Form No.
Revision History Revision Date -- 2001 Initial Issue. A 2002 Updated Hydraulic chapter. B 2003 Updated Electrical chapter. C 2004 Updated Hydraulic chapter. D 2005 Updated Electrical chapter. E 2007 Updated Hydraulic chapter. F 2009 Updated Engine chapter. G 2015 Updated Hydraulic and Electrical chapters. H 03/2018 Added revision history. I 10/2018 Updated Hydraulic chapter. J 03/2019 Updated Wheels, Brakes and Chassis chapter.
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. 01088SL (Rev. L) Service Manual GroundsmasterR 3500--D Models 30821, 30839 and 30843 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 (Models 30821, 30839 and 30843). REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
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Electrical Schematics and Diagrams . . . . . . . . . . 5 - 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4 Electrical System Quick Checks . . . . . . . . . . . . . . 5 - 7 Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 - 24 1 1 2 3 Chapter 3 - Kubota Diesel Engine Introduction . . . . . . . . . . . . .
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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 defeat interlock system. It 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- D Page 1 - 5 Safety Numerous safety and instruction decals are affixed to the Groundsmaster 3500- D. 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 Kubota Diesel Engine 1 1 2 2 2 3 3 3 4 5 6 6 Hydraulic Systems PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . .
Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 -- 2 Rev.
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. 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 # 6 -- 32 UNC 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 -- 40 UNF # 8 -- 32 UNC 13 + 2 25 + 5 282 + 30 # 8 -- 36 UNF # 10 -- 24 UNC 18 + 2 30 + 5 339 + 56 # 10 -- 32 UNF SAE Grade 5 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 2 or Strong
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 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 Recommended Torque* 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.
Lubrication Safety Traction Unit Product Records and Maintenance CAUTION Before servicing or making adjustments to the machine, stop engine, lower cutting units, set parking brake, and remove key from the ignition switch. Kubota Diesel Engine Hydraulic Systems Figure 2 Electrical System The traction unit bearings and bushings that must be lubricated are: Rear cutting unit pivot (Fig. NO TAG), Front cutting unit pivot (Fig. 2), Sidewinder cylinder ends (qty. 2) (Fig. 3), Steering pivot (Fig.
Figure 7 Figure 4 2 Figure 8 Figure 5 Figure 9 Figure 6 Product Records and Maintenance Page 2 -- 8 Groundsmaster 3500--D
Wheels, Brakes, and Chassis Electrical System Hydraulic Systems Kubota Diesel Engine Figure 10 Groundsmaster 3500--D Page 2 -- 9 Product Records and Maintenance Product Records and Maintenance Figure 12 (See note) Figure 11 Safety
Cutting Units Each cutting unit has two grease fittings per blade spindle. Either fitting can be used for greasing, which ever is more accessible. Under normal conditions, lubricate spindle bearings with No. 2 General Purpose Lithium Base Grease or Molybdenum base grease, after every 50 hours of operation. IMPORTANT: Lubricate cutting units immediately after washing. This helps to purge water out of bearings and increases bearing life. 1. Wipe grease fitting with a clean rag.
1. Clean traction unit, cutting units, and the engine thoroughly. 1. Drain engine oil from the oil pan and replace the drain plug. 2. Check tire pressure. Inflate all tires to 14 to 18 psi (0.97 to 1.24 Bar). 2. Remove and discard oil filter. Install new oil filter. 6. Lightly sand and use touch--up paint on painted areas that are scratched, chipped, or rusted. Repair any dents in the metal body. 7. Service battery and cables as follows: A.
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Kubota Diesel Engine Product Records Table of Contents Safety Chapter 3 Wheels, Brakes, Electrical Hydraulic Kubota Diesel Engine INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Kubota Workshop Manual . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the diesel engine used in the Groundsmaster 3500- D. test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Kubota Workshop Manual, Diesel Engine, 05 Series.
Item Description Kubota D1105, 4- Cycle, 3 Cylinder, Liquid Cooled, Diesel Engine Bore mm (in.) 78.0 (3.07) Stroke mm (in.) 78.4 (3.09) Total Displacement cc (cu. in.) 1123 (68.53) 1- 2- 3 Combustion Chamber Spherical Type Fuel No. 2 Diesel Fuel (ASTM D975) Fuel Capacity liters (gallons) 41.
Adjustments Adjust Throttle Cable 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 2. Position throttle control lever all the way to the SLOW position so it stops against the control panel slot (Fig. 5). 4 3 3. Loosen cap screw securing the throttle cable to the swivel enough to loosen the cable (Fig. 6). 4. Hold speed control lever on the injection pump against the low idle stop.
Service and Repairs Safety Replace Traction Belt 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. 3 4 5 6 CAUTION Be careful when removing or applying tension from or to the torsion spring of the idler pulley. The spring is under heavy load and may cause personal injury. Figure 8 1. Torsion spring 2. Idler pulley 3. Pump mounting plate 4. Drive belt 5. Flywheel pulley 6.
Bleed Fuel System 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake. 2. Make sure fuel tank is at least half full. Unlatch and raise hood. 2 DANGER Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running or hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine.
IMPORTANT: This procedure should be used only if the fuel system has been purged of air through normal priming procedures (see Bleed Fuel System) and engine will not start. 1 3 2 Product Records 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake. Unlatch and raise hood. Safety Bleed Air from Fuel Injectors DANGER 3. #3 injector nozzle Hydraulic Because diesel fuel is highly flammable, use caution when storing or handling it.
Muffler and Air Cleaner 19 RIGHT 8 FRONT 19 2 1 21 4 10 7 19 20 9 11 12 18 22 14 5 6 23 13 24 3 17 16 15 3 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. Air inlet hose (upper) Air inlet hose (lower) Flange nut Flange head screw Flat washer Cap screw Air filter mount Hose clamp Kubota Diesel Engine (Rev. G) 9. 10. 11. 12. 13. 14. 15. 16. Air cleaner body Flange head screw Hex nut Lock washer Mounting band assembly Muffler Muffler bracket Exhaust guard (if equipped) Page 3 - 8 17. 18. 19. 20.
Muffler Removal (Fig. 11) Safety CAUTION 2 1 2. Open engine hood to gain access to engine. Figure 12 3. Remove exhaust guard from frame (if equipped). 1. Flange head nut 2. Flange head screw 3. Muffler plate 4. Muffler bracket 4. Remove both flange head nuts and screws securing the muffler plate to the muffler bracket (Fig. 12). Air Cleaner Removal (Fig. 11) 5. Remove four hex nuts and lock washers from the exhaust manifold studs. Separate muffler flange from the exhaust manifold.
Fuel System 42 7 29 28 10 30 22 9 22 32 47 22 5 46 1 20 8 27 41 3 33 2 37 24 22 18 17 12 14 16 22 40 26 25 22 21 15 19 13 31 44 38 36 22 45 43 35 22 34 39 6 22 11 23 4 Figure 13 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Cap screw Fuel tank Fuel hose strap Cap screw Fuel cap Tank support Fuel gauge Grommet Connector fitting Stand pipe R- clamp Barb fitting Cap screw Flange hex nut Lock washer Flat washer Kubota Diesel Engine (Rev. G) 17. 18. 19. 20. 21.
Fuel Tank Installation (Fig. 13) DANGER Check Fuel Lines and Connections 3. Connect seat switch to the electrical harness. Route seat switch wire under seat support strap. Secure seat support straps and seat to the frame with hex flange head screws. 4. Check for correct seat operation and that seat switch wires and connector are not pinched and do not contact any moving parts. Check fuel lines and connections at intervals recommended in your Operator’s Manual. Kubota Diesel Engine 5. Fill fuel tank.
Radiator (Serial Number Below 313999999) RIGHT 10 18 17 22 28 FRONT 5 11 9 34 30 6 32 9 31 14 13 16 8 19 33 35 15 20 29 4 26 28 25 3 21 2 12 36 27 24 25 23 37 38 1 7 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Draincock 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 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
6. Remove expansion tank and bracket from the top fan shroud. 9. Pull radiator carefully from the radiator frame. If engine has been running, the radiator may be hot and cause burns. Work on radiator only when the engine and radiator are cool. 2. Unlatch and open engine hood. 3. Clean engine area thoroughly of all dirt and debris. 10.Plug any openings to prevent contamination. Installation 4. Remove lower radiator shield. Release wire form latch and allow oil cooler to pivot out (Fig. 17). 1.
Radiator and Oil Cooler Assembly (Serial Number Above 314000000) 9 8 7 6 6 5 25 4 2 1 7 11 10 28 27 3 12 26 32 13 7 25 24 22 9 14 21 31 15 23 30 29 6 13 17 RIGHT FRONT 16 18 20 7 9 19 Figure 18 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 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Safety 3. Place a suitable container under the radiator to collect the coolant. Open draincock valve, and completely drain the radiator. IMPORTANT: Follow all local codes and regulations when recycling or disposing engine coolant. 1 5. Place a suitable container under the hydraulic filter to collect the hydraulic fluid. The container should have a 6 gal. (23 Ltr.) minimum capacity.
Engine 39 1 37 21 36 15 16 11 2 5 9 6 13 37 35 34 32 23 22 24 28 17 41 10 38 40 11 12 11 43 18 20 31 33 20 27 RIGHT 25 26 29 30 16 14 6 2 9 19 5 11 16 8 FRONT 7 4 Figure 20 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Kubota engine Engine mount Engine mount Flange nut Cap screw Hex flange head screw External lock washer Lock nut Hardened washer Machine screw Hardened washer Cap screw Engine mounting bracket (front) Engine mounting bracket (LH) 15. 16. 17. 18. 19. 20. 21. 22.
A. Battery and wire harness grounds (Fig. 21). 4 3 Safety 8. Disconnect wire harness and electrical wires from the following: 6 B. Glow plug bus (Fig. 22) and fuel stop solenoid. Figure 21 1. Battery ground cable 2. Wire harness ground 3. Throttle cable 11. Remove traction control cable from the neutral arm assembly on the piston pump. Remove all hydraulic hoses from the piston and gear pumps (see Piston Pump Removal in Chapter 4- Hydraulic System). 4. Support bracket 5. Speed control lever 6.
Note: The cap screw next to the torsion spring does not have a flat washer with it. 1 2 B. Remove five cap screws, four washers, and five spacers securing the pump mount plate to the engine. 4 2 C. Remove four cap screws and hardened washers securing the right engine mounting bracket and hydrostat to the engine. 3 16.As necessary, remove engine mounts, front engine mounting bracket, throttle support bracket and left engine mounting bracket. 2 1 Installation 1.
15.Connect both battery cables at the battery (see Battery Service in Chapter 5 - Electrical system). B. Glow plug bus (Fig. 22) and fuel stop solenoid. 16.Install air cleaner to the engine. Connect air hose to air cleaner and radiator. C. High temperature warning switch (Fig. 23). D. High temperature shutdown switch, alternator, and low oil pressure switch (Fig. 24). 17.Adjust throttle cable (see Adjust Throttle Cable). 18.Bleed fuel system (see Bleed Fuel System). 11.
