Page 1
27 Rotary Cutting Deck
Groundsmaster 3500 Traction Unit
Model No. 30822—210002001 and Up
Form No. 3326-156
Operator ’s Manual
English (EN)
Page 2
Contents
Introduction
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 3. . . . . . . . . . . . . . . .
Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Equipment 3. . . . . . . . . . . . . . . . . . . . . . .
Dimensions 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 4. . . . . . . . . . . . . . . . . . . . .
Setup 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Carrier Frame 5. . . . . . . . . . . . . . . . .
Adjusting the Height of Cut 5. . . . . . . . . . . . . . . . .
Adjusting the Roller Scraper 6. . . . . . . . . . . . . . . .
Installing the Mulching Baffle (Optional) 6. . . . . .
Operation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Tips 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Greasing the Bearings 7. . . . . . . . . . . . . . . . . . . . . .
Cutting Deck Service Latch 7. . . . . . . . . . . . . . . . .
Separating the Cutting Decks from the Traction
Unit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting the Cutting Decks to the Traction Unit 8
Blade Plane 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting the Blade Plane 8. . . . . . . . . . . . . . . . . .
Adjusting the Blade Plane 9. . . . . . . . . . . . . . . . . .
Removing the Cutter Blade 9. . . . . . . . . . . . . . . . .
Inspecting and Sharpening the Blade 10. . . . . . . . . .
Blade Stopping Time 10. . . . . . . . . . . . . . . . . . . . . .
Servicing the Rear Roller 10. . . . . . . . . . . . . . . . . . .
Servicing the Front Roller 12. . . . . . . . . . . . . . . . . .
Cutting Deck Storage 12. . . . . . . . . . . . . . . . . . . . . .
Page
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 model and serial
numbers are stamped into a plate on the rear of the mower
deck, under the cover.
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.
2001 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
All Rights Reserved
Printed in the USA
2
Page 3
Safety
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.
98-7818
1. Warning—torque the blade bolt to 85–110 ft.-lb (115–149 N⋅m).
Read the operator’s manual for further instructions.
104-1086
43-8480
Specifications
Note: Specifications and design subject to change without
notice.
Optional Equipment
Mulching Baffle Kit
(contains parts for three decks)
Model No. 30824
Dimensions
Overall length 33.8 in. (85.8 cm)
Overall width 34 in. (86.4 cm)
Overall height 9.6 in. (24.4 cm) to carrier
mount
10-1/2 in. (26.7 cm) at 3/4 in.
height of cut
13-3/4 in. (34.9 cm) at 4 in.
height of cut
Roller footprint
Front to back
Rear roller
Front rollers
29.8 in. (75.7 cm) full length
18.5 in. (47 cm) between front
29.3 in. (74.4 cm)
rollers
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General Specifications
Welded 10 GA (.1345 in.) and 12 GA (.1036 in.) steel. Spindle support is 3/16 in.
Chamber Construction
Blade Heat treated steel
Tip Speed 16,300 ft./min. nominal
Blade Plane
(factory pre-set)
Height of Cut 3/4–4 in. (1.91–10.16 cm) in 1/4 in. (.64 cm) increments
Deck Drive
high-strength steel and 10 GA exterior channels, withstands multiple blade impact
tests. Deck frame is welded 1-1/2 in. square tubing and 7 GA (.1793 in.) side
supports, protects chamber, withstands collisions.
Height of Cut 2.00 (5.08 cm)
Right or left side 2.15 (5.46 cm)
Side to side within .03 in. (.08 cm) of each other
Blade rake approximately 5/16 in. (.79 cm)
Hydraulic, closed loop, integrated relief. High efficiency press. balanced gear type
pump. High efficiency press. Balanced gear type motor. Recommended oil is Mobil
DTE 15M (Mobil EAL biodegradable compatible).
Spindles
Discharge Rear, even clipping distribution in wet or dry conditions
Mulching Baffle (Optional) Pre-drilled mounting holes provided in decks
Front Rollers
Rear Roller
Anti-Scalp Cup 6 in. (15.2 cm) standard
Roller Scraper
Suspension Non-steering carrier frame
Weight 190 lb. (86 kg)
1-1/4 in. (3.17 cm) shaft, greasable, tapered roller bearing, ductile iron housing
which withstands multiple impact tests.
