Form No.
Revision History Revision Date -- 2014 A 03/2018 Added revision history. B 03/2019 Updated Electrical chapter. C 12/2019 Updated Chapter 1 Safety Statements. D 05/2020 Updated Electrical Drawings. E 06/2021 Updated Engine chapter. © THE TORO COMPANY 2021 Description Initial Issue. This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies).
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
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PART NO. 14209SL (Rev. E) Service Manual Groundsmaster 3500 R Models 30807 and 30809 Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Groundsmaster 3500--D (Model 30807) and 3500--G (Model 30809). REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
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Chapter 6 - Electrical System General Safety Instructions . . . . . . . . . . . . . . . . . . 1 - 1 Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 - 5 General Information . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6 Electrical System Quick Checks .
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Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3 JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 4 SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
While Operating 1. Always wear your seat belt. 10.When starting the engine: 2. Do not run the engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could be deadly. A. Engage parking brake. B. Be sure traction pedal is in neutral and blade drive is in disengage position. 3. Sit on the seat when starting and operating the machine. 4. Check interlock switches daily for proper operation (see Chapter 5 - Electrical System).
1. Before servicing or making adjustments to the machine, stop the engine and remove key from switch to prevent accidental starting of the engine. 2. Check performance of all interlock switches daily. Do not disable or bypass interlock system components. The interlock system is for your protection. 3. To ensure entire machine is in good operating condition, frequently check and keep all nuts, bolts, screws and hydraulic fittings tight. 4.
Jacking Instructions CAUTION 1 When changing attachments, tires, or performing other service, use correct blocks, hoists, and jacks. Make sure machine is parked on a solid level floor such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands or solid wood blocks to support the raised machine.
Safety and Instruction Decals Groundsmaster 3500 Page 1 - 5 Safety Numerous safety and instruction decals are affixed to the Groundsmaster 3500. If any decal becomes illegible or damaged, install a new decal. Part numbers for replacement decals are listed in your Parts Catalog. Order replacement decals from your Authorized Toro Distributor.
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Product Records and Maintenance Product Records and Maintenance Table of Contents 1 1 2 2 2 3 3 4 5 6 6 Kubota Diesel Engine PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 0.
The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut) and mating part, then back off fastener 1/4 of a turn. Measure the torque required to tighten the fastener until the lines match up. Hydraulic Systems Fastener Identification Product Records and Maintenance These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in−lb in−lb N−cm 10 + 2 13 + 2 147 + 23 # 6 − 32 UNC # 6 − 40 UNF # 8 − 32 UNC 13 + 2 25 + 5 # 10 − 24 UNC 30 + 5 SAE Grade 8 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 5 or Stronger Nuts) in−lb N−cm in−lb N−cm 15 + 2 170 + 20 23 + 2 260 +
M5 X 0.8 57 + 5 in−lb 640 + 60 N−cm 78 + 7 in−lb 885 + 80 N−cm M6 X 1.0 96 + 9 in−lb 1018 + 100 N−cm 133 + 13 in−lb 1500 + 150 N−cm M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m 27 + 2 ft−lb 36 + 3 N−m M10 X 1.5 38 + 4 ft−lb 52 + 5 N−m 53 + 5 ft−lb 72 + 7 N−m M12 X 1.75 66 + 7 ft−lb 90 + 10 N−m 92 + 9 ft−lb 125 + 12 N−m M16 X 2.0 166 + 15 ft−lb 225 + 20 N−m 229 + 22 ft−lb 310 + 30 N−m M20 X 2.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque* Thread Size Square Head Hex Socket 1/4 − 20 UNC 140 + 20 in−lb 73 + 12 in−lb 5/16 − 18 UNC 215 + 35 in−lb 145 + 20 in−lb 3/8 − 16 UNC 35 + 10 ft−lb 18 + 3 ft−lb 1/2 − 13 UNC 75 + 15 ft−lb 50 + 10 ft−lb 7/16 − 20 UNF Grade 5 65 + 10 ft−lb 88 + 14 N−m 1/2 − 20 UNF Grade 5 80 + 10 ft−lb 108 + 14 N−m M12 X 1.25 Class 8.
Kubota Diesel Engine Safety Chapter 3 3 4 4 4 4 6 6 7 7 7 8 Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . 9 Clean Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . 9 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Item Description Kubota D1105- E3B or D1105- E4B, 4- Stroke, Liquid Cooled, OHV Diesel Number of Cylinders 3 Bore in. (mm) 3.07 (78.0) Stroke in. (mm.) 3.09 (78.4) 68.53 (1123) Firing Order 1 (fan end) - 2 - 3 (flywheel end) Combustion Chamber Spherical Type Fuel No.
Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the diesel engine used in the Groundsmaster 3500- D (Model 30807). Service and repair parts for Kubota gasoline engines are supplied through your local Toro Distributor. If a parts list is not available, be sure to provide your distributor with the Toro model and serial number. Most repairs and adjustments require tools which are commonly available in many service shops.
Safety Product Records Kubota Diesel Engine Hydraulic Wheels, Brakes, Electrical This page is intentionally left blank.
Service and Repairs Air Cleaner and Muffler 10 11 12 14 19 16 21 15 4 13 18 3 12 17 20 12 7 8 1 5 9 2 6 4 5 Figure 2 1. 2. 3. 4. 5. 6. 7. Exhaust guard Cap screw Muffler Flange head screw Flange nut Muffler bracket Hex nut Kubota Diesel Engine 8. 9. 10. 11. 12. 13. 14. Lock washer Exhaust gasket Hose clamp Air inlet hose (upper) Hose clamp Air cleaner body Filter cover Page 3 − 6 15. 16. 17. 18. 19. 20. 21.
Check Air Filter, Dust Cup, & Burp Valve Safety The air cleaner body, air filter, dust cup, and burp valve should be checked daily, prior to operation. IMPORTANT: Any leaks in the air cleaner system will cause serious engine damage. Make sure that all air cleaner components are in good condition and are properly secured during operation. 4 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. Unlatch and raise hood. 1 4.
Fuel System 6 12 13 11 8 22 9 18 5 17 14 7 16 4 1 10 19 44 3 42 33 41 2 43 15 33 Thread Sealant 40 39 Thread Sealant 38 37 36 16 7 26 25 24 7 27 35 34 28 20 33 23 22 Thread Sealant 31 21 32 33 17 7 29 30 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Cap screw Fuel tank Cap screw Fuel cap Heat shield Hex flange head screw Hose clamp Stand pipe Connector fitting Bushing Seat support strap Foam Cap screw Flat washer Spacer Kubota Diesel Engine 16. 17. 18.
Fuel Tank Installation (Fig. 5) DANGER 5. Install crossover fuel hose if removed and fill fuel tank. 3 2. Remove fuel from the tank into a suitable container. If necessary, remove crossover fuel hose to drain tank completely. 4 3. Remove seat and seat support straps from the frame. Note location of spacers under front of seat support straps. Disconnect seat switch from the electrical harness (Fig. 6). 5 1 2 4. Remove fuel hose strap and both fuel hoses from the fuel tank.
Radiator − Radiator/Hydraulic Fluid Cooler Traction Units Prior to Serial No 314000001 10 18 17 22 15 28 5 11 9 34 30 6 16 13 32 9 31 8 14 35 25 3 20 29 19 33 21 4 26 28 27 2 12 36 24 25 23 37 1 38 7 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Drain−cock valve Flange head screw Flange nut Carriage bolt Radiator Fan shroud (top) Fan shroud (bottom) Flange head screw Hose clamp Radiator frame Radiator cap Radiator foam seal Flange head screw Kubota Diesel Engine 14. 15. 16.
9 8 7 6 Safety Traction Units Serial No 314000001 & Up 7 5 11 25 4 10 28 27 3 12 26 Kubota Diesel Engine 13 1 7 25 24 22 9 14 21 15 31 16 23 6 29 13 30 Hydraulic 2 32 Product Records 6 17 18 FRONT Electrical 20 7 9 19 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Expansion tank Hose clamp Coolant hose Flange head screw Radiator bracket − RH Carriage bolt Flange nut Radiator bracket − top Flange head screw Frame casting Cap screw Groundsmaster 3500−D 12. 13. 14. 15.
Removal Units prior to serial no. 314000001 use a separate hydraulic oil cooler. The hydraulic oil cooler on later units is combined with the radiator assembly. It is not necessary to drain the hydraulic system when removing the radiator on early units prior to serial no. 314000001. 2 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1 3 2. Open and remove engine hood from the machine. Figure 9 CAUTION 1.
A. Upper radiator hose to the water pump. 9. Make sure drain- cock valve is closed. Fill radiator with coolant to the bottom of the filler neck. 10.Install engine hood to the machine. Close and latch hood. B. Lower radiator hose to the engine block. Safety 7. Connect following hoses to the radiator or radiator/oil cooler assembly: D. Air hose to the air cleaner. Wheels, Brakes, Electrical Hydraulic Kubota Diesel Engine 8.
Diesel Engine 1 Thread Sealant 8 5 2 6 9 6 10 7 3 13 11 12 4 26 41 42 15 31 40 30 16 44 43 36 38 37 35 34 32 47 17 18 14 34 to 42 ft--lbs (46 to 57 Nm) Terminal Protector 19 48 26 20 23 24 25 27 46 45 21 28 29 30 22 4 31 32 39 39 33 34 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Removal 5 2. Open and remove engine hood from the machine. Slide seat all the way forward. 3. Disconnect both battery cables at the battery (see Battery Service in Chapter 6 − Electrical System). 5. Remove muffler from the exhaust manifold and muffler bracket (see Muffler Removal in this Chapter). 1 Figure 11 1. Battery ground cable 2. Wire harness ground 3. Throttle cable 4. Support bracket 5. Speed control lever 6. Fuel hose 2 6.
1 RIGHT FRONT 2 3 4 5 6 10 9 8 7 Figure 15 1. 2. 3. 4. Engine mount bracket Flange nut Flange screw Pump mount plate 5. Hardened washer 6. 10 mm cap screw (4) 7. 8 mm cap screw (1) CAUTION 8. Hardened washer 9. Long spacer (4) 10. Short spacer (1) CAUTION Make sure lift or hoist can support the total weight of the engine before removing the cap screws from the engine and engine brackets. One person should operate lift or hoist while the other person guides the engine out of the machine. 13.
9. Install top fan shroud to the radiator. Install expansion tank and bracket to the top fan shroud (see Radiator Installation in this Chapter). B. Remove five cap screws, washers, and spacers securing the pump mount plate to the engine. 10.Connect wire harness and electrical wires to the following: C. Remove two cap screws and flange nuts securing the pump support to the engine mount bracket and remove the hydrostat and pump assembly from the engine. A.
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Kubota Gasoline Engine Safety Chapter 4 Fuel Evaporative Control System (Unit Serial No. Prior to 315000001) . . . . . . . . . 10 Carbon Canister Removal . . . . . . . . . . . . . . . . . 11 Carbon Canister Installation . . . . . . . . . . . . . . . . 11 Radiator/Hydraulic Fluid Cooler . . . . . . . . . . . . . . 12 Radiator Removal . . . . . . . . . . . . . . . . . . . . . . . . 13 Radiator Installation . . . . . . . . . . . . . . . . . . . . . . . 13 Engine . . . . . . . . . . . . . . . . . . . . . . .
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Item Description Kubota, Vertical, 4−Cycle, 3 Cylinder, Liquid Cooled, Gasoline Engine Bore in. (mm) 2.93 (74.5) Stroke in. (mm) 2.90 (73.6) Total Displacement cu. In. (cc) 58.68 (962) 9.2:1 Ignition Timing 31_ BTDC @ 3600 rpm Ignition System Full Transistor Battery Ignition Type Firing Order 1−2−3 NGK BKR6E 0.028 to 0.031 (0.7 to 0.8) Intake & Exhaust Valve Clearance in. (mm) (check when engine is cold) 0.0065 + 0.0001 (0.165 + 0.
Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the gasoline engine used in the Groundsmaster 3500−G (Model 30809). Service and repair parts for Kubota gasoline engines are supplied through your local Toro Distributor. If a parts list is not available, be sure to provide your distributor with the Toro model and serial number. Most repairs and adjustments require tools which are commonly available in many service shops.
Product Records 1 2 Hydraulic If the engine ECU identifies that an engine problem exists, the check engine light on the Operator’s Control Panel will illuminate. The engine speed may be reduced or the engine might stop. The Kubota Gasoline Service Tool (KGST) software, the Ecom interface driver and diagnostic cable, and the Kubota Diagnostic Manual should be used to provide assistance in identifying the cause of the problem and any repairs that are necessary.