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Groundsmaster 3500- D Page 4 - 1 Hydraulic System (Rev. G) Product Records and Manuals Kubota Diesel Engine Check Hydraulic Lines and Hoses . . . . . . . . . . . . . 62 Flush Hydraulic System . . . . . . . . . . . . . . . . . . . . . . 63 Filtering Closed- Loop Traction Circuit . . . . . . . . . 64 Charge Hydraulic System . . . . . . . . . . . . . . . . . . . . 65 Hydraulic Tank and Hydraulic Oil Filter . . . . . . . . . 66 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Piston Pump (Hydrostat) Maximum Operating Pressure Charge Pressure Traction Circuit Relief Pressure (Forward Only) Variable displacement piston pump 3000 PSI (207 bar) 100 to 150 PSI (6.
Safety General Information Traction Unit Operator’s Manual Product Records and Manuals The Traction Unit Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Check Hydraulic Fluid The hydraulic system on Groundsmaster 3500- D machines is designed to operate on high quality hydraulic fluid.
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.
2. As a preventative measure against leakage, it is recommended that the face seal O- ring be replaced any time the connection is opened. Make sure the O- ring is installed and properly seated in the fitting groove. Lightly lubricate the O- ring with clean hydraulic oil. Size 4 (1/4 in. nominal hose or tubing) 6 (3/8 in.) 8 (1/2 in.) 10 (5/8 in.) 12 (3/4 in.) 16 (1 in.) 3. Place the hose/tube against the fitting body so that the flat face of the hose/tube sleeve fully contacts the Oring in the fitting.
Hydraulic Fitting Installation (SAE Straight Thread O- Ring Fitting into Component Port) Non- Adjustable Fitting (Fig. 40) 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. 42) Back- up Washer 4. Turn back the lock nut as far as possible. Make sure the back up washer is not loose and is pushed up as far as possible (Step 1 in Figure 43). O- ring Figure 42 IMPORTANT: Before installing fitting into port, determine port material. If fitting is to be installed into an aluminum port, installation torque is reduced. 6.
Relieving Hydraulic System Pressure Before disconnecting or performing any work on the Groundsmaster 3500- D hydraulic system, all pressure in the hydraulic system must be relieved. Park machine on a level surface with the cutting units lowered and off. Turn key switch to OFF and allow engine to stop. To relieve hydraulic pressure in traction circuit, move traction lever to both forward and reverse directions.
Groundsmaster 3500- D Page 4 - 9 LOWER PORT FORWARD P3 M6 UPPER PORT TOP PORT HYDROSTAT INTERNAL CASE DRAIN 100- 150 psi 3000 psi DUMP VALVE TRACTION WHEEL MOTORS M4 M5 All solenoids are shown as de- energized P1 P1 Wheels, Brakes, and Chassis OIL FILTER OIL COOLER T1 MANIFOLD BLOCK G1 T2 D1 1500 psi Electrical System STRAINER BV LC1 ST M2 GEAR PUMP CHG R1 3200 psi DECK ON- OFF P2 M1 IN Hydraulic System 250 psi BACKPRESSURE LV G2 CR CF AUX OUT IN Hydraulic S
Hydraulic System (Rev.
Groundsmaster 3500−D G1 P1 M1 Page 4 − 11 BREATHER MOWER MANIFOLD S LC2 DECK MOTOR #3 1.19 CID 1500 PSI RV DECK MOTOR #1 1.19 CID T1 M2 25 psi CHG T2 D1 CF DECK MOTOR #2 1.19 CID ST LC1 Electrical System 1.44 CID 100−150 psi 17.1 GPM LIFT AND SIDEWINDER VALVE DIESEL 1: 0.96 GAS 1: 0.84 OUT ENGINE RATED SPEED DIESEL 3000 RPM GAS 3200 RPM G2 Wheels, Brakes, and Chassis CR LV IN A B Hydraulic System 200−300 psi C2 s Hydraulic System 3500 psi .060” 11.3 GPM 12.
Hydraulic System (Rev.
The rear wheel motor has a small check valve across its ports that allows the rear motor to over run during tight turns in the forward direction. The traction circuit operates essentially the same in reverse as it does in forward. However, there are a few differences in operation. When the reverse traction pedal is depressed, the cable from the pedal positions the swash plate in the traction pump (P3) so oil flows out of the upper port.
Hydraulic System (Rev.
When the solenoid valve (R1) is de- energized as the PTO switch is DISENGAGED, brake relief cartridge (BV) shifts to its closed position, blocking return flow from the deck motors and slowing the cutting blades Solenoid valve (R1) is de- energized with the engine running when either the cutting unit drive switch is in DISENGAGE or the transport/mow slide is in TRANSPORT. Solenoid valve (R1) by- passes flow from the cutting unit motors directly to the hydraulic reservoir.
Hydraulic System (Rev.
When the cutting unit shift lever is released, spring action returns the valve to its original position and bypasses flow back to the hydrostat stopping lift cylinder movement. The cylinder position is locked in place by the load holding checks in the lift control valve.
Hydraulic System (Rev.
When the cutting unit shift lever is released, spring action returns and detents the valve into the float position while by- passing flow back to the hydrostat. The pilot valve remains shifted to allow the lift cylinders to float until the lift control valve is moved to the raise position. When the cutting units are to be lowered, the 2- spool valve is positioned by moving the cutting unit shift lever to LOWER. Pressure from gear pump (P2) is used to shift the pilot valve in the 2- spool valve.
Hydraulic System (Rev.
Shift Sidewinder Left Shift Sidewinder Right Wheels, Brakes, and Chassis Electrical System When the sidewinder is to be shifted right, the 2- spool valve is positioned by moving the cutting unit shift lever to RIGHT. Flow is directed to the cap end of the sidewinder cylinder. Hydraulic pressure against the cylinder piston moves the rod causing the sidewinder cylinder to extend right.
Hydraulic System (Rev.
The steering control valve returns to the neutral position when turning is complete. Product Records and Manuals When a left turn is made with the engine running, the turning of the steering wheel positions the spool valve so that flow goes through the top of the spool. Flow entering the steering control valve at the IN port goes through the spool and is routed to two places.
Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Toro Part Number: TOR47009 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.
Hydraulic Test Fitting Kit Safety Toro Part Number: TOR4079 This kit includes a variety of O- ring Face Seal fittings to enable the connection of test gauges into the system. Product Records and Manuals The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings. Kubota Diesel Engine Figure 46 Measuring Container Toro Part Number: TOR4077 Hydraulic System Use this graduated container for doing hydraulic motor efficiency testing (motors with case drain lines only).
O- Ring Kit Toro Part Number: 117- 2727 The kit includes O- rings in a variety of sizes for face seal and port seal hydraulic connections. It is recommended that O- rings be replaced whenever a hydraulic connection is loosened. Figure 49 Wheel Hub Puller Toro Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors.
High Flow Hydraulic Filter Kit Safety Toro Part Number: TOR6011 Figure 52 Hydraulic System NOTE: This kit does not include hydraulic hoses (see Hydraulic Hose Kit TOR6007 above). Kubota Diesel Engine If a component failure occurs in the closed loop traction circuit, contamination from the failed part will remain in the circuit until removed. When connecting hydraulic test gauges in order to test traction circuit components or after replacing a failed traction circuit component (e.g.
Troubleshooting The charts that follow contain 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 test procedures. Problem Possible Cause Hydraulic oil leaks from system. Fitting(s), hose(s), or tube(s) are loose or damaged. O- ring(s) or seal(s) are missing or damaged. Hydraulic fluid foams. Oil level in reservoir is low. Hydraulic system has wrong type of oil.
Possible Cause Wheel motor will not turn. Brakes are binding. Key on wheel motor shaft is sheared or missing. Safety Problem Wheel motor will not hold load in neutral. Make up fluid from charge pump is not available. Cutting unit gear pump (P1) is noisy (cavitation). Reservoir oil level is low. Hydrostat ball check valves are damaged. Suction line is restricted. Product Records and Manuals Internal parts in wheel motor are damaged. Solenoid valve (R1) is stuck open.
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 circuits during various operational checks (See the Special Tools section in this Chapter). Before Performing Hydraulic Tests IMPORTANT: All obvious areas such as oil supply, filter, binding linkages, loose fasteners, or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem.
Wheels, Brakes, and Chassis Electrical System This page is intentionally blank. Groundsmaster 3500- D Page 4 - 31 Hydraulic System (Rev.
Traction Circuit Working Pressure Test (Using Pressure Gauge) FORWARD M5 TRACTION WHEEL MOTORS M4 TOP PORT M6 LOWER PORT BI- PASS VALVE UPPER PORT 3000 psi TRACTION RELIEF 100 to 150 psi FROM HYDRAULIC MANIFOLD (CHARGE) PORT P3 PISTON PUMP (HYDROSTAT) TO GEAR PUMP SUCTION THROUGH CASE DRAIN High Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev.
Procedure for Traction Circuit Working Pressure Test: 2 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off. 1 3. Read Precautions for Hydraulic Testing. 4. Make sure that traction pedal is adjusted to the neutral position (see Adjust Traction Drive for Neutral in the Adjustments Section). Hydraulic tube with plug 2. Floor plate Kubota Diesel Engine 5. Remove plug from hydraulic tube connected to front wheel motors (Fig. 53).
Piston Pump (P3) Flow and Traction Relief Pressure Test (Using Tester with Pressure Gauges and Flow Meter) M5 FORWARD TRACTION WHEEL MOTORS M4 TOP PORT M6 LOWER PORT BI- PASS VALVE UPPER PORT 3000 psi TRACTION RELIEF 100 to 150 psi FROM HYDRAULIC MANIFOLD (CHARGE) PORT P3 PISTON PUMP (HYDROSTAT) TO GEAR PUMP SUCTION THROUGH CASE DRAIN High Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev.
3. Read Precautions for Hydraulic Testing. B. The relief valve leaks or is faulty and needs replacement. 4. Make sure that traction pedal is adjusted to the neutral position (see Adjust Traction Drive for Neutral in the Adjustments Section). C. The hydrostat needs to be repaired or replaced as necessary. 15.If the traction relief valve tests out properly, verify pump flow as follows: CAUTION One front wheel and the rear wheel will be off the ground during testing.
Charge Relief Valve Pressure Test M5 TRACTION WHEEL MOTORS M4 FORWARD TOP PORT M6 BI- PASS VALVE LOWER PORT UPPER PORT TO HYDRAULIC MANIFOLD (P1) PORT 3000 psi FROM HYDRAULIC MANIFOLD (CHG) PORT 100 to 150 psi CHARGE RELIEF TO STEERING CONTROL VALVE (IN) PORT P3 ENGINE P1 P2 RPM HYDROSTAT FROM OIL FILTER INTERNAL CASE DRAIN GEAR PUMP STRAINER High Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev.
