Toro Groundsmaster 3500-D Service Manual
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Toro Groundsmaster 3500-D Service Manual

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See also: Operator's Manual
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.
REFER TO THE OPERATOR'S MANUAL FOR OPER-
ATING,
MAINTENANCE
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.
E The Toro Company - - 2001, 2002, 2003, 2004, 2005, 2007, 2009
Groundsmaster
AND
ADJUSTMENT

Service Manual

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: A NOTE 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.
PART NO. 01088SL (Rev. F)
3500- -D
R

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Summary of Contents for Toro Groundsmaster 3500-D

  • Page 1: Service Manual

    IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- vent damage to systems or components on the machine. E The Toro Company - - 2001, 2002, 2003, 2004, 2005, 2007, 2009...
  • Page 2 This page is intentionally blank. Groundsmaster 3500--D...

  • Page 3: Table Of Contents

    Table Of Contents Chapter 1 - - Safety Chapter 5 - - Electrical System General Safety Instructions ....1 -- 1 Electrical Schematics and Diagrams .
  • Page 4 This page is intentionally blank. Groundsmaster 3500--D...

  • Page 5: General Safety Instructions

    The GROUNDSMASTER 3500--D was tested and certi- can result in injury. To reduce the potential for any injury, fied by TORO for compliance with existing standards comply with the following safety instructions. and specifications as identified in the Operator’s Manu- al.

  • Page 6: While Operating

    While Operating 1. Always wear your seatbelt. angle increases to a Toro recommended maximum limit of 25 degrees, the risk of a rollover increases to a moder- 2. Do not run the engine in a confined area without ade- ate level.
  • Page 7 6. Before disconnecting or performing any work on the void the product warranty of The Toro Company. hydraulic system, all pressure in system must be re- lieved by stopping engine and lowering cutting units to the ground.

  • Page 8: Jacking Instructions

    Jacking Instructions CAUTION 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.

  • Page 9: Product Records

    Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......MAINTENANCE ....... EQUIVALENTS AND CONVERSIONS .

  • Page 10: Equivalents And Conversions

    Equivalents and Conversions 0.09375 Product Records and Maintenance Groundsmaster 3500--D Page 2 - - 2 Rev. E...

  • Page 11: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
  • Page 12 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Grade 1, 5, & SAE Grade 1 Bolts, Screws, Studs, & SAE Grade 5 Bolts, Screws, Studs, & SAE Grade 8 Bolts, Screws, Studs, & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
  • Page 13 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Class 10.9 Bolts, Screws, and Studs with Thread Size Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...
  • Page 14 Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque* Thread Size Thread Size Square Head Hex Socket 7/16 -- 20 UNF 65 + 10 ft--lb 88 + 14 N--m Grade 5 1/4 -- 20 UNC 140 + 20 in--lb...

  • Page 15: Lubrication

    Lubrication Traction Unit CAUTION Before servicing or making adjustments to the machine, stop engine, lower cutting units, set parking brake, and remove key from the ignition switch. Figure 1 The traction unit has grease fittings that must be lubri- cated regularly with No. 2 General Purpose Lithium Base Grease.
  • Page 16 Figure 7 Figure 4 Figure 8 Figure 5 Figure 9 Figure 6 Product Records and Maintenance Groundsmaster 3500--D Page 2 - - 8...
  • Page 17 Figure 10 Figure 12 (See note) Figure 11 Groundsmaster 3500--D Product Records and Maintenance Page 2 - - 9...
  • Page 18 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.

  • Page 19: Preparation For Seasonal Storage

    C. Coat cable terminals and battery posts with Grafo 11. Check anti--freeze protection and add as needed for 112X skin--over grease (Toro Part No. 505-47) or pe- expected minimum temperature in your area (see troleum jelly to prevent corrosion.
  • Page 20 This page is intentionally blank. Product Records and Maintenance Groundsmaster 3500--D Page 2 - - 12 Rev. E...

  • Page 21: Introduction 3

    Chapter 3 Kubota Diesel Engine Table of Contents INTRODUCTION ......Fuel/Water Separator .

  • Page 22: Introduction

    Service and repair parts for Kubota engines are sup- commonly available in many service shops. Special plied through your Authorized Toro Distributor. If no tools are described in the Kubota Workshop Manual, parts list is available, be prepared to provide your distrib- Diesel Engine, 05 Series.

  • Page 23: Specifications

    Specifications Item Description Make / Designation Kubota, 4--Cycle, 3 Cylinder, Liquid Cooled, Diesel Engine Horse Power 32 HP @ 2800 RPM Bore mm (in.) 78.0 (3.07) Stroke mm (in.) 78.4 (3.09) Total Displacement cc (cu. in.) 1123 (68.53) Torque N--m (ft--lb) 68.2 (50.3) @ 2000 RPM Firing Order 1--2--3...

  • Page 24: General Information

    General Information Check Engine Oil The engine is shipped with oil in the crankcase. Howev- er, oil level must be checked before and after the engine is first started. Crankcase holds about 4.0 qts. (3.8 l) with filter. IMPORTANT: Check level of oil every 5 operating hours or daily.
  • Page 25 Fill Fuel Tank 3. Fill fuel tank to the bottom of the filler neck. Do not DANGER overfill. Install cap to the neck. 4. Wipe up any fuel that may have spilled to prevent a Because diesel fuel is highly flammable, use cau- fire hazard.

  • Page 26: Adjustments

    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.
  • Page 27 Adjust Alternator/Fan Belt Condition and tension of alternator/fan belt should be checked after the first 10 hours of operation and every 50 operating hours thereafter. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch.

  • Page 28: Service And Repairs

    Service and Repairs Change Engine Oil and Filter Change engine oil and filter initially after the first 50 hours of operation. Thereafter, change oil every 50 hours and oil filter every 100 hours. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch.
  • Page 29 Replace Traction Belt 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. Unlatch and raise hood. 2. Insert nut driver or small piece of pipe onto the end of the torsion spring of the idler pulley.
  • Page 30 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. DANGER Because diesel fuel is highly flammable, use cau- tion when storing or handling it.
  • Page 31 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.
  • Page 32 Muffler and Air Cleaner Figure 15 1. Air inlet hose (upper) 9. Air cleaner body 17. Cap screw 2. Air inlet hose (lower) 10. Flange head screw 18. Filter cover 3. Flange nut 11. Hex nut 19. Hose clamp 4. Flange head screw 12.
  • Page 33 Muffler Removal CAUTION The muffler and exhaust 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.
  • Page 34 Check Air Filter, Dust Cup, & Burp Valve Compressed Air Method The air cleaner body, air filter, dust cup, and burp valve A. Blow compressed air from inside to the outside of should be checked daily, prior to operation. dry filter element. Do not exceed 100 psi to prevent damage to the element.
  • Page 35 Fuel/Water Separator DANGER 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.

