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caution - Toro Media

1. INVA ei E EE ONIH33IS id NIVHG 3SVO TVNH3LNI xnv IT 1 H3MOd a i NYNL bel TE eee l i 1 ES E 1H9IH HOS 71 HANIVHLS S19V4 34 1 Y i 8 Y 1 v Sg ino y A ME j L E d Y i 7 Aa T Y I I Ej Sa 0001 IWLSOHGAH 1 ONIH33lS 1 I 7 2d dec di i H NI E LAA a LEY 3unssa3udxova isd osz Ee AAWA H3QNIM3GIS LJ1 no NI a 2X A0 lis SHO E Ju I B z Il aal L Bn l i i d i 431009 bn aan D l ee T gt isd 0008 I f t I uo i j yganimaais A l i d J39 H H I CB Ll a a e gt isd 002 i iB 1HOd 1HOd v ane H3ddn INVA H3MO1 dus I 19018 SSvd l8 dvay Q103INVIA 9 g v BH OH 19 i fa ei Il J 1 9N On NA 1NOHJ i um 340 NO HOA dor Owi HVvau WAA en i AG SHOLOW 133HM NOLLOVEL i di LESS g Isd 0081 a E oad L PW Lu Ae 3ivid i ES av3ihyina gt L YIANIMIAIS en HA q U
2. Niva 3SVO TVNH3LINI s I lVISOHGAH I I Ax gt 1 4 eg 4 1 Ed Y e p lio Er L i TI egdoet o0 A 1 y re We pool isd 000 ek L4 140a 1HOd uaddn ZAC H3MO 1 dina Ip UPN 1HOd dOL aBseyD eunssejd wo MOJA A uonong 10 unay ainssajq UBIH p1eM104 SHNDIID UONI d 00SE Jo1seuuipunoJc Groundsmaster 3500 D Page 4 12 Hydraulic System Rev G Traction Circuits Forward The traction circuit of the hydraulic system consists of a hydrostat connected in a closed loop circuit to three or bital vane wheel motors The engine drives traction pump P3 indirectly through pulleys and a V belt The traction pump is a variable dis placement piston pump The traction pedal connects through a cable to the trunnion shaft and swash plate of the pump With the engine running and the traction ped al in the neut
3. BLACK BLUE BROWN FUSIBLE LINK GY GN OR PK GRAY GREEN ORANGE PINK RED TAN VIOLET WHITE YELLOW RED BLACK SPLICE Control Current Indication Current Logic Direction Schematic from machine with Serial Number 90101 to 230999999 shown OPTION 2 CAS SS SEAT SWITCH ALTERNATOR gt B CEOs ee REG eet TTP KS rer T m RO Comm a a 4 jM 2 E A A ie R IT q L m HOUR 6500 MFD R BK ul METER i OR OPTION 1 SHUTDOWN d H SEAT SWITCH 11026 eo E zl o o c uu 7 6 l CLOSED WHEN OCCUPIED gt 3 i R BK PK Y j 87 WARNING OS 25 o 4 105 C SR BN OR PARKING BRAKE 1 LOW OIL PRESS IN OFF POSITION T i SEAT RELAY BK 5g OR ol az S a EM BZ on A bs e GE ra NEUTRAL RELAY o E e DW pA u5 NOT USED l ij 33 Bra ML ALLLLLLLLLL LL E m 5 0 CH S 30 if 1 D L a m 87 C NO d o gt ENGINE in
4. BLACK BLUE BROWN FUSIBLE LINK GY GRAY GN GREEN OR ORANGE PK PINK RED TAN VIOLET WHITE YELLOW RED BLACK SPLICE R BK OPTION 2 FOR E E SEAT SWITCH ALTERNATOR RUN SOLENOID gt Ke B PK cone T 8 0 R HOLD g 1 i z 5 s Y HOUR 6500 MFD RIBK YYYY E HR METER OR GY PULL u OPTION 1 SHUTDOWN Uu e SEAT SWITCH 110 C a A 5 E UU gg CLOSED WHEN OCCUPIED o Y R BK PK e WARNING NOTTE 3 o 30 gt 105 C Eg G BN OR PARKING BRAKE 1 LOW OIL PRESSURE w T 87a IN OFF POSITION Ww o ls SEAT RELAY Bk o N r wu d OR co D z FL zz Wa D Q OR Z pg UE FL Ip G FL b es cB NEUTRAL RELAY M E Le e h E B NOT USED Start P o Sue 0 5 lU SES RE respon XR Roe uere o es venei verint e MENE b Dorta 87 C NO E o f iz o L 9 BU gt i ENGINE B z 6 8 CLOSED IN NEUTRAL Got H A GROUND x a o Be 85 Coen 86 PARKING BRAKE 2 TEN SE Sis VER dl pS AA ESO A EAS e D ENGINE BK NEUTRAL MS OR VIO VIO SWITCH D4 LA 1 2 l KI o E E 1 2 y FRAME GAUGE BK ROTARY DECKS ON OFF y GROUND AERE CLUSTER TERMINALS 1 AND 2 KI x Ms DECKS OFF D2 l y OR F3 5
5. ul NIVHG 3SVO IVNYALNI INVA 1 ONIH331S Ad 1 H3MOd A Fi xnv e H3NIVHIS T y 1 D ISd 000 1no Y 0 1 S24 Ih is i 1 IWLSOHGAH i ONIH33IS cc ZA gt aa LY AS j Hn X Wis i isd 06 Se z n 3unssa3udxova isd osz GENEE E gt AD a NW N 1S 6HO E ld Y 05 9600 T L Ge va I 25 li I j A i 31009 O li Ue c ISd 000 A Az vn ll b r 39L _ lt I Y3ANIMIAIS zc Pee y E E LL j l E gt DU i 1HOd 1HOd isd 00Z u3adn IMYA H3MO1 ian I te 0038 SSYd 19 uvau Y i i CIOSINVIN SS occ l FT ipd EP NERONI x19 AN i NE dm AG 13H BE Pa I A eg ee ee aes yaja 230 N0 1HOd dOL QuvMHOd WEE v xod ew SHOLOW 133HM NOLLOVHL ad i ud i We 2 gt g isd 00S L e Fan j AW warring Pow g ZN LW ig da3auivaars MOL lt St yoza a 1431 uonons JO unay eBrey eunssejd MOT ainssaid YIH umog 1In2412 YT d 009 Je sSewpunols Groundsmaster 3500 D Page 4 18 Hydraulic System Rev G Lift Circuit Down Lower Cutting Units Circuit
6. SEAT P4 switch SEAT P5 switch 30 85 SEAT era P8 Rey 87 86 J10 CAPACITOR J11 PARKING BRAKE P6 swircH i1 NC J19 DIODE D3 J20 NEUTRAL P17 swrmcn e J8 BACKLAP SWITCH NO J9 PARKING BRAKE P21 switch 2 NO STARTER ALTERNATOR FUSEBEOCK P19 P20 P23 P3 J7 GLOW CONTROLLER P1 Ji J2 GLOW PLUG real Pip SABT S oe H 3b Be P13 85 86 30 87 J5 1 2 8 4 5 6 7 8 11213 112 123456 112 PINK 1 RED BLUE PINK ORANGE RED BLACK PINK RED ORANGE 2 ORANGE WHITE BLUE VIOLET RED TAN ORANGE GRAY 1 OPTIONAL LIGHT J13 BLUE RED ORANGE 2 SP5 3 E VIOLET PINK PINK GRAY 4 Ce ORANGE VIOLET VIOLET 5 Y 2 YELLOW YELLOW PINK 6 P14 A Ia LJ IGNITION B 4 See SP1 D SWITCH s 5 BLUE PINK m GRAY 2 3 YELLOW RED BLACK 4 J18 B YELLOW WHITE ORANGE BLASK HIGH TEMP 1 YELLOW ORANGE GRAY GLOW 2 ORANGE nine PINK BLACK CLUSTER GROUND his WA PINK Pil ORANGE A BATTERY 5 WHITE TAN B OILPRESS 6 GRAY ORANGE e SP4 BLACK TAN 30 1 BLUE GREEN INTERLOCK gs 2 YELLOW GREEN RELAY 87A 3 P10 87 la ORANGE ORANGE A 86 5 BLACK BLACK A BLACK B BLACK SP3 A PINK HOUR RED BLACK METER P22 BLACK BLACK EAG 5 BLACK MES GREEN PINK YELLOW HEDIBEACN BLACK mu nee BLUE A ENGINE BLACK e BLACK REEN GROUND
7. OPTION 2 Gef Ge Ge KO SEAT SWITCH ALTERNATOR RUN SOLENOID i k B SESCH r PK X 4 S YYY D 4 D DEN AME r R HOLD 2 7 mios q a HOUR 6500 MFD R BK III mi w METER OR PULL 2 i OPTION 1 SEAT SWITCH P gt g hl A AN 4 CLOSED WHEN OCCUPIED 89 se Pic Y i R BK l WARNING 20 o 105 C BW BN OR PARKING BRAKE 1 WA LOW OIL PRESSURE w a IN OFF POSITION T bas a SEAT RELAY BK Ed oO Fla OR i z Z SE S i FS OR A ps A T AME cB NEUTRAL RELAY YN HI gt N AC Ed 2I NOT USED g wo Ia 4 196 Wall all eeta ee et A E EESE E a ES S 30 o Ls a 1 x gt amp o 3 CLOSED IN NEUTRAL S E Bu e ei B 5 ES 9 PARKING BRAKE 2 d 5 5 gt 3 BACKLAP E i lt a o 0 e PK o Sor a GN TR E o O A IN MERA AE ai MUA gt Ma A A IA ce komm D1 l NEUTRAL L gt ENGINE ii O EN G VIO VIO SWITCH D a 4 N EL 1 y R GAUGE s BK ROTARY DECKS ON OFF WA NES CLUSTER D 1 mE 2 Sa q b M d DECKS ON ge HU D2 85 m e F3 5A dO m Y HAS MIO 87a INTERLOCK RELAY F1 15A OR PK PK i IGNITION A NOTE ROTARY DECKS ON OFF SWITCH ON CONSOLE F2 SWITCH E INCLUDES TERMINALS SHOWN IN TWO PLACES ON THIS 5 SCHEMATIC
8. STARTER ALTERNATOR GLOW CONTROLLER GLOW RELAY FUSE BLOCK SINGLE FUSE START G Bt RL Bt nt 30 85 874 87 86 GLOW PLUGS FI z d F4 P35 PI9 P20 P23 P3 JI P36 J5 2 3 4 5 6 7 8 12 4 8 c o o 3 6 k 3 034775 l BLUE s z a RED ORANGE E d BROWN E PINK RED l WHITE PINK 3 BLACK MT m VIOLET 2 BLUE SP gt 2 a 3 4 ORANGE PINK PINK A 5 SP5 TAN BROWN 8 RED BLACK C TAN D YELLOW E BLACK BLACK E E SP3 LA PINK BLUE A 1B GREEN 8 en WHITE BLACK 28 WHITE x E P32 F lA PINK 5 1B GRAY VIOLET H 2A PINK 28 ORANGE P4 E BLACK pe x RED BLACK SP4 a ORANGE 8 a BLACK d ch BLACK SP BLACK Alo 3 BLUE WHITE GREEN 8 BLACK Nn X o 3 m GREEN YELLOW A x R P26 5 BLACK 8 3 x a 3 z j 4 ze tc en 0 A B 2 B 8 A B 12 34 5 71 8 9 o PULL P HOLD vA J6 Je P37 PIS PI8 P7 P38 P27 RUN SOLENOID OVER TEMP FUEL PUMP REEL TRANSPORT REEL UP REEL ON OFF DIODE DI ENGINE ou WARNING OVER TEMP GE MOW LIMIT SW zz zoooooco PRESS SHUTDOWN S8822 0 m lt oa Groundsmaster 3500 D Harness Diagram Serial Numbers 314000001 and Up P3I SEAT SW PARKING BRAKE 1 NC NEUTRAL SW BACKLAP Page 8 13 Rev G P36 P3 ALTERNATOR RL JA ENGINE OIL PRESSURE J21 OVERTEMP SHUT DOWN JT ALTERNATOR B P7 REEL UP L
9. YACNIMACIS Hydraulic Schematics IMYA NIVY 3SVO TVNH3INI ONIHH3IS gt H3NIVHIS u3wod 29 xnv u wa Ji ivisouaaH PE isd 0001 ino as CEN i LE Y l dnd Hv39 vam L r 1 Lg l 10 ACH NI Zad 3UNSSIVAADVE Isd osz T T T isd OS 00L IMYA HSCNIMACIS LIN D E oe SHO ytd a 1no NI 2o ap E 431009 c 5 i J z F x i TO isd 000 PI ii 101 GC t ES uo r id r f bd y I e dl E li GN li 39 1 i xU i LL EES L isd ooze 1HOd 1HOd 9 g v EN IH uaddn JMA H3MO1 ds I X00709 dwna uvau co GIO3INVW E Ep gt AN Ga I I i CH Ya 1NOH4 A yoad oodd OU ava J 1HOd dOL en 2 a i ul g E Isd 00S x930 zL SHOLON 133HM NOILOVH L 1HOlH p Sind VU J gt p om Y avaHing zc sta ES di E H3QNIAGIS ZN LN La p MEE Sana DAS T JN KR pezibJoue ap o3a se UMOUS 9 18 SpiOU9JOS IV 1331 0090000v2 Mojag sJequinw jeues oneuieuos IINEIP H G 00S Je1seuispunout Page4 9 Hydraulic System Rev G Ground
10. IANIMIOIS NIVHG 3SVO TVNH3 LNI JN YANIVYLS y amp L L KA A 1 IWLSOHGAH i VEROS Lo PES oe unns CY t yO Ed i yA a Sg ES T j ar ee Uwe sse es el E M saos ooo A0 is SHO d SR 1 LA wg d 431009 CALS 1 L be sd 0008 LE 101 a ee Eege Keen 4j T 3o E 1 y H Ez isd 002 1HOd 1HOd HH u3ddn IMYA H3MO1 ll B 9018 SSvd I8 i E QIOJINVA HH 19 a e i I i EIN i i NA 440 NO qd xad 1HOd dOL div Mos SHOLOW 133HM NOLLOVH L i f A 7 GE i AN isd 00S L b a SL C i le ES Pow CN LN LO AS MOL lt uonons Jo unay eBreyo almsseld MOT amsseld YIH dn unai ur1 d 009 Je1seuupunoJc Groundsmaster 3500 D Page 4 16 Hydraulic System Rev G Lift Circuit Up Raise Cutting Units The gear pump P2 is directly coupled to the hydrostat through gear pump P1 It supplies hydraulic pressure charge pressure for operating the power steering sys tem raising and lowering the cutting units operating the sidewinder unit and maintaining 100 to 150 PSI 6 9 to 10 0 bar to the low pressure side of the traction circuit The pump takes its suction from the hydraulic reservoir During conditions of not lifting or lowering cutting units flow from the gear pump P2 is by passed through the power steering valve 2 spo
11. Figure 28 1 Bearing cups 4 Arbor press 2 Large snap ring 5 Support 3 Large spacer 6 Arbor press base Figure 29 1 Bottom seal installation 2 Upper seal installation Cutting Units Rev D Carrier Frame The front and rear cutting units require different mount ing positions on the carrier frames 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 It does however limit the clearance of the cutting deck to carrier when cresting sharp knolls 2 For heights of cut in the 2 1 2 to 4 inch 6 4 to 10 2 cm range the front cutting units should be mounted in the upper front mounting holes Fig 30 of the carrier frame NOTE This increases the cutting deck to carrier clear ance due to the higher position of the cutting deck but will cause the cutting decks to reach their maximum up travel sooner Rear Carrier Frame 1 For all heights of cut the rear cutting deck should be mounted in the rear mounting holes Fig 30 of the carrier frame Cutting Units Rev D Page 7 20 Rev E Figure 30 3 Rear mounting hole 1 Lower front mtg hole 2 Upper front mtg hole Groundsmaster 3500 D Ch
12. 61 Groundsmaster 3500 D Page 4 1 Chapter 4 Hydraulic System 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 vota nz 68 Front Wheel Motors 70 Rear Wheel Motor 72 Wheel Motor Service 74 Rotary Cutting Motors 76 Rotary Cutting Motor Service Haldex 78 Rotary Cutting Motor Service Casappa 82 Hydraulic Manifold 84 Hydraulic Manifold Service Serial Numbers Below 240000600 86 Hydraulic Manifold Service Serial Numbers 240000601 to 313999999 90 Hydraulic Manifold Service Serial Numbers Above 314000000 92 Control Valve 94 Control Valve Service 96 Piston PUMP aci 100 Piston Pump Service 104 Gear RUMP so esie WAWA 106 Gear Pump Service Serial Numbers Below 260000400 108 Gear Pump Service Serial Numbers Above 260000400 112 Steering Control Valve 114 Steering Control Valve Service Serial Numbers Below 240000000
13. Figure 86 1 Front plate 6 Idler gear 11 Front wear plate 2 Back plate 7 Cap screw 12 O ring 3 Body 8 Back up gasket 13 Shaft seal 4 Dowel 9 Rear wear plate 14 Retaining ring 5 Drive gear 10 Pressure seal 15 Relief valve kit 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 2 Use a marker to make a diagonal line across the front plate body and back plate for assembly purposes Fig 87 IMPORTANT Avoid using excessive clamping pressure on the motor housing to prevent distorting the housing 3 Clamp mounting flange of motor in a vise with the shaft end down 4 Loosen cap screws from the back plate 5 Remove motor from the vise Turn motor so that the shaft end is facing down Remove cap screws 6 Remove back plate from the body Hydraulic System Rev G Page 4 78 7 Carefully remove body Lift body straight up to re move Make sure the rear wear plate remains on the drive and idler gear shafts Remove and discard O rings from the body Locate and retrieve dowel pins MARKER LINE Figure 87 Groundsmaster 3500 D IMPORTANT Note position of the open and closed side of the wear plates before removing Also iden tify wear plates front and rear with a marker for proper assembly 8 Carefully remove rear wear plate idler gear drive gear and front wear plate
14. A Remove extension spring from the cable support bracket and neutral arm Groundsmaster 3500 D Page 4 101 Hydraulic System Rev G Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 4 Disconnect all hydraulic hoses connected to the hy draulic fittings on the piston and gear pumps Allow hoses to drain into a suitable container and plug hose openings to prevent contamination Support piston and gear pumps when removing them from the pump support and pump mount plate to prevent them from falling and causing personal injury 5 Remove fasteners and spacers securing the pump mount plate to the engine and pump support Note loca tion of cap screws washers nuts and spacers for as sembly purposes Pull pump mount plate with pumps pump pulley and idler assembly from the machine 6 Remove both cap screws and flat washers securing gear pump to the piston pump Separate gear pump and O ring from the piston pump Plug openings of gear pump to prevent contamination 7 f hydraulic fittings are to be removed from piston pump mark fitting orientation to allow correct assembly Remove hydraulic fittings and O rings from the piston pump as needed 8 Remove pulley from the taper lock bushing A Remove cap screws securing pulley to the taper lock bushing IMPORTANT Excessiv
15. Figure 14 Seat support strap Hex flange head screw Electrical harness 4 Fuel hose strap 5 Fuel supply hose 6 Fuel return hose on Kubota Diesel Engine Rev G o E 2 2 Ek SE KI Radiator Serial Number Below 313999999 Draincock valve Flange head screw Flange nut Carriage bolt Radiator Fan shroud top Fan shroud bottom Flange head screw Hose clamp 10 Radiator frame 11 Radiator cap 12 Radiator foam seal 13 Flange head screw WONOARPWNHS Removal 1 Park machine on a level surface lower cutting units Figure 15 Reservoir bracket Wire form latch Oil cooler bracket Bracket clamp Screw Lock nut Radiator shield lower Magnetic catch Oil cooler Radiator hose upper Radiator hose lower Hose clamp Hydraulic tube Hydraulic tube Oil cooler hose Grommet Foam seal Expansion tank hose Expansion tank Glow plug relay Thread forming screw Flange lock nut Bulkhead nut Tube assembly Nut 3 Place a suitable container under the radiator to col lect the coolant Open draincock valve and completely stop engine engage parking brake and remove key from the ignition switch drain the radiator IMPORTANT Follow all local codes and regulations when recycling or disposing engine coolant 2 Open and remove engine hood from the machine Do not open radiator cap or dra
16. 116 Steering Control Valve Service Serial Numbers Above 240000000 117 Sidewinder 118 Front Lift Cylinder 120 Rear Lift Cylinder 122 Lift Cylinder Service 124 Steering Cylinder 126 Steering Cylinder Service 128 ROSS TORQMOTOR MG MF ME AND MJ SE RIES SERVICE PROCEDURE EATON MEDIUM DUTY PISTON PUMP REPAIR IN FORMATION MODEL 70160 VARIABLE DISPLACE MENT PISTON PUMP ROSS HYDRAGUIDE HYDROSTATIC STEERING SYSTEM HGF SERIES SERVICE PROCEDURE SAUER DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Hydraulic System Rev G e SE CS a z N cs gt gt N 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 9 to 10 bar 3000 PSI 207 bar Gear Pump Maximum Operating Pressure 2 stage positive displacement gear type pump 3200 PSI 221 bar Wheel Motors Front Maximum Operating Pressure Orbital rotor motor 2000 PSI 138 bar Wheel Motor Rear Maximum Operating Pressure Orbital rotor motor 3000 PSI 207 bar Hydraulic Manifold Relief Pressure 3200 PSI 221 bar Cutting Unit Motor Cross over Relief Pressure Maximum
17. Use a multimeter to make sure that continuity exists be tween each terminal pin in connector P1 and connector Figure 26 J1 at the starter Fig 26 If any of the fusible links are open replace the complete harness Groundsmaster 3500 D Page 5 17 Electrical System Rev G 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 tempera ture shutdown switch is on the alternator side of the en gine Fig 27 A CAUTION Make sure engine is cool before removing the temperature switch 1 Lower coolant level in the engine and remove the temperature switch 2 Put switch in a container of oil with a thermometer and slowly heat the oil Fig 28 CAUTION Handle the hot oil with extreme care to prevent personal injury or fire 3 Check continuity of the switch with a multimeter ohms setting A The high temperature warning switch is normally open and should close between 216 to 226 F 102 to 108 C B The high temperature shutdown switch is normal ly open and should close between 225 to 235 F 107 to 113 C 4 Allow oil to cool while observing temperature A The high temperature warning switch should open at about 208 F 98 C B The high temperature shutdown switch should open at about 219 F 104 C 5 Replace switch if necessary Elec
18. 1l I I 9N j 1 147 ON a 1NOHJ l x930 NEE 1HOddOL Oe AAN SHOLOW 133HM NOLLOVH L i o NA il A i TI 7 CY isd 0081 wu 8 al NEIN word Y y e K LM 1HOIH AD 31Wld 4 Nal avaH ina x Y SIN 7 USCNIMAGIS en m ta Ka MOL lt uonong Jo unay eBseyD eunssejd wo eunssejg UBIH 4514 pueix3 11n241 Jepuiwepis dG 009 Je sewpunols Groundsmaster 3500 D Page 4 20 Hydraulic System Rev G Sidewinder Circuit The gear pump P2 is directly coupled to the hydrostat through gear pump P1 It supplies hydraulic pressure charge pressure for operating the power steering sys tem raising and lowering the cutting units operating the sidewinder unit and maintaining 100 to 150 PSI 6 9 to 10 0 bar to the low pressure side of the traction circuit The pump takes its suction from the hydraulic reservoir During conditions of not lifting or lowering the cutting units flow from the gear pump is by passed through the power steering valve 2 spool lift sidewinder valve and hydraulic manifold directly to the hydrostat and the charge relief valve Flow then returns to the hydraulic tank Shift Sidewinder Right 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 side winder cylinder Hydraulic pressure against the cylin
19. Rotor Stator Drive plate Thrust bearing spacer Thrust bearing For repair of the steering control valve see the Ross Hydraguide Hydrostatic Steering System HGF Series Service Procedure at the end of this chapter Hydraulic System Rev G Page 4 116 Face seal Push nut Seal spacer Upper cover plate Input shaft Retaining ring Nut Retaining plate Upper cover amp jacket assembly Bushing Seal Special bolt Seal ring white Groundsmaster 3500 D Steering Control Valve Service Serial Numbers Above 240000000 2 SE O a Y ER 2O 20 to 24 ft Ib 27 to 33 N m Figure 1 Sleeve 9 Dust seal ring 118 16 Outer gearwheel 2 Cross pin 10 Housing 17 End cover 3 Ring 11 Cardan shaft 18 O ring 5 used 4 Spool 12 Spacer 19 Screw fitting ports L R T 5 Bearing assembly 13 O ring 20 Screw fitting ports P and E 6 Shaft seal 14 Distribution plate 21 P port check ball 7 Ball stop 15 Inner gearwheel 22 Spring set 8 Ball NOTE For service of the steering control valve see the Sauer Danfoss Steering Unit Type OSPM Service Manual at the end of this chapter Groundsmaster 3500 D Page 4 117 Hydraulic System Rev G Sidewinder OONDAPYNS Bushing Scissor link Scissor mount Cap screw Flat washer Lock nut Scissor frame Hydraulic cylinder Spacer 10 Flat washer 11 Cap screw Hydraulic System Rev G Figure
20. ENGINE ui z m amp CLOSED IN NEUTRAL z 9 a i 85 Ch 86 TI E lt a o o e pK A e 7 UN O A ENGINE BK 3 3 3 3 NEUTRAL D Se H VIO vio SWITCH D4 O O IA Y NJ FRAME 1 2 GROUND GAUGE BK Ste eech BATTERY CLUSTER ROTARY DECKS ON OFF TERMINALS 1 AND 2 DECKS OFF 86 85 O Y F3 A 1 87 O 5 Mee R 30 i VIO 87a S INTERLOCK RELAY BK D PK PK ICNITION A NOTE ROTARY DECKS ON OFF SWITCH ON CONSOLE SWITCH INCLUDES TERMINALS SHOWN IN TWO PLACES ON THIS BU 9 E ROTARY DECKS ON OFF SCHEMATIC OPTIONAL i TERMINALS 5 AND 6 i 7 ARAN LIGHT F4 5A 5 6 NOT SUPPLIED gt PK BU GN a 5 DECKS OFF E TRANSPORT MOW ROTARY DECKS DRIVE SOLENOID Y 30 R 87 GLOW PLUGS 3 L Ge 85 Y CY 86 STOP NONE GLOW RELAY ON PREHEAT B I A X Y START B l S KUBOTA BU GLOW PLUG Ge CONTROLER OR 1 4 d VIO 2 5s L r Groundsmaster 3500 D 3 6 Crank Circuits Power Current BLACK GY GRAY RED Control Current e ss Indication Current BLUE GN GREEN TAN Y YELLOW Logic Direction BROWN OR ORANGE VIOLET R BK RED BLACK Schematic from machine with Serial FUSIBLE LINK PK PINK WHITE SP SPLICE Number 90101 to 230999999 shown Page8 5 Rev E R BK
21. Traction pump or wheel motor s are worn or damaged No traction exists in either direction Brake is not released Oil level in reservoir is low Hydrostat by pass valve is open Traction pump drive belt loose or broken Charge pressure is low Traction pump or wheel motor s are worn or damaged Hydraulic System Rev G Page 4 28 Groundsmaster 3500 D Wheel motor will not turn Brakes are binding Key on wheel motor shaft is sheared or missing Internal parts in wheel motor are damaged Wheel motor will not hold load in Make up fluid from charge pump is not available neutral Hydrostat ball check valves are damaged Reservoir oil level is low Suction line is restricted Suction line has an air leak Blades will not turn Solenoid valve R1 is stuck open An electrical problem exists See Chapter 5 Electrical System Gear pump P1 is damaged Blades s turn too slowly Gear pump P1 is inefficient see Testing Cutting motor has internal leakage or malfunctioning cross over relief valve see Testing Hydraulic Spindle bearing s are damaged Cutting units will not lift or lift slowly Engine speed is too low Lift cylinder linkage is binding or broken Lift cylinder bushings are binding Reservoir oil level is low Charge pump P2 pressure or flow is insufficient Charge pump P2 is damaged Implement relief valve 1000 PSI is stuck open Lift cylinders leak internally Steering control valv
22. Bushing Spacer Hose clamp Fuel prefilter if equipped Fuel water separator Fuel fitting Flange head screw Flange nut Seat support strap Foam Hex flange head screw Insert nut Fuel hose Page 3 10 Fuel hose Fuel hose Fuel hose Fuel hose Fuel hose Fuel hose R clamp Fuel pump Spacer Cap screw Hose stem Fuel hose Hose clamp Flat washer Heat shield Groundsmaster 3500 D Because diesel fuel is highly flammable use cau tion 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 out side and wipe up any spilled diesel fuel before starting the engine Store fuel in a clean safety approved container and keep cap in place Use diesel fuel for the engine only not for any other purpose Check Fuel Lines and Connections Check fuel lines and connections at intervals recom mended in your Operator s Manual 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch Unlatch and raise hood 2 Check fuel lines for deterioration damage leaks or loose connections Replace hoses clamps and con nections as necessary Fuel Tank Removal Fig 13 1 Park machine on a level surface lower cutting units stop engine engage parking
23. 16 4 Disconnect both battery cables at the battery see Battery Service in Chapter 5 Electrical System 5 Remove muffler from the exhaust manifold and muf fler bracket see Muffler Removal 6 Drain radiator from the drain cock valve into a suit able container see Radiator Removal Disconnect coolant hoses from the water pump and engine block 7 Remove coolant expansion tank and bracket from the top fan shroud Remove top fan shroud from the ra diator see Radiator Removal Groundsmaster 3500 D 8 Disconnect wire harness and electrical wires from the following A Battery and wire harness grounds Fig 21 B Glow plug bus Fig 22 and fuel stop solenoid C High temperature warning switch Fig 23 D High temperature shutdown switch alternator and low oil pressure switch Fig 24 9 Disconnect throttle cable from the support and swiv el on the speed control lever Fig 21 10 Disconnect fuel hose from the fuel water separator Fig 21 and front injector nozzle 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 12 Remove cable ties securing the wire harness to the front lift tab and other engine parts Connect hoist or lift to the front and rear lift tabs Fig 22 and 23 A CAUTION Make sure lift or hoist can support the total weight of the e
24. 2 U S to Metric Conversions 2 TORQUE SPECIFICATIONS 3 Fastener Identification 3 Using a Torque Wrench with an Offset Wrench 3 Standard Torque Inch Series 4 Standard Torque Metric Fasteners 5 Other Torque Specifications 6 Conversion Factors 6 Product Records Insert a copy of the Operator s Manual and Parts Cata log for your Groundsmaster 3500 D at the end of this chapter Additionally if any optional equipment or ac cessories have been installed to your Groundsmaster insert the Installation Instructions Operator s Manuals and Parts Catalogs for those options at the end of this chapter Maintenance Maintenance procedures and recommended service in tervals for the Groundsmaster 3500 D are covered in the Operator s Manual Refer to that publication when performing regular equipment maintenance Groundsmaster 3500 D Page 2 1 Product Records and Maintenance Rev G Equivalents and Conversions Decimal and Millimeter Equivalents Rev E Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 82 0 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 16 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125
25. Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 3 Remove hydraulic manifold from the machine using Figure 91 as guide 4 If hydraulic fittings are to be removed from manifold mark fitting orientation to allow correct assembly Installation Fig 91 1 If hydraulic fittings were removed from manifold install fittings to manifold using marks made during the removal process to properly orientate fittings 2 Install hydraulic manifold to the frame using Figure 91 as guide 3 Make sure hydraulic tank is full Add correct oil if nec essary see Check Hydraulic System Fluid 2 E g 5 gt Groundsmaster 3500 D Page 4 85 Hydraulic System Rev G E o pe N gt 77 Hydraulic Manifold Service Serial Numbers Below 240000600 30 to 35 Ft Ib 41 to 47 N m 30 to 35 Ft Ib 41 to 47 N m t Loctite 242 4 to 6 Ft Ib 5 to 8 N m 30 to 35 Ft Ib 41 to 47 N m Figure 92 1 Manifold body 6 SRVcartridge valve R1 11 O ring 2 Logic cartridge valve LC1 7 Sealkit 12 Plug SAE 4 3 Seal kit 8 SRV coil 13 O ring 4 Braking cartridge valve BV 9 Nut 14 Plug SAE 8 5 Seal kit 10 Plug SAE 2 15 O ring Note The ports on the manifold are marked for easy 2 Remove nut securing solenoid to the SRV cartr
26. Neutral Arm Assembly ie SE CO a z N UO LR gt N Figure 1 Pump assembly 12 Lock nut 105 23 Flange head screw 2 Hose 13 Spacer 24 Cable support bracket 3 Extension spring 14 Traction stud 25 Ball bearing 4 Pump mount plate 15 Traction control cable 26 Flat washer 5 Neutral bracket 16 Flat washer 27 Lock nut 6 Flange nut 17 Ball joint 28 Cap screw 7 Flange head screw 18 Lock nut 29 Pump lever 8 Neutral arm 19 Cap screw 30 Cap screw 9 Flange bushing 20 Flat washer 31 Flat washer 10 Thrust washer 21 Hub assembly 32 Cap screw 11 90 grease fitting 22 Flange nut 33 Mount Piston Pump Removal Fig 104 amp 105 B Disconnect traction control cable from the pump lever 1 Remove traction belt from the pulley see Replace Traction Belt C Remove both flange head screws securing the neutral bracket to the piston pump Remove flange 2 Remove neutral arm assembly from the piston pump nut and flange head screw securing the neutral as follows bracket to the pump mount plate D Remove cap screw and flat washer securing the A CAUTION pump lever to the piston pump trunnion E Separate pump lever from pump trunnion and The extension spring is under tension and may neutral bracket from mount plate cause personal injury during removal Use cau tion when removing spring from the pump lever 3 Drain hydraulic oil from hydraulic tank see Change Hydraulic Fluid in this section
27. 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 OPER ATING MAINTENANCE AND ADJUSTMENT INSTRUCTIONS For reference insert a copy of the Operator s Manual and Parts Catalog for your machine into Chapter 2 of this service manual Additional copies of the Operator s Manual and Parts Catalog are avail able on the internet at www Toro com The Toro Company reserves the right to change product specifications or this publication without notice PART NO 01088SL Rev G Service Manual Groundsmaster 3500 D Models 30821 30839 and 30843 This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE ANOTE will give general information about the correct operation maintenance service testing or repair of the machine IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 2001 2002 2003 2004 2005 2007 2009 2015 This page is intentionally blank Groundsmaster 3500 D Table Of Contents Chapter 1 Safety Chap
28. lt Do not operate sidewinder while performing test The test gauge hose may get hit by the sidewind er carrier and rupture and cause personal injury 7 Drive machine in the forward direction Observe test gauge A Pressure while transporting the machine over a flat level surface should be about 500 PSI B Pressure driving the machine up a steep hill should be about 3300 PSI but can reach relief set tings 3500 PSI C Pressure while mowing should range between 1000 to 2000 PSI and will vary with terrain condi tions 8 Release traction pedal and turn off machine 9 Disconnect test gauge and hose from the hydraulic tube Install plug into tube opening 10 If specification is not met the hydrostat needs to be repaired or replaced as necessary Groundsmaster 3500 D Page 4 33 Hydraulic System Rev G Piston Pump P3 Flow and Traction Relief Pressure Test Using Tester with Pressure Gauges and Flow Meter gt M5 gt TRACTION WHEEL MOTORS Y TOP PORT p TRACTION RELIEF Y t a 100 to 150 psi FROM HYDRAULIC MANIFOLD CHARGE PORT 3 Sa tas e EE EELER PISTON PUMP HYDROSTAT OG PUMP SUCTION High Pressure T EAR THROUGH CASE DRAIN Low Pressure Return or Suction gt Flow Hydraulic System Rev G Page 4 34 Groundsmaster 35
29. vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of a thread sealant Loctite degree of lubrication on the fastener presence of a prevailing torque feature hard ness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 1 Grade 5 Inch Series Bolts and Screws As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass material strength fastener size length of thread en gagement etc The standard method of verifying torque shall be per formed 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 S P e EF ent Class 8 8 Class 10 9 Metric Bolts and Screws Using a Torque Wrench with an Offset Wrench Use of an offset wrench e g crowfoot wrench will affect torque wrench calibration due to the effective change of torque wrench length When using a torque wrench with an offset wrench multiply the listed torque recommen dation by the calculated torque conversion factor Fig 4 to determine prope
30. 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 5 8 in 1 50 0 25 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 Fitting a 1 Figure 40 Fitting Fitting Port Side Installation Torque Into Dash Size Thread Size Steel Port 7 116 20 15 to 19 ft Ib 21 to 25 N m 1 2 20 18 to 22 ft Ib 25 to 29 N m 9 16 18 34 to 42 ft lb 47 to 56 N m 3 4 16 58 to 72 ft lb 79 to 97 N m 7 8 14 99 to 121 ft Ib 135 to 164 N m 11 16 12 134 to 164 ft lb 182 to 222 N m 1 3 16 12 160 to 196 ft lb 217 to 265 N m 1 5 16 12 202 to 248 ft Ib 274 to 336 N m 15 8 12 247 to 303 ft Ib 335 to 410 N m Figure 41 Hydraulic System Rev G Page4 6 Installation Torque Into Aluminum Port 9 to 11 ft lb 13 to 15 N m 11 to 15 ft Ib 15 to 20 N m 20 to 26 ft Ib 28 to 35 N m 35 to 43 ft Ib 48 to 58 N m 60 to 74 ft lb 82 to 100 N m 81 to 99 ft Ib 110 to 134 N m 96 to 118 ft Ib 131 to 160 N m 121 to 149 ft Ib 165 to 202 N m 149 to 183 ft Ib 202 to 248 N m Groundsmaster 3500 D Adjustable Fitting Fig 42 1 Make sure all threads and sealing surfaces of fitting and component port are free of burrs nicks scratches or any foreign material 2 Asa preventative measure against leakage it is rec ommended that the O ring be replaced any time the connection is opened 3 Lightly lubricate the O ring with clean hydraulic oil Fitting threads shoul
31. 2 Unlatch and raise hood 3 Remove hair pin securing hood pivot to pivot brack et 4 Slide hood to right lift other side and remove hood 5 Reverse procedure to reinstall hood Groundsmaster 3500 D Page 6 23 Cap screw Lock bracket Cap screw Flat washer Locknut Wheels Brakes and Chassis om o w L4 a a o o 2 o o oe 5 3 c This page is intentionally blank Wheels Brakes and Chassis Page 6 24 Groundsmaster 3500 D TORO Table of Contents SPECIFICATIONS TROUBLESHOOTING Factors That Can Affect Quality of Cut SPECIAL TOOLS veina an EEN ADJUSTMENTS Height of Cut Adjustment Adjust Roller Scraper Blade Plane Inspection and Adjustment Groundsmaster 3500 D Chapter 7 Cutting Units iig 2 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 13 Rear Roller Service Greasable Bearings with Bearing Nut 14 Front Roller Service 16 Blade Spindle Servi
32. 25 260 30 353 41 475 45 644 61 660 60 895 81 Note Reduce torque values listed in the table above on the fastener size the aluminum or base material by 25 for lubricated fasteners Lubricated fasteners strength length of thread engagement etc are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite Note The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75 of the mini Note Torque values may have to be reduced when mum proof load specified in SAE J429 The tolerance is installing fasteners into threaded aluminum or brass approximately 10 of the nominal torque value Thin The specific torque value should be determined based height nuts include jam nuts Product Records and Maintenance Page 2 4 Groundsmaster 3500 D Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Regular Height Nuts Class 8 or Stronger Nuts Thread Size M5 X 0 8 M6 X 1 0 57 5 in Ib 96 9 in Ib M8 X 1 25 M10X1 5 19 2 ft lb 38 4 ft lb M12X 1 75 M16 X 2 0 M20 X 2 5 Note Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite 66 7 ft lb 166 15 ft lb 325 33 ft lb Note Torque values may have to be reduced when installing fasteners into threaded aluminum or
33. 3 Mount shaft securely in a vise by clamping on the cle vis of the shaft A Coat shaft with a light coat of clean hydraulic oil B Slide cylinder gland assembly onto the shaft Install piston and lock nut onto the shaft Torque nut from 24 to 30 ft Ib 33 to 41 N m C Remove shaft from the vise IMPORTANT Prevent damage when clamping the hydraulic cylinder into a vise clamp on the clevis only 4 Mount clevis of the barrel in a vice 5 Coat all internal parts with a light coat of clean hy draulic oil Slide piston shaft and cylinder gland assem bly into the barrel being careful not to damage the seals 6 Secure head into the barrel with the retaining ring Hydraulic System Rev G e SE GO a z N cs gt gt N This page is intentionally blank Hydraulic System Rev G Page 4 130 Groundsmaster 3500 D Table of Contents ELECTRICAL SCHEMATICS AND DIAGRAMS SPECIAL TOOLS TROUBLESHOOTING Starting Problems General Run amp Transport Problems Cutting Deck Operating Problems ELECTRICAL SYSTEM QUICK CHECKS Battery Test Open Circuit Test Charging System Test Glow Plug System Test Check Operation of Interlock Switches COMPONENT TESTING Ignition Switch Glow Relay Interlock Neutral Seat and High Temperature Shutdown Relays Hour Meter SRV Valve Solenoid Diode Assemblies Warning Light Cluster Serial Number Below 240000000 Indicator Lights Serial Number Above 240000000 Grou
34. Back up gasket For service procedures of a Casappa motor referto Dis assembly Inspection and Assembly steps listed in Rotary Cutting Motor Service Haldex Refer to Figure 90 for torque specifications Hydraulic System Rev G Page 4 82 Front wear plate Front plate Shaft seal Washer Retaining ring Seal Groundsmaster 3500 D ie SE O a z N UO LR gt N This page is intentionally blank Groundsmaster 3500 D Page 4 83 Hydraulic System Rev G Hydraulic Manifold oouonBRONZ Hose clamp O ring Barb fitting Stud Straight hydraulic fitting O ring Flange head nut O ring O ring Hydraulic System Rev G Figure 91 Straight hydraulic fitting O ring Hydraulic hose Hydraulic hose Straight hydraulic fitting O ring O ring Hydraulic tube Page 4 84 Hydraulic hose Hydraulic manifold O ring Straight hydraulic fitting O ring O ring 90 hydraulic fitting O ring Groundsmaster 3500 D Removal 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 Clean hydraulic manifold before doing any disas sembly 2 Label all hydraulic connections for assembly pur poses
35. Complete steps 9 to 13 E Ifspecifications are not met checkthe relief valve in the rear wheel motor for damage If relief valve is not damaged wheel motor needs to be repaired or replaced 17 Disconnect tester from hydraulic fitting and hose Reconnect hose to pump connection Hydraulic System Rev G 2 E 5 gt lt Cutting Deck Circuit Pressure Test FROM DECK MOTOR CASE DRAINS gt TO LEFT FRONT DECK MOTOR lt q FROM REAR DECK MOTOR 1500 psi HYDRAULIC MANIFOLD BLOCK R1 3200 psi TOOL wil COOLER FROM FRONT LIFT CYLINDER FROM REAR LIFT CYLINDER 7 Ki LV TO HYDROSTAT FROM LIFT VALVE CHARGE CIRCUIT OUT PORT TO STEERING CONTROL gie VALVE IN PORT A 1 FROM STEERING CONTROL VALVE OUT PORT H CL N FROM HYDROSTAT INTERNAL CASE DRAIN GEAR PUMP Z ja High Pressure Low Pressure Return or Suction gt Flow aa WA FROM OIL FILTER STRAINER Hydraulic System Rev G Page 4 42 Groundsmaster 3500 D Procedure for Cutting Deck Circuit Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on alevel surface with the cutting units lowered and off Make sure engine is off and the parking brake is e
36. E 2 E 5 E 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 lubri cate spindle bearings with No 2 General Purpose Lithi um 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 bear ings and increases bearing life 1 Wipe grease fitting with a clean rag IMPORTANT Do not apply too much pressure or grease seals will be permanently damaged Figure 13 2 Apply grease until a small amount appears at bottom of spindle housing under deck 3 Wipe excess grease away Product Records and Maintenance Page 2 10 Groundsmaster 3500 D Preparation for Seasonal Storage Traction Unit 1 Clean traction unit cutting units and the engine thor oughly 2 Check tire pressure Inflate all tires to 14 to 18 psi 0 97 to 1 24 Bar 3 Check all fasteners for looseness tighten as neces sary 4 Lubricate all grease fittings and pivot points see Lu brication 5 Cover entire length of the Sidewinder cross tube with a light oil to prevent rust After storage wipe off all oil 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 Remove batte
37. Fig 21 15 Connect both battery cables at the battery see Bat tery Service in Chapter 5 Electrical system 16 Install air cleaner to the engine Connect air hose to air cleaner and radiator 17 Adjust throttle cable see Adjust Throttle Cable 18 Bleed fuel system see Bleed Fuel System 19 Install engine hood to the machine Close and latch hood 20 Check hydraulic oil level Adjust as needed 21 Adjust traction drive for neutral see Adjust Traction Drive for Neutral in Chapter 4 Hydraulic System Kubota Diesel Engine Rev G o 2 74 Ek lt 8 A OH This page is intentionally blank Kubota Diesel Engine Rev G Page 3 20 Groundsmaster 3500 D Table of Contents SPECIFICATIONS 000 eee ee eee 2 GENERAL INFORMATION 3 Traction Unit Operator s Manual 3 Check Hydraulic Fluid 3 Towing Traction Unit 3 Hydraulic Hoses 4 Hydraulic Hose and Tube Installation 5 Hydraulic Fitting Installation 6 Relieving Hydraulic System Pressure 8 Traction Circuit Closed Loop Component Failure 8 HYDRAULIC SCHEMATICS 9 Serial Numbers Below 240000600 9 Serial Numbers 240000601 to 313999999 10 Serial Numbers Above 314000000 11 HYDRAULIC FLOW DIAGRAMS 12 Traction Circuits 12
38. GLOW J5 E SR OVERTEMP START P5 RELAY SOLENOID SEAT SEAT P9 INTERLOCK cr E P19 SWITCH BE RELAY 1 RELAY CAPACITOR PEN A i SUBE EHH P BRAKE SOLENOID J6 ES Ge BACKLAP P23 TEMP P6 SWITCH CONTROLLER G SWITCH T J9 P13 P20 4 Gi dq El D J18 D2 D3 D1 J13 P14 PTIONAL Geer IGNITION SWITCH L n E HE P15 P11 ER GAUGE CUTTING UNIT P16 SOLENOID CLUSTER FUSE BLOCK P17 NEUTRAL SWITCH Groundsmaster 3500 D Harness Drawing Serial Numbers 90101 to 230999999 Page 8 9 ALTERNATOR RUN SOLENOID 5 HOLD UJUI nas R Av SE i A w E PULL w o 7o GY 105C OVER TEMP WARNING Be GN ENGINE OIL PRESSURE BU W gt 110C OVER TEMP GN SHUTDOWN ay W TED FUEL PUMP Lu 5 o GLOW PLUGS 3 oR PK E E W EN o H E amp S PK E 3 H Fu Q4 GLOW PLUG dE Ope Sb E a 3 E CONTROLLER BN oz TE SO m KUBOTA 3 6 5 a g i i gt gt SS NEM Es zi E 3 START 4 4 TEMP lt lt 1 9 d d vio HR HOUR ME