Two 5 in. (12.7 cm) diameter, ductile iron w/hollow core, sealed bearings, close
location to blade
One 3 in. (7.6 cm) diameter, steel, sealed bearings, exterior shaft seal, full length,
close location to blade
Welded straight edge and 5/16 in. (.79 cm) diameter rod; located below centerline
for self cleaning
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 have been received. Without these parts, total setup cannot be
completed.
Description Qty. Use
Decal 1 Apply to cutting deck for CE
Parts Catalog 1
Operator’s Manual 1 Read before operating the machine.
Registration Card 1 Fill out and return to Toro.
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Page 5
Adjusting the Carrier Frame
Adjusting the Height of Cut
The front and rear cutting decks require different mounting
positions.
The front cutting deck has two mounting positions
depending on what height-of-cut and degree of deck
rotation is desired. The rear cutting deck has one mounting
position for proper alignment with the sidewinder under
frame.
Front Cutting Decks
1. For heights of cut in the 3/4 to 3 inch range, the front
carrier frames should be mounted in the lower front
mounting holes (Fig. 1).
Note: This permits more up travel of the cutting decks
relative to tractor when approaching quick uphill changes
in terrain. It does however limit the clearance of the
chamber to carrier when cresting sharp knolls.
1
Important This cutting deck often cuts approximately
1/4 inch lower than a reel cutting unit with the same bench
setting. It may be necessary to have these rotary cutting
deck’s bench set 1/4 inch above that of reels cutting in the
same area.
Important Access to the rear cutting units is greatly
improved by removing the cutting unit from the tractor. If
the unit is equipped with a Sidewinder, sidewind the
cutting units to the right, remove the rear cutting unit, and
slide it out to the right side.
1. Lower cutting deck to ground, stop engine, and remove
key from ignition switch.
2. Loosen capscrew securing each height of cut bracket to
height of cut plate (front and each side) (Fig. 2).
3. Beginning with front adjustment, remove capscrew.
2
3
2 3
Figure 1
1. Front deck mounting hole (upper)
2. Front deck mounting hole (lower)
3. Rear deck mounting hole
2. For heights of cut in the 2–1/2 to 4 inch range, the front
carrier frames should be mounted in the upper front
mounting holes (Fig. 1).
Note: This increases the chamber to carrier clearance due
to the higher position of the cutting chamber, but will cause
the cutting deck to reach their maximum up travel sooner.
Rear Cutting Decks
For all heights of cut, the rear cutting deck should be
mounted in the rear mounting holes (Fig. 1).
1
Figure 2
1. Height of cut bracket
2. Height of cut plate
4. While supporting chamber, remove spacer (Fig. 2).
5. Move chamber to desired height-of-cut and install
spacer into designated height-of-cut hole and slot
(Fig. 3).
Figure 3
3. Spacer
6. Position taped plate in line with spacer.
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Page 6
7. Install capscrew finger tight.
8. Repeat steps 4–7 for each side adjustment.
9. Tighten all three capscrews to 30 ft.-lb. (41 N⋅m).
Note: Adjustments of more than 1-1/2 inch may require
temporary assembly to an intermediate height to prevent
binding (e.g. changing from 1.25 in. to 2.75 in.
height-of-cut).
Adjusting the Roller Scraper
The rear roller scraper is designed to work best when there
is an even gap of .02–.04 inches between the scraper and
roller.
1. Loosen the top 2 mounting screws and the lower 2
flange nuts (Fig. 4).
1
1
m–5421
Figure 5
1. Mulching baffle
3. Verify that mulching baffle does not interfere with
either tip of blade and does not protrude inside the
surface of the rear chamber wall.
2
3
m–5417
Figure 4
1. Roller scraper
2. Mounting screw
2. Slide the scraper up or down until a gap of .02–.04 in. is
achieved between the rod and the roller.
3. Secure the mounting screws and flange nuts to 30 ft.-lb.
(41 N⋅m) in an alternating sequence.
3. Flange nut
Installing the Mulching Baffle
(Optional)
1. Thoroughly clean debris from mounting holes on rear
wall and left side wall of chamber.
2. Install mulching baffle in rear opening and secure with
5 flange head screws (Fig. 5).
Operation
Note: Determine the left and right sides of the machine
from the normal operating position.