  • Page 36: Fuel System

    Fuel System 32 47 9 22 Figure 21 1. Cap screw 17. Tee fitting 33. Fuel hose 2. Fuel tank 18. Barb fitting 34. Fuel hose 3. Fuel hose strap 19. Barb fitting 35. Fuel hose 4. Cap screw 20. Bushing 36.
  • Page 37 Fuel Tank Installation (Fig. 21) DANGER 1. Position fuel tank to the machine. 2. Connect both fuel hoses to the tank and secure with Because diesel fuel is highly flammable, use cau- tion when storing or handling it. Do not smoke hose clamps and fuel hose strap.
  • Page 38 Replace Fuel Pre- -Filter (Fig. 23) Replace fuel pre--filter after every 400 operating hours or yearly, whichever occurs first. The pre--filter is located on the inside of the frame just below the fuel/water sepa- rator. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch.
  • Page 39 This page is intentionally blank. Groundsmaster 3500--D Page 3 - - 19 Kubota Diesel Engine...
  • Page 40 Radiator 24 25 Figure 24 1. Draincock valve 14. Reservoir bracket 27. Hydraulic tube 2. Flange head screw 15. Wire form latch 28. Oil cooler hose 3. Flange nut 16. Oil cooler bracket 29. Grommet 4. Carriage bolt 17. Bracket clamp 30.
  • Page 41 Removal 9. Pull radiator carefully from the radiator frame. 1. Park machine on a level surface, lower cutting units, 10.Plug any openings to prevent contamination. stop engine, engage parking brake, and remove key Installation from the ignition switch. 1. Remove any plugs used during the removal proce- 2.
  • Page 42 Clean Radiator and Oil Cooler (Fig. 25) 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.
  • Page 43 This page is intentionally blank. Groundsmaster 3500--D Page 3 - - 23 Kubota Diesel Engine...
  • Page 44 Engine 30 16 Figure 27 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.
  • Page 45 8. Disconnect wire harness and electrical wires from the following: A. Battery and wire harness grounds (Fig. 28). B. Glow plug bus (Fig. 29) and fuel stop solenoid. C. High temperature warning switch (Fig. 30). D. High temperature shutdown switch, alternator, and low oil pressure switch (Fig.
  • Page 46 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.
  • Page 47 10.Connect wire harness and electrical wires to the fol- 14.Connect throttle cable to the support and swivel on lowing: the speed control lever (Fig. 28). A. Engine grounds to the battery and wire harness 15.Connect both battery cables at the battery (see Bat- (Fig.
  • Page 48 This page is intentionally blank. Kubota Diesel Engine Groundsmaster 3500--D Page 3 - - 28 Rev. D...

  • Page 49: Hydraulic Schematic 4

    Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......Flush Hydraulic System .
  • Page 50 Specifications Item Description Piston Pump (Hydrostat) Variable displacement piston pump Maximum Operating Pressure 3000 PSI (207 bar) Charge Pressure 100 to 150 PSI (6.9 to 10 bar) Traction Circuit Relief Pressure (Forward Only) 3000 PSI (207 bar) Gear Pump 2 stage positive displacement gear type pump Maximum Operating Pressure 3200 PSI (221 bar) Wheel Motors (Front)

  • Page 51: Hydraulic Fitting Installation

    General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure WARNING to weather, sun, chemicals, very warm storage condi- tions, or mishandling during operation or maintenance. Before disconnecting or performing any work These conditions can cause damage or premature dete- on hydraulic system, relieve all pressure in rioration.
  • Page 52 SAE Straight Thread O- -Ring Port - - Non- -adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the o--ring seal when this type of fit- ting shows signs of leakage. O- -Ring 3.

  • Page 53: Towing Traction Unit

    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 hydrostat pump (Fig. 6) and rotate it 90 to open the by--pass valve.

  • Page 54: Hydraulic System Fluid

    Donax TD IMPORTANT: Mobil EAL 224H is the only biodegrad- Texaco able oil tested and recommended by Toro. Contamina- IMPORTANT: Group 1 fluids are recommended for use tion by mineral--based hydraulic fluids will change the at typical ambient temperatures of 32...

  • Page 55: Check Hydraulic System Fluid

    Check Hydraulic System Fluid 1. Position machine on a level surface, lower cutting units, and stop engine. 2. Clean area around filler neck and cap of the hydraulic tank. Remove cap from the filler neck. 3. Remove dipstick from the filler neck and wipe it with a clean rag.

  • Page 56: Traction Circuit (Closed Loop) Component Failure

    Traction Circuit (Closed Loop) Component Failure The Groundsmaster 3500--D traction circuit is a closed Once the filter has been placed in the traction circuit, loop system that includes the hydrostat and two (2) place the machine on jack stands and operate the trac- wheel motors.

  • Page 57: Hydraulic Schematic

    Hydraulic Schematic Groundsmaster 3500--D Page 4 - - 9 Hydraulic System (Rev. D)

  • Page 58: Hydraulic Flow Diagrams

    Hydraulic Flow Diagrams Hydraulic System (Rev. D) Page 4 - - 10 Groundsmaster 3500--D...

  • Page 59: Traction Circuits

    Traction Circuits Forward the loss of hydraulic fluid from the closed loop circuit that must be replenished. The traction circuit of the hydraulic system consists of a hydrostat connected in a closed loop circuit to three or- The charge pump (P2) is a fixed displacement gear bital vane wheel motors.
  • Page 60 Hydraulic System (Rev. D) Page 4 - - 12 Groundsmaster 3500--D...

  • Page 61: Cutting Unit Circuit

    Cutting Unit Circuit Cutting Unit Blade Braking The gear pump (P1) is directly coupled to the the hydros- When the solenoid valve (R1) is de--energized as the tat which is driven by the engine. Taking its suction di- PTO switch is DISENGAGED, brake relief cartridge rectly from the hydraulic tank, the gear pump (P1) (BV) shifts to its closed position, blocking return flow supplies oil flow to the manifold block and to the cutting...
  • Page 62 Hydraulic System (Rev. D) Page 4 - - 14 Groundsmaster 3500--D...

  • Page 63: Lift Circuit (Up)

    Lift Circuit (Up) Raise Cutting Units When the cutting units are to be raised, the 2--spool valve is positioned by moving the cutting unit shift lever The gear pump (P2) is directly coupled to the hydrostat to RAISE. Flow is directed to cap ends of the lift cylin- through gear pump (P1).
  • Page 64 Hydraulic System (Rev. D) Page 4 - - 16 Groundsmaster 3500--D...

  • Page 65: Lift Circuit (Down)

    Lift Circuit (Down) Lower Cutting Units the cap end of the lift cylinders. Flow from the cap end of the lift cylinders causes the cutting units to lower. At Circuit operation for lowering the cutting units is similar the same time, the fluid relieved from the cap end of the to raising them.
  • Page 66 Hydraulic System (Rev. D) Page 4 - - 18 Groundsmaster 3500--D...

  • Page 67: Sidewinder Circuit

    Sidewinder Circuit The gear pump (P2) is directly coupled to the hydrostat draulic fluid out of the cylinder, back through the spool through gear pump (P1). It supplies hydraulic pressure and hydraulic manifold, and to the hydrostat. When the (charge pressure) for operating the power steering sys- cutting unit shift lever is released, spring action returns tem, raising and lowering the cutting units, operating the the valve to its original position and by--passes flow back...
  • Page 68 Hydraulic System (Rev. D) Page 4 - - 20 Groundsmaster 3500--D...

  • Page 69: Steering Circuit

    Steering Circuit The gear pump (P2) is directly coupled to the hydrostat. the oil flow to the cylinder is proportional to the amount It supplies hydraulic pressure to the power steering of the turning on the steering wheel. Fluid leaving the valve for turning the rear wheel and maintaining 100 to cylinder flows back through the spool valve then through 150 PSI (6.9 to 10.0 Bar) to the low pressure side of the...

  • Page 70: Special Tools

    Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Toro Part Number: TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.

  • Page 71: Measuring Container

    Hydraulic Test Fitting Kit Toro Part Number: TOR4079 This kit includes a variety of o--ring Face Seal fittings to enable the connection of test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings.
  • Page 72 O- -Ring Kit Toro Part Number: 16- -3799 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. Figure 14...
  • Page 73 This page is intentionally blank. Groundsmaster 3500--D Page 4 - - 25 Hydraulic System (Rev. D)

  • Page 74: Troubleshooting

    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. Problem Possible Cause Hydraulic oil leaks from system.
  • Page 75 Problem Possible Cause 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.