39. L JJ ROTARY DECKS ON OFF OPTIONAL TERMINALS 5 AND 6 LIGHT F4 5A NOT SUPPLIED Ly el FR et E eg sw 4 DECKS ON BK TRANSPORT MOW ROTARY DECKS BU IN MOW DRIVE SOLENOID R SS 87 GLOW PLUGS 8 OR pk 85 CYY Y 86 STOP NONE Lo ON PREHEAT B l A X Y GEQVURELAY START B l S KUBOTA m BU GLOW PLUG Sie CONTROLER OR 1 4 jig 2 Groundsmaster 3500 D 2 5 t T Run Circuits Mow S S BK Power Current BLACK GRAY RED Control Current Ds e Indication Current BLUE GREEN TAN YELLOW CA gt Logic Direction BROWN ORANGE VIOLET RED BLACK Schematic from machine with Serial FUSIBLE LINK PINK WHITE SPLICE Number 90101 to 230999999 shown Page 8 7 Rev E GLOW RELAY
40. Ll M isd 00S Sed D 31009 Po bad o IPS we I CZ LD 4 z9 e eo T Eet AM N pu SE 1804 ei LL u3ddn INIA H3MO1 ig SSYd Ad yoote Se CTO3INVA 9 8 v Is n na ed ooze n SEN 4 S vA 3 isd ZI 2 E zon 0051 1HOd dO 5 8 d IE 8 o3a u uvau gt eL N JJ m awd 4 3 2 o EI E avihyina YA ES 5 ANS ZW LN La Sn 3 Be d 3 E yosa LANA SHOLOW 133HM NOLLOVEL aa ADE d pazI6 19u9 op S UMOUS 3 8 SPIOUAJOS V 000007 LE anoqy siaquiny enas oneuiauos 91 NeIp H a 00SE Je sewspunoly Hydraulic System Rev G Page 4 11 Groundsmaster 3500 D Hydraulic Flow Diagrams ANWA l NHS o YANIVHLS u3MOd 59 xnv 3 o H ER 4 m isd 0001 1 x m Il P 1 AR z ll dWNd HVI zd Via H VJ Harl 5 J FY o 10 amp lt 3UNSSIY4ADVE Ed Oe 1 TEE IMYA HSGNIMAGIS L4I7 Dy is SHO id NI gt SS lz z9 f 431000 l I 110 i ben j gt 7 107 uo JL i 2 II ll 39 m Il i E LL jw v e 5 ems isd 002 9 a v c0 HH s ool 1n uvau E QIOJINVW nin XK 19 D 131 INOW E yoza HONO uvad A EN SA al i l isd 00S L o3a dis eL 1HOlH ap L DN ew 7 AlWd eel MES Bx A avaHying m H3aNiMwaats S i HA Ig Ss UNE oaa 1431
41. Locknut 119 Welded pin Flange head screw Lock nut Spacer Hydraulic tube Hydraulic tube 90 hydraulic fitting Bulkhead lock nut Straight hydraulic fitting Hydraulic hose Page 4 118 90 hydraulic fitting Hydraulic hose Scissor link O ring O ring O ring Retaining ring Lower frame Frame Pinch point decal Groundsmaster 3500 D Removal Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 1 Remove hydraulic cylinder from the frame using Fig ure 119 as guide 2 If hydraulic fittings are to be removed from cylinder mark fitting orientation to allow correct assembly Installation 1 If hydraulic fittings were removed from cylinder install fittings to cylinder using marks made during the removal process to properly orientate fittings 2 Install hydraulic cylinder to the frame using Figure 119 as guide 3 Make sure hydraulic tank is full Add correct oil if nec essary see Check Hydraulic System Fluid 4 Adjust scissors mount as follows A Shift sidewinder fully to the left fully retract cylin der B Loosen four cap screws and locknuts securing the scissor mount to lower frame C The gap between the scissor frame and lower frame and the gap between the scissor frame and the sidewinder carrier must be equ
42. Procedure for Manifold Relief Valve R1 Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 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 S manifold port M1 Figure 62 Figure 62 Note Analternativeto using manifold port M1 would de sHysrauiie mano 2 Manifold port M1 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 5 Install tester in series with the hose and hydraulic fit ting Make sure the flow control valve on tester is fully open Hydraulic A CAUTION Keep away from decks during test to prevent per sonal injury from the cutting blades 6 Start engine and move throttle to full speed 3050 50 RPM Engage the cutting units 7 Watch pressure gauge carefully while slowly closing Figure 63 the flow control valve to fully closed 1 Hydraulic manifold 2 Manifold port M1 8 System pressure should be from 3350 to 3600 PSI as the relief valve lifts A If specification is not met shut off engine and clean or replace SRV valve R1 Return to step 5 B If this specification is met proceed to step 9 9 Disengage cutting units
43. Rear Roller Service Greasable Bearings with Retaining Ring Roller Disassembly Fig 18 1 Remove retaining ring from both ends of roller 2 Hit end of roller shaft with a soft face hammer to re move seals and bearing from one end of roller Hit other end of roller shaft to remove seals and bearing from oth er end of roller Be careful not to drop roller shaft 3 Discard seals and bearings Roller Assembly Fig 18 NOTE Asoft face hammer can be used with the special tools listed see Special Tools to assemble the roller however use of a press is recommended 1 Use installation tool TOR4065 and handle TOR4073 to install inner oil seal into each end of roller tube 2 Install ball bearings Figure 18 ns 1 Roller shaft 6 Washer NOTE Ball bearings have a press fit into the roller tube 2 Outer seal 7 Inner seal and a slip fit onto the roller shaft 3 Retaining ring 8 Ball bearing 4 Outer oil seal 9 Inner oil seal 5 Grease fitting 10 Roller tube IMPORTANT If ball bearing has a seal on one side install bearing with seal orientated toward the out side of the roller A Use tool TOR4066 and handle TOR4073 to install ball bearing into one end of roller tube B Install roller shaft from opposite end of roller Be carefu
44. aa a e 2 Plug in style diodes Fig 14 Multimeter Multimeter Red Lead Black Lead Continuity on Terminal on Terminal RE Electrical System Rev G Page 5 12 Groundsmaster 3500 D Warning Light Cluster Serial Numbers Below 240000000 NOTE Individual light bulbs can be tested by removing them from the lighting cluster and applying 12 VDC to COOLANT their wiring terminals Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON PREHEAT position with the engine not running Also it should light with the engine running when the oil pressure drops below 7 PSI 0 4 kg cm 1 Disconnect gray wire from the oil pressure switch 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 High Temperature Water Warning Light When the coolant temperature is above 221 F 105 C the high temperature light should come on However the high temperature shutdown switch and relay do not stop the engine until the coolant temperature is above 230 F 110 C Glow Light oE Oo 1 gt oo 25 Lu The glow light should come on when the ignition switch is placed in ON PREHEAT prior to placing the ignition switch in START The glow light stays on for 10 seconds while left in ON PREHEAT Battery Light The battery light sho
45. digital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from the measured value of the component you are test ing 1 Make sure ignition switch is in the OFF position Dis connect the connector from the solenoid 2 Using a digital multimeter touch one test lead to the Figure 30 1 Injection pump 2 Fuel stop solenoid Figure 31 1 Cap screw 2 Fuel stop solenoid 4 Common Black wire 5 Hold coil Red wire pin ofthe black wire and the other test lead to the pin of 3 Gasket 6 Pull coil White wire the white wire Fig 31 The resistance of the pull coil should be about 0 33 ohms 3 Using a digital multimeter touch one test lead to the pin of the black wire and the other test lead to the pin of the red wire Fig 31 The resistance of the hold coil should be about 12 2 ohms 4 Connect solenoid to the wiring harness Electrical System Rev G Page 5 20 Groundsmaster 3500 D 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 en gine Fig 32 The fuel stop solenoid includes two coils for operation the pull coil and the hold coil When the ignition switch is turned
46. gt XL e d ino i y SE ene EE CS eh jt SE V 1 I a 3 zi Leg zi I IWLSOHGAH ONIS3SIS Ee p 1 KE Y ed ld re L IA r NI it d UU E Oa NA E I Y i X d up I WA d aes EE 3unssaudyova Ed Oe Minos 1 TA Ba 1 a 3A IVAH3QNIM3GIS LJIl ino NI j 4 A e gt f i Isd OSL 01001 I L 1 I BR i ES l F I i 31009 C 110 1 DA Ho PA i Isd 000 d 1 Ey H i 1l yo i i 1 uxawwaas i i E J V 1 F 7 F7 LL IRA ES E EG A L Ee i 5 I i I 1HOd 1HOd 1 u3ddn 3NA H3MO1 35d 1 X009 1 SSVd 18 Se i QIOJINVIA S 9 a v TT Ss uy I a 19 I AIN i ALON n i 1 ON a LINOHS 1 i J LYOd dOL dy VMyOY 1 SHOLOW 133HM NOLLOVH L i XQ 1 Aq ZL NEIN ru N WA E GE ZEN anion PUN pl 3 vld I D wk Y avapmnna 1 zw LW La CSW Y H3aNiwadis l ME am 1 MOJA lt CH 5 uonons jo umy i A A eBrey almssaig MO C LA e ainssalg YH ag A yn241 Mun Dunn r I EE E Se e E aa 4 G 00SE Je sewpunosy Groundsmaster 3500 D Page 4 14 Hydraulic System Rev G Cutting Unit Circuit Mow The gear pump P1 is directly coupled to the the hydros tat which is driven by the engine Taking its suction di rectly from the hydraulic tank the gear pump P1 supplies oil flow to the manifold block and to the cutting unit motors Solenoid valve R1 is de energized with the engine running when either the cutting unit drive
47. gt m 8 CLOSED IN NEUTRAL i gt 6 BY 2 El GROUND BK 2 9 T 3 o e T 85 YYY 86 PARKING BRAKE 2 BACKLAP SEN eS FF NOV Pe ENE e EA NAS D1 NEUTRAL A ENGINE Es 3 G gt H VIO VIO SWITCH D4 e LA 1 2 KI Q vi 1 2 A GAUGE y rm BK ROTARY DECKS ON OFF FRAME BATTERY CLUSTER 71 GERMINAES A AND R LA GROUND BEEN y DECKS OFF 9 S UUU Bs i 86 85 OR 7 a d F3 5A f E SS vio f 87a BU INTERLOCK RELAY WA A E F1 15A PK PK i IGNITION A NOTE ROTARY DECKS ON OFF SWITCH ON CONSOLE SWITCH F2 INCLUDES TERMINALS SHOWN IN TWO PLACES ON THIY BU gt ROTARY DECKS ON OFF SCHEMATIC OPTIONAL i TERMINALS 5 AND 6 LLL NOT SUEPLIED Se f 5 6 MM El m efe im NEC UN Pr b SSS A 6 6 PK o w BU GN a DECKS OFF BK TRANSPORT MOW ROTARY DECKS BU DRIVE SOLENOID 0 R 3 87 GLOW PLUGS 3 OR pex 5 YY 86 STOP NONE p ON PREHEAT B I A X Y GLOW BEEN START B l S BU GLOW PLUG CONTROLER PK OR VIO m g 2 Groundsmaster 3500 D s Run Circuits Transport BK Power Current Page8 6 Rev E R BK
48. new bearings with their matched spacer set and snap ring must always be installed when the spindle housing is being replaced Replacement bearings are sold only with a matched snap ring and spacer set These parts cannot be purchased separately 1 If large snap ring was removed or if replacing the spindle housing install snap ring into spindle housing groove Make sure snap ring is seated in groove IMPORTANT If bearings are being replaced make sure to use the large spacer inside spacer and spacer ring that are included in new bearing set 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 as sembly is correct by supporting the first bearing cup and pressing the second against it Fig 28 4 Pack the bearing cones with grease Apply a film of grease on lips of seals 5 Install lower bearing and seal into bottom of spindle housing Note The bottom seal must have the lip facing out down Fig 29 6 Slide spacer ring and inside spacer into spindle housing then install upper bearing and seal into top of housing Note The upper seal must have the lip facing out up Fig 29 7
49. 17 Install the four screws and hand tighten 18 Place mounting flange of the pump into a vise with soft jaws Alternately torque the screws from 38 to 43 ft Ib 51 to 58 N m 19 Remove pump from vise 20 Place a small amount of clean hydraulic oil in the inlet of the pump and rotate the drive shaft away from the inlet one revolution If any binding is noted disassemble the pump and check for assembly problems Groundsmaster 3500 D ie SE O a z N UO LR gt N This page is intentionally blank Groundsmaster 3500 D Page 4 111 Hydraulic System Rev G Gear Pump Service Serial Numbers Above 260000400 Figure 1 Front cover 8 Dowel pin 112 15 Front thrust plate 2 Pressure seal 9 Seal 16 Idler gear 3 Back up gasket 10 Body 17 Drive gear 4 Front thrust plate 11 Seal 18 Rear thrust plate 5 Idler gear 12 Splined connecting shaft 19 Rear cover 6 Drive shaft 13 Pressure seal 20 Washer 4 used 7 Rear thrust plate 14 Back up gasket 21 Cap screw 4 used Disassembly Fig 112 NOTE The gear pump must be replaced as a complete assembly Individual gears housings and thrust plates are not available separately Disassemble gear pump for cleaning inspection and seal replacement only 1 Plug pump ports and thoroughly clean exterior of pump with cleaning solvent Make sure work area is clean 2 Use a marker to make a diagonal line across the gear pump for assembly purposes Fig 113
50. 3 CLUSTER GAUGE Seu JI SCM LIGHT SWITCH OPTIONAL JB o LIGHT L OPTIONAL Ji J6 P36 ENGINE OIL PRESSURE GLOW RETE OVER TEMP SWITCH Di IGNITION SWITCH 5 Pr T 4 5 a HIH 1 H I H Hen El es 2 2 Ap BA ya A EN O P35 SINGLE FUSE P20 STARTER 6 P27 318 DIODE 01 IGNITION SWITCH O SERIAL NUMBERS Im ABOVE 260000400 P19 START SOLENOID PARK ING BRAKE NC P28 BACKLAP gt J9 BACKLAP NOT USED J8 BACKLAP NOT USED P6 PARKING BRAKE 1 NC P16 Er 5p FUSE BLOCK o EICHER moo Groundsmaster 3500 D Harness Drawing Serial Numbers 240000001 to 313999999 Page 8 12 Rev G LIGHT sis OPTIONAL JI4 LIGHT SW OPTIONAL jig X Y A IGNITION SW pra B R OIL P33 ALT CLUSTER GAUGE OT P34 GLOW HOUR METER ez G2 ENGINE GROUND J3
51. 4 2 Chapter 8 Electrical Diagrams re General Information 4 3 Hydraulic Schematic 4 9 Electrical Schematics and Diagrams Hydraulic Flow Diagrams 4 10 Special Tools 4 sss s LEE RE 4 22 5 Troubleshooting 4 26 25 E A ENTE S EUN 4 28 332 Adjustments 4 54 ui Service and Repairs 4 56 ROSS TORQMOTOR MG MF ME AND MJ SE RIES SERVICE PROCEDURE EATON MEDIUM DUTY PISTON PUMP REPAIR IN FORMATION MODEL 70160 VARIABLE DISPLACE MENT PISTON PUMP ROSS HYDRAGUIDE HYDROSTATIC STEERING SYSTEM HGF SERIES SERVICE PROCEDURE SAUER DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL d 22 N 58 mz nO os oc Electrical Diagrams Groundsmaster 3500 D Rev G This page is intentionally blank Groundsmaster 3500 D TORO Table of Contents GENERAL SAFETY INSTRUCTIONS 1 Supervisor s Responsibilities 1 Before Operating 1 While Operating 2 Maintenance and Service 3 JACKING INSTRUCTIONS 4 General Safety Instructions The GROUNDSMASTER 3500 D was tested and certi fied by TORO for compliance with existing standards and specifications as identified in the Operator s Manu al Although hazard control and accident prevention are
52. A X Y START B 1 S KUBOTA BU GLOW PLUG CONTROLER Groundsmaster 3500 D Glow Circuits Power Current Control Current BLACK GRAY RED ME ndication Current BLUE GREEN TAN YELLOW Logic Direction BROWN ORANGE VIOLET RED BLACK Schematic from machine with Serial FUSIBLE LINK PINK WHITE SPLICE Number 90101 to 230999999 shown Page8 4 Rev E R BK ii m OPTION 42 SEAT SWITCH ALTERNATOR RUN SOLENOID gt B p PK H a4 i i 9 0 R z e i a 6500 MFD R BK L d HOUR 5 o B METER OR GY r OPTION 1 l SHUTDOWN 0 a SEAT SWITCH 110 C BK i USI oe CLOSED WHEN OCCUPIED 85 PK t SC Y 87 REK 7 rco GY BN OR PARKING BRAKE 1 SN S LOW OIL PRESSURE w IN OFF POSITION T ER w EAT RELAY FL J e 5s BK ce on 8 58 a vus FL KS i Ug OR Z ps FL JB G FL 5 TU re NEUTRAL RELAY a 5 A D GE H NOT USED Start SP T u a A d On Sr hl RR E E a 2 8 30 o 4 hoy m 87 c NO 5 E rc o c z 9 e
53. Cutting Unit Circuit 14 Lift Circuit Up 16 Lift Circuit Down 18 Sidewinder Circuit 20 Steering Circuit 22 SPECIAL TOOLS 002s 24 TROUBLESHOOTING 28 TESTING A oer Ee rt od e 30 Traction Circuit Working Pressure Test 32 Piston Pump P3 Flow amp Traction Relief Pressure Test 34 Charge Relief Valve Pressure Test 36 Gear Pump P2 Flow Test 38 Wheel Motor Efficiency Test 40 Cutting Deck Circuit Pressure Test 42 Gear Pump P1 Flow Test 44 Manifold Relief Valve R1 Pressure Test 46 Logic Counterbalance Valve LC1 Pressure Test 48 Deck Motor Efficiency Case Drain Test 50 Lift and Steering Control Valve Relief Pressure Test 52 Steering Control Valve Test 54 ADJUSTMENTS 56 Adjust Traction Drive for Neutral 56 Braking Valve Adjustment 57 SERVICE AND REPAIRS 58 General Precautions for Removing and Installing Hydraulic System Components 58 Change Hydraulic Fluid 59 Replace Hydraulic Oil Filter 60 Replace Traction Belt
54. Disconnect test gauge with hose from manifold block Reconnect plug to the hydraulic manifold port G2 Figure 65 1 Hydraulic manifold 2 Manifold port G2 Figure 66 1 Hydraulic manifold 2 Manifold port G2 Figure 67 1 Manifold assembly 3 2 Logic valve LC1 Hex cap Hydraulic System Rev G Hydraulic Deck Motor Efficiency Case Drain Test Using Tester with Pressure Gauges and Flow Meter TO HYDRAULIC MANIFOLD PORT D1 FROM HYDRAULIC MANIFOLD PORT M1 RIGHT LEFT DECK MOTOR MEASURING CONTAINER DECK MOTOR TO HYDRAULIC MANIFOLD PORT M2 Note Over a period of time a deck motor can wear in ternally A worn motor may by pass oil to its case drain causing the motor to be less efficient Eventually enough oil loss will cause the deck motor to stall under heavy cutting conditions Continued operation with a worn inefficient motor can generate excessive heat cause damage to seals and other components in the hy draulic system and affect quality of cut Hydraulic System Rev G Page 4 50 High Pressure Low Pressure REAR DECK MOTOR Return or Suction gt Flow Milliliters in 15 sec Ounces in 15 sec 95 3 2 189 6 4 284 9 6 378 12 8 473 16 0 568 19 2 662 22 4 756 25 6 dejoja lala loii a 852 28 8 946 32 0 A o Note One meth
55. Figure 113 Hydraulic System Rev G Page 4 112 Groundsmaster 3500 D IMPORTANT Use caution when clamping gear pump in a vise to avoid distorting any pump compo nents 3 Secure the front cover of the pump in a vise with the drive shaft pointing down 4 Loosenthe four 4 cap screws that secure pump as sembly 5 Remove pump from vise and remove fasteners 6 Supportthe pump assembly and gently tap the pump case with a soft face hammer to loosen the pump sec tions Be careful to not drop parts or disengage gear mesh IMPORTANT Markthe relative positions of the gear teeth and the thrust plates so they can be reassem bled in the same position Do not touch the gear sur faces as residue on hands may be corrosive to gear finish 7 Remove the thrust plates and seals from each pump section Before removing each gear set apply marking dye to mating teeth to retain timing Pump efficiency may be affected if the teeth are not installed in the same position during assembly Keep the parts for each pump section together do not mix parts between sections Groundsmaster 3500 D Page 4 113 8 Clean all pump parts Check all components for burrs scoring nicks and other damage 9 Replace the entire pump assembly if parts are ex cessively worn or scored Assembly Fig 112 1 Apply clean hydraulic oil to all parts before assem bling NOTE Pressure seals and back up gaskets fit in grooves machined into th
56. Groundsmaster 3500 D Page 4 27 Hydraulic System Rev G Troubleshooting The charts that follow contain information to assist in Refer to the Testing section of this Chapter for precau troubleshooting There may possibly be more than one tions and specific test procedures cause for a machine malfunction 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 One of the pump suction lines has an air leak Incompatible hydraulic oils mixed in system Water in hydraulic system Hydraulic system operates hot Transmission pressure is high due to load or brakes applied Oil level in reservoir is low or inlet filter is loose or clogged Oil is contaminated or oil viscosity is too light Oil cooler is damaged or plugged By pass relief is stuck open or air flow is obstructed Hydrostat by pass valve is open or defective Charge pressure is low Wheel motor s or cutting unit motor s are worn or damaged Traction pump is worn or damaged Neutral is difficult to find or unit op External control linkage is misadjusted disconnected binding or erates in one direction only damaged Traction pump is worn or damaged Traction response is sluggish Hydrostat by pass valve is open or worn Brake is not released Charge pressure is low Hydraulic oil is very cold
57. Hex flange head screw Removal Installation 1 Park machine on a level surface lower cutting units 1 Install any new seat parts using Figure 10 as a guide stop engine engage parking brake and remove key from the ignition switch 2 Position seat and support straps to the fuel tank and frame 2 Remove four hex flange head screws securing the seat support straps to the frame 3 Attach electrical connector to the seat switch 4 Secure seat support straps to the frame with four hex flange head screws 3 Disconnect electrical connector from the seat switch Separate seat from the frame 4 Remove seat parts as necessary to make repairs us ing Figure 10 as a guide Groundsmaster 3500 D Page 6 9 Wheels Brakes and Chassis Front Wheel and Brake Anti seize Lubricant 45 to 65 ft lb 61 to 88 N m 250 to 350 ft lb 6 339 to 474 N m Figure 11 1 Lug nut 12 Brake lever 23 Spacer 2 Drive stud 13 Lock nut 24 Wheel shield 3 Wheel rim 14 Cap screw 25 Cotter pin 4 Tire 15 Brake bracket 26 Clevis pin 5 Wheel hub 16 Return spring 27 Clevis 6 Lock nut 17 Brake shoe 28 Jam nut 7 Hydraulic wheel motor 18 Backing plate 29 Flange bushing 8 Brake drum 19 Cam shaft 30 Brake pivot bracket 9 Woodruff key 20 Retainer clip 31 Brake pivot shaft 10 Cotter pin 21 Lock nut 32 Hex flange head screw 11 Adjustment rod 22 Cap screw 33 Hex flange nut Removal Fig 11 2 Jack up fron
58. Ib 61 to 88 N m 6 Lower rear wheel to the ground Wheels Brakes and Chassis no o E n LU E E o o 2 o P oe 5 3 c Brake Lever Linkages Pop rivet Control panel cover Cover bracket Flange nut Hex flange head screw Magnet support Hex washer head screw Strike bracket Magnetic catch 10 Flat washer 11 Lock nut 12 Cotter pin 13 Bumper pad PENDA Wheels Brakes and Chassis Figure 14 Hex socket flat head screw Parking brake link Clevis pin Clevis pin Lever assembly Parking brake spacer Slotted hex head screw Frame Switch Flat washer Lock nut Cap screw Page 6 14 Brake pivot shaft Clevis pin Flange bushing Brake pivot bracket Hex flange head screw Cotter pin Brake cam shaft Brake lever Retainer clip Adjustable clevis Jam nut Adjustment rod Groundsmaster 3500 D 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove control panel cover from the machine IMPORTANT When removing the adjustable clevis 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 Remove and replace parts as necessary to repair brake linkages 4 Install co
59. J3 L m RED BLACK RED BLACK e E YELLOW ORANGE VIOLET RED BLACK BLACK ORANGE WHITE GRAY YELLOW GREEN BLUE WHITE PINK RED BLACK VIOLET BROWN BROWN 1233 45 1 2 3 A B A B AlB 1 2 83 4 5 6 7 8 J16 J17 gar J4 J6 J21 J12 P15 P18 P7 NO NC J14 J15 5 d a e az a En T P DIODE D2 Z OO 8 zOr 85 S Zo Q up 12 DIODE D1 P9 ES UE ree amp ot ES 35 d EK 653 a Za ce xo DECK ON OFF HIGH TEMP P2 o 955 iz p ES 23 ut SWITCH SHUT DOWN RUN 9g 3 En E RELAY solenon E Groundsmaster 3500 D F Harness Diagram Serial Numbers 90101 to 230999999 Page 8 8 ALTERNATOR P8 J7 OIL SWITCH J4 Ji J2 Qu P1 DECK UP DOWN SWITCH P7 TRANSPORT MOW a SWITCH SEAT P18 y H SWITCH ve P4 Los ENGINE O a O J3 GROUND m T E Li 8 DECK ON OFF po FUEL SWITCH SOLENOID Dio
60. LC1 7 Solenoid cartridge valve S 2 4 Hex head plug 5 Logic cartridge valve LC2 8 Solenoid coil 3 4 Zero leak plug 6 Relief valve RV 9 Nut NOTE The ports on the manifold are marked for easy identification of components Examples RV is the deck circuit braking valve and P1 is the gear pump connection port see Hydraulic Schematic to identify the function of the hydraulic lines and cartridge valves at each port location Hydraulic System Rev G Page 4 92 Groundsmaster 3500 D NOTE The Groundsmaster 3500 D hydraulic man ifold uses several zero leak plugs These plugs have a tapered sealing surface on the plug head that is de signed to resist vibration induced plug loosening The zero leak plugs also have an O ring as a secondary seal If zero leak plug removal is necessary lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug the impact will allow plug removal with less chance of damage to the socket head of the plug For hydraulic manifold service procedures refer to Hy draulic Manifold Service Serial Numbers 240000601 to 313999999 in this section Refer to Figure 99 for car tridge valve and plug installation torque E SE SO 0 ES 2 Groundsmaster 3500 D Page 4 93 Hydraulic System Rev G Control Valve Control valve 2 spool Hydraulic fitting straight 90 hydraulic fitting Hydraulic fitting straight Flange nut Knob 90 h
61. Operating Pressure Gear motor 1500 PSI 103 bar 2250 PSI 155 bar Steering Control Valve Maximum Operating Pressure Implement Steering and Lift Relief Valve Pressure Distributor valve with rotary meter 1800 PSI 124 bar 1000 PSI 69 bar Hydraulic Filter 10 Micron spin on cartridge type Hydraulic Oil See Hydraulic System Fluid in General Information Section Hydraulic Reservoir 6 Gal U S 22 6 L Hydraulic System Rev G Page 4 2 Groundsmaster 3500 D General Information Traction Unit Operator s Manual The Traction Unit Operator s Manual provides informa tion regarding the operation general maintenance and maintenance intervals for your Groundsmaster ma chine Refer to that publication for additional information when servicing the machine Check Hydraulic Fluid The hydraulic system on Groundsmaster 3500 D ma chines is designed to operate on high quality hydraulic fluid The hydraulic system reservoir holds approxima tely 6 gallons 22 6 liters of hydraulic fluid Check level of hydraulic fluid daily See Traction Unit Operator s Manual for fluid level checking procedure and hydraulic oil recommendations Figure 34 1 Hydraulic reservoir 2 Capand dipstick Towing Traction Unit In case of emergency the Groundsmaster 3500 D can be towed for a short distance However Toro does not recommend this as a standard procedure 1 Locate by pass valve on
62. Radiator 13 Kubota Diesel Engine Rev G o 2 74 Ek lt 8 A OH Radiator and Oil Cooler Assembly Serial Number Above 314000000 Figure 18 1 Expansion tank 12 Radiator 23 Hydraulic hose 2 Hose clamp 13 Straight fitting 24 Lower radiator hose 3 Coolant hose 14 Draincock 25 Hose clamp 4 Flange head screw 15 Lower radiator shield 26 Hex nut 5 Radiator bracket RH 16 Radiator bracket LH 27 Relay 6 Carriage bolt 17 Elbow fitting 28 Upper radiator hose 7 Flange nut 18 Magnet 29 Flange nut 8 Radiator bracket top 19 Radiator bracket bottom 30 Straight fitting 9 Flange head screw 20 Lower fan shroud 31 Expansion tank support 10 Frame casting 21 Upper fan shroud 32 Flange head screw 11 Cap screw 22 Hydraulic tube NOTE On machines with serial number above 314000000 the hydraulic oil cooler is combined with the CAUTION radiator as shown in Figure 18 Removal Do not open radiator cap or drain coolant if the radiator or engine is hot Pressurized hot cool ant can escape and cause burns Ethylene gly col antifreeze is poisonous Dispose of coolant properly or store it in a properly labeled contain er away from children and pets 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Open and remove engine hood from the machine Kubota D
63. Remove both spool caps and slide the spool assem blies from their bores 3 Remove O ring and bushing from each spool as sembly 4 Remove wiper seals and O rings from the spool bore ends that are opposite the spool caps Note Disassemble spool assemblies only if the re taining ring spacer spring or washer need replacing 5 Remove seat retaining plugs back up washers O rings and check springs from the valve body 6 Remove check poppets seats O rings and plung ers from the valve body 7 Remove solid plug back up washer and O ring from the opposite end of the plunger 8 Remove plug and O ring from the top of the valve body next to the detent plug 9 Remove detent plug and O ring from the valve body Remove disc spring and detent plunger from the body Inspection 1 Inspect spools and spool bores for wear If wear is excessive replace valve with new one 2 Inspect springs and replace as necessary 3 Inspect plunger detent plunger and check poppet for wear Replace as necessary 4 Inspect seat spacer and bushing for wear Replace as necessary 5 Inspect disc and washer Replace as necessary 6 Inspect cap and plugs for damaged threads and in spect O ring sealing surfaces Replace as necessary Assembly IMPORTANT Do not wipe parts with dry paper tow els or rags Lint may cause damage to the hydraulic system Hydraulic System Rev G Page 4 98 A CAUTION Use eye p
64. Shut off engine 10 Disconnect tester from manifold and hose Recon nect hydraulic hose that was disconnected for test pro cedure Figure 64 1 Hydraulic deck motor 3 Relief valve 2 Inlet hose Groundsmaster 3500 D Page 4 47 Hydraulic System Rev G Logic Counterbalance Valve LC1 Pressure Test D1 lt FROM DECK MOTOR CASE DRAINS gt TO LEFT FRONT DECK MOTOR FROM REAR DECK MOTOR TO HYDRAULIC TANK T2 1500 psi HYDRAULIC MANIFOLD BLOCK R1 3200 psi TO OIL KS COOLER FROM FRONT LIFT CYLINDER FROM REAR LIFT CYLINDER ST TO HYDROSTAT a CHARGE CIRCUIT P1 ENGINE RPM la N gt FROM HYDROSTAT INTERNAL CASE DRAIN GEAR PUMP FROM OILFILTER Ss Y STRAINER Hydraulic System Rev G Page 4 48 LVI gp FROM LIFT VALVE OUT PORT TO STEERING CONTROL VALVE IN PORT FROM STEERING CONTROL VALVE OUT PORT High Pressure Low Pressure Return or Suction gt Flow Groundsmaster 3500 D Procedure for Logic Counterbalance Valve LC1 Pressure Test NOTE Ifthe counterbalance system is functioning the machine should normally settle slightly when the engine is started 1 Make sure hydraulic oil is at normal operating tem perature by operati
65. UNF 80 10 ft Ib Grade 5 88 14 N m 108 14 N m M12 X 1 25 Class 8 8 M12 X 1 5 80 10 ft Ib Class 8 8 For steel wheels and non lubricated fasteners 80 10 ft lb 108 14 N m 108 14 N m Thread Cutting Screws Zinc Plated Steel Baseline Torque Type A Type B 85 15 in Ib Hole size material strength material thickness 4 fin ish must be considered when determining specific torque values All torque values are based on non lubri cated fasteners 0 5 in 16 7in N cm X 0 08851 in Ib N m X 0 7376 ft lb Groundsmaster 3500 D Lubrication Traction Unit Before servicing or making adjustments to the machine stop engine lower cutting units set parking brake and remove key from the ignition switch Product Records o T E E o E cs E o The traction unit has grease fittings that must be lubri Figure 1 cated regularly with No 2 General Purpose Lithium Base Grease If machine is operated under normal conditions lubricate bearings and bushings after every 50 hours of operation Bearings and bushings must be lubricated daily when operating conditions are extreme ly dusty and dirty Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings resulting in accelerated wear Lubricate bearings and bushings immediately after every washing regardless of the interval listed The traction unit bearings and bushings tha
66. and the engine OFF Make sure all electrically operated control valves are actuated Return ignition switch to OFF when pressure has been relieved Remove key from the ignition switch 3 Put caps or plugs on any hydraulic lines hydraulic fit tings and components left open or exposed to prevent contamination 4 Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed 5 Note the position of hydraulic fittings especially el bow fittings on hydraulic components before removal Mark parts if necessary to make sure they will be aligned properly when reinstalling hydraulic hoses and tubes Hydraulic System Rev G Page 4 58 After Repair or Replacement of Components 1 Check oil level in the hydraulic reservoir and add cor rect oil if necessary Drain and refill hydraulic system reservoir and change oil filter if component failure was severe or system is contaminated see Flush Hydraulic System 2 Lubricate O rings and seals with clean hydraulic oil before installing hydraulic components 3 Make sure caps or plugs are removed from the hy draulic tubes hydraulic fittings and components before reconnecting 4 Use proper tightening methods when installing hy draulic hoses and fittings see Hydraulic Fitting Installa tion 5 After repairs check control linkages or cables for proper adjustment binding or broken parts 6 After disconnecting or replacing
67. any Groundsmaster 3500 D 14 If retaining ring and seal exist in front plate remove them from the front plate Make sure to not damage the front plate counter bore when removing components 15 Discard all removed seals and gaskets Inspection Fig 109 1 Remove all nicks and burrs from all pump parts with emery cloth Groundsmaster 3500 D Page 4 109 A CAUTION Use eye protection such as goggles when using compressed air 2 Clean all parts with solvent Dry all parts with com pressed air 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 B Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas Scoring rough surfaces or wear on gear shafts indi cates need for replacement C Gear teeth should be free of excessive scoring and wear Any broken or nicked gear teeth must be replaced D Inspect gear face edge for sharpness Sharp edges of gears will mill into wear plates and thus must be replaced Figure 111 3 Gear teeth 1 Gear shaft spline 2 Gear shaft 4 Gear face edge 4 Inspect gear bodies for excessive scoring gouges or wear Evidence of damage indicates need for compo nent replacement Hydraulic System Rev G 2 ER GO a Y UO LR gt on lt 5 Inspect wear plates for the following A Bearing areas should not have excessive
68. any hydraulic com ponents operate machine functions slowly until air is out of system see Charge Hydraulic System 7 Check for hydraulic oil leaks Shut off engine and cor rect leaks if necessary Check oil level in hydraulic reser voir and add correct oil if necessary Groundsmaster 3500 D Change Hydraulic Fluid Change hydraulic fluid after every 400 operating hours or yearly under normal conditions If fluid becomes con taminated 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 cut ting 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 Disconnect suction hose and let hydraulic fluid flow into drain pan Reinstall hose when hydraulic fluid stops draining 3 Fill hydraulic tank with approximately 6 gallons 22 6 liters of hydraulic fluid Refer to Check Hydraulic Fluid IMPORTANT Use only hydraulic fluids specified Other fluids could cause system damage 4 Install hydraulic tank cap Start engine and use all hy draulic controls to distribute hydraulic fluid throughout the system Also check for leaks then stop the engine 5 Check level of hydraulic fluid and add enough fluid to raise level to FULL mark on dipstick DO NOT OVER FILL Fig
69. brake and remove key from the ignition switch Unlatch and raise hood 2 Remove fuel from the tank into a suitable container Crossover fuel hose removal may assist to drain tank completely 3 Remove seat and seat support straps from the frame Note location of spacers under front of seat sup port straps Disconnect seat switch from the electrical harness Fig 14 4 Remove fuel hose strap and both fuel hoses from the fuel tank Pull tank from the machine Fig 14 Drain and Clean Fuel Tank Drain and clean the fuel tank every 2 years Also drain and clean the fuel tank if the fuel system becomes con taminated or if the machine is to be stored for an ex tended period 1 Remove fuel tank from the machine see Fuel Tank Removal 2 Flush fuel tank out with clean diesel fuel Make sure tank is free of contaminates and debris 3 Install fuel tank to the machine see Fuel Tank Instal lation Groundsmaster 3500 D Page 3 11 Fuel Tank Installation Fig 13 1 Position fuel tank to the machine 2 Connect both fuel hoses to the tank and secure with hose clamps and fuel hose strap 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 5 Fill fuel tank
70. brass The specific torque value should be determined based Groundsmaster 3500 D Class 8 8 Bolts Screws and Studs with Page 2 5 Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 225 20 N m 229 22 ft lb 310 30 N m 450 37 tb JL 610 50N m on the fastener size the aluminum or base material strength length of thread engagement etc Note The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 10 ofthe nominal torque value Product Records and Maintenance Product Records o OO E o E cs E o Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size 1 4 20 UNC 140 20 in Ib 73 12 in Ib 215 35 in Ib 145 20 in lb 5 16 18 UNC 3 8 16 UNC 35 10 ft lb 18 3 ft lb 50 10 ft lb 1 2 13 UNC 75 15 ft lb Thread Cutting Screws Zinc Plated Steel Type 1 Type 23 or Type F Thread Size Baseline Torque No 6 32 UNC 20 5 in Ib No 8 32 UNC 30 5 in Ib No 10 24 UNC 38 7 in Ib 1 4 20 UNC 85 15 in Ib 5 16 18 UNC 110 20 in Ib 3 8 16 UNC 200 100 in Ib Conversion Factors in Ib X 11 2985 N cm ft Ib X 1 3558 N m Product Records and Maintenance Page 2 6 Wheel Bolts and Lug Nuts Thread Size Recommended Torque 7 16 20 UNF 65 10 ft lb Grade 5 1 2 20
71. cell specific gravity is 0 050 or greater or the lowest cell specific gravity is less than 1 225 charge the bat tery Charge at the recommended rate and time giv en in Charging or until all cells specific gravity is 1 225 or greater with the difference in specific gravity between the highest and lowest cell less than 0 050 If these charging conditions can not be met replace the battery 3 Perform a high discharge test with an adjustable load tester This is one of the most reliable means of testing a battery as it simulates the cold cranking test A commercial bat tery load tester is required to perform this test A CAUTION Follow the manufacturer s instructions when us ing a battery tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 4 VDC recharge the battery B Ifthe battery has been charged apply a 150 amp load for 15 seconds to remove the surface charge Use a battery load tester following the manufactur er s instructions C Make sure battery terminals are free of corrosion Electrical System Rev G Page 5 26 D Measure the temperature of the center cell E Connect a battery load tester to the battery termi nals following the manufacturer s instructions Connect a digital multimeter to the battery terminals F Apply a test load of one half the Cranking Perfor mance see Battery Specifications rating of the bat te
72. connector to the fuel stop sole noid 9 Bleed fuel system Groundsmaster 3500 D Page 5 19 Figure 29 3 Fuel filter 4 Fuel stop solenoid 1 Fuel pump 2 Fuel hose discharge Fuel Pump Specifications Pump Capacity 23 5 fl oz min ml min Max Current 0 9 amp Draw Note Fuel pump specifications for machines equipped with a Biodiesel Conversion Kit are as follows Pump Capacity Pressure 64 fl oz min 1 9 liters min 7 PSI 48 3 kPa Electrical System Rev G o o E DI E o N gt n 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 injec tion pump 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 ener gized and the pull coil retracts the solenoid plunger Once the plunger is retracted the hold coil will keep it re tracted for continued engine operation When the sole noid is de energized the plunger extends to shut off fuel supply to the engine causing the engine to stop running The fuel stop solenoid is grounded through the common black wire of the solenoid wire connector NOTE Refer to Chapter 8 Electrical Diagrams when troubleshooting the fuel stop solenoid Testing NOTE Prior to taking small resistance readings witha
73. cylinders This counterbalance pressure transfers cut ting unit weight to the machine to improve traction Hydraulic System Rev G 2 SE D I a 0 cs gt 2 I ANIWA SNIH33IS H3MOd H gt KAY pi ISd 0001 13 I I H3NIVHIS NIVHGO 3SVO TWNHALNI A 1 Ee IWLSOHGAH SES IS e Zd ld S Ax gt Te UI Yea 1 W I 3UNSSIYAADVE ed osz as t 7 Li q 3 WAUuUsawiwadis L3n wej NI w oe des o ENER me cios E EC A rf ur 1S SH ME Y L Lr3 wei i z9 g d I i 431009 gt mk d P isd 000 191 Il Yo i Y3ANIMIAIS li tr Np 2 H L I li isd 002 l1HOd l1HOd iH u3ddn INVA H3MO1 I p 19078 ssvd 18 I ES GIOJINVIA HH SK 19 i fa ei T
74. for neutral see Adjust Traction Drive for Neutral Hydraulic System Rev G e SE O a z N cs gt gt N Piston Pump Service 1 Key 2 Drive shaft 3 Bearing 4 Cap screw 3 used per plate 5 Cover plate 6 O ring 7 Shim 8 Bearing cone 9 Key 10 Cam plate 11 Rotating kit 12 Gasket 13 Cam plate 14 Bearing 15 Dowel pin 16 Back plate Figure O ring 107 Plug Spring Seat Bypass valve Cap screw Cap screw Shaft seal Cover plate Washer 3 used per plate Relief valve Coupler Housing Retaining ring Thrust washer Thrust bearing NOTE For repair of the piston pump see the Eaton Medium Duty Piston Pump Repair Information Model 70160 Variable Displacement Piston Pump atthe end of this chapter IMPORTANT If a piston pump failure occurred re fer to Traction Circuit Closed Loop Component Failure in the General Information section for infor mation regarding the importance of removing con tamination from the traction circuit Hydraulic System Rev G Page 4 104 Washer Shaft seal Retaining ring Retaining ring Cam plate insert Retaining ring Washer Charge relief spring Charge relief poppet Charge relief housing O ring Cartridge O ring Bleed off spring Bleed off valve poppet Bearing cup Groundsmaster 3500 D ie SE O a z N UO LR gt N This page is int
75. from the front plate 9 Remove and discard back up gaskets and pressure seals from wear plates 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 11 Remove and discard shaft seal from the front plate Inspection 1 Remove any nicks and burrs from all parts with emery cloth A CAUTION Use eye protection such as goggles when using compressed air 2 Clean all parts with solvent Dry all parts with com pressed air 3 Inspect drive gears and idler gears for the following Fig 88 A Drive gear shaft spline should be free of twisted or broken teeth B Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas Scoring rough surfaces or wear on gear shafts indi cates need for replacement C Gear teeth should be free of excessive scoring and wear Any broken or nicked gear teeth must be replaced D Inspect gear face edge for sharpness Sharp edges of gears will mill into wear plates and thus must be replaced 4 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 Groundsmaster 3500 D Page 4 79 C Thickness of wear plates should be equal 5 Inspect fr