Operating Tips
Mow When Grass is Dry
Mow either in the late morning to avoid the dew, which
causes grass clumping, or in late afternoon to avoid the
damage that can be caused by direct sunlight on the
sensitive, freshly mowed grass.
Select the Proper Height-of-Cut Setting to
Suit Conditions
Remove approximately one inch or no more than 1/3 of the
grass blade when cutting. In exceptionally lush and dense
grass you may have to raise your height–of–cut setting
another notch.
Always Start Mowing with Sharp Blades
A sharp blade cuts cleanly and without tearing or shredding
the grass blades like a dull blade. Tearing and shredding
causes the grass to turn brown at the edges which impairs
growth and increases susceptibility to diseases. Make sure
blade is in good condition and a full sail is present.
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Page 7
Check Condition of Deck
After Operating
Make sure cutting chambers are in good condition.
Straighten any bends in chamber components to assure
correct blade tip/chamber clearance.
To ensure optimum performance, clean underside of mower
housing. If residue is allowed to build up in mower
housing, cutting performance will decrease.
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
Caution
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 and disconnect the wire from the spark plug before you do any
maintenance. Set the wire aside so that it does not accidentally contact the spark plug.
Greasing the Bearings
Each cutting deck has two grease fittings per spindle. Either
fitting can be used, which ever is more accessible. If
machine is operated under normal conditions, lubricate
blade spindle bearings (Fig. 6) with No. 2 general purpose
lithium base grease or molybdenum base grease, after every
50 hours of operation. Pump grease into fitting until a small
amount appears at bottom of spindle housing (under deck).
4. Release latch rod (Fig. 7) from front carrier frame
retainer.
Figure 6
Cutting Deck Service Latch
When servicing cutting decks, use the service latch to
prevent injury.
1. Center cutting deck sidewinder with the traction unit.
2. Raise cutting decks to transport position.
1
Figure 7
1. Service latch hook
5. Lift outside of front cutting decks and place latch over
frame pin mounted on front of operators platform
(Fig. 7).
6. Sit on operator seat and start traction unit.
7. Lower cutting decks to mow position.
8. Turn off machine and remove key.
9. Reverse procedure to unlatch cutting decks.
3. Set parking brake and turn off machine.
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Page 8
Separating the Cutting Decks
Mounting the Cutting Decks to
from the Traction Unit
1. Position machine on level surface, lower cutting decks
to floor, shut engine off, and engage parking brake.
2. Disconnect and remove hydraulic motor from deck
(Fig. 8). Cover top of spindle to prevent contamination.
1
1
Figure 8
1. Motor mounting screws
the Traction Unit
1. Position machine on a level surface and shut engine off.
2. Move cutting deck into position in front of traction unit.
3. Slide deck carrier frame onto lift arm pivot pin. Secure
with lynch pin (Fig. 9).
4. Install hydraulic motor to deck (Fig. 8). Make sure
o-ring in is position and not damaged.
5. Grease spindle.
Blade Plane
The rotary deck comes from the factory preset at 2.00 inch
height-of-cut and blade rake of 0.31 inch. The left-hand and
right-hand heights are also preset to within ±0.03 inch of
the other.
The cutting deck is designed to withstand blade impacts
without deformation of the chamber. If a solid object is
struck, inspect the blade for damage and blade plane for
accuracy.
Inspecting the Blade Plane
3. Remove lynch pin securing deck carrier frame to lift
arm pivot pin (Fig. 9).
1
2
Figure 9
1. Lynch pin 2. Lift arm pivot pin
4. Roll the cutting deck away from the traction unit.
1. Remove hydraulic motor from cutting deck and remove
cutting deck from tractor.
2. Use hoist (or minimum of two people) and place cutting
deck on flat table.
3. Mark one end of blade with paint pen or marker. Use
this end of blade to check all heights.
4. Position cutting edge of marked end of blade at 12
o’clock (straight ahead in direction of mowing)
(Fig. 10) and measure height from table to cutting edge
of blade.
6 o’clock
9 o’clock
12 o’clock
3 o’clock
Figure 10
5. Rotate marked end of blade to the 3 and 9 o’clock
positions (Fig. 10) and measure heights.
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Page 9
6. Compare 12 o’clock measured height to the height of
cut setting. It should be within .03 inch. The 3 and 9
o’clock heights should be .15±.03 inch higher than the
12 o’clock setting and within .03 in. of each other.