  • Page 76: Testing

    Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment WARNING such as pressure gauges and flow meters in the circuits during various operational checks (See the Special Before disconnecting or performing any work Tools section in this Chapter).
  • Page 77 This page is intentionally blank. Groundsmaster 3500--D Page 4 - - 29 Hydraulic System (Rev. D)

  • Page 78: Traction Circuit Working Pressure Test

    Traction Circuit Working Pressure Test (Using Pressure Gauge) TRACTION WHEEL MOTORS TOP PORT BI--PASS LOWER UPPER VALVE PORT PORT 3000 psi TRACTION RELIEF 100 to 150 psi FROM HYDRAULIC MANIFOLD (CHARGE) PORT PISTON PUMP (HYDROSTAT) High Pressure TO GEAR PUMP SUCTION Low Pressure THROUGH CASE DRAIN Return or Suction...
  • Page 79 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 a level surface with the cutting units lowered and off. Make sure engine is off. 3.

  • Page 80: Piston Pump (P3) Flow & Traction Relief Pressure Test

    Piston Pump (P3) Flow and Traction Relief Pressure Test (Using Tester with Pressure Gauges and Flow Meter) TRACTION WHEEL MOTORS TOP PORT BI--PASS LOWER UPPER VALVE PORT PORT 3000 psi TRACTION RELIEF 100 to 150 psi FROM HYDRAULIC MANIFOLD (CHARGE) PORT PISTON PUMP (HYDROSTAT) High Pressure...
  • Page 81 Procedure for Piston Pump (P3) Flow and Traction 13.Verify traction relief valve setting by closing flow con- Relief Pressure Test: trol valve on tester. System pressure should be 3500 PSI as the relief valve lifts. If pressure can not be met or 1.

  • Page 82: Charge Relief Valve Pressure Test

    Charge Relief Valve Pressure Test TRACTION WHEEL MOTORS TOP PORT BI--PASS LOWER UPPER VALVE PORT PORT TO HYDRAULIC MANIFOLD (P1) PORT 3000 psi FROM HYDRAULIC MANIFOLD (CHG) PORT 100 to 150 psi CHARGE RELIEF TO STEERING CONTROL VALVE (IN) PORT ENGINE HYDROSTAT GEAR PUMP...
  • Page 83 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.

  • Page 84: Gear Pump (P2) Flow Test

    Gear Pump (P2) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO HYDRAULIC MANIFOLD (P1) PORT TO STEERING CONTROL VALVE (IN) PORT TO TOTO ENGINE GEAR PUMP FROM HYDROSTAT CASE DRAIN FROM OIL FILTER High Pressure Low Pressure Return or Suction STRAINER Flow...
  • Page 85 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. RIGHT 2. Park machine on a level surface with the cutting units FRONT lowered and off. Make sure engine is off and the parking brake is engaged.

  • Page 86: Wheel Motor Efficiency Test

    Wheel Motor Efficiency Test (Using Tester with Pressure Gauges and Flow Meter) FRONT WHEEL MOTOR TESTING SHOWN TRACTION WHEEL MOTORS TOP PORT LOWER UPPER DUMP PORT PORT VALVE 3000 psi TRACTION RELIEF 100 to 150 psi FROM HYDRAULIC MANIFOLD (CHG) PORT PISTON PUMP High Pressure (HYDROSTAT)
  • Page 87 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.

  • Page 88: Cutting Deck Circuit Pressure Test

    Cutting Deck Circuit Pressure Test FROM DECK MOTOR CASE DRAINS TO LEFT FRONT DECK MOTOR FROM REAR DECK MOTOR TO HYDRAULIC TANK 1500 psi HYDRAULIC DECK MANIFOLD ON--OFF BLOCK 3200 psi TO OIL COOLER FROM FRONT LIFT CYLINDER FROM REAR LIFT CYLINDER FROM LIFT VALVE TO HYDROSTAT...
  • Page 89 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 a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged.

  • Page 90: Gear Pump (P1) Flow Test

    Gear Pump (P1) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO HYDRAULIC MANIFOLD (P1) PORT TO STEERING CONTROL VALVE (IN) PORT TO TOTO ENGINE GEAR PUMP FROM HYDROSTAT CASE DRAIN FROM OIL FILTER STRAINER High Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev.
  • Page 91 Procedure for Gear Pump (P1) Flow Test: Note: Over a period of time, the gears and wear plates in the pump can wear. A worn pump will by pass oil and make the pump less efficient. Eventually, enough oil loss RIGHT will occur to cause the cutting unit motors to stall under heavy cutting conditions.

  • Page 92: Manifold Relief Valve (R1) Pressure Test

    Manifold Relief Valve (R1) Pressure Test FROM DECK MOTOR CASE DRAINS TO LEFT FRONT DECK MOTOR FROM REAR DECK MOTOR TO HYDRAULIC TANK 1500 psi HYDRAULIC MANIFOLD BLOCK DECK ON--OFF 3200 psi TO OIL COOLER FROM FRONT LIFT CYLINDER FROM REAR LIFT CYLINDER FROM LIFT VALVE TO HYDROSTAT...
  • Page 93 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.

  • Page 94: Logic (Counterbalance) Valve (Lc1) Pressure Test

    Logic (Counterbalance) Valve (LC1) Pressure Test FROM DECK MOTOR CASE DRAINS TO LEFT FRONT DECK MOTOR FROM REAR DECK MOTOR TO HYDRAULIC TANK 1500 psi DECK ON--OFF HYDRAULIC MANIFOLD BLOCK 3200 psi TO OIL COOLER FROM FRONT LIFT CYLINDER FROM REAR LIFT CYLINDER FROM LIFT VALVE TO HYDROSTAT...
  • Page 95 Procedure for Logic (Counterbalance) Valve (LC1) 8. Lower cutting units. Shut off engine. Pressure Test: 9. Disconnect test gauge with hose from manifold NOTE: If the counterbalance system is functioning, the block. Reconnect plug to the hydraulic manifold port machine should normally settle slightly when the engine (G2).

  • Page 96: Deck Motor Efficiency -- Case Drain Test

    DECK MOTOR MANIFOLD PORT (M2) Flow Toro # TOR4077 Note: Over a period of time, a deck motor can wear in- Note: One method to identify a possibly bad deck mo- ternally. A worn motor may by--pass oil to its case drain tor is to have another person observe the machine while causing the motor to be less efficient.
  • Page 97 2. Rear case drain hose 5. Front RH case drain milliliters (e.g. Toro #TOR4077) and collect hydraulic 3. Rear T- -fitting 6. Front T- -fitting fluid for 15 seconds. After 15 seconds, remove hose end from container.

  • Page 98: Lift And Steering Control Valve Relief Pressure Test

    Lift and Steering Control Valve Relief Pressure Test TO HYDRAULIC MANIFOLD (ST) PORT TO LIFT VALVE (IN) PORT 1000 psi TO HYDRAULIC POWER MANIFOLD STEERING (P1) PORT VALVE GEAR PUMP ENGINE STRAINER High Pressure FROM Low Pressure OIL FILTER Return or Suction Flow FROM HYDROSTAT INTERNAL CASE DRAIN...
  • Page 99 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 RIGHT minutes. FRONT 2. Park machine on a level surface with the cutting units lowered and off.

  • Page 100: Steering Control Valve Test

    Steering Control Valve Test STEERING CYLINDER OPEN FITTING PLUG POWER STEERING VALVE (LEFT TURN) High Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev. D) Page 4 - - 52 Groundsmaster 3500--D...
  • Page 101 Procedure for Steering Control Valve Test: 5. If either of these performance tests indicate a steer- ing problem, determine if the steering cylinder is faulty 1. Make sure hydraulic oil is at normal operating tem- using the following procedure. perature by operating the machine for approximately 10 minutes.