76. hose 19 Cutting deck 6 Hydraulic adapter 13 O ring 20 O ring 7 Hydraulic hose 14 O ring Hydraulic System Rev G Page 4 76 Groundsmaster 3500 D Removal Fig 84 Note Note position of hydraulic hoses when remov ing from the rotary motors Proper positioning is critical when reconnecting hydraulic hoses The inlet to the mo tor is opposite from the relief valve Fig 85 1 Remove two cap screws that secure hydraulic motor to the cutting unit Fig 85 Remove hydraulic motor from deck and O ring from top of spindle housing 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 1 If hydraulic fittings were removed from motor install fittings to motor using marks made during the removal process to properly orientate fittings 2 Position O ring to top of spindle housing Install hy draulic motor to the cutting unit with two cap screws 3 Install hydraulic hoses to rotary motors using Figure 84 as a guide 4 Make sure hydraulic tank is full Add correct oil if nec essary see Check Hydraulic System Fluid Figure 85 1 Hydraulic deck motor 3 Relief valve 2 Inlet hose 4 Cap screw 2 E Been cs E lt Groundsmaster 3500 D Page 4 77 Hydraulic System Rev G Rotary Cutting Motor Service Haldex 38 to 43 ft Ib 51 to 58 N m
77. hydraulic cylin der shaft clevis when removing the right front lift arm 3 Disconnect hydraulic cylinder from the front lift arms by removing external retaining rings and pins Figure 18 4 Remove both flange head screws and carrier stop cm pin ETEA 5 Aa point decal E utting unit pivot sna ap screw bracket from the lift arm pivot shafts 4 Carrler frame 8 Frame bushing 4 Thrust washer 9 Lift arm bushing 5 Slide lift arm off the pivot shaft 5 Lift arm LH shown 10 Grease fitting 6 Disassemble lift arm as necessary using Figure 17 as a guide Installation 1 Assemble lift arm using Figure 17 as a guide 2 Slide lift arm onto the lift arm pivot shaft 3 Secure carrier stop bracket with both flange head screws to the lift arm pivot shafts NOTE Install both spacers to the hydraulic cylinder shaft clevis when installing the right front lift arm Figure 19 Hydraulic hoses 3 Clearance Hydraulic cylinder 4 Secure hydraulic cylinder to the lift arm with pins and external retaining rings Na 5 Route hydraulic hoses so they clear the lift arm by 0 040 to 0 120 inch 1 0 to 3 0 mm when the lift arm is fully raised Fig 19 ao 2 7 52 m e nO o oc 6 Adjust lift arms to proper clearance see Adjust Front Lift Arms 7 Install cutting unit to the front lift arm pivot shaft see Cutting Unit Installation 8 Grease front lift arms see Lubrication in Chapter 2 Produc
78. hydraulic cylinder clevis IMPORTANT Use a protective covering around the hydraulic cylinder rod when rotating the rod to pre vent damage to the rod C Grasp cylinder rod near the jam nut and rotate the rod D Raise cutting units and check clearance Repeat steps A through C as necessary Tighten jam nut on hydraulic cylinder rod when clearance is correct NOTE If rear lift arm makes clunking noises during transport the clearance can be reduced IMPORTANT The lack of clearance at the rear wear bar can damage the rear lift arm 1 Wear bar n A s LI 1 Groundsmaster 3500 D Page 6 7 lt SEI h H y Figure 8 2 Bumper strap Figure 9 Rear hydraulic cylinder 2 Jam nut Rev G Wheels Brakes and Chassis Service and Repairs Standard Seat Figure 9 1 Seat incl 4 thru 7 14 amp 15 7 Seat shell 13 Seat adjuster 2 Cap screw 8 Seat belt 14 Cap screw 3 Spring lock washer 9 Seat adjuster with latch 15 Seat switch 4 Edging clip 10 Flange hex nut 16 Hex flange head screw 5 Edging 11 Cap screw 17 Seat support strap 6 Seat cushion 12 Lock washer 18 Hex flange head screw Removal Installation 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove four hex flange head screws securing the seat support straps to the frame Note location of spacers under front of seat
79. hydrostat pump Fig 35 and rotate it 90 to open the by pass valve This open position should be horizontal Fig 36 IMPORTANT Do not tow the machine faster than 2 to 3 mph because the drive system may be damaged If machine must be moved a considerable distance more than a few feet transport it on a truck or trailer Figure 35 1 Hydrostat 2 By pass valve 2 Slowly tow machine ES Ee YA 3 Before starting engine close by pass valve by rotat ing it 90 This closed position should be vertical Fig 36 Do not start engine when by pass valve is open Oo O LN Ss Figure 36 1 Valve closed position 2 Valve open position Groundsmaster 3500 D Page 4 3 Hydraulic System Rev G 2 L cs gt lt E o N gt 77 Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather sun chemicals very warm storage condi tions or mishandling during operation and maintenance These conditions can cause hose damage and deterio ration Some hoses are more susceptible to these conditions than others Inspect all machine hydraulic hoses frequently for signs of deterioration or damage Hard cracked cut abraded charred leaking or otherwise damaged hose Kinked crushed flattened or twisted hose Blistered soft degraded or loose hose cover Cracked damaged or badly corroded hose fittings When replacing a
80. negative battery post NOTE This test provides a relative condition of the bat tery Load testing of the battery will provide additional and more accurate information Charging System Test This is a simple test used to determine if a charging sys tem is functioning It will tell you if the charging system has an output but not its capacity Tool required Digital multimeter set to DC volts Test instructions Connect the positive multimeter lead to the positive battery post and the negative multimeter lead to the negative battery post Keep the test leads connected to the battery posts and record the battery voltage NOTE Upon starting the engine the battery voltage will drop and then should increase once the engine is running NOTE Depending upon the condition of the battery charge and battery temperature the charging system voltage will increase at different rates as the battery charges Glow Plug System Test This is a fast simple test that can help to determine the integrity and operation of the Groundsmaster 3500 D glow plug system The test should be run anytime hard starting cold engine is encountered on a diesel engine equipped with a glow plug system Tool s required Digital multimeter and or inductive Ammeter AC DC Current Transducer Test instructions Properly connect the ammeter to the digital multimeter refer to manufacturers instructions Groundsmaster 3500 D Page5 7 Volt
81. of wheel motors Hydraulic Hose Kit Toro Part Number TOR6007 This kit includes hydraulic fittings and hoses needed to connect high flow hydraulic filter kit TOR6011 to ma chine hydraulic traction system components Hydraulic System Rev G Page 4 26 Figure 49 Figure 50 Figure 51 Groundsmaster 3500 D High Flow Hydraulic Filter Kit Toro Part Number TOR6011 The high flow hydraulic filter kit is designed with large flow 40 GPM 150 LPM and high pressure 5000 PSI 345 bar capabilities This kit provides for bi direc tional filtration which prevents filtered debris from being allowed back into the circuit regardless of flow direction If a component failure occurs in the closed loop traction circuit contamination from the failed part will remain in the circuit until removed When connecting hydraulic test gauges in order to test traction circuit components or after replacing a failed traction circuit component e g piston pump or wheel motor the high flow hydraulic fil ter can be installed in the traction circuit The filter will ensure that contaminates are removed from the closed Figure 52 loop and thus do not cause additional component dam age NOTE This kit does not include hydraulic hoses see Hydraulic Hose Kit TOR6007 above 2g 5 5 S 2O NOTE Replacement filter element is Toro part number TOR6012 Filter element cannister tightening torque is 25 ft Ib 34 N m
82. ofthe motor and rotate the drive shaft away from the inlet one revolution If any binding is noted disassemble the pump and check for assembly problems Hydraulic System Rev G Page 4 80 Relief Valve Service IMPORTANT Do not remove the relief valve as sembly unless testing shows it to be faulty The re lief valve assembly must be replaced as a complete unit 1 When removing or installing the relief valve motor should be removed from deck and positioned horizon tally with the relief valve pointed down Fig 89 This process will prevent relief valve from falling into motor passages 2 Remove plug O ring spring and relief valve from the backplate Do not attempt to remove the seat from the back plate 3 Clean and inspect removed parts Visually inspect relief valve bore and seat in the back plate 4 Apply hydraulic oil to components Replace the relief valve assembly install relief valve spring O ring and plug into the backplate Tighten plug RELIEF VALVE KIT Figure 89 Groundsmaster 3500 D ie SE O a z N UO LR gt N This page is intentionally blank Groundsmaster 3500 D Page 4 81 Hydraulic System Rev G Rotary Cutting Motor Service Casappa Figure 90 1 Socket head screw 4 used 8 Rear wear plate 2 Washer 4 used 9 O ring 3 Back plate 10 Dowel pin 4 used 4 Anti cavitation valve 11 Body 5 Relief valve 12 Idler gear 6 Pressure seal 13 Drive gear 7
83. operation for lowering the cutting units is similar to raising them However pressure is relieved from the lift cylinders and this action allows them to lower During conditions of not lifting or lowering cutting units flow from the gear pump is by passed through the pow er steering valve 2 spool lift sidewinder valve and hy draulic manifold directly to the hydrostat and the charge relief valve Flow then returns to gear pump P1 inlet 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 This shifting of the pilot valve allows hydraulic pressure to relieve from Groundsmaster 3500 D Page 4 19 the cap end of the lift cylinders Flow from the cap end of the lift cylinders causes the cutting units to lower At the same time the fluid relieved from the cap end ofthe lift cylinders goes into the rod end of the cylinders and back through the hydraulic manifold to the hydrostat When the cutting unit shift lever is released spring ac tion 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 un til the lift control valve is moved to the raise position The logic cartridge valve LC1 in the manifold block maintains 250 PSI 17 2 bar back pressure on the lift
84. out contamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves Use compressed air for cleaning IMPORTANT Use care when handling the cartridge valve Slight bending or distortion of the stem tube can cause binding and malfunction 7 Reinstall the SRV cartridge valve A Lubricate new O rings of seal kit with clean hy draulic oil and install The O rings must be arranged properly on the cartridge valve for proper operation and sealing Fig 94 B Thread valve carefully into port R1 The valve should go in easily without binding C Torque cartridge valve using a deep socket from 30 to 35 ft Ib 41 to 47 N m D Install solenoid coil to the cartridge valve Apply Loctite 242 or equivalent to the threads of the valve Torque nut from 4 to 6 ft Ib 5 to 8 N m 8 If problems still exist remove valve and clean again or replace valve Figure 93 Manifold assembly 3 Braking valve BV 2 SRV cartridge valve R1 4 Logic valve LC1 ch 2 5 Been cs gt lt Figure 94 1 SRV cartridge valve 4 Seal kit backup rings 2 Solenoid coil 5 Solenoid nut 3 Seal kit O rings Groundsmaster 3500 D Page 4 87 Hydraulic System Rev G Braking and Logic Cartridge Valves Fig 92 and 93 1 Make sure manifold is clean before removing the cartridge IMPORTANT Use care when handling the cartridge valve Slight bending or distortion of the s
85. pipe may be hot To avoid possible burns allow the engine and ex haust system to cool before working on the muf fler 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Open engine hood to gain access to engine 3 Remove exhaust guard from frame if equipped 4 Remove both flange head nuts and screws securing the muffler plate to the muffler bracket Fig 12 5 Remove four hex nuts and lock washers from the ex haust manifold studs Separate muffler flange from the exhaust manifold Remove muffler from the machine 6 Remove exhaust gasket Replace gasket if dam aged or torn Muffler Installation Fig 11 Note Make sure muffler flange and exhaust manifold sealing surfaces are free of debris or damage that may prevent a tight seal 1 Place exhaust gasket on the exhaust manifold IMPORTANT Finger tighten all fasteners before se curing the muffler plate to the muffler bracket so there is no preload on the exhaust manifold 2 Position muffler flange to the exhaust manifold with four lock washers and hex nuts 3 Position muffler plate to the muffler bracket with both flange head screws and nuts Fig 12 4 Tighten muffler flange hex nuts and then muffler plate screws and nuts 5 Install exhaust guard to frame if equipped 6 Close and latch engine hood Groundsmaster 3500 D Page 3 9 Figure 12 3 M
86. pressure gauge carefully while slowly closing the flow control valve until 2000 PSI is obtained Do not close tester load valve fully Verify with a phototac that the pump speed is 3100 RPM while maintaining 2000 PSI 9 Flow indication should be 11 8 GPM minimum 10 Shut off engine 11 Disconnect tester from gear pump fitting and hose Reconnect hose to the pump 12 If flow was less than 11 8 GPM or a pressure of 2000 PSI cannot be obtained check for restriction in the pump intake line If line is not restricted remove gear pump P1 and repair or replace as necessary Groundsmaster 3500 D Page 4 45 Hydraulic System Rev G Manifold Relief Valve R1 Pressure Test FROM DECK MOTOR CASE DRAINS TO LEFT FRONT DECK MOTOR lt lt FROM REAR DECK MOTOR TO HYDRAULIC TANK T2 1500 psi HYDRAULIC MANIFOLD BLOCK R1 3200 psi COOLER FROM FRONT LIFT 4h CYLINDER FROM REAR LIFT CYLINDER Lv FROM LIFT VALVE TO HYDROSTAT A Ee CHARGE CIRCUIT OUT PORT TO STEERING CONTROL VALVE IN PORT ENGINE FROM STEERING CONTROL VALVE OUT PORT i GEAR PUMP High Pressure FROM HYDROSTAT gt INTERNAL CASE DRAIN Dee Low Pressure Return or Suction FROM OIL FILTER gt 4 STRAINER Flow Hydraulic System Rev G Page 4 46 Groundsmaster 3500 D
87. readings Electrical System Rev G o o E DI E o N gt n Solenoid Valve Coil The solenoid valve coil on the hydraulic control manifold Fig 39 can be replaced without opening the hydraulic system Removal 1 Park machine on a level surface lower cutting decks engage parking brake stop engine and remove key from the ignition switch 2 Disconnect the wire harness electrical connector from the solenoid valve coil 3 Remove the nut from the spool assembly 4 Slide the coil assembly from the solenoid valve stem Discard the coil 5 Clean any corrosion or dirt from the valve stem Installation 1 Slide new coil assembly onto the solenoid valve stem 2 Install the nut onto the spool assembly and torque nut 60 in lb 6 8 N m do not over tighten 3 Connectthe wire harness electrical connector to the solenoid valve coil 1 Hydraulic manifold 2 Solenoid valve R1 Electrical System Rev G Page 5 28 Figure 39 3 Solenoid valve coil 4 Nut Groundsmaster 3500 D Table of Contents SPECIFICATIONS SPECIAL TOOLS aa EA ADJUSTMENTS Adjust Brake Lever Adjust Brakes Adjust Front LiftArms Adjust Front Lift Arm Carrier Stop Bracket Assembly 45 nos aa io ie KIA Adjust Rear Lift Arm SERV
88. rear lift arm see Lubrication in Chapter 2 Product Records and Maintenance Wheels Brakes and Chassis om o E n LU E E o o 2 o P oe 5 3 c Sidewinder Carrier 67 to 83 ft Ib 91 to 113 Nm Figure 21 1 Lower frame 6 Flange nut 10 Bearing cap 2 Sidewinder carrier assembly 7 Cap screw 11 Lock nut 3 Slide bracket 8 Thrust washer 12 Liftarm RH shown 4 Plastic slide 9 Slide support bar 13 Liftarm pivot shaft 5 Flange head screw Disassembly Assembly 1 Park machine on a level surface lower cutting units 1 Assemble sidewinder carrier using Figures 21 as stop engine engage parking brake and remove key guide from the ignition switch A Donotlubricate sidewinder crosstube as bearing 2 Disassemble sidewinder carrier as needed using caps and slides are self lubricating Figures 17 20 and 21 as guides B Tighten the bearing cap screws from 67 to 83 ft lb 91 to 113 Nm 2 Use Figures 17 and 20 to complete the assembly process see Front Lift Arms and Rear Lift Arm Wheels Brakes and Chassis Page 6 22 Groundsmaster 3500 D Hood Removal Figure 22 1 Flange screw 7 Flat washer 2 Trim seal 8 Flex draw latch 3 Locknut 9 Rivet 4 Hood screen 10 Pop rivet 5 Hood 11 Washer 6 Pivot bracket 12 Hair pin 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch
89. see Cutting Blade Removal and Installation 6 Remove cap screws and flange nuts securing spindle housing to deck Slide spindle housing assem bly out the bottom of the deck Remove spindle plate from top of deck 7 Loosen and remove spindle nut from top of spindle shaft 8 Press the spindle shaft out of the spindle housing us ing an arbor press The shaft spacer remains on the spindle shaft as the shaft is being removed 9 Remove seals from spindle housing 10 Allow the bearings inside spacer and spacer ring to fall out of the spindle housing 11 Using a punch and hammer drive both of the bearing cups out of the spindle housing Also drive the large spacer out of the housing 12 The large snap ring should remain inside the spindle housing because it is difficult to remove 1 DAIAPRPNA Cap screw Figure 26 2 Hydraulic motor ge AE 131 to 159 ft Ib 178 to 216 N m Spindle housing Spindle plug Spindle shaft Oil seal Shaft spacer Spindle nut Cutting Units Rev D Page7 18 Rev E Figure 27 7 Grease fitting 8 Bearing 9 Spacer ring 10 Spacer set 2 piece 11 Bearing 12 Large snap ring Groundsmaster 3500 D Assembly IMPORTANT If new bearings will be installed into a used spindle housing that has the original large snap ring installed discard the snap ring that came with the new bearings because it is not necessary to replace the original snap ring However
90. shaft 5 Remove Uni ring and O ring from the piston Re move O ring back up ring rod seal and dust seal from the head Assembly 1 Make sure all parts are clean before assembly 2 Coat new O rings Uni ring rod seal back up ring and dust seal with with clean hydraulic oil A Install Uni ring and O ring to the piston B Install rod seal O ring back up ring and dust seal to the head Groundsmaster 3500 D Page 4 125 IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surface before mount ing in a vice 3 Mount shaft securely in a vise by clamping on the cle vis of the shaft A Coat shaft with with clean hydraulic oil B Slide head onto the shaft Install rod seal onto shaft and into head C Install piston and nut onto the shaft Torque nut from 24 to 30 ft Ib 33 to 41 N m D Remove shaft from the vise IMPORTANT Prevent damage when clamping the hydraulic cylinder into a vise clamp on the clevis only 4 Mount barrel in a vice 5 Coat all internal parts with a light coat of clean hy draulic oil Slide piston shaft and head assembly into the barrel being careful not to damage the seals 6 Secure head in the barrel with internal collar using a spanner wrench Tighten collar until snug and the outer end of the collar is flush with end of the barrel 7 Ifclevis was removed from cylinder shaft fully retract cylinder shaft and thread jam nut and cle
91. switch to dis engage return key switch to OFF and remove key from the ignition switch NOTE Moving steering wheel with engine off may un seat implement relief valve If steering or lift circuits ap pear weak or inoperative after machine is returned to service repeat relieving hydraulic system pressure pro cedure Traction Circuit Closed Loop Component Failure The Groundsmaster 3500 D traction circuit is a closed loop system that includes the hydrostat and two 2 wheel motors If a component in the traction circuit should fail debris and contamination from the failed component will circulate throughout the traction circuit This contamination can damage other components in the circuit so it must be removed to prevent additional component failure If a component failure occurs in the traction circuit it is critical that the entire traction circuit be disassembled drained and thoroughly cleaned to ensure that all con tamination is removed from the circuit If any debris re mains in the traction circuit and the machine is operated the debris can cause additional component failure An additional step for removing all traction circuit con tamination would be to temporarily install a high pres sure hydraulic oil filter see Special Tools into the circuit The filter could be used when connecting hydraulic test gauges in order to test traction circuit components or af ter replacing a failed traction circuit component e g h
92. the battery with a solution of baking soda and water then rinse it with clean water D Checkthatthe cover seal is not broken away Re place the battery if the seal is broken or leaking E Checkthe electrolyte level in each cell If the level is below the tops of the plates in any cell fill all cells with distilled water between the minimum and maxi mum fill lines Charge at 15 to 25 amps for 15 min utes to allow sufficient mixing of the electrolyte Electrical System Rev G Se 23 O V 25 DI 2 Conduct a hydrometer test of the battery electrolyte IMPORTANT Make sure the area around the cells is clean before opening the battery caps A Measure the specific gravity of each cell with a hydrometer Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm up the hydrometer At the same time take the tem perature of the cell B Temperature correct each cell reading For each 10 F 5 5 C above 80 F 26 7 C add 0 004 to the specific gravity reading For each 10 F 5 5 C be low 80 F 26 7 C subtract 0 004 from the specific gravity reading Example Cell Temperature 100 F Cell Gravity 1 245 100 F minus 80 F equals 20 F 37 7 C minus 26 7 C equals 11 0 C 20 F multiply by 0 004 10 F equals 0 008 11 C multiply by 0 004 5 5 C equals 0 008 ADD conversion above 0 008 Correction to 80 F 26 79C 1 253 C If the difference between the highest and lowest
93. the lower frame as closely to the side plate as possible Fig 1 2 Ifthe front tire is to be removed position the jack se curely under the front wheel motor 3 Use jack stands or hardwood blocks under the square tube or wheel motors to support the machine Jacking the Rear End 1 The preferred method for removing the rear fork the rear wheel or the rear wheel motor is to lift the rear end of the machine from above A Secure a chain fall or hoist to the rear casting Fig 2 B Chock both front tires Lift rear tire off the ground C Use jack stands or hardwood blocks under the frame to support the machine Fig 3 2 Ifthe rear of the machine cannot be lifted from above A Chock both front tires IMPORTANT Make sure jack is as close to the rear fork as possible when jacking the rear wheel B Place jack securely under the rear wheel motor as close to the fork as possible Fig 3 Jack rear tire off the ground C Use jack stands or blocks under the frame to sup port the machine Safety Page 1 4 Figure 1 1 Square tube 2 Side plate y Figure 2 1 Rear tire 2 Rear casting Figure 3 3 Rear fork 1 Frame 2 Rear wheel motor Groundsmaster 3500 D Chapter 2 Product Records and Maintenance Table of Contents FE 35 PRODUCT RECORDS ANNE 1 35 MAINTENANCE 4 ense ehe en 1 EE EQUIVALENTS AND CONVERSIONS 2 as Decimal and Millimeter Equivalents
94. ties open load valve completely in the hydraulic tester to minimize the possibility of damaging components 6 Install fittings finger tight and far enough to make sure that they are not cross threaded before tightening them with a wrench 7 Position tester hoses to prevent rotating machine parts from contacting and damaging the hoses or tester 8 Check oil level in the hydraulic tank After connecting test equipment make sure tank is full 9 Check control linkages for improper adjustment binding or broken parts 10 All hydraulic tests should be made with the hydraulic oil at normal operating temperature 11 If a traction circuit problem exists consider perform ing one or more of the following tests Traction Circuit Working Pressure Charge Relief Valve Pressure Pis ton Pump P3 Flow amp Traction Relief Pressure and or Wheel Motor Efficiency Tests 12 If a cutting circuit problem exists consider perform ing one or more of the following tests Cutting Deck Cir cuit Pressure Manifold Relief Valve R1 Pressure Logic Counterbalance Valve LC1 Pressure Gear Pump P1 Flow and or Deck Motor Efficiency Tests 13 If a steering or lift circuit problem exists consider per forming one or more ofthe following tests Steering and Lift Relief Pressure Gear Pump P2 Flow and or Steer ing Control Valve Tests Groundsmaster 3500 D ie SE O a z N UO LR gt N This page is intentionally blank Gro
95. with both flange head screws and flange nuts 6 Connect following hoses to the radiator A Upper radiator hose to the water pump B Lower radiator hose to the engine block C Coolant hose to the expansion tank D Air hose to the air cleaner 7 Secure glow plug relay to the radiator assembly with both thread forming screws 8 Make sure draincock valve is closed Fill radiator with coolant 9 Install engine hood to the machine Close and latch hood Clean Radiator and Oil Cooler Fig 16 The radiator and oil cooler should be checked for dirt and debris daily and hourly if conditions are extremely dusty and dirty 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch Groundsmaster 3500 D Page 3 If engine has been running the radiator may be hotand 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 4 Remove lower radiator shield Release wire form latch and allow oil cooler to pivot out Fig 17 5 Clean both sides of oil cooler and radiator area thor oughly with water or compressed air 6 Pivot oil cooler back and latch into position Install lower shield Close and latch hood Figure 16 1 Oil cooler 3 Wire form latch 2 Radiator Figure 17 1 Oil cooler pivoted out 3 Wire form latch 2
96. with the following safety instructions the turf condition and the rollover risk To determine which hills or slopes may be safely operated on use the inclinometer provided with each machine To perform a site survey lay a 4 foot long 2 by 4 inch piece of wood onthe slope surface and measurethe angle ofthe slope The piece of wood will average the slope but will nottake into consideration dips or holes THE MAXIMUM SIDE HILL ANGLE SHOULD NOT BE GREATER THAN 25 DEGREES chine Never allow children to operate the machine or adults to operate it without proper instructions 3 Become familiar with the controls and know how to stop the machine and engine quickly 4 Do not carry passengers on the machine Keep ev eryone especially children and pets away from the areas of operation Safety 5 Keep all shields safety devices and decals in place Repair or replace damaged malfunctioning or illegible shields safety devices or decals before operating the machine 6 Always wear substantial shoes Do not operate ma chine while wearing sandals tennis shoes or sneakers Do not wear loose fitting clothing because it could get caught in moving parts and possibly cause personal in jury 7 Wearing safety glasses safety shoes long pants and ahelmetis advisable and required by some local or dinances and insurance regulations 8 Make sure the work area is clear of objects which might be picked up and thrown by the b
97. 00 D Procedure for Piston Pump P3 Flow and Traction Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off 3 Read Precautions for Hydraulic Testing 4 Make sure that traction pedal is adjusted to the neu tral position see Adjust Traction Drive for Neutral in the Adjustments Section One front wheel and the rear wheel will be off the ground during testing Make sure machine is supported so it will not move and accidentally fall to prevent injuring anyone under machine 5 Block up one front traction wheel and the rear wheel off the floor to allow flow through the traction circuit dis connect brake linkage to the raised front wheel see Wheels and Brakes Chapter 7 6 Chock remaining front wheel to prevent movement of the machine 7 Attach a heavy chain to the rear ofthe machine frame and something immovable in the shop 8 Make sure parking brake is on 9 Disconnect hose from the lower hydraulic fitting on the engine side of the hydrostat Fig 54 10 Install tester in series with the pump and the discon nected hose Make sure the tester flow control valve is fully open 11 Start engine and move throttle to full speed 3050 50 RPM Use extreme caution when taking gauge read ings The fronttire on the gro
98. 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meiers 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance Page 2 2 Groundsmaster 3500 D Torque Specifications Recommended fastener torque values are listed in the following tables For critical applications as determined by Toro either the recommended torque or a torque that is unique to the application is clearly identified and spe cified in this Service Manual 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 Ser
99. 14 684 3 32 0 09375 2 881 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 6 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 040625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 16 0 4375 11 112 15 6 0 9375 23 812 29 64 0 463125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0
100. 4 24 Figure 44 Figure 45 Groundsmaster 3500 D Hydraulic Test Fitting Kit Toro Part Number TOR4079 Toro Test Fitting Kit es l TOR4079 ang Les This kit includes a variety of O ring Face Seal fittings to Fitting Tool Number aes enable the connection of test gauges into the system cas pe ES us T si Y Led The kit includes tee s unions reducers plugs caps pe i and male test fittings E ine wa Spe B e e je C T eT K CN Figure 46 Measuring Container Toro Part Number TOR4077 Use this graduated container for doing hydraulic motor efficiency testing motors with case drain lines only Measure efficiency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system 2 L 5 gt SE The table in Figure 48 provides gallons per minute GPM conversion for measured milliliter or ounce leak age Milliliters in 15 sec Figure 48 Groundsmaster 3500 D Page 4 25 Hydraulic System Rev G 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 connec tion is loosened Wheel Hub Puller Toro Part Number TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft
101. 6 5hrs 22 hrs 170 5 amps 5 amps 5 amps 5 amps 171 to 5 8hrs 11 5 hrs 17 3 hrs 23 hrs 250 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 250 10 amps 10 amps 10 amps 10 amps A CAUTION Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60 F 15 5 C before connecting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are explosive keep open flame and elec trical spark away from the battery Do not smoke Nausea may result if the gases are inhaled Un plug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts 3 Following the manufacturer s instructions con nect the charger cables to the battery Make sure a good connection is made 4 Charge the battery following the manufacturer s instructions 5 Occasionally check the temperature of the battery electrolyte If the temperature exceeds 125 F 51 69C or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 6 Three hours prior to the end of the charging mea sure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 003 change in specific gravity for three consecutive
102. 6 As necessary remove engine mounts front engine mounting bracket throttle support bracket and left en gine mounting bracket Installation 1 If removed install engine mounts front engine mounting bracket throttle support bracket and left en gine mounting bracket Also make sure that all switches and sensors are installed on engine 2 Install hydrostat and pump mount plate to the engine as follows Figs 25 and 26 A Secure right engine mounting bracket and hy drostat to the engine with four hardened washers and cap screws Note Do not install flat washer with cap screw near the torsion spring to prevent the spring from binding B Secure pump mount plate to the engine with five spacers four washers and five cap screws C Install traction belt to the engine flywheel and hy drostat pulleys see Replace Traction Belt 3 Connect hoist or lift to the front and rear engine lift tabs Fig 22 and 23 One person should operate lift or hoist while the other person guides the engine into the machine IMPORTANT Make sure not to damage the engine fuel and hydraulic lines electrical harness or other parts while installing the engine 4 Position engine slowly into the machine 5 Secure all three engine mounts to the engine mount ing brackets with cap screws washers and flange nuts 6 Secure wire harness to the front lift tab and the en gine with cable ties Kubota Diesel Engine Rev G Pag
103. A M m VIO 87a So s 15A INTERLOCK RELAY BK OR PK PK IGNITION NOTE ROTARY DECKS ON OFF SWITCH ON CONSOLE F2 SWITCH INCLUDES TERMINALS SHOWN IN TWO PLACES ON THIS BU e SCHEMATIC ROTARY DECKS ON OFF GER TERMINALS 5 AND 6 3 2 gt 5 E YY LIGHT F4 SA 5 6 NOT SUPPLIED Y PK o w BU o GN amp DECKS OFF TRANSPORT MOW ROTARY DECK BU PK DRIVE SOLENOID 30 R 87 GLOW PLUGS 3 OR pk 8 7T Y 86 STOP NONE ON PREHEAT B lzA X Y GLOW RELAY START B 1 S KUBOTA Ce Deeg LET BU GLOW PLUG CONTROLER PK on 1 4 VIO 2 5 a Groundsmaster 3500 D BK Electrical Schematic Serial Numbers 90101 to 230999999 All relays and solenoids are shown as de energized Page 8 3 Rev E R BK SES I GE OPTION 2 SEAT SWITCH ALTERNATOR RUN SOLENOID gt B np o ees ij A E FAM a H D i R HOLD 3 l a HOUR 6500 MFD R BK L e FEA S a METER OR GY PUL
104. D Procedure for Steering Control Valve Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Perform the Lift and Steering Control Valve Relief Pressure and Gear Pump P2 Flow tests to make sure that pump and relief valve are functioning correctly NOTE This steering test procedure will be affected by incorrect rear tire pressure binding in the hydraulic steering cylinder extra weight on the vehicle and or binding of the steering fork assembly Make sure that these items are checked before proceeding with any hy draulic testing procedure 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 move ment 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 The steering control valve should respond to each steering wheel movement B When steering wheel is released steering control should return to the neutral position with no addition al turning Groundsmaster 3500 D Page 4 55 5 If either of these performance tests indicate a steer ing problem determine if the steering cylinder is faulty using the follo
105. D moj lt uonong Jo umay eBrey amsselig w01 ainssalg YH un 14619 uno119 Duueee G 00S selsewpunoly Groundsmaster 3500 D Page 4 22 Hydraulic System Rev G Steering Circuit The gear pump P2 is directly coupled to the hydrostat It supplies hydraulic pressure to the power steering valve for turning the rear wheel and maintaining 100 to 150 PSI 6 9 to 10 0 Bar to the low pressure side of the traction circuit The pump takes its suction from the hy draulic reservoir With the steering wheel in the neutral position rear wheel positioned straight ahead the engine running and the spool valve in the center position flow enters the steering control valve at the IN port and goes through the spool valve by passing the rotary meter V1 and steer ing cylinder Flow leaves the control valve through the AUX port to the hydrostat to be available for the lift circuit and then to the hydrostat charge Right Turn When a right turn is made with the engine running the turning of the steering wheel positions the spool valve so that flow goes through the bottom of the spool Flow en tering the steering control valve at the IN port goes through the spool and is routed to two places First most of the flow through the valve is by passed out the AUX port back through the 2 spool valve to the hydrostat Second the remainder of the flow is drawn through the rotary meter V1 and out por
106. E o o oe 5 3 e Rear Fork and Wheel 250 to 350 ft Ib 339 to 474 N m 35 34 2533 2 45 to 65 ft Ib 61 to 88 N m 16 60 to 80 ft lb 94 81 to 108 N m Y 651085 ft lb ya 88 to 115 N m Y LN in o Figure 13 1 Hydraulic steering cylinder 14 Drive stud 27 Hex flange head screw 2 Ball joint 15 Wheel hub 28 Bushing 3 External retaining ring 16 Lock nut 29 Cap screw 4 Grease fitting 17 45 hydraulic fitting 30 Lock nut 5 Grease fitting plug 18 Hydraulic motor 31 O ring 6 Jamnut 19 Hydraulic hose 32 O ring 7 Rear fork 20 Hydraulic hose 33 O ring 8 Cap screw 21 Lug nut 34 O ring 9 Lock washer 22 Clamp 35 Hose assembly 10 Thrust washer 23 Spacer 36 Hose assembly 11 Tire 24 Clamp 37 Valve stem 12 Hex socket head screw 25 Hydraulic fitting 38 Wheel rim 13 Lock nut 26 Rear casting 39 Woodruff key Wheels Brakes and Chassis Page 6 12 Groundsmaster 3500 D Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove hood from the machine see Hood Remov al Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 3 Jack up rear wheel enough to allow the removal of the rear fork 4 Remove lug nuts from drive studs Remove tire and wheel rim from wheel hub 5 Separate hydraulic cylinder from
107. E OIL WARNING OVER TEMP REEL DRIVE SOL REEL UP PRESS SHUTDOWN LIMIT SW Groundsmaster 3500 D Harness Diagram Serial Numbers 240000001 to 313999999 PIT SEAT SW SEAT SW SERIAL NUMBERS FROM 240000001 TO 270999999 PARKING BRAKE 1 NC NEUTRAL SW BACKLAP Page 8 11 Rev G REEL P7 UP LIMIT SWITCH e SW ITCH JUMPER Ji LIGHT OPTIONAL A P18 TRANSPORT MOW Rech EDT Ph A SEAT SWITCH FUEL PUMP dh SERIAL NUMBERS ABOVE 280000000 p17 NEUTRAL SW ITCH P23 START SOLENOID B B ENGINE GROUND 7 9 P12 ALTERNATOR B REL ON OFF PS SEAT SWITCH SERIAL NUMBERS P15 FROM 240000001 REEL DRIVE SOL J21 FUEL SOLENOID L ee TO 270999999 TEMP SWITCH je BINA P22 y PB SHUTDOWN SC HOUR METER 2 E GLOW CONTROLLER 3 P34 E CLUSTER GAUGE BIR Hin P3 FR T ALTERNATOR A D D I 1
108. Engine Bore mm in 78 0 3 07 Stroke mm in 78 4 3 09 Total Displacement cc cu in 1123 68 53 Firing Order 1 2 3 Combustion Chamber Spherical Type Fuel No 2 Diesel Fuel ASTM D975 Fuel Capacity liters gallons 41 7 11 Fuel Injection Pump Bosch MD Type Mini Pump Governor Centrifugal Mechanical Low Idle no load 1400 50 RPM High Idle no load 3050 50 RPM Direction of Rotation Counterclockwise Viewed from Flywheel Injection Nozzles Mini Nozzle DNOPD Engine Oil See Traction Unit Operator s Manual for viscosity and API classification recommendations Oil Pump Gear Driven Trochoid Type Crankcase Oil Capacity liters U S qt 3 8 4 0 with Filter Starter 12 VDC 1 4 KW Alternator Regulator 12 VDC 40 AMP Dry Weight kilograms U S Ibs 98 0 215 0 Coolant Capacity liters U S qt 5 7 6 0 with 0 9 1 0 Reservoir Groundsmaster 3500 D Page 3 3 Kubota Diesel Engine Rev G o E 2 5 Ek GE 2 OH 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 2 Position throttle control lever all the way to the SLOW position so it stops against the control panel slot Fig 5 3 Loosen cap screw secu
109. Fig 1 3 Adjust travel of brake lever until a force of 30 to 40 Ibs 133 to 178 N is required to actuate lever A Turn adjustment knob clockwise to increase force B Turn adjustment knob counterclockwise to de crease force 4 Tighten set screw after adjustment has been at tained Di 2 o KK Sg m e nO o oc Groundsmaster 3500 D Page 6 3 Rev D Wheels Brakes and Chassis Adjust Brakes 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 Check brake adjustment as follows A Park machine on a level surface lower cutting units stop engine and remove key from the ignition switch B Rotate by pass valve on the piston pump 90 de grees to allow front wheels to turn freely Fig 2 Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety C Chock rear wheel Jack up both front wheels and support the machine with hardwood blocks D Apply the parking brake The force to actuate the brake lever should be from 30 to 40 Ibs 133 to 178 N E With the parking brake applied use a torque wrench on the wheel hub lock nut to identify the break away torque at each front wheel The mini mum break away torque with the parking applied should be 300 ft lb 407 N m If adjustment is necessary adjust brakes as follows A Remove both front wheel assemblies from the machi
110. ICE AND REPAIRS Standard Seat Groundsmaster 3500 D Chapter 6 Wheels Brakes and Chassis 2 Deluxe Seat ores wath ae t ca es ae 9 2 Front Wheel and Brake 10 3 Rear Fork and Wheel 12 3 Brake Lever Linkages 14 4 Steering Column 16 5 Front Lift Arms 0 0 e eee eee eee 18 Rear HAM iii ewe 20 6 Sidewinder Carrier 22 7 Hood Removal 23 8 8 Page 6 1 Rev G Wheels Brakes and Chassis ao 925 YN 52 a 20 out oc Ss 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 Page6 2 Rev E Groundsmaster 3500 D Adjustments Adjust Brake Lever Brake lever adjustment should be checked every 200 hours SE 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 Figure 1 2 Set screw 2 Loosen set screw on the adjustment knob
111. IMIT SW P18 TRANSPORT MOW 315 LIGHT OPTIONAL Ph SEAT SW J3 ENGINE GROUND P17 NEUTRAL SW P38 REEL ON OFF P2 RUN SOLENOID P15 REEL DRIVE SOL J6 OVERTEMP 43 W ARNING GLOW CONTROLLER P23 STARTER B P34 OT GLOW CLUSTER GAUGE P33 OIL ALT 313 LIGHT SW OPTIONAL J14 LIGHT OPTIONAL P14 IGNITION SW P20 STARTER M ST P 28 PARKING BACKLAP e oi BRAKE NC o GE O P19 START Groundsmaster 3500 D Harness Drawing Serial Numbers 314000001 and Up Page 8 14 Rev G