Service and Repairs Air Cleaner and Muffler 5 1 22 − 28 ft−lbs (30 − 38 N−m) 13 3 4 2 25 5 6 7 24 23 13 8 10 22 − 28 ft−lbs (30 − 38 N−m) 5 22 6 13 11 12 9 21 14 30 to 44 ft−lb (41 to 59 N−m) 15 28 16 27 13 20 26 19 18 17 Figure 4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Muffler flange cover Muffler cover Muffler Exhaust gasket Flange nut Flange head screw Muffler bracket Muffler mount tube Oxygen (O2) sensor Flange head screw Kubota Gasoline Engine 11. 12. 13. 14. 15. 16. 17. 18. 19.
Muffler Removal (Fig. 4) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. Unlatch and raise hood. 2. Check air cleaner body for damage that could cause possible air leaks. Make sure dust cup seals completely to the air cleaner body (Fig. 5). 3. Check burp valve and dust cup for damage. 4. Make sure air hoses connecting the air cleaner to the engine and radiator are secured tightly and free of possible air leaks.
Fuel System 175 to 200 in−lb (20 to 22 N−m) 13 26 RIGHT 12 FRONT 14 15 16 11 10 9 8 7 19 20 17 18 22 21 6 17 6 1 19 5 5 27 26 25 23 24 4 2 3 4 Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. Fuel tank Hose clamp Fuel hose − crossover Protective trim Bushing Elbow fitting Spacer Flat washer Cap screw Kubota Gasoline Engine 10. 11. 12. 13. 14. 15. 16. 17. 18. Seat support strap Pump gasket Fuel pump Fuel pump cap Flange screw Flat washer Heat shield Hose clamp Foam Page 4 − 8 19. 20. 21. 22.
3. Install fuel tank to the machine (see Fuel Tank Installation). Fuel Tank Removal (Fig. 6) Fuel Tank Installation (Fig. 6) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. Unlatch and raise hood. 1. Position fuel tank to the machine. 2. Remove fuel from the tank into a suitable container. If necessary, remove crossover fuel hose to drain tank completely. 2.
Fuel Evaporative Control System (Unit Serial No. Prior to 315000001) 19 10 7 9 1 RIGHT 1 12 11 1 7 8 FRONT 7 1 6 5 4 3 Thread Sealant 2 13 1 1 5 1 1 14 1 15 16 1 17 18 7 7 Figure 7 1. 2. 3. 4. 5. 6. 7. Hose clamp Fuel hose Elbow fitting Tee fitting Straight barb fitting Anchor clamp Cap screw 8. 9. 10. 11. 12. 13.
Carbon Canister Removal Safety 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1 2 VIEW FROM ABOVE Figure 8 1. Vacuum check valve 2. Cable tie 3. Inspect carbon cannister and attached hoses for damage or obvious leaks. A damaged or leaking cannister should be replaced. 3. Lower intake hose CARBON CANISTER CONNECTIONS 4. Note hose routing, cable tie and anchor clamp locations.
Radiator/Hydraulic Fluid Cooler RIGHT 9 8 7 6 FRONT 6 7 5 11 25 4 10 28 27 3 2 12 26 13 1 32 7 25 24 22 9 14 21 15 31 16 23 6 29 13 30 17 18 20 7 9 19 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Expansion tank Hose clamp Coolant hose Flange head screw Radiator bracket − RH Carriage bolt Flange nut Radiator bracket − top Flange head screw Frame casting Cap screw Kubota Gasoline Engine 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Radiator Removal Safety 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. CAUTION 1 3 5. Disconnect following hoses from the radiator/hydraulic fluid cooler: A. Upper radiator hose to the water pump. B. Lower radiator hose to the coolant inlet tube at engine. C. Coolant hose to the expansion tank. 1. Remove any plugs from the radiator/hydraulic fluid cooler and hydraulic system used during the removal procedure. 2.
9. Prime the hydraulic pumps (see Prime the Hydraulic Pumps in Chapter 5− Hydraulic System in this manual). 10.Start the unit and run engine to normal operating temperature. Use all of the hydraulic controls while the engine is running to distribute the hydraulic fluid throughout the system. Stop the engine and check the fluid levels. Adjust as necessary. 11. Install engine hood to the machine. Close and latch hood.
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Engine 3 8 9 RIGHT 10 FRONT 11 7 13 12 6 18 5 4 14 3 3 8 1 2 32 30 22 26 15 31 20 21 11 28 16 17 12 19 27 5 24 25 8 9 11 10 12 33 35 34 34 to 42 ft--lbs (46 to 57 Nm) Terminal Protector 29 23 10 Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Pump mount plate Mount bracket -- front Cap screw Wire harness bracket Hardened washer Cap screw Mount bracket -- RH Flange head screw Engine mount Flange nut Hardened washer Lock nut Kubota Gasoline Engine 13. 14. 15. 16.
Engine Removal 2 Safety 1 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 6. Place a suitable container under the radiator/hydraulic fluid cooler to collect the coolant. Open drain− cock valve, and completely drain the radiator. 7. Disconnect following hoses from the radiator/hydraulic fluid cooler: Figure 13 1. Alternator 2. Harness connections 11.
RIGHT FRONT 1 2 3 4 5 6 10 9 8 7 Figure 14 1. 2. 3. 4. Engine mount bracket Flange nut Flange screw Pump mount plate Kubota Gasoline Engine 5. Hardened washer 6. 10 mm cap screw (4) 7. 8 mm cap screw (1) Page 4 − 18 8. Hardened washer 9. Long spacer (4) 10.
B. Fusible link harness at starter. C. Connector at battery B+ terminal. B. Remove five cap screws, washers, and spacers securing the pump mount plate to the engine. D. Engine grounds to the battery and wire harness. Torque the engine ground bolt to 34 to 42 ft--lbs (46 to 57 N·m) and apply a coat of aerosol terminal protector. C. Remove two cap screws and flange nuts securing the pump support to the engine mount bracket and remove the hydrostat and pump assembly from the engine. 17.
18.Fill the hydraulic fluid reservoir. 19.Prime the hydraulic pumps (see Prime the Hydraulic Pumps in Chapter 5-- Hydraulic System in this manual). 20.Start the unit and run engine to normal operating temperature. Use all of the hydraulic controls while the engine is running to distribute the hydraulic fluid throughout the system. 21.Stop the engine and check the hydraulic fluid and coolant levels. Adjust as necessary. 22.Adjust traction drive for neutral.
Chapter 5 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Relieving Hydraulic System Pressure . . . . . . . . . . . 3 Traction Circuit Component Failure . . . . . . . . . . . . . 3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Hose and Tube Installation (O−Ring Face Seal Fitting) . . . . .
Specifications Item Description Piston Pump (Hydrostat) Charge Relief Pressure Traction Circuit Relief Pressure (Forward Only) Maximum Displacement Variable displacement piston pump 100 to 150 PSI (6.9 to 10 Bar) 3500 PSI (241.3 Bar) 1.44 cu. in./rev (23.6 cc/rev) Gear Pump Displacement Section 1 (P1) Displacement Section 2 (P2) 2 stage fixed displacement gear type pump 0.95 cu. In./rev (15.65 cc/rev) 0.33 cu. in./rev (5.
General Information Operator’s Manual The Traction Unit and Cutting Unit Operator’s Manuals provide information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to these publications for additional information when servicing the machine. Before disconnecting or performing any work on the Groundsmaster 3500 hydraulic system, all pressure in the hydraulic system must be relieved.
Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions or mishandling during operation and maintenance. These conditions can cause hose damage and deterioration. Some hoses are more susceptible to these conditions than others.
Hydraulic Hose and Tube Installation (O−Ring Face Seal Fitting) C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The markings on the nut and fitting body will verify that the connection has been properly tightened. 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. 2.
Hydraulic Fitting Installation (SAE Straight Thread O−Ring Fitting into Component Port) Non−Adjustable Fitting (Fig. 4) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.) method. 2.
Adjustable Fitting (Fig. 6) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is recommended that the O−ring be replaced any time the connection is opened. Lock Nut 3. Lightly lubricate the O−ring with clean hydraulic oil. Fitting threads should be clean with no lubricant applied. Back−up Washer 4. Turn back the lock nut as far as possible.
Special Tools Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges. Use gauges as recommended in Testing section of this chapter.
40 GPM Hydraulic Tester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 1. LOAD VALVE: A simulated working load is created in the circuit by turning the valve to restrict flow. 2. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure. 3.
High Flow Hydraulic Filter Kit The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi−directional filtration which prevents filtered debris from being allowed back into the circuit regardless of flow direction. If a component failure occurs in the closed loop traction circuit, contamination from the failed part will remain in the circuit until removed.
Hydraulic Test Fitting Kit This kit includes a variety of O−ring Face Seal fittings to enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Toro Part Number: TOR4079 Figure 14 Measuring Container Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only).
Remote Starter Switch After flushing the hydraulic system or replacing a hydraulic component (e.g. gear pump, piston pump, wheel motor), it is necessary to prime the hydraulic pumps. A remote starter switch (Fig. 17) can be used for this purpose. Obtain a remote starter switch locally. IMPORTANT: When using a remote starter switch, it is highly recommended to include a 20 amp in−line fuse between the battery and switch connector for circuit protection.
Wheel Hub Puller Toro Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors.
Page 5 − 14 G2 LOWER PORT P3 200−300 psi 100−150 psi 3500 psi G1 UPPER PORT HYDROSTAT M6 TOP PORT INTERNAL CASE DRAIN BY−PASS VALVE M4 M5 TRACTION WHEEL MOTORS All solenoids are shown as de−energized FORWARD Hydraulic System OIL FILTER OIL COOLER P1 STRAINER GEAR PUMP P1 M1 P2 CHG ST S1 3200 psi 1500 psi LC1 BV CR M2 CF LV G2 250 psi BACK PRESSURE OUT S.W.
Page 5 − 15 G2 LOWER PORT FORWARD P3 G1 UPPER PORT HYDROSTAT M6 TOP PORT INTERNAL CASE DRAIN 200−300 psi 100−150 psi 3500 psi BY−PASS VALVE M4 M5 TRACTION WHEEL MOTORS All solenoids are shown as de−energized OIL FILTER OIL COOLER P1 STRAINER GEAR PUMP P1 RV P2 CHG 3200 psi 1500 psi M1 ST S M2 CR LC1 LC2 CF LV G2 250 psi BACK PRESSURE OUT S.W.
Page 5 − 16 G2 LOWER PORT FORWARD Hydraulic System P3 G1 UPPER PORT HYDROSTAT M6 TOP PORT INTERNAL CASE DRAIN 200−300 psi 100−150 psi 3500 psi BY−PASS VALVE M4 M5 TRACTION WHEEL MOTORS High Pressure Low Pressure (Charge) Return or Suction Flow Direction OIL FILTER OIL COOLER P1 STRAINER GEAR PUMP P1 RV P2 CHG 3200 psi 1500 psi M1 ST S M2 CR LC1 LC2 CF LV G2 250 psi BACK PRESSURE OUT S.W. BULKHEAD PLATE IN A NOTE: Hydraulic Schematic for Unit Serial No.
Traction Circuit The mow/transport slide control on Groundsmaster 3500 machines has positions for mow and transport. The mow position allows traction pedal inputs that are appropriate for mow speeds by limiting the movement of the traction pedal and the piston pump swash plate. The transport position allows full movement of the traction pedal so complete pump swash rotation is possible. Forward The engine drives traction pump (P3) indirectly through pulleys and a V−belt.
Page 5 − 18 G2 LOWER PORT FORWARD P3 G1 UPPER PORT HYDROSTAT M6 TOP PORT INTERNAL CASE DRAIN 200−300 psi 100−150 psi 3500 psi BY−PASS VALVE M4 M5 TRACTION WHEEL MOTORS High Pressure Low Pressure (Charge) Return or Suction Flow Direction OIL FILTER OIL COOLER T1 MANIFOLD BLOCK G1 T2 P1 P1 M1 STRAINER GEAR PUMP D1 Groundmaster 3500 Cutting Unit Circuit (Units Prior to Serial No.
Page 5 − 19 G2 LOWER PORT FORWARD P3 G1 UPPER PORT HYDROSTAT M6 TOP PORT INTERNAL CASE DRAIN 200−300 psi 100−150 psi 3500 psi BY−PASS VALVE M4 M5 TRACTION WHEEL MOTORS High Pressure Low Pressure (Charge) Return or Suction Flow Direction OIL FILTER OIL COOLER T1 MANIFOLD BLOCK GEAR PUMP P1 P1 P2 ST M2 Hydraulic System CHG S ENERGIZED RV 3200 psi 1500 psi M1 STRAINER G1 T2 D1 Groundmaster 3500 Cutting Unit Circuit (Unit Serial No.
Cutting Unit Circuit Cutting Unit Blade Braking (Units Prior to Serial No. 314000001) Mow The gear pump (P1) is directly coupled to the the hydrostat which is driven by the engine. Taking its suction directly from the hydraulic tank, the gear pump (P1) supplies fluid flow to the manifold block and to the cutting unit motors. Solenoid valve (S or S1) is de−energized with the engine running when either the PTO switch is in DISENGAGE, or the transport/mow slide is in TRANSPORT.