  • Page 102: Adjustments

    Adjustments Adjust Traction Drive for Neutral If the machine creeps when the traction pedal is in the 4. Start engine and rotate cam hex in both directions to neutral position, the traction adjustment cam needs ad- determine mid position of neutral span. When properly justment.

  • Page 103: Braking Valve Adjustment

    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.

  • Page 104: Service And Repairs

    Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- 1. Check oil level in the hydraulic reservoir and add cor- tem, park machine on a level surface, engage parking rect oil if necessary.

  • Page 105: Change Hydraulic Fluid

    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.

  • Page 106: Replace Hydraulic Oil Filter

    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.

  • Page 107: Replace Traction Belt

    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. CAUTION Be careful when removing or applying tension from or to the torsion spring of the idler pulley.

  • Page 108: Flush Hydraulic System

    System Fluid. Other fluids may cause system IMPORTANT: Flush hydraulic system when chang- damage. If changing to biodegradable fluid, use Toro Ing from petroleum base hydraulic fluid to a biode- Biodegradable Hydraulic Fluid for this step.

  • Page 109: Charge Hydraulic System

    Charge Hydraulic System NOTE: When initially starting the hydraulic system with 10.Make sure traction pedal and lift control lever are in new or rebuilt components such as motors, pumps, or neutral. Start engine and run it at low idle of 1800 rpm. lift cylinders, it is important that the hydraulic system be The charge pump should pick up oil and fill the hydraulic charged properly.

  • Page 110: Hydraulic Tank And Hydraulic Oil Filter

    Hydraulic Tank and Hydraulic Oil Filter EARLY MODELS Hydraulic Thread Sealant Anti- -seize lubricant 30 to 60 in- -lb (3.4 to 6.8 N- -m) Figure 41 Grommet 12. O- -ring 23. O- -ring Flange head screw 13. Oil filter element 24.
  • Page 111 Hydraulic Tank Removal Hydraulic Tank Installation 1. Drain hydraulic oil from Hydraulic tank (see Change 1. Apply anti--seize lubricant or equivalent to the two Hydraulic Fluid). flange head screws that secure the hydraulic tank. Tighten the tank mounting screws from 30 to 60 in--lb 2.

  • Page 112: Oil Cooler

    Oil Cooler Removal CAUTION The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before working on the oil cooler. 1. Remove oil cooler using Figures 42 and 43 as guides.
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  • Page 114: Front Wheel Motors

    Front Wheel Motors RIGHT FRONT Figure 44 Lock nut Frame O- -ring Spacer Hydraulic tube Hydraulic fitting Socket head screw Hydraulic tube 10. O- -ring Hydraulic wheel motor Hydraulic System (Rev. D) Page 4 - - 66 Groundsmaster 3500--D...
  • Page 115 Removal 3. Remove tire and wheel assembly, wheel hub, and brake drum from the hydraulic motor. Remove brake as- 1. Park machine on a level surface, lower cutting units, sembly, brake bracket, and wheel shield from the frame stop engine, engage parking brake, and remove key (see Front Wheel and Brake Removal in Chapter 6 -- from the ignition switch.

  • Page 116: Rear Wheel Motor

    Rear Wheel Motor 45 to 65 ft- -lb (61 to 88 N- -m) 250 to 350 ft- -lb (339 to 474 N- -m) Figure 45 Lug nut Hydraulic hose 11. Hydraulic motor Drive stud O- -ring 12. Rear fork Tire and rim assembly hydraulic fitting 13.
  • Page 117 8. If hydraulic fittings are to be removed from wheel mo- 4. Install wheel motor to the rear fork using Figure 45 as tor, mark fitting orientation to allow correct assembly. guide. Installation (Fig. 45) 5. Install tire and rim assembly to machine. 1.

  • Page 118: Wheel Motor Service

    Wheel Motor Service 45 to 55 ft- -lb (60 to 76 N- -m) Figure 46 Dirt seal 11. Coupling shaft 20. Vane Bearing 12. Thrust bearing 21. Stator Housing 13. Drive link 22. Manifold Back- -up washer 14. Cap screw 23.
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  • Page 120: Rotary Cutting Motors

    Rotary Cutting Motors Figure 47 Hydraulic motor Hydraulic fitting 15. O- -ring O- -ring Hydraulic hose 16. O- -ring O- -ring 10. Hydraulic T- -fitting 17. O- -ring Hydraulic elbow 11. Hydraulic hose 18. Cap screw Hydraulic hose 12. Hydraulic hose 19.
  • Page 121 Removal (Fig. 47) 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. 48). 1. Remove two cap screws that secure hydraulic motor to the cutting unit (Fig.

  • Page 122: Rotary Cutting Motor Service (Haldex)

    Rotary Cutting Motor Service (Haldex) 38 to 43 ft- -lb (51 to 58 N- -m) Figure 49 Front plate Idler gear 11. Front wear plate Back plate Cap screw 12. O- -ring Body Back- -up gasket 13. Shaft seal Dowel Rear wear plate 14.
  • Page 123 IMPORTANT: Note position of the open and closed C. Thickness of wear plates should be equal. side of the wear plates before removing. Also, iden- 5. Inspect front plate and back plate for damage or tify wear plates (front and rear) with a marker for wear.
  • Page 124 9. Install rear wear plate with pressure seal side up and Relief Valve Service open side of the pressure seal pointing to the inlet side IMPORTANT: Do not remove the relief valve as- of the motor. sembly unless testing shows it to be faulty. The re- 10.Apply a light coating of petroleum jelly to new o--rings lief valve assembly must be replaced as a complete and o--ring grooves in the body.
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  • Page 126: Rotary Cutting Motor Service (Casappa)

    Rotary Cutting Motor Service (Casappa) 33 ft- -lb (45 N- -m) 26 ft- -lb (35 N- -m) 26 ft- -lb (35 N- -m) Figure 53 1. Socket head screw (4 used) 8. Rear wear plate 14. Front wear plate 2. Washer (4 used) 9.
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  • Page 128 Hydraulic Manifold RIGHT FRONT Figure 54 Hose clamp 10. Straight hydraulic fitting 18. Hydraulic hose O- -ring 11. O- -ring 19. Hydraulic manifold Barb fitting 12. Hydraulic hose 20. O- -ring Stud 13. Hydraulic hose 21. Straight hydraulic fitting Straight hydraulic fitting 14.
  • Page 129 Removal (Fig. 54) Installation (Fig. 54) Note: The ports on the manifold are marked for easy 1. If hydraulic fittings were removed from manifold, identification of components. Example: BV is the deck install fittings to manifold using marks made during the circuit braking valve and P1 is the gear pump connection removal process to properly orientate fittings.
  • Page 130 Hydraulic Manifold Service (Serial Number Below 240000600) Loctite 242 4 to 6 Ft- -lb (5 to 8 N- -m) 30 to 35 Ft- -lb (41 to 47 N- -m) 30 to 35 Ft- -lb (41 to 47 N- -m) 30 to 35 Ft- -lb (41 to 47 N- -m) RIGHT FRONT...
  • Page 131 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.
  • Page 132 Braking and Logic Cartridge Valves (Fig. 55 and 56) 1. Make sure manifold is clean before removing the cartridge. IMPORTANT: Use care when handling the cartridge valve. Slight bending or distortion of the stem tube can cause binding and malfunction. 2.
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  • Page 134 Hydraulic Manifold Service (Serial Number Above 240000600) 60 in- -lb (6.8 N- -m) 35 ft- -lb (47 N- -m) 25 ft- -lb (34 N- -m) 45 to 50 ft- -lb (61 to 68 N- -m) 120 in- -lb (13.6 N- -m) RIGHT FRONT Figure 60...
  • Page 135 Cartridge Valve Service (Fig. 60) 7. Reinstall the cartridge valve into the manifold block: 1. Make sure the manifold is clean before removing the A. Lubricate new seal kit components with clean hy- valve. draulic oil and install on valve. The o--rings, sealing rings and backup rings must be arranged properly on 2.

