck rotation you desire.

1. For heights of cut in the 2 to 7.6 cm (3/4 to 3 inches) range, mount the front carrier frames in the lower, front mounting holes (Figure 16).

   Note: This permits more up travel of the cutting decks relative to the machine when approaching sudden changes in uphill terrain. It does, however, limit the clearance of the chamber to the carrier when cresting sharp, small hills.

   

   Figure 16

   1. Upper, front deck mounting hole
   2. Lower, front deck mounting hole
   3. Rear deck mounting hole

2. For heights of cut in the 6.3 to 10 cm (2-1/2 to 4 inches) range, mount the front carrier frames in the upper, front mounting holes (Figure 16).

   Note: This increases the chamber to carrier clearance due to the higher position of the cutting chamber, but causes the cutting deck to reach its maximum up travel more quickly.

The front and rear cutting decks require different mounting positions. The rear cutting deck has 1 mounting position for proper alignment with the sidewinder under frame.

For all heights of cut, mount the rear cutting deck in the rear mounting holes (Figure 16).

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine-Oil Level.

Before you start the engine and use the machine, check the cooling system; refer to Checking the Cooling System.

Before you start the engine and use the machine, check the hydraulic system; refer to Checking the Hydraulic System.

Use only clean, fresh diesel fuel or biodiesel fuels with low (<500 ppm) or ultra low (<15 ppm) sulfur content. The minimum cetane rating should be 40. Purchase fuel in quantities that can be used within 180 days to ensure fuel freshness.

The fuel tank capacity is approximately 42 L (11 US gallons).

Use summer grade diesel fuel (No. 2-D) at temperatures above -7° C (20° F) and winter grade (No. 1-D or No. 1-D/2-D blend) below that temperature.

Using winter grade fuel at lower temperatures provides lower flash point and cold flow characteristics which will ease starting and reduce fuel filter plugging.

Using summer-grade fuel above -7° C (20° F) contributes toward longer fuel pump life and increased power compared to winter-grade fuel.

Biodiesel Ready

This machine can also use a biodiesel blended fuel of up to B20 (20% biodiesel, 80% petrodiesel). The petrodiesel portion should be low or ultra low sulfur. Observe the following precautions:

• The biodiesel portion of the fuel must meet specification ASTM D6751 or EN14214.

• The blended fuel composition should meet ASTM D975 or EN590.

• Biodiesel blends may damage painted surfaces.

• Use B5 (biodiesel content of 5%) or lesser blends in cold weather

• Monitor seals, hoses, gaskets in contact with fuel as they may degrade over time.

• Fuel filter plugging may occur for a time after converting to biodiesel blends.

• Contact your distributor for more information about biodiesel fuel.

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 fuel that may have spilled.

   

   Figure 25

   1. Fuel-tank cap

The correct air pressure in the tires is 97 to 124 kPa (14 to 18 psi) as shown in Figure 26.

Important: Maintain pressure in all tires to ensure a good quality of cut and proper machine performance.Check the air pressure in all the tires before operating the machine.

Figure 26

Torque the wheel-lug nuts to 61 to 88 N∙m (45 to 65 ft-lb).

1. Drive the machine slowly to a large, open area..

2. Lower the cutting unit(s), shut off the engine, and engage the parking brake.

3. While sitting on the seat, the engine must not start with either the cutting-unit switch engaged or the traction pedal engaged.

   Note: Correct the problem if it is not operating properly.

4. While sitting on the seat, put the traction pedal in NEUTRAL, the parking brake OFF, and the cutting unit switch in the OFF position.

   Note: The engine should start. Rise from the seat and slowly press the traction pedal, and the engine should shut off in 1 to 3 seconds. If it does not shut off, there is a malfunction in the interlock system that you should correct before resuming operation.

Note: The machine is equipped with an interlock switch on the parking brake. The engine shuts off when you press the traction pedal with the parking brake engaged.

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.

The module is divided into inputs and outputs. Inputs and outputs are identified by green LED indicators mounted on the printed circuit board.