112. Inspect the spindle shaft to make sure it is free of burrs or nicks that could possibly damage the seals Also make sure that lubrication hole in shaft is clean Lubricate the shaft with grease 8 Install spindle spacer onto shaft Carefully slide spindle shaft through spindle housing The bottom seal and spindle spacer fit together when the spindle is installed fully 9 Thread spindle nut onto shaft and tighten nut from 131 to 159 ft lb 178 to 216 N m Groundsmaster 3500 D Page 7 19 Rev E IMPORTANT When greasing spindles grease passes into the center of the shaft and out to fill the bearing cavity of the housing If grease does not come out of lower seal when greasing check lu brication hole in spindle shaft for obstruction 10 Install spindle plug to top of spindle housing Attach a hand pump grease gun to either grease fitting and fill housing cavity with grease until grease starts to come out of lower seal NOTE Pneumatic grease guns can produce air pockets when filling large cavities 11 Install spindle housing and spindle plate to deck with cap screws and flange nuts Notches on housing and plate should be aligned to front of deck 12 Install cutting blade anti scalp cup and bolt see Cutting Blade Removal and Installation Tighten blade bolt from 85 to 110 ft lb 115 to 149 N m 13 Position O ring to top of spindle housing Install hy draulic motor to the cutting unit with two cap screws
113. L a OPTION 1 SHUTDOWN 10 SEAT SWITCH 110 C Bk UUJ D CLOSED WHEN OCCUPIED 85 99 y o R BK FK WARNING M T Y i 105 C E GY IER em E PARKING BRAKE 1 30 P LOWOILPRESS w i IN OFF POSITION T w y e i i EU SEAT RELAY BK H YA 5 rpg Ee Be Y OR WEE L A FQ om A ps i Kiss cB NEUTRAL RELAY 2 u 3 a S T NOT USED Start 1 T B Bi 4 A i 5 Oo Brey RNS i x ens SR ES E lt E mi m m 30 o fi ES d m i 87 C NO o o gt ENGINE n z m a CLOSED IN NEUTRAL roce BY Sr gt 310 f Ld GROUND z 3 6 oi A E 85 YY Y 86 gi PARKING BRAKE 2 BACKLAP EOM CAE E ls NEUTRAL SEENEN ZN Di ENGINE OR G e G VO V SWITCH D4 S i ke 1 2 ri 1 2 i es GROUND GAUGE d BK BATTERY CLUSTER 1 ROTARY DECKS ON OFF OR 1 4q 2 y TERMINALS 1 AND 2 de 86 M oe DECKS OFF D2 1 Y OR 5 4 F 5A 87 3 Lg 20 BB vio sra INTERLOCK RELAY BK F1 15A e OR PK P y D IGNITION NOTE ROTARY DECKS ON OFF SWITCH ON CONSOLE F2 SWITCH i 1 INCLUDES TERMINALS SHOWN IN TWO PLACES ON THIS BU gt Se I t ROTARY DECKS ON OFF SCHEMATIC ger Geesen TERMINALS 5 AND 6 Ee 0 LIGHT F4 5A n e MR NOT SUPPLIED L a y gt A PK w BU o GN B E DECKS OFF K TRANSPORT MOW ROTARY DECKS e DRIVE SOLENOID GLOW PLUGS 3 STOP NONE ON PREHEAT B I
114. M NOTIIVEL N poziDJouo op se uMOUS ale SPIOUAJOS Y 666666 1 01 L090000v2 sJequinwN jeues oneuiauos oineap H a 00S JeiseuispunoJc Groundsmaster 3500 D Page 4 10 Hydraulic System Rev G SNIH33IS YACNIMACdIS NIVHG 3SVO 1VNH3LNI FM Gi FATWA 9NIH33IS H3MOd T EG re H3NIVHIS ES EE S J ae P e lVISOHGAH CG isd 0001 t EE E E EQ x 4 LA me Y d E ca ed td NL 5 s d LJ isd 008 002 E dWNd HD Ee INVA WS Lan aunssaud Dol Ka a sd 081 001 a NI ova aS T does E ino 39 uo 1s ou ta E A 4
115. NE GROUND J3 P4 P32 P6 STARTER ALTERNATOR GLOW CONTROLER GLOW RELAY FUSE BLOCK SINGLE FUSE START G B R L B 30 85 87A 87 86 GLOW PLUGS FI zi F4 P35 Pig P20 P23 P3 J7 P36 J5 1 2 3 4 5 6 7 8 2 OF a 8 c 1 2 3 5 6 DEE de x a RED ORANGE z x o SEI Z 2 c BROWN BLACK UI a PINK 2 7 5 RED 2 BLACK o PINK 3 GRAY m WHITE VIOLET 3 4 z 5 BLUE SP y 6 6 z a a ORANGE PINK PINK A SP5 TAN BROWN B RED BLACK e TAN H YELLOW E Y BLACK BLACK d E SP3 A PINK BLUE GREEN 2 WHITE BLACK WHITE I E F PINK GRAY VIOLET i PINK ORANGE Ze 9 BLACK A 3 x RED BLACK SP 4 a ORANGE 8 a BLACK BLACK SP BLACK BLUE WHITE GREEN 8 BLACK Y x o 3 B YELLOW GREEN 5 BLACK 3 Li x E m 3 3 t D m 0 AB TS A B int A 2 3 4 5 6 1 8 2 SERIAL NUMBERS YELLOW PULL Di HOLD 44 J6 J21 Ze PIS P18 PT NO pio P27 ABOVE 260000400 BLACK GE RUN SOLENOID OVER TEMP FUEL PUMP TRANSPORT MOW REEL ON OFF DIODE DI ENGIN
116. O ring as a secondary seal If zero leak plug removal is necessary lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug the impact will allow plug removal with less chance of damage to the socket head of the plug Cartridge Valve Service Fig 97 1 Make sure the manifold is clean before removing the valve 2 If cartridge is solenoid operated remove nut secur ing solenoid to the cartridge valve Carefully slide sole noid coil off the valve IMPORTANT Use care when handling the cartridge valve Slight bending or distortion of the stem tube can cause binding and malfunction 3 Remove cartridge valve with a deep socket wrench Note correct location for O rings sealing rings and backup rings Remove and discard seal kit 4 Visually inspect the port in the manifold for damage to the sealing surfaces damaged threads or contamina tion 5 Visually inspect cartridge valve for damaged sealing surfaces and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in small valve orifices or seal areas causing malfunction B If valve sealing surfaces appear pitted or dam aged the hydraulic system may be overheating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air Groundsmaster 3500 D Page 4 91 6 Clean cartridge valve using clean mineral spirits Submerge v
117. RH actuator LH actuator Groundsmaster 3500 D Removal Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 1 Remove front lift cylinder from the frame and lift arm using Figure 121 as guide Figure 122 WER 1 Lift cylinder 3 Clearance 2 If hydraulic fittings are to be removed from lift cylin 2 Hydraulic hoses der mark fitting orientation to allow correct assembly Installation 1 If hydraulic fittings were removed from lift cylinder install fittings to cylinder using marks made during the removal process to properly orientate fittings IMPORTANT With lift arms raised fully hydraulic hoses should be routed as shown in Figure 122 Make sure clearance between hydraulic hose and lift arm is from 0 040 to 0 120 inches 1 0 to 3 0 mm Do not loosen hoses for repositioning without re lieving system hydraulic pressure first 2 5 Been 5 gt lt 2 Install front lift cylinder to the frame and lift arm using Figure 121 as guide 3 Make sure hydraulic tank is full Add correct oil if nec essary See Check Hydraulic System Fluid 4 Adjust front lift arm see Adjust Front Lift Arm in Chapter 7 Cutting Units Groundsmaster 3500 D Page 4 121 Hydraulic System Rev G Rear Lift Cylinder Hydraulic tube Bulkhead locknut Hydraulic T fitti
118. RPM for a minimum of 2 minutes Increase engine speed to high idle 3050 50 RPM for a minimum of 1 minute under no load 12 Raise and lower cutting units several times Turn steering wheel fully left and right several times 13 Shut off engine and check for hydraulic oil leaks Check oil level in hydraulic tank and add correct amount of oil if necessary 14 Operate the machine for 2 hours under normal oper ating conditions 15 Check condition of hydraulic oil If the new fluid shows any signs of contamination repeat steps 1 through 14 again until oil is clean If changing to biode gradable fluid repeat steps 1 through 14 again at least once and until the oil is clean 16 Assume normal operation and follow recommended maintenance intervals Hydraulic System Rev G 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 transmit ting throughout the system If a closed loop hydraulic system filtering tool is not used to ensure system clean liness repeat failures and subsequent damage to other hydraulic components in the system will occur To effec tively remove contamination from closed loop traction circuit use of the Toro high flow hydraulic filter and hy draulic hose kit are recommended see Special Tools in this chapter 1 Park machine on a level surface stop engi
119. Remove two cap screws that secure hydraulic motor to the cutting unit Fig 7 Remove hydraulic motor from deck and O ring from top of spindle housing 3 Cover top of spindle housing to prevent contamina tion 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 5 Note location of thrust washer on lift arm pivot shaft 6 Remove cutting unit from lift arm pivot shaft Roll the cutting unit away from the traction unit Installation 1 Position machine on aclean level surface Lower lift arms stop engine engage parking brake and remove key from the ignition switch 2 Install cutting unit onto pivot shaft A On the front cutting units slide thrust washer and then cutting unit carrier frame onto pivot shaft Note front right and left carrier frames are identical except for the location of the service latch rod Fig 9 B On the rear cutting unit slide cutting unit carrier frame and then thrust washer onto pivot shaft 3 Install lynch pin onto the pivot shaft Fig 8 4 Remove plug or cover from top of spindle housing if installed 5 Position O ring to top of spindle housing Install hy draulic motor to the cutting unit with two cap screws Fig 7 6 Lubricate spindle and carrier frame grease fittings see Lubrication in Chapter 2 Product Records and Maintenance Figure 7 1 Cap screw 2 Hydraulic
120. TER i GR GLOW D EE oR AMP 2 L5 e 1 d sala SROUND 5 PK qp rc Ede R LQ FL ES YA E v PK FL FUSIBLE LINK Va wr B Start SP pom 3 BK 2 A START LA H2V BU BU SS PK 2 B HIGH TEMP SW 1 B PTOCOIL BK BU W gt BN gE 2 2 6 IGN SW C RUN PK W BK gt R BK Me 2 2 PARKING BRAKE yp PTOSW ENGINE L ENGINE GROUND ER PARKING BRAKE 2 E BACKLAP GE NOTUSED 2 E SEAT SW 1 F GROUND GY gt SEAT SWITCH 2 G NEUTRAL SW GN o NEUTRAL SWITCH 2 4 IGN sw S FRAME GROUND BATTERY ue 1 3 STANDARD CONTROL MODULE OPTIONAL vi SEAT SWITCH BK STOP NONE RUN Bel A X Y PAN START B l S B A GN BU REEL DRIVE TRANSPORT MOW REEL UP S Y BK SOLENOID SWITCH LIMIT SWITCH D X IGNITION SWITCH JUMPER Poe p OFE RUN START E 1EI 15A 1F3 10A p a B l OR Jj Y BK Bic o3 T 5 o Ae el Af ola s AAN T MO CE a PTO SWITCH 1F2 10A x abe y Ek BU w BU Groundsmaster 3500 D o OPTIONAL LIGHT 7 ERE NE SWITCH OPTIONAL LIGHT Electrical Schematic IDN INO 4 E T BR Sek SERIAL NUMBER Serial Numbers 240000001 and Up 2 COMB us ABOVE 314000001 Vis f MEM cm All relays and solenoids PTO SWITCH are shown as de energized Page 8 10 Rev G LIGHT OPTIONAL JIS JI4 LIGHT SW OPTIONAL jig IGNITION SW 4 0 oO ee gt vin Jig OIL P33 ALT CLUSTER GAUGE OT P34 GLOW HOUR METER P22 ENGI
121. ack up ring 3 Piston 7 Rod seal 11 Retaining ring 4 Uni ring 8 Cylinder gland 12 Dust seal Hydraulic System Rev G Page 4 128 Groundsmaster 3500 D Disassembly 1 Remove oil from the steering cylinder into a drain pan by slowly pumping the cylinder shaft Plug both ports and clean the outside of the cylinder IMPORTANT Prevent damage when clamping the hydraulic cylinder into a vise clamp on the clevis only 2 Mount clevis end of steering cylinder in a vice Re move retaining ring 3 Remove plugs from ports Extract shaft cylinder gland and piston by carefully twisting and pulling on the shaft IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surface before mount ing in a vice 4 Mount shaft securely in a vise by clamping on the cle vis of the shaft Remove lock nut and piston from the shaft Slide cylinder gland off the shaft 5 Remove Uni ring and O ring from the piston 6 Remove back up ring O rings and rod seal from the cylinder gland Assembly 1 Make sure all parts are clean before reassembly Groundsmaster 3500 D Page 4 129 2 Coat new O rings Uni ring rod seal and back up ring with with clean hydraulic oil A Install Uni ring and O ring to the piston B Install O rings back up ring and rod seal to the cylinder gland IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surface before mount ing in a vice
122. age Measured Battery Charge Level Fully charged 10096 7596 charged 12 68 V or higher 12 45 V 12 24 V 5096 charged 12 06 V 2596 charged 11 89 V 096 charged Start the engine and run at high idle 3200 RPM Allow the battery to charge for at least 3 minutes Record the battery voltage After running the engine for at least 3 minutes battery voltage should be at least 0 50 volt higher than initial bat tery voltage Example of a charging system that is functioning At least 0 50 volt over initial battery voltage Initial Battery Voltage 12 30 v Battery Voltage after 3 Minute Charge 12 95 v Set the multimeter to the correct scale With the ignition switch in the OFF position place the ammeter pickup around the main glow plug power supply wire and read the meter priorto activatingthe glow plug system Adjust the meter to read zero if applicable Activate the glow plug system see Traction Unit Operator s Manual and record the multimeter results The Groundsmaster 3500 D glow plug system should have a reading of approximately 27 Amps Electrical System Rev G T o E DI E o N E 77 Check Operation of Interlock Switches A 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 The machine i
123. ake 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 1 Make sure the engine is off Locate switch for testing 2 Disconnect electrical connector from the switch 3 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi Figure 24 nals 1 Parking brake switch 2 Parking brake lever 4 When the switch plunger is extended there should be continuity between the switch terminals 5 When the switch plunger is depressed there should be no continuity between the switch terminals 6 Reconnect switch connector SE o 1 ta oo So lu Figure 25 1 Transport Mow switch Fusible Link Harness The Groundsmaster 3500 D uses three 3 fusible links for circuit protection These fusible links are located in d FUSIBLE LINK H a harness that connects the starter B terminal to the wmn Ff FUSIBLEUNK Ld eme HARNESS FUSIBLE LINK SA main wire harness If any of these links should fail cur rentto the protected circuit will cease Refer to wire har ness drawings in Chapter 8 Electrical Diagrams for additional fusible link information p O s
124. al distances with in 0 060 inch 1 5 mm D Tighten four cap screws and lock nuts to secure the scissor mount Figure 120 1 Scissor frame 3 Sidewinder carrier 2 Lower frame 4 Gaps 2 E Been 5 gt lt Groundsmaster 3500 D Page 4 119 Hydraulic System Rev G Front Lift Cylinder 90 hydraulic fitting Hydraulic cylinder Flange nut Flange head screw Hydraulic hose Centering wire Hydraulic hose Hydraulic hose 10 Hydraulic hose 11 Slide bracket 12 Flange nut 13 Plastic slide 14 Flange head screw 15 Lift arm pivot shaft 16 Roll pin 17 Cap screw 18 Flange head screw 19 Cap screw 20 Bearing cap 21 Jam nut 22 Cap screw oouommRo9oNza Hydraulic System Rev G Sidewinder carrier assembly Figure Locknut 121 Thrust washer Slide support bar Pin Spacer External retaining ring Bulkhead nut Hydraulic tube Bulkhead nut Carrier stop bracket Nut Flange nut O ring O ring RH liftarm LH liftarm Cap screw Shaft Thrust washer Lynch pin Rod Cap screw Page 4 120 Cap screw Torsion spring Grease fitting Hair pin RH deck stop LH deck stop Rivet Rubber bumper Flange nut Flange head screw RH pivot bracket LH pivot bracket Front carrier frame Flat washer Latch tube Latch rod Rod clip Rivet Actuator bracket Carriage screw
125. al rings 15 Commutator seal 24 End cover 6 Back up washer 16 Commutator 25 Ball 7 Inner seal 17 Woodruff key 26 Spring 8 Thrust washer 18 Wear plate 27 Plug 9 Thrust bearing 19 Rotor 28 O ring 10 Bearing Note The wheel motor illustrated in Figure 83 is the rear motor The three wheel motors are identical in construction except for some minor differences The right front and rear wheel motors have reverse timed manifolds and the front left motor does not The end cover of the rear motor has a check valve consisting of a ball and spring and both front motors lack this feature IMPORTANT Ifa wheel motor failure occurred refer to Traction Circuit Closed Loop Component Fail ure in the General Information section for informa tion regarding the importance of removing contamination from the traction circuit Hydraulic System Rev G Page 4 74 Note For repair of the wheel motors see the Ross Torqmotor MG MF MP MB ME and MJ Series Ser vice Procedure at the end of this chapter Groundsmaster 3500 D ie SE O a z N UO LR gt N This page is intentionally blank Groundsmaster 3500 D Page 4 75 Hydraulic System Rev G Rotary Cutting Motors Figure 84 1 Hydraulic motor 8 Hydraulic fitting 15 O ring 2 O ring 9 Hydraulic hose 16 O ring 3 O ring 10 Hydraulic T fitting 17 O ring 4 Hydraulic elbow 11 Hydraulic hose 18 Cap screw 5 Hydraulic hose 12 Hydraulic
126. alve in clean mineral spirits to flush out con tamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves Be ex tremely careful not to damage cartridge Use com pressed air for cleaning 7 Reinstall the cartridge valve into the manifold block A Lubricate new seal kit components with clean hy draulic oil and install on valve The O rings sealing rings and backup rings must be arranged properly on the cartridge valve for proper operation and sealing IMPORTANT Use care when handling the valve cartridge 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 C Torque cartridge valve using a deep socketto val ue identified in manifold illustration Fig 97 D If cartridge is solenoid operated carefully install solenoid coil to the cartridge valve Torque nut to val ue identified in manifold illustration Fig 97 8 If problems still exist remove valve and clean again or replace valve Figure 98 3 Solenoid valve R1 4 Braking valve BV 1 Manifold assembly 2 Logic valve LC1 Hydraulic System Rev G 2g 5 5 S 2O Hydraulic Manifold Service Serial Numbers Above 314000000 20 ft Ibs 27 1 N m 20 ft Ibs 27 1 N m ee RIGHT Figure 99 1 Manifold body 4 Logic cartridge valve
127. ap screws to pull seal out of roller bl Figure 16 assembly 1 Roller 4 Retaining ring 2 Roller shaft 5 Oil seal NOTE Seals will be destroyed when servicing the rear 3 Bearing roller Do not re use seals that have been removed Bearing Removal Fig 16 188 dia 2 NOTE The bearings are pressed onto the roller shaft 625 dia and loose fit into the roller 1 Remove seals from roller Remove retaining rings from roller shaft catch ring removal notch with pick and pull ring from shaft 1 Tap 1 4 20 UNC 2 2 Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until free from bearing and housing 3 Remove second bearing from shaft by supporting Figure 17 bearing on inner race and tapping on roller shaft 4 Discard removed bearings Inspect shaft retaining rings and roller for damage Replace components as needed Roller Assembly Fig 16 1 Press new bearing onto one end of roller shaft Apply pressure equally to inner and outer bearing races 2 Place spiral retaining ring on same end of shaft as installed bearing 3 Install shaft with single bearing into roller 4 Install second new bearing onto roller shaft Apply pressure equally to inner and outer bearing races The inner race will contact shoulder of shaft before outer race contacts shoulder of roller Cutting Units Rev D Page 7 12 Rev E Groundsmaster 3500 D
128. apter 8 Electrical Diagrams Table of Contents ELECTRICAL SCHEMATICS AND DIAGRAMS 3 Electrical Schematic Serial Numbers 90101 to 230999999 0 cece a 3 Glow Circuits 4 Crank Circuits 5 Run Circuits Transport 6 Run Circuits Mow 7 Harness Diagram Serial Numbers 90101 to 230999999 8 Harness Drawing Serial Numbers 90101 to 230999999 9 Electrical Schematic Serial Numbers 240000001 and Up 10 Harness Diagram Serial Numbers 240000001 to 313999999 11 Harness Drawing Serial Numbers 240000001 to 313999999 ccoo 12 Harness Diagram Serial Numbers 314000001 and Up ius Ix ERR 13 Harness Drawing Serial Numbers 314000001 and UD ie enm wr lum m eae Vane ERU RES 14 n o T 5 o DI Groundsmaster 3500 D Page8 1 Rev G Electrical Diagrams o E c Ki o n e This page is intentionally blank Electrical Diagrams Page 8 2 Groundsmaster 3500 D
129. ate Apply a light coating of clean hydraulic oil to gear faces Hydraulic System Rev G E L3 5 gt 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 installa tion 12 Gently slide the body onto the assembly Firm hand pressure should be sufficient to engage the dowels 13 Check to make sure that the surface of the rear wear plate is slightly below the face of the body If the wear plate is not below the body check assembly for a shifted pressure seal backup seal or O ring Correct before proceeding 14 Apply a light coating of petroleum jelly to the exposed side of the back plate 15 Place back plate on assembly using marker line for proper location Firm hand pressure should be sufficient to engage the dowels 16 Install the four screws and hand tighten IMPORTANT Avoid using excessive clamping pressure on the motor housing to prevent distorting the housing 17 Place mounting flange of the motor into a vise and al ternately torque the screws from 38 to 43 ft Ib 51 to 58 N m 18 Remove motor from vise 19 Place a small amount of clean hydraulic oil in the inlet
130. ce 18 Carrier Frame 20 Page7 1 Rev E Cutting Units Rev D Specifications MOUNTING All cutting units are supported by equal length independent lift arms and are interchangeable to all three cutting unit positions 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 HEIGHT OF CUT RANGE 3 4 to 4 inch 1 91 to 10 16 cm in 1 4 inch 64 cm increments Height of cut ad justment is made by repositioning deck on deck frame DECK DRIVE Closed loop integrated relief hydraulic system operates cutting deck hydraulic motors Blade spindles are 1 1 4 inch shafts supported by greasable tapered roller bearings CUTTING BLADE Each cutting unit equipped with 27 inch 68 6 cm length 25 inch 6 mm thick heat treated steel blade Anti scalp cup installed on cutting blade The standard blade is optimized for most cutting applications Optional high lift angle sail and Atomic blades are available for those situations where the stan dard blade is not ideal Cutting Units Rev D Page 7 2 DISCHARGE Clippings are discharged from the rear of the mowing decks Pre drilled mounting holes allow at tachment of optional mulching baffle CUTTING UNIT LIFT Cutting units are controlled with one lever SUSPENSION SYSTEM A fully floating suspension with hydraulic counterbalance Main center
131. cking plate retaining clip return springs brake shoes and cam shaft were removed as a complete brake assembly secure backing plate to the brake bracket with four cap screws and lock washers Tighten fasteners 4 Attach adjustment rod to the brake lever Secure ad justment rod with cotter pin 5 Thoroughly clean wheel motor shaft and wheel hub taper 6 Install woodruff key to the slot on the hydraulic motor shaft Slide wheel hub and brake drum assembly onto the shaft 7 Secure wheel hub and brake drum to the hydraulic motor shaft with lock nut NOTE For proper brake operation the brake shoes and backing plate must be concentrically aligned with the brake drum 8 Toalign brake shoes and drum apply parking brake Then tighten four socket head screws and lock nuts that secure the brake bracket and wheel motor to the frame 9 Place wheel onto drive studs and wheel hub Secure wheel with lug nuts on drive studs 10 Lower wheel to ground Torque lug nuts from 45 to 65 ft lb 61 to 88 N m in a criss cross pattern Torque lock nut from 250 to 350 ft lb 339 to 474 kg m 11 Check and adjust brakes see Adjust Brakes Figure 12 1 Return spring 5 Retaining clip 2 Brake shoe toe end 6 Cam shaft 3 Brake shoe heel end 7 Anchor pin 4 Backing plate Rev D Wheels Brakes and Chassis a o w G D Ei o 7
132. d be clean with no lubricant applied 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 IMPORTANT Before installing fitting into port de termine port material If fitting is to be installed into an aluminum port installation torque is reduced 5 Install the fitting into the port and tighten finger tight until the washer contacts the face of the port Step 2 in Figure 43 Make sure that the fitting does not bottom in the port during installation 6 Toputthe fitting in the desired position unscrew it by the required amount to align fitting with incoming hose or tube but no more than one full turn Step 3 in Figure 43 7 Hold the fitting in the desired position with a wrench and use a torque wrench to tighten the lock nut to the recommended installation torque shown in Figure 41 This tightening process will require the use of an offset wrench e g crowfoot wrench Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offset wrench will be lower than the listed installation torque see Using a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 Product Records and Maintenance 8 Ifatorque wrench is not available or if space at the port prevents use of atorque wrench an alterna
133. dependent partially upon the design and configuration of the machine these factors are also dependent upon the awareness concern and proper training of the per sonnel involved in the operation transport mainte nance and storage of the machine Improper use or maintenance by the operator or owner of the machine Supervisor s Responsibilities 1 Make sure operators are thoroughly trained and fa miliar with the Operator s Manual Operator s Video and all the operating and safety decals on the machine 2 Be sure to establish your own special procedures and work rules for unusual operating conditions e g slopes too steep for machine operation Survey mow ing site completely to determine which hills can be operated on safely When performing this site survey always use common sense and take into consideration Before Operating 1 Operate machine only after reading and understand ing the contents of the Operator s Manual and viewing the Operator s Video Copies of the Operator s Manual are available on the internet at www Toro com 2 Only trained operators who are skilled in slope op eration and who have read the Operator s Manual and viewed the Operator s Video should operate the ma Groundsmaster 3500 D Pagel 1 Rev F Chapter 1 S afety can result in injury To reduce the potential for any injury comply with the following safety instructions WARNING To reduce the potential for injury or death com ply
134. der piston moves the rod causing the sidewinder cylinder to extend right At the same time the piston pushes the hy Groundsmaster 3500 D Page 4 21 draulic fluid out of the cylinder back through the spool and hydraulic manifold and to the hydrostat When the cutting unit shift lever is released spring action returns the valve to its original position and by passes flow back to the hydrostat and stopping cylinder movement The cylinder position is locked in place since there is no com plete circuit of flow to and from the sidewinder cylinder Shift Sidewinder Left When the sidewinder is to be shifted left the 2 spool valve is positioned by moving the cutting unit shift lever to LEFT Flowis directed to the rod end of the sidewinder cylinder Hydraulic pressure against the cylinder piston moves the rod causing the sidewinder to retract left At the same time the piston pushes the hydraulic fluid out of the cylinder back through the spool and hydraulic manifold and to the hydrostat When the cutting unit shift lever is released spring action returns the valve to its original position and by passes flow back to the hy drostat stopping cylinder movement The cylinder posi tion is locked in place Hydraulic System Rev G e SE CS a z N cs gt gt N
135. der 3 Jam nuts 2 Rear fork Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 5 Remove steering cylinder from the frame and rear fork using Figure 126 as guide 6 If hydraulic fittings are to be removed from steering cylinder mark fitting orientation to allow correct assem bly Installation Fig 126 1 If hydraulic fittings were removed from steering cylin der install fittings to cylinder using marks made during the removal process to properly orientate fittings 2 Install steering cylinder to the frame and rear fork us ing Figure 126 as guide When securing cylinder ball joints to machine tighten the first jam nut from 65 to 85 ft lb 88 to 115 N m then tighten the second jam nut to the same specification 3 Mount rear wheel to the machine with four 4 lug nuts Lower machine to the ground Torque lug nuts in a crossing pattern from 45 to 65 ft Ib 61 to 88 N m 4 Make sure hydraulic tank is full Add correct oil if nec essary see Traction Unit Operator s Manual Groundsmaster 3500 D Page 4 127 Hydraulic System Rev G Steering Cylinder Service 24 to 30 ft Ib 33 to 41 N m Figure 1 Barrel with clevis 5 O ring 129 9 O ring 2 Lock nut 6 Piston rod 10 B
136. e 5 Remove pump from the vise Turn pump so that the shaft end is facing down Remove cap screws 6 Remove back plate from the rear body 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 IMPORTANT Note position of the open and closed side of the wear plates before removing from the adapter plate Also identify wear plates front and rear for proper reassembly 8 Carefully remove rear wear plate idler gear drive gear and front wear plate from the adapter plate 9 Remove coupler from the drive gear shaft 10 Remove adapter plate 11 Carefully remove front 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 front body IMPORTANT Note position of the open and closed side of the wear plates before removing from the front plate Also identify wear plates front and rear for proper reassembly 12 Carefully remove rear wear plate idler gear drive gear and front wear plate from front plate 13 Remove back up gasket and pressure seal from all wear plates NOTE Gear pumps on early production machines may have had a shaft seal and retaining ring in the front plate Pumps used on later production machines did not have a seal or retaining ring The seal and retaining ring are not needed on
137. e 3 18 Figure 25 1 Cap screw 3 Torsion spring 2 Spacer 4 Pump mount plate Figure 26 1 Long spacer 4 used 4 Hardened washer 2 Flat washer 3 used 5 10mm cap screw 3 8 mm cap screw 4 used 6 Short spacer 7 Install all hydraulic hoses to the piston and gear pumps Install traction control cable to the neutral arm assembly on the piston pump see Piston Pump Installa tion in Chapter 4 Hydraulic System 8 Connect fuel hose to the fuel water separator Fig 21 and front injector nozzle 9 Install top fan shroud to the radiator Install expan sion tank and bracket to the top fan shroud see Radiator Installation Groundsmaster 3500 D 10 Connect wire harness and electrical wires to the fol lowing A Engine grounds to the battery and wire harness Fig 21 B Glow plug bus Fig 22 and fuel stop solenoid C High temperature warning switch Fig 23 D High temperature shutdown switch alternator and low oil pressure switch Fig 24 11 Secure wire harness to engine with cable ties at loca tions noted during engine removal 12 Connect coolant hoses to the water pump and en gine block Make sure drain cock valve is closed Fill ra diator with coolant see Check Cooling System 13 Install muffler to the exhaust manifold and muffler bracket see Muffler Installation Groundsmaster 3500 D Page 3 19 14 Connect throttle cable to the support and swivel on the speed control lever
138. e 9 side and wipe up any spilled diesel fuel before dc Air bleed screw 2 Injection pump starting the engine Store fuel in a clean safety approved container and keep cap in place Use diesel fuel for the engine only not for any other purpose 3 Open air bleed screw on the fuel injection pump IMPORTANT The engine should normally start af ter the bleeding procedures are followed However if the engine does not start air may be trapped be tween injection pump and injectors see Bleed Air from Fuel Injectors 4 Turn ignition key switch to the ON position The elec tric fuel pump will begin operation and force air out around the air bleed screw Leave key in the ON position until a solid stream of fuel flows out around the air bleed screw Tighten screw and turn key to OFF 5 Clean up any spilled fuel 6 Close and secure hood Kubota Diesel Engine Rev G Page 3 6 Groundsmaster 3500 D Bleed Air from Fuel Injectors IMPORTANT This procedure should be used only if the fuel system has been purged of air through nor mal priming procedures see Bleed Fuel System and engine will not start 1 Park machine on a level surface lower cutting units stop engine and engage parking brake Unlatch and raise hood Figure 10 1 1 injector nozzle 3 3 injector nozzle 2 2 nozzle behind hose Because diesel fuel is highly flammable use cau tion when storing or handling it Do not smoke while filling t
139. e as it does in forward However there are a few dif ferences 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 Cil flow out of the upper port goes to the wheel motors and turns them inthe reverse direction Oil flowing out of the wheel motors returns to the lower port of the hydrostat and is continuously pumped out of the upper port Oil by passes the rear motor in reverse because of the check valve inside the rear wheel motor Hydraulic System Rev G e SE CS a z N D gt gt N INVA e ONIH33IS Ge de RA NIVA 3SVO TVNH3LNI S I L SC YANIVHLS Y I T Y Kei A i
140. e engine check for leaks and re check hydraulic fluid level Hydraulic System Rev G Page 4 60 Groundsmaster 3500 D 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 2 Insert nut driver or small piece of pipe onto the end of the torsion spring of the idler pulley 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 76 1 Torsion spring 4 V belt 2 Idler pulle 5 Flywheel pulle 3 Push down and forward on the spring end to unhook 3 Pump mounting plate 6 Hidrostat pulloy the spring from the pump mounting plate 4 Remove V belt from the engine flywheel and hy drostat pulleys 5 Install new V belt onto the engine flywheel and hy drostat pulleys 6 Insert nut driver or small piece of pipe onto the end of the torsion spring of the idler pulley 7 Push down and back on the spring end to get the spring under the pump mounting plate notch Then re lease the spring slowly to lock it into place Groundsmaster 3500 D Page 4 61 Hydraulic System Rev G Check Hydraulic Lines and Hoses Check hydraulic lines and hoses daily for leaks kinked lines loose mounting supports wear loose fittings weather deterioration and chemical deterioration Make any necessary repairs before o
141. e hydraulic manifold The cutting unit drive switch used on machines with serial number below 314000000 is a six 6 terminal rocker switch The switch terminals are marked as shown in Fig 20 The circuitry of the ignition switch is shown in the chart below With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each position Verify continuity between switch terminals 4 Figure 19 Control panel 2 Cutting unit drive switch SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS BACK OF SWITCH ENGAGE DISENGAGE e Figure 20 Se 23 oo 2 o DI The cutting unit drive switch is located on the control panel and allows the decks to be engaged or disen gaged Along with additional switches in the interlock system the cutting unit drive switch controls the sole noid valve on the hydraulic manifold The cutting unit ge s drive switch used on machines with serial number Em above 314000000 is a six 6 terminal switch that is illus O a2 trated in Fig 21 E H H H Wess The switch terminals are marked as shown in Fig 21 The circuitry of the ignition switch is shown in the chart to the right With the use of a multimeter ohms setting BACK OF SWITCH the switch functi
142. e is defective Cutting units raise but will not stay Lift cylinders leak internally up Check valve within the lift control valve leaks Steering Problems See Ross Troubleshooting Guide in the Hydraguide Hydrostatic Steering System HGF Series Service Procedure or Sauer Danfoss Steering Unit Type OSPM Service Manual at the end of this chap EH Turning steering wheel turns ma Hoses to the steering cylinder are reversed chine in the opposite direction Groundsmaster 3500 D Page 4 29 Hydraulic System Rev G 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 ahydraulic component is the source of the problem Precautions for Hydraulic Testing Failure to use gauges with recommended pres sure psi rating as listed in test procedures could result in damage to the gauge and possible personal injury from leaking hot oil All testing should be performed by two 2 people One person should be in the seat to oper ate the machine and the other should read and record test results Keep body and hands away from pin hole leaks or n
143. e of burrs nicks scratches or any foreign material 2 Asapreventative measure against leakage it is rec ommended 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 3 Place the hose tube against the fitting body so that the flat face ofthe hose tube sleeve fully contacts the O ring in the fitting 4 Thread the swivel nut onto the fitting by hand While holding the hose tube with a wrench use a torque wrench to tighten the swivel nut to the recommended installation torque shown in Figure 39 This tightening process will require the use of an offset wrench e g crowfoot wrench Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using atorque wrench with an offset wrench will be lower than the listed installation torque see Using a Torque Wrench with an Offset Wrench in the Torque Specifica tions section of Chapter 2 Product Records and Main tenance 5 Ifa torque wrench is not available or if space at the Swivel nut prevents use of a torque wrench an alternate method of assembly is the Flats From Wrench Resist ance F F W R method Fig 2 A Usinga wrench tighten the swivel nut onto the fit ting until light wrench resistance is reached approxi mately 30 in Ib B Mar
144. e or unequal pressure on the cap screws can break the bushing flange B Insert cap screws into threaded removal holes of the pulley Tighten screws progressively and evenly until the pulley is loose on the bushing Remove pulley from the bushing 9 Loosen set screw that secures bushing to piston pump Remove bushing from the pump shaft 10 Remove both lock nuts flat washers and cap screws that secure the piston pump to the pump mount plate Remove pump from plate Hydraulic System Rev G Page 4 102 11 If hydraulic fittings are to be removed from pump mark fitting orientation to allow correct assembly Piston Pump Installation Fig 104 amp 105 1 If hydraulic fittings were removed from piston pump install fittings to pump using marks made during the re moval process to properly orientate fittings 2 Position and secure piston pump to the pump mount plate with both flat washers cap screws and lock nuts 3 Place key into pump shaft slot Slide taper lock bush ing onto the piston pump shaft with bushing flange to ward pump housing 4 Make sure that tapered surfaces of pulley and taper lock bushing are thoroughly clean no oil grease dirt rust etc 5 Position pulley to taper lock bushing and align non threaded holes of pulley with threaded holes of bushing Loosely install three 3 cap screws with lock washers to bushing and pulley 6 Install O rings and hydraulic fittings to their or
145. ected hose Figure 70 leading to the steering control valve 1 Gear pump P2 2 To steering control valve 6 Make sure steering wheel is positioned so the rear wheel points directly ahead 7 Start engine and move throttle to full speed 3050 50 RPM 2 E L3 5 gt IMPORTANT Do not allow pressure to exceed 1500 PSI IMPORTANT Hold steering wheel at full lock only long enough to get a system pressure reading Holding the steering wheel against the stop for an extended period may damage the steering control valve 8 Watch pressure gauge carefully while turning the steering wheel completely in one direction and holding 9 System pressure should be from 845 to 995 PSI as the relief valve lifts Return steering wheel to the center position If specification is not met shut off engine and repair or replace steering control valve 10 Disconnect T connector with test gauge from pump connection and hose Reconnect hydraulic hose to gear pump P2 Groundsmaster 3500 D Page 4 53 Hydraulic System Rev G Steering Control Valve Test STEERING CYLINDER OPEN FITTING 7 PLUG POWER STEERING VALVE LEFT TURN Y EN FS High Pressure Low Pressure Return or Suction gt Flow Hydraulic System Rev G Page 4 54 Groundsmaster 3500
146. ecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 1 Remove steering control valve from the steering col umn using Figures 114 115 and 116 as guides Installation 1 Install steering control valve to the steering column using Figures 114 115 and 116 as guides When instal ling steering control valve note position of end cover protrusion as shown Fig 116 Figure 115 2 Make sure hydraulic tank is full Add correct oil if nec E E EC Tilt bracke Friction disc essary see Check Hydraulic System Fluid 2 Steering valve bracket 6 Steering tilt lever o 3 Jam nut 7 Steering arm E 4 Flat washer 8 Friction disc gt I Figure 116 1 Cap screw 5 Steering control valve 2 Flange nuts 6 Steering tilt lever 3 Steering valve bracket 7 End cover protrusion 4 Steering arm Groundsmaster 3500 D Page 4 115 Hydraulic System Rev G Steering Control Valve Service Serial Numbers Below 240000000 oouommRoNza Note 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 Figure Isolation manit id Drive link Metering ring Socket head screw Commutator seal Commutator cover Commutator ring Commutator Drive link spacer
