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Groundsmaster 3500--D This page is intentionally blank.
Page 3 - Table Of Contents
Rev. G Groundsmaster 3500- D Table Of Contents Chapter 1 - Safety General Safety Instructions 1 - 1 . . . . . . . . . . . . . . . . . . Jacking Instructions 1 - 4 . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 2 - Product Records and Maintenance Product Records 2 - 1 . . . . . . . . . . ....
Page 5 - Chapter 1; Table of Contents; Supervisor’s Responsibilities; Safety
Rev. F Groundsmaster 3500--D Page 1 -- 1 Safety Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS 1 . . . . . . . . . . . . Supervisor’s Responsibilities 1 . . . . . . . . . . . . . . . . . Before Operating 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating 2 . . ...
Page 6 - While Operating; DO NOT EXCEED A 25 DEGREE SIDE HILL
Rev. F Groundsmaster 3500--D Page 1 -- 2 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 ...
Page 7 - Maintenance and Service
Rev. F Groundsmaster 3500--D Page 1 -- 3 Safety 12.Raise the cutting units when driving from one work area to another. 13.Do not touch 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 ...
Page 9 - Chapter 2; Product Records and Maintenance
Rev. G Groundsmaster 3500- D Page 2 - 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS 1 . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSION...
Page 10 - Equivalents and Conversions
0.09375 Rev. E Groundsmaster 3500--D Page 2 -- 2 Product Records and Maintenance Equivalents and Conversions
Page 11 - Torque Specifications; reduced by 25% for lubricated fasteners; Fastener Identification
Rev. G Groundsmaster 3500- D Page 2 - 3 Product Records and Maintenance 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 clearl...
Page 14 - Other Torque Specifications; Grade 5; Conversion Factors
Groundsmaster 3500--D Page 2 -- 6 Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended Torque Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 + ...
Page 19 - Preparation for Seasonal Storage; Traction Unit
Groundsmaster 3500--D Page 2 -- 11 Product Records and Maintenance 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; ti...
Page 21 - Chapter 3; Kubota Diesel Engine
Groundsmaster 3500- D Page 3 - 1 Kubota Diesel Engine (Rev. G) Chapter 3 Kubota Diesel Engine Table of Contents INTRODUCTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Kubota Workshop Manual 2 . . . . . . . . ...
Page 22 - Introduction; Operator’s Manual
Groundsmaster 3500- D Page 3 - 2 Kubota Diesel Engine (Rev. G) Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the diesel engine used in the Groundsmaster 3500- D. Most repairs and adjustments require tools which are commonly ava...
Page 23 - Specifications
Groundsmaster 3500- D Page 3 - 3 Kubota Diesel Engine (Rev. G) Specifications Item Description Make / Designation Kubota D1105, 4- Cycle, 3 Cylinder, Liquid Cooled, Diesel Engine Bore mm (in.) 78.0 (3.07) Stroke mm (in.) 78.4 (3.09) Total Displacement cc (cu. in.) 1123 (68.53) Firing Order 1- 2- 3 C...
Page 24 - Adjustments; Adjust Throttle Cable
Groundsmaster 3500- D Page 3 - 4 Kubota Diesel Engine (Rev. G) 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...
Page 25 - Service and Repairs; Replace Traction Belt; CAUTION; Be careful when removing or applying tension
Groundsmaster 3500- D Page 3 - 5 Kubota Diesel Engine (Rev. G) Service and Repairs 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...
Page 26 - Bleed Fuel System; DANGER
Groundsmaster 3500- D Page 3 - 6 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. DANGER Because diesel fuel is highly flammable, use c...
Page 27 - Bleed Air from Fuel Injectors
Groundsmaster 3500- D Page 3 - 7 Kubota Diesel Engine (Rev. G) 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 surfa...
Page 28 - Muffler and Air Cleaner
Groundsmaster 3500- D Page 3 - 8 Kubota Diesel Engine (Rev. G) Muffler and Air Cleaner Figure 11 1. Air inlet hose (upper) 2. Air inlet hose (lower) 3. Flange nut 4. Flange head screw 5. Flat washer 6. Cap screw 7. Air filter mount 8. Hose clamp 9. Air cleaner body 10. Flange head screw 11. Hex nut ...