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. Figure 55 1. 90o hydraulic fitting 2. Piston pump 5. Make sure that traction pedal is in neutral and the parking brake is engaged. 6. Start engine and operate engine at full speed (3050 + 50 RPM).
Gear Pump (P2) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO HYDRAULIC MANIFOLD (P1) PORT TO STEERING CONTROL VALVE (IN) PORT TO TOTO ENGINE P1 P2 GEAR PUMP RPM FROM HYDROSTAT CASE DRAIN FROM OIL FILTER High Pressure Low Pressure STRAINER Hydraulic System (Rev.
Procedure for Gear Pump (P2) Flow Test: Safety 2 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. RIGHT 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 4. Disconnect hose connection on the gear pump (P2) leading to the steering control valve (Fig. 56). 1 5.
Wheel Motor Efficiency Test (Using Tester with Pressure Gauges and Flow Meter) M5 FRONT WHEEL MOTOR TESTING SHOWN FORWARD TRACTION WHEEL MOTORS M4 TOP PORT M6 LOWER PORT UPPER PORT DUMP VALVE 3000 psi TRACTION RELIEF 100 to 150 psi FROM HYDRAULIC MANIFOLD (CHG) PORT P3 PISTON PUMP (HYDROSTAT) TO GEAR PUMP SUCTION THROUGH CASE DRAIN High Pressure Low Pressure Return or Suction Flow Figure 57 NOTE: Over a period of time, a wheel motor can wear internally.
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. WARNING The rear wheel will be off the ground during front wheel motor testing. Make sure machine is supported so it will not move and accidentally fall to prevent injuring anyone under machine. 6.
Cutting Deck Circuit Pressure Test TO HYDRAULIC TANK D1 FROM DECK MOTOR CASE DRAINS TO LEFT FRONT DECK MOTOR FROM REAR M2 DECK MOTOR M1 T2 1500 psi HYDRAULIC MANIFOLD BLOCK DECK ON- OFF G1 TO OIL COOLER BV R1 3200 psi T1 CF FROM FRONT LIFT CYLINDER CR FROM REAR LIFT CYLINDER LC1 G2 P1 CHG ST TO HYDROSTAT CHARGE CIRCUIT FROM STEERING CONTROL VALVE (OUT) PORT P1 P2 GEAR PUMP FROM HYDROSTAT INTERNAL CASE DRAIN Hydraulic System (Rev.
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Safety Procedure for Cutting Deck Circuit Pressure Test: 1 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. Product Records and Manuals 2 3. Read Precautions for Hydraulic Testing. 4. Remove plug from hydraulic manifold port (G1). Figure 59 Hydraulic manifold 2.
Gear Pump (P1) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO HYDRAULIC MANIFOLD (P1) PORT 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 (Rev.
Procedure for Gear Pump (P1) Flow Test: Safety 2 Note: Over a period of time, the gears and wear plates in the pump can wear. A worn pump will by pass oil and make the pump less efficient. Eventually, enough oil loss will occur to cause the cutting unit motors to stall under heavy cutting conditions. Continued operation with a worn, inefficient pump can generate excessive heat and cause damage to the seals and other components in the hydraulic system. RIGHT 1 1.
Manifold Relief Valve (R1) Pressure Test FROM DECK MOTOR CASE DRAINS TO LEFT FRONT DECK MOTOR TO HYDRAULIC TANK D1 FROM REAR DECK MOTOR M2 M1 T2 1500 psi BV HYDRAULIC MANIFOLD BLOCK G1 DECK ON- OFF R1 3200 psi TO OIL COOLER T1 CF FROM FRONT LIFT CYLINDER CR FROM REAR LIFT CYLINDER LC1 G2 P1 CHG ST TO HYDROSTAT CHARGE CIRCUIT P1 P2 FROM STEERING CONTROL VALVE (OUT) PORT GEAR PUMP High Pressure Low Pressure Return or Suction FROM OIL FILTER STRAINER Hydraulic System (Rev.
1 2 Product Records and Manuals 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 3. Read Precautions for Hydraulic Testing. 4. Disconnect hose connection from hydraulic fitting on manifold port (M1) (Figure 62). Note: An alternative to using manifold port (M1) would be to disconnect the inlet hydraulic hose to the front, left deck motor. The motor inlet is opposite from the relief valve on the motor (Figure 64).
Logic (Counterbalance) Valve (LC1) Pressure Test TO HYDRAULIC TANK D1 FROM DECK MOTOR CASE DRAINS TO LEFT FRONT DECK MOTOR FROM REAR M2 DECK MOTOR M1 T2 1500 psi BV DECK ON- OFF HYDRAULIC MANIFOLD BLOCK G1 R1 3200 psi TO OIL COOLER T1 CF FROM FRONT LIFT CYLINDER CR FROM REAR LIFT CYLINDER LC1 G2 P1 CHG ST TO HYDROSTAT CHARGE CIRCUIT FROM STEERING CONTROL VALVE (OUT) PORT P1 P2 GEAR PUMP FROM HYDROSTAT INTERNAL CASE DRAIN Hydraulic System (Rev.
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 1 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. Kubota Diesel Engine 2 3. Read Precautions for Hydraulic Testing. 4. Remove plug from hydraulic manifold port (G2) (Fig. 65 and 66). 5. Install test gauge with hydraulic hose attached to port (G2). Figure 65 1. Hydraulic manifold 2.
Deck Motor Efficiency - Case Drain Test (Using Tester with Pressure Gauges and Flow Meter) TO HYDRAULIC MANIFOLD PORT (D1) FROM HYDRAULIC MANIFOLD PORT (M1) LEFT DECK MOTOR RIGHT DECK MOTOR MEASURING CONTAINER High Pressure TO HYDRAULIC MANIFOLD PORT (M2) REAR DECK MOTOR Low Pressure Return or Suction Flow Toro # TOR4077 Note: Over a period of time, a deck motor can wear internally. A worn motor may by- pass oil to its case drain causing the motor to be less efficient.
11. Stop cutting units by positioning the PTO switch to the DISENGAGE position. Stop engine. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 12.Identify amount of oil collected in the container. Record test results. 3. Park the machine on a level surface with the cutting units raised and off. Make sure engine is off and the parking brake is engaged. 14.
Lift and Steering Control Valve Relief Pressure Test TO HYDRAULIC MANIFOLD (ST) PORT TO LIFT VALVE (IN) PORT L V1 OUT 1000 psi STEERING IN R AUX TO HYDRAULIC MANIFOLD (P1) PORT POWER STEERING VALVE GEAR PUMP ENGINE RPM P1 P2 STRAINER High Pressure FROM OIL FILTER Low Pressure Return or Suction Flow FROM HYDROSTAT INTERNAL CASE DRAIN Hydraulic System (Rev.
Procedure for Lift and Steering Control Valve Relief Pressure Test: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Safety 2 RIGHT 1 4. Disconnect hose connection on gear pump (P2) leading to the steering control valve (Fig. 70). 5. Install T- connector with test gauge in series with the discharge of the gear pump and the disconnected hose leading to the steering control valve. Figure 70 1. Gear pump (P2) 2.
Steering Control Valve Test STEERING CYLINDER OPEN FITTING PLUG AUX OUT IN 1000 psi V1 L R POWER STEERING VALVE (LEFT TURN) High Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev.
3. Drive machine slowly in a figure eight on a flat level surface. A. There should be no shaking or vibration in the steering wheel or rear wheel. B. Steering wheel movements should be followed immediately by a corresponding rear wheel movement without the steering wheel continuing to turn. 4. Stop unit with the engine running. Turn steering wheel with small quick movements in both directions. Let go of the steering wheel after each movement. A.
Adjustments Adjust Traction Drive for Neutral If the machine creeps when the traction pedal is in the neutral position, the traction adjustment cam needs adjustment. 4. Start engine and rotate cam hex in both directions to determine mid position of neutral span. When properly set, neither wheel that is off the floor should turn. 1. Park the machine on a level surface and turn the engine off. 5. Tighten locknut to secure adjustment.
Braking Valve Adjustment Product Records and Manuals Safety The 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.
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 oil level in the hydraulic reservoir and add correct oil if necessary.
Change hydraulic fluid after every 400 operating hours or yearly, under normal conditions. If fluid becomes contaminated, the complete hydraulic system must be flushed (see Flush Hydraulic System). Contaminated fluid looks milky or black when compared to clean oil. 1. Position machine on a level surface, lower the cutting units, stop the engine, engage the parking brake and remove key from ignition switch. 2. Thoroughly clean area around the hydraulic suction hose at gear pump (Fig. 73).
Replace Hydraulic Oil Filter The hydraulic system oil filter must be changed initially, after the first 10 hours of operation, and thereafter every 200 hours of operation or yearly, whichever comes first. Use a genuine Toro oil filter (Part No. 54- 0110) for replacement. 1 IMPORTANT: Use of any other filter may void the warranty on some components. 1. Position machine on a level surface, lower the cutting units, stop the engine, engage the parking brake and remove key from ignition switch. 2 2.
Replace Traction Belt 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. Raise hood. 3 1 4 2. Insert nut driver or small piece of pipe onto the end of the torsion spring of the idler pulley. 5 6 CAUTION Be careful when removing or applying tension from or to the torsion spring of the idler pulley. The spring is under heavy load and may cause personal injury. 3.
Product Records and Manuals Wheels, Brakes, and Chassis Electrical System Hydraulic System 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. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury.
Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or if the system is contaminated (oil 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 Filtering of a closed- loop hydraulic system after a major component failure (e.g. traction (piston) pump or wheel motor) is a requirement to prevent debris from transmitting throughout the system. If a closed- loop hydraulic system filtering tool is not used (to ensure system cleanliness) repeat failures and subsequent damage to other hydraulic components in the system will occur.
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. 10.Make sure traction pedal and lift control lever are in neutral. Start engine and run it at low idle of 1800 rpm. The charge pump should pick up oil and fill the hydraulic system.
Hydraulic Tank and Hydraulic Oil Filter EARLY MODELS 14 18 32 16 6 31 8 Hydraulic Thread Sealant 33 30 9 12 15 8 11 27 26 27 28 25 24 4 23 19 29 19 22 29 7 22 1 5 2 21 10 20 17 8 13 3 Anti- seize lubricant 30 to 60 in- lb (3.4 to 6.8 N- m) Figure 78 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Grommet Flange head screw Barb fitting Check fitting Flat washer Hydraulic tank O- ring Hose clamp Barb fitting (straight) Flange head screw Elbow fitting Hydraulic System (Rev. G) 12. 13. 14. 15.
1. Apply anti- seize lubricant or equivalent to the two 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 using Figure 78 as a guide. 2. Remove hydraulic tank using Figure 78 as a guide. Discard and replace any O- rings that are removed. Hydraulic Tank Inspection (Fig. 78) 1. Clean hydraulic tank and suction strainer with solvent. 2. Inspect hydraulic tank for leaks, cracks, or other damage. 2.