The start-circuit input is energized by 12 VDC. All other inputs are energized when the circuit is closed to ground. Each input has an LED that illuminates when the specific circuit is energized. Use the input LEDs for switch and input-circuit troubleshooting.

Output circuits are energized by an appropriate set of input conditions. The 3 outputs include PTO, ETR, and START. Output LEDs monitor the relay condition, indicating the presence of voltage at 1 of 3 specific output terminals.

Output circuits do not determine output-device integrity, so electrical troubleshooting includes output-LED inspection, conventional device, and wire-harness-integrity testing. Measure the disconnected-component impedance, impedance through the wire harness (disconnect at SCM), or by temporarily ”test energizing” the specific component.

The SCM does not connect to an external computer or handheld device, cannot be programmed again, and does not record intermittent fault troubleshooting data.

The decal on the SCM includes only symbols. The 3 LED output symbols are shown in the output box, while all other LEDs are inputs as shown in Figure 27.

Figure 27

1. Backlap (input)
2. High temperature (input)
3. In seat (input)
4. PTO switch (input)
5. Parking brake—off (input)
6. Neutral position (input)
7. PTO (output)
8. Start (output)
9. ETR (output)
10. Start (input)
11. Power (input)

Here are the logical troubleshooting steps for the SCM device.

1. Determine the output fault that you are trying to resolve (PTO, START, or ETR).

2. Move key switch to the ON position and ensure that the red, power LED illuminates.

3. Move all of the input switches to ensure that all LEDs change state.

4. Position the input devices at the appropriate position to achieve the appropriate output.

   Note: Use the following logic chart to determine the appropriate input condition.

5. Review the following repair options if a specific output LED illuminates.

   • If a specific output LED illuminates without the appropriate output function, check the output harness, connections, and component.

     Note: Repair as required.

   • If a specific output LED does not illuminate, check both fuses.

   • If a specific output LED does not illuminate and the inputs are in the appropriate condition, install a new SCM and determine if the fault disappears.

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.

• (–) Indicates a circuit closed to ground—LED On

• (O) Indicates a circuit open to ground or de-energized—LED Off

• (+) Indicates an energized circuit (clutch coil, solenoid, or start input)—LED On

• A blank indicates a circuit that is not involved with the logic chart.

To troubleshoot, turn on the key without starting the engine. Identify the specific function that does not work and work across the logic chart. Inspect the condition of each input LED to ensure that it matches the logic chart.

If the input LEDs are correct, check the output LED. If the output LED illuminates but the device is not energized, measure the available voltage at the output device, the continuity of the disconnected device, and the potential voltage on the ground circuit (floating ground).

Important: In an emergency, you can tow the machine for a short distance. Do not tow the machine at faster than 3 to 4 km/h (2 to 3 mph); otherwise, you may damage the drive system. If you must move the machine a considerable distance, transport it on a truck or trailer.

1. Locate the bypass valve on the pump and rotate it 90° (Figure 28).

   

   Figure 28

   1. Bypass valve

2. Before starting the engine, close the bypass valve by rotating it 90° (1/4 turn).

   Important: Do not start the engine when the valve is open, as this may cause damage.

1. Ensure that the PTO is disengaged.

2. Park the machine on a level surface.

3. Set the parking brake.

4. Lower the cutting unit(s) if necessary.

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. Allow machine components to cool before performing maintenance.

1. Unlatch and raise the hood.

2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 30).

   

   Figure 30

   1. Hairpin cotter

3. Slide the hood to the right side, lift the other side, and pull it out of the brackets.

Note: Reverse this procedure to install the hood.

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. Set the parking brake and turn off the machine.

4. Release the latch rod from the front carrier-frame retainer (Figure 31).

   

   Figure 31

   1. Service-latch hook

5. Lift the outside of the front cutting decks and place the latch over the frame pin mounted on the front of the operator's platform (Figure 31).

6. Sit on the operator’s seat and start the machine.

7. Lower the cutting decks to the mow position.

8. Turn off the machine and remove the key.

9. Reverse this procedure to unlatch the cutting decks.

The machine has grease fittings that you must lubricate regularly with No. 2 lithium grease. Also, lubricate the machine immediately after every washing.