Page 30 - Fuel System
Groundsmaster 3500- D Page 3 - 10 Kubota Diesel Engine (Rev. G) Fuel System Figure 13 1. Cap screw 2. Fuel tank 3. Fuel hose strap 4. Cap screw 5. Fuel cap 6. Tank support 7. Fuel gauge 8. Grommet 9. Connector fitting 10. Stand pipe 11. R- clamp 12. Barb fitting 13. Cap screw 14. Flange hex nut 15. ...
Page 33 - Installation; If engine has been running, the radiator may be
Groundsmaster 3500- D Page 3 - 13 Kubota Diesel Engine (Rev. G) 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 ...
Page 34 - Radiator and Oil Cooler Assembly (Serial Number Above 314000000); Removal; Do not open radiator cap or drain coolant if the
Groundsmaster 3500- D Page 3 - 14 Kubota Diesel Engine (Rev. G) Radiator and Oil Cooler Assembly (Serial Number Above 314000000) Figure 18 1. Expansion tank 2. Hose clamp 3. Coolant hose 4. Flange head screw 5. Radiator bracket - RH 6. Carriage bolt 7. Flange nut 8. Radiator bracket - top 9. Flange ...
Page 36 - Engine
Groundsmaster 3500- D Page 3 - 16 Kubota Diesel Engine (Rev. G) Engine Figure 20 1. Kubota engine 2. Engine mount 3. Engine mount 4. Flange nut 5. Cap screw 6. Hex flange head screw 7. External lock washer 8. Lock nut 9. Hardened washer 10. Machine screw 11. Hardened washer 12. Cap screw 13. Engine ...
Page 41 - Chapter 4; Hydraulic System
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 1 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Traction Unit Operator’s Manual 3 . . . . . . . . . . . . ....
Page 43 - General Information; Traction Unit Operator’s Manual; Check level; Towing Traction Unit
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 3 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...
Page 44 - Hydraulic Hoses; WARNING; Keep body and hands away from pin hole leaks or
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 4 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 ...
Page 45 - Hydraulic Hose and Tube Installation (O- Ring Face Seal Fitting); Fitting Dash Size
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 5 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 free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against le...
Page 49 - Hydraulic Schematics; Hydraulic
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 9 Hydraulic Schematics D G2 100 0 psi AUX OU T IN PO WER STEE R IN G VA LV E IN OUT C B A REAR RIG H T LEFT ST CR CF CHG LC 1 LV T1 MA N IF O LD BL OCK M2 T2 3000 ps i TRACTIO N WHEEL M O TO RS FOR W A R D TO P P O R T OI L CO O LER STRAIN E R...
Page 52 - Hydraulic Flow Diagrams; ac
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 12 Hydraulic Flow Diagrams D G2 100 0 psi AU X OUT IN POW E R ST EERI N G VA LV E IN OUT C B A REAR RIG H T LEF T ST CR CF CH G LC1 LV T1 MA N IFOL D BLO C K M2 T2 3000 psi TRACTIO N WHEEL M O TO RS FO R W A R D TOP P ORT OI L CO O LER STRAI N...
Page 53 - Traction Circuits; Forward
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 13 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-...
Page 55 - Cutting Unit Circuit; Mow
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 15 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 t...
Page 57 - Raise Cutting Units
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 17 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 cutti...
Page 59 - Lower Cutting Units
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 19 Lift Circuit (Down) Lower Cutting Units Circuit 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 lifti...
Page 61 - Sidewinder Circuit; Shift Sidewinder Right
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 21 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...
Page 63 - Steering Circuit; Right Turn
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 23 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...
Page 64 - Special Tools; Hydraulic Pressure Test Kit
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 24 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 mat...
Page 67 - High Flow Hydraulic Filter Kit
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 27 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 w...
Page 68 - Troubleshooting; Problem
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 28 Troubleshooting The charts that follow contain information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the Testing section of this Chapter for precau- tions and specific test p...