Cutting Unit Blade Braking (Unit Serial No. 314000001 & Up) TO DECK MOTORS When the solenoid valve (S) is de−energized, the flow to the cutting deck motors and the relief valve (RV) is removed allowing relief valve (RV) to shift. The shifted relief valve removes flow from the orifice at the logic cartridge (LC2), causing a balanced pressure condition which shifts the logic cartridge, blocking the return oil path from the deck motors (Fig. 21).
Page 5 - 22 G2 LOWER PORT FORWARD P3 M6 INTERNAL CASE DRAIN G1 UPPER PORT TOP PORT HYDROSTAT 200- 300 psi 100- 150 psi 3500 psi BY- PASS VALVE M4 M5 TRACTION WHEEL MOTORS High Pressure Low Pressure (Charge) Return or Suction Flow Groundmaster 3500 Lift Circuit (Up) OIL FILTER OIL COOLER T1 MANIFOLD BLOCK GEAR PUMP P1 P1 RV ST S M2 CR LC1 LC2 CF LV G2 250 psi BACK PRESSURE OUT S.W.
Lift Circuit (Up) Raise Cutting Units The gear pump (P2) is directly coupled to the hydrostat through gear pump (P1) and driven by the engine. It supplies hydraulic pressure for operating the power steering system, raising and lowering the cutting units, operating the sidewinder unit, and replenishing the closed loop traction circuit (charge pressure). The pump takes its suction directly from the hydraulic tank.
Page 5 - 24 G2 LOWER PORT FORWARD P3 200- 300 psi 100- 150 psi 3500 psi G1 UPPER PORT HYDROSTAT M6 TOP PORT INTERNAL CASE DRAIN BY- PASS VALVE M4 M5 TRACTION WHEEL MOTORS High Pressure Low Pressure (Charge) Return or Suction Flow OIL FILTER T1 P1 GEAR PUMP D1 P1 RV ST S M2 CR LC1 LC2 CF LV G2 250 psi BACK PRESSURE OUT S.W. BULKHEAD PLATE IN A REAR DECK B RIGHT DECK LEFT DECK E T P V1 C D POWER STEERING VALVE 1000 psi LIFT/S.W.
Lift Circuit (Down) & Counterbalance Lower Cutting Units The gear pump (P2) is directly coupled to the hydrostat through gear pump (P1) and driven by the engine. It supplies hydraulic pressure for operating the power steering system, raising and lowering the cutting units, operating the sidewinder unit, and replenishing the closed loop traction circuit (charge pressure). The pump takes its suction directly from the hydraulic tank.
Page 5 - 26 G2 LOWER PORT FORWARD P3 G1 UPPER PORT HYDROSTAT M6 TOP PORT INTERNAL CASE DRAIN 200- 300 psi 100- 150 psi 3500 psi BY- PASS VALVE M4 M5 TRACTION WHEEL MOTORS High Pressure Low Pressure (Charge) Return or Suction Flow OIL COOLER OIL FILTER GEAR PUMP P1 P1 RV P2 CHG 3200 psi 1500 psi M1 ST S M2 CR LC1 LC2 CF LV G2 250 psi BACK PRESSURE OUT S.W.
Sidewinder Circuit The gear pump (P2) is directly coupled to the hydrostat through gear pump (P1) and driven by the engine. It supplies hydraulic pressure for operating the power steering system, raising and lowering the cutting units, operating the sidewinder unit, and replenishing the closed loop traction circuit (charge pressure). The pump takes its suction directly from the hydraulic tank. spool valve and hydraulic manifold, and to the hydrostat.
Page 5 - 28 G2 LOWER PORT FORWARD P3 M6 INTERNAL CASE DRAIN G1 UPPER PORT TOP PORT HYDROSTAT 200- 300 psi 100- 150 psi 3500 psi BY- PASS VALVE M4 M5 TRACTION WHEEL MOTORS High Pressure Low Pressure (Charge) Return or Suction Flow Groundmaster 3500 Steering Circuit (Right Turn) OIL FILTER OIL COOLER T1 MANIFOLD BLOCK GEAR PUMP P1 P1 RV ST S M2 CR LC1 LC2 CF LV G2 250 psi BACK PRESSURE OUT S.W.
Steering Circuit With the steering wheel in the neutral position, the engine running, and the lift/sidewinder spool valve in the center position, flow enters the steering control valve at the P port and goes through the valve, by−passing the rotary meter (V1) and steering cylinder. Flow leaves the steering control valve through the E port, passes through the lift/sidewinder valve, hydraulic manifold, hydrostat and charge relief valve, and continues on to the gear pump inlet and hydraulic tank.
Troubleshooting The chart that follows contains information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the Testing section of this Chapter for precautions and specific hydraulic test procedures. Review the hydraulic schematic and information on hydraulic system operation in the Hydraulic Flow Diagrams section of this Chapter. This information will be useful during the hydraulic troubleshooting process.
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Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the various hydraulic circuits to perform various operational checks (See the Special Tools section in this chapter). Remember that pressure specifications that appear on hydraulic schematics are the design specifications for the specific component.
NOTE: Engine−to−Pump ratio is 1:0.88 for diesel units and 1:0.83 for gasoline units. In other words, 1 engine RPM = 0.88 pump RPM for a diesel powered unit. 4. The inlet and the outlet hoses must be properly connected and not reversed (hydraulic tester with pressure and flow capabilities) to prevent damage to the hydraulic tester or components. 5.
Traction Circuit Testing − Charge Pressure Test M5 TRACTION WHEEL MOTORS M4 FORWARD TOP PORT M6 TESTER WITH PRESSURE GUAGE AND FLOW METER LOWER PORT BY−PASS VALVE UPPER PORT TO HYDRAULIC MANIFOLD (P1) PORT TEE CONNECTOR AND PRESSURE GUAGE 3500 psi FROM HYDRAULIC MANIFOLD (CHG) PORT 100 to 150 psi CHARGE RELIEF 200−300 psi TO STEERING CONTROL VALVE (IN) PORT ENGINE P1 P2 RPM P3 FROM OIL FILTER GEAR PUMP HYDROSTAT STRAINER INTERNAL CASE DRAIN High Pressure Low Pressure Return or Suction
Traction Circuit Testing − Charge Pressure Test: 2 The charge pressure test is the first in a series of tests recommended to determine traction circuit performance. A charge pressure drop of more than 20% indicates an internal leak in the piston pump/hydrostat. Continued unit operation can generate excessive heat, cause damage to seals and other components in the hydraulic system, and affect overall machine performance.
Traction Unit Testing − Wheel Motor Efficiency Tests FRONT WHEEL MOTORS FRONT WHEEL MOTORS M4 M4 TESTER WITH PRESSURE GAUGES AND FLOW METER LOWER PORT FORWARD FRONT WHEEL MOTOR TEST (individually) M5 FORWARD FRONT WHEEL MOTOR TEST (together) M5 TESTER WITH PRESSURE GAUGES AND FLOW METER M6 REAR WHEEL MOTOR BY−PASS VALVE M6 REAR WHEEL MOTOR UPPER PORT PISTON PUMP (HYDROSTAT) LOWER PORT 3500 psi TRACTION RELIEF PISTON PUMP (HYDROSTAT) UPPER PORT REAR WHEEL MOTOR TEST M5 FROM HYDRAULIC MANIFO
Traction Circuit Testing − Wheel Motor Efficiency Test: There are moments during wheel motor operation (geroller position) when fluid flow through the motor is less restricted. If a wheel motor is tested in this position, the test results will be higher should not be used to determine wheel motor efficiency. Test wheel motors in three (3) different wheel positions to obtain accurate test results. Record test readings for all three (3) wheel positions.
10.Release traction pedal, shut engine off, and record test results. 11. Rotate each front wheel 120 degrees and retest. Repeat this procedure until each wheel motor has been tested in three (3) different positions. Proceed to testing rear wheel motor If test results are within specification.
7. Slowly depress forward traction pedal until 1000 to 1500 PSI (68.9 to 103.4 Bar) is displayed on the pressure gauge. 9. Rotate rear wheel 120 degrees and retest. Repeat this procedure until wheel motor has been tested in three (3) different positions. Flow meter should read less than 1.5 GPM (5.7 LPM). 10.If specifications are not met, repair or replace worn wheel motor. Hydraulic System 8. Release traction pedal, shut engine off, and record test results.
Traction Circuit Testing − Piston Pump/Hydrostat (P3) Flow and Relief Pressure Test M5 FORWARD TRACTION WHEEL MOTORS M4 TOP PORT TESTER WITH PRESSURE GAUGES AND FLOW METER LOWER PORT M6 BY−PASS VALVE UPPER PORT 3500 psi TRACTION RELIEF 100 to 150 psi FROM HYDRAULIC MANIFOLD (CHARGE) PORT 200 to 300 psi P3 PISTON PUMP (HYDROSTAT) Low Pressure Return or Suction TO GEAR PUMP SUCTION THROUGH CASE DRAIN Hydraulic System High Pressure Flow Page 5 − 42 Groundsmaster 3500
Traction Circuit Testing − Piston Pump/Hydrostat (P3) Flow and Relief Pressure Test: The hydrostat flow test is the third in a series of tests recommended to determine traction circuit performance. The final traction circuit test is verifying the hydrostat relief valve operation. This test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 12% indicates an internal leak or malfunctioning relief valve in the piston pump/hydrostat.
NOTE: The relief valve setting is 3500 PSI (241 Bar). An additional 100 to 150 PSI (6.9 to10.3 Bar) is necessary to overcome system charge pressure before the relief valve opens. E. Release traction pedal, open flow control valve fully, move throttle to low speed and turn the engine off. 14.If relief pressure can not be met or is greater than specified, the traction relief valve is faulty and should be replaced. Hydraulic System 15.The Under Load test flow reading (step 12.
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Cutting Deck Circuit Testing − Pressure Test FROM DECK MOTOR CASE DRAINS TO LEFT FRONT DECK MOTOR D1 M1 FROM REAR DECK MOTOR M2 TO HYDRAULIC TANK T2 1500 psi RV LC2 1500 psi G1 TEST GAUGE 3200 psi TO OIL COOLER HYDRAULIC MANIFOLD BLOCK S T1 LC1 G2 LV P1 CHG ST TO HYDROSTAT CHARGE CIRCUIT CR CF FROM LIFT VALVE (OUT) PORT FROM FRONT LIFT CYLINDER FROM REAR LIFT CYLINDER ENGINE RPM TO STEERING CONTROL VALVE (IN) PORT FROM STEERING CONTROL VALVE (OUT) PORT P1 P2 FROM HYDROSTAT INTERNAL
Cutting Deck Circuit Testing − Pressure Test: Cutting deck circuit pressure is the first in a series of tests recommended to check cutting deck circuit performance. The results from this test will help determine which component(s) are the cause of cutting deck performance issues. Unit Serial No.
11. If pressure specifications are not met, consider the following: A. Manifold relief valve is faulty (see Cutting Deck Circuit − Manifold Relief Valve Pressure Test in this chapter) B. Gear pump (P1) is faulty (see Cutting Deck Circuit − Gear Pump (P1) Flow Under Load Test in this chapter) Hydraulic System C. The blade braking valve (BV − Unit Serial No. Prior to 31400000) or the blade braking relief valve and/ or logic cartridge (RV and LC2 − Unit Serial No. 314000001 & Up) is faulty.
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Cutting Deck Circuit Testing − Deck Motor Efficiency/Case Drain Test TO HYDRAULIC MANIFOLD PORT (D1) FROM HYDRAULIC MANIFOLD PORT (M1) LEFT DECK MOTOR TESTER WITH PRESSURE GAUGE AND FLOW METER MEASURING CONTAINER RIGHT DECK MOTOR High Pressure Low Pressure TO HYDRAULIC MANIFOLD PORT (M2) REAR DECK MOTOR Return or Suction Flow Toro # TOR4077 Hydraulic System Page 5 − 50 Groundsmaster 3500
Cutting Deck Circuit Testing − Deck Motor Efficiency/Case Drain Test 1 The deck motor efficiency/case drain test is the second in a series of tests recommended to check cutting deck circuit performance. Over a period of time, a deck motor can wear internally. This test measures case drain volume while restricting flow across the motor ports. Case drain volume under load of more than 9% of total motor flow indicates the gears and wear plates in the motor have worn.
12.Hold disconnected motor case drain hose into a container graduated in ounces or milliliters (e.g. Toro #TOR4077) and collect hydraulic fluid for 30 seconds. After 30 seconds, remove hose end from container. 16.Remove tester and reconnect hydraulic hoses. 13.Record amount of fluid collected in the container. 18.Repeat test with remaining deck motors as needed. 14.Disengage cutting decks, set throttle to low speed and stop engine. 19.Install deck motors after testing is completed.