147. ective troubleshooting and repairs you must have a good understanding of the electrical circuits and A CAUTION components used on this machine see Electrical Dia grams Chapter 8 Remove all jewelry especially rings and watches before doing any electrical trouble If the machine has any interlock switches by passed shooting or testing Disconnect the battery they must be reconnected for proper troubleshooting cables unless the test requires battery voltage and safety Starting Problems Starter solenoid clicks but starter will not crank Low battery charge if solenoid clicks problem is not in safety interlock system Loose or corroded battery cables Loose or corroded ground Faulty wiring at the starter Faulty starter solenoid Nothing happens when start attempt is made The traction pedal is not in neutral position or the neutral switch is faulty Cutting unit drive switch is in the ENGAGE position or faulty Parking brake is disengaged with seat unoccupied The engine is too hot or the over temperature shut down relay is faulty The battery is dead Fuse F1 or F3 is faulty or blown Loose or corroded battery or ground cables Loose or corroded ground Wiring in the crank circuit see Electrical Diagrams Chapter 8 is loose corroded or damaged The ignition switch is faulty Starter solenoid wiring loose corroded or damaged Starter solenoid is faulty The interlock relay is faulty E
148. ee Special Tools loosen wheel hub from wheel motor 7 Remove wheel hub and motor from vise Remove lock nut and hub from motor shaft Locate and retrieve woodruff key Groundsmaster 3500 D 8 Ifhydraulic fittings are to be removed from wheel mo tor mark fitting orientation to allow correct assembly Installation Fig 82 1 If hydraulic fittings were removed from wheel motor install fittings to motor using marks made during the re moval process to properly orientate fittings 2 Thoroughly clean wheel motor shaft and wheel hub taper 3 Lock wheel hub in a vise Install woodruff key into the wheel motor shaft Slide motor shaft into hub and secure with lock nut Torque lock nut from 250 to 350 ft lb 339 to 474 N m Remove wheel motor and hub from vise Groundsmaster 3500 D Page 4 73 4 Install wheel motor to the rear fork using Figure 82 as guide 5 Install tire and rim assembly to machine 6 Lower the machine to the ground 7 Torque rear wheel lug nuts from 45 to 65 ft Ib 61 to 88 N m 8 Make sure hydraulic tank is full Add correct oil if nec essary see Check Hydraulic System Fluid Hydraulic System Rev G 2 E E L3 Ki E I Wheel Motor Service 45 to 55 ft Ib 60 to 76 N m Figure 83 1 Dirt seal 11 Coupling shaft 20 Vane 2 Bearing 12 Thrust bearing 21 Stator 3 Housing 13 Drive link 22 Manifold 4 Back up washer 14 Cap screw 23 Commutator ring 5 Se
149. eel must be raised off the ground or the machine will move during adjustment Make sure machine is supported so it will not accidentally fall injuring anyone under machine 2 Raise one front wheel and rear wheel off floor and place support blocks under frame 3 Loosen locknut on traction adjustment cam Engine must be running so final adjustment of the traction adjustment cam can be performed To guard against possible personal injury keep hands feet face and other parts of the body away from the muffler other hot parts of the engine and any rotating parts Hydraulic System Rev G Page 4 56 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 5 Tighten locknut to secure adjustment 6 Stop engine 7 Remove support blocks and lower the machine to the ground Test drive the machine to make sure it does not move when in the neutral position Readjust if neces sary Figure 71 1 Adjustment cam 2 Lock nut Groundsmaster 3500 D Braking Valve Adjustment The braking valve BV on the hydraulic manifold con trols 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 If blade stopping time is incorrect adju
150. engine engage parking brake and remove key from the ignition switch Unlatch and raise hood 2 Insert nut driver or small piece of pipe onto the end of the torsion spring of the idler pulley o Be careful when removing or applying tension S 5 from or to the torsion spring of the idler pulley 35 The spring is under heavy load and may cause E 3 personal injury Figure 8 3 1 Torsion spring 4 Drive belt a 3 Push down and forward on the spring end to unhook A Pun KE plate 2 Atos KINA the spring from the pump mounting plate 4 Remove drive belt from the engine flywheel and hy drostat pulleys 5 Install replacement drive belt onto the engine fly wheel and hydrostat pulleys 6 Insert nut driver or small piece of pipe onto the end of the torsion spring of the idler pulley 7 Push down and back on the spring end to get the spring under the pump mounting plate notch Then re lease the spring slowly to lock it into place Groundsmaster 3500 D Page 3 5 Kubota Diesel Engine Rev G 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 Because diesel fuel is highly flammable use cau tion 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 out Figur
151. entionally blank Groundsmaster 3500 D Page 4 105 Hydraulic System Rev G Gear Pump 27 to 31 ft Ib 37 to 42 N m Figure 1 Piston pump 7 Hydraulic barb Q amp ing 13 909 hydraulic fitting 2 Gear pump 8 O ring 14 O ring 3 Hydraulic hose tank suction 9 O ring 15 Cap screw 4 Hydraulic hose hydraulic manifold 10 90 hydraulic fitting 16 Flat washer 5 Hydraulic hose steering valve 11 O ring 17 O ring 6 Hose clamp 12 O ring Removal Fig 108 1 Remove muffler from the engine to gain access to the gear pump see Muffler Removal in Chapter 3 Ku bota Diesel Engine 2 Drain hydraulic oil from hydraulic tank see Change Hydraulic Fluid in this section Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 3 Remove gear pump from the piston pump using Fig ure 108 as guide 4 f hydraulic fittings are to be removed from pump mark fitting orientation to allow correct assembly Hydraulic System Rev G Page 4 106 Installation Fig 108 1 If hydraulic fittings were removed from gear pump install fittings to pump using marks made during the re moval process to properly orientate fittings IMPORTANT Position gear pump to the piston pump so that the gear pump suction port is facing down 2 Install gear pump to the piston pu
152. er moves in 10 to 15 seconds proceed to step 13 13 Operate the traction pedal in the forward and reverse directions The wheels off the floor should rotate in the proper direction A If the wheels rotate in the wrong direction stop engine remove lines from rear of hydrostat pump and reverse the connections B If the wheels rotate in the proper direction stop engine 14 Adjust traction pedal to the neutral position see Ad just Traction Drive for Neutral 15 Check operation of the traction interlock switch see Check Interlock System in Chapter 5 Electrical Sys tems 16 Remove blocks from wheels and lower machine Re move chocks from remaining wheel 17 If the traction pump or a wheel motor was replaced or rebuilt run the traction unit so all wheels turn slowly for 10 minutes 18 Operate traction unit by gradually increasing its work load to full over a 10 minute period 19 Stop the machine Check hydraulic tank and fill if necessary Check hydraulic components for leaks and tighten any loose connections Hydraulic System Rev G Hydraulic Tank and Hydraulic Oil Filter Grommet Flange head screw Barb fitting Check fitting Flat washer Hydraulic tank O ring Hose clamp Barb fitting straight 10 Flange head screw 11 Elbow fitting OONDASPYNS Hydraulic System Rev G Anti seize lubricant 30 to 60 in Ib 3 4 to 6 8 N m Figure 78 O ring Cil filter element Shoulder
153. ere the flat and curved sail parts of the blade meet Fig 11 Since sand and abrasive material can wear away the metal that connects the flat part and sail of the blade check the blade before using the machine If wear is noticed replace the blade 3 Inspect cutting edges of all blades Sharpen the cut ting edges if they are dulled or nicked Sharpen only the top of the cutting edge and maintain the original cutting angle to make sure of sharpness Fig 12 The blade will remain balanced if the same amount of metal is re moved from both cutting edges 4 To check blade for being straight and parallel re move blade see Cutter Blade Removal and Installation and lay it on a level surface The ends of the blade must be slightly lower than the center and the cutting edge must be lower than the heel of the blade If the blade is higher at the ends than the center or if cutting edge is Cutting Units Rev D Page 7 10 85 to 110 ft lb 115 to 149 N m Figure 10 1 Cutting blade 3 Blade bolt 2 Anti scalp cup 4 Spindle shaft higher than the heel the blade is bent or warped and must be replaced FLAT PART OF BLADE FORMED Figure 11 SHARPEN AT THIS ANGLE ONLY 4 BLADE END VIEW Figure 12 Groundsmaster 3500 D Rear Roller 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 de
154. f the engine must be running to perform a mainte nance adjustment keep hands feet clothing and any other parts of the body away from the cutting units and any moving parts Keep everyone away 10 Do not overspeed the engine by changing governor settings To assure safety and accuracy have an Autho rized Toro Distributor check maximum engine speed with a tachometer 11 Engine must be shut off before checking oil or adding oil to the crankcase 12 To insure optimum performance and safety use gen uine TORO replacement parts and accessories Re placement parts and accessories made by other manufacturers could be dangerous and such use could void the product warranty of The Toro Company Safety Jacking Instructions When changing attachments tires or performing other service use correct blocks hoists and jacks Make sure machine is parked on a solid lev el floor such as a concrete floor Prior to raising machine remove any attachments that may inter fere with the safe and proper raising of the ma chine Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the machine is not properly sup ported by blocks or jack stands the machine may move or fall which may result in personal injury Use the following positions when jacking up the ma chine Jacking the Front End 1 If the front wheel motor is to be removed position jack securely under the square tube of
155. gap of 020 to 040 inch 51 to 1 02 mm is achieved between the scraper rod and roller 4 Secure mounting bracket fasteners to 30 ft Ib 41 N m 5 On scraper rods equipped with lock nuts Fig 3 tighten scraper rod lock nut to 65 in Ib 8 5 N m NOTE On scraper rods equipped with lock nuts Fig 3 if one side of scraper rod becomes worn it can be ro tated in the mounting brackets 180 degrees for a new edge Cutting Units Rev D Page 7 6 O EE i Figure 3 4 Scraper bracket 5 Roller mount 6 Flange head screw 1 Rear roller 2 Scraper rod 3 Lock nut Figure 4 4 Flange head screw 5 Cap screw with jam nut 1 Rear roller 2 Scraper rod 3 Roller mount Groundsmaster 3500 D Blade Plane Inspection and Adjustment If a solid object is struck by the cutting deck the blade plane of the deck should be inspected Blade Plane Inspection 1 Remove cutting unit to be inspected see Cutting Unit Removal and Installation 2 Use hoist or minimum of two people and place cut ting 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 5 Rotate marked end of blade to the 3 and 9 o clock positions and measure heights 6 Compare 12 o clock measured height to the he
156. ge Also carefully inspect seating surface and threads of bearing lock nuts Replace all damaged components Assembly Fig 19 1 Install inner seals into roller tube making sure that seal lip and garter spring faces end of tube Use inner seal tool see Special Tools and soft face hammer to ful ly seat seals against roller shoulder Fig 20 Apply a small amount of grease around the lip of both inner seals after installation IMPORTANT During assembly process frequently check that bearings rotate freely and do not bind If any binding is detected consider component re moval and reinstallation 2 Install new bearing and outer seals into one end of roller tube A Position a new bearing into one end of roller tube Use bearing outer seal tool see Special Tools with a soft face hammer to fully seat bearing against roller shoulder Fig 21 After bearing installation make sure that it rotates freely with no binding B Apply a small amount of grease around the lip of both outer seals C 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 against roller shoulder Fig 22 Make sure that bearing still freely rotates after seal installation D Using the same process install second outer seal making sureto not crush the installed outer seal Again make sure that bearing sti
157. ge Hobbs H source to the other terminal of the hour meter 00001 1 10 3 The hour meter should move 1 10 of an hour in six HOURS minutes 4 Disconnect the voltage source from the hour meter Figure 10 SRV Valve Solenoid The hydraulic system on the Groundsmaster 3500 D uses a solenoid valve coil on the hydraulic manifold Fig 12 When the solenoid valve coil is energized spool shift in the valve will direct hydraulic flow to the cutting decks Two versions of solenoid coils have been used on the Groundsmaster 3500 D Earlier coils had a short har ness with a two pin connector Fig 11 Later coils use a use a connector incorporated into the coil body Fig 12 Function and testing of the coils is the same SE o w t oo So ui Testing 1 Make sure engine is off Disconnect wire harness electrical connector from the solenoid valve coil Figure 11 1 Manifold assembly 3 Coil connector NOTE Prior to taking small resistance readings witha 25 Solenoidivalye digital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from the measured value of the component you are test ing 2 Measure resistance between the two connector ter minals on the solenoid coil The resistance should be approximately 7 2 ohms 3 Reconnect electrical connec
158. glow relay and glow plugs see Electrical Dia grams Chapter 8 B Verify continuity of the circuitry from the battery to ignition switch glow controller glow lamp glow relay and ground see Electrical Diagrams Chap ter 8 C Replace parts as necessary 6 Connect electrical connector to the fuel stop sole noid MADE IN JAPAN x C z EH Ee a c o A TOE 10 17095 65061 ODEL IGCIOI6A VC SPARI PLIG CA LID J D Glow indicator lamp goes out and glow plugs de Figure 34 energize after 10 seconds 1 Glow controller end view 3 Side view 2 Top view 4 Place ignition switch in the START position Verify the following while in the START position A Glow indicator lamp is out B Glow relay is energized C Glow plugs are energized D Power exists at terminal 1 of the glow controller NOTE Ifthereis no power to terminal 1 ofthe glow con troller verify continuity of the circuitry from the ignition switch to the controller and perform Step 4 again see Electrical Diagrams Chapter 8 Electrical System Rev G Page 5 22 Groundsmaster 3500 D Standard Control Module Groundsmaster 3500 D machines with Serial Numbers above 240000000 are equipped with a Standard Control Module to monitor and control electrical components re quired for safe operation This Module is attached to the back of the instrument panel Inputs from the neutral parking brake PTO ignition and hig
159. h Back 2 Floor plate bracket off stop bolts if reducing the clearance between the lift arm and the floor plate bracket Fig 5 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 C Install pin to clevis Fully raise front lift arms and check clearance Repeat steps A and B if necessary D Tighten jam nut on the hydraulic cylinder when clearance is correct IMPORTANT The lack of clearance at the front stops can damage the lift arms 4 With the front lift arms fully raised make sure clear i ance between each lift arm and stop bolt is from 0 005 Figure 5 to 0 040 inch 0 13 to 1 02 mm If the clearance is not 1 Stop bolt 3 Clearance in this range adjust stop bolts as necessary Fig 5 scirem P 2 02 7 3 as no owt o S Figure 6 1 Hydraulic cylinder 2 Jam nut Groundsmaster 3500 D Page6 5 Rev G Wheels Brakes and Chassis 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 2 Make sure that pivot brackets items 6 and 9 are not overtightened They should pivot and return freely 3 Toallow horizontal movement ofthe actuators items 2 and 8 loosen carriage screws and flange nuts that se cure actuators to actuator mount brackets 4 To allow vertical move
160. h temperature switches are monitored by the Module Output to the PTO deck drive solenoid engine starter motor fuel pump and engine run solenoid are controlled based on the inputs received by the Module The Standard Control Module does not connect to an external computer or hand held device can not be re programmed and does not record intermittent fault data The Standard Control Module can be used to check op eration of machine switches by monitoring the LED of the module Ifa Module LED does not illuminate e g the in seat input LED does not illuminate with the seat occu pied and the ignition switch in the run position testing of the switch and circuit wiring would be required Refer to the Traction Unit Operator s Manual for addi tional Standard Control Module information Control Module Inputs Fig 36 The Power input LED should be illuminated when the ignition key switch is in the RUN or START position The Start input LED should be illuminated when the igni tion key switch is in the START position The Neutral input LED should be illuminated when the traction pedal is in the neutral position The Parking Brake Off input LED should be illuminated when the parking brake is not engaged The PTO Switch input LED should be illuminated when the PTO switch is engaged The In Seat input LED should be illuminated when the operator is sitting in the seat The Over Temperature Shutdown input LED should be illum
161. he removal process to properly orientate fittings 2 Install rear lift cylinder to the frame and lift arm using Figure 123 as guide 3 Make sure hydraulic tank is full Add correct oil ifnec essary see Check Hydraulic System Fluid 4 Adjust rear lift arm see Adjust Rear Lift Arm in Chap ter 7 Cutting Units Hydraulic System Rev G 2 ER CS a Y KE gt on lt Lift Cylinder Service 24 to 30 ft Ib 33 to 41 N m 1 Grease fitting 2 Barrel with clevis 3 Nut 4 Uni ring 5 Piston Hydraulic System Rev G Internal collar Dust seal Shaft Nut Clevis Groundsmaster 3500 D Disassembly 1 Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft Plug both ports and clean the outside of the cylinder IMPORTANT Prevent damage when clamping the hydraulic cylinder into a vise clamp on the clevis only 2 Mount lift cylinder in a vice Remove internal collar with a spanner wrench 3 Remove plugs from ports Extract shaft head and piston by carefully twisting and pulling on the shaft IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surface before mount ing in a vice 4 Mount shaft securely in a vise by clamping on the cle vis of the shaft Remove lock nut and piston from the shaft Slide head off the
162. he fuel tank Do not fill fuel tank o E sg Su 23 while engine is running hot or when machine is E in an enclosed area Always fill fuel tank outside a and wipe up any spilled diesel fuel before start ing the engine Store fuel in a clean safety ap proved container and keep cap in place Use die sel fuel for the engine only not for any other pur pose 2 Loosen pipe connection to the No 1 injector nozzle and holder assembly 3 Move throttle to FAST position 4 Turn ignition switch to START and watch for fuel flow around connector Turn key to OFF when solid flow is observed Tighten pipe connector securely to the injec tor nozzle 5 Repeat steps on the remaining injector nozzles Clean up any spilled fuel 6 Close and secure hood Groundsmaster 3500 D Page 3 7 Kubota Diesel Engine Rev G Muffler and Air Cleaner Air inlet hose upper Air inlet hose lower Flange nut Flange head screw Flat washer Cap screw Air filter mount Hose clamp ONDARON Kubota Diesel Engine Rev G Figure 11 Air cleaner body Flange head screw Hex nut Lock washer Mounting band assembly Muffler Muffler bracket Exhaust guard if equipped Page 3 8 Cap screw Filter cover Hose clamp Plug Lock nut Compression spring Bolt Evacuator valve Groundsmaster 3500 D Muffler Removal Fig 11 The muffler and exhaust
163. hydraulic fitting on the bottom of the hydrostat Fig 58 NOTE An alternate testing location would be at the hy draulic hose connection to the hydraulic tube under the left floor plate 10 Install flow tester in series with the pump and the dis connected hose Make sure the tester flow control valve is fully open 11 Start engine and move throttle to full speed 3050 50 RPM Groundsmaster 3500 D Page 4 41 1 Lower hydraulic fitting 2 Piston pump Use extreme caution when performing test The fronttire on the ground will be trying to move the machine forward 12 Slowly push traction pedal in forward direction until 1000 PSI is displayed on the pressure gauge 13 Motor internal leakage will be shown on flow meter in GPM Flow should be less than 1 5 GPM for the tested wheel motor 14 If specifications are not met the tested wheel motor needs to be repaired or replaced as necessary 15 If remaining front wheel motor requires testing com plete steps 5 to 14 for the remaining motor 16 If rear wheel motor requires testing A Both front wheel motors should have hydraulic lines connected Block up both front wheels off the ground Release parking brake so front wheels can turn B Attach a heavy chain to the rear of the machine frame and an immovable object to prevent the ma chine from moving during testing C Position rear wheel on the ground and chock rear wheel to prevent it from turning D
164. hydraulic hose be sure that the hose is straight not twisted before tightening the fittings This can be done by observing the imprint layline on the hose Use two wrenches when tightening a hose hold the hose straight with one wrench and tighten the hose swivel nut onto the fitting with the second wrench see Hydraulic Hose and Tube Installation in this sec tion If the hose has an elbow at one end tighten the swivel nut on that end before tightening the nut on the straight end of the hose For additional hydraulic hose information refer to Toro Service Training Book Hydraulic Hose Servicing Part Number 94813SL Hydraulic System Rev G Page 4 4 Before disconnecting or performing any work on hydraulic system relieve all pressure in system see Relieving Hydraulic System Pressure in this section 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 in jected into the skin it must be surgically re moved within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Groundsmaster 3500 D Hydraulic Hose and Tube Installation O Ring Face Seal Fitting 1 Make sure threads and sealing surfaces of the hose tube and the fitting are fre
165. ic 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 Tester Pressure and Flow Toro Part Number TOR214678 This tester requires O ring Face Seal ORFS adapter fittings for use on this machine see Hydraulic Test Fit ting Kit TOR4079 in this section 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 LOW PRESSURE GAUGE Low range gauge to pro vide accurate reading at low pressure 0 to 1000 PSI A protector valve cuts out when pressure is about to exceed the normal range for the gauge The cutout pressure is adjustable 4 HIGH PRESSURE GAUGE High range gauge which accommodates pressures beyond the capacity of the low pressure gauge 0 to 5 000 PSI 5 FLOW METER This meter measures actual oil flow in the operating circuit with a gauge rated at 15 GPM 6 OUTLET HOSE A hose from the outlet side of the hydraulic tester connects to the hydraulic system circuit Hydraulic System Rev G Page
166. idge identification of components Examples BV is the deck circuit braking valve and P1 isthe gear pump connection port See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port location SRV Cartridge Valve Fig 92 and 93 1 Make sure the manifold is clean before removing the cartridge valve Hydraulic System Rev G Page 4 86 valve Slide solenoid off the valve IMPORTANT Use care when handling the cartridge valve Slight bending or distortion of the stem tube can cause binding and malfunction 3 Remove SRV cartridge valve from port R1 using a deep socket wrench Groundsmaster 3500 D 4 Visually inspect the port in the manifold for damage to the sealing surfaces damaged threads or contami nation 5 Visually inspect cartridge valve for damaged sealing surfaces or contamination A Contamination may cause valves to stick or hang up Contaminants can become lodged in small valve orifices or seal areas causing malfunction B If valve sealing surfaces appear pitted or dam aged the hydraulic system may be overheating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air 6 Clean cartridge valve using clean mineral spirits Submerge valve in clean mineral spirits to flush out con tamination Use a probe wood dowel or brass drift to push the internal spool in and out 20 to 30 times to flush
167. iesel Engine Rev G Page 3 14 Groundsmaster 3500 D 3 Place a suitable container under the radiator to col lect the coolant Open draincock valve and completely drain the radiator IMPORTANT Follow all local codes and regulations when recycling or disposing engine coolant 4 Remove glow plug relay from the radiator assembly Position relay away from the radiator 5 Place a suitable container under the hydraulic filter to collect the hydraulic fluid The container should have a6 gal 23 Ltr minimum capacity Disconnect the hy draulic hose below the filter head or remove the hydraul ic filter element and drain the hydraulic system Fig 19 6 Disconnect the coolant hoses from the radiator oil cooler assembly A Upper radiator hose to the water pump B Lower radiator hose to the engine block C Coolant hose to the expansion tank D Air hose to the air cleaner 7 Disconnect the hydraulic hoses from the oil cooler section of the radiator oil cooler assembly A Hydraulic tube from top of hydraulic fluid cooler B Hydraulic hose from bottom of hydraulic fluid cooler 8 Remove expansion tank from the fan shroud 9 Remove expansion tank bracket and both fan shrouds from radiator assembly 10 Remove flange head screws securing the top and bottom of the radiator frame to the radiator Remove four carriage bolts and lock nuts securing the radiator to the radiator frame 11 Carefully remove radiator from
168. ight of cut setting It should be within 090 inch 2 3 mm The 3 and 9 o clock heights should be 150 090 inch 3 8 2 3 mm higher than the 12 o clock setting and within 090 inch 2 3 mm of each other If any of these measurements are not within specification proceed to Adjusting Blade Plane Adjusting Blade Plane Start with front bracket adjustment and change one height of cut bracket at a time 1 Remove height of cut bracket front left or right from deck frame 2 Position 060 inch and or 030 inch shims between the deck frame and bracket to achieve the desired blade height setting 3 Install height of cut bracket to deck frame with re maining shims assembled below the height of cut bracket NOTE Socket head bolt and spacer for front bracket are held together with Loctite to prevent spacer from fal ling inside the deck frame 4 Secure front height of cut bracket to deck frame with socket head bolt spacer and flange nut 5 Verify 12 o clock height Re adjust if needed Groundsmaster 3500 D Page 7 7 6 Determine if one or both RH and LH height of cut brackets need to be adjusted If the 3 or 9 o clock side is 150 090 inch 3 8 2 3 mm higher than the new front height then no adjustment is needed for that side Adjust other side if needed to within 090 inch 2 3 mm of correct side 7 Adjust right and or left height of cut brackets by re peating steps 1 thru 3 8 Secure r
169. ight and or left height of cut brackets with carriage bolts and flange nuts 9 Verify 12 3 and 9 o clock heights 12 o clock 9 o clock 3 o clock Ev Ix NY 6 o clock Figure 5 Figure 6 2 Shims 1 Height of cut bracket Cutting Units Rev D Service and Repairs Never install or work on the cutting units or lift arms with the engine running Always stop en gine and remove key first Blade Stopping Time The blades of the cutting deck are to come to acomplete 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 To verify blade stopping time have a second person stand back a safe distance from the machine and watch the blade on one of the cutting decks When the machine operator disengages the cutting decks record the time it takes for the blade to come to a complete stop If this time is greater than 7 seconds the braking valve BV on the hydraulic manifold needs adjustment See Brak ing Valve Adjustment in the Adjustments section of Chapter 4 Hydraulic System Cutting Units Rev D Page7 8 Rev E Groundsmaster 3500 D Cutting Unit Removal and Installation Removal 1 Position machine on a clean level surface Lower cutting units stop engine engage parking brake and remove key from the ignition switch 2
170. ighten all three cap screws to 30 ft lb 41 N m NOTE Adjustments of more than 1 1 2 inch may re quire temporary assembly to an intermediate height to prevent binding of the deck chamber Figure 1 1 Height of cut bracket 3 Spacer 2 Height of cut plate 4 Cap screw HEIGHT OF CUT L e a on Ld Figure 2 Groundsmaster 3500 D Page 7 5 Cutting Units Rev D 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 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 On scraper rods equipped with lock nuts Fig 3 loosen lock nut securing one end of scraper rod to mounting bracket For proper roller scraper adjustment there should be approximately 005 to 020 inch 13 to 51 mm end play in loosened rod 2 Loosen left and right scraper bracket mounting fas teners only enough to allow mounting brackets to be ad justed A Early models use two flange head screws on each scraper bracket B Later models use one flange head screw and one cap screw with jam nut on each side of roller 3 Slide scraper brackets up or down until a
171. iginal positions on the piston pump Note Ifinstalling a new gear pump to the piston pump make sure to remove the plug from the suction port of the gear pump Fig 106 The gear pump suction fitting must be on the same side as the trunnion of the piston pump 7 Remove plugs from the gear pump Secure O ring and gear pump to the piston pump with both flat washers and cap screws Torque fasteners from 27 to 31 ft Ib 37 to 42 N m Figure 106 1 Gear pump 2 Suction port Groundsmaster 3500 D Support piston and gear pumps when installing them to the machine to prevent them from falling and causing personal injury 8 Position pump mount plate with pumps pump pulley and idler assembly to the machine Install fasteners and spacers securing the pump mount plate to the engine and pump support Tighten fasteners securely 9 Remove plugs from hydraulic hoses Connect all hy draulic hoses as follows A Secure O rings fittings and hydraulic hoses to the gear pump B Connect hydraulic suction hose from the hydrau lic tank to the gear pump barb fitting with hose clamp C Secure O rings fittings and hydraulic hoses to the piston pump 10 Install neutral arm assembly to the piston pump as follows A Position neutral bracket to the mount plate and the pump lever to the pump trunnion B Secure pump lever to the piston pump trunnion with flat washer and cap screw C Secure neutral bracket to the pum
172. ignment mark on one end of the roller shaft 3 Tighten fasteners that secure each end of roller to roller mounts 4 If equipped install scraper rod assembly to roller mounts Adjust scraper rod see Adjust Roller Scraper in the Adjustments section 5 If roller design allows greasing lubricate roller grease points Groundsmaster 3500 D Page 7 11 DF Figure 13 Cutting deck frame 6 Cap screw Flange head screw 7 Rear roller Cap screw 8 Cap screw if equipped Roller mount 9 Grease fitting Skid bracket EARLY STYLE 1 2 on Figure 14 Roller mount 3 Set screw Scraper rod early style 4 Locknut Figure 15 Roller scraper 4 Cap screw Scraper plate 5 Jam nut Cap screw Rev E Cutting Units Rev D Rear Roller Service Non Greasable Bearings Seal Removal Fig 16 5 Install second spiral retaining ring onto roller shaft to secure second bearing 1 Using a 1 4 inch thick 3 X 3 square piece of steel make a seal removal tool as shown in Figure 17 6 Install new seals to 030 inch 76 mm recessed into roller 2 Slide seal removal tool over roller shaft 3 Using the tool as a template locate mark and drill two 7 64 inch 109 inch diameter holes in outer face of seal 4 Screw two No 8 164 inch diameter by 3 4 inch long self tapping screws into outer face of seal 5 Installtwo 1 4 20 by 1 inch long cap screws into seal removal tool 6 Alternately tighten c
173. in coolant if the 4 Remove glow plug relay from the radiator assembly radiator or engine is hot Pressurized hot cool ant can escape and cause burns Ethylene gly col antifreeze is poisonous Dispose of coolant properly or store itin a properly labeled contain er away from children and pets Kubota Diesel Engine Rev G Position relay away from the radiator 5 Disconnect following hoses from the radiator A Upper radiator hose to the water pump B Lower radiator hose to the engine block C Coolant hose to the expansion tank D Air hose to the air cleaner Page 3 12 Groundsmaster 3500 D 6 Remove expansion tank and bracket from the top fan shroud 7 Remove both fan shrouds from radiator assembly 8 Remove flange head screws securing the top and bottom of the radiator frame to the radiator Remove four carriage bolts and lock nuts securing the radiator to the radiator frame 9 Pull radiator carefully from the radiator frame 10 Plug any openings to prevent contamination Installation 1 Remove any plugs used during the removal proce dures 2 Position radiator carefully to the radiator frame 3 Secure radiator assembly to the radiator frame with four carriage bolts and lock nuts Secure top and bottom of radiator to frame with flange head screws 4 Secure both fan shrouds to the radiator assembly with flange head screws 5 Secure expansion tank bracket and tank to the top fan shroud
174. inated when excessive engine coolant temperature causes the high temperature shutdown switch to close The Backlap input LED is not used on the Groundsmas ter 3500 D Groundsmaster 3500 D Page 5 23 Control Module Outputs Fig 36 The Start output LED should be illuminated when the ignition key switch is in the START position with the trac tion pedal in neutral the PTO switch off and either the seat occupied or parking brake engaged The Run output LED should be illuminated when the ignition key switch is in the ON position and inputs from the neutral parking brake PTO seat and over tempera ture switches indicate safe engine operation e g seat occupied and parking brake disengaged when traction pedal is depressed The PTO output LED should be illuminated when the ignition key switch is in the ON position and the PTO Switch is pulled out Note If Module Over Temperature Warning input LED is illuminated PTO output LED will not be illuminated and PTO will not be engaged regard less of PTO switch position Figure 35 1 Standard Control Module Figure 36 1 Power input LED 6 Neutral input LED 2 Start input LED 7 Park brake off input LED 3 Engine run output LED 8 PTO switch input LED 4 Start output LED 9 In seat input LED 5 PTO output LED 10 High temp input LED 11 Backlap input not used Electrical System Rev G o Si E o E m Service and Repairs NOTE For more electrical com
175. inding Torque valve to 30 to 35 ft Ib 41 to 47 N m C If problems still exist remove valve and clean again or replace valve Figure 95 1 Braking cartridge valve 3 Sealkit backup rings 2 Sealkit O rings Figure 96 1 Logic cartridge valve 3 Sealkit backup rings 2 Sealkit O rings Hydraulic System Rev G Page 4 88 Groundsmaster 3500 D ie SE O a z N UO LR gt N This page is intentionally blank Groundsmaster 3500 D Page 4 89 Hydraulic System Rev G Hydraulic Manifold Service Serial Numbers 240000601 to 313999999 4 CL 60 in Ib 6 8 N m 35 ft Ib 47 N m 45 to 50 ft Ib 7 lt 61 to 68 N m 120 in Ib 13 6 N m Figure 97 1 Manifold body 4 Nut 6 Solenoid cartridge valve R1 2 NWD 4 plug 5 Solenoid coil 7 Braking cartridge valve BV 3 Logic cartridge valve LC1 NOTE The ports on the manifold are marked for easy identification of components Examples BV is the deck circuit braking valve and P1 isthe gear pump connection port see Hydraulic Schematic to identify the function of the hydraulic lines and cartridge valves at each port location Hydraulic System Rev G Page 4 90 Groundsmaster 3500 D NOTE The Groundsmaster 3500 D hydraulic man ifold uses several zero leak plugs These plugs have a tapered sealing surface on the plug head that is de signed to resist vibration induced plug loosening The zero leak plugs also have an
176. ine whether continuity exists between the various terminals for each position Verify continuity between switch terminals SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS OFF NONE NONE ON PREHEAT BAHI X Y START NONE Groundsmaster 3500 D Page 5 9 A CAUTION When testing electrical components for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected Figure 5 1 Switch 3 Hex nut 2 Key 4 Lock washer Figure 6 Electrical System Rev G bd o E 0 weg to oo 25 Lu 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 num bers below 240000000 two of the four relay connec tions are secured with screws Fig 7 On machines with serial numbers above 240000000 the glow relay is at tached to the wire harness with a four wire connector Fig 8 1 Verify coil resistance between terminals 86 and 85 with a multimeter ohms setting A On machines with serial numbers below 240000000 resistance should be from 41 to 51 ohms B On machines with serial numbers above 240000000 resistance should be approximately 72 ohms 2 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to termi
177. inefficient motor can generate excessive heat cause damage to seals and other components in the hydraulic system and affect overall machine performance Hydraulic System Rev G Page 4 40 Groundsmaster 3500 D Procedure for Wheel Motor Efficiency Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 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 Make sure that traction pedal is adjusted to the neu tral position see Adjust Traction Drive for Neutral in the Adjustments Section 5 Attach a heavy chain to the rear of the machine frame and an immovable object to prevent the machine from moving during testing The rear wheel will be off the ground during front wheel motor testing Make sure machine is sup ported so it will not move and accidentally fall to prevent injuring anyone under machine 6 Block up the rear wheel off the ground to allow flow through the traction circuit 7 Chock front wheel being tested to prevent rotation of the wheel Make sure parking brake is on 8 Disconnect hydraulic lines from front wheel motor that is not being tested Cap disconnected hydraulic lines and plug ports in wheel motor to prevent contami nation 9 Disconnect hose from the lower
178. into front plate 7 Lubricate the front idler gear shaft with clean hydrau lic oil Install idler gear shaft into the remaining position in the wear plate Apply a light coating of clean hydraulic oil to gear faces Hydraulic System Rev G Page 4 110 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 Apply a light coating of petroleum jelly to new O rings and O ring grooves in the front body Install new O rings to the front body 10 Install locating dowels in front body Align marker line on the body and front plate IMPORTANT Do not dislodge pressure seals back up gaskets or O rings during pump assem bly 11 Gently slide the front body onto the assembly Firm hand pressure should be sufficient to engage the dow els 12 Check to make sure that the surface of the wear plate is slightly below the face of the front body If the wear plate is not below the front body check assembly for a shifted pressure seal or O ring Correct before proceed ing 13 Apply alight coating of petroleum jelly to the exposed side of the adapter plate 14 Place adapter plate on assembly using marker line for proper location Firm hand pressure should be suffi cient to engage the dowels 15 Install coupler into drive gear 16 Follow above procedure to install back section of the pump using the same precautions lubrication and alignment
179. ion pedal setting or reduce engine speed to decrease hydraulic flow through the filter Hydraulic System Rev G Page 4 64 7 With engine running at low idle speed slowly de press the forward traction pedal to the full forward posi tion to allow flow through the traction circuit and high flow filter Keep traction circuit engaged for five 5 min utes while gradually increasing both forward pressure ontraction pedal and engine speed Monitor filter indica tor to make sure that green color is showing during op eration 8 With engine running at high idle speed and traction pedal moved to the forward direction periodically apply brakes to increase pressure in traction circuit While monitoring filter indicator continue this process for an additional five 5 minutes IMPORTANT If using a filter that is not the bi direc tional Toro high flow filter do not press the traction pedal in the reverse direction If flow is reversed when using a filter that is not bi directional debris from the filter will re enter the traction circuit 9 With engine running at high idle speed alternately move traction pedal from forward to reverse While mon itoring filter indicator continue this process for an addi tional five 5 minutes 10 Shut engine off and remove key from ignition switch 11 Remove high flow hydraulic filter and hydraulic hose kit from machine Reconnect hydraulic hose to rear wheel motor fitting Make sure to p