Oil Cooler Note: On Groundsmaster 3500- D machines with serial numbers above 314000000, the hydraulic oil cooler is combined with the radiator. Removal 2 CAUTION The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before working on the oil cooler. 1. Remove oil cooler using Figures 79 and 80 as guides. 1 Figure 79 1. Oil cooler 2. Latch Inspection RIGHT CAUTION 1 FRONT Use eye protection such as goggles when using compressed air. 2 1.
Wheels, Brakes, and Chassis Groundsmaster 3500- D Page 4 - 69 Electrical System This page is intentionally blank. Hydraulic System (Rev.
Front Wheel Motors 5 7 3 8 9 10 6 4 8 RIGHT 9 10 FRONT 2 1 Figure 81 1. 2. 3. 4. Lock nut Spacer Socket head screw Hydraulic wheel motor Hydraulic System (Rev. G) 5. 6. 7. Frame Hydraulic tube Hydraulic tube Page 4 - 70 8. O- ring 9. Hydraulic fitting 10.
1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 3. Remove tire and wheel assembly, wheel hub, and brake drum from the hydraulic motor. Remove brake assembly, brake bracket, and wheel shield from the frame (see Front Wheel and Brake Removal in Chapter 6 Wheels, Brakes, and Miscellaneous). Safety Removal 2. Jack up front of equipment enough to allow the removal of the front wheel.
Rear Wheel Motor 1 45 to 65 ft- lb (61 to 88 N- m) 15 2 5 250 to 275 ft- lb (339 to 373 N- m) 7 8 13 6 3 7 8 12 13 4 14 RIGHT 9 10 11 FRONT Figure 75 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. 75) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch.
Installation (Fig. 75) 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. 8. Make sure hydraulic tank is full. Add correct oil if necessary (see Check Hydraulic System Fluid).
Wheel Motor Service 12 13 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 19 20 18 Figure 83 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.
Wheels, Brakes, and Chassis Groundsmaster 3500- D Page 4 - 75 Electrical System This page is intentionally blank. Hydraulic System (Rev.
Rotary Cutting Motors 12 11 12 11 12 14 8 12 2 15 3 4 1 9 10 5 7 16 13 8 9 15 5 7 18 5 9 14 7 2 3 4 2 19 6 17 1 3 20 4 Figure 84 1. 2. 3. 4. 5. 6. 7. Hydraulic motor O- ring O- ring Hydraulic elbow Hydraulic hose Hydraulic adapter Hydraulic hose Hydraulic System (Rev. G) 8. 9. 10. 11. 12. 13. 14. Hydraulic fitting Hydraulic hose Hydraulic T- fitting Hydraulic hose Hydraulic hose O- ring O- ring Page 4 - 76 15. 16. 17. 18. 19. 20.
Removal (Fig. 84) Note: Note position of hydraulic hoses when removing from the rotary motors. Proper positioning is critical when reconnecting hydraulic hoses. The inlet to the motor is opposite from the relief valve (Fig. 85). 4 2 2. Remove hydraulic hoses from rotary motors using Figure 84 as a guide. 3. If hydraulic fittings are to be removed from motor, mark fitting orientation to allow correct assembly. Installation (Fig. 84) 4 1 Figure 85 1. Hydraulic deck motor 2. Inlet hose 3. Relief valve 4.
Rotary Cutting Motor Service (Haldex) 11 14 13 1 10 4 8 6 12 9 8 3 2 10 12 5 15 38 to 43 ft- lb (51 to 58 N- m) 1. 2. 3. 4. 5. Front plate Back plate Body Dowel Drive gear 6. 7. 8. 9. 10. Figure 86 Idler gear Cap screw Back- up gasket Rear wear plate Pressure seal Disassembly (Fig. 86) 1. Plug motor ports and clean the outside of the motor thoroughly. After cleaning, remove plugs and drain any oil out of the motor. 7 11. 12. 13. 14. 15.
5. Inspect front plate and back plate for damage or wear. 8. Carefully remove rear wear plate, idler gear, drive gear, and front wear plate from the front plate. 2 10.Turn front plate over, with seal side up, and remove the retaining ring using snap ring pliers. IMPORTANT: Make sure not to damage the counter bore when removing the shaft seal from the front plate. 4 1. 2. 3. 4. Gear teeth Gear face edge 2. Clean all parts with solvent. Dry all parts with compressed air. 3.
9. Install rear wear plate with pressure seal side up and open side of the pressure seal pointing to the inlet side of the motor. 10.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. 11. Install locating dowels in body. Align marker line on the body and front plate. IMPORTANT: Do not dislodge seals during installation. 12.Gently slide the body onto the assembly. Firm hand pressure should be sufficient to engage the dowels. 13.
Wheels, Brakes, and Chassis Groundsmaster 3500- D Page 4 - 81 Electrical System This page is intentionally blank. Hydraulic System (Rev.
Rotary Cutting Motor Service (Casappa) 33 ft- lb (45 N- m) 26 ft- lb (35 N- m) 2 3 4 11 1 10 10 13 7 6 6 16 8 17 5 7 9 9 10 26 ft- lb (35 N- m) 12 14 18 15 19 Figure 90 1. 2. 3. 4. 5. 6. 7. Socket head screw (4 used) Washer (4 used) Back plate Anti- cavitation valve Relief valve Pressure seal Back up gasket 8. 9. 10. 11. 12. 13. Rear wear plate O- ring Dowel pin (4 used) Body Idler gear Drive gear 14. 15. 16. 17. 18. 19.
Wheels, Brakes, and Chassis Groundsmaster 3500- D Page 4 - 83 Electrical System This page is intentionally blank. Hydraulic System (Rev.
Hydraulic Manifold 8 13 15 5 16 6 8 5 14 8 5 6 22 11 21 10 20 9 12 22 21 20 2 20 21 19 22 18 1 23 25 3 24 RIGHT 17 FRONT 4 7 Figure 91 1. 2. 3. 4. 5. 6. 7. 8. 9. Hose clamp O- ring Barb fitting Stud Straight hydraulic fitting O- ring Flange head nut O- ring O- ring Hydraulic System (Rev. G) 10. 11. 12. 13. 14. 15. 16. 17. Straight hydraulic fitting O- ring Hydraulic hose Hydraulic hose Straight hydraulic fitting O- ring O- ring Hydraulic tube Page 4 - 84 18. 19. 20. 21.
Installation (Fig. 91) Note: The ports on the manifold are marked for easy identification of components. Example: BV is the deck circuit braking valve and P1 is the gear pump connection port. (See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port location). 1. If hydraulic fittings were removed from manifold, install fittings to manifold using marks made during the removal process to properly orientate fittings. 1.
Hydraulic Manifold Service (Serial Numbers Below 240000600) Loctite 242 4 to 6 Ft- lb (5 to 8 N- m) 9 30 to 35 Ft- lb (41 to 47 N- m) 8 30 to 35 Ft- lb (41 to 47 N- m) 4 2 14 5 3 12 10 10 13 30 to 35 Ft- lb (41 to 47 N- m) 15 6 11 11 11 10 7 RIGHT 10 11 13 FRONT 12 11 10 11 11 10 13 10 1 12 Figure 92 1. 2. 3. 4. 5. Manifold body Logic cartridge valve (LC1) Seal kit Braking cartridge valve (BV) Seal kit 6. 7. 8. 9. 10.
4 Safety 5. Visually inspect cartridge valve for damaged sealing surfaces or contamination. 2 3 1 B. If valve sealing surfaces appear pitted or damaged, the hydraulic system may be overheating or there may be water in the system. Figure 93 Manifold assembly SRV cartridge valve (R1) 3. 4. Braking valve (BV) Logic valve (LC1) 3 6. Clean cartridge valve using clean mineral spirits. Submerge valve in clean mineral spirits to flush out contamination.
Braking and Logic Cartridge Valves (Fig. 92 and 93) 2 1. Make sure manifold is clean before removing the cartridge. 3 3 1 IMPORTANT: Use care when handling the cartridge valve. Slight bending or distortion of the stem tube can cause binding and malfunction. 3 2 2 2. Remove cartridge valve using a deep socket wrench. Note: Do not loosen locknut on top of valve. 3. Visually inspect port in the manifold for damage to the sealing surfaces, damaged threads, or contamination. 4.
Wheels, Brakes, and Chassis Groundsmaster 3500- D Page 4 - 89 Electrical System This page is intentionally blank. Hydraulic System (Rev.
Hydraulic Manifold Service (Serial Numbers 240000601 to 313999999) 4 60 in- lb (6.8 N- m) 5 35 ft- lb (47 N- m) 25 ft- lb (34 N- m) 6 3 45 to 50 ft- lb (61 to 68 N- m) 7 120 in- lb (13.6 N- m) 1 2 RIGHT FRONT Figure 97 1. Manifold body 2. NWD #4 plug 3. Logic cartridge valve (LC1) 4. Nut 5. Solenoid coil 6. Solenoid cartridge valve (R1) 7. Braking cartridge valve (BV) NOTE: The ports on the manifold are marked for easy identification of components.
IMPORTANT: Use care when handling the cartridge valve. Slight bending or distortion of the stem tube can cause binding and malfunction. B. Thread cartridge valve carefully into manifold port. The valve should go in easily without binding. D. If cartridge is solenoid operated, carefully install solenoid coil to the cartridge valve. Torque nut to value identified in manifold illustration (Fig. 97). 4.
Hydraulic Manifold Service (Serial Numbers Above 314000000) 25 ft- lbs (34 N- m) 20 ft- lbs (27.1 N- m) 4 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 9 20 ft- lbs (27.1 N- m) FRONT 3 RIGHT 60 in- lb (6.8 N- m) Figure 99 1. Manifold body 2. #4 Hex head plug 3. #4 Zero leak plug 4. Logic cartridge valve (LC1) 5. Logic cartridge valve (LC2) 6. Relief valve (RV) 7. Solenoid cartridge valve (S) 8. Solenoid coil 9.
Product Records and Manuals Safety NOTE: The Groundsmaster 3500- D hydraulic manifold uses several zero leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening. The zero leak plugs also have an O- ring as a secondary seal.
Control Valve 6 13 25 1 12 11 17 14 9 5 17 7 21 26 25 15 27 5 10 8 14 5 16 9 21 7 20 25 21 4 2 18 21 21 23 25 24 22 19 3 21 Figure 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 (Rev. G) 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal 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 control valve from the frame using Figures 100 and 101 as guides. 2 3 Figure 101 1. 2. Spool valve Support bracket 3. 4. Flange head screws Frame Kubota Diesel Engine 2. If hydraulic fittings are to be removed from control valve, mark fitting orientation to allow correct assembly.