If any of these measurements are not within specification,
proceed to Adjusting the Blade Plane, page 9.
Removing the Cutter Blade
The blade must be replaced if a solid object is hit, the blade
is out of balance or if the blade is bent. Always use genuine
Toro replacement blades to be sure of safety and optimum
performance. Never use replacement blades made by other
manufacturers because they could be dangerous.
Adjusting the Blade Plane
Start with front adjustment (change one bracket at a time).
1. Remove height-of-cut bracket, (front, left, or right)
from deck frame (Fig. 11).
2. Adjust .06 in. shims and/or .03 in. shim between the
deck frame and bracket to achieve the desired height
setting (Fig. 11).
1
2
Figure 11
1. Height of cut bracket 2. Shims
1. Raise cutting deck to highest position, shut the engine
off, and engage the parking brake. Block cutting deck to
prevent it from falling accidentally.
2. Grasp end of blade using a rag or thickly padded glove.
Remove blade bolt, anti-scalp cup, and blade from
spindle shaft (Fig. 12).
2
1
Figure 12
1. Blade bolt 2. Anti-scalp cup
3. Install blade, sail facing toward cutting deck, with
anti-scalp cup and blade bolt (Fig. 12). Tighten blade
bolt to 85–110 ft.-lb. (115–149 N⋅m).
3. Install height-of-cut bracket to deck frame with
remaining shims assembled below the height-of-cut
bracket.
4. Secure socket head bolt/spacer and flange nut.
Note: Socket head bolt/spacer are held together with
Loctite to prevent spacer from falling inside the deck
frame.
5. Verify 12 o’clock height and adjust if needed.
6. Determine if only one or both (right-hand and left-hand)
height-of-cut brackets need to be adjusted. If the 3 or 9
o’clock side is .15±.03 in. higher than the new front
height then no adjustment is needed for that side. Adjust
other side to within ±.03 in. of correct side.
7. Adjust right and/or left height-of-cut brackets by
repeating steps 1 thru 3.
8. Secure carriage bolts and flange nuts.
9. Again, verify 12, 3, and 9 o’clock heights.
Danger
A worn or damaged blade can break, and a piece
of the blade could be thrown into the operator’s or
bystander’s area, resulting in serious personal
injury or death.
• Inspect the blade periodically for wear or
damage.
• Never weld a broken or cracked blade.
• Always replace a worn or damaged blade.
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Page 10
Inspecting and Sharpening the
Blade
to make sure of sharpness (Fig. 14). The blade will
remain balanced if same amount of metal is removed
from both cutting edges.
1. Raise cutting deck to highest position, shut the engine
off, and engage the parking brake. Block cutting deck to
prevent it from falling accidentally.
2. Examine cutting ends of the blade carefully, especially
where the flat and curved parts of the blade meet
(Fig. 13-A). Since sand and abrasive material can wear
away the metal that connects the flat and curved parts of
the blade, check the blade before using the machine. If
wear is noticed (Fig. 13-B), replace the blade; refer to
Removing the Cutter Blade, page 9.
Danger
If the blade is allowed to wear, a slot will form
between the sail and flat part of the blade
(Fig. 13-C). eventually a piece of the blade may
break off and be thrown from under the housing,
possibly resulting in serious injury to yourself or
bystanders.
• Inspect the blade periodically for wear or
damage.
• Always replace a worn or damaged blade.
SHARPEN AT THIS
ANGLE ONLY
END VIEW
Figure 14
4. To check blade for being straight and parallel, lay blade
on a level surface and check its ends. Ends of blade
must be slightly lower than the center, and cutting edge
must be lower than the heel of the blade. This blade will
produce good quality of cut and require 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.
5. Install blade, sail facing toward cutting deck, with
anti-scalp cup and blade bolt. Tighten blade bolt to
85–110 ft.-lb. (115–149 N⋅m).
Blade Stopping Time
The blades of the cutting deck are to come to a complete
stop in approximately 5 seconds after the cutting deck
engagement switch is shut down.
Figure 13
3. Inspect cutting edges of all blades. Sharpen the cutting
edges if they are dull or nicked. Sharpen only the top of
the cutting edge and maintain the original cutting angle
Note: Make sure the decks are lowered onto a clean section
of turf or hard surface to avoid thrown dust and debris.