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Cutting Deck Circuit Testing − Manifold Relief Valve Pressure Test FROM DECK MOTOR CASE DRAINS TESTER WITH PRESSURE GAUGES AND FLOW METER D1 M1 TO LEFT FRONT DECK MOTOR FROM REAR DECK MOTOR M2 TO HYDRAULIC TANK T2 1500 psi RV LC2 1500 psi G1 3200 psi TO OIL COOLER HYDRAULIC MANIFOLD BLOCK S T1 LC1 G2 LV P1 CHG ST TO HYDROSTAT CHARGE CIRCUIT CR CF FROM LIFT VALVE (OUT) PORT FROM FRONT LIFT CYLINDER FROM REAR LIFT CYLINDER ENGINE RPM TO STEERING CONTROL VALVE (IN) PORT FROM STEERING C
Cutting Deck Circuit Testing − Manifold Relief Valve Pressure Test: Unit Serial No. Prior to 314000001 Test the performance of the manifold relief valve (S or S1) to make sure that the maximum amount of fluid is available to the cutting deck motors up to the set relief pressure. This test also ensures that pump (P1) is capable of generating enough pressure to open a properly functioning manifold relief valve. The manifold relief valve is part of the cutting deck solenoid valve.
Cutting Deck Circuit Testing − Gear Pump (P1) Flow Test TO HYDRAULIC MANIFOLD (P1) PORT TESTER WITH PRESSURE GAUGES AND FLOW METER TO STEERING CONTROL VALVE (IN) PORT TO TOTO ENGINE P1 P2 RPM GEAR PUMP FROM HYDROSTAT CASE DRAIN FROM OIL FILTER STRAINER High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 5 − 56 Groundsmaster 3500
Cutting Deck Circuit Testing − Gear Pump (P1) Flow Test: 2 The gear pump (P1) flow test is the last in a series of tests recommended to determine cutting deck circuit performance. This test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 15% indicates the gears and wear plates in the pump have worn. A worn pump will by−pass hydraulic fluid and make the pump less efficient.
Steering/Lift/Sidewinder Circuit Testing − Gear Pump (P2) Flow Test TO HYDRAULIC MANIFOLD (P1) PORT TESTER WITH PRESSURE GAUGES AND FLOW METER TO STEERING CONTROL TO TOTO VALVE (IN) PORT ENGINE P1 P2 RPM GEAR PUMP FROM HYDROSTAT CASE DRAIN FROM OIL FILTER High Pressure Low Pressure STRAINER Return or Suction Flow Hydraulic System Page 5 − 58 Groundsmaster 3500
Steering/Lift/Sidewinder Circuit Testing − Gear Pump (P2) Flow Test: 2 Gear pump (P2) is designed to satisfy both steering cylinder and lift/sidewinder cylinder needs simultaneously (at full speed throttle). The Gear Pump (P2) Flow Test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 15% indicates the gears and wear plates in the pump have worn.
12.Disconnect tester and reconnect hose to pump. NOTE: If necessary, circuit relief valve pressure test can be conducted with tester in the same location as for this test (see Steering/Lift/Sidewinder Circuit − Relief Valve Pressure Test in this chapter).
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Steering/Lift/Sidewinder Circuit Testing − Relief Valve Pressure Test TO HYDRAULIC MANIFOLD (ST) PORT TO LIFT VALVE (IN) PORT L V1 T 1000 psi STEERING P R E POWER STEERING VALVE TEST GAUGE TO HYDRAULIC MANIFOLD (P1) PORT GEAR PUMP ENGINE RPM P1 P2 STRAINER FROM OIL FILTER High Pressure Low Pressure Return or Suction FROM HYDROSTAT INTERNAL CASE DRAIN Hydraulic System Flow Page 5 − 62 Groundsmaster 3500
Steering/Lift/Sidewinder Circuit Testing − Relief Valve Pressure Test: 2 The relief valve for the steering, lift, and sidewinder circuits is integrated into the steering control valve. If both steering and lift operations perform poorly, perform the relief valve pressure test and gear pump (P2) flow test (see Steering/Lift/Sidewinder Circuit − Gear Pump (P2) Flow Test in this chapter).
Steering/Lift/Sidewinder Circuit Testing − Steering Control Valve and Steering Cylinder Test STEERING CYLINDER OPEN FITTING PLUG E T P 1000 psi V1 L R POWER STEERING VALVE (LEFT TURN) High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 5 − 64 Groundsmaster 3500
Unit steering performance will be affected by incorrect rear tire pressure, binding in the hydraulic steering cylinder, extra weight on the vehicle, and/or binding of the steering fork assembly. Make sure that these conditions are checked and functioning properly before proceeding with any steering system hydraulic testing. 1. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Drive machine slowly in a figure eight on a flat level surface.
Adjustments Blade Braking Valve (BV) Adjustment (Traction Units Prior to No 314000001) The blade braking valve (BV) on the hydraulic manifold controls the stopping time for the cutting deck blades. The braking valve is adjustable. If adjustment of the braking valve is correct, the cutting deck blades should come to a complete stop within 7 seconds after the PTO switch is disengaged.
Blade Braking Relief Valve (RV) Adjustment (Traction Units No 314000001 & Up) The blade braking relief valve (RV) on the hydraulic manifold works in conjunction with logic cartridge valve (LC2) to control the stopping time for the cutting deck blades. The relief valve is adjustable. If adjustment of the relief valve is correct, the cutting deck blades should come to a complete stop within 7 seconds after the PTO switch is disengaged.
Counterbalance Logic Valve (LC1) Adjustment FROM DECK MOTOR CASE DRAINS TO LEFT FRONT DECK MOTOR D1 TO HYDRAULIC TANK M1 FROM REAR DECK MOTOR M2 T2 RV 1500 psi LC2 S 3200 psi HYDRAULIC MANIFOLD BLOCK G1 LC1 TO OIL COOLER G2 T1 TEST GAUGE LV P1 CHG ST TO HYDROSTAT CHARGE CIRCUIT CR CF FROM LIFT VALVE (OUT) PORT FROM FRONT LIFT CYLINDER FROM REAR LIFT CYLINDER ENGINE RPM TO STEERING CONTROL VALVE (IN) PORT FROM STEERING CONTROL VALVE (OUT) PORT P1 P2 GEAR PUMP FROM HYDROSTAT INTERN
Counterbalance Logic Valve (LC1) Adjustment: Unit Serial No. Prior to 314000001 The counterbalance system helps distribute the overall unit weight across the drive wheels and cutting decks for improved traction and reduced turf marking. The system is functioning properly if the machine settles slightly when the engine is started while the cutting decks are in the fully lowered position. 4 3 1 1. Park machine on a level surface with the cutting units lowered and PTO switch off.
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting units or attachments, and stop engine. Remove key from the ignition switch. 1. Check fluid level in the hydraulic tank and add correct hydraulic fluid if necessary.
Check Hydraulic Lines and Hoses IMPORTANT: Check hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings or deterioration. Make all necessary repairs before operating the machine. WARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury.
Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or if the system is contaminated (fluid appears milky, black, or contains metal particles). IMPORTANT: Flush hydraulic system when changIng from petroleum base hydraulic fluid to a biodegradable fluid such as Toro Biodegradable Hydraulic Fluid. Operate machine under normal operating conditions for at least four (4) hours before draining.
Filtering Closed−Loop Traction Circuit 1. Park machine on a level surface, stop engine and remove key from ignition switch. WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 − Safety. 2. Raise and support machine so all wheels are off the ground. NOTE: If a wheel motor was replaced, install high flow filter to the inlet (when traveling forward) of new wheel motor instead of to the inlet (when traveling forward) of the traction pump.
Charge Hydraulic System NOTE: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps, or lift cylinders, it is important that the hydraulic system be charged properly. Air must be purged from the system and its components to reduce the chance of damage. IMPORTANT: Change hydraulic fluid filter whenever hydraulic components are repaired or replaced. 8.
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Hydraulic Tank and Hydraulic Fluid Filter 14 18 16 6 80 to 87 ft−lbs (108.4 to 117.9 N−m) 30 9 12 15 27 26 28 25 24 4 23 8 11 19 22 29 7 17 8 10 13 3 20 21 22 1 5 2 Anti−seize lubricant 30 to 60 in−lb (3.4 to 6.8 N−m) Figure 47 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Grommet Flange head screw Barb fitting Check fitting Flat washer Hydraulic tank O–ring Hose clamp Barb fitting (straight) Flange head screw Hydraulic System 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Hydraulic Tank Removal Hydraulic Tank Installation 1. Drain hydraulic fluid from Hydraulic tank. 2. Remove hydraulic tank (Fig. 47). Discard and replace any O–rings that are removed. 1. Apply anti−seize lubricant or equivalent to the four (4) flange head screws that secure the hydraulic tank. Tighten the tank mounting screws from 30 to 60 in−lb (3.4 to 6.8 N−m). Install tank (Fig 47). Hydraulic Tank Inspection (Fig. 47) 2. Lubricate and install new O−ring on suction strainer. 1.
Hydraulic Fluid Cooler CAUTION The radiator and hydraulic fluid cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before working on the hydraulic fluid cooler. 2 Removal (Diesel Engine) 1 Traction Unit Serial No. Prior to 314000001, remove hydraulic fluid cooler (Fig. 48 and 49). Traction Unit Serial No. 314000001 & Up, remove radiator/hydraulic fluid cooler assembly (see Radiator/Hydraulic Fluid Cooler Removal in Chapter 3 − Kubota Diesel Engine). Figure 48 1.
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Piston Pump/Hydrostat Assembly 10 26 27 25 28 58 25 45 50 7 44 49 48 43 47 42 8 5 29 12 54 1 24 45 53 40 32 9 13 77 to 93 ft−lb (105 to 127 N−m) 27 3 33 30 40 38 55 6 56 34 40 51 4 46 1018 37 41 31 30 21 20 36 27 to 31 ft−lb (37 to 42 N−m) 11 41 2 RIGHT 35 57 22 23 90 to 120 in−lb (10.2 to 13.6 N−m) 52 17 16 39 FRONT 19 15 (tighten in 3 equal steps) 14 Blue Loctite Figure 50 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Drive Belt Removal (Fig. 50) 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the ignition switch. 2. Raise and support hood. CAUTION CAUTION Use caution when installing torsion spring end onto the pump mount plate. Applying tension to the spring may cause personal injury during installation. 4. Apply pump drive belt tension with torsion spring on idler arm (Fig. 51).
Neutral Arm Assembly 1 4 23 24 7 22 18 21 19 20 6 5 7 9 12 8 9 10 14 12 3 2 11 32 33 29 16 17 15 16 31 13 26 25 27 30 28 Figure 52 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Pump assembly Hose Extension spring Pump mount plate Neutral bracket Flange nut Flange head screw Neutral arm Flange bushing Thrust washer 90o grease fitting Hydraulic System 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Neutral Arm Removal (Fig. 52) Neutral Arm Installation (Fig. 52) 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the ignition switch. 1. Install key into trunnion slot. Position neutral bracket to the mount plate and the pump lever and hub assembly to the pump trunnion. 2. Raise and support hood. 2. Secure pump lever and hub assembly to the piston pump trunnion with flat washer and cap screw. 3.
Piston Pump/Hydrostat 1 RIGHT FRONT 2 3 4 5 6 10 9 8 7 Figure 53 1. 2. 3. 4. Engine mount bracket Flange nut Flange screw Pump mount plate 5. Hardened washer 6. 10 mm cap screw (4) 7. 8 mm cap screw (1) Piston Pump/Hydrostat Removal (Fig. 50 and 53) 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the ignition switch. 2. Raise and support hood. 3. Remove pump drive belt (see Drive Belt Removal in this chapter). 4.
8. Disconnect all hydraulic hoses connected to the hydraulic fittings on the piston pump/hydrostat and gear pump. Allow hoses to drain into a suitable container. Plug hose and fitting openings to prevent contamination. Remove plugs before installing gear pump to piston pump 1 CAUTION Support pump assembly during removal to prevent them from falling and causing personal injury or component damage. 2 9. Support hydraulic pump assembly to prevent it from shifting. 10.
4. Place key into piston pump shaft slot. Slide taper lock bushing onto the piston pump shaft with bushing flange toward pump housing. IMPORTANT: When tightening taper lock bushing cap screws, tighten in three (3) equal steps and in a circular pattern. 5. Make sure that tapered surfaces of pump pulley and taper lock bushing are thoroughly clean (no oil, grease, dirt, rust, etc.). 11. Secure taper lock bushing and pump pulley by tightening three (3) cap screws to a torque from 90 to 120 in−lb (10.2 to 13.