The grease fitting locations and quantities are as follows:

• Rear cutting-unit pivot (Figure 32)

  

  Figure 32

• Front cutting-unit pivot (Figure 33)

  

  Figure 33

• 2 sidewinder-cylinder ends (Figure 34)

  

  Figure 34

• Steering pivot (Figure 35)

  

  Figure 35

• 2 rear lift-arm pivots and lift cylinder (Figure 36)

  

  Figure 36

• 2 left, front lift-arm pivots and lift cylinder (Figure 37)

  

  Figure 37

• 2 right, front lift-arm pivots and lift cylinder (Figure 38)

  

  Figure 38

• Neutral-adjustment mechanism (Figure 39)

  

  Figure 39

• Mow/transport slide (Figure 40)

  

  Figure 40

• Belt-tension pivot (Figure 41)

  

  Figure 41

• Steering cylinder (Figure 42).

  

  Figure 42

  Note: If desired, an additional grease fitting may be installed at the other end of the steering cylinder. Remove the tire, install the fitting, grease the fitting, remove the fitting, and install the plug (Figure 43).

  

  Figure 43

• 2 (per cutting unit) cutting unit spindle-shaft bearings (Figure 44)

  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 deck).

  

  Figure 44

• 2 (per cutting unit) rear roller bearings (Figure 45)

  

  Figure 45

  Note: Ensure that the grease groove in each roller mount aligns with the grease hole in each end of the roller shaft. To help align the groove and hole, there is also an alignment mark on an end of the roller shaft.

  Important: Do not lubricate the Sidewinder cross tube. The bearing blocks are self-lubricated.

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. Also, inspect the rubber intake-hose connections at the air cleaner and turbocharger to ensure that the connections are complete.

Ensure that the cover is seated correctly and seals with the air-cleaner body.

Servicing the Air-Cleaner Cover

Maintenance Service Interval	Maintenance Procedure
Every 50 hours	Remove the air-cleaner cover and clean out the debris. Do not remove the filter.

Check the air-cleaner body for damage which could cause an air leak. Replace a damaged air cleaner body.

Clean the air-cleaner cover (Figure 49).

Figure 49

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.

1. Perform the pre-maintenance procedure; refer to Preparing the Machine for Maintenance

2. Ensure that the fuel tank is at least half full.

3. Unlatch and raise the hood.

   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.

   Never smoke when handling fuel, and stay away from an open flame or where fuel fumes may be ignited by a spark.

4. Open the air-bleed screw on the fuel-injection pump (Figure 53).

   

   Figure 53

   1. Air-bleed screw on the fuel-injection pump

5. Turn the key in the ignition switch to the ON position.

   Note: The electric fuel pump will operate, 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. Tighten the screw and turn the key to the OFF position.

Note: Normally, the engine should start after performing this procedure. However, if the engine does not start, there may be air trapped between the injection pump and injectors; refer to Bleeding Air from the Injectors.

Note: Use this procedure only if the fuel system has been purged of air through normal priming procedures and the engine does not start; refer to Bleeding the Fuel System.

1. Loosen the pipe connection to the No. 1 nozzle and holder assembly (Figure 54).

   

   Figure 54

   1. Fuel injectors

2. Move the throttle to the FAST position.

3. Turn the key in the key switch to the START position and watch the fuel flow around the connector.

   Note: Turn the key to the OFF position when solid flow is observed.

4. Tighten the pipe connector securely.

5. Repeat this procedure on the remaining nozzles.

Maintain the battery-electrolyte level properly and keep the top of the battery. If you store the machine in a hot location, the battery will discharge more rapidly than if you store the machine in a cool location.

Maintain the cell level with distilled or demineralized water. Do not fill the cells above the bottom of the split ring inside each cell. Install the filler caps with the vents pointing to the rear (toward the fuel tank).