To verify this stopping time, have a second person stand
back from the deck at least 20 feet and watch the blades on
one of the cutting decks. Have the operator shut the cutting
decks down and record the time it takes for the blades to
come to a complete stop. If this time is greater than 7
seconds, the braking valve needs adjustment. Call your
Toro Distributor for assistance in making this adjustment.
Servicing the Rear Roller
Disassembly
1. Remove mounting screws and nuts securing the scraper
to roller mounts (Fig. 15). Remove scraper and plates.
2. Remove mounting screws securing roller mounts to rear
of deck frame (Fig. 15). Remove roller mounts.
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Page 11
3. Remove the lower screws securing each end of roller to
roller mounts (Fig. 15).
1
2
1
2
4
3
m–5417
Figure 15
1. Rear roller
2. Scraper
3. Roller mount
4. Lower screw
Seal Removal
Using a 1/4 in. thick, 3 in. x 3 in. square piece of steel and
the following specifications, make a seal removal tool
(Fig. 16).
.188 in. dia. (2)
.625 in. dia.
3
4
5
Figure 17
1. Roller
2. Roller shaft
3. Ball bearing
4. Retaining ring
5. Oil seal
5. Alternate tightening sequence of 1/4 in. capscrews to
pull seal out of housing.
Note: Seal will be destroyed when servicing the rear roller.
Do not attempt to re-use these seals.
Bearing Removal
Reference: The bearings are pressed on to the shaft
(.0003–.0016 in. interference) and loose fit to housing
(.0020–.0035 in. clearance).
.625 in.
.625 in.
1/4–20 UNC (2)
1.05
in.
1.05
in.
Figure 16
1. Slide seal tool over roller shaft.
2. Using the tool as a template, locate, mark, and drill 2
holes (7/64 in. [.109 in.] diameter) in outer face of seal.
3. Screw 2 self-tapping screws (No. 8 [.164 in.] x 3/4 in.)
into outer face of seal.
4. Install 2 capscrews (1/4 x 1 in.) into seal tool.
1. Remove spiral retaining ring (Fig. 17). Catch removal
notch with pick and pull ring off shaft. Repeat on other
end.
2. Loosely secure roller assembly in bench vise and lightly
tap one end of roller shaft until free from housing.
3. Remove second bearing from shaft. Support bearing on
inner race and tap on roller shaft.
4. Inspect bearings, shaft, and spiral retaining ring for
damage. Replace damaged components. Re-assemble
roller.
Assembly
1. Press bearing onto one end of shaft. Apply pressure to
inner race only.
2. Install spiral retaining ring on same end as assembled
bearing.
3. Install shaft with single bearing into tube assembly.
4. Install second bearing into roller assembly. Press only
on inner race. The inner race will contact shoulder of
shaft before outer race contacts shoulder of housing.
5. Install second spiral retaining ring.
6. Press new seal flush to .03 in. recessed into housing.
Repeat for other side.
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Page 12
Servicing the Front Roller
Cutting Deck Storage
Disassembly
1. Remove roller mounting bolt (Fig. 18).
2. Insert punch through end of roller housing and drive
opposite bearing out by alternating taps to opposite side
of inner bearing race. There should be a 1/16 in.
(.06 in.) lip of inner race exposed.
3
2
4
1
Figure 18
1. Front roller
2. Mounting bolt
3. Bearing
4. Bearing spacer
If cutting deck is separated from traction unit for any length
of time, install spindle plug (94-2703) in top of spindle to
protect spindle from dust and water.
3. Push second bearing out in press.
4. Inspect roller housing, bearings, and bearing spacer for
damage (Fig. 18). Replace damaged components and
re-assemble.
Assembly
1. Press first bearing into roller housing (Fig. 18). Press on
outer race only or equally on inner and outer race.
2. Insert spacer (Fig. 18).
3. Press second bearing into roller housing (Fig. 18)
pressing equally on inner and outer race until the inner
race comes in contact with spacer.
4. Install roller assembly into deck frame.
Important Securing roller assembly with a gap larger
than .06 in. creates a side load on bearing and can lead to
premature bearing failure.
5. Verify that there is no more than a .06 in. gap between
roller assembly and the roller mount brackets of the
deck frame. If there is a gap over .06 in., install enough
5/8 in. diameter washers to take up the slop.
6. Secure mounting bolt to 80 ft.-lb. (108 N⋅m).
12
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