Control Valve Service 10 to 12 ft- lb (14 to 16 N- m) 18 28 25 9 26 15 1 19 30 to 42 ft- lb (41 to 57 N- m) 5 27 17 12 20 23 9 22 29 7 24 30 4 26 6 25 4 11 30 to 35 ft- lb (41 to 48 N- m) 21 1 5 27 10 2 27 5 1 12 8 14 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 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
26 25 1 27 5 9 1 7 Safety 6 Product Records and Manuals 15 9 25 17 19 18 21 1 27 5 29 30 23 22 Kubota Diesel Engine 26 24 Hydraulic System 28 14 12 16 Wheels, Brakes, and Chassis 13 Electrical System 4 20 12 8 3 Figure 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- D 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
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.
Wheels, Brakes, and Chassis Groundsmaster 3500- D Page 4 - 99 Electrical System This page is intentionally blank. Hydraulic System (Rev.
Piston Pump 10 RIGHT 28 26 27 25 FRONT 25 50 43 49 42 24 12 9 40 45 7 44 47 8 29 5 1 54 45 53 48 13 77 to 93 ft- lb (105 to 127 N- m) 38 Antiseize Lubricant 32 27 3 33 30 40 46 1018 37 4 35 90 to 120 in- lb (10.2 to 13.6 N- m) 34 51 41 27 to 31 ft- lb (37 to 42 N- m) 11 2 23 52 17 16 39 56 40 31 30 21 20 36 55 6 22 41 57 19 15 14 Figure 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Neutral Arm Assembly 24 7 18 22 21 19 20 6 5 7 9 Product Records and Manuals 23 Safety 1 4 8 3 9 10 11 14 32 16 17 29 31 13 26 25 27 16 15 12 33 30 28 Hydraulic System 2 Kubota Diesel Engine 12 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Lock nut 105 Spacer Traction stud Traction control cable Flat washer Ball joint Lock nut Cap screw Flat washer Hub assembly Flange nut Piston Pump Removal (Fig. 104 & 105) 1.
11. If hydraulic fittings are to be removed from pump, mark fitting orientation to allow correct assembly. 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. Disconnect all hydraulic hoses connected to the hydraulic fittings on the piston and gear pumps. Allow hoses to drain into a suitable container and plug hose openings to prevent contamination.
9. Remove plugs from hydraulic hoses. Connect all hydraulic hoses as follows: A. Secure O- rings, fittings, and hydraulic hoses to the gear pump. IMPORTANT: When tightening bushing cap screws, tighten in three equal steps and in a circular pattern. 13.Secure taper lock bushing by tightening three (3) cap screws to a torque from 90 to 120 in- lb (10.2 to 13.6 N- m) in three equal steps and in a circular pattern to secure pulley and taper lock bushing. B.
Piston Pump Service 40 41 19 43 42 18 17 39 4 22 22 38 23 15 12 11 5 6 48 29 10 20 37 19 14 8 15 17 18 47 44 9 45 46 8 3 48 6 2 1 7 24 30 31 25 26 4 31 32 30 33 35 28 21 16 13 38 26 27 34 Figure 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 Bearing cone Key Cam plate Rotating kit Gasket Cam plate Bearing Dowel pin Back plate 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
Wheels, Brakes, and Chassis Groundsmaster 3500- D Page 4 - 105 Electrical System This page is intentionally blank. Hydraulic System (Rev.
Gear Pump 5 9 10 4 3 6 7 8 12 11 13 14 2 1 RIGHT 15 FRONT 16 17 27 to 31 ft- lb (37 to 42 N- m) Figure 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. 108 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 Removal (Fig. 108) Installation (Fig. 108) 1.
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Gear Pump Service (Serial Numbers Below 260000400) 1 8 10 11 12 18 14 17 3 12 6 15 14 9 4 10 14 8 8 10 13 7 11 5 12 2 19 12 38 to 43 ft- lb (51 to 58 N- m) 16 9 10 8 Figure 1. 2. 3. 4. 5. 6. 7. Front plate Back plate Front body Rear body Drive gear Front idler gear Rear idler gear 8. 9. 10. 11. 12. 13. Back- up gasket 109 Rear wear plate Pressure seal Front wear plate O- ring Adapter Plate Disassembly (Fig. 109) 14. 15. 16. 17. 18. 19.
3. Clamp mounting flange of pump in a vise with the shaft end down. 7. Carefully remove rear 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 rear body. 3. Inspect drive gears and idler gears for the following (Fig. 111): A. Drive gear shaft spline should be free of twisted or broken teeth. IMPORTANT: Note position of the open and closed side of the wear plates before removing from the adapter plate.
5. Inspect wear plates for the following: A. Bearing areas should not have excessive wear or scoring. B. Face of wear plates that are in contact with gears should be free of wear, roughness or scoring. C. Thickness of wear plates should be equal. 6. Inspect front plate, back plate, and adapter plate for damage or wear. 8. Install rear wear plate with pressure seal side up and open side of the pressure seal pointing to the suction side of the pump. 9.
Wheels, Brakes, and Chassis Groundsmaster 3500- D Page 4 - 111 Electrical System This page is intentionally blank. Hydraulic System (Rev.
Gear Pump Service (Serial Numbers Above 260000400) 18 11 10 12 19 14 17 2 8 3 6 1 3 2 20 15 13 16 21 13 14 33 ft- lb (45 N- m) 9 8 7 5 4 Figure 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 112 Seal Body Seal Splined connecting shaft Pressure seal Back- up gasket 15. 16. 17. 18. 19. 20. 21.
5. Remove pump from vise and remove fasteners. 6. Support the pump assembly and gently tap the pump case with a soft face hammer to loosen the pump sections. Be careful to not drop parts or disengage gear mesh. IMPORTANT: Mark the relative positions of the gear teeth and the thrust plates so they can be reassembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. 1. Apply clean hydraulic oil to all parts before assembling.
Steering Control Valve 8 9 RIGHT 20 to 26 ft- lb (28 to 35 N- m) 11 14 20 27 7 FRONT 21 39 40 10 12 17 28 32 19 33 18 23 2 4 6 22 24 5 35 37 42 8 34 38 44 46 41 26 25 3 36 41 45 3 43 1 29 30 31 13 15 16 2 Figure 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Removal 2 1 Safety 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. 5 8 7 1. Install steering control valve to the steering column using Figures 114, 115, and 116 as guides. When installing steering control valve, note position of end cover protrusion as shown (Fig. 116). 2. Make sure hydraulic tank is full.
Steering Control Valve Service (Serial Numbers Below 240000000) 1 2 7 3 2 5 4 17 8 3 9 18 3 34 19 6 12 14 20 13 21 22 3 10 11 36 41 11 23 33 15 24 30 25 11 3 16 26 27 37 28 38 29 39 31 32 40 35 Figure 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Nut Port cover Seal ring O- ring Relief valve cartridge Plug Coil spring Port manifold Spring Drive assembly Alignment pin Valve ring Valve plate Spring 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
Safety Steering Control Valve Service (Serial Numbers Above 240000000) 8 7 Product Records and Manuals 6 10 5 4 3 2 11 1 12 22 13 Kubota Diesel Engine 9 14 Hydraulic System 15 21 13 16 20 13 18 20 to 24 ft- lb (27 to 33 N- m) Electrical System 17 Figure 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 118 Housing Cardan shaft Spacer O- ring Distribution plate Inner gearwheel 16. 17. 18. 19.
Sidewinder 18 19 17 14 13 26 26 1 7 19 11 14 13 9 1 20 1 12 10 31 25 10 11 12 1 22 RIGHT 27 FRONT 27 24 5 9 21 15 6 15 16 28 1 4 30 8 2 3 23 28 32 29 Figure 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 (Rev. G) 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Removal 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 1. Remove hydraulic cylinder from the frame using Figure 119 as guide. Installation 1 Figure 120 1. 2. Scissor frame Lower frame 3. 4. Sidewinder carrier Gaps Hydraulic System 1.
Front Lift Cylinder 9 6 RIGHT 4 FRONT 34 57 47 42 39 41 40 15 55 32 43 48 28 63 44 58 59 62 61 45 33 46 10 18 49 54 51 21 22 20 26 53 60 31 16 30 28 37 66 29 5 7 12 3 23 24 13 33 53 64 56 27 26 28 17 28 38 33 65 50 8 35 1 36 52 20 25 24 19 2 13 11 14 Figure 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Removal 2 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 1. Remove front lift cylinder from the frame and lift arm using Figure 121 as guide. Figure 122 1. 2. Lift cylinder Hydraulic hoses 3. Clearance Kubota Diesel Engine 2. If hydraulic fittings are to be removed from lift cylinder, mark fitting orientation to allow correct assembly.
Rear Lift Cylinder 36 40 37 16 3 12 30 15 12 11 28 10 12 13 46 13 15 2 21 14 42 17 44 49 48 9 7 24 38 29 39 5 31 27 41 20 4 46 45 46 23 25 13 6 22 2 18 1 35 33 34 32 47 12 8 RIGHT 26 FRONT 43 19 12 2 3 12 Figure 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
1. If hydraulic fittings were removed from lift cylinder, install fittings to cylinder using marks made during the removal process to properly orientate fittings. 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 rear lift cylinder from the frame and lift arm using Figure 123 as guide. 2.
Lift Cylinder Service 2 3 4 1 5 6 7 8 9 10 11 24 to 30 ft- lb (33 to 41 N- m) 12 13 14 15 1 1 3 2 12 9 13 5 4 6 7 8 10 11 14 15 1 Figure 1. 2. 3. 4. 5. Grease fitting Barrel with clevis Nut Uni- ring Piston Hydraulic System (Rev. G) 6. 7. 8. 9. 10. O- ring 124 O- ring Back- up ring Rod seal Head Page 4 - 124 11. 12. 13. 14. 15.
IMPORTANT: Do not clamp vise jaws against the shaft surface. Protect shaft surface before mounting in a vice. 4. Mount shaft securely in a vise by clamping on the clevis of the shaft. Remove lock nut and piston from the shaft. Slide head off the shaft. 5. Remove Uni- ring and O- ring from the piston. Remove O- ring, back- up ring, rod seal, and dust seal from the head. Assembly 1. Make sure all parts are clean before assembly. 2.
Steering Cylinder 8 3 1 4 7 6 5 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 1. 2. 3. 4. Hydraulic hose Hydraulic hose O- ring Hydraulic fitting Hydraulic System (Rev. G) 5. 6. 7. 8. O- ring 126 Steering cylinder Ball joint Retaining ring Page 4 - 126 9. 10. 11. 12.
2 1 Product Records and Manuals NOTE: The rear tire must be removed to allow sufficient clearance to remove the steering cylinder from the machine. Figure 127 WARNING 1. Steering cylinder 2. Jam nuts Kubota Diesel Engine Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 - Safety. 3 2. Jack or lift rear wheel off the ground. 2 3. Remove rear wheel from the drive studs and wheel hub. 4.
Steering Cylinder Service 1 11 12 10 9 8 7 6 5 4 3 2 2 24 to 30 ft- lb (33 to 41 N- m) 3 4 1 5 8 6 9 10 11 7 12 Figure 1. 2. 3. 4. Barrel with clevis Lock nut Piston Uni- ring Hydraulic System (Rev. G) 5. 6. 7. 8. O- ring 129 Piston rod Rod seal Cylinder gland Page 4 - 128 9. 10. 11. 12.