  • Page 136: Control Valve

    Control Valve Figure 62 Control valve (2- -spool) 10. Cotter pin 19. Carriage screw Hydraulic fitting (straight) 11. Valve lever 20. O- -ring hydraulic fitting 12. Valve actuator trunnion 21. O- -ring Hydraulic fitting (straight) 13. Shoulder bolt 22. Hydraulic tube Flange nut 14.
  • Page 137 Removal WARNING 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 63 1. Remove control valve from the frame using Figures Spool valve Flange head screws 62 and 63 as guides.

  • Page 138: Control Valve Service

    Control Valve Service 10 to 12 ft- -lb (14 to 16 N- -m) 30 to 42 ft- -lb (41 to 57 N- -m) 30 to 35 ft- -lb (41 to 48 N- -m) 20 to 25 ft- -lb 30 to 35 ft- -lb (27 to 34 N- -m) (41 to 48 N- -m) Figure 64...
  • Page 139 Figure 65 Check poppet 11. Valve body 21. Plunger Grooved plunger 12. O- -ring 22. Plunger detent Spacer 13. Retaining ring 23. Detent spring Spool 14. Washer 24. O- -ring Seat 15. Seat retaining plug 25. O- -ring Solid plug 16.
  • Page 140 Disassembly CAUTION 1. Plug all ports and clean the outside of the valve thor- oughly. Use eye protection such as goggles when using compressed air. IMPORTANT: Match- -mark spools to their associat- ed bores before disassembly. Spools must be rein- 1.
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  • Page 142: Piston Pump

    Piston Pump RIGHT FRONT 77 to 93 ft- -lb (105 to 127 N- -m) Antiseize Lubricant 27 to 31 ft- -lb (37 to 42 N- -m) 90 to 120 in- -lb (10.2 to 13.6 N- -m) Figure 66 Piston pump 20.
  • Page 143 Neutral Arm Assembly Figure 67 Pump assembly 12. Lock nut 23. Flange head screw Hose 13. Spacer 24. Cable support bracket Extension spring 14. Traction stud 25. Ball bearing Pump mount plate 15. Traction control cable 26. Flat washer Neutral bracket 16.
  • Page 144 11. If hydraulic fittings are to be removed from pump, WARNING mark fitting orientation to allow correct assembly. Piston Pump Installation (Fig. 66 & 67) Before disconnecting or performing any work 1. If hydraulic fittings were removed from piston pump, on the hydraulic system, all pressure in the install fittings to pump using marks made during the re- system must be relieved.
  • Page 145 11. Install traction belt to the pump pulley (see Replace CAUTION Traction Belt). 12.Using a straight edge across the lower face of the Support piston and gear pumps when installing pump pulley, verify traction belt alignment across engine them to the machine to prevent them from falling and pump pulleys.

  • Page 146: Piston Pump Service

    Piston Pump Service 40 41 Figure 69 1. Key 17. O- -ring 33. Washer 2. Drive shaft 18. Plug 34. Shaft seal 3. Bearing 19. Spring 35. Retaining ring 4. Cap screw (3 used per plate) 20. Seat 36. Retaining ring 5.
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  • Page 148: Gear Pump

    Gear Pump RIGHT FRONT 27 to 31 ft- -lb (37 to 42 N- -m) Figure 70 Piston pump Hydraulic barb fitting 13. 90 hydraulic fitting Gear pump O- -ring 14. O- -ring Hydraulic hose (tank suction) O- -ring 15. Cap screw Hydraulic hose (hydraulic manifold) 10.
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  • Page 150: Gear Pump Service (Serial Numbers Below 260000400)

    Gear Pump Service (Serial Numbers Below 260000400) 38 to 43 ft- -lb (51 to 58 N- -m) Figure 71 Front plate Back- -up gasket 14. Dowel Back plate Rear wear plate 15. Coupler Front body 10. Pressure seal 16. Drive gear Rear body 11.
  • Page 151 3. Clamp mounting flange of pump in a vise with the CAUTION shaft end down. 4. Loosen cap screws from the back plate. Use eye protection such as goggles when using 5. Remove pump from the vise. Turn pump so that the compressed air.
  • Page 152 5. Inspect wear plates for the following: 8. Install rear wear plate with pressure seal side up and open side of the pressure seal pointing to the suction A. Bearing areas should not have excessive wear or side of the pump. scoring.
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  • Page 154: Gear Pump Service (Serial Numbers Above 260000400)

    Gear Pump Service (Serial Numbers Above 260000400) 33 ft- -lb (45 N- -m) Figure 39 Front cover Dowel pin 15. Front thrust plate Pressure seal Seal 16. Idler gear Back- -up gasket 10. Body 17. Drive gear Front thrust plate 11.
  • Page 155 IMPORTANT: Use caution when clamping gear 8. Clean all pump parts. Check all components for pump in a vise to avoid distorting any pump compo- burrs, scoring, nicks and other damage. nents. 9. Replace the entire pump assembly if parts are ex- 3.

  • Page 156: Steering Control Valve

    Flange head screw 19. Hydraulic fitting 34. Steering shield Steering valve bracket 20. Steering wheel nut 35. O- -ring Cap screw 21. Toro decal 36. O- -ring Pivot hub 22. Hydraulic hose 37. O- -ring Steering cover 23. Hydraulic hose 38.
  • Page 157 Removal WARNING 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 steering control valve from the steering col- umn using Figures 74, 75, and 76 as guides.

  • Page 158: Steering Control Valve Service (Serial Numbers Below 240000000)

    Steering Control Valve Service (Serial Numbers Below 240000000) Figure 77 15. Isolation manifold 29. Face seal Port cover 16. Drive link 30. Push nut Seal ring 17. Metering ring 31. Seal spacer O- -ring 18. Socket head screw 32. Upper cover plate Relief valve cartridge 19.

  • Page 159: Steering Control Valve Service (Serial Numbers Above 240000000)

    Steering Control Valve Service (Serial Numbers Above 240000000) 20 to 24 ft- -lb (27 to 33 N- -m) Figure 78 1. Sleeve 9. Dust seal ring 16. Outer gearwheel 2. Cross pin 10. Housing 17. End cover 3. Ring 11. Cardan shaft 18.

  • Page 160: Sidewinder

    Sidewinder RIGHT FRONT Figure 79 Bushing 12. Lock nut 23. 90 hydraulic fitting Scissor link 13. Welded pin 24. Hydraulic hose Scissor mount 14. Flange head screw 25. Scissor link Cap screw 15. Lock nut 26. O- -ring Flat washer 16.
  • Page 161 Removal WARNING 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 79 as guide.

  • Page 162: Front Lift Cylinder

    Front Lift Cylinder RIGHT FRONT 8 35 1 Figure 81 hydraulic fitting 23. Lock nut 45. Cap screw Hydraulic cylinder 24. Thrust washer 46. Torsion spring Sidewinder carrier assembly 25. Slide support bar 47. Grease fitting Flange nut 26. Pin 48.
  • Page 163 Removal WARNING 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 81 as guide.