Page 72 - Traction Circuit Working Pressure Test (Using Pressure Gauge)
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 32 Traction Circuit Working Pressure Test (Using Pressure Gauge) High PressureLow PressureReturn or Suction Flow M4 M5 BI- PASS VALVE P3 PISTON PUMP LOWER PORT UPPERPORT M6 TO GEAR PUMP SUCTION 100 to 150 psi TOP PORT FOR W ARD TRACTION WHEEL ...
Page 73 - Procedure for Traction Circuit Working Pressure; Do not operate sidewinder while performing test.
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 33 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 a...
Page 74 - Gauges and Flow Meter)
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 34 Piston Pump (P3) Flow and Traction Relief Pressure Test (Using Tester with Pressure Gauges and Flow Meter) High PressureLow PressureReturn or Suction Flow M4 M5 BI- PASS VALVE P3 PISTON PUMP LOWER PORT UPPER PORT M6 TO GEAR PUMP SUCTION 100...
Page 76 - Charge Relief Valve Pressure Test
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 36 Charge Relief Valve Pressure Test High PressureLow PressureReturn or Suction Flow M4 M5 BI- PASS VALVE P3 HYDROSTAT P1 P2 ENGINE RPM GEAR PUMP LOWER PORT UPPER PORT M6 INTERNAL CASE DRAIN 100 to 150 psi STRAINER TOP PORT FO R W A R D TRACTI...
Page 77 - Procedure for Charge Relief Valve Pressure Test:
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 37 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 of...
Page 80 - FRONT WHEEL MOTOR TESTING SHOWN
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 40 Wheel Motor Efficiency Test (Using Tester with Pressure Gauges and Flow Meter) Figure 57 High PressureLow PressureReturn or SuctionFlow M4 M5 DUMP VALVE P3 PISTON PUMP LOWER PORT UPPER PORT M6 TO GEAR PUMP SUCTION 100 to 150 psi TOP PORT FO...
Page 82 - Cutting Deck Circuit Pressure Test
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 42 Cutting Deck Circuit Pressure Test P1 P2 ENGINE RPM GEAR PUMP STRAINER G1 T2 D1 M1 M2 MANIFOLD BLOCK T1 P1 LV CHG CF CR ST FROM LIFT VALVE G2 FROM DECK MOTOR CASE DRAINS FROM REAR TO LEFT FRONT DECK MOTOR TO HYDRAULIC TANK TO OIL COOLER TO ...
Page 83 - Procedure for Cutting Deck Circuit Pressure Test:; Keep away from decks during test to prevent per-
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 43 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 o...
Page 87 - Procedure for Manifold Relief Valve (R1) Pressure
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 47 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...
Page 92 - Lift and Steering Control Valve Relief Pressure Test
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 52 Lift and Steering Control Valve Relief Pressure Test P1 P2 ENGINE RPM GEAR PUMP L R V1 STRAINER STEERING POWER STEERING VALVE IN OUT AUX 1000 psi FROM HYDROSTAT INTERNAL CASE DRAIN TO HYDRAULIC MANIFOLD TO HYDRAULIC MANIFOLD (ST) PORT TO LI...
Page 94 - Steering Control Valve Test
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 54 Steering Control Valve Test L R V1 STEERING POWER STEERING VALVE (LEFT TURN) IN OUT AUX 10 00 psi PLUG High PressureLow PressureReturn or Suction Flow CYLINDER OPEN FITTING
Page 96 - Adjust Traction Drive for Neutral; One front wheel and rear wheel must be raised
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 56 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. WARNIN...
Page 97 - Braking Valve Adjustment; decrease
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 57 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 shou...
Page 99 - Change Hydraulic Fluid; IMPORTANT: Use only hydraulic fluids specified.
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 59 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 flui...
Page 100 - Replace Hydraulic Oil Filter; IMPORTANT: Use of any other filter may void the
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 60 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...
Page 102 - Check Hydraulic Lines and Hoses
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 62 Check Hydraulic Lines and Hoses WARNING Keep body and hands away from pin hole leaksor nozzles that eject hydraulic fluid under highpressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping underpressure can...
Page 103 - Flush Hydraulic System
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 63 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 cha...