Keep the top of the battery clean by washing it periodically with a brush dipped in ammonia or a solution of bicarbonate of soda. Flush the top surface with water after cleaning. Do not remove the filler caps while cleaning the battery.

The battery cables must be tight on the terminals to provide good electrical contact.

If the terminals have corrosion, disconnect the cables (the negative (–) cable first) and scrape the clamps and terminals separately. Connect the cables (positive (+) cable first) and coat the terminals with petroleum jelly.

The fuses in machines electrical system are located under console cover.

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. Chock or block the front and rear wheels on one side.

3. Raise the opposite front and rear wheel off the floor and place support blocks under the frame.

   Warning

   If the machine is not supported adequately, it may accidentally fall, injuring anyone under the machine.

   A front wheel and a rear wheel must be raised off the ground; otherwise, the machine will move during adjustment.

4. Loosen the locknut on the traction adjustment cam (Figure 55).

   

   Figure 55

   1. Traction adjustment cam
   2. Locknut

   Warning

   The engine must be running so that you can make a final adjustment of the traction adjustment cam. Contact with hot or moving parts can result in personal injury.

   Keep your hands, feet, face, and other body parts away from the muffler, other hot parts of the engine, and rotating parts.

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.

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.

Clean debris off the radiator and oil cooler daily (Figure 56).

Figure 56

1. Oil cooler
2. Access panel
3. Radiator

Clean the radiator hourly if conditions are extremely dusty and dirty; refer to Cleaning the Cooling System.

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 5.7 L (6 US qt).

1. Check the coolant level in the expansion tank (Figure 57).

   Note: With a cold engine, the coolant level should be approximately midway between the marks on the side of the tank.

   

   Figure 57

   1. Expansion tank

2. If the coolant level is low, remove the expansion-tank cap and replenish the system.

   Note: Do not overfill.

3. Install the expansion-tank cap.

1. Turn the engine off and raise the hood.

2. Clean the engine area thoroughly of all debris.

3. Remove the access panel (Figure 58).

   

   Figure 58

   1. Oil cooler
   2. Radiator
   3. Access panel

4. Unlatch the oil cooler and pivot it rearward (Figure 59).

   

   Figure 59

5. Clean both sides of the oil cooler and radiator area thoroughly with water or compressed air.

6. Pivot the oil cooler back into position.

7. Install the access panel and close the hood.

1. Loosen the set screw securing the knob to the parking-brake lever (Figure 60).

   

   Figure 60

   1. Knob
   2. Set screw
   3. Parking-brake lever

2. Torque the knob to 41 to 68 N∙m (30 to 40 in-lb) to actuate the lever.

3. Tighten the set screw.

1. Position the throttle lever rearward so that it stops against the control-panel slot.

2. Loosen the throttle-cable connector on the injection-pump-lever arm (Figure 63).

   

   Figure 63

   1. Injection-pump-lever arm

3. Hold the injection-pump-lever arm against the low-idle stop and tighten the cable connector.

4. Loosen the screws securing the throttle control to the control panel.

5. Push the throttle-control lever completely forward.

6. Slide the stop plate until it contacts the throttle lever and tighten the screws securing the throttle control to the control panel.

7. If the throttle does not stay in position during operation, torque the locknut, used to set the friction device on the throttle lever, to 5 to 6 N∙m (40 to 55 in-lb).

   Note: The maximum force required to operate the throttle lever should be 27 N∙m (20 in-lb).

The machines 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. See the parts catalog or Toro distributor for part numbers.)

Alternate fluids: If the Toro fluid is not available, you may use other fluids provided they meet all the following material properties and industry specifications. Do not use 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.

Important: The ISO VG 46 Multigrade fluid has been found to offer optimal performance in a wide range of temperature conditions. For operation in consistently high ambient temperatures, 65° F (18° C) to 120° F (49° C), ISO VG 68 hydraulic fluid may offer improved performance.