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. Protect shaft surface before mounting in a vice. 3. Mount shaft securely in a vise by clamping on the clevis of the shaft. B. Slide cylinder gland assembly onto the shaft. Install piston and lock nut onto the shaft. Torque nut from 24 to 30 ft- lb (33 to 41 N- m). 4.
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Groundsmaster 3500- D Page 5 - 1 15 15 16 16 17 17 18 19 20 21 22 23 24 24 24 25 28 Electrical System (Rev. G) Product Records and Manuals Cutting Unit Drive Switch (Serial Number Below 314000000) . . . . . . . . . . . . . . . . . . . . . . . Cutting Unit Drive Switch (Serial Number Above 314000000) . . . . . . . . . . . . . . . . . . . . . . . Neutral Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematics and Diagrams The electrical schematics and other electrical drawings for the Groundsmaster 3500- D are located in Chapter 8 - Electrical Diagrams. Electrical System (Rev.
Special Tools Safety Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter Product Records and Manuals The meter can test electrical components and circuits for current, resistance, or voltage. Kubota Diesel Engine NOTE: Toro recommends the use of a DIGITAL VoltOhm- Amp multimeter when testing electrical circuits.
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Electrical Diagrams - Chapter 8). 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. If the machine has any interlock switches by- passed, they must be reconnected for proper troubleshooting and safety.
Engine cranks, but does not start. Wiring in the crank circuit (see Electrical Diagrams Chapter 8) is loose, corroded, or damaged. Engine run solenoid or fuel pump is faulty. The fuel tank is empty. An engine or fuel system problem exists. The glow circuit does not operate properly. The glow circuit does not operate properly. Wiring in the glow circuit (see Electrical Diagrams Chapter 8) is loose, corroded, or damaged. The glow relay or glow plug controller is faulty. Fuse F4 is blown or faulty.
Cutting Deck Operating Problems The cutting units will not run with the mow/transport slide in MOW and the cutting unit drive switch in ENGAGE with the rotary decks lowered. Wiring to the cutting unit drive circuit (see Electrical Diagrams - Chapter 8) is loose, corroded, or damaged. Fuse F4 is faulty or blown. The SRV coil (R1) on the hydraulic manifold is faulty or the valve is stuck. The cutting unit drive switch is faulty. The cutting unit up limit or mow/transport slide is faulty or misadjusted.
Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Voltage Measured Battery Charge Level 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery should be at a temperature of 60o to 100oF (16o to 38oC). 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. 12.
Check Operation of Interlock Switches 2. With operator on the seat, the engine must not start with either the cutting unit drive switch in the ENGAGE position or the traction pedal engaged. Correct problem if not operating properly. 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.
NOTE: For more component testing information, see the Kubota Workshop Manual, Diesel Engine, 05 Series. CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected. Ignition Switch Y A Kubota Diesel Engine The ignition (key) switch has three positions (OFF, ON/ PREHEAT, and START). The terminals are marked as shown. The circuitry of the ignition switch is shown in the chart below.
Glow Relay The glow relay is attached to the radiator assembly. When energized, the glow relay allows electrical current to the engine glow plugs. Two styles of glow relays have been used on the Groundsmaster 3500- D. On machines with serial numbers below 240000000, two of the four relay connections are secured with screws (Fig. 7). On machines with serial numbers above 240000000, the glow relay is attached to the wire harness with a four wire connector (Fig. 8).
Hour Meter Safety 1. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter. Hobbs 00001 HOURS 3. The hour meter should move 1/10 of an hour in six minutes. 1 10 Product Records and Manuals QUARTZ Kubota Diesel Engine + 4. Disconnect the voltage source from the hour meter. BACK Figure 10 SRV Valve Solenoid The hydraulic system on the Groundsmaster 3500- D uses a solenoid valve coil on the hydraulic manifold (Fig. 12).
Diode Assemblies The diodes D1, D2, and D4 provide logic for the interlock switches. Diode D3 is used for circuit protection from inductive voltage spikes when the interlock relay is de- energized. Two types of diodes have been used on the Groundsmaster 3500- D: 2 1. On early production machines, the diodes are located within the main wiring harness that lies under the hydraulic tank and control console (Fig. 13). 2. Later production machines use diodes that plug into the wiring harness (Fig. 14).
NOTE: Individual light bulbs can be tested by removing them from the lighting cluster and applying 12 VDC to their wiring terminals. FRONT OIL (RED) COOLANT (RED) Safety Warning Light Cluster (Serial Numbers Below 240000000) GLOW (AMBER) BATTERY (AMBER) 2. Ground gray wire to the engine block. 3. Turn the ignition switch to ON/PREHEAT; the light should come on. 4. Turn the ignition switch to OFF. Connect gray wire to the oil pressure switch. A F B E Kubota Diesel Engine 1.
Indicator Lights (Serial Numbers Above 240000000) Charge Indicator Light 2 3 The charge indicator light should come on when the ignition switch is in the ON position with the engine not running. Also, it should illuminate with an improperly operating charging circuit while the engine is running. 4 1 Engine Oil Pressure Light The engine oil pressure light should come on when the ignition switch is in the ON position with the engine not running.
Cutting Unit Drive Switch (Serial Number Below 314000000) NORMAL CIRCUITS OTHER CIRCUITS ENGAGE 5+6 2+3 DISENGAGE 1+2 4+5 Product Records and Manuals 1 Figure 19 1. Control panel 2. Cutting unit drive switch BACK OF SWITCH Hydraulic Systems SWITCH POSITION 2 Electrical System Figure 20 Cutting Unit Drive Switch (Serial Number Above 314000000) The cutting unit drive switch is located on the control panel and allows the decks to be engaged or disengaged.
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. 6. Switch adjustment: neutral switch should be installed so that the pin on the traction pedal (neutral position) is centered with the switch. 1. Disconnect electrical connector from the neutral switch. 2 2.
Parking Brake and Transport/Mow Switches Safety 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. Disconnect electrical connector from the switch. 3.
High Temperature Warning and Shutdown Switches 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. The high temperature shutdown switch is on the alternator side of the engine (Fig. 27). 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.
The fuel pump is attached to the frame just outboard of the fuel injection pump. Safety Fuel Pump 2 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 firing. 3. Disconnect fuel hose (pump discharge) from the fuel filter. 5. Place fuel hose (pump discharge) into a large, graduated cylinder sufficient enough to collect 1 quart (0.95 liter).
Fuel Stop Solenoid (Solenoid With 3 Wire Connector) The fuel stop solenoid must be energized for the engine to run. It is mounted on the engine block near the injection pump. 2 The fuel stop solenoid includes two coils for operation: the pull coil and the hold coil. When the ignition switch is turned to START, the fuel stop solenoid is initially energized and the pull coil retracts the solenoid plunger. Once the plunger is retracted, the hold coil will keep it retracted for continued engine operation.
Fuel Stop Solenoid (Solenoid With 2 Wire Connector) The fuel stop solenoid used on the Groundsmaster 3505- D must be energized for the diesel engine to run. The solenoid is mounted to the injection pump on the engine (Fig. 32). The fuel stop solenoid includes two coils for operation: the pull coil and the hold coil. When the ignition switch is turned to START, the fuel stop solenoid is initially energized and the pull coil retracts the solenoid plunger.
Glow Controller The controller is located under the right, lower corner of the instrument panel. NOTE: Refer to Electrical Diagrams - Chapter 8 when troubleshooting the glow controller. Controller Operation 1. When the ignition switch is placed in the RUN position, the controller energizes the glow plugs and lights up the glow lamp for 10 seconds. 2. When the ignition switch is held in the START position, the glow plugs will energize while the switch is held in START and the glow lamp will not light. 3.
The Standard Control Module does not connect to an external computer or hand held device, can not be reprogrammed, and does not record intermittent fault data. The Standard Control Module can be used to check operation of machine switches by monitoring the LED of the module. If a Module LED does not illuminate (e.g. the in seat input LED does not illuminate with the seat occupied and the ignition switch in the run position), testing of the switch and circuit wiring would be required.
Service and Repairs NOTE: For more electrical component repair information, see the Kubota Workshop Manual, Diesel Engine, 05 Series. Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery and charge it fully (see Battery Service). 2. Either store battery on a shelf or on the machine. 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5. To help prevent the battery from freezing, make sure it is fully charged (see Battery Service).
Battery Service Safety 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. 2 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. Kubota Diesel Engine 1 Figure 37 1.
2. Conduct a hydrometer test of the battery electrolyte. D. Measure the temperature of the center cell. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. E. Connect a battery load tester to the battery terminals following the manufacturer’s instructions. Connect a digital multimeter to the battery terminals. A. Measure the specific gravity of each cell with a hydrometer.
To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is available in most shops. 25% 0% 80 or less 3.8 hrs @ 3 amps 7.5 hrs @ 3 amps 11.3 hrs @ 3 amps 15 hrs @ 3 amps 81 to 125 5.3 hrs @ 4 amps 10.5 hrs @ 4 amps 15.8 hrs @ 4 amps 21 hrs @ 4 amps 126 to 170 5.5 hrs @ 5 amps 11 hrs @ 5 amps 16.
Solenoid Valve Coil The solenoid valve coil on the hydraulic control manifold (Fig. 39) can be replaced without opening the hydraulic system. 4 3 Removal 1. Park machine on a level surface, lower cutting decks, engage parking brake, stop engine and remove key from the ignition switch. 60 in- lb (6.8 N- m) 2 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.
2 2 3 3 4 5 6 7 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Rear Lift Arm . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Tire pressure 14 to 18 PSI (0.97 to 1.24 bar) Wheel lug nut torque 45 to 65 ft--lb (61 to 88 N--m) 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. Figure 1 Wheels, Brakes, and Chassis Page 6 -- 2 Rev.
Brake lever adjustment should be checked every 200 hours. 2 1 3 CAUTION 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. 1. Park machine on a level surface, lower cutting units, stop engine, and remove key from the ignition switch. 2. Loosen set screw on the adjustment knob (Fig. 1). Figure 1 1. Brake lever 2. Set screw 3. Adjustment knob Hydraulic Systems 3.
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 the Service and Repairs 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.
2 1 IMPORTANT: Keep front cutting units on the lift arms when performing this adjustment. 1 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: B. Adjust front hydraulic cylinder by backing off jam nut on the cylinder, removing the pin from the clevis, and rotating the clevis (Fig. 6). Kubota Diesel Engine Figure 4 1. Lift arm 2. Floor plate bracket 3.
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 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 wear strap on the top of the rear cutting unit wear bar and bumper strap is from 0.020 to 0.100 inch (0.51 to 2.54 mm) (Fig. 8). 3. If the clearance is not in this range, attain proper clearance by adjusting the rear hydraulic cylinder as follows (Fig. 9): 1 Figure 8 1.