Page 104 - Filtering Closed - Loop Traction Circuit
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 64 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....
Page 105 - Charge Hydraulic System
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 65 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 s...
Page 106 - Hydraulic Tank and Hydraulic Oil Filter
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 66 Hydraulic Tank and Hydraulic Oil Filter 1. Grommet 2. Flange head screw 3. Barb fitting 4. Check fitting 5. Flat washer 6. Hydraulic tank 7. O - ring 8. Hose clamp 9. Barb fitting (straight) 10. Flange head screw 11. Elbow fitting 12. O - r...
Page 108 - Oil Cooler
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 68 Oil Cooler Note: On Groundsmaster 3500- D machines with se- rial numbers above 314000000, the hydraulic oil cooler is combined with the radiator. Removal CAUTION The radiator and oil cooler may be hot. To avoid possible burns, allow the eng...
Page 110 - Front Wheel Motors
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 70 Front Wheel Motors 1. Lock nut 2. Spacer 3. Socket head screw 4. Hydraulic wheel motor 5. Frame 6. Hydraulic tube 7. Hydraulic tube 8. O - ring 9. Hydraulic fitting 10. O - ring Figure 81 FRONT RIGHT 5 3 6 8 9 10 7 8 9 4 2 1 10
Page 112 - Rear Wheel Motor
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 72 Rear Wheel Motor 1. Lug nut 2. Drive stud 3. Tire and rim assembly 4. Wheel hub 5. Hydraulic hose 6. Hydraulic hose 7. O - ring 8. 45 o hydraulic fitting 9. Lock nut 10. Socket head screw 11. Hydraulic motor 12. Rear fork 13. O - ring 14. W...
Page 114 - Wheel Motor Service; IMPORTANT: If a wheel motor failure occurred, refer
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 74 Wheel Motor Service 1. Dirt seal 2. Bearing 3. Housing 4. Back- up washer 5. Seal rings 6. Back- up washer 7. Inner seal 8. Thrust washer 9. Thrust bearing 10. Bearing 11. Coupling shaft 12. Thrust bearing 13. Drive link 14. Cap screw 15. C...
Page 116 - Rotary Cutting Motors
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 76 Rotary Cutting Motors 1. Hydraulic motor 2. O - ring 3. O - ring 4. Hydraulic elbow 5. Hydraulic hose 6. Hydraulic adapter 7. Hydraulic hose 8. Hydraulic fitting 9. Hydraulic hose 10. Hydraulic T- fitting 11. Hydraulic hose 12. Hydraulic ho...
Page 124 - Hydraulic Manifold
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 84 Hydraulic Manifold 1. Hose clamp 2. O - ring 3. Barb fitting 4. Stud 5. Straight hydraulic fitting 6. O - ring 7. Flange head nut 8. O - ring 9. O - ring 10. Straight hydraulic fitting 11. O - ring 12. Hydraulic hose 13. Hydraulic hose 14. ...
Page 125 - Before disconnecting or performing any work
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 85 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...
Page 127 - Use eye protection such as goggles when using
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 87 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 st...
Page 134 - Control Valve
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 94 Control Valve 1. Control valve (2- spool) 2. Hydraulic fitting (straight) 3. 90 o hydraulic fitting 4. Hydraulic fitting (straight) 5. Flange nut 6. Knob 7. 90 o hydraulic fitting 8. Valve actuator bracket 9. Shoulder bolt 10. Cotter pin 11...
Page 136 - Control Valve Service
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 96 Control Valve Service 1. Check poppet 2. Grooved plunger 3. Spacer 4. Spool 5. Seat 6. Solid plug 7. Seat retaining plug with port 8. Bushing 9. Check spring 10. Spool cap 11. Valve body 12. O - ring 13. Retaining ring 14. Washer 15. Seat r...
Page 140 - Piston Pump
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 100 Piston Pump 1. Piston pump 2. Straight hydraulic fitting 3. Cap screw 4. Lock nut 5. 90 o hydraulic fitting 6. 90 o hydraulic fitting 7. 90 o hydraulic fitting 8. 90 o hydraulic fitting 9. 90 o hydraulic fitting 10. Washer 11. Hydraulic ho...