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Piston Pump/Hydrostat Service 21 22 41 40 39 19 38 17 37 27 16 15 36 14 17 20 15 4 26 15 25 42 24 7 43 44 45 8 46 10 6 18 13 11 12 35 9 6 28 3 2 1 33 32 29 30 31 30 29 46 8 5 26 4 23 18 34 Figure 55 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Key Drive shaft Bearing Cap screw (3 used per plate) Cover plate O–ring Shim kit Bearing cone Key Swashplate Rotating kit Gasket Valve plate Bearing Dowel pin Back plate Hydraulic System 17. 18. 19. 20. 21. 22.
IMPORTANT: If a piston pump failure occurred, refer to Traction Circuit (Closed Loop) Component Failure in this chapter for information regarding the importance of removing contamination from the traction circuit. CHARGE RELIEF VALVE 4 NOTE: The traction circuit charge relief valve and the bleed off valve for traction circuit cooling are attached to the piston pump back plate assembly (Fig. 56).
Piston Pump/Hydrostat Crush Ring Replacement 4 5 29 ft−lb (39 N−m) 8 7 2 3 v 9 10 6 1 Figure 57 1. 2. 3. 4. Crush ring Shims Cover plate Housing 5. Camplate (control shaft) 6. Bearing cone 7. Bearing cup Piston Pump Crush Ring Replacement (Fig. 57) 5. Install washers and cap screws to the cover plate and housing. Torque cap screws to 29 ft−lbs (39 N−m). NOTE: The shims replace the crush ring in the cover plate.
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Gear Pump 9 5 10 4 12 11 13 14 2 1 RIGHT 15 FRONT 17 16 8 7 3 6 Figure 58 1. 2. 3. 4. 5. 6. Piston pump Gear pump Hydraulic hose (tank suction) Hydraulic hose (hydraulic manifold) Hydraulic hose (steering valve) Hose clamp 7. 8. 9. 10. 11. 12. Hydraulic barb fitting O–ring O–ring 90o hydraulic fitting O–ring O–ring 13. 14. 15. 16. 17. 90o hydraulic fitting O–ring Cap screw Flat washer O–ring 5. Label hydraulic hoses and fittings on gear pump for assembly purposes. Removal (Fig. 58) 1.
Installation (Fig. 58) Remove plugs before installing gear pump to piston pump 1. If fittings were removed from gear pump, lubricate and place new O−rings onto fittings. Install fittings into pump openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 1 2. Make sure mounting and O−ring sealing surfaces on the gear pump and piston pump are clean. 2 3.
Gear Pump Service 19 14 18 17 11 10 12 2 8 3 6 1 3 2 20 16 21 13 15 13 14 33 ft−lb (45 N−m) 9 8 7 5 4 Figure 60 1. 2. 3. 4. 5. 6. 7. Front cover Pressure seal Back−up gasket Front thrust plate Idler gear Drive shaft Rear thrust plate 8. 9. 10. 11. 12. 13. 14. Dowel pin Seal Body Seal Splined connecting shaft Pressure seal Back−up gasket 15. 16. 17. 18. 19. 20. 21. Front thrust plate Idler gear Drive gear Rear thrust plate Rear cover Washer (4 used) Cap screw (4 used) Disassembly (Fig.
IMPORTANT: Use caution when clamping gear pump in a vise to avoid distorting any pump components. 3. Secure the front cover of the pump in a vise with the drive shaft pointing down. 8. Clean all pump parts. Check all components for burrs, scoring, nicks and other damage. 9. Replace the entire pump assembly if parts are excessively worn or scored. Assembly (Fig. 60) 4. Loosen the four (4) cap screws that secure pump assembly. 1. Apply clean hydraulic fluid to all parts before assembling. 5.
Front Wheel Motors 5 7 3 8 9 10 6 4 RIGHT 8 FRONT 9 10 2 1 1. 2. 3. 4. Lock nut Spacer Socket head screw Hydraulic wheel motor Hydraulic System Figure 62 5. Frame 6. Hydraulic tube 7. Hydraulic tube Page 5 − 96 8. O–ring 9. Hydraulic fitting 10.
Removal (Fig. 62) Installation (Fig. 62) 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the ignition switch. 1. If adapters were removed from wheel motor, lubricate and place new O−rings onto fittings. Install adapters into motor openings and tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). WARNING 2.
Rear Wheel Motor 1 70 to 90 ft−lb (95 to 122 N−m) 2 5 7 8 13 15 6 3 7 4 300 to 400 ft−lb (407 to 542 N−m) 8 12 14 13 9 11 10 Figure 63 1. 2. 3. 4. 5. Lug nut Drive stud Tire and rim assembly Wheel hub Hydraulic hose 6. 7. 8. 9. 10. Hydraulic hose O–ring 45o hydraulic fitting Lock nut Socket head screw Removal (Fig. 63) 11. 12. 13. 14. 15. Hydraulic motor Rear fork O–ring Woodruff key Lock nut 5. Secure wheel hub in a vise.
Installation (Fig. 63) 5. Install tire and rim assembly to machine. 1. If hydraulic fittings were removed from wheel motor, install fittings to motor using marks made during the removal process to properly orientate fittings. 6. Lower the machine to the ground. 2. Thoroughly clean wheel motor shaft and wheel hub taper. 3. Lock wheel hub in a vise. Install woodruff key into the wheel motor shaft. Slide motor shaft into hub and secure with lock nut. Torque lock nut from 300 to 400 ft−lb (407 to 542 N−m).
Wheel Motor Service 13 12 45 to 55 ft−lb (60 to 76 N−m) 11 10 3 1 4 5 6 7 8 9 8 14 27 2 15 16 17 28 26 25 24 28 27 23 22 21 20 19 18 Figure 64 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Dirt seal Bearing Housing Back−up washer Seal rings Back−up washer Inner seal Thrust washer Thrust bearing Bearing 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
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Hydraulic Manifold 21 CF CR 17 18 18 11 M1 22 M2 CHG 16 20 D1 15 11 19 T1 19 P1 26 14 25 24 27 13 12 23 25 11 24 10 T2 23 28 4 1 9 3 5 RIGHT 2 6 LV FRONT ST 8 Traction Units Prior to Serial No 314000001 7 Figure 65 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Hose clamp 90o hydraulic fitting Barb fitting Hydraulic hose − T2 O–ring Hydraulic hose − ST Flange head nut Stud Hydraulic tube − LV O–ring Hydraulic System 11. 12. 13. 14. 15. 16. 17. 18. 19.
21 CF CR 18 22 M2 T1 17 11 M1 CHG 16 20 D1 18 19 15 11 P1 19 26 14 25 13 24 27 12 23 25 10 24 11 T2 23 28 4 1 9 3 5 RIGHT 2 6 LV Hydraulic System FRONT ST 8 Traction Units Serial No 314000001 & Up 7 Figure 66 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Hose clamp 90o hydraulic fitting Barb fitting Hydraulic hose − T2 O–ring Hydraulic hose − ST Flange head nut Stud Hydraulic tube − LV O–ring Groundsmaster 3500 11. 12. 13. 14. 15. 16. 17. 18. 19.
Removal (Fig. 65 and 66) Installation (Fig. 65 and 66) NOTE: The ports on the manifold are marked for easy identification of components. Example: port LV connects the the lift valve circuit and port P1 connects the gear pump (P1). See Hydraulic Schematics in this chapter to identify the function of the hydraulic lines and cartridge valves at each port location. 1.
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Hydraulic Manifold Service 5 Traction Units Prior to Serial No 314000001 60 in−lb (6.8 N−m) 6 25 ft−lbs (34 N−m) 25 ft−lb (34 N−m) 7 4 50 ft−lbs (68 N−m) 8 20 ft−lbs (27.1 N−m) 1 25 ft−lbs (24 N−m) 2 RIGHT 3 FRONT Figure 67 1. Manifold body 2. #4 Hex head plug 3. #4 Zero leak plug Hydraulic System 4. Logic cartridge valve (LC1) 5. Nut 6. Solenoid coil Page 5 − 106 7. Solenoid cartridge valve (S1) 8.
Traction Units Serial No 314000001 & Up 25 ft−lbs (34 N−m) 4 20 ft−lbs (27.1 N−m) 5 25 ft−lbs (34 N−m) 6 25 ft−lb (34 N−m) 3 3 25 ft−lbs (34 N−m) 1 7 8 2 20 ft−lbs (27.1 N−m) FRONT 3 RIGHT 60 in−lb (6.8 N−m) Figure 68 1. Manifold body 2. #4 Hex hd plug 3. #4 Zero leak plug Groundsmaster 3500 4. Logic cartridge valve (LC1) 5. Logic cartridge valve (LC2) 6. Relief valve (RV) Page 5 − 107 7. Solenoid cartridge valve (S) 8. Solenoid coil 9.
Cartridge Valve Service (Fig. 67 and 68) NOTE: The ports on the manifold are marked for easy identification of components. Example: port LV connects the the lift valve circuit and port P1 connects the gear pump (P1). See Hydraulic Schematics in this chapter to identify the function of the hydraulic lines and cartridge valves at each port location. NOTE: The Groundsmaster 3500 hydraulic manifold uses several zero leak plugs.
Cutting Deck Motor The hydraulic motors used on all cutting decks are the same. 2 Removal 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1 2. Read the General Precautions for Removing and Installing Hydraulic System Components in this chapter. 3. To prevent contamination of hydraulic system during deck motor removal, thoroughly clean exterior of motor. 4. Disconnect hydraulic lines from deck motor.
Cutting Deck Motor Service 33 ft−lb (45 N−m) 26 ft−lb (35 N−m) 19 18 16 13 9 8 5 6 3 1 17 15 10 14 7 12 6 11 2 4 12 26 ft−lb (35 N−m) 7 10 Figure 71 1. 2. 3. 4. 5. 6. 7. Dust seal (2 used) Retaining ring Flange washer Shaft seal Front flange Pressure seal Backup gasket 8. 9. 10. 11. 12. 13. Front wear plate Drive gear Dowel pin (4 used) Idler gear O–ring Body 14. 15. 16. 17. 18. 19.
5. Remove motor from the vise. Turn motor so that the shaft end is facing down. Remove cap screws. 6. Separate rear cover from body. Lift rear cover from motor. 7. Carefully remove body. Lift body straight up to remove. Make sure the rear wear plate remains on the drive and idler gear shafts. Remove and discard O–rings from the body. Locate and retrieve dowel pins. IMPORTANT: Note position of the open and closed side of the wear plates before removing.
Assembly (Fig. 71) NOTE: When assembling the motor, check the marker line on each part to make sure the parts are properly aligned during assembly. 1. Lubricate O–rings, pressure seals, back−up gaskets and wear plate grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic fluid. 9. Apply a light coating of petroleum jelly to new O–rings and O–ring grooves in the body. Install new O–rings to the body. 10.Install locating dowels in body.
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Steering Control Valve 20 to 26 ft--lb (28 to 35 N--m) 8 9 11 14 20 27 21 7 38 39 10 12 17 28 32 19 Blue Loctite 242 5to 7ft--lb (6.8 to 9.5N--m) 2 18 23 4 6 22 24 5 34 36 8 33 37 41 43 45 40 26 25 3 35 40 44 3 43 1 29 30 31 13 15 16 2 Figure 75 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Removal (Fig. 75) 3 1 WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in the General Information section. 1. Remove Philips head screws and steering wheel cap from steering wheel. 2 2. Remove the nut securing the steering wheel to the steering control valve and pull the steering wheel from the control valve. 3. Remove the steering cover. 5. Disconnect hydraulic lines from steering valve.
Steering Control Valve Service 8 9 7 6 10 5 4 3 2 11 1 12 22 13 14 15 21 13 16 20 13 17 18 20 to 24 ft−lb (27 to 33 N−m) 19 Figure 77 1. 2. 3. 4. 5. 6. 7. 8. Sleeve Cross pin Ring Spool Bearing assembly Shaft seal Ball stop Ball 9. 10. 11. 12. 13. 14. 15. Dust seal ring Housing Cardan shaft Spacer O–ring Distribution plate Inner gearwheel 16. 17. 18. 19. 20. 21. 22.
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Steering Cylinder 8 7 6 5 3 1 4 8 5 No. 2 General Purpose Grease 2 7 10 3 No. 2 General Purpose Grease 9 4 65 to 85 ft−lb (88 to 115 N−m) 12 9 11 65 to 85 ft−lb (88 to 115 N−m) Figure 78 1. 2. 3. 4. Hydraulic hose Hydraulic hose O–ring Hydraulic fitting Hydraulic System 5. 6. 7. 8. O–ring Steering cylinder Ball joint Retaining ring Page 5 − 118 9. 10. 11. 12.
Removal (Fig. 78) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. NOTE: The rear wheel must be removed to allow sufficient clearance to remove the steering cylinder from the machine. 2. Install steering cylinder to the frame and rear fork using. When securing cylinder ball joints to machine, tighten the first jam nut from 65 to 85 ft−lb (88 to 115 N−m), then tighten the second jam nut to the same specification. 3.