  • Page 164: Rear Lift Cylinder

    Rear Lift Cylinder 16 3 RIGHT FRONT 43 19 Figure 83 Hydraulic tube 18. Hydraulic tube 34. Rebound washer Bulkhead locknut 19. Hydraulic tube 35. Thrust washer Hydraulic T- -fitting 20. Tube clamp 36. Lynch pin Hydraulic hose 21. O- -ring 37.
  • Page 165 Removal Installation 1. If hydraulic fittings were removed from lift cylinder, WARNING install fittings to cylinder using marks made during the removal process to properly orientate fittings. Before disconnecting or performing any work 2. Install rear lift cylinder to the frame and lift arm using on the hydraulic system, all pressure in the Figure 83 as guide.

  • Page 166: Lift Cylinder Service

    Lift Cylinder Service 24 to 30 ft- -lb (33 to 41 N- -m) Figure 84 Grease fitting O- -ring 11. Internal collar Barrel with clevis O- -ring 12. Dust seal Back- -up ring 13. Shaft Uni- -ring Rod seal 14. Nut Piston 10.
  • Page 167 Disassembly IMPORTANT: Do not clamp vise jaws against the shaft surface. Protect shaft surface before mount- 1. Remove oil from lift cylinder into a drain pan by slowly ing in a vice. pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder.

  • Page 168: Steering Cylinder

    Steering Cylinder No. 2 General Purpose Grease No. 2 General Purpose Grease 65 to 85 ft- -lb (88 to 115 N- -m) 65 to 85 ft- -lb (88 to 115 N- -m) Figure 86 Hydraulic hose O- -ring Jam nuts Hydraulic hose Steering cylinder 10.
  • Page 169 Removal (Fig. 86) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. NOTE: The rear tire must be removed to allow sufficient clearance to remove the steering cylinder from the ma- chine.

  • Page 170: Steering Cylinder Service

    Steering Cylinder Service 24 to 30 ft- -lb (33 to 41 N- -m) Figure 89 Barrel with clevis O- -ring O- -ring Lock nut Piston rod 10. Back- -up ring Piston Rod seal 11. Retaining ring Uni- -ring Cylinder gland 12.
  • Page 171 Disassembly 2. Coat new o--rings, Uni--ring, rod seal, and back--up ring with with clean hydraulic oil. 1. Remove oil from the steering cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports A. Install Uni--ring and o--ring to the piston. and clean the outside of the cylinder.
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  • Page 173: Electrical Schematics And Diagrams 5

    Chapter 5 Electrical System Table of Contents ELECTRICAL SCHEMATICS AND DIAGRAMS . . . Indicator Lights (Serial Number Above SPECIAL TOOLS ......240000000) .

  • Page 174: Electrical Schematics And Diagrams

    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. D) Page 5 - - 2 Groundsmaster 3500--D...

  • Page 175: Special Tools

    Multimeter The meter can test electrical components 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.

  • Page 176: Troubleshooting

    Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and CAUTION components used on this machine (see Electrical Dia- grams -- Chapter 8). Remove all jewelry, especially rings and If the machine has any interlock switches by--passed, watches, before doing any electrical trouble- shooting or testing.
  • Page 177 Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Wiring in the crank circuit (see Electrical Diagrams -- Chapter 8) is loose, corroded, or damaged. Engine run solenoid or fuel pump is faulty. The fuel tank is empty. An engine or fuel system problem exists.

  • Page 178: Cutting Deck Operating Problems

    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.

  • Page 179: Battery Test (Open Circuit Test)

    Electrical System Quick Check Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals. 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery 12.45 V 75% charged should be at a temperature of 60...

  • Page 180: Check Operation Of Interlock Switches

    Check Operation of Interlock Switches 2. With operator on the seat, the engine must not start with either the cutting unit drive switch in the ENGAGE CAUTION position or the traction pedal engaged. Correct problem if not operating properly. The interlock switches are for the operator’s 3.

  • Page 181: Component Testing

    Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION circuit (e.g. unplug the ignition switch connector before doing a continuity check on the switch). When testing electrical components for continu- NOTE: For more component testing information, see ity with a multimeter (ohms setting), make sure the Kubota Workshop Manual, Diesel Engine, 05 Se- that power to the circuit has been disconnected.

  • Page 182: Glow Relay

    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.

  • Page 183: Hour Meter

    Hour Meter 1. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter. Hobbs 2. Connect the negative (--) terminal of the voltage QUARTZ source to the other terminal of the hour meter. 0 0 0 0 HOURS 3.

  • Page 184: Diode Assemblies

    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.

  • Page 185: Warning Light Cluster

    Warning Light Cluster (Serial Numbers Below 240000000) NOTE: Individual light bulbs can be tested by removing FRONT them from the lighting cluster and applying 12 VDC to COOLANT their wiring terminals. (RED) (RED) 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.

  • Page 186: Indicator Lights

    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...

  • Page 187: Cutting Unit Drive Switch

    Cutting Unit Drive Switch The cutting unit drive switch is located on the control panel (Fig. 19). This rocker switch allows the decks to be engaged or disengaged. Along with additional switches in the interlock system, the cutting unit drive switch con- trols the solenoid valve on the hydraulic manifold.

  • Page 188: Neutral Switch

    Neutral Switch The neutral switch is a proximity type, normally open 6. Switch adjustment: neutral switch should be reed switch that closes when the traction pedal is in the installed so that the pin on the traction pedal (neutral neutral position. The neutral switch is located under the position) is centered with the switch.

  • Page 189: Parking Brake And Transport/Mow Switches

    Parking Brake and Transport/Mow Switches The switches used for the parking brake and transport/ mow are the same, normally closed switch. The parking brake switch is located under the dash cover and opens when the parking brake lever is engaged. The transport/ mow switch is located under the floor plate and opens when the transport/mow slide is in the transport position.
  • Page 190 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.

  • Page 191: Fuel Pump

    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.

  • Page 192: Fuel Stop Solenoid (Solenoid With 3 Wire Connector)

    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.

  • Page 193: Fuel Stop Solenoid (Solenoid With 2 Wire Connector)

    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. 31). The fuel stop solenoid includes two coils for operation: the pull coil and the hold coil.

  • Page 194: Glow Controller

    Glow Controller The controller is located under the right, lower corner of 5. If any of the conditions in Step 3 are not met or power the instrument panel. to terminal 1 exists and any of the other conditions in Step 4 are not met: NOTE: Refer to Electrical Diagrams -- Chapter 8 when troubleshooting the glow controller.

  • Page 195: Standard Control Module

    Standard Control Module Groundsmaster 3500--D machines with Serial Numbers Control Module Outputs (Fig. 35) above 240000000 are equipped with a Standard Control The Start output LED should be illuminated when the Module to monitor and control electrical components re- ignition key switch is in the START position with the trac- quired for safe operation.

  • Page 196: Service And Repairs

    Service and Repairs NOTE: For more electrical component 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: 4. Store battery in a cool atmosphere to avoid quick de- terioration of the battery charge.

  • Page 197: Battery Service

    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. CAUTION When working with batteries, use extreme cau- tion to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes.
  • Page 198 2. Conduct a hydrometer test of the battery electrolyte. D. Measure the temperature of the center cell. IMPORTANT: Make sure the area around the cells is E. Connect a battery load tester to the battery termi- clean before opening the battery caps. nals following the manufacturer’s instructions.
  • Page 199 6. Apply a light coat of grease on all battery posts and Battery Battery Charge Level cable connectors to reduce corrosion after connections Reserve (Percent of Fully Charged) are made. Capacity Capacity (Minutes) 7. Connect a digital multimeter (set to amps) between 80 or less 3.8 hrs 7.5 hrs...