Page 141 - Neutral Arm Assembly; The extension spring is under tension and may
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 101 Neutral Arm Assembly 1. Pump assembly 2. Hose 3. Extension spring 4. Pump mount plate 5. Neutral bracket 6. Flange nut 7. Flange head screw 8. Neutral arm 9. Flange bushing 10. Thrust washer 11. 90 o grease fitting 12. Lock nut 13. Spacer ...
Page 144 - Piston Pump Service; fer to Traction Circuit (Closed Loop) Component
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 104 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 ...
Page 146 - Gear Pump
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 106 Gear Pump 1. Piston pump 2. Gear pump 3. Hydraulic hose (tank suction) 4. Hydraulic hose (hydraulic manifold) 5. Hydraulic hose (steering valve) 6. Hose clamp 7. Hydraulic barb fitting 8. O - ring 9. O - ring 10. 90 o hydraulic fitting 11....
Page 150 - IMPORTANT: Do not dislodge pressure seals,
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 110 5. Inspect wear plates for the following: A. Bearing areas should not have excessive wear or scoring. B. Face of wear plates that are in contact with gears should be free of wear, roughness or scoring. C. Thickness of wear plates should be...
Page 152 - diagonal
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 112 Gear Pump Service (Serial Numbers Above 260000400) 1. Front cover 2. Pressure seal 3. Back- up gasket 4. Front thrust plate 5. Idler gear 6. Drive shaft 7. Rear thrust plate 8. Dowel pin 9. Seal 10. Body 11. Seal 12. Splined connecting sha...
Page 154 - Steering Control Valve
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 114 Steering Control Valve 1. Steering arm 2. Flange nut 3. Flange head screw 4. Steering valve bracket 5. Cap screw 6. Pivot hub 7. Steering cover 8. Cap screw 9. Toro decal 10. Ball knob 11. Steering tilt lever 12. Steering control valve 13....
Page 156 - Steering Control Valve Service (Serial Numbers Below 240000000)
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 116 Steering Control Valve Service (Serial Numbers Below 240000000) 1. Nut 2. Port cover 3. Seal ring 4. O - ring 5. Relief valve cartridge 6. Plug 7. Coil spring 8. Port manifold 9. Spring 10. Drive assembly 11. Alignment pin 12. Valve ring 1...
Page 157 - Steering Control Valve Service (Serial Numbers Above 240000000)
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 117 Steering Control Valve Service (Serial Numbers Above 240000000) 1. Sleeve 2. Cross pin 3. Ring 4. Spool 5. Bearing assembly 6. Shaft seal 7. Ball stop 8. Ball 9. Dust seal ring 10. Housing 11. Cardan shaft 12. Spacer 13. O - ring 14. Distr...
Page 158 - Sidewinder
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 118 Sidewinder 1. Bushing 2. Scissor link 3. Scissor mount 4. Cap screw 5. Flat washer 6. Lock nut 7. Scissor frame 8. Hydraulic cylinder 9. Spacer 10. Flat washer 11. Cap screw 12. Lock nut 13. Welded pin 14. Flange head screw 15. Lock nut 16...
Page 160 - Front Lift Cylinder
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 120 Front Lift Cylinder 1. 90 o hydraulic fitting 2. Hydraulic cylinder 3. Sidewinder carrier assembly 4. Flange nut 5. Flange head screw 6. Hydraulic hose 7. Centering wire 8. Hydraulic hose 9. Hydraulic hose 10. Hydraulic hose 11. Slide brac...
Page 162 - Rear Lift Cylinder
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 122 Rear Lift Cylinder 1. Hydraulic tube 2. Bulkhead locknut 3. Hydraulic T- fitting 4. Hydraulic hose 5. 90 o hydraulic fitting 6. Hydraulic hose 7. Hydraulic tube 8. Straight hydraulic fitting 9. Castor bushing 10. Hydraulic cylinder 11. Thr...
Page 164 - Lift Cylinder Service
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 124 Lift Cylinder Service 1. Grease fitting 2. Barrel with clevis 3. Nut 4. Uni- ring 5. Piston 6. O - ring 7. O - ring 8. Back- up ring 9. Rod seal 10. Head 11. Internal collar 12. Dust seal 13. Shaft 14. Nut 15. Clevis Figure 124 1 2 3 4 5 6...