Steering Cylinder Service 1 11 12 10 9 8 7 6 5 4 3 2 40 ft−lb (54 N−m) 2 3 4 1 5 8 6 9 10 11 7 12 Figure 81 1. 2. 3. 4. Barrel with clevis Lock nut Piston Uni−ring Hydraulic System 5. 6. 7. 8. O–ring Piston rod Rod seal Cylinder gland Page 5 − 120 9. 10. 11. 12.
Disassembly Assembly 1. Remove hydraulic fluid from the steering cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1. Make sure all parts are clean before reassembly. 2. Mount clevis end of steering cylinder in a vice. Remove retaining ring. 3. Remove plugs from ports. Extract shaft, cylinder gland, and piston by carefully twisting and pulling on the shaft. IMPORTANT: Do not clamp vise jaws against the shaft surface.
Lift/Sidewinder Control Valve 13 6 12 14 17 11 17 1 25 9 7 8 21 5 27 15 26 10 25 14 5 5 16 21 7 25 4 21 20 18 2 25 21 21 23 9 24 21 22 3 19 Figure 82 1. 2. 3. 4. 5. 6. 7. 8. 9. Control valve (2−spool) Hydraulic fitting (straight) 90o hydraulic fitting Hydraulic fitting (straight) Flange nut Knob 90o hydraulic fitting Valve actuator bracket Shoulder bolt Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 82) 1 4 WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in the General Information section. 1. Remove cover from operator’s control panel. 2. Remove control valve from the frame. 3 3. If hydraulic fittings are to be removed from control valve, note and mark fitting orientation to allow correct assembly. 2 Figure 83 Installation 1.
Lift/Sidewinder Control Valve Service 10 to 12 ft−lb (14 to 16 N−m) 18 26 28 9 15 25 1 19 4 to 5 ft−lb (5.4 to 6.8 N−m) 5 27 17 12 20 23 9 22 29 24 30 7 6 4 26 25 4 11 30 to 35 ft−lb (41 to 48 N−m) 21 27 1 5 10 2 27 5 1 12 14 8 9 16 13 10 3 29 30 20 to 25 ft−lb (27 to 34 N−m) 7 30 to 35 ft−lb (41 to 48 N−m) Figure 84 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
6 26 25 1 27 5 1 9 7 15 9 26 25 17 19 18 1 21 27 5 29 30 23 22 24 4 14 12 16 13 20 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Check poppet Grooved plunger Spacer Spool Seat Solid plug Seat retaining plug with port Bushing Check spring Spool cap Groundsmaster 3500 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Figure 85 Valve body O–ring Retaining ring Washer Seat retaining plug Spool spring Disc Plug Detent plug Wiper seal Page 5 − 125 8 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Disassembly 1. Plug all ports and clean the outside of the valve thoroughly. IMPORTANT: Match−mark spools to their associated bores before disassembly. Spools must be reinstalled to the bore from which they were removed. 2. Remove both spool caps and slide the spool assemblies from their bores. 3. Remove O–ring and bushing from each spool assembly. 4. Remove wiper seals and O–rings from the spool bore ends that are opposite the spool caps.
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Front Lift Cylinder 9 6 4 RIGHT FRONT Anti−seize Lubricant 15 39 41 40 34 57 47 42 55 43 48 31 5 16 21 22 20 66 63 28 26 3 7 28 37 32 29 30 12 23 24 13 33 53 44 58 59 60 62 61 28 26 28 38 33 17 45 33 46 10 18 53 64 56 27 20 25 24 19 65 49 54 50 51 8 35 1 52 36 2 13 11 14 Figure 86 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Removal (Fig. 86) 2 WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in the General Information section. 1 3 1. Remove front lift cylinder from the frame and lift arm. Figure 87 2. If hydraulic fittings are to be removed from lift cylinder, note and mark fitting orientation to allow correct assembly. 1. 2. Lift cylinder Hydraulic hoses 3. Clearance Installation 1.
Rear Lift Cylinder 36 40 35 16 3 12 37 30 15 12 11 28 10 12 13 46 17 13 15 2 21 14 42 2 48 1 49 46 23 39 31 27 41 20 4 32 46 45 7 24 5 18 44 25 9 13 6 22 38 29 33 34 47 12 8 26 RIGHT 43 19 12 2 FRONT 3 12 Figure 88 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Installation Removal (Fig. 88) 1. If hydraulic fittings were removed from lift cylinder, install fittings to cylinder using marks made during the removal process to properly orientate fittings. WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in the General Information section. 2. Install rear lift cylinder to the frame and lift arm. 3. Make sure hydraulic tank is full.
Lift Cylinder Service 2 3 4 5 1 6 7 8 9 10 11 12 40 ft−lb (54 N−m) 13 14 15 1 1 2 3 9 12 13 5 4 6 7 8 10 11 14 15 1 Figure 89 1. 2. 3. 4. 5. Grease fitting Barrel with clevis Nut Uni−ring Piston Hydraulic System 6. 7. 8. 9. 10. O–ring O–ring Back−up ring Rod seal Head Page 5 − 132 11. 12. 13. 14. 15.
Disassembly 1. Remove hydraulic fluid from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. IMPORTANT: Prevent damage when clamping the hydraulic cylinder into a vise; clamp on the clevis only. 2. Mount lift cylinder in a vice. Remove internal collar with a spanner wrench. 3. Remove plugs from ports. Extract shaft, head, and piston by carefully twisting and pulling on the shaft.
Sidewinder 18 19 17 14 13 26 1 7 1 19 26 14 11 13 9 1 20 12 10 31 25 10 11 12 1 22 RIGHT 5 9 15 16 28 27 32 27 21 FRONT 15 6 24 1 4 23 28 2 3 30 8 29 Figure 91 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Bushing Scissor link Scissor mount Cap screw Flat washer Lock nut Scissor frame Hydraulic cylinder Spacer Flat washer Cap screw Hydraulic System 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Removal (Fig. 91) WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in the General Information section. 4 3 2 The hydraulic cylinder used in the Groundsmaster 3500 sidewinder assembly is a non−serviceable cylinder. Replace the cylinder if it becomes worn or damaged. 1 Figure 92 1. Remove hydraulic cylinder from the frame. 2.
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Chapter 6 Electrical System Table of Contents Diode Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . CAN−bus Termination Resistor (Gasoline Engines Only) . . . . . . . . . . . . . . . . . . Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neutral Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information Operator’s Manual The traction unit Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine. Electrical Drawings The electrical schematic and wire harness drawings for the Groundsmaster 3500−D Model 30807 and the Groundsmaster 3500−G Model 30809 are located in Chapter 9 − Foldout Drawings.
Kubota Gasoline Engine − Electrical Components The engine used in the Groundsmaster 3500−G features an electronic control unit (ECU) that controls a common rail fuel injection system, electronic throttle valve (ETV), and a catalytic muffler exhaust system with a pre−muffler oxygen (O2) sensor.
Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The multimeter can test electrical components and circuits for current (amps), resistance (ohms) or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL VoltOhm- Amp multimeter when testing electrical circuits.
Battery Terminal Protector Aerosol spray that should be used on battery terminals, ring terminals, and fork terminals to reduce corrosion problems. Apply battery terminal protector to the connection after the battery cable, ring terminal, or fork terminal has been secured.
Troubleshooting (SCM) (see Standard Control Module in this chapter). If the machine has had any interlock switches by−passed, they must be reconnected for proper troubleshooting and safety. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage.
Starting Problems (continued) Problem Possible Causes Starter solenoid clicks, but starter will not crank Low battery charge. NOTE: If the solenoid clicks, the problem is not in the in- Loose or corroded battery cables. terlock circuit. Loose or corroded ground. Faulty wiring at the starter. Faulty starter solenoid. Faulty starter motor. Engine cranks, but does not start. The fuel tank is empty. The fuel pump or fuel pump circuit wiring is faulty.
General Run and Transport Problems Engine stops running during operation (operator sitting on seat and unit moving). Operator not in center of seat (seat switch is not depressed). The seat switch is faulty or seat switch circuit wiring is loose, corroded or damaged. The parking brake was engaged or the parking brake switch is faulty or parking brake switch circuit wiring is loose, corroded or damaged. Fuel tank is empty or very low and unit is operating on a slope or grade. The fuel pump is faulty.
Cutting Deck Operating Problems The cutting units will not run during the following normal operating conditions: Operator in seat or parking brake engaged Mow/transport switch in MOW PTO switch in ENGAGE Operator in seat − the seat switch is faulty or seat switch circuit wiring is loose, corroded or damaged. Parking brake engaged − the parking brake switch is faulty or parking brake switch circuit wiring is loose, corroded or damaged.
Electrical System Quick Check Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Voltage Measured Battery Charge Level 12.68V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery should be at a temperature of 60 to 100F (16 to 38C). The ignition key should be off and all accessories turned off. Connect the positive (+) meter lead to the positive battery post and the negative (−) meter lead to the negative battery post.
Check Operation of Interlock Switches CAUTION The interlock switches are for the operator’s protection; do not disconnect them. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before operating the machine. 1 The machine is equipped with a number of interlock switches. The engine will not start, or if the engine is running, the engine will stop if one or more of the interlock conditions are met.
Standard Control Module (SCM) Groundsmaster 3500 machines are equipped with a Standard Control Module to monitor and control electrical components required for safe operation. This Module is attached to the back of the instrument panel. coolant temperature exceeds 230F(110C) causing the high temperature warning switch to close. The Over Temperature Shutdown input LED is not used with gasoline powered units.
Standard Control Module (SCM) Logic Chart Example: To start the engine the following conditions must be met: the ignition key is in START, the operator is in the seat, the traction control pedal is in the neutral position and the parking brake is applied. When these conditions are met the Energize to Run (ETR) and Engine Start relays are energized.
Component Testing For accurate resistance and/or continuity checks, disconnect the component being tested from its electrical circuits (e.g. unplug the ignition switch connector before doing a continuity check on the switch). NOTE: For additional electrical component testing information, see the Kubota Workshop Manual for 05 Series Diesel Engines, or the Kubota Workshop and Diagnostics Manuals for WG972 Gasoline Engines.
Glow Controller (Diesel Engines Only) The controller is located under the instrument panel. NOTE: Refer to Foldout Drawings − Chapter 9 in this manual when troubleshooting the glow controller. Controller Operation 1. When the ignition switch is placed in the RUN position, the controller energizes the glow plug relay and illuminates the glow lamp for 10 seconds. 2.
Glow Relay (Diesel Engine Only) The glow relay is attached to the radiator assembly. When energized, the glow relay allows electrical current to the engine glow plugs. 3. Disconnect voltage and leads from the terminals. 1. Verify coil resistance between terminals 86 and 85 with a multimeter (ohms setting). Resistance should be approximately 72 ohms (Fig. 13). 86 2. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85.
Diode Assemblies Groundsmaster 3500 machines use diodes that plug into the wiring harness (Fig. 16). Location of the diodes is under the control console. Multimeter Red Lead (+) on Terminal Multimeter Black Lead (- ) on Terminal Continuity Female Male YES Male Female NO Diode D1 is used on both diesel and gasoline powered units. Diode D1 is used to protect the PTO solenoid valve coil from reverse polarity. Diodes D2 and D3 are used on gasoline powered units only.
Indicator Lights Charge Indicator Light The charge indicator light should come on when the ignition switch is in the ON position with the engine not running. It should also illuminate while the engine is running and the charging circuit is malfunctioning. used to identify the cause of the problem and any repairs that are necessary.
PTO Switch The PTO switch is located on the control panel. Most Groundsmaster 3500 machines use a pull type switch (shown in Fig. 20) while early production diesel powered units use a rocker switch (shown in Fig. 21). The switch allows the decks to be engaged or disengaged. Along with additional switches in the interlock system, the PTO switch controls the solenoid valve on the hydraulic manifold. The switch terminals are marked as shown in Fig. 20 and 21.
Neutral Switch The neutral switch is a proximity type, normally open reed switch that closes when the traction pedal is in the neutral position. The neutral switch is located under the floor support plate. 2 1 1. Disconnect electrical connector from the neutral switch. 2. Check the continuity of the switch by connecting a multimeter (ohms setting) across the switch connector terminals. 3. With the traction pedal in the neutral position, there should be continuity between the two switch leads. 4.
Seat Switch The seat switch is normally open and closes when the operator is on the seat. If the neutral switch is open when the operator raises out of the seat, the engine will stop. 2 The standard seat uses a switch that is fastened to the underside of the seat (Fig. 24). The deluxe seat has a switch that is mounted to the seat base under the cushion. The switch electrical connector for either seat type is located directly under the seat. Testing is the same for either switch type: 1 1.