  • Page 200: Solenoid Valve Coil

    Solenoid Valve Coil The solenoid valve coil on the hydraulic control manifold (Fig. 38) can be replaced without opening the hydraulic system. Removal 1. Park machine on a level surface, lower cutting 60 in- -lb (6.8 N- -m) decks, engage parking brake, stop engine and remove key from the ignition switch.

  • Page 201: Special Tools 6

    Chapter 6 Wheels, Brakes, and Chassis Table of Contents SPECIFICATIONS ......Deluxe Seat .

  • Page 202: Specifications

    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.

  • Page 203: Adjustments

    Adjustments Adjust Brake Lever Brake lever adjustment should be checked every 200 hours. CAUTION Before and after adjusting the brakes, always check the brakes in a wide open area that is flat and free of other persons and obstructions. 1. Park machine on a level surface, lower cutting units, Figure 1 stop engine, and remove key from the ignition switch.

  • Page 204: Adjust Brakes

    Adjust Brakes C. If brakes can not be adjusted properly, repair or replace brake components as necessary. CAUTION D. After adjustment is complete, install both front wheel assemblies to the machine (see Front Brake Before and after adjusting the brakes, always and Wheel Installation in the Service and Repairs check the brakes in a wide open area that is flat section).

  • Page 205: Adjust Front Lift Arms

    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.

  • Page 206: Adjust Rear Lift Arm

    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 .020 to .100 inch (0.51 to 2.54 mm) (Fig.
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  • Page 208: Service And Repairs

    Service and Repairs Standard Seat Figure 9 1. Seat (incl. 4 thru 7, 14, & 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.

  • Page 209: Deluxe Seat

    Deluxe Seat 39 40 Figure 10 1. Plate 18. Washer 35. Screw 2. Rivet 19. Nut 36. Cover 3. Screw 20. Swing arm assembly (incl. 28 & 42) 37. Clamp 4. Wear parts kit (incl. 8 thru 11) 21. Adjusting rail (RH) 38.

  • Page 210: Front Wheel And Brake

    Front Wheel and Brake RIGHT FRONT Anti- -seize Lubricant 45 to 65 ft- -lb (61 to 88 N- -m) 250 to 350 ft- -lb (339 to 474 N- -m) Figure 11 1. Lug nut 12. Brake lever 23. Spacer 2. Drive stud 13.
  • Page 211 IMPORTANT: DO NOT hit wheel hub, wheel hub E. Position both brake shoes on the backing plate so puller or wheel motor with a hammer during wheel that the concave heels attach to the anchor pin. hub removal or installation. Hammering may cause F.

  • Page 212: Rear Fork And Wheel

    Rear Fork and Wheel 250 to 350 ft- -lb 65 to 85 ft- -lb (339 to 474 N- -m) (88 to 115 N- -m) 45 to 65 ft- -lb (61 to 88 N- -m) 60 to 80 ft- -lb (81 to 108 N- -m) 65 to 85 ft- -lb (88 to 115 N- -m) Figure 13...
  • Page 213 Removal Installation 1. Park machine on a level surface, lower cutting units, 1. Position rear fork through the frame. stop engine, engage parking brake, and remove key 2. Install lock washer, thrust washer, and cap screw to from the ignition switch. the rear fork shaft.

  • Page 214: Brake Lever Linkages

    Brake Lever Linkages Figure 14 1. Pop rivet 14. Hex socket flat head screw 26. Brake pivot shaft 2. Control panel cover 15. Parking brake link 27. Clevis pin 3. Cover bracket 16. Clevis pin 28. Flange bushing 4. Flange nut 17.
  • Page 215 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.

  • Page 216: Steering Column

    Steering control valve bracket 19. Hydraulic fitting 34. Steering shield Cap screw 20. Steering wheel nut 35. O- -ring Pivot hub 21. Toro decal 36. O- -ring Steering cover 22. Hydraulic hose 37. O- -ring Cap screw 23. Hydraulic hose 38.
  • Page 217 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.

  • Page 218: Front Lift Arms

    Front Lift Arms RIGHT FRONT 8 35 1 Figure 17 hydraulic fitting 23. Lock nut 45. Cap screw Hydraulic cylinder 24. Thrust washer 46. Torsion spring Sidewinder carrier assembly 25. Slide support bar 47. Grease fitting Flange nut 26. Pin 48.
  • Page 219 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 hydraulic cylin- der shaft clevis when removing the right, front lift arm.

  • Page 220: Rear Lift Arm

    Rear Lift Arm 16 3 17 2 RIGHT 43 19 FRONT 200 to 250 ft- -lb (271 to 339 N- -m) Figure 20 Hydraulic tube 17. Hydraulic tube 33. Cap screw Bulkhead locknut 18. Hydraulic tube 34. Rebound washer Hydraulic T- -fitting 19.
  • Page 221 Removal 2. Slide rear lift arm onto rear pivot shaft making sure that the lift cylinder shaft of the rear lift arm slides into the 1. Park machine on a level surface, lower cutting units, clevis of the hydraulic cylinder. stop engine, engage parking brake, and remove key from the ignition switch.

  • Page 222: Sidewinder Carrier

    Sidewinder Carrier RIGHT FRONT 67 to 83 ft- -lb (91 to 113 Nm) Figure 21 Lower frame Flange nut 10. Bearing cap Sidewinder carrier assembly Cap screw 11. Lock nut Slide bracket Thrust washer 12. Liftarm (RH shown) Plastic slide Slide support bar 13.

  • Page 223: Hood Removal

    Hood Removal Figure 22 1. Flange screw 7. Flat washer 13. Cap screw 2. Trim- -seal 8. Flex draw latch 14. Lock bracket 3. Locknut 9. Rivet 15. Cap screw 4. Hood screen 10. Pop rivet 16. Flat washer 5. Hood 11.
  • Page 224 This page is intentionally blank. Wheels, Brakes, and Chassis Page 6 - - 24 Groundsmaster 3500--D...

  • Page 225: Troubleshooting 7

    Chapter 7 Cutting Units Table of Contents SPECIFICATIONS ......SERVICE AND REPAIRS .

  • Page 226: Specifications

    Specifications MOUNTING: All cutting units are supported by equal DISCHARGE: Clippings are discharged from the rear of length, independent lift arms and are interchangeable to the mowing decks. Pre--drilled mounting holes allow at- all three cutting unit positions. tachment of optional mulching baffle. CONSTRUCTION: Deck chamber is welded 10 and 12 CUTTING UNIT LIFT: Cutting units are controlled with gauge steel.

  • Page 227: Troubleshooting

    Troubleshooting There are a number of factors that can contribute to un- Remember that the “effective” or actual height--of--cut satisfactory quality of cut, some of which may be turf depends on cutting unit weight and turf conditions. Ef- conditions. Turf conditions such as excessive thatch, fective height--of--cut will be different than the bench set “sponginess”...

  • Page 228: Special Tools

    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.

  • Page 229: Adjustments

    Adjustments CAUTION 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.

  • Page 230: Adjust Roller Scraper

    Adjust Roller Scraper If cutting deck is equipped with a rear roller scraper, EARLY STYLE 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.

  • Page 231: Blade Plane Inspection/Adjustment

    Blade Plane Inspection and Adjustment If a solid object is struck by the cutting deck, the blade 6. Determine if one or both (RH and LH) height--of--cut plane of the deck should be inspected. 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 Blade Plane Inspection front height, then no adjustment is needed for that side.

  • Page 232: Service And Repairs

    Service and Repairs CAUTION 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 a complete stop in approximately 5 seconds after the cutting deck engagement switch is shut down.