Premium Biodegradable Hydraulic Fluid-Mobil EAL EnviroSyn 46H

Important: Mobil EAL EnviroSyn 46H is the only synthetic biodegradable fluid approved by Toro. This fluid is compatible with the elastomers used in Toro hydraulic systems and is suitable for a wide-range of temperature conditions. This fluid is compatible with conventional mineral oils, but for maximum biodegradability and performance the hydraulic system should be thoroughly flushed of conventional fluid. The oil is available in 19 L (5 US gallons) containers or 55-gallon drums from your Mobil Distributor.

Important: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic system oil is available in 20 mL (2/3 oz) bottles. One bottle is sufficient for 15 to 22 L (4 to 6 US gallons) of hydraulic oil. Order Part No. 44-2500 from your authorized Toro distributor.

Use the following procedure to check the hydraulic fluid:

1. Perform the pre-maintenance procedure; refer to Preparing the Machine for Maintenance.

2. Clean the area around the filler neck and hydraulic-tank cap (Figure 64).

   

   Figure 64

   1. Hydraulic-tank cap

3. Remove the hydraulic-tank cap (Figure 64).

4. Remove the dipstick from the filler neck and wipe it with a clean rag.

5. 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.

6. If the level is low, add the appropriate fluid to raise the level to the FULL mark.

7. Install the dipstick and cap onto the filler neck.

Use a genuine Toro replacement filter, Part No. 86-3010.

Important: Using any other filter may void the warranty on some components.

1. Perform the pre-maintenance procedure; refer to Preparing the Machine for Maintenance.

2. Pinch off the hose to the filter-mounting plate.

3. Clean around the filter-mounting area, place a drain pan under the filter, and remove the filter (Figure 65).

   

   Figure 65

   1. Hydraulic filter

4. Lubricate the new filter gasket and fill the filter with hydraulic fluid.

5. 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.

7. Start the engine and let it run for approximately 2 minutes to purge air from the system.

8. Stop the engine and check for leaks.

If the fluid becomes contaminated, contact your local Toro distributor to flush the system. Contaminated fluid looks milky or black.

1. Turn the engine off and raise the hood.

2. Disconnect the hydraulic line or remove the hydraulic filter and let the hydraulic fluid flow into a drain pan (Figure 65 and Figure 66).

   

   Figure 66

   1. Hydraulic line

3. Install the hydraulic line when the hydraulic fluid stops draining (Figure 66).

4. Fill the reservoir (Figure 67) with approximately 13.2 L (3.5 US gallons) of hydraulic fluid; refer to Checking the Hydraulic System.

   Important: Use only the hydraulic fluids specified. Other fluids could damage the system.

   

   Figure 67

   1. Hydraulic-tank cap

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 stop the engine.

8. Check the fluid level and add enough to raise the level to the FULL mark on the dipstick.

   Note: Do not overfill.

Check the hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating the machine.

1. Perform the pre-maintenance procedure; refer to Preparing the Machine for Maintenance.

2. Remove the hydraulic-motor-mounting screws and disconnect and remove the hydraulic motor from the deck (Figure 68).

   Important: Cover the top of the spindle to prevent contamination.

   

   Figure 68

   1. Motor-mounting screws

3. Remove the lynch pin or retaining nut securing the deck carrier frame to the lift-arm-pivot pin (Figure 69).

   

   Figure 69

   1. Lynch pin
   2. Lift-arm-pivot pin

4. Roll the cutting deck away from the traction unit.

1. Perform the pre-maintenance procedure; refer to Preparing the Machine for Maintenance.

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 69).

4. Using the hydraulic-motor-mounting screws, install the hydraulic motor to the deck (Figure 68).

   Note: Ensure that the O-ring is properly positioned and not damaged.

5. Grease the spindle.

The rotary deck comes from the factory preset at 5 cm (2 inches) height-of-cut and blade rake of 7.9 mm (0.31 inch). The left and right heights of cut are also preset to within ± 0.7 mm (0.03 inch) of the other.

The cutting deck is designed to withstand blade impacts without deforming the chamber. If the blade strikes a solid object, inspect the blade for damage and the blade plane for accuracy.

Inspect the front roller for wear, excess wobble, or binding. Service or replace the roller or components if any of these conditions exist.