Page 166 - Steering Cylinder
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 126 Steering Cylinder 1. Hydraulic hose 2. Hydraulic hose 3. O - ring 4. Hydraulic fitting 5. O - ring 6. Steering cylinder 7. Ball joint 8. Retaining ring 9. Jam nuts 10. Frame 11. Rear fork 12. Rear casting Figure 126 8 9 12 11 9 1 8 5 7 2 3...
Page 167 - Before jacking up the machine, review and follow
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 127 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: The rear tire must be removed to allow sufficient clearance to remove the steering...
Page 168 - Steering Cylinder Service
Groundsmaster 3500- D Hydraulic System (Rev. G) Page 4 - 128 Steering Cylinder Service 1. Barrel with clevis 2. Lock nut 3. Piston 4. Uni- ring 5. O - ring 6. Piston rod 7. Rod seal 8. Cylinder gland 9. O - ring 10. Back- up ring 11. Retaining ring 12. Dust seal Figure 129 1 2 3 4 5 6 7 8 9 10 12 11...
Page 171 - Chapter 5; Electrical System
Groundsmaster 3500- D Page 5 - 1 Electrical System (Rev. G) Chapter 5 Electrical System Table of Contents ELECTRICAL SCHEMATICS AND DIAGRAMS 2 . . . SPECIAL TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 4 . . . . . . . . . . . . . . . . . . . . . . . . . Starting ...
Page 172 - Electrical Schematics and Diagrams
Groundsmaster 3500- D Page 5 - 2 Electrical System (Rev. G) Electrical Schematics and Diagrams The electrical schematics and other electrical drawings for the Groundsmaster 3500- D are located in Chapter 8 - Electrical Diagrams.
Page 173 - Multimeter
Groundsmaster 3500- D Page 5 - 3 Electrical System (Rev. G) 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 components and circuits for current, resistance, or voltage. NOTE: Toro recommend...
Page 175 - General Run and Transport Problems
Groundsmaster 3500- D Page 5 - 5 Electrical System (Rev. G) 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 ...
Page 176 - Cutting Deck Operating Problems
Groundsmaster 3500- D Page 5 - 6 Electrical System (Rev. G) Cutting Deck Operating Problems The cutting units will not run with the mow/transport slide in MOW and the cutting unit drive switch in ENGAGE with the rotary decks lowered. Wiring to the cutting unit drive circuit (see Electrical Diagrams ...
Page 177 - Electrical System Quick Check; Voltage Measured; Charging System Test; At least 0.50 volt over initial battery voltage.; Glow Plug System Test
Groundsmaster 3500- D Page 5 - 7 Electrical System (Rev. G) 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 o to 100 o F (16 o to...
Page 178 - The interlock switches are for the operator’s
Groundsmaster 3500- D Page 5 - 8 Electrical System (Rev. G) Check Operation of Interlock Switches CAUTION The interlock switches are for the operator’s protection; do not disconnect them. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches be...
Page 179 - Component Testing; When testing electrical components for continu-; Ignition Switch
Groundsmaster 3500- D Page 5 - 9 Electrical System (Rev. G) 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 m...
Page 181 - Hour Meter; Hobbs; SRV Valve Solenoid; Testing
Groundsmaster 3500- D Page 5 - 11 Electrical System (Rev. G) Hour Meter 1. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter. 2. Connect the negative (- ) terminal of the voltage source to the other terminal of the hour meter. 3. The hour meter should mo...
Page 182 - Diode Assemblies
Groundsmaster 3500- D Page 5 - 12 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...
Page 186 - Neutral Switch; Seat Switch
Groundsmaster 3500- D Page 5 - 16 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 connecto...
Page 187 - Parking Brake and Transport/Mow Switches; Fusible Link Harness
Groundsmaster 3500- D Page 5 - 17 Electrical System (Rev. G) 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 en...