180. itting on the piston pump coming from the hydraulic manifold port CHG Connect T connector and pressure gauge to Figure 55 the fitting and hose connection 1 90 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 7 Pressure gauge should read from 100 to 150 PSI 8 Ifcharge relief pressure specification is not met con sider the following 2 5 Been 5 gt lt A The piston pump charge relief valve is faulty Re pair or replace the piston pump charge relief valve see Piston Pump Service in the Service and Repairs section B Gear pump P2 is faulty steering and lift circuits are also affected 9 Adynamic charge pressure test can be performed as follows A With T connector and pressure gauge still con nected sit in the operator seat and press the traction pedal to forward B While machine is moving monitor the charge pressure reading on the pressure guage C The charge pressure should drop no more than 15 from initial test reading Step 7 above A pres sure drop of more than 15 indicates a traction cir cuit leak e g a worn or damaged piston pump and or wheel motor 10 Shut off engine 11 Disconnect gauge and T connection from the 90 hydraulic fitting and hose connection Reconnect hose to the hydrostat Groundsmaster 3500 D Page 4 37 H
181. k the swivel nut and fitting body Hold the hose tube with a wrench to prevent it from turning Fitting Dash Size Hose Tube Side Thread Size 9 16 18 C Useasecond wrench to tighten the nutto the cor rect Flats From Wrench Resistance F F W R The markings on the nut and fitting body will verify thatthe connection has been properly tightened Size F F W R 4 1 4 in nominal hose or tubing 1 2 to 3 4 6 3 8 in 1 2 to 3 4 8 1 2 in 1 2 to 3 4 10 5 8 in 1 2 to 3 4 12 3 4 in 1 8 to 1 2 16 1 in 1 8 to 1 2 Swivel Nut Fitting Body Tube or Hose 2 5 L3 5 gt Figure 37 Mark Nut Final and Body Position Initial Position Extend Line AT WRENCH RESISTANCE AFTER TIGHTENING Figure 38 Installation Torque 18 to 22 ft Ib 25 to 29 N m 11 16 16 13 16 16 1 14 13 16 12 17 16 12 111 16 12 27 to 33 ft Ib 37 to 44 N m 37 to 47 ft lb 51 to 63 N m 60 to 74 ft Ib 82 to 100 N m 85 to 105 ft Ib 116 to 142 N m 110 to 136 ft Ib 150 to 184 N m 140 to 172 ft lb 190 to 233 N m Figure 39 Groundsmaster 3500 D Page4 5 Hydraulic System Rev G 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 2 Asapreventative measure agai
182. ke drum wheel hub and tire and wheel assembly to the hydraulic motor see Front Wheel and Brake Installation in Chapter 6 Wheels Brakes and Miscellaneous 3 Lower the machine to the ground Hydraulic System Rev G E SE D I a 0 cs gt 20 Rear Wheel Motor 1 amp ______ 45t0 65 ft lb 61 to 88 N m 250 to 350 ft Ib 339 to 474 N m Figure 82 1 Lugnut 6 Hydraulic hose 11 Hydraulic motor 2 Drive stud 7 O ring 12 Rear fork 3 Tire and rim assembly 8 45 hydraulic fitting 13 O ring 4 Wheel hub 9 Locknut 14 Woodruff key 5 Hydraulic hose 10 Socket head screw 15 Lock nut Removal Fig 82 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Jack up rear of equipment enough to allow the re moval of the rear wheel 3 Remove rear tire and rim assembly from machine Hydraulic System Rev G Page 4 72 4 Remove rear wheel motor with wheel hub attached from the rear fork using Figure 82 as guide 5 Secure wheel hub in a vise Loosen but do not re move lock nut that secures wheel hub to wheel motor IMPORTANT DO NOT hit wheel hub wheel hub puller or wheel motor with a hammer during wheel hub removal or installation Hammering may cause damage to the wheel motor 6 Using hub puller s
183. l from the control valve 4 Remove steering cover from the steering control valve bracket 5 Remove four lock nuts and flat washers securing the steering control valve to the steering control valve bracket 6 Remove both hex flange nuts cap screws and pivot hubs securing the steering control valve bracket to the steering arm Slide bracket from the steering control Figure 16 valve and steering arm 1 Tilt bracket 5 Friction disc 7 Remove and replace parts as necessary to repair d valve bracket S qu steering lever am nu eering arm steering column using Figure 15 as a guide 4 Flat washer 8 Friction disc Assembly 1 Make sure lever and friction discs are properly as sembled to the steering control valve bracket using Fig ures 15 and 16 as a guide 2 Position steering control bracket to the steering con trol valve and steering arm Secure bracket to the steer ing arm with pivot hubs cap screws and hex flange nuts 3 Secure steering control valve bracket to the steering control valve studs with four flat washers and lock nuts 4 Secure steering cover to the steering control valve bracket with cap screws ao 2 N 52 m e nO o oc 5 Install steering wheel to the steering control valve Torque steering wheel nut from 20 to 26 ft lb 28 to 35 N m 6 Secure steering wheel cap to the steering wheel with six philips head screws Groundsmaster 3500 D Page6 17 Rev E Wheels Brake
184. l not to damage the inner oil seals C Put roller in a vertical position and support shaft and bearing with tool TOR4067 D Use tool TOR4067 to install second ball bearing 3 Use tool TOR4068 to install inner seal 4 Use tool TOR4069 to install outer seal 5 Install retaining ring so that side with sharp edges faces end of roller out 6 Use tool TOR4071 to install outer oil seal 7 Use tool TOR4067 to install washer 8 Putopposite end of roller facing up and support bot tom end with tool TOR4067 Repeat steps 3 7 9 Use a hand operated grease gun and No 2 general purpose lithium base grease to lubricate bearings until grease appears at washer Wipe off excess grease Groundsmaster 3500 D Page 7 13 Rev E Cutting Units Rev D Rear Roller Service Greasable Bearings with Bearing Nut Disassembly Fig 19 1 Remove bearing lock nut from each end of roller shaft 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 roll er tube by tapping on opposite end of shaft Remove shaft from roller tube 3 Carefully remove inner seal from both ends of roller tube taking care to not damage tube surfaces 4 Discard removed seals and bearings 5 Clean roller shaft and all surfaces on the inside of the roller tube Inspect components for wear or dama
185. l tool see Special Tools and soft face hammer to lightly seat seal Fig 24 Make sure that shaft and bearings still freely ro tate after seal installation E Using the same process install second outer seal making sure to not crush the installed outer seal Again make sure that shaft and bearings still freely rotate IMPORTANT Make sure that all grease is removed from shaft threads to prevent bearing lock nut loos ening 5 Thoroughly clean threads on both ends of roller shaft NOTE If original bearing lock nut s are being used apply Loctite 7242 or equivalent to threads of lock nut s 6 Install bearing lock nut onto each end of the roller shaft Make sure that outer seals are not damaged dur ing nut installation Torque lock nuts from 50 to 60 ft lb 68 to 81 N m 7 If set screw was removed from either end of roller shaft apply Loctite 242 or equivalent to threads of re moved set screw and install into roller shaft Tighten set screw until it bottoms in shaft and is recessed in shaft IMPORTANT When roller assembly is installed to cutting deck make sure that grease groove in each roller mount aligns with the grease hole in each end of roller shaft Groundsmaster 3500 D Page 7 15 Rev E NOTE After roller is installed to cutting deck lubricate roller grease fittings rotate roller to properly distribute grease in bearings and clean excess grease from roller ends A properly assembled roller sho
186. lades While Operating 1 Always wear your seatbelt 2 Donotrun the engine in a confined area without ade quate ventilation Exhaust fumes are hazardous and could be deadly 3 Sit on the seat when starting and operating the ma chine 4 Check interlock switches daily for proper operation see Chapter 5 Electrical System Do not rely entirely on safety switches shut off engine before getting off seat If a switch fails replace it before operating the ma chine The interlock system is for your protection so do not bypass it 5 Operator must be skilled and trained in how to drive onhillsides Failure to use caution on slopes or hills may cause vehicle to tip or roll possibly resulting in personal injury or death 6 Thistriplex mower has a unique drive system for su perior traction on hills The uphill wheel will not spin out and limit traction like conventional triplexes If operated ona side hill that is too steep rollover may occur before losing traction 7 Before backing up look to the rear and assure no one is behind the machine Watch out for traffic when near or crossing roads Always yield the right of way 8 Keep hands feet and clothing away from moving parts and the deck discharge area 9 The slope angle at which the machine will tip is de pendent on many factors Among these are mowing conditions such as wet or undulating turf speed espe cially in turns position ofthe cutting units tire pressu
187. lectrical System Rev G Page 5 4 Groundsmaster 3500 D Starting Problems continued Engine cranks but does not start The glow circuit does not operate properly Engine cranks but should not with the cutting unit drive switch in the ENGAGE position General Run and Transport Problems Engine stops running during operation operator sitting on seat Battery does not charge Groundsmaster 3500 D Page5 5 Possible Causes 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 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 The cutting unit drive switch is faulty or short circuited Short circuit in cutting unit neutral switch circuit Operator moved too far forward on seat seat switch is not depressed The engine overheated The parking brake was engaged or the parking brake Switch No 1 failed The seat relay or seat switch failed The high temperature shutdown relay failed Fuse F1 or F3 is faulty or blown The run solenoid or fuel pump failed Wiring in the run circuit see Electrical Diagrams Chapter 8 is broken or disconnected Loose or broken wire s Fault
188. let and the exhaust outlet with weatherproof tape 11 Check anti freeze protection and add as needed for expected minimum temperature in your area see Check Cooling System in Chapter 3 Kubota Diesel En gine Product Records and Maintenance Product Records o t i i o E cs E o This page is intentionally blank Product Records and Maintenance Page 2 12 Groundsmaster 3500 D Rev E Chapter 3 Kubota Diesel Engine Table of Contents INTRODUCTION ooo 2 Operator s Manual 2 Kubota Workshop Manual 2 SPECIFICATIONS 3 ADJUSTMENTS an c cece wai 4 Adjust Throttle Cable 4 a SERVICE AND REPAIRS 5 Replace Traction Belt 5 E E Bleed Fuel System 6 E E Bleed Air from Fuel Injectors 7 2 Muffler and Air Cleaner 8 Fuel System ies sira a eee 10 Radiator Serial Number Below 313999999 12 Radiator and Oil Cooler Assembly Serial Number Above 314000000 14 ENGINE init hited Ata Ae iA 16 Removal ua A 16 Installation 18 KUBOTA WORKSHOP MANUAL DIESEL ENGINE 05 SERIES Groundsmaster 3500 D Page 3 1 Kubota Diesel Engine Rev G Introduction This Chapter gives information about specifications maintenance trouble
189. ll freely rotates Cutting Units Rev D 50 to 60 ft Ib 68 to 81 N m Figure 19 1 Roller tube 5 Outer seal 2 Roller shaft 6 Bearing lock nut 3 Inner seal 7 Set screw 4 Bearing Page7 14 Rev E E Vi ZA Figure 20 Roller tube 3 Inner seal tool 2 Inner seal mb f A Ve ST Figure 21 4 Washer 5 Bearing outer seal tool 1 Roller tube 2 Inner seal 3 Bearing Groundsmaster 3500 D 3 From the roller tube end with only the inner seal installed carefully install the roller shaft into the roller tube Make sure that seals are not damaged as shaft is installed 4 Install new bearing and outer seals into second end of roller tube A Position a second new bearing to roller shaft and tube Position washer see Special Tools on bearing to allow pressing on both inner and outer bearing races simultaneously B Use washer and bearing outer seal tool see Special Tools with a soft face hammer to fully seat bearing Fig 23 After bearing installation make sure that shaft freely rotates and that no binding is detected If necessary lightly tap bearing and or shaft ends to align shaft and bearings Remove washer from roller 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 sea
190. luid Hydraulic System Rev G Page 4 68 Groundsmaster 3500 D ie SE O a z N UO LR gt N This page is intentionally blank Groundsmaster 3500 D Page 4 69 Hydraulic System Rev G Front Wheel Motors Figure 81 1 Lock nut 5 Frame 8 O ring 2 Spacer 6 Hydraulic tube 9 Hydraulic fitting 3 Socket head screw 7 Hydraulic tube 10 O ring 4 Hydraulic wheel motor Hydraulic System Rev G Page 4 70 Groundsmaster 3500 D Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Jack up front of equipment enough to allow the re moval of the front wheel IMPORTANT DO NOT hit wheel hub wheel hub pull er or motor with a hammer during removal or instal lation Hammering may cause damage to the hydraulic motor Groundsmaster 3500 D Page 4 71 3 Remove tire and wheel assembly wheel hub and brake drum from the hydraulic motor Remove brake as sembly brake bracket and wheel shield from the frame see Front Wheel and Brake Removal in Chapter 6 Wheels Brakes and Miscellaneous 4 Remove wheel motor from frame using Figure 81 as guide Installation 1 Install wheel motor to frame using Figure 81 as guide 2 Install wheel shield brake bracket and brake as sembly to the frame Install bra
191. ment of the actuator mount brackets item 3 loosen carriage screws and flange nuts that secure actuator mount brackets to lift arms 5 Simultaneously move both actuators against back of the carrier stop bracket and pivot brackets Secure actu ators items 2 and 8 to actuator mount brackets with carriage screws and flange nuts 6 With pivot brackets tipped forward slide actuator mount brackets down so that the actuators just contact the pivot brackets Secure actuator mount brackets to lift arms with carriage screws and flange nuts Wheels Brakes and Chassis DAIAPRON A Page6 6 Rev G Figure 7 LH lift arm 7 RH lift arm LH actuator 8 RH actuator Actuator mount bracket 9 Horizontal screw Vertical screw LH pivot bracket RH pivot bracket 10 Carrier stop bracket 11 Return spring Groundsmaster 3500 D Adjust Rear Lift Arm 1 Park machine on a level surface and engage parking brake 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 fol lows Fig 9 A Lower cutting units turn engine off and remove key from the ignition switch B Back off jam nut from the rear
192. motor Figure 8 1 Lynch pin 2 Lift arm pivot shaft Figure 9 1 Service latch rod Groundsmaster 3500 D Page 7 9 Rev E Cutting Units Rev D Cutting Blade Removal and Installation The cutting blade must be replaced if a solid object is hit the blade is out of balance or ifthe blade is bent Always use genuine TORO replacement blades to be sure of safety and optimum performance Never use replace ment blades made by other manufacturers because they could be dangerous 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 Block cutting deck to prevent it from falling accidentally 2 Grasp end of cutting blade using a rag or thickly padded glove Remove blade bolt anti scalp cup and blade from spindle shaft 3 Install blade sail facing toward cutting deck anti scalp cup and blade bolt Tighten bolt from 85 to 110 ft Ib 115 to 149 N m Inspecting and Sharpening Blade 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 Block cutting deck to prevent it from falling accidentally Do not try to straighten a blade that is bent Never weld a broken or cracked blade Always use a new blade to assure continued safety certification of the product 2 Examine cutting ends of the blade carefully espe cially wh
193. mp using Figure 108 as guide Torque pump mounting cap screws from 27 to 31 ft Ib 37 to 42 N m 3 Fill hydraulic tank with new hydraulic fluid see Trac tion Unit Operator s Manual 4 Install muffler to the engine see Muffler Installation in Chapter 3 Kubota Diesel Engine Groundsmaster 3500 D ie SE O a z N UO LR gt N This page is intentionally blank Groundsmaster 3500 D Page 4 107 Hydraulic System Rev G Gear Pump Service Serial Numbers Below 260000400 Figure 1 Front plate 8 Back up gaske09 14 Dowel 2 Back plate 9 Rear wear plate 15 Coupler 3 Front body 10 Pressure seal 16 Drive gear 4 Rear body 11 Front wear plate 17 Shaft seal if equipped 5 Drive gear 12 O ring 18 Retaining ring if equipped 6 Front idler gear 13 Adapter Plate 19 Cap screw 7 Rear idler gear Disassembly Fig 109 MARKER LINE 1 Plug pump ports and clean the outside of the pump thoroughly After cleaning remove plugs and drain any oil out of the pump 2 Use a marker to make a diagonal line across the front plate front body adapter plate rear body and back plate for assembly purposes Fig 110 IMPORTANT Avoid using excessive clamping pressure on the pump housing to prevent distorting the housing Figure 110 Hydraulic System Rev G Page 4 108 Groundsmaster 3500 D 3 Clamp mounting flange of pump in a vise with the shaft end down 4 Loosen cap screws from the back plat
194. nal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85 3 Disconnect voltage and leads from the terminals Figure 8 Interlock Neutral Seat and High Temperature Shutdown Relays These relays are located in the control panel on ma chines with Serial Numbers below 240000000 1 Verify coil resistance between terminals 86 and 85 with a multimeter ohms setting Resistance should be from 80 to 90 ohms There should be continuity between terminals 87A and 30 2 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85 3 Disconnect voltage from terminal 85 and multimeter lead from terminal 87 4 Connect multimeter ohms setting leads to relay ter minals 30 and 87A Apply 12 VDC to terminal 85 The relay should make and break continuity between termi nals 30 and 87A as 12 VDC is applied and removed from terminal 85 5 Disconnect voltage and multimeter leads from the relay terminals Electrical System Rev G Page 5 10 Figure 9 Groundsmaster 3500 D Hour Meter 1 Connectthe positive terminal of a 12 VDC source to the positive terminal of the hour meter 2 Connect the negative terminal of the volta
195. ndsmaster 3500 D Chapter 5 Electrical System 2 Cutting Unit Drive Switch Serial Number 3 Below 314000000 15 4 Cutting Unit Drive Switch Serial Number 4 Above 314000000 15 5 Neutral Switch 16 6 Seat Switch 16 7 Parking Brake and Transport Mow Switches 17 7 Fusible Link Harness 17 7 High Temp Warning and Shutdown Switches 18 7 Fuel PUMP zoe eee a 19 8 Fuel Stop Solenoid Solenoid With 3 Wire 9 Connector 20 9 Fuel Stop Solenoid Solenoid With 2 Wire 10 CONNECION ores ere tva aos 21 Glow Controller 22 10 Standard Control Module 23 11 SERVICE AND REPAIRS 24 11 Battery Storage 24 12 Battery Care 24 Battery Service 25 13 Solenoid Valve Coil 28 14 Page 5 1 Electrical System Rev G T o E o E LU E o N E 77 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 G Page 5 2 Groundsmaster 3500 D Special Tools Order special tools from your Toro Distributor Some tools may also be available from a local supplier Multimeter The meter can test electrical comp
196. ne see Front Brake and Wheel Removal inthe Service and Repairs section B Adjust brakes by turning clevis to increase or de crease shoe pressure on the brake drum Fig 3 Make sure that brake shoes do not drag against drums with the parking brake lever released Wheels Brakes and Chassis pn Page6 4 Rev D C If brakes can not be adjusted properly repair or replace brake components as necessary 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 E Lower front wheels to the ground F Before starting engine close by pass valve on pump by rotating it 90 degrees Fig 2 Figure 2 1 Piston pump 2 By pass valve Figure 3 Clevis 4 Wheel hub Adjustment rod 5 Cotter pin Brake lever 6 Jam nut Groundsmaster 3500 D Adjust Front Lift Arms 1 Park machine on a level surface fully raise cutting units stop engine engage parking brake and remove key from the ignition switch IMPORTANT Keep front cutting units on the lift arms when performing this adjustment 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 Figure 4 A Lower front liftarms stop engine engage parking 1 Lift arm 3 Clearance brake and remove key from the ignition switc
197. ne and re move key from ignition switch Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Raise and support machine so all wheels are off the ground NOTE If a wheel motor was replaced install high flow filter to the inlet when traveling forward of new wheel motor instead of to the inlet when traveling forward of the traction pump This will prevent system contamina tion from entering and damaging the new motor 3 Thoroughly clean junction of hydraulic hose and lower fitting on rear wheel motor Fig 77 Disconnect hose from lower fitting on wheel motor 4 Connect Toro high flow hydraulic filter in series be tween wheel motor fitting and disconnected hose Use hydraulic hose kit see Special Tools in this chapter to connect filter to machine Make sure that fitting and hose connections are properly tightened IMPORTANT Use only hydraulic fluids specified in Operator s Manual Other fluids could cause system damage 5 After installing high flow filter to machine check and fill hydraulic reservoir with new hydraulic oil as required 6 Sit in the operator s seat and start engine Run en gine at low idle speed and check for any hydraulic leak age from filter and hose connections Correct any leaks before proceeding IMPORTANT While engaging the traction circuit monitor the high flow hydraulic filter indicator If the indicator should show red either reduce tract
198. ness 1 Fuel stop solenoid 1 Fuel stop solenoid 2 Pull coil terminal Groundsmaster 3500 D Page 5 21 Figure 32 2 Harness connector Figure 33 3 Hold coil terminal Electrical System Rev G T Q T o E m 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 posi tion 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 posi tion the glow plugs will energize while the switch is held in START and the glow lamp will not light 3 When the ignition switch is released from START to RUN the glow plugs will de energize and the glow lamp will remain off Controller Checks 1 Make sure there is power from the battery 2 Disconnect electrical connector to the fuel stop sole noid to prevent the engine from starting 3 Place ignition switch in the RUN position Verify the following while in the RUN position A Glow indicator lamp is on B Glow relay is energized C Glow plugs are energized 5 Ifany of the conditions in Step 3 are not met or power to terminal 1 exists and any of the other conditions in Step 4 are not met A Verify continuity of the circuitry from the battery to the
199. ng Hydraulic hose 90 hydraulic fitting Hydraulic hose Hydraulic tube Straight hydraulic fitting Castor bushing 10 Hydraulic cylinder 11 Thrust washer 12 O ring 13 Bulkhead locknut 14 Bulkhead elbow union 15 Hydraulic hose 16 Hydraulic hose 17 Hydraulic tube oouOonPRON Hydraulic System Rev G Figure Hydraulic tud 3 Hydraulic tube Tube clamp O ring Cap screw Lock nut Rear pivot shaft Jam nut Washer Lift arm assembly Flange head screw Thrust washer Grease fitting Cutting unit pivot shaft Cap screw Cap screw Page 4 122 Rebound washer Thrust washer Lynch pin Poprivet Wear strip Rear cutting unit frame Grease fitting O ring Guard Cap screw Cap screw Lock nut External retaining ring Pin Flat washer O ring Groundsmaster 3500 D Removal Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 1 Remove rear lift cylinder from the frame and lift arm using Figure 123 as guide 2 If hydraulic fittings are to be removed from lift cylin der mark fitting orientation to allow correct assembly Groundsmaster 3500 D Page 4 123 Installation 1 If hydraulic fittings were removed from lift cylinder install fittings to cylinder using marks made during t
200. ng the machine for approximately 10 minutes 2 Park machine on alevel 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 Remove plug from hydraulic manifold port G2 Fig 65 and 66 5 Install test gauge with hydraulic hose attached to A CAUTION port G2 Keep away from decks during test to prevent per sonal injury from the cutting blades 6 Start engine and move throttle to full speed 3050 50 RPM Do not engage or raise the cutting units 7 The standard counterbalance pressure should be 250 PSI with a range of 180 to 300 psi Adjustment of the Logic valve LC1 can be performed as follows Note Donotremove the Logic valve from the hydrau lic manifold for adjustment A Remove hex cap from logic valve Fig 67 B Loosen locknut C To increase pressure setting turn the adjust ment shaft on the valve in a clockwise direction A 1 8 turn on the shaft will make a measurable change in counterbalance pressure D To decrease pressure setting turn the adjust ment shaft on the valve in a counterclockwise direc tion A 1 8 turn on the shaft will make a measurable change in counterbalance pressure E Tighten locknut Check counterbalance pressure and readjust as needed F Replace hex cap to Logic valve LC1 Groundsmaster 3500 D Page 4 49 8 Lower cutting units Shut off engine 9
201. ngage parking brake B Besuretraction pedal is in neutral and blade drive is in disengage position C After engine starts release parking brake and keep foot off traction pedal Machine must not move If movement is evident the neutral control linkage is incorrectly adjusted therefore shut engine off and adjust until machine does not move when traction pedal is released see Adjust Traction Drive for Neu tral in the Adjustments section of Chapter 4 Hy draulic System 11 This product may exceed noise levels of 85 dB A at the operator position Ear protectors are recommended for prolonged exposure to reduce the potential of per manent hearing damage Groundsmaster 3500 D 12 Raise the cutting units when driving from one work area to another 13 Do nottouch engine muffler exhaust pipe or hydrau lic tank while engine is running or soon after it has stopped because these areas could be hot enough to cause burns 14 If a cutting unit strikes a solid object or vibrates ab normally stop immediately Turn engine off wait for all motion to stop and inspect for damage Maintenance and Service 1 Before servicing or making adjustments to the ma chine 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 condi tion freq
202. ngaged 3 Read Precautions for Hydraulic Testing 4 Remove plug from hydraulic manifold port G1 5 Install test gauge with hydraulic hose attached to the manifold port G1 A CAUTION Keep away from decks during test to prevent per sonal injury from the cutting blades 6 Start engine and move throttle to full speed 3050 50 RPM Engage the cutting units 7 Watch pressure gauge carefully while mowing with the machine 8 Cutting circuit pressure should be from 1000 to 1500 PSI and will vary depending on mowing conditions 9 Disengage cutting units Shut off engine 10 Disconnect test gauge with hose from manifold block Reconnect plug to the hydraulic manifold port G1 Figure 59 1 Hydraulic manifold 2 Manifold port G1 2 3 L 5 gt lt Figure 60 1 Hydraulic manifold 2 Manifold port G1 Groundsmaster 3500 D Page 4 43 Hydraulic System Rev G Gear Pump P1 Flow Test Using Tester with Pressure Gauges and Flow Meter TO HYDRAULIC MANIFOLD P1 PORT A gt TO STEERING CONTROL VALVE IN PORT ENGINE A RPM GEAR PUMP FROM HYDROSTAT 3 CASE DRAIN Li I I I T I I I L FROM OIL FILTER STRAINER High Pressure Low Pressure Return or Suction Flow Hydraulic System Rev G Page 4 44 Groundsmaster 3500 D Procedure for Gear Pump P1 Flow Test N
203. ngine before removing the cap screws from the engine and engine brackets 13 Remove flange nuts cap screws and washers se curing three engine mounts to the engine mounting brackets A CAUTION One person should operate lift or hoist while the other person guides the engine out of the ma chine IMPORTANT Make sure not to damage the engine fuel and hydraulic lines electrical harness or other parts while removing the engine 14 Remove engine slowly from the machine 15 Separate hydrostat and pump mount plate from the engine as follows Figs 25 and 26 A Remove traction belt from the engine flywheel and hydrostat pulleys see Replace Traction Belt Figure 21 1 Battery ground cable 4 Support bracket 2 Wire harness ground 5 Speed control lever 3 Throttle cable 6 Fuel hose Kubota Diesel Engine Figure 22 1 Glow plug wire 3 Fuel return hose 2 Rear injector nozzle 4 Rear lift tab Figure 23 1 Temp warning switch 2 Front lift tab Figure 24 1 Temp shutdown switch 3 Low oil press switch 2 Alternator Groundsmaster 3500 D Page 3 17 Kubota Diesel Engine Rev G Note The cap screw next to the torsion spring does not have a flat washer with it B Remove five cap screws four washers and five spacers securing the pump mount plate to the en gine C Remove four cap screws and hardened washers securing the right engine mounting bracket and hy drostat to the engine 1
204. ngs 3 Using a wrench turn strainer into tank port at least 1 1 2 to 2 full turns beyond finger tight 4 Fill hydraulic tank with new hydraulic fluid see Change Hydraulic Fluid Hydraulic System Rev G E SE D I a 0 cs gt 2 I Oil Cooler Note On Groundsmaster 3500 D machines with se rial numbers above 314000000 the hydraulic oil cooler is combined with the radiator Removal 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 1 Oil cooler 2 Latch guides Inspection Use eye protection such as goggles when using compressed air 1 Back flush oil cooler with cleaning solvent After cool er is clean make sure all solvent is drained from the cooler 2 Dry inside of oil cooler using compressed air in the opposite direction of the oil flow 3 Plug both ends of oil cooler Clean exterior of cooler Make sure oil cooler fins are clear of dirt and debris 4 The oil cooler should be free of corrosion cracked tubes or excessive pitting of tubes Figure 80 1 Oil cooler 4 Hose clamp Installation 2 Barb fitting 5 Flow to oil filter 3 Hydraulic hose 6 Flow from manifold 1 Install oil cooler using Figures 79 and 80 as guides 2 Make sure hydraulic tank is full Add correct oil if nec essary see Check Hydraulic System F
205. nother person reads the tester and measures deck motor case drain leakage Make sure traction pedal is in NEUTRAL Start engine and move the throttle to full speed 3050 50 RPM A CAUTION Keep away from decks during test to prevent per sonal injury from rotating parts 9 Engage decks by positioning the PTO switch to the ENGAGE position While watching hydraulic tester pressure gauge slowly close flow control valve until a pressure of 1200 PSI is obtained 10 After achieving 1200 PSI place disconnected motor case drain hose into a container graduated in ounces or milliliters e g Toro TOR4077 and collect hydraulic fluid for 15 seconds After 15 seconds remove hose end from container Groundsmaster 3500 D Page 4 51 11 Stop cutting units by positioning the PTO switch to the DISENGAGE position Stop engine 12 Identify amount of oil collected in the container Re cord test results 13 If flow was greater than 22 4 ounces 662 millili ters repair or replace the tested deck motor 14 Relieve hydraulic system pressure See Relieving Hydraulic System Pressure in the General Information section Disconnect tester from motor and hose Re connect hydraulic hoses 15 Repeat test with other deck motors as needed 16 Install cutting blades after testing is completed see Cutting Unit Operator s Manual Figure 68 3 Relief valve 4 Case drain hose 1 Deck motor 2 Return line Figure 69 4 Fr
206. nst leakage it is rec ommended that the O ring be replaced any time the connection is opened 3 Lightly lubricate the O ring with clean hydraulic oil Fitting threads should be clean with no lubricant applied IMPORTANT Before installing fitting into port de termine port material If fitting is to be installed into an aluminum port installation torque is reduced 4 Install the fitting into the port Then use a torque wrench and socket to tighten the fitting to the recom mended installation torque shown in Figure 41 NOTE Use of an offset wrench e g crowfoot wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offset wrench will be less than the recommended installation torque See Using a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 Product Records and Maintenance to determine necessary con version information 5 Ifa torque wrench is not available or if space at the port prevents use of a torque wrench an alternate meth od of assembly is the Flats From Finger Tight F F F T method A Install the fitting into the port and tighten it down full length until finger tight B If port material is steel tighten the fitting to the listed F F F T If port material is aluminum tighten fit ting to 60 of listed F F F T Size F F F T 4 1 4 in nominal hose or tubing 1 00
207. ntrol panel cover to the machine IMPORTANT Always check and adjust brakes any time brake linkages are disassembled or repaired 5 Adjust brake linkages see Adjust Brakes P3 2 KK n m lt oO o oc ECT Groundsmaster 3500 D Page 6 15 Wheels Brakes and Chassis Steering Column CON rons Steering arm Flange nut Flange head screw Steering control valve bracket Cap screw Pivot hub Steering cover Cap screw Toro decal Ball knob Steering tilt lever Steering control valve Tilt bracket Cap screw Flat washer Wheels Brakes and Chassis Figure 15 Flange nut Steering wheel Hydraulic fitting Hydraulic fitting Steering wheel nut Toro decal Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic hose Tilt steering boss Friction disc Friction disc Flat washer Page6 16 Rev E 20 to 26 ft lb Jam nut Lock nut Flat washer Steering shield O ring O ring O ring O ring Philips head screw Steering wheel cap Flat washer Cap screw Slope indicator Lock nut Groundsmaster 3500 D Disassembly 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove philips head screws and steering wheel cap from the steering wheel 3 Remove steering wheel nut from the steering control valve Pull steering whee
208. od to identify a possibly bad deck mo tor is to have another person observe the machine while mowing in dense turf A bad motor will run slower pro duce fewer clippings and could cause a different ap pearance in the turf Groundsmaster 3500 D Procedure for Deck Motor Efficiency Case Drain Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Remove blades from all cutting decks Lower the cut ting units 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 4 Read Precautions for Hydraulic Testing Note The deck motors are connected in series To isolate a faulty motor you may have to test all three mo tors in the circuit by starting with the upstream motor first 5 Forthe suspected bad deck motor disconnect return hose from the motor Note the return hose is on the mo tor side that includes the relief valve Fig 68 6 Install hydraulic tester pressure and flow in series with the motor and the disconnected return hose Make sure the tester flow control valve is fully open 7 Disconnect hose from deck motor case drain at the bulkhead T fitting Fig 69 Plug the T fitting Place open end of disconnected case drain hose into a drain pan 8 One person should sit on the seat and operate the machine while a
209. ol lift sidewinder valve and hydraulic manifold directly to the hydrostat and the charge relief valve Flow then returns to the hydraulic tank Groundsmaster 3500 D Page 4 17 When the cutting units are to be raised the 2 spool valve is positioned by moving the cutting unit shift lever to RAISE Flow is directed to cap ends of the lift cylin ders Hydraulic pressure against the cylinder pistons moves their shafts causing the cutting units to raise At the same time the pistons push the hydraulic fluid out of the lift cylinders and back through the hydraulic man ifold to the hydrostat When the cutting unit shift lever is released spring ac tion returns the valve to its original position and by passes 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 G ie SE CS a z N cs gt gt N r
210. onents and circuits for current resistance or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Battery Terminal Protector Battery Terminal Protector Toro Part No 107 0392 is an aerosol spray that should be used on battery termi nals to reduce corrosion problems Apply terminal pro tector after battery cable has been secured to battery terminal Dielectric Gel Toro Part Number 107 0342 Dielectric gel should be used to prevent corrosion of un sealed connection terminals To ensure complete coat ing of terminals liberally apply gel to both component and wire harness connector plug connector to compo nent unplug connector reapply gel to both surfaces and reconnect harness connector to component Connec tors should be thoroughly packed with gel for effective results Do not use dielectric gel on sealed connection terminals as the gel can unseat connector seals during assembly Groundsmaster 3500 D Page5 3 Figure 1 o Si E o E m Figure 2 DOW CORNING 111 SILICONE COMPOUND NOTE MAY EXE DISCI OF EYE CONTACT IMMEDIATELY WITH WATER Figure 3 Electrical System Rev G Troubleshooting For eff
211. ons may betestedto determine whether Figure 21 continuity exists between the various terminals for each 1 COM B terminal 4 COMC terminal position Verify continuity between switch terminals 2 NOB terminal 5 NOC terminal 3 NC B terminal 6 NCC terminal NOTE Only cutting unit drive switch terminals COM C d NO C t D Sech are used on Groundsmaster 3500 ma SWITCH CLOSED OPEN POSITION CIRCUITS CIRCUITS OFF DOWN COMB NCB COMB NOB COM C NCC COMC NOC ON UP COM B NOB COMB NC B COM C NOC COMC NCC Groundsmaster 3500 D Page 5 15 Electrical System Rev G 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 1 Disconnect electrical connector from the neutral switch 2 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals 3 With the traction pedal in the neutral position there should be continuity between the two switch leads 4 Slowly depress the traction pedal The continuity tes ter should show no continuity as the pedal is moved in either the forward or reverse direction 5 Reconnect switch after testing Seat Switch The seat switch is normally open and closes when the operator is on the seat If the neutral switch or traction interlock switch is open when the operator raise
212. ont LH case drain 5 Front RH case drain 6 Front T fitting 1 Deck motor 2 Rear case drain hose 3 Rear T fitting Hydraulic System Rev G 2 5 cs gt lt Lift and Steering Control Valve Relief Pressure Test TO HYDRAULIC MANIFOLD ST PORT TO LIFT VALVE N PORT STEERING a I I I I I I I I I I I I L r I I I I I I I I L LI OUT 11000 psi aa Je e mm e dd lt TO HYDRAULIC MANIFOLD POWER P1 PORT STEERING VALVE GEAR PUMP STRAINER High Pressure FROM Low Pressure OIL FILTER Return or Suction gt Flow FROM HYDROSTAT INTERNAL CASE DRAIN Hydraulic System Rev G Page 4 52 Groundsmaster 3500 D Procedure for Lift and Steering Control Valve Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on alevel 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 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 disconn
213. ont plate and back plate for damage or wear Figure 88 3 Gear teeth 1 Gear shaft spline 2 Gear shaft 4 Gear face edge Assembly Fig 86 Note When assembling the motor check the marker line on each part to make sure the parts are properly aligned during assembly 1 Lubricate O rings pressure seals back up gas kets and wear plate groves with a thin coat of petroleum jelly Lubricate all other internal parts freely with clean hydraulic oil 2 Install new shaft seal in front plate with seal part num ber facing out Seal should be pressed into place until it reaches the bottom of the bore 3 Install retaining ring into the groove ofthe front plate 4 Place front plate shaft seal side down on a flat sur face 5 Install the pressure seals flat side outward into the grooves in the wear plates Follow by carefully placing the backup gaskets flat side outward between the pressure seals and the grooves in the wear plate 6 Apply alight coating of petroleum jelly to the exposed side of the front plate 7 Lubricate the drive gear shaft with clean hydraulic oil Insert the drive end of the drive shaft through the wear plate with the pressure seal side down and the open side of the pressure seal pointing to the inlet side of the mo tor Carefully install shaft into front plate 8 Lubricate the idler gear shaft with clean hydraulic oil Install idler gear shaft into the remaining position in the wear pl