Service and Repairs Standard Seat 8 3 2 4 5 1 6 7 8 3 2 15 14 9 13 16 12 11 18 10 10 17 18 Figure 9 1. 2. 3. 4. 5. 6. Seat (incl. 4 thru 7, 14, & 15) Cap screw Spring lock washer Edging clip Edging Seat cushion 7. 8. 9. 10. 11. 12. Seat shell Seat belt Seat adjuster with latch Flange hex nut Cap screw Lock washer 13. 14. 15. 16. 17. 18. Seat adjuster Cap screw Seat switch Hex flange head screw Seat support strap Hex flange head screw Removal Installation 1.
8 9 5 6 43 44 45 12 Product Records and Manuals 1 2 38 7 32 10 37 36 33 35 34 23 31 24 5 30 29 28 27 26 25 11 14 51 22 13 19 Kubota Diesel Engine 39 3 4 42 40 41 Safety Deluxe Seat 50 16 50 15 18 48 47 17 45 44 43 49 46 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Plate Rivet Screw Wear parts kit (incl.
Front Wheel and Brake 33 31 25 26 11 9 29 27 22 7 30 32 28 18 14 17 23 24 16 8 3 10 20 12 4 13 15 21 19 RIGHT 2 17 FRONT Anti- seize Lubricant 45 to 65 ft- lb (61 to 88 N- m) 5 1 250 to 275 ft- lb (339 to 373 N- m) 6 Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Lug nut Drive stud Wheel rim 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.
NOTE: The brake lever, backing plate, retaining clip, return springs, brake shoes, and cam shaft can be removed as a complete brake assembly. 8. If it is desired to remove the brake assembly from the brake bracket, remove four cap screws and lock nuts securing the assembly to the bracket. 9. Disassemble brake assembly as follows (Fig. 13): A. Remove return springs from the brake shoes. Remove brake shoes from the backing plate. B.
Rear Fork and Wheel 250 to 275 ft- lb (339 to 373 N- m) 35 2 34 25 33 6 4 3 45 to 65 ft- lb (61 to 88 N- m) 1 21 16 65 to 85 ft- lb (88 to 115 N- m) 36 25 29 24 60 to 80 ft- lb (81 to 108 N- m) 8 27 10 9 28 4 22 23 26 30 65 to 85 ft- lb (88 to 115 N- m) 6 28 19 14 17 11 20 38 32 17 31 7 37 15 2 39 13 3 18 12 5 Figure 14 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
2. Remove hood from the machine (see Hood Removal). WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 -- Safety. 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. 4. Secure hydraulic cylinder to the rear fork as follows: A.
Brake Lever Linkages 2 1 3 3 9 9 19 24 23 7 25 8 22 8 20 5 6 18 4 21 7 15 12 11 17 10 15 13 12 26 16 27 14 28 29 35 12 30 36 37 31 34 32 33 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.
Safety 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. Product Records and Manuals IMPORTANT: When removing the adjustable clevis from either the brake pivot shaft or adjustment rod or the brake lever from the cam shaft on the brake assembly, make sure to matchmark both parts. Marking both parts will make reassembly and brake adjustment easier. 3.
Steering Column 8 9 11 14 27 20 to 26 ft--lb (28 to 35 N--m) 20 7 21 39 40 10 12 17 28 32 19 33 18 23 2 4 6 22 24 39 5 35 37 8 34 38 42 26 25 41 3 36 41 44 3 43 1 29 30 31 13 15 16 2 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Disassembly 2 1 2. Remove philips head screws and steering wheel cap from the steering wheel. 3 Product Records and Manuals Safety 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 3. Remove steering wheel nut from the steering control valve. Pull steering wheel from the control valve. 4 6 7 6. Remove both hex flange nuts, cap screws, and pivot hubs securing the steering control valve bracket to the steering arm.
Front Lift Arms 9 6 4 RIGHT FRONT 34 57 47 42 39 41 40 55 43 48 66 63 28 44 58 59 62 61 45 33 46 10 18 49 54 51 50 52 21 22 20 26 53 60 31 16 30 28 37 32 29 15 5 7 12 3 23 24 13 33 53 64 56 27 26 28 17 28 38 33 65 8 35 1 36 20 25 24 19 2 13 11 14 Figure 17 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Removal 5 2 8 1 8 3 3. Disconnect hydraulic cylinder from the front lift arms by removing external retaining rings and pins. 4. Remove both flange head screws and carrier stop bracket from the lift arm pivot shafts. 5. Slide lift arm off the pivot shaft. 7 4 6 Figure 18 1. 2. 3. 4. 5. Lynch pin Cutting unit pivot shaft Carrier frame Thrust washer Lift arm (LH shown) 6. Disassemble lift arm as necessary using Figure 17 as a guide. 6. 7. 8. 9. 10.
Rear Lift Arm 36 40 16 3 12 39 30 15 12 11 28 10 12 13 46 13 15 2 17 2 13 6 22 41 14 42 21 9 20 4 44 41 26 31 46 33 34 32 27 47 12 46 23 25 37 48 45 7 24 38 29 5 18 1 35 8 RIGHT 43 19 12 FRONT 2 200 to 250 ft--lb (271 to 339 N--m) 3 12 Figure 20 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
2. Remove cutting unit from the pivot shaft of the rear lift arm (see Cutting Unit Removal). 3. Remove external retaining ring and thrust washer from the lift cylinder shaft of the rear lift arm. 4. Remove flange head screw and thrust washer from the rear pivot shaft. 5. Slide rear lift arm from rear pivot shaft and hydraulic cylinder. 6. Disassemble lift arm as necessary using Figure 20 as a guide. 4. Install rear cutting unit to the pivot shaft of the rear lift arm (see Cutting Unit Removal). 5.
Sidewinder Carrier 2 6 13 1 12 11 8 10 4 RIGHT 10 FRONT 9 4 8 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 Liftarm (RH shown) Liftarm pivot shaft Disassembly Assembly 1.
Product Records and Manuals Safety Hood Removal 18 Kubota Diesel Engine 2 6 12 4 Hydraulic Systems 3 5 1 13 9 16 14 10 Figure 22 1. 2. 3. 4. 5. 6. Flange screw Trim--seal Locknut Hood screen Hood Pivot bracket 7. 8. 9. 10. 11. 12. Flat washer Flex draw latch Rivet Pop rivet Washer Hair pin 13. 14. 15. 16. 17. Cap screw Lock bracket Cap screw Flat washer Locknut 1.
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SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8 Blade Stopping Time . . . . . . . . . . . . . . . . . . . . . . . . 8 Cutting Unit Removal and Installation . . . . . . . . . . 9 Cutting Blade Removal and Installation . . . . . . . . 10 Inspecting and Sharpening Blade . . . . . . . . . . . . . 10 Rear Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Rear Roller Service (Non--Greasable Bearings) 12 Rear Roller Service (Greasable Bearings with Retaining Ring) . . . .
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 is welded 10 and 12 gauge steel. Deck frame is welded 1--1/2 inch square tubing with 7 gauge side supports. CUTTING UNIT LIFT: Cutting units are controlled with one lever.
1. Maximum governed engine speed. Check maximum governed engine speed. Adjust speed to specifications if necessary. 2. Blade speed. All deck blades should rotate at the same speed. See items in Troubleshooting Section of Chapter 4 -Hydraulic System. 3. Tire pressure. Check each tire’s pressure. Adjust to pressures specified in Specifications Section of Chapter 6 -Wheels and Brakes. 4. Blade condition. Sharpen blades if their cutting edges are dull or nicked. Inspect blade sail for wear or damage.
Special Tools Order these special tools from your Toro Distributor. Cutting Unit Tool Kit - TOR4070 This tool kit includes special tools used to assemble the cutting unit rear roller that has greasable bearings with a grease fitting on the ends of the roller shaft.
Safety Adjustments CAUTION Product Records and Manuals Never install or work on the cutting units or lift arms with the engine running. Always stop engine and remove key first. IMPORTANT: This cutting deck often cuts approximately 1/4 inch lower than a reel cutting unit with the same bench setting. It may be necessary to have these rotary cutting deck’s bench set 1/4 inch above that of reels cutting in the same area.
Adjust Roller Scraper If cutting deck is equipped with a rear roller scraper, there should be an even gap of .020 to .040 inch (.51 to 1.02 mm) between the scraper rod and rear roller. EARLY STYLE 1 5 Two styles of roller scrapers have been available for the Groundsmaster 3500--D. Early models used a scraper rod that was fastened to brackets with lock nuts (Fig. 3). The scraper system used on later models has a one piece scraper component (Fig. 4). The adjustment method for both styles is similar.
1. Remove cutting unit to be inspected (see Cutting Unit Removal and Installation). 2. Use hoist (or minimum of two people) and place cutting deck on flat table. 3. Mark one end of blade with paint pen or marker. Use this end of blade to check all heights. 4. Position cutting edge of marked end of blade at 12 o’clock (straight ahead in direction of mowing). Measure height from table to cutting edge of blade. 7. Adjust right and/or left height--of--cut brackets by repeating steps 1 thru 3. 8.
Service and Repairs CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop engine and remove key first. Blade Stopping Time The blades of the cutting deck are to come to a complete stop in approximately 5 seconds after the cutting deck engagement switch is shut down. NOTE: When checking blade stopping time, make sure the decks are lowered onto a clean section of turf or hard surface to avoid dust and debris.
Cutting Unit Removal and Installation Safety Removal 3. Cover top of spindle housing to prevent contamination. Spindle plug (Toro Part # 94--2703) can be used to cover spindle. 4. Remove lynch pin securing deck carrier frame to lift arm pivot shaft (Fig. 8). Figure 7 1. Cap screw 2. Hydraulic motor Hydraulic Systems 6. Remove cutting unit from lift arm pivot shaft. Roll the cutting unit away from the traction unit. Installation 1. Position machine on a clean, level surface.
Cutting Blade Removal and Installation The cutting blade must be replaced if a solid object is hit, the blade is out of balance, or if the blade is bent. Always use genuine TORO replacement blades to be sure of safety and optimum performance. Never use replacement blades made by other manufacturers because they could be dangerous. 4 1 1. Park machine on a level surface, raise cutting units to highest position, stop engine, engage parking brake, and remove key from the ignition switch.
Three types of rear rollers have been used on the Groundsmaster 3500--D. One roller design has sealed bearings with no grease fittings on the roller shaft. The second design has grease fittings in the roller shaft ends. The third design has grease fittings incorporated into the roller fasteners. Removal and installation of the rear roller from the cutting deck is the same, regardless of roller type. 2 9 3 1 Safety Rear Roller 8 3 4 2 Removal (Fig. 13) 1.
Rear Roller Service (Non--Greasable Bearings) Seal Removal (Fig. 16) 1. Using a 1/4 inch thick, 3” X 3” square piece of steel, make a seal removal tool as shown in Figure 17. 2. Slide seal removal tool over roller shaft. 5. Install second spiral retaining ring onto roller shaft to secure second bearing. 6. Install new seals to .030 inch (.76 mm) recessed into roller. 3. Using the tool as a template, locate, mark, and drill two 7/64 inch (.109 inch diameter) holes in outer face of seal. 2 3 4 4.