Parking Brake and Transport/Mow Switches The switches used for the parking brake and transport/ mow are the same, normally closed switch. The parking brake switch is located under the dash cover and opens when the parking brake lever is engaged. The transport/ mow switch is located under the floor plate and opens when the transport/mow slide is in the transport position. 2 The Standard Control Module monitors the operation of the parking brake switch.
Fusible Links The Groundsmaster 3500 uses a number of fusible links for circuit protection. A number of fusible links are located in a harness that connects the starter B+ terminal to the main wire harness. Power from the alternator, power to the ignition switch, and in the case of diesel powered units, power to the glow relay is protected by the fusible link harness.
High Temperature Warning and Shutdown Switches (Diesel Engines Only) The high temperature warning and shutdown switches are located on the water pump housing, which is located on the rear end of the engine block (alternator end) (Fig. 31). 3 1 CAUTION 2 Make sure engine is cool before removing the temperature switch. 1. Lower coolant level in the engine and remove the temperature switch. 2. Put switch in a container of oil with a thermometer and slowly heat the oil (Fig. 32). Figure 31 1. Temp.
Oil Pressure Switch The engine oil pressure switch is located on the engine below the alternator (Fig.33). The oil pressure switch is a normally closed switch that opens with pressure. The oil pressure switch should open at approximately 8 PSI (0.56 kg/cm2). 1 If low engine oil pressure allows the oil pressure switch to close during engine operation, the engine oil pressure light should illuminate.
Fuel Pump (Diesel Engine Only) The fuel pump is attached to the left frame rail near the engine. 2 4 Operational Test 1. Park machine on a level surface, lower cutting decks, stop engine, and engage parking brake. Unlatch and raise hood. 1 2. Disconnect electrical connector from the fuel stop solenoid to prevent the engine from starting. 3. Disconnect the fuel hose between the pump and the filter/separator (pump discharge) at the filter separator. 4.
Fuel Pump (Gasoline Engine Only) 6 175 to 200 in−lb (20 to 22 N−m) 7 1 4 5 8 1 2 9 4 6 B (−) 3 A (+) Figure 35 4. Hose clamp 5. Fuel rail 6. Pump electrical connector The electric fuel pump used on the Groundsmaster 3500−G is a positive displacement in−tank pump that provides pressurized fuel to the engine fuel rail in a return−less system (Fig. 35). The fuel pump assembly includes a regulator to maintain fuel pressure.
5. If fuel pump does not operate or pressure is low, test the pump while supplying power directly, bypassing the engine ECU and PWR relay. 6. After testing is completed, remove pressure gauge from fuel supply hose. Connect fuel supply hose to engine fuel rail and secure with hose clamp. Fuel Pump Specifications A. Disconnect fuel pump electrical connector. B. Connect a jumper from the A (+) terminal of the pump connector (red wire) to the mating A (+) terminal of the wire harness connector. C.
Electronic Throttle Control (Gasoline Engine Only) The engine speed on the Groundsmaster 3500−G is controlled by an electronic throttle system. The system includes an electronic throttle control at the operator’s control panel and a throttle control valve at the Kubota gasoline engine. The engine ECU uses the position of the throttle control at the operator panel as an input to determine the appropriate signal output for the throttle control valve at the engine to set the engine speed.
Hydraulic Cartridge Solenoid Valve Coils The hydraulic system on the Groundsmaster 3500 uses a solenoid valve coil to actuate a cartridge valve on the hydraulic manifold (Fig. 39). When the solenoid valve coil is energized, spool shift in the valve will direct hydraulic flow to the cutting decks. 4. If solenoid coil needs replacement, see Hydraulic Cartridge Valve Coil in the Service and Repairs section of this chapter. 1 Testing 2 1. Make sure engine is off.
Service and Repairs NOTE: For additional electrical component service and repair information, see the Kubota Workshop Manual for 05 Series Diesel Engines, or the Kubota Workshop and Diagnostics Manuals for WG972 Gasoline Engines. Battery Care 1. The top of the battery must be kept clean. lf the machine is stored in a location where temperatures are extremely high, the battery will discharge more rapidly than if the machine is stored in a location where temperatures are cool. B.
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. 1 2 CAUTION When working with batteries, use extreme caution to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries. 1 Figure 40 Electrolyte Specific Gravity Fully charged: 1.
1. Replace battery if case is cracked or leaking. 2. Check battery terminal posts for corrosion. Use wire brush to clean corrosion from posts. IMPORTANT: Before cleaning the battery, tape or block vent holes to the filler caps and make sure the caps are on tightly. 3. Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap, overcharging, loose terminal post or overfilling. Also, check battery case for dirt and oil.
Minimum Voltage Battery Electrolyte Temperature 9.6 70F (and up) 21.1C (and up) 9.5 60F 15.6C 9.4 50F 10.0C 9.3 40F 4.4C 9.1 30F −1.1C 8.9 20F −6.7C 8.7 10F −12.2C 8.5 0F −17.8C I. If the test voltage is below the minimum, replace the battery. If the test voltage is at or above the minimum, return the battery to service. Battery Charging Battery Reserve Capacity (Minutes) 75% 50% 25% 0% 80 or less 3.8 hrs @ 3 amps 7.5 hrs @ 3 amps 11.
Hydraulic Cartridge Solenoid Valve Coil The solenoid valve coil on the hydraulic control manifold (Fig. 42) can be replaced without opening the hydraulic system. 1 Removal 1. Park machine on a level surface, lower cutting decks, engage parking brake, stop engine and remove key from the ignition switch. 2 3 4 2. Disconnect the wire harness electrical connector from the solenoid valve coil. 3. Remove the nut from the spool assembly. 4. Slide the coil assembly from the solenoid valve stem. Discard the coil.
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Chapter 7 Wheels, Brakes, and Chassis Table of Contents 2 2 3 3 4 5 6 8 8 Deluxe Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Front Wheel and Brake . . . . . . . . . . . . . . . . . . . . . 10 Rear Fork and Wheel . . . . . . . . . . . . . . . . . . . . . . . 12 Brake Lever Linkages . . . . . . . . . . . . . . . . . . . . . . 14 Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Front Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Tire pressure 14 to 18 PSI (97 to 124 kPa) 70 to 90 ft- lb (95 to 122 N- m) Wheel lug nut torque Special Tools Order special tools from your Toro Distributor. Wheel Hub Puller Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors.
Adjustments Adjust Brakes C. If brakes can not be adjusted properly, repair or replace brake components as necessary. CAUTION D. After adjustment is complete, install both front wheel assemblies to the machine (see Front Brake and Wheel Installation in this section). Before and after adjusting the brakes, always check the brakes in a wide open area that is flat and free of other persons and obstructions. E. Lower front wheels to the ground. 1. Check brake adjustment as follows: F.
Adjust Front Lift Arms 1. Park machine on a level surface, fully raise cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2 1 IMPORTANT: Keep front cutting units on the lift arms when performing this adjustment. 3 2. Make sure clearance between each lift arm and floor plate bracket is from 0.18 to 0.32 inch (4.6 to 8.1 mm) (Fig. 4). 3. If the clearance is not in this range, attain proper clearance as follows: A.
Adjust Front Lift Arm Carrier Stop Bracket Assembly 1. Park machine on a level surface, fully raise cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 7 2. Make sure that pivot brackets (items 6 and 9) are not overtightened. They should pivot and return freely. 8 10 3. To allow horizontal movement of the actuators (items 2 and 8), loosen carriage screws and flange nuts that secure actuators to actuator mount brackets. 4.
Adjust Rear Lift Arm NOTE: If rear lift arm makes clunking noises during transport, the clearance should be adjusted/reduced. 1. Park machine on a level surface and engage parking brake. 2 IMPORTANT: This adjustment must be performed with the rear cutting unit attached to the rear lift arm. 2. Raise lift arms. Make sure clearance between one end of wear strip and bumper bar on frame is from .020 to .100 inch (0.51 to 2.54 mm) when other end of wear strip is in contact with bumper bar (Fig. 8).
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Service and Repairs Standard Seat 1 6 5 2 7 8 9 4 3 2 3 13 4 15 17 19 18 20 22 23 10 14 16 21 12 11 14 22 20 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. Seat (incl. 4 thru 7, 14, & 15) Seat belt Lock washer Cap screw Armrest Cap screw Flange hex nut Screw 9. 10. 11. 12. 13. 14. 15. 16. Hex flange hd screw Spacer Armrest bracket Washer Hex flange hd screw Seat support strap Seat adjuster with latch Seat adjuster 17. 18. 19. 20. 21. 22. 23.
Deluxe Seat 8 9 8 2 6 5 3 4 4 3 19 5 6 20 20 1 23 22 12 11 16 15 13 23 18 10 7 17 14 21 Figure 11 Bottom cushion Back cushion Seat belt Flat washer Flat washer Cap screw Bottom cover Armrest kit 9. 10. 11. 12. 13. 14. 15. 16. Back cover Seat switch Adjusting track - RH Track - LH Support strap Flange nut Knob kit Weight indicator 17. 18. 19. 20. 21. 22. 23.
Front Wheel and Brake 33 31 25 9 22 26 29 30 27 28 11 13 7 32 18 10 23 14 Blue Loctite 242 17 250 to 275 ft- lb (339 to 373 N- m) 3 24 20 12 4 15 21 17 RIGHT 19 FRONT 16 Anti- seize Lubricant 8 2 5 70 to 90 ft- lb (95 to 122 N- m) 1 6 Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Lug nut Drive stud Button head screw Wheel and tire Wheel hub Lock nut Hydraulic wheel motor Brake drum Woodruff key Cotter pin Adjustment rod 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
IMPORTANT: DO NOT hit wheel hub, wheel hub puller or wheel motor with a hammer during wheel hub removal or installation. Hammering may cause damage to the wheel motor. 3. If the brake assembly was not disassembled but was removed as a complete assembly, secure backing plate to the brake bracket with four cap screws and lock washers. Tighten fasteners. 5. Using hub puller (see Special Tools), loosen wheel hub from wheel motor. 4. Attach adjustment rod to the brake lever.
Rear Fork and Wheel 35 34 25 33 300 to 400 ft- lb (407 to 542 N- m) 6 4 3 8 27 65 to 85 ft- lb (88 to 115 N- m) 36 25 29 24 65 to 85 ft- lb (88 to 115 N- m) 1 70 to 90 ft- lb (95 to 122 N- m) 21 16 2 60 to 80 ft- lb (81 to 108 N- m) 10 9 28 4 22 23 26 30 65 to 85 ft- lb (88 to 115 N- m) 14 6 28 19 17 38 11 20 37 15 32 39 17 13 31 7 18 2 3 12 5 Figure 14 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Removal Installation 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Position rear fork through the frame. 2. Remove hood from the machine. 2. Install lock washer, thrust washer, and cap screw to the rear fork shaft. Torque cap screw from 60 to 80 ft- lb (81 to 108 N- m). Make sure fork turns freely. 3. Install hydraulic motor to the rear fork. Secure motor to the fork with four hex socket head screws and lock nuts.
Brake Lever Linkages 2 1 3 3 9 9 19 24 7 23 25 22 8 5 8 20 6 18 4 7 21 15 10 11 17 15 12 16 12 26 13 27 14 35 12 28 29 30 36 37 31 34 33 32 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Pop rivet Control panel cover Cover bracket Flange nut Hex flange head screw Magnet support Hex washer head screw Strike bracket Magnetic catch Flat washer Lock nut Cotter pin Bumper pad Wheels, Brakes, and Chassis 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove control panel cover from the machine. IMPORTANT: When removing the adjustable clevis, adjustment rod, or the brake lever, make sure to mark both parts. Marking both parts will make reassembly and brake adjustment easier. 3. Remove and replace parts as necessary to repair brake linkages. 4. Install control panel cover to the machine.
Steering Column 20 to 26 ft- lb (28 to 35 N- m) 8 9 11 14 20 27 21 7 38 39 10 12 17 28 Blue Loctite 242 32 19 2 18 23 4 6 22 24 5 34 36 41 8 33 37 43 45 40 26 25 3 35 40 44 3 43 1 29 30 31 13 15 16 2 Figure 16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Disassembly 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2 2. Remove philips head screws and steering wheel cap from the steering wheel. 1 3. Remove steering wheel nut from the steering control valve. Pull steering wheel from the control valve. 6 4. Remove cover from the steering control valve bracket. 3 5. Remove four flange screws securing the steering control valve to the steering control valve bracket. 6.
Front Lift Arms 9 6 4 RIGHT FRONT Anti- seize Lubricant 34 57 47 42 40 15 39 41 55 43 48 44 58 63 28 60 62 61 21 22 20 26 28 26 28 51 23 24 13 38 33 20 25 24 19 65 49 54 3 33 53 64 56 27 17 45 33 46 10 18 5 66 53 59 31 16 28 37 32 29 30 7 12 50 8 35 1 52 36 2 13 11 14 Figure 18 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Removal (Fig. 18) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove cutting units (see Chapter 8 - Cutting Deck and Carrier Frame in this manual). NOTE: Remove both spacers from the hydraulic cylinder clevis when removing the right, front lift arm. 3. Disconnect hydraulic cylinder from the front lift arms by removing external retaining rings and pins. 5. Route hydraulic hoses so they clear the lift arm by 0.