214. ools are used to assemble the cutting unit rear Bearna installa roller that has greasable bearings and a bearing lock nut mies cov used to retain the bearings 115 0852 Inner Seal Tool 115 0853 Bearing Outer Seal Tool 107 8133 Bearing Installation Washer PP e Eat ff EN KE Inner Seal Bearing Outer Seal Tool Tool Figure 3 Cutting Units Rev D Page 7 4 Rev E Groundsmaster 3500 D Adjustments Never install or work on the cutting units or lift arms with the engine running Always stop en gine and remove key first Height of Cut Adjustment IMPORTANT This cutting deck often cuts approxi mately 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 NOTE Check carrier frame position before adjusting height of cut See Carrier Frame 1 Lower cutting deck to ground stop engine and re move key from ignition switch 2 Loosen cap screw securing each height of cut bracket to height of cut plate front and each side 3 Beginning with front adjustment remove cap screw 4 While supporting deck chamber remove spacer 5 Move deck chamber to desired height of cut and install spacer into designated height of cut hole and slot 6 Position tapped height of cut plate in line with spacer and install cap screw finger tight 7 Repeat steps 4 6 for each side adjustment 8 T
215. ork on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section IMPORTANT Make sure to clean around any hy draulic connections that will be disassembled 2 Drain hydraulic tank see Change Hydraulic Fluid 3 Drain hydraulic system Drain all hoses tubes and components while the system is warm 4 Change and replace oil filter see Replace Hydraulic Oil Filter 5 Inspect and clean hydraulic oil tank see Hydraulic Tank Inspection Groundsmaster 3500 D Page 4 63 6 Reconnect all hydraulic hoses lines and compo nents that were disconnected while draining system NOTE Use only hydraulic fluids specified in Check Hy draulic System Fluid Other fluids may cause system damage If changing to biodegradable fluid use Toro Biodegradable Hydraulic Fluid for this step 7 Fill hydraulic tank with new hydraulic fluid see Change Hydraulic Fluid 8 Disconnect fuel stop solenoid lead to prevent the en gine from starting Make sure traction pedal and the lift control lever are in the neutral position 9 Turn ignition key switch and engage starter for ten 10 seconds to prime the traction and gear pumps Wait fifteen 15 seconds to allow the starter motor to cool and then repeat cranking procedure again 10 Connect electrical connector on fuel stop solenoid 11 Start engine and let it idle at low speed 1750 50
216. ote Overaperiod oftime 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 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 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 61 1 Gear pump P1 2 To hydraulic manifold 3 Read Precautions for Hydraulic Testing 4 Disconnect hose connection on the gear pump P1 leading to port P1 on the hydraulic manifold Fig 61 5 Installtester in series with the gear pump and the dis connected hose leading to port P1 on the hydraulic manifold 2 E L3 5 gt 6 Make sure the flow control valve on the tester is fully open 7 Start engine and move throttle to full speed 3050 50 RPM Do not engage the cutting units IMPORTANT In this test the hydraulic tester is positioned before the manifold relief valve Pump damage can occur if the oil flow is fully restricted by fully closing the tester flow control valve Do not close tester valve fully when performing test 8 Watch
217. ozzles that eject hydraulic fluid under high pressure Do not use hands to search for leaks use paper or cardboard 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 Gan grene may result from such an injury 1 Clean machine thoroughly before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hy draulic equipment Contamination will cause excessive wear of components 2 Put metal caps or plugs on any hydraulic lines left open or exposed during testing or removal of compo nents Hydraulic System Rev G Page 4 30 Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 3 The engine must be in good operating condition Use a phototac when performing a hydraulic test Engine speed can affect the accuracy of the tester readings Check actual speed of the pump when performing flow testing 4 The inlet and the outlet hoses must be properly con nected and not reversed tester with pressure and flow capabilities to prevent damage to the hydraulic tester or components 5 When using tester with pressure and flow capabili
218. p mount plate with flange head screw and flange nut Secure neu tral bracket to the piston pump with both flange head screws D Connect traction control cable to the pump lever The extension spring is under tension and may cause personal injury during installation Use caution when installing the spring to the pump lever E Install extension spring to the cable support bracket and neutral arm Groundsmaster 3500 D Page 4 103 11 Install traction belt to the pump pulley see Replace Traction Belt 12 Using a straight edge across the lower face of the pump pulley verify traction belt alignment across engine and pump pulleys Slide pulley and taper lock bushing on pump shaft so that traction belt and straight edge are aligned indicating correct position of pump pulley Se cure taper lock bushing in position with set screw 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 Ib 10 2 to 13 6 N m in three equal steps and in a circular pattern to se cure pulley and taper lock bushing 14 Check that belt alignment is still correct If needed loosen and re adjust pulley and taper lock bushing loca tion on pump shaft to allow for correct belt alignment 15 Fill hydraulic tank with new hydraulic fluid see Trac tion Unit Operator s Manual 16 Adjust traction drive
219. perating equipment 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 in jected into the skin it must be surgically re moved within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury 2 E L3 5 gt Hydraulic System Rev G Page 4 62 Groundsmaster 3500 D 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 con tains metal particles IMPORTANT Flush hydraulic system when chang Ing from petroleum base hydraulic fluid to a biode gradable fluid such as Toro Biodegradable Hydraulic Fluid Operate machine under normal op erating conditions for at least four 4 hours before draining IMPORTANT If a component failure occurred in the traction circuit refer to Traction Circuit Closed Loop Component Failure in the General Informa tion section for information regarding the impor tance of removing contamination from the traction circuit 1 Park machine on alevel surface Lower cutting units stop engine and engage parking brake Remove key from the ignition switch Before disconnecting or performing any w
220. pivot allows side to side oscillation Individual decks supported with two front rollers and one full width rear roller WEIGHT Complete cutting unit weighs 190 Ib 86 kg OPTIONAL EQUIPMENT Refer to Cutting Unit Opera tor s Manual for cutting deck options Groundsmaster 3500 D Troubleshooting There are a number of factors that can contribute to un satisfactory quality of cut some of which may be turf conditions Turf conditions such as excessive thatch sponginess or attempting to cut off too much grass height may not always be overcome by adjusting the machine It is important to remember that the lower the height of cut the more critical these factors are Factors That Can Affect Quality of Cut Remember that the effective or actual height of cut depends on cutting unit weight and turf conditions Ef fective height of cut will be different than the bench set height of cut 1 Maximum governed engine speed Check maximum governed engine speed Adjust speed to specifications if necessary 2 Blade speed 3 Tire pressure 4 Blade condition 5 Mower housing condition 6 Height of cut 7 Cutting unit alignment and ground following All deck blades should rotate at the same speed See items in Troubleshooting Section of Chapter 4 Hydraulic System Check each tire s pressure Adjust to pressures specified in Specifications Section of Chapter 6 Wheels and Brakes Sharpen blades if their cut
221. ponent repair informa tion 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 3 Leave cables disconnected if the battery is stored on the machine Battery Care 1 Battery electrolyte level must be properly main tained The top of the battery must be kept clean If the machine is stored in a location where temperatures are extremely high the battery will run down more rapidly than if the machine is stored in a location where temper atures are cool Wear safety goggles and rubber gloves when working with electrolyte Charge battery in a well ventilated place so gasses produced while charging can dissipate Since the gases are explosive keep open flames and electrical sparks away from the battery do not smoke Nausea may result if the gases are inhaled Un plug charger from electrical outlet before con necting or disconnecting charger leads to or from battery posts 2 Keep top of battery clean by washing periodically with a brush dipped in ammonia or bicarbonate of soda Electrical System Rev G Page 5 24 4 Store battery in a cool atmosphere to avoid quick de terioration of the battery charge 5 To help prevent the battery from freezing make sure it is fully charged see Battery Service solution Flush
222. ps Length 9 05 inches 22 99 cm Width 6 03 inches 15 31 cm Height 8 50 inches 21 58 cm Removal Fig 37 and 38 IMPORTANT Be careful not to damage terminal posts or cable connectors when removing the bat tery cables 1 Remove battery cover from the frame Loosen bat tery retainer securing the back of the battery to the bat tery support 2 Loosen nut on ground cable first and remove cable from battery This should prevent short circuiting the battery other components or the operators hands 3 Loosen nut on positive cable and remove cable from battery 4 Make sure battery vent caps are on tightly 5 Remove battery from the battery compartment to a service area to allow better access for service Inspection Maintenance and Testing 1 Perform the following inspections and maintenance A Check for cracks Replace battery if cracked or leaking B Check battery terminal posts for corrosion Use wire brush to clean corrosion from posts Groundsmaster 3500 D Page 5 25 Figure 37 2 Battery cover Figure 38 1 Ground cable 2 Positive cable IMPORTANT Before cleaning the battery tape or block vent holes to the filler caps and make sure the caps are on tightly C Check for signs of wetness or leakage on the top ofthe battery which might indicate a loose or missing filler cap overcharging loose terminal post or over filling Also check battery case for dirt and oil Clean
223. r 2 Install roller assembly into deck frame Cutting Units Rev D Page7 16 Rev E Figure 25 3 Spacer 4 Front roller 1 Mounting bolt 2 Bearing NOTE Securing roller assembly with a gap larger than 060 inch 1 52 mm creates a side load on bearings and can lead to premature bearing failure 3 Verify that there is no more than a 060 inch 1 52 mm gap between roller assembly and the roller mount brackets of the deck frame If this gap is larger than 060 inch 1 5 mm shim excess clearance with 5 8 wash ers 4 Insert mounting bolt and tighten to 80 ft lb 108 N m Groundsmaster 3500 D This page is intentionally blank Groundsmaster 3500 D Page 7 17 Rev E Cutting Units Rev D 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 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 Stop en gine and remove key from the ignition switch Block up the cutting unit so it cannot fall accidentally If required for easier service remove cutting unit see Cutting Unit Removal and Installation 5 Remove cutting blade anti scalp cup and bolt
224. r fluid leaks and proper engine operation 12 After running engine for a shorttime stop engine and make sure hydraulic tank is full Add correct oil if neces sary Kubota Diesel Engine Rev G o 2 74 Ek GE 2 a Engine Figure 20 1 Kubota engine 15 Engine mounting bracket RH 29 Lock washer 2 Engine mount 16 Cap screw 30 Flat washer 3 Engine mount 17 Pulley 31 Flange head screw 4 Flange nut 18 Bolt 32 Flat washer 5 Cap screw 19 Flange nut 33 R clamp 6 Hex flange head screw 20 Washer 34 Lock washer 7 External lock washer 21 Exhaust gasket 35 Hex nut 8 Lock nut 22 Throttle swivel 36 Wire harness 9 Hardened washer 23 Lock nut 37 Hose clamp 10 Machine screw 24 Slotted hex head screw 38 Radiator hose upper 11 Hardened washer 25 Throttle cable clamp 39 Radiator hose lower 12 Cap screw 26 Cap screw 40 Throttle support bracket 13 Engine mounting bracket front 27 R clamp 41 Pump mount plate 14 Engine mounting bracket LH 28 Lock nut Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Open and remove engine hood from the machine see Hood Removal in Chapter 6 Wheels Brakes and Chassis Slide seat all the way forward 3 Disconnect air hose from the air cleaner and radiator Remove air cleaner from the engine Kubota Diesel Engine Rev G Page 3
225. r tightening torque Tightening torque when using a torque wrench with an offset wrench will be lower than the listed torque recommen dation Example The measured effective length of the torque wrench distance from the center of the handle to the center of the square drive is 18 The measured effective length of the torque wrench with the offset wrench installed distance from the center of the handle to the center of the offset wrench is 19 The calculated torque conversion factor for this torque wrench with this offset wrench would be 18 19 0 947 Groundsmaster 3500 D Page2 3 If the listed torque recommendation for a fastener is from 76 to 94 ft Ib the proper torque when using this torque wrench with an offset wrench would be from 72 to 89 ft Ib Offset wrench Torque wrench effective length of j torque wrench A S zi effective length of torgue wrench 4 offset wrench TORQUE CONVERSION FACTOR A B Figure 4 Product Records and Maintenance Rev G Product Records o OO i i o E 5 i Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Grade 1 5 amp BI SAE Grade 1 Bolts Screws Studs amp B SAE Grade 5 Bolts Screws Studs amp P SAE Grade 8 Bolts Screws Studs amp Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts Height N
226. ral position traction pump P3 supplies no flow to the wheel motors When the traction pedal is pressed to the forward position the cable from the pedal positions the swash plate in the traction pump so oil flows out of the lower port Oil flow out of the lower port goes to the wheel motors and turns them in the forward direction Oil flowing out of the wheel motors returns to the upper port of the hydrostat and is continuously pumped out of the lower port 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 pump uses a small amount of hydraulic fluid for internal lubrication Fluid is designed to leak across pump parts into the case drain This leakage results in Groundsmaster 3500 D Page 4 13 the loss of hydraulic fluid from the closed loop circuit that must be replenished The charge pump P2 is a fixed displacement gear pump It is driven directly off the traction pump The pump replenishes the closed loop traction circuit with fluid from the hydraulic tank The charge relief valve supplies sufficient pressure so that charge pump flow is guided to the low pressure side of the traction circuit through one of two check valves Pump flow in excess of replenishment requirements is relieved through the charge relief valve back to the gear pump inlet Reverse The traction circuit operates essentially the same in re vers
227. rally with clean hydraulic fluid and install into its valve body bore 15 Install O ring and detent plug into its proper bore Torque plug from 30 to 42 ft Ib 41 to 57 N m Groundsmaster 3500 D ie SE O a z N UO LR gt N This page is intentionally blank Groundsmaster 3500 D Page 4 99 Hydraulic System Rev G Piston Pump 90 to 120 in Ib 10 2 to 13 6 N m Piston pump Straight hydraulic fitting Cap screw Lock nut 90 hydraulic fitting 90 hydraulic fitting 90 hydraulic fitting 90 hydraulic fitting 90 hydraulic fitting 10 Washer 11 Hydraulic hose 12 Suction hose 13 Flange nut 14 Idler pivot pin 15 Grease fitting 16 Flange nut 17 Retaining ring 18 Cap screw 19 Thrust washer SAONPARNN Hydraulic System Rev G ec KS e Figure Idler pulley 104 Spacer Torsion spring Idler arm Hose clamp Flange nut Cap screw Flange head screw Pump support Spacer Cap screw Flat washer Spacer Pump mount plate Pump mount spacer Pulley Cap screw Lock washer Taper lock bushing Page 4 100 27 to 31 ft Ib 37 to 42 N m V belt O ring O ring O ring O ring O ring O ring Flat washer O ring Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic hose Bushing Gear pump O ring Flat washer Socket head screw Idler arm spacer Groundsmaster 3500 D
228. re and operator experience At side hill slope angles of 20 degrees or less the risk of a rollover is low As the slope Safety Pagel 2 Rev F 9 Fill fuel tank with diesel fuel before starting engine Avoid spilling any fuel Since fuel is highly flammable handle it carefully A Use an approved fuel container B Do notremove cap from fuel tank when engine is hot or running C Do not smoke while handling diesel fuel D Fill fuel tank outdoors and not over one inch from the top of the tank bottom of the filler neck Do not overfill angle increases to a Toro recommended maximum limit of 25 degrees the risk of a rollover increases to a moder ate level DO NOT EXCEED A 25 DEGREE SIDE HILL ANGLE BECAUSE THE RISK OF AROLLOVER AND SERIOUS INJ URY OR DEATH IS VERY HIGH The Groundsmaster 3500 D is equipped with an angle indi cator mounted on the steering tube which indicates the side hill angle the machine is operating on and identifies the recommended maximum limit of 25 degrees Stay alert for holes in terrain and other hidden hazards which can cause a sudden change inside hill angle Use extreme caution when operating close to sand traps ditches creeks steep hillsides or other hazards Re duce speed when making sharp turns Do not turn on hills Avoid sudden stops and starts Use reverse pedal for braking Cutting units must be lowered when going down slopes for steering control 10 When starting the engine A E
229. ring 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 Tighten cable to the swivel with cap screw Fig 6 5 Loosen screws securing throttle control lever to the control panel Fig 5 6 Push throttle control lever all the way to the FAST position Slide stop plate until it contacts throttle control lever and tighten screws securing throttle control to control panel Fig 5 Note Attach spring scale where the throttle cable is attached to the control lever Fig 7 7 Ifthrottle control lever does not stay in position during operation torque lock nut and cap screw usedto tighten the friction disc from 40 to 55 in Ib 4 5 to 6 2 N m The force required to operate the throttle control lever should be 20 Ib 89 N Torque fasteners as necessary Fig 7 8 Close and secure hood Figure 5 3 Stop plate 1 Throttle control lever 2 Screws Kubota Diesel Engine Rev G Page3 4 Figure 6 3 Speed control lever 4 Low idle stop 1 Throttle cable 2 Swivel Figure 7 4 Friction disc 5 Spring scale 6 Throttle cable 1 Throttle control lever 2 Lock nut 3 Cap screw Groundsmaster 3500 D Service and Repairs Replace Traction Belt 1 Park machine on a level surface lower cutting units stop
230. roperly tighten hose see Hydraulic Hose and Tube Installation in the Gener al Information section of this chapter 12 Lower machine to ground 13 Check oil level in hydraulic reservoir and add correct oil if necessary Figure 77 2 Lower fitting Groundsmaster 3500 D 1 Rear wheel motor Charge Hydraulic System NOTE When initially starting the hydraulic system with new or rebuilt components such as motors pumps or lift cylinders it is important that the hydraulic system be charged properly Air must be purged from the system and its components to reduce the chance of damage IMPORTANT Change hydraulic oil filter whenever hydraulic components are repaired or replaced 1 Park machine on a level surface and turn engine off 2 Make sure all hydraulic connections lines and com ponents are secured tightly 3 Ifcomponent failure was severe or the system is con taminated flush and refill hydraulic system and tank see Flush Hydraulic System 4 Make sure hydraulic tank is full Add correct oil if nec essary see Check Hydraulic System Fluid 5 Disconnect fuel stop solenoid lead to prevent the en gine from starting 6 Check control cable to the hydrostat for proper ad justment binding or broken parts 7 Make sure traction pedal and the lift control lever are in the neutral position Turn ignition key switch and en gage starter for ten 10 seconds to prime the traction and gear pumps Wait fif
231. rotection such as goggles when using compressed air 1 Clean all metal parts with solvent and blow dry with compressed air 2 Replace check poppets O rings and back up washers with new ones 3 Install new O rings into the valve body 4 Slide bushings and new O rings over the spools 5 If a spool was disassembled install washer spool spring spacer and retaining ring to the spool 6 Lubricate spools liberally with clean hydraulic fluid and install into their proper bore 7 Install spool caps into valve body Torque caps from 20 to 25 ft Ib 27 to 34 N m 8 Lubricate both plungers liberally with clean hydraulic fluid and install into their proper bore 9 Install new O rings seats check poppets and check springs into the plunger bores 10 Install O rings back up washers and seat retaining plugs into their plunger bores Torque both plugs from 30 to 35 ft Ib 41 to 48 N m 11 Install new O ring back up washer and solid plug into the bore with the grooved plunger Torque plug from 30 to 35 ft Ib 41 to 48 N m 12 Install new O ring seat check poppet check spring new O ring back up washer and seat retaining plug into the bore with the plunger Torque plug from 30 to 35 ft Ib 41 to 48 N m 13 Install O ring and plug into the top of the valve body next to the detent plug bore Torque plug from 10 to 12 ft Ib 14 to 16 N m 14 Lubricate plunger detent spring and disc libe
232. rust plates Body seals fit in grooves machined in body faces 2 Assemble pump sections starting at front cover end Apply grease or petroleum jelly to new section seals to hold them in position during gear pump assembly 3 After pump has been assembled tighten cap screws by hand Rotate the drive shaftto check for binding Pro tect the shaft if using a pliers to rotate shaft 4 Tighten the four 4 cap screws evenly in a crossing pattern to a torque of 33 ft Ib 45 N m Hydraulic System Rev G 2 ER GO a Y UO LR gt N lt Steering Control Valve oouogmmRoQoN za Steering arm Flange nut Flange head screw Steering valve bracket Cap screw Pivot hub Steering cover Cap screw Toro decal Ball knob Steering tilt lever Steering control valve Tilt bracket Cap screw Flat washer Flange nut Hydraulic System Rev G Figure Steering whddl4 Hydraulic fitting Hydraulic fitting Steering wheel nut Toro decal Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic hose Tilt steering boss Friction disc Friction disc Flat washer Jam nut Page 4 114 27 20 to 26 ft Ib Lock nut Flat washer Steering shield O ring O ring O ring O ring Philips head screw Steering wheel cap Flat washer Flange nut Slope indicator Decal Lock nut Cap screw Groundsmaster 3500 D Removal Before disconn
233. ry for 15 seconds G Take a voltage reading at 15 seconds then re move the load H Using the table below determine the minimum voltage for the cell temperature reading Voltage 3s CACIONES 383 See Battery Electrolyte Temperature 40 F 4 49C ss xw ec 1220 T7BC l Ifthe test voltage is below the minimum replace the battery If the test voltage is at or above the mini mum return the battery to service 5 A 9 3 1 T4 D Installation IMPORTANT To prevent possible electrical prob lems install only a fully charged battery 1 Make sure ignition and all accessories are off 2 Make sure battery compartment is clean and re painted if necessary 3 Make sure all battery cables battery retainer and electrical connections are in good condition 4 Place battery in its compartment Make sure battery is level and flat Connect positive cable connector onto positive battery post Tighten cap screw and lock nut with two wrenches IMPORTANT The nut and flat washer must be on top of the battery retainer during installation to pre vent the cap screw from hitting hydraulic hard lines when the sidewinder is shifted 5 Secure battery retainer Do not overtighten to pre vent cracking or distorting the battery case Groundsmaster 3500 D 6 Apply a light coat of grease on all battery posts and cable connectors to reduce corrosion after connections are made 7 Connect a digital multimeter
234. ry terminals from the battery posts see Battery Service in Chapter 5 Electrical Sys tem B Clean battery terminals and posts with a wire brush and baking soda solution C Coat cable terminals and battery posts with Grafo 112X skin over grease Toro Part No 505 47 or pe troleum jelly to prevent corrosion D Every 30 days check battery electrolyte levels and fill battery as necessary see Battery Care in Chapter 5 Electrical System E Every 60 days recharge battery slowly for 24 hours to prevent sulfate from forming on the battery plates see manufacturer s instructions for battery charger Groundsmaster 3500 D Page 2 11 Traction Unit Engine 1 Drain engine oil from the oil pan and replace the drain plug 2 Remove and discard oil filter Install new oil filter 3 Refill oil pan with approximately 4 0 quarts 3 8 1 of SAE10W 30 motor oil 4 Start engine and run at idle speed for approximately two minutes 5 Stop engine 6 Drain all fuel thoroughly from the fuel tank fuel lines and water fuel separator see Water Fuel Separator and Fuel System in Chapter 3 Kubota Diesel Engine 7 Flush the fuel tank with fresh clean diesel fuel see Fuel System in Chapter 3 Kubota Diesel Engine 8 Re secure all fuel system fittings 9 Clean and service the air cleaner assembly see Ser vice Air Filter Dust Cup and Burp Valve in Chapter 3 Kubota Diesel Engine 10 Seal air cleaner in
235. s and Chassis Front Lift Arms ONDARON 90 hydraulic fitting Hydraulic cylinder Sidewinder carrier assembly Flange nut Flange head screw Hydraulic hose Centering wire Hydraulic hose Hydraulic hose Hydraulic hose Slide bracket Flange nut Plastic slide Flange head screw Lift arm pivot shaft Roll pin Cap screw Flange head screw Cap screw Bearing cap Jam nut Cap screw Wheels Brakes and Chassis Figure 17 Lock nut Thrust washer Slide support bar Pin Spacer External retaining ring Bulkhead nut Hydraulic tube Bulkhead nut Carrier stop bracket Nut Flange nut O ring O ring RH liftarm LH liftarm Cap screw Shaft Thrust washer Lynch pin Rod Cap screw Page 6 18 Cap screw Torsion spring Grease fitting Hair pin RH deck stop LH deck stop Rivet Rubber bumper Flange nut Flange head screw RH pivot bracket LH pivot bracket Front carrier frame Flat washer Latch tube Latch rod Rod clip Rivet Actuator bracket Carriage screw RH actuator LH actuator Groundsmaster 3500 D Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove cutting units from the pivot shaft of the front lift arms see Cutting Unit Removal NOTE Remove both spacers from the
236. s equipped with an interlock switch on the parking brake The engine will stop if the traction pedal is depressed with the parking brake en gaged 1 Make sure all bystanders are away from the area of operation Keep hands and feet away from rotary decks Electrical System Rev G Page 5 8 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 3 With operator on the seat the traction pedal in neu tral the parking brake off and the cutting unit drive switch in the DISENGAGE position the engine should start Lift off the seat and slowly depress traction pedal the engine should stop in one to three seconds Correct problem if not operating properly Groundsmaster 3500 D Component Testing For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit e g unplug the ignition switch connector before doing a continuity check on the switch NOTE For more component testing information see the Kubota Workshop Manual Diesel Engine 05 Se ries Ignition Switch 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 With the use of a multimeter ohms setting the switch functions may be tested to determ
237. s out of the seat the engine will stop The standard seat uses a switch that is fastened to the underside of the seat Fig 23 The deluxe seat has a switch that is mounted to the seat base under the cush ion The switch electrical connector for either seat type is located directly under the seat Testing is the same for either switch type 1 Make sure the engine is off Remove seat by remov ing four cap screws that secure seat mounting straps to traction unit 2 Disconnect electrical connector from the switch 3 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals 4 With no pressure on the seat there should be no continuity between the seat switch terminals 5 Press directly onto the seat switch through the seat cushion There should be continuity as the seat cushion approaches the bottom of its travel 6 Reconnect switch connector Reinstall seat assem bly Electrical System Rev G Page 5 16 6 Switch adjustment neutral switch should be installed so that the pin on the traction pedal neutral position is centered with the switch Figure 22 1 Neutral switch 3 Switch bracket 2 Floor support plate Figure 23 1 Standard seat switch 2 Electrical connector Groundsmaster 3500 D Parking Brake and Transport Mow Switches The switches used for the parking brake and transport mow are the same normally closed switch The parking br
238. screw Suction strainer Dipstick Filter head Hydraulic tank cap Hose clamp Hydraulic hose Tee fitting Hydraulic hose Page 4 66 EARLY MODELS 2 31 Hydraulic SOS SE 8 CO Thread Sealant 33 Q 197 27 O ring O ring O ring O ring Hydraulic hose suction Hydraulic tube from oil cooler Hydraulic hose from manifold O ring Barb fitting early models Suction strainer early models Barb fitting early models Groundsmaster 3500 D Hydraulic Tank Removal 1 Drain hydraulic oil from Hydraulic tank see Change Hydraulic Fluid 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 sol vent 2 Inspect hydraulic tank for leaks cracks or other damage Groundsmaster 3500 D Page 4 67 Hydraulic Tank Installation 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 Ib 3 4 to 6 8 N m Install tank using Figure 78 as a guide 2 Thread suction strainer into hydraulic tank Note Early models used a two piece suction strainer assem bly On early models only use hydraulic thread sealant on threads of suction strainer and barb fittings during re assembly Do not apply sealant to the first thread of the fitti
239. set to amps between the negative battery post and the negative ground cable connector The reading should be less than 0 1 amp If the reading is 0 1 amp or more the unit s electri cal system should be tested and repaired 8 Connect negative ground cable connector to the negative battery post Tighten cap screw and lock nut with two wrenches Charging To minimize possible damage to the battery and allow the battery to be fully charged the slow charging meth od is presented here This charging method can be ac complished with a constant current battery charger which is available in most shops CAUTION Follow the manufacturer s instructions when us ing a battery charger NOTE Using specific gravity of the battery cells is the most accurate method of determining battery condition 1 Determine the battery charge level from either its specific gravity or open circuit voltage Battery Charge Specific Open Circuit Level Gravity Voltage 10096 1 265 12 68 7 E 2 Determine the charging time and rate using the manufacturer s battery charger instructions or the following table Groundsmaster 3500 D Page 5 27 Battery Battery Charge Level Reserve Percent of Fully Charged Capacity Minutes 80 or less 3 8hrs 7 5hrs 11 3 hrs 15 hrs 3 amps 3 amps 3 amps 3 amps 81 to 125 5 3hrs 10 5 hrs 15 8 hrs 21 hrs 4amps 4amps 4 amps 4 amps 126 to 5 5 hrs 11 hrs 1
240. shooting testing and repair of the diesel engine used in the Groundsmaster 3500 D 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 The use of some specialized test equipment is explained However the cost of the Operator s Manual The Traction Unit Operator s Manual provides informa tion regarding the operation general maintenance and maintenance intervals for the Kubota diesel engine that powers your Groundsmaster 3500 D Refer to this pub lication for additional information when servicing the machine Kubota Workshop Manual The engine that powers your Groundsmaster machine is aKubota model D1105 The Kubota Workshop Manu al is available for these engines Make sure that the cor rect engine manual is used when servicing the engine on your Groundsmaster 3500 D Kubota Diesel Engine Rev G Page 3 2 test equipment and the specialized nature of some re pairs may dictate that the work be done at an engine re pair facility Service and repair parts for Kubota engines are sup plied through your Authorized Toro Distributor If no parts list is available be prepared to provide your distrib utor with the Toro model and serial number Groundsmaster 3500 D Specifications Item Description Make Designation Kubota D1105 4 Cycle 3 Cylinder Liquid Cooled Diesel
241. sign 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 Removal Fig 13 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 If cutting deck is equipped with roller scraper re move roller scraper from deck A If equipped with early style roller scraper Fig 14 loosen one locknut that secures roller scraper rod to mounting bracket B Remove fasteners securing left and right scraper rod brackets to roller mounts Figs 14 and 15 C Remove scraper rod assembly from cutting deck 3 Remove four 4 mounting screws securing roller mounts to rear of deck frame Remove roller mounts and rear roller assembly from deck frame 4 Loosen fasteners securing each end of roller to roller mounts Remove mounts from roller Installation Fig 13 1 Place roller assembly into roller mounts 2 Install roller and roller mount assembly into rear of deck frame Secure assembly to deck frame with flange head screws IMPORTANT If roller design includes grease fittings in roller fasteners items 8 and 9 in Fig 13 make sure the grease groove in each roller mount aligns with the grease hole in each end of the roller shaft To help align the groove and hole there is also an al
242. smaster 3500 D Bee NIVIO Zeg TVNN3INI S STO Ges Q NINIVYLS AR a xnv o M a Mm y gt y y a I E 1 isd oooi 100 IWLSONGAH 2 i We i S SE amp zd td BONS 7 eaa am 7 E WS Se e NI tl I UM 1 isd QGL 00L i 3NVA MS 131 E MEE i4 100 M Ex p 3HnSS3Nd X2V8 ISU OSZ li f d I I 421003 119 150 900 gt m M t t CH gt ES T ES 7 Il T l v HH H z5 X d Il l m EX EX z th LL J y K 1NOd BEEN HAD 83m01 2018 du D isd QOZE C104 INVW LS X t 19 z e UO Eh 3 e lNOd dOL ayy M04 BEN ih E W Sd 00S gt 8 2 M 31v1d ID E E avaHying T W S NEP SE Za 7 ey SSC E 135 a H SUOLOW TH
243. ssary 18 Disconnect tester from hydraulic fitting and hose Reconnect hose to pump connection 19 Reconnect brake linkage to wheel see Wheels and Brakes Chapter 7 AW 9 gt ECH 3 Figure 54 1 Lower hydraulic fitting 2 Piston pump Hydraulic System Rev G 2g 5 5 S 2O Charge Relief Valve Pressure Test e TRACTION WHEEL MOTORS d FORWARD BI PASS TOP PORT UPPER PORT o 3000 psi gt 8 100 to 150 psi CHARGE RELIEF a IA T e Hydraulic System Rev G l l l l l I E La ont l l l l Page 4 36 TO HYDRAULIC MANIFOLD P1 PORT M FROM HYDRAULIC MANIFOLD CHG PORT TO STEERING CONTROL VALVE IN PORT po ENGINE A e GEAR PUMP FROM OIL gt FILTER L STRAINER ER High Pressure Low Pressure Return or Suction gt Flow Groundsmaster 3500 D Procedure for Charge Relief Valve Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 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 to the rear 90 hydraulic f
244. ssembly as follows Fig 12 A Remove return springs from the brake shoes Re move brake shoes from the backing plate B Matchmark brake cam and brake lever to assure proper alignment during reassembly Remove re taining clip from the brake cam Pull brake lever from the cam Remove cam from backing plate 10 The brake bracket and wheel shield can be removed as follows A Remove lock nuts spacers and cap screws se curing the brake bracket wheel shield and hydraulic motor to the frame B Separate bracket and shield from the frame Installation Fig 11 1 Insert four cap screws through the frame hydraulic motor spacers wheel shield and brake bracket Se cure with lock nuts but do not fully tighten 2 Assemble brake assembly as follows Fig 12 A Secure backing plate to the brake bracket with four cap screws and lock washers B Apply antiseize lubricant to cam shaft splines In sert cam shaft through the backing plate C Attach brake lever to the cam shaft Make sure matchmarks are aligned properly Secure lever to shaft with retaining clip D Lubricate brake shoe pivot points with a light coating of grease Groundsmaster 3500 D Page 6 11 E Position both brake shoes onthe backing plate so that the concave heels attach to the anchor pin F Insert both return springs into the holes of both brake shoes Make sure shoes fit snuggly against the anchor pin and cam 3 Ifthe brake lever ba
245. stment of the braking valve BV can be performed as follows NOTE Do not remove the braking valve from the hy draulic manifold for adjustment 1 Loosen lock nut on braking valve Fig 72 2 To decrease blade stopping time turn the adjust ment shaft on the valve in a counterclockwise direction Figure 72 1 Manifold assembly 2 Braking valve BV 3 To increase blade stopping time turn the adjust ment shaft on the valve in a clockwise direction 4 Tighten lock nut to secure adjustment 2 5 Ben 5 gt SE 5 Check blade stopping time and readjust braking valve as needed Groundsmaster 3500 D Page 4 57 Hydraulic System Rev G Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1 Before removing any parts from the hydraulic sys tem park machine on a level surface engage parking brake lower cutting units or attachments and stop en gine Remove key from the ignition switch 2 Clean machine before disconnecting removing or disassembling any hydraulic components Make sure hydraulic components hoses connections and fittings are cleaned thoroughly Always keep in mind the need for cleanliness when working on hydraulic components Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil Controls must be operated with the ignition switch in RUN
246. support straps 3 Disconnect electrical connector from the seat switch Separate seat from the frame 4 Remove seat parts as necessary to make repairs us ing Figure 9 as a guide Wheels Brakes and Chassis Page 6 8 1 Install any new seat parts using Figure 9 as a guide 2 Position seat spacers and support straps to the fuel tank and frame 3 Connect electrical connector to the seat switch 4 Secure seat support straps to the frame with four hex flange head screws Groundsmaster 3500 D Deluxe Seat Figure 10 1 Plate 18 Washer 35 Screw 2 Rivet 19 Nut 36 Cover 3 Screw 20 Swing arm assembly incl 28 amp 42 37 Clamp 4 Wear parts kit incl 8 thru 11 21 Adjusting rail RH 38 Shock absorber 5 Tension spring set 22 Bottom trim 39 Nut 6 Handle grip 23 Seat frame 40 Washer Bo ey 7 Adjusting lever 24 Screw 41 Bushing kit incl 39 amp 40 KK 8 Cover 25 Seat switch incl 24 26 amp 27 42 Backrest plate E 9 Bumper 26 Spring washer 43 Cap screw 5 5 10 Bushing 27 Nut 44 Lock washer r o 11 Pad 28 Back plate pivot 45 Seat belt 25 12 Backrest cushion 29 Threaded clevis 46 Hex flange nut 13 Hex head machine screw 30 Nut 47 Flat washer 14 Arm rests 31 Washer 48 Cap screw 15 Bottom cushion 32 Backrest trim 49 Hex flange head screw 16 Adjusting rail LH 33 Tension spring set 50 Seat support strap 17 Screw 34 Spindle adjuster incl 29 thru 31 35 amp 36 51
247. switch is in DISENGAGE or the transport mow slide is in TRANS PORT Solenoid valve R1 by passes flow from the cut ting unit motors directly to the hydraulic reservoir Solenoid valve R1 is energized with the engine run ning when the cutting unit drive switch is in ENGAGE and the transport mow slide is in MOW When ener gized solenoid valve R1 allows gear pump P1 flow out manifold block port M1 to the cutting unit motors When solenoid valve R1 is energized brake relief car tridge BV is shifted opens to allow oil return from the cutting unit motors Oil flows through the left right and then rear cutting unit motors as it turns the motors The oil then returns into manifold block port M2 the oil cooler the oil filter and to gear pump P1 inlet If cutting unit circuit pressure exceeds relief pressure of 3200 PSI 221 bar solenoid valve R1 shifts to allow circuit pressure relief Groundsmaster 3500 D Page 4 15 Cutting Unit Blade Braking 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 The inertia of the rotating cutting blades however effec tively turns the deck motors into pumps causing an in crease in pressure as the flow from the motors comes up against the closed brake relief cartridge BV When this pressure builds to approxima