Rear Roller Service (Greasable Bearings with Retaining Ring) 1 1. Remove retaining ring from both ends of roller. Safety Roller Disassembly (Fig. 18) 2 3 4 2. Hit end of roller shaft with a soft face hammer to remove seals and bearing from one end of roller. Hit other end of roller shaft to remove seals and bearing from other end of roller. Be careful not to drop roller shaft. 3. Discard seals and bearings. Roller Assembly (Fig.
Rear Roller Service (Greasable Bearings with Bearing Nut) Disassembly (Fig. 19) 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.
1 3 2 4 C. Apply a small amount of grease around the lip of both outer seals. D. Carefully install first outer seal into roller tube making sure that seal lip (and garter spring) faces end of tube. Use bearing/outer seal tool (see Special Tools) and soft face hammer to lightly seat seal (Fig. 24). Make sure that shaft and bearings still freely rotate after seal installation. 1 4. Outer seal 5. Bearing/outer seal tool 2 3 4 5 6 E.
Front Roller Service Disassembly (Fig. 25) 1. Remove roller mounting bolt. 2. Remove roller assembly from carrier frame. 1 3. To remove bearings and 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. 2 B. Remove spacer. Remove second bearing from roller using a press. 4. Inspect roller housing, bearings, and bearing spacer for damage or wear.
Cutting Units Wheels, Brakes, and Chassis Groundsmaster 3500--D Page 7 -- 17 Rev. E Electrical Systems This page is intentionally blank. Cutting Units (Rev.
Blade Spindle Service Disassembly 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1 2. Remove two cap screws that secure hydraulic motor to the cutting unit (Fig. 26). Remove hydraulic motor and O--ring from deck. 3. Cover top of spindle to prevent contamination. Spindle plug (Toro Part # 94--2703) can be used to cover spindle. 4. Start the engine and raise the cutting unit.
2. Using an arbor press, push large spacer into top of spindle housing. The spacer should fit tightly against the snap ring. 3. Thoroughly oil the bearing cups. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the spacer previously installed, and the bottom bearing cup must contact the snap ring. Make sure that the assembly is correct by supporting the first bearing cup and pressing the second against it (Fig 28). 12.
Carrier Frame The front and rear cutting units require different mounting positions on the carrier frames. 2 Front Carrier Frame 1. For heights of cut in the 3/4 to 3 inch (1.9 to 7.6 cm) range, the front cutting units should be mounted in the lower front mounting holes (Fig. 30) of the carrier frame. NOTE: This permits more up travel of the cutting decks relative to the tractor when approaching quick uphill changes in terrain.
Electrical Diagrams Product Records and Manuals Table of Contents Safety Chapter 8 Electrical Diagrams Wheels, Brakes, and Chassis Electrical Systems Hydraulic Systems Kubota Diesel Engine ELECTRICAL SCHEMATICS AND DIAGRAMS . . . 3 Electrical Schematic (Serial Numbers 90101 to 230999999) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Glow Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Crank Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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R/BK OPTION #2 SEAT SWITCH ALTERNATOR RUN SOLENOID PK B R FUEL PUMP (HOLD) L (PULL) SHUTDOWN 110_C (+) (+) 6500 MFD HOUR METER HR OR (--) 85 (CLOSED WHEN OCCUPIED) Y BN W PARKING BRAKE #1 OR (IN OFF POSITION) ENGINE GROUND (--) R 1 OR 2 FRAME GROUND 87 1 OR NEUTRAL RELAY 86 NEUTRAL SWITCH VIO GAUGE CLUSTER GN 86 OR D1 1 15 A Y 30 87a VIO BU BK INTERLOCK RELAY OR B A S F2 BU I PK X NOTE: ROTARY DECKS ON/OFF SWITCH ON CONSOLE INCLUDES TERMINALS SHOWN IN TWO PLAC
R/BK OPTION #2 SEAT SWITCH ALTERNATOR RUN SOLENOID PK B FUEL PUMP R (HOLD) L (PULL) SHUTDOWN 110_C (+) (+) 6500 MFD HOUR METER HR OR (--) 85 (CLOSED WHEN OCCUPIED) GY LOW OIL PRESS BN W 30 PARKING BRAKE #1 OR (IN OFF POSITION) T (--) FRAME GROUND R OR 1 30 VIO 86 NEUTRAL SWITCH VIO GAUGE CLUSTER GN D1 1 ROTARY DECKS ON/OFF (TERMINALS 1 AND 2) (DECKS OFF) Y BU BK INTERLOCK RELAY 15 A OR A B S F2 BU I PK PK X ROTARY DECKS ON/OFF (TERMINALS 5 AND 6) OPTIONAL LIGHT
R/BK OPTION #2 SEAT SWITCH ALTERNATOR RUN SOLENOID PK B FUEL PUMP R (HOLD) L (PULL) SHUTDOWN 110_C (+) (+) OR GY BK (CLOSED WHEN OCCUPIED) 85 PARKING BRAKE #1 30 Y BN W LOW OIL PRESSURE OR (IN OFF POSITION) ENGINE GROUND (--) FRAME GROUND R 1 OR 87a NEUTRAL SWITCH VIO 86 5A Y PARKING BRAKE #2 BACKLAP D1 1 ROTARY DECKS ON/OFF (TERMINALS 1 AND 2) (DECKS OFF) Y BU BK INTERLOCK RELAY 15 A OR B A S F2 BU I X NOTE: ROTARY DECKS ON/OFF SWITCH ON CONSOLE INCLUDES TERMINALS
R/BK OPTION #2 SEAT SWITCH ALTERNATOR RUN SOLENOID PK B (HOLD) L (PULL) SHUTDOWN 110_C GY OPTION #1 SEAT SWITCH (--) BK 85 (CLOSED WHEN OCCUPIED) Y GY BN W LOW OIL PRESS PARKING BRAKE #1 OR (IN OFF POSITION) ENGINE GROUND R BK 1 OR 2 87 1 86 NEUTRAL SWITCH VIO GAUGE CLUSTER GN NO BACKLAP PARKING BRAKE #2 D1 1 ROTARY DECKS ON/OFF (TERMINALS 1 AND 2) (DECKS OFF) Y BU BK INTERLOCK RELAY 15 A OR B A S F2 BU I OPTIONAL LIGHT (NOT SUPPLIED) PK PK IGNITION SWITCH Y X NOT
R/BK OPTION #2 SEAT SWITCH ALTERNATOR RUN SOLENOID PK B (HOLD) L (PULL) SHUTDOWN 110_C GY OPTION #1 SEAT SWITCH (--) BK 85 (CLOSED WHEN OCCUPIED) Y GY BN W (IN OFF POSITION) ENGINE GROUND R BK R OR 1 2 D2 1 86 87a NEUTRAL SWITCH GAUGE CLUSTER S F2 BU I D1 1 2 2 BU BK PK NOTE: ROTARY DECKS ON/OFF SWITCH ON CONSOLE INCLUDES TERMINALS SHOWN IN TWO PLACES ON THIS SCHEMATIC.
GLOW RELAY STARTER FUSE BLOCK P16 1 2 3 RED 4 5 6 7 P19 P20 P23 START G B+ 8 BLUE 1 ORANGE PINK 2 ALTERNATOR 3 P3 J7 R L B+ 1 2 GLOW CONTROLLER P1 J1 J2 P13 85 86 30 87 1 2 3 4 5 PINK RED J13 BLUE VIOLET TAN P14 IGNITION SWITCH 1 2 A 3 B 4 S 5 J18 VIOLET SP1 BLUE PINK YELLOW YELLOW GLOW 2 ORANGE GROUND 3 PINK (+) 4 PINK BATTERY 5 WHITE OIL PRESS 6 GRAY PINK WHITE ORANGE 1 2 3 4 TAN 1 2 85 3 87A RED/BLACK 4 87 BLACK 5
FUEL PUMP DECK UP/DOWN SWITCH J12 P7 TRANSPORT/MOW SWITCH P18 SEAT SWITCH P4 J3 P2 J5 ALTERNATOR P8 ENGINE GROUND J4 SEAT SWITCH START SOLENOID SEAT RELAY PARKING BRAKE J6 P23 P6 TEMP SWITCH G P21 P9 INTERLOCK RELAY J8 CAPACITOR J10 P10 P8 J11 BACKLAP SWITCH GLOW CONTROLLER P22 J9 P20 J1 OVERTEMP RELAY P5 P19 OIL SWITCH P12 GLOW PLUG START SOLENOID J7 DECK ON/OFF SWITCH FUEL SOLENOID P13 HOUR METER J18 J2 D2 P1 D3 D1 P14 J13 OPTIONAL LIGHT GLOW RELAY IGNIT
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 VIO START 1 4 LAMP 2 5 + 12V 3 6 OR PK R BN (+) TEMP HR GLOW HOUR METER (--) GROUND CLUSTER GAUGE 85 K4 GLOW PLUG CONTROLLER KUBOTA 86 30 GLOW RELAY 87 PK OR GLOW PK OR OVER TEMP.
122--0259 Rev.
122--1521 Rev.
ORANGE RED RED FUSIBLE LINK BROWN BLACK PINK RED BLACK BLACK PINK BLUE PINK GRAY VIOLET PINK ORANGE (SERIAL NUMBERS FROM 240000001 TO 270999999) GRAY PINK BLUE PINK WHITE PINK TAN BROWN RED/BLACK TAN YELLOW WHITE BLACK BLACK BLUE PINK GREEN WHITE/BLACK WHITE PINK GRAY VIOLET PINK BLACK RED/BLACK BLACK ORANGE BLACK BLACK BLACK BLUE/WHITE GREEN BLACK BLACK YELLOW GREEN BLACK BLUE BLACK GREEN RED/BLACK PINK ORANGE (SERIAL NUMBERS ABOVE 260000400) YELLOW BLACK
(SERIAL NUMBERS ABOVE 280000000) (SERIAL NUMBERS FROM 240000001 TO 270999999) (SERIAL NUMBERS ABOVE 260000400) Groundsmaster 3500--D Harness Drawing (Serial Numbers 240000001 to 313999999) Page 8 -- 14
RED RED FUSIBLE LINK PINK BLUE ORANGE BROWN PINK BLACK RED PINK WHITE BLACK ORANGE GRAY PINK BLUE PINK VIOLET PINK 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 GREEN BLUE/WHITE BLACK BLACK GREEN YELLOW TAN BLACK BLUE BLACK GREEN RED/BLACK PINK ORANGE Groundsmaster 3500--D Harness Diagram (Serial Numbers 314000001 to 403440000) Page 8 -- 15
Groundsmaster 3500--D Harness Drawing (Serial Numbers 314000001 to 403440000) Page 8 -- 16
122--1523 Rev.
122--1523 Rev.