Rear Lift Arm Blue Loctite 242 16 3 12 12 15 13 46 17 2 21 14 42 44 11 13 6 22 2 18 1 49 26 35 28 10 12 48 9 7 24 38 29 39 5 31 20 4 27 41 46 45 46 23 25 37 30 15 13 36 40 33 34 32 Anti- seize Lubricant 47 12 8 RIGHT 43 19 12 FRONT 2 3 200 to 250 ft- lb (271 to 339 N- m) 12 Figure 20 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Removal (Fig. 20) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove cutting unit from the pivot shaft of the rear lift arm (see Chapter 8 - Cutting Deck and Carrier Frame in this manual). 3. Remove external retaining ring and thrust washer from the lift cylinder shaft. 4. Remove flange head screw and thrust washer from the rear pivot shaft. 3.
Sidewinder Carrier 2 6 1 13 12 11 8 10 4 10 RIGHT 9 4 8 FRONT 67 to 83 ft- lb (91 to 113 Nm) 3 7 5 Figure 21 1. 2. 3. 4. 5. Lower frame Sidewinder carrier assembly Slide bracket Plastic slide Flange head screw 6. 7. 8. 9. Flange nut Cap screw Thrust washer Slide support bar 10. 11. 12. 13. Bearing cap Lock nut Lift arm (RH shown) Lift arm pivot shaft Disassembly Assembly 1.
Chapter 8 Cutting Decks Table of Contents Cutting Decks SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 Factors That Can Affect Quality of Cut . . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ADJUSTMENTS . . . . . . . . . . . . . . . .
Specifications MOUNTING: All cutting units are supported by equal length, independent lift arms and are interchangeable to all three cutting unit positions. DISCHARGE: Clippings are discharged from the rear of the mowing decks. Pre−drilled mounting holes allow attachment of optional mulching baffle. CONSTRUCTION: Deck chamber and frame are welded steel construction reinforced with channels and plates. CUTTING DECK LIFT: Cutting decks are controlled with one (1) lift lever.
General Information CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine and remove key from ignition switch first. Operator’s Manual Cutting Decks The Cutting Deck Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for the cutting deck on your Groundsmaster machine. Refer to that publication for additional information when servicing the cutting deck.
Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess”, uneven ground conditions or attempting to cut off too much grass height may not always be overcome by adjusting the machine. It is important to remember that the lower the height−of−cut, the more critical these factors are.
Special Tools Order special tools from your Toro Distributor. Rear Roller Bearing and Seal Installation Tools These tools are used to assemble the cutting deck rear roller.
Adjustments CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine and remove key from ignition switch first. See the Cutting Deck Operator’s Manual for adjustment procedures for cutting decks on the Groundsmaster 3500. Blade Stopping Time The blades of the cutting decks are to come to a complete stop in approximately five (5) seconds after the PTO is disengaged.
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Service and Repairs CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine and remove key from ignition switch first. Blade Spindle Assembly 11 33 to 36 ft−lb (44.7 to 48.8 N−m) 2 12 1 3 4 6 5 8 7 RIGHT 85 to 110 ft−lb (115 to 149 N−m) FRONT 9 10 Figure 4 1. 2. 3. 4. Flange nut (6 used) Hydraulic deck motor Spindle plate Cutting deck Cutting Decks 5. 6. 7. 8. O−ring Spindle assembly Drive stud (6 used) Cutting blade Page 8 − 8 9. 10. 11.
Removal (Fig. 4) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1 2. Remove two (2) socket head screws and flat washers that secure hydraulic motor to the cutting deck (Fig. 5). Remove hydraulic motor and O−ring from deck. 2 3. Cover top of spindle to prevent debris from entering spindle. A spindle plug (see Special Tools in this chapter) can be used to cover spindle.
Blade Spindle Service Disassembly (Fig. 6) 1. Remove blade spindle from cutting deck (see Blade Spindle Removal in this section). 2 6 2. Loosen and remove spindle nut from top of spindle shaft. 4 131 to 159 ft−lb (178 to 215 N−m) 3. Remove the spindle shaft from the spindle housing which may require the use of an arbor press. The spindle shaft spacer should remain on the spindle shaft as the shaft is being removed. 11 10 9 12 8 7 4.
3. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the outer bearing spacer previously installed, and the bottom bearing cup must contact the large snap ring. Make sure that the assembly is correct by supporting the first bearing cup and pressing the second cup against it (Fig 8). PRESS 4 4. Pack the bearing cones with grease. Apply a film of grease on lips of oil seals. 6 2 5 5.
Rear Roller 2 29 to 35 ft−lb (40 to 47 N−m) 1 3 4 5 6 7 RIGHT Blue Loctite 242 FRONT 8 29 to 35 ft−lb (40 to 47 N−m) Figure 10 1. Deck frame 2. Rear roller assembly 3. Grease fitting Cutting Decks 4. Roller shaft screw 5. Roller mount 6. Flange head screw Page 8 − 12 7. Skid bracket 8.
Removal (Fig. 10) 30 ft−lb (41 N−m) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 4 2. If cutting deck is equipped with a roller scraper (Fig. 11), remove fasteners securing left and right scraper rod brackets to roller mounts. Remove scraper rod assembly. 1 3 29 to 35 ft−lb (40 to 47 N−m) 2 3. Remove four (4) flange head screws securing roller mounts to rear of deck frame.
Rear Roller Service Disassembly (Fig. 12) 2 1. Remove bearing lock nut from each end of roller shaft. 50 to 60 ft−lb (68 to 81 N−m) 3 4 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube. Remove second set of outer seals and bearing from roller tube by tapping on opposite end of shaft. Remove shaft from roller tube. 5 6 7 1 2 4 3 5 3.
3. From the roller tube end with only the inner seal installed, carefully install the roller shaft into the roller tube. Make sure that seals are not damaged as shaft is installed. NOTE: After roller is installed to cutting deck, lubricate roller grease fittings, rotate roller to properly distribute grease in bearings and clean excess grease from roller ends. A properly assembled roller should rotate with less than 5 in−lbs (0.68 N−m) resistance. 4.
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Front Roller Service Disassembly (Fig. 18) 1. Remove roller mounting bolt. 2. Remove roller assembly from carrier frame. 3. To remove bearings and bearing spacer: A. Insert punch through end of roller and drive opposite bearing out by alternating taps to opposite side of inner bearing race. There should be a lip of inner race exposed for this process. 1 2 B. Remove bearing spacer. Remove second bearing from roller using a press. 3 65 to 95 ft−lb (89 to 128 N−m) 4.
Cutting Deck Carrier Frame 2 20 9 RIGHT 4 3 21 6 22 FRONT 6 16 1 3 5 4 17 7 5 17 18 19 8 1 25 13 12 11 32 10 3 24 14 26 4 15 5 31 29 30 27 28 23 33 Figure 19 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Front carrier frame Rear carrier frame Lynch pin Thrust washer Pivot pin Grease fitting Front right lift arm Front left lift arm Rear lift arm Latch rod Latch tube 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Removal and Installation (Fig. 19) 1. Position the machine on a level surface, lower the cutting decks to the floor, shut the engine off, and engage the parking brake. IMPORTANT: Support the cutting deck hydraulic motor when removed from the deck. Do not allow the hydraulic motor to hang from the hydraulic hoses. 1 2. Disconnect and remove the hydraulic motor from the deck (Fig. 20). Cover the top of the spindle to prevent contamination. Figure 20 1. Motor mounting screws 3.
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Chapter 9 Foldout Drawings Table of Contents Groundsmaster 3500 Page 9 -- 1 Foldout Drawings Foldout Drawings ELECTRICAL DRAWING DESIGNATIONS . . . . . . . 2 HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . 3 Groundsmaster 3500--D Hydraulic Schematic (Units Prior to Serial No. 314000001) . . . . . . . . 3 Groundsmaster 3500--D Hydraulic Schematic (Unit Serial No. 314000001 & Up) . . . . . . . . . . . 4 ELECTRICAL SCHEMATICS AND DIAGRAMS . . .
Electrical Drawing Designations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. ABBREVIATION COLOR BK BLACK BR or BN BROWN BU BLUE GN GREEN GY GRAY OR ORANGE PK PINK R or RD RED T TAN VIO VIOLET W or WH WHITE Y or YE YELLOW Numerous harness wires used on Groundsmaster machines include a line with an alternate color.
LEFT DECK M2 RIGHT DECK D1 M4 M1 M2 S.W. BULKHEAD PLATE T2 REAR M5 LIFT TRACTION WHEEL MOTORS FRONT M1 BV 1500 psi REAR DECK FORWARD M3 TOP PORT G1 M6 S1 A 3200 psi MANIFOLD B C BLOCK BY--PASS UPPER VALVE PORT T1 LC1 PORT SIDEWINDER LOWER G2 G2 G1 OIL COOLER LV 3500 psi P1 CHG ST CR CF OUT 250 psi BACK 100--150 psi OIL FILTER IN D LIFT/S.W.
LEFT DECK M2 RIGHT DECK D1 M4 M2 M1 S.W. BULKHEAD PLATE REAR M5 LIFT TRACTION WHEEL MOTORS FRONT M1 T2 REAR RV DECK FORWARD M3 LC2 1500 psi TOP PORT S 3200 M6 psi G1 A B C MANIFOLD BLOCK BY--PASS UPPER VALVE PORT T1 LC1 PORT SIDEWINDER LOWER G2 G2 G1 OIL COOLER LV 3500 psi P1 CHG ST CR CF OUT 250 psi BACK 100--150 psi OIL GEAR FILTER PUMP PRESSURE IN D LIFT/S.W.
ALTERNATOR RUN SOLENOID (HOLD) B R/BK R L R W (PULL) W GY 105C OVER TEMP WARNING PK GN ENGINE OIL PRESSURE 110C OVER TEMP SHUTDOWN BU/W GN GY W 1 4 LAMP 2 5 + 12V 3 6 OR PK R (+) TEMP HR GLOW HOUR METER (--) GROUND CLUSTER GAUGE VIO START BN GLOW 85 K4 GLOW PLUG CONTROLLER KUBOTA 86 30 GLOW RELAY 87 PK OR OVER TEMP.
122--1521 Rev.
ORANGE RED RED FUSIBLE LINK PINK BLUE BROWN PINK BLACK RED PINK WHITE BLACK GRAY PINK BLUE PINK VIOLET PINK ORANGE PINK BROWN TAN RED/BLACK TAN YELLOW WHITE BLACK PINK BLACK BLUE GREEN WHITE/BLACK WHITE PINK GRAY VIOLET PINK BLACK RED/BLACK BLACK ORANGE BLACK BLACK BLACK BLUE/WHITE GREEN BLACK BLACK GREEN YELLOW (SERIAL NUMBER ABOVE 314000001) TAN BLACK BLACK BLUE BLACK GREEN RED/BLACK PINK ORANGE Groundsmaster 3500--D Harness Diagram (Serial Numbers Below 40344
(SERIAL NUMBER ABOVE 314000001) Groundsmaster 3500--D Harness Drawing (Serial Numbers Below 403440000) Page 9 -- 8
122--1523 Rev.
122--1523 Rev.
ENGINE INTERCONNECT 122--1552 Rev A Groundsmaster 3500--G Electrical Schematic (sheet 1 of 2) All relays and solenoids are shown as de-- energized.
122--1552 Rev A Groundsmaster 3500--G Electrical Schematic (sheet 2 of 2) All relays and solenoids are shown as de-- energized.
P05 P04 BLUE/BLACK PINK BLACK/WHITE TAN P29 BLACK GRAY P03 BLACK/WHITE J07 ORANGE P23 ORANGE P30 BLACK PINK BLUE J19 BLUE/BLACK P35 P16 PINK J15 P24 ORANGE ORANGE J01 J14 J13 WHITE PINK BROWN RED/BLACK TAN BROWN/WHITE BLACK BLUE P14 ORANGE TAN P31 BLACK/WHITE J18 YELLOW WHITE/BLACK P32 PINK P33 VIOLET WHITE P34 BLACK PINK BROWN/WHITE PINK ORANGE BLACK GREEN BLACK P06 P17 PINK PINK P32 BLACK P13 J02 BLACK BLACK BLACK BLACK WHITE YELLOW/BLACK BLACK/ORANGE RED/BLA
Groundsmaster 3500--G Harness Drawing (Serial Numbers Below 402700000) Page 9 -- 14
122--1524 Rev.
122--1524 Rev.