248. t R Pressure retracts the piston for a rightturn The rotary meter V1 ensures that Groundsmaster 3500 D Page 4 23 the oil flow to the cylinder is proportional to the amount of the turning on the steering wheel Fluid leaving the cylinder flows back through the spool valve then through the OUT port and to the hydrostat The steering control valve returns to the neutral position when turning is complete Left Turn When a left turn is made with the engine running the turning ofthe steering wheel positions the spool valve so that flow goes through the top ofthe spool Flow entering the steering control valve at the IN port goes through the spool andis routed to two places As in a rightturn most of the flow through the valve is by passed out the AUX port back through the 2 spool valve to the hydrostat Also like a right turn the remainder of the flow is drawn through rotary meter V1 but goes out port L Pressure extends the piston for a left turn The rotary meter V1 ensures that the oil flow to the cylinder is proportional to the amount of the turning on the steering wheel Fluid leaving the cylinder flows back through the spool valve then through the OUT port and to the hydrostat The steering control valve returns to the neutral position when turning is complete Hydraulic System Rev G 2 ER CO a Y UO LR gt on lt Special Tools Order these special tools from your Toro Distributor Hydraul
249. t Records and Maintenance Groundsmaster 3500 D Page 6 19 Wheels Brakes and Chassis Rear Lift Arm 200 to 250 ft Ib 271 to 339 N m Hydraulic tube Bulkhead locknut Hydraulic T fitting Hydraulic hose 90 hydraulic fitting Hydraulic hose Hydraulic tube Straight hydraulic fitting Castor bushing 10 Hydraulic lift cylinder 11 Thrust washer 12 O ring 13 Bulkhead locknut 14 Bulkhead elbow union 15 Hydraulic hose 16 Hydraulic hose WONDAPWON gt Wheels Brakes and Chassis Figure 20 Hydraulic tube Hydraulic tube Hydraulic tube Tube clamp Flat washer Cap screw Lock nut Rear pivot shaft Jam nut Washer Lift arm assembly Flange head screw Thrust washer Grease fitting Cutting unit pivot shaft Cap screw Page 6 20 Cap screw Rebound washer Thrust washer Lynch pin Rear cutting unit frame Wear strip Poprivet Grease fitting O ring Guard Cap screw Cap screw Lock nut External retaining ring Pin O ring Groundsmaster 3500 D Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove cutting unit from the pivot shaft of the rear lift arm see 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
250. t must be lu bricated are Rear cutting unit pivot Fig NO TAG Front cutting unit pivot Fig 2 Sidewinder cylinder ends qty 2 Fig 3 Steering pivot Fig 4 Rear lift arm pivot and lift cylinder qty 2 Fig 5 Left front lift arm pivot and lift cylinder qty 2 Fig 6 Right front lift arm pivot and lift cylinder qty 2 Fig 7 Neutral adjust mecha nism Fig 8 Mow Transport slide Fig 9 Belt tension pivot Fig 10 and Steering cylinder Fig 11 Figure 2 Note f desired an additional grease fitting may be installed in other end of steering cylinder Tire must be removed plug removed fitting installed greased fitting removed and plug reinstalled Fig 12 IMPORTANT Do not lubricate Sidewinder cross tube bearing blocks are self lubricated IMPORTANT Lubricate bearings and bushings im mediately after washing This helps to purge water out of bearings and increases bearing life 1 Wipe each grease fitting with a clean rag Figure 3 IMPORTANT Do not apply too much pressure or grease seals will be permanently damaged 2 Apply grease until pressure is felt against handle 3 Wipe excess grease away Groundsmaster 3500 D Page 2 7 Product Records and Maintenance Figure 9 Figure 6 Product Records and Maintenance Page 2 8 Groundsmaster 3500 D Groundsmaster 3500 D Page 2 9 Figure 12 See note Product Records and Maintenance Product Records o o c
251. t wheel and use wood blocks to keep the front tire off the floor 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key 3 Remove lug nuts from drive studs Pull wheel from from the ignition switch drive studs and wheel hub NOTE The installation torque of the lock nut is from WA R N ING 250 to 350 ft lb 339 to 474 N m Use impact wrench to loosen lock nut from the hydraulic motor shaft Before jacking up the machine review and follow 4 Loosen but do not remove lock nut from the hydrau J acking Instructions in Chapter 1 Safety lic motor shaft Release parking brake Wheels Brakes and Chassis Page 6 10 Rev F Groundsmaster 3500 D IMPORTANT DO NOT hit wheel hub wheel hub puller or wheel motor with a hammer during wheel hub removal or installation Hammering may cause damage to the wheel motor 5 Using hub puller see Special Tools loosen wheel hub from wheel motor 6 Remove lock nut hub and brake drum from motor shaft Locate and retrieve woodruff key 7 Remove cotter pin from the adjustment rod Sepa rate adjustment rod from the brake lever NOTE The brake lever backing plate retaining clip return springs brake shoes and cam shaft can be re moved as a complete brake assembly 8 Ifitis desired to remove the brake assembly from the brake bracket remove four cap screws and lock nuts se curing the assembly to the bracket 9 Disassemble brake a
252. te meth od of assembly is the Flats From Finger Tight F F F T method Hold the fitting in the desired position with a wrench and if port material is steel tighten the lock nut with a second wrench to the listed F F F T Step 4 in Fig ure 43 If port material is aluminum tighten fitting to 6096 of listed F F F T Size F F F T 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 5 8 in 1 50 0 25 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 Groundsmaster 3500 D Page4 7 Lock Nut P NS Back up Washer O ring Figure 42 Figure 43 Hydraulic System Rev G 2 E L3 5 gt 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 To relieve hydraulic pressure in steering and lift circuits ro tate steering wheel in both directions To relieve cutting unit system pressure turn key switch to ON engine not running Move PTO switch to engage which will energize the solenoid valve on hydraulic man ifold to relieve circuit pressure Move PTO
253. teen 15 seconds to allow the starter motor to cool and then repeat cranking proce dure again 8 Reconnect fuel stop solenoid lead Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 9 Raise one front and rear wheel off the floor and place support blocks under the frame Chock remaining front wheel to prevent movement of the machine One front wheel and the rear wheel will be off the ground during testing Make sure machine is supported so it will not move and accidentally fall to prevent injuring anyone under machine Groundsmaster 3500 D Page 4 65 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 If there is no indication of fill in 30 seconds stop the engine and determine the cause 11 After the hydraulic system starts to show signs of fill actuate lift control lever until the lift cylinder rod moves in and out several times If the cylinder rod does not move after 10 to 15 seconds or the pump emits abnor mal sounds shut the engine off immediately and deter mine cause or problem Inspect for the following A Loose filter or suction lines Incorrect hydraulic hose routing B C Loose or faulty coupler on the pump D Blocked suction line E Faulty charge relief valve F Faulty charge pump Gear Pump P2 12 If cylind
254. tely 1500 PSI 103 bar brake relief cartridge BV opens which allows hy draulic flow to return to tank and reduces return pres sure When return pressure drops below 1500 PSI 103 bar brake relief cartridge BV reseats to further slow the cutting blades This action repeats several times in a very short time frame as the blades finally come to a stop Once the blades have stopped brake relief car tridge BV remains closed to keep the deck motors from rotating Hydraulic System Rev G 2 ER O a Y UO LR gt N lt SNIVA ONIH33IS H3MOd NES 8 XNY SNIH33IS ISd 0001 H3QNIM3GIS JMA H3ONIM3GIS LHIl mo NI 13 1NOyW3 A IS 93a Ne vay ew Lee oaa 1331 3 1Vld avaHy1ng 3unss3uaMova Sd ose
255. tem tube can cause binding and malfunction 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 contamina tion 4 Visually inspect cartridge valve for damaged sealing surfaces or contamination A Contamination may cause valves to stick or hang up Contaminates can become lodged in small valve orifices or seal areas causing malfunction B If sealing surfaces appear pitted or damaged the hydraulic system may be overheating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air 5 Clean cartridge valve using clean mineral spirits Submerge valve in clean mineral spirits to flush out con tamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves Use compressed air for cleaning IMPORTANT Use care when handling the cartridge valve Slight bending or distortion of the stem tube can cause binding and malfunction 6 Reinstall cartridge valve A Lubricate new O rings and backup rings of seal kit with clean hydraulic oil and install The O rings and backup rings must be arranged properly on the cartridge valve for proper operation and sealing Figs 95 and 96 B Thread cartridge valve carefully into the applica ble port Fig 92 The valve should go in easily with out b
256. temperature warning light should come on To test the high temperature warning light and circuit wir ing turn ignition switch to the ON position and ground the gray wire attached to high temperature sender lo cated on the engine water pump housing see Tempera ture Sender in this Chapter The high temperature warning light should illuminate Glow Plug Indicator Light The glow plug light should come on when the ignition switch is placed in the ON position prior to placing the ignition switch in START The light should stay lit for approximately 6 seconds while the ignition switch is left in the ON position Testing Indicator Lights 1 Apply 12 VDC to terminals 1A and 2A Fig 18 2 Ground terminals 1B and 2B Fig 18 3 Both indicator lights should illuminate Electrical System Rev G Page 5 14 Figure 17 3 High temp shutdown 4 Glow plug indicator 1 Charge indicator 2 Engine oil pressure Figure 18 1 Charge indicator 4 Glow plug indicator 2 Engine oil pressure 5 Indicator light front 3 High temperature 6 Indicator light back Groundsmaster 3500 D Cutting Unit Drive Switch Serial Number Below 314000000 The cutting unit drive switch is located on the control panel Fig 19 This switch allows the decks to be en gaged or disengaged Along with additional switches in the interlock system the cutting unit drive switch con trols the solenoid valve on th
257. ter 5 Electrical System General Safety Instructions 1 1 Electrical Schematics and Diagrams Jacking Instructions 1 4 Special Tools Troubleshooting Chapter 2 Product Records and Maintenance Electrical System Quick Checks Component Testing 9 Product Records 2 1 Service and Repairs 8 S Maintenance 2 1 ER Equivalents and Conversions 2 2 Chapter 6 Wheels Brakes and Chassis E oS Torque Specifications 2 3 3 Specifications as Chapter 3 Kubota Diesel Engine Special Tools Adjustments y ee bv SPEED LI E Introduction e en REENED 3 2 Service and Repairs 5 Specifications 3 3 35 General Information 3 4 Chapter 7 Cutting Units E 3 AQUSIMENTS es ximo Tied Ines cedit aree TUNA 3 6 E Service and Repairs 3 8 Specifications A KUBOTA WORKSHOP MANUAL DIESEL ENGINE Troubleshooting 05 SERIES Special TOONS seve said geben ia rta dd Adjustments 9 Chapter 4 Hydraulic System Service and Repairs E S 92 Specifications Bet a e Rar aa E avere ARR acd ee
258. the radiator frame 12 Plug any openings to prevent contamination Installation 1 Remove all plugs used during the removal proce dures 2 Position radiator carefully to the radiator frame 3 Secure radiator assembly to the radiator frame with four carriage bolts and lock nuts Secure top and bottom of radiator to frame with flange head screws 4 Secure both fan shrouds to the radiator assembly with flange head screws Groundsmaster 3500 D Page 3 15 PHA WW Wm A onc Se ma NI Figure 19 1 Hydraulic filter element 2 Hydraulic filter head 3 Hydraulic hose 5 Secure expansion tank bracket and tank to the top fan shroud with both flange head screws and flange nuts 6 Connect the following hydraulic hoses to the oil cool er section of the radiator oil cooler assembly A Hydraulic tube to top of hydraulic fluid cooler B Hydraulic hose to bottom of hydraulic fluid cooler 7 Connect following coolant hoses to the radiator oil cooler assembly A Upper radiator hose to the water pump B Lower radiator hose to the engine block C Coolant hose to the expansion tank D Air hose to the air cleaner 8 Secure glow plug relay to the radiator assembly with both thread forming screws 9 Make sure draincock valve in radiator is closed Fill radiator with coolant to the bottom of the filler neck 10 Install engine hood to the machine Close and latch hood 11 Start engine Check fo
259. the rear fork as fol lows A Remove both jam nuts securing the ball joint to the rear fork B Separate ball joint from the rear fork C Swing cylinder clear of the rear fork 6 Remove four lock nuts and hex socket head screws securing the hydraulic motor to the rear fork Remove motor from the fork and position it away from the fork Support rear fork to prevent its falling during re moval and installation Personal injury or dam age to the fork may result from improper han dling 7 Remove cap screw thrust washer and lock washer from the rear fork shaft 8 Lower rear fork from machine 9 Check bushings for wear and damage Replace if necessary Groundsmaster 3500 D Page 6 13 Rev D Installation 1 Position rear fork through the frame 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 Swing cylinder to the rear fork B Install ball joint to rear fork C Secure ball joint to the rear fork with both jam nuts Tighten the first jam nut from 65 to 85 ft lb 88 to 115 N m then tighten the second jam nut to the same specification 5 Secure wheel rim to the wheel hub with four lug nuts Torque nuts from 45 to 65 ft
260. ting edges are dull or nicked Inspect blade sail for wear or damage Replace blade if needed Make sure that cutting chambers are in good condition Keep underside of deck clean Debris buildup will reduce cutting performance Make sure all cutting units are set at the same height of cut Set units as specified in the Cutting Unit Operator s Manual Check lift arms and cutting unit pivot linkages for wear damage or binding Also inspect for bent or damaged pivot shafts 8 Roller condition All rollers should rotate freely Replace roller bearings if worn or damaged Groundsmaster 3500 D Page 7 3 Cutting Units Rev D 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 TOR4064 Spanner Wrench TOR4065 Inner Oil Seal Installer TOR4066 Bearing Installer TOR4067 Shaft Support Tool TOR4068 Inner Seal Installer TOR4869 Outer Seal Installer TOR4071 Outer Oil Seal Installer TOR4072 Shaft Seal Protector TOR4073 Handle TOR4074 Spline Insert Tool Figure 1 Rear Roller Grease Nozzle 107 1998 This tool is used to grease the cutting unit rear roller bearings when equipped with a grease fitting on the ends of the roller shaft Figure 2 Rear Roller Bearing and Seal Installation Tools These t
261. to 57 N m T v OC N Po ke fe SN te SE Hydraulic System Rev G Figure 1 Check poppet 11 Valve body 102 2 Grooved plunger 12 O ring 3 Spacer 13 Retaining ring 4 Spool 14 Washer 5 Seat 15 Seat retaining plug 6 Solid plug 16 Spool spring 7 Seat retaining plug with port 17 Disc 8 Bushing 18 Plug 9 Check spring 19 Detent plug 10 Spool cap 20 Wiper seal Page 4 96 30 30 to 35 ft Ib 41 to 48 N m 30 to 35 ft Ib 41 to 48 N m Plunger Plunger detent Detent spring O ring O ring Back up washer O ring O ring O ring Back up washer Groundsmaster 3500 D WK ULL ptt oe SSIS gt A Ya E BOK Tc i AAA Hydraulic System S i i E Figure 1 Check poppet 11 Valve body 103 21 Plunger 2 Grooved plunger 12 22 Plunger detent 3 Spacer 13 Ret g ring 23 Detent spring 4 Spool 14 24 O ring 5 Seat 15 Seat retaining plug 25 O ring 6 Solid plug 16 Spool spring 26 Back up washer 7 Seat retaining plug with port 17 Di 27 O ring 8 Bushi 18 Plu 28 O ring 9 Ch pring 19 Detent plug 29 O ring 10 Spool cap Wi 30 Back up wash Groundsmaster 3500 D Page 4 97 Hydraulic System Rev G Disassembly 1 Plug all ports and clean the outside of the valve thor oughly IMPORTANT Match mark spools to their associat ed bores before disassembly Spools must be rein stalled to the bore from which they were removed 2
262. to START the fuel stop solenoid is initially ener gized and the pull coil retracts the solenoid plunger Once the plunger is retracted the hold coil will keep it re tracted for continued engine operation When the sole noid is de energized the plunger extends to shut off fuel supply to the engine causing the engine to stop running The fuel stop solenoid is grounded through the solenoid housing NOTE Refer to Chapter 8 Electrical Diagrams when troubleshooting the fuel stop solenoid In Place Testing NOTE Prior to taking small resistance readings with a digital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from the measured value of the component you are test ing 1 Make sure ignition switch is in the OFF position Dis connect wire harness connector from fuel stop solenoid 2 Using a digital multimeter touch one test lead to the pull coil terminal and the other test lead to the fuel stop solenoid frame ground Fig 33 The resistance of the pull coil should be less than 1 ohm but not zero 3 Using a digital multimeter touch one test lead to the hold coil terminal and the other test lead to the fuel stop solenoid frame ground Fig 33 The resistance of the hold coil should be approximately 15 ohms 4 Connect solenoid to the wiring har
263. top surface with water after cleaning Do not remove the fill cap while cleaning 3 Battery cables must be tight on terminals to provide good electrical contact Connecting cables to the wrong post could re sult in personal injury and or damage to the electrical system 4 If corrosion occurs at terminals disconnect cables Always disconnect negative cable first Scrape clamps and terminals separately Reconnect cables with positive cable first Coat terminals with petro leum jelly 5 Check electrolyte level every 25 operating hours and every 30 days if machine is in storage 6 Maintain cell level with distilled or demineralized wa ter Do not fill cells above the fill line Groundsmaster 3500 D Battery Service The battery is the heart of the electrical system With regular and proper service battery life can be extended Additionally battery and electrical component failure can be prevented A CAUTION When working with batteries use extreme cau tion 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 Electrolyte Specific Gravity Fully charged 1 265 corrected to 80 F 26 7 C Discharged less than 1 240 Battery Specifications BCI Group Size 55 585 CCA at 0 F 17 89 C Reserve Capacity of 95 minutes at 80 F 26 7 C Dimensions including terminal posts and ca
264. tor to the solenoid 4 If solenoid coil needs replacement see PTO Sole noid Valve Coil in the Service and Repairs section of this chapter Figure 12 1 Manifold assembly 2 Solenoid valve coil Groundsmaster 3500 D Page 5 11 Electrical System Rev G Diode Assemblies The diodes D1 D2 and D4 provide logic for the interlock switches Diode D3 is used for circuit protection from in ductive voltage spikes when the interlock relay is de en ergized Two types of diodes have been used on the Groundsmaster 3500 D 1 On early production machines the diodes are lo cated 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 Location of the diodes is un derih trol Figure 13 SE 1 Diode 3 Female terminal blade 2 Male terminal blade 4 Clear PVC tubing NOTE Machines equipped with the standard control module serial numbers above 240000000 use only one diode Testing The diodes can be individually tested using a digital multimeter diode test or ohms setting and the tables below 1 Diodes located within the main harness Fig 13 Multimeter Multimeter Figure 14 Red Lead Black Lead Continuity 1 Diode 3 Female terminal on on 2 Male terminal Terminal Blade Terminal Blade
265. trical System Rev G Page 5 18 Figure 27 1 Temp warning switch 3 Water pump housing 2 Temp shutdown switch Groundsmaster 3500 D Fuel Pump The fuel pump is attached to the frame just outboard of the fuel injection pump Operational Test 1 Park machine on a level surface lower cutting decks stop engine and engage parking brake Unlatch and raise hood 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 4 Make sure fuel hoses attached to the fuel pump are free of obstructions 5 Place fuel hose pump discharge into a large grad uated cylinder sufficient enough to collect 1 quart 0 95 liter IMPORTANT When testing the fuel pump DO NOT turn ignition switch to START 6 Collect fuel in the graduated cylinder by turning igni tion switch to the RUN position Allow pump to run for time listed below then return switch to OFF A For most Groundsmaster 3500 D machines the amount of fuel collected in the graduated cylinder should be approximately 11 8 fl oz 350 ml after thirty 30 seconds B For machines that are equipped with a Biodiesel Conversion Kit the amount of fuel collected in the graduated cylinder should be approximately 16 fl oz 475 ml after fifteen 15 seconds 7 Replace fuel pump as necessary Install fuel hose to the fuel filter 8 Reconnect electrical
266. uently check and keep all nuts bolts screws and hydraulic fittings tight 4 Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition be fore applying pressure to the system 5 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 suffi cient force to penetrate skin and do serious damage If fluid is injected into the skin it must be surgically re moved within a few hours by a doctor familiar with this form of injury or gangrene may result 6 Before disconnecting or performing any work on the hydraulic system all pressure in system must be re lieved by stopping engine and lowering cutting units to the ground Groundsmaster 3500 D Page 1 3 Rev F 15 Before getting off the seat A Move traction pedal to neutral B Set the parking brake C Disengage the cutting units and wait for the blades to stop spinning D Stop the engine and remove key from the ignition switch 16 Whenever machine is left unattended make sure key is removed from ignition switch and parking brake is set 7 If major repairs are ever needed or if assistance is desired contact an Authorized Toro Distributor 8 Toreduce potential fire hazard keep the engine area free of excessive grease grass leaves and accumula tion of dirt 9 I
267. uffler plate 4 Muffler bracket 1 Flange head nut 2 Flange head screw Air Cleaner Removal Fig 11 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch Unlatch and raise hood 2 Remove air cleaner components as needed using Figure 11 as a guide Air Cleaner Installation Fig 11 IMPORTANT Any leaks in the air cleaner system will cause serious engine damage Make sure that all air cleaner components are in good condition and are properly secured during assembly 1 Assemble air cleaner system using Figure 11 asa guide A When installing air cleaner orientate the evacua tor valve on the air cleaner cover so that the valve is pointing in a downward position B Make sure that air cleaner hoses do not contact the engine or exhaust system after assembly To en sure clearance move and or rotate air cleaner body in air cleaner strap if necessary 2 After all air cleaner components have been installed lower and secure hood Kubota Diesel Engine Rev G o E 2 74 Ek GE E OH Fuel System WONAARPWONS 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 Figure 13 Tee fitting Barb fitting Barb fitting
268. uld come on when the ignition switch is in the ON PREHEAT position with the engine not running or with an improperly operating charging circuit while the engine is running 1 Turn ignition switch to ON PREHEAT the battery light should come on 2 Turn ignition switch to OFF Figure 16 Groundsmaster 3500 D Page 5 13 Electrical System Rev G Indicator Lights Serial Numbers Above 240000000 Charge Indicator Light The charge indicator light should come on when the igni tion switch is in the ON position with the engine not run ning Also it should illuminate with an improperly operating charging circuit while the engine is running 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 Also it should illuminate with the engine run ning if the engine oil pressure drops to an unsafe level IMPORTANT If the oil pressure indicator light is il luminated with the engine running shut off the en gine immediately To test the oil pressure light and circuit wiring ground the wire attached to oil pressure switch located on the en gine near the oil filter Turn ignition switch to the ON posi tion the engine oil pressure light should come on indicating correct operation of the indicator light and cir cuit wiring High Temperature Warning Light If the engine coolant temperature reaches 221 F 105 C approximate the high
269. uld rotate with less than 5 in Ibs 0 68 N m resistance Figure 22 1 Roller tube 4 Outer seal 2 Inner seal 5 Bearing outer seal tool 3 Bearing Figure 23 1 Roller tube 4 Bearing 2 Roller shaft 5 Washer 3 Inner seal 6 Bearing outer seal tool N N N X E PA p YA yyy WAZA EZ APL LA LEE PLL ERE LL P wi Figure 24 1 Roller tube 4 Bearing 2 Roller shaft 5 Outer seal 3 Inner seal 6 Bearing outer seal tool Cutting Units Rev D Front Roller Service Disassembly Fig 25 1 Remove roller mounting bolt 2 Remove roller assembly from carrier frame 3 To remove bearings and spacer A Insert punch through end of roller and drive oppo site bearing out by alternating taps to opposite side of inner bearing race There should be alip ofinner race exposed for this process B Remove spacer Remove second bearing from roller using a press 4 Inspect roller housing bearings and bearing spacer for damage or wear Replace components as needed Assembly Fig 25 1 Install bearings and bearing spacer into roller A Press first bearing into housing Press on outer race only or equally on inner and outer races B Insert bearing spacer C Press second bearing into roller housing press ing equally on inner and outer races until the inner race comes in contact with the space
270. und will be trying to move the machine forward 12 Slowly push traction pedal fully to forward position Groundsmaster 3500 D Page 4 35 13 Verify traction relief valve setting by closing flow con trol valve on tester System pressure should be 3500 PSI as the relief valve lifts If pressure can not be met or is exceeded with traction pedal fully depressed release traction pedal and open flow control valve fully 14 If specification is not met consider the following A The traction belt may be worn and slipping see Replace Traction Belt B The relief valve leaks or is faulty and needs re placement 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 A Apply traction pedal until pressure gauge reads 1000 PSI Verify with a phototac that the pump speed is 2350 RPM engine speed approximately 2450 RPM B Observe flow gauge TESTER READING should be approximately 12 5 GPM 16 Release traction pedal and turn off machine Note If pressure is good under no load but drops be low specification when under traction load the piston pump and or wheel motor s should be suspected of wear When a pump and or motor is worn or damaged the charge pumpis not able to keep up with internal leak age in the traction circuit See Test 3 17 If specifications are not met the hydrostat needs to be repaired or replaced as nece
271. undsmaster 3500 D Page 4 31 Hydraulic System Rev G Traction Circuit Working Pressure Test Using Pressure Gauge e Eemer TRACTION WHEEL MOTORS Y FORWARD 3000 psi TRACTION RELIEF A E j FROM HYDRAULIC MANIFOLD CHARGE PORT Sodom PISTON PUMP HYDROSTAT EE eee TEE OG PUMP SUCTION High Pressure T EAR THROUGH CASE DRAIN Low Pressure Return or Suction gt Flow Hydraulic System Rev G Page 4 32 Groundsmaster 3500 D Procedure for Traction Circuit Working Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on alevel surface with the cutting units lowered and off Make sure engine is off 3 Read Precautions for Hydraulic Testing 4 Make sure that traction pedal is adjusted to the neu tral position see Adjust Traction Drive for Neutral in the Adjustments Section Figure 53 1 Hydraulic tube with plug 2 Floor plate 5 Remove plug from hydraulic tube connected to front wheel motors Fig 53 Connect test gauge with a hy draulic hose attached to the hydraulic tube opening Make sure hose is long enough so the operator can read gauge while driving the machine 6 Start engine and move throttle to full speed 3050 50 RPM 2 5 Been 5 gt
272. ure 73 1 Gear pump 2 Suction hose from tank Been cs E lt Figure 74 1 Hydraulic tank 2 Cap Groundsmaster 3500 D Page 4 59 Hydraulic System Rev G 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 re placement IMPORTANT Use of any other filter may void the warranty on some components 1 Position machine on a level surface lower the cut ting units stop the engine engage the parking brake and remove key from ignition switch 2 Clamp hose leading to the oil filter head from the hy draulic tank to prevent draining the hydraulic tank Figure 75 1 Hydraulic oil filter 2 Rear wheel 3 Clean area around filter mounting surface Place drain pan under filter and remove filter Properly dispose of filter 4 Fill the new filter with hydraulic fluid and lubricate fil ter gasket 5 Assure filter mounting surface is clean Screw filter on until filter gasket contacts mounting plate Then tight en filter an additional 3 4 turn 6 Fill hydraulic tank with approximately 6 gallons 22 6 liters of hydraulic fluid Refer to Change Hydraulic Fluid Remove clamp from hydraulic hose 7 Start engine and let run for about two minutes to purge air from the hydraulic system Stop th
273. ure gauge carefully while slowly closing the flow control valve until 800 PSI is obtained Verify with a phototac that the pump speed is 3100 RPM while maintaining 800 PSI 9 Flow indication should be 3 6 GPM minimum 10 Shut off engine NOTE If necessary Steering and Lift Relief Pressure Test can be conducted with tester as placed for this test 11 If flow was less than 3 6 GPM or a pressure of 800 PSI cannot be obtained check for restrictionin the pump intake line If line is not restricted remove gear pump P2 and repair or replace as necessary 12 Disconnect tester from gear pump fitting and hose Reconnect hose to the pump Figure 56 1 Gear pump P2 2 To steering control valve 2 E L3 5 gt Groundsmaster 3500 D Page 4 39 Hydraulic System Rev G Wheel Motor Efficiency Test Using Tester with Pressure Gauges and Flow Meter M TRACTION WHEEL Y MOTORS FRONT WHEEL MOTOR TESTING SHOWN TOP PORT FORWARD doc eos 100 to 150 psil gt o 2 L High Pressure Low Pressure Return or Suction Flow Figure 57 NOTE Over a period of time a wheel motor can wear internally A worn motor may by pass oil to its case drain causing the motor to be less efficient Eventually enough oil loss will cause the wheel motor to stall under heavy load conditions Continued operation with a worn
274. uts SAE J995 Grade 2 or Stronger Nuts ff SAE J995 Grade 2 or Stronger Nuts ll SAE J995 Grade 5 or Stronger Nuts 147 23 350 30 485 45 6 32 UNC 6 40 UNF 8 32 UNC 8 36 UNF 675 70 10 24 UNC 475 45 339 56 ollo gt 00 eo dv fie a lo gt Ke o al al I I I Ke al al 765 70 10 32 UNF 540 45 1 4 20 UNC 48 7 599 79 100 10 1125 100 140 15 1580 170 1 4 28 UNF 53 7 65 10 734 113 115 10 1300 100 160 15 1800 170 5 16 18 UNC 115 15 105 17 1186 169 200 25 2250 280 300 30 3390 340 5 16 24 UNF 138 17 128 17 1446 192 225 25 2540 280 325 30 3670 340 E a o I I I N N N al E M N gt al ww N O N o o a wo I I I I I I I I I I N N Co Co N N N al al N o lo N N a X ER N I I I I I o A a wo o ala o B a o a o l loi do io I I I I I I I I a lo o A alo 1 2 13 UNC 30 3 102 11 105 10 142 14 1 2 20 UNF 32 3 72 9 8 115 11 120 10 163 14 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 20 285 27 5 8 18 UNF 75 10 95 15 129 20 170 15 230 20 240 20 325 27 3 4 10 UNC 93 12 140 20 190 27 265 25 359 34 375 35 508 47 3 4 16 UNF 115 15 165 25 224 34 300 25 407 34 420 35 569 47 7 8 9 UNC 140 20 225 25 305 34 430 45 583 61 600 60 813 81 7 8 14 UNF 155
275. vis onto shaft Adjust center to center length to dimension shown in Figure 125 before tightening jam nut 10 125 to 10 500 25 72 to 26 67 cm Figure 125 Hydraulic System Rev G E E L3 Ki E I E o N E 77 Steering Cylinder No 2 General Purpose Grease 65 to 85 ft Ib m 88 to 115 N m E ge 65 to 85 ft Ib 88 to 115 N m Figure 1 Hydraulic hose 5 O ring 126 9 Jam nuts 2 Hydraulic hose 6 Steering cylinder 10 Frame 3 O ring 7 Ball joint 11 Rear fork 4 Hydraulic fitting 8 Retaining ring 12 Rear casting Hydraulic System Rev G Page 4 126 Groundsmaster 3500 D Removal Fig 126 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch NOTE Therear tire must be removed to allow sufficient clearance to remove the steering cylinder from the ma chine MAA Figure 127 1 Steering cylinder 2 Jam nuts Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Jack or lift rear wheel off the ground 3 Remove rear wheel from the drive studs and wheel hub 4 Thoroughly clean hydraulic hose ends and fittings on steering cylinder to prevent hydraulic system contami A 2 nation gt E s E Figure 128 El 1 Steering cylin
276. 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 Installation 1 Assemble lift arm using Figure 20 as a guide A If the rear lift arm pivot shaft item 24 was re moved from frame thoroughly clean tapered sur faces of shaftand frame Position pivot shaftto frame and secure with washer and jam nut Torque jam nut from 200 to 250 ft Ib 271 to 339 N m B If the cutting unit pivot shaft item 31 was re moved from lift arm apply antiseize lubricantto pivot shaft before inserting into lift arm Secure pivot shaft with two 2 cap screws items 32 and 33 and wash er item 34 Groundsmaster 3500 D Page 6 21 Rev D 2 Slide rear lift arm onto rear pivot shaft making sure that the lift cylinder shaft ofthe rear lift arm slides into the clevis of the hydraulic cylinder 3 Secure hydraulic cylinder clevis to the lift cylinder shaft of the rear lift arm with the thrust washer and exter nal retaining ring 4 Install rear cutting unit to the pivot shaft of the rear lift arm see Cutting Unit Removal 5 Adjust lift arm to proper clearance see Adjust Rear Lift Arm IMPORTANT Make sure hosesare free of twists and sharp bends Raise cutting units and shift them to the left Rear cutting unit hoses must not contact the traction cable bracket If required reposition fit tings and hoses 6 Grease
277. 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 Assembly Fig 109 Note When assembling the pump check the marker line on each part to make sure the parts are properly aligned during reassembly 1 Lubricate O rings pressure seals back up gas kets and wear plates with a thin coat of petroleum jelly Lubricate all other internal parts freely with clean hy draulic oil NOTE A seal and retaining ring are not necessary in the front plate The gear pump seal kit does not include these parts 2 Place front plate on a flat surface with the internal machined surface facing up 3 Apply a light coating of petroleum jelly to the pres sure seals back up gaskets and wear plate grooves 4 Install the pressure seals flat side outward into the grooves in the wear plates Follow by carefully placing the backup gaskets flat side outward between the pressure seals and the groove in the wear plate 5 Apply alight coating of petroleum jelly to the exposed side of the front plate 6 Lubricate the drive gear shaft with clean hydraulic oil Insert the drive end of the drive shaft through the wear plate with the pressure seal side down and the open side of the pressure seal pointing to the suction side of the pump Carefully install shaft
278. wing procedure A Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged B Turn the steering wheel all the way to the left counterclockwise so the steering cylinder rod is ful ly extended C Turn engine off D Read Precautions for Hydraulic Testing E Remove hydraulic hose from the 90 fitting on the rod end of the steering cylinder Plug the end of the hose F With the engine off continue turning the steering wheel to the left counterclockwise with the steering cylinder fully extended Observe the open fitting on the steering cylinder as the wheel is turned If oil comes out of the fitting while turning the steering wheel to the left the steering cylinder has internal leakage and must be repaired or replaced G Remove plug from the hydraulic hose Recon nect hose to the steering cylinder fitting 6 If steering problem exists and steering cylinder tested acceptably steering control requires service see Steering Control Valve and Steering Control Valve Ser vice in the Service and Repairs section Hydraulic System Rev G 2 ER CS x Y UO LR gt on lt Adjustments Adjust Traction Drive for Neutral If the machine creeps when the traction pedal is in the neutral position the traction adjustment cam needs ad justment 1 Park the machine on a level surface and turn the en gine off One front wheel and rear wh
279. y drostat or wheel motor The filter will ensure that contaminates are removed from the closed loop and thus do not cause additional component damage Hydraulic System Rev G Page 4 8 Once the filter has been placed in the traction circuit place the machine on jack stands and operate the trac tion circuit to allow oil flow through the circuit With the machine raised off the ground the traction circuit will have maximum oil flow at minimum pressure to mini mize damage from any remaining contamination The filter will remove contamination from the closed loop traction circuit during operation Remove the filter from the machine after contamination has been removed from the traction circuit IMPORTANT When operating the traction system with the high pressure filter installed make sure that flow is always directed through the filter e g do not press the traction pedal in the reverse direction ifthe filter is placed for forward direction flow If flow is reversed debris from the filter will re enter the traction circuit Groundsmaster 3500 D ONIV331S
280. y alternator Dead battery Alternator warning lamp is faulty or burned out Alternator warning lamp wiring is loose corroded or damaged Electrical System Rev G Electrical System Cutting Deck Operating Problems The cutting units will not run with the mow transport Wiring to the cutting unit drive circuit see Electrical slide in MOW and the cutting unit drive switch in Diagrams Chapter 8 is loose corroded or ENGAGE with the rotary decks lowered 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 There is insufficient hydraulic oil pressure to turn the cutting units see Troubleshooting in Chapter 4 Hydraulic System The cutting units run but should not run when raised The SRV coil R1 on the hydraulic manifold is faulty or the valve is stuck Electrical System Rev G Page 5 6 Groundsmaster 3500 D Electrical System Quick Check Battery Test Open Circuit Test Use a multimeter to measure the voltage between the battery terminals Set multimeter to the DC volts setting The battery should be at a temperature of 60 to 100 F 16 to 38 C 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
281. ydraulic System Rev G Gear Pump P2 Flow Test Using Tester with Pressure Gauges and Flow Meter TO HYDRAULIC MANIFOLD P1 PORT TO STEERING CONTROL VALVE IN PORT ENGINE A RPM GEAR PUMP FROM HYDROSTAT CASE DRAIN T FROM OIL FILTER High Pressure Low Pressure Return or Suction gt Flow STRAINER Hydraulic System Rev G Page 4 38 Groundsmaster 3500 D Procedure for Gear Pump P2 Flow Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 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 on the gear pump P2 leading to the steering control valve Fig 56 5 Installtester in series with gear pump and the discon nected hose leading to the steering control valve 6 Make sure the flow control valve on the tester is fully open 7 Start engine and move throttle to full speed 3050 50 RPM Do not engage the cutting units IMPORTANT In this test the hydraulic tester is positioned before the manifold relief valve Pump damage can occur if the oil flow is fully restricted by fully closing the tester flow control valve Do not close tester valve fully when performing test 8 Watch press
282. ydraulic fitting Valve actuator bracket Shoulder bolt OOND RON Hydraulic System Rev G Figure Cotter pin 100 Valve lever Valve actuator trunnion Shoulder bolt Link Bolt Lock nut Push nut Hydraulic fitting Page 4 94 Carriage screw O ring O ring Hydraulic tube Hydraulic tube Hydraulic hose O ring Hydraulic hose Hydraulic tube Groundsmaster 3500 D Removal Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section Figure 101 1 Remove control valve from the frame using Figures 1 Spool valve 3 Flange head screws 100 and 101 as guides 2 Support bracket 4 Frame 2 If hydraulic fittings are to be removed from control valve mark fitting orientation to allow correct assembly Installation 1 If hydraulic fittings were removed from control valve install fittings to valve using marks made during the re moval process to properly orientate fittings 2 Install control valve to the frame using Figures 100 and 101 as guides 2g 5 5 S 2O 3 Make sure hydraulic tank is full Add correct oil if nec essary see Check Hydraulic System Fluid Groundsmaster 3500 D Page 4 95 Hydraulic System Rev G Control Valve Service 10 to 12 ft lb 14 to 16 N m 30 to 42 ft IbB 19 41

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