  • Page 233: Cutting Unit Removal And Installation

    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.

  • Page 234: Cutting Blade Removal And Installation

    The cutting blade must be replaced if a solid object is hit, the blade is out of balance, or if the blade is bent. Always use genuine TORO replacement blades to be sure of safety and optimum performance. Never use replace- ment blades made by other manufacturers because they could be dangerous.

  • Page 235: Rear Roller

    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 design has grease fittings in the roller shaft ends. The third design has grease fittings incorporated into the roller fasteners.

  • Page 236: Rear Roller Service (Non--Greasable Bearings)

    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.

  • Page 237: Rear Roller Service (Greasable Bearings With Retaining Ring)

    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.

  • Page 238: Rear Roller Service (Greasable Bearings With Bearing Nut)

    Rear Roller Service (Greasable Bearings with Bearing Nut) Disassembly (Fig. 19) 50 to 60 ft- -lb 1. Remove bearing lock nut from each end of roller (68 to 81 N- -m) 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.
  • Page 239 3. From the roller tube end with only the inner seal NOTE: After roller is installed to cutting deck, lubricate installed, carefully install the roller shaft into the roller roller grease fittings, rotate roller to properly distribute tube. Make sure that seals are not damaged as shaft is grease in bearings and clean excess grease from roller installed.

  • Page 240: Front Roller Service

    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.
  • Page 241 This page is intentionally blank. Rev. E Groundsmaster 3500--D Page 7 - - 17 Cutting Units (Rev. D)

  • Page 242: Blade Spindle Service

    (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.
  • Page 243 Assembly IMPORTANT: When greasing spindles, grease passes into the center of the shaft and out to fill the IMPORTANT: If new bearings will be installed into a bearing cavity of the housing. If grease does not used spindle housing that has the original large come out of lower seal when greasing, check lu- snap ring installed, discard the snap ring that came brication hole in spindle shaft for obstruction.

  • Page 244: Carrier Frame

    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.

  • Page 245: Electrical Schematics And Diagrams 8

    Chapter 8 Electrical Diagrams Table of Contents ELECTRICAL SCHEMATICS AND DIAGRAMS . . . Harness Drawing (Serial Numbers 90101 Electrical Schematic (Serial Numbers 90101 to 230999999) ......to 230999999) .
  • Page 246 This page is intentionally blank. Electrical Diagrams Page 8 - - 2 Groundsmaster 3500--D...

  • Page 247: Electrical Schematic (Serial Numbers 90101 To 230999999)

    R/BK OPTION #2 SEAT SWITCH ALTERNATOR RUN SOLENOID (- -) (HOLD) 6500 MFD R/BK HOUR METER (PULL) OPTION #1 (- -) SHUTDOWN SEAT SWITCH 110_C (CLOSED WHEN OCCUPIED) R/BK WARNING 105_C PARKING BRAKE #1 LOW OIL PRESSURE (IN OFF POSITION) SEAT RELAY NEUTRAL RELAY NOT USED...

  • Page 248: Glow Circuits

    R/BK OPTION #2 SEAT SWITCH ALTERNATOR RUN SOLENOID (- -) (HOLD) 6500 MFD HOUR R/BK METER OPTION #1 (PULL) (- -) SEAT SWITCH SHUTDOWN 110_C (CLOSED WHEN OCCUPIED) R/BK WARNING PARKING BRAKE #1 105_C LOW OIL PRESS (IN OFF POSITION) SEAT RELAY NEUTRAL RELAY NOT USED...

  • Page 249: Crank Circuits

    R/BK OPTION #2 SEAT SWITCH ALTERNATOR RUN SOLENOID (- -) (HOLD) R/BK 6500 MFD HOUR METER OPTION #1 (PULL) (- -) SEAT SWITCH SHUTDOWN 110_C (CLOSED WHEN OCCUPIED) R/BK WARNING PARKING BRAKE #1 105_C LOW OIL PRESSURE (IN OFF POSITION) SEAT RELAY NEUTRAL RELAY NOT USED...

  • Page 250: Run Circuits (Transport)

    R/BK OPTION #2 SEAT SWITCH ALTERNATOR RUN SOLENOID (- -) (HOLD) 6500 MFD R/BK HOUR METER (PULL) OPTION #1 (- -) SEAT SWITCH SHUTDOWN 110_C (CLOSED WHEN OCCUPIED) R/BK WARNING PARKING BRAKE #1 105_C LOW OIL PRESS (IN OFF POSITION) SEAT RELAY NEUTRAL RELAY NOT USED...

  • Page 251: Run Circuits (Mow)

    R/BK OPTION #2 SEAT SWITCH ALTERNATOR RUN SOLENOID (- -) (HOLD) 6500 MFD HOUR R/BK METER (PULL) OPTION #1 (- -) SHUTDOWN SEAT SWITCH 110_C (CLOSED WHEN OCCUPIED) R/BK WARNING PARKING BRAKE #1 105_C LOW OIL PRESSURE (IN OFF POSITION) SEAT RELAY NEUTRAL RELAY NOT USED...

  • Page 252: Harness Diagram (Serial Numbers 90101 To 230999999)

    GLOW RELAY STARTER ALTERNATOR FUSE BLOCK GLOW PLUG GLOW CONTROLLER START PINK SEAT ORANGE BLUE BLACK PINK PINK SWITCH ORANGE WHITE ORANGE BLUE VIOLET GRAY ORANGE (OPTIONAL LIGHT) BLUE ORANGE SEAT VIOLET PINK GRAY PINK SWITCH VIOLET VIOLET ORANGE YELLOW YELLOW PINK IGNITION...

  • Page 253: Harness Drawing (Serial Numbers 90101 To 230999999)

    FUEL PUMP DECK UP/DOWN SWITCH TRANSPORT/MOW SWITCH SEAT SWITCH ENGINE GROUND DECK ON/OFF FUEL SWITCH SOLENOID GLOW PLUG OVERTEMP ALTERNATOR RELAY START SEAT SOLENOID INTERLOCK SEAT CAPACITOR RELAY RELAY SWITCH PARKING BRAKE START GLOW SOLENOID BACKLAP SWITCH CONTROLLER TEMP SWITCH SWITCH HOUR METER...

  • Page 254: Electrical Schematic (Serial Numbers 240000001 And Up)

    ALTERNATOR RUN SOLENOID (HOLD) R/BK (PULL) 105C OVER TEMP WARNING ENGINE OIL PRESSURE BU/W 110C OVER TEMP SHUTDOWN R/BK FUEL PUMP GLOW PLUGS (3) GLOW PLUG CONTROLLER KUBOTA TEMP START HOUR METER GLOW LAMP (--) GROUND + 12V FUSIBLE LINK R/BK Start 2--A...

  • Page 255: Harness Diagram (Serial Numbers 240000001 And Up)

    ORANGE BLUE BROWN BLACK PINK BLACK PINK GRAY VIOLET WHITE (SERIAL NUMBERS FROM 240000001 TO 270999999) BLUE ORANGE PINK PINK BROWN RED/BLACK YELLOW BLACK BLACK PINK BLUE GREEN WHITE/BLACK WHITE PINK GRAY VIOLET PINK ORANGE BLACK RED/BLACK ORANGE BLACK BLACK BLACK BLUE/WHITE GREEN...

  • Page 256: Harness Drawing (Serial Numbers 240000001 And Up)

    (SERIAL NUMBERS ABOVE 280000000) (SERIAL NUMBERS FROM 240000001 TO 270999999) (SERIAL NUMBERS ABOVE 260000400) Groundsmaster 3500--D Harness Drawing (Serial Numbers 240000001 and up) Page 8 - - 12 Rev. F...

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