Page 188 - Make sure engine is cool before removing the; Handle the hot oil with extreme care to prevent; VOA
Groundsmaster 3500- D Page 5 - 18 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...
Page 189 - Fuel Pump; Operational Test; Fuel Pump Specifications
Groundsmaster 3500- D Page 5 - 19 Electrical System (Rev. G) 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. Disconne...
Page 190 - Fuel Stop Solenoid (Solenoid With 3 Wire Connector)
Groundsmaster 3500- D Page 5 - 20 Electrical System (Rev. G) 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 p...
Page 191 - Fuel Stop Solenoid (Solenoid With 2 Wire Connector); In Place Testing; ectric
Groundsmaster 3500- D Page 5 - 21 Electrical System (Rev. G) 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 ...
Page 192 - Glow Controller; Controller Operation
Groundsmaster 3500- D Page 5 - 22 Electrical System (Rev. G) 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 p...
Page 194 - Battery Storage; Connecting cables to the wrong post could re-
Groundsmaster 3500- D Page 5 - 24 Electrical System (Rev. G) 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: 1. Remove the battery and charge i...
Page 198 - Solenoid Valve Coil
Groundsmaster 3500- D Page 5 - 28 Electrical System (Rev. G) 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 engin...
Page 200 - Order special tools from your Toro Distributor.; Wheel Hub Puller; The wheel hub puller allows safe removal of the wheel
Rev. E Groundsmaster 3500--D Page 6 -- 2 Wheels, Brakes, and Chassis 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 ...
Page 201 - Adjust Brake Lever; Before and after adjusting the brakes, always
Rev. D Groundsmaster 3500--D Page 6 -- 3 Wheels, Brakes,and Chassis 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 obstructi...
Page 202 - Adjust Brakes
Rev. D Groundsmaster 3500--D Page 6 -- 4 Wheels, Brakes, and Chassis Adjust Brakes 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. Check brake adjustment as follows: A. Park machine on a level surf...
Page 203 - Adjust Front Lift Arms; IMPORTANT: Keep front cutting units on the lift
Rev. G Groundsmaster 3500- D Page 6 - 5 Wheels, Brakes,and Chassis 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 th...
Page 204 - Adjust Front Lift Arm Carrier Stop Bracket Assembly
Rev. G Groundsmaster 3500- D Page 6 - 6 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...
Page 205 - Adjust Rear Lift Arm
Rev. G Groundsmaster 3500- D Page 6 - 7 Wheels, Brakes,and Chassis 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 ...
Page 206 - Standard Seat
Groundsmaster 3500--D Page 6 -- 8 Wheels, Brakes, and Chassis Service and Repairs Standard Seat 1. Seat (incl. 4 thru 7, 14, & 15) 2. Cap screw 3. Spring lock washer 4. Edging clip 5. Edging 6. Seat cushion 7. Seat shell 8. Seat belt 9. Seat adjuster with latch 10. Flange hex nut 11. Cap screw 1...
Page 207 - Deluxe Seat
Groundsmaster 3500--D Page 6 -- 9 Wheels, Brakes,and Chassis Deluxe Seat 1. Plate 2. Rivet 3. Screw 4. Wear parts kit (incl. 8 thru 11) 5. Tension spring set 6. Handle grip 7. Adjusting lever 8. Cover 9. Bumper 10. Bushing 11. Pad 12. Backrest cushion 13. Hex head machine screw 14. Arm rests 15. Bot...
Page 208 - Front Wheel and Brake
Rev. F Groundsmaster 3500--D Page 6 -- 10 Wheels, Brakes, and Chassis Front Wheel and Brake 1. Lug nut 2. Drive stud 3. Wheel rim 4. Tire 5. Wheel hub 6. Lock nut 7. Hydraulic wheel motor 8. Brake drum 9. Woodruff key 10. Cotter pin 11. Adjustment rod 12. Brake lever 13. Lock nut 14. Cap screw 15. B...
Page 210 - Rear Fork and Wheel
Groundsmaster 3500--D Page 6 -- 12 Wheels, Brakes, and Chassis Rear Fork and Wheel 1. Hydraulic steering cylinder 2. Ball joint 3. External retaining ring 4. Grease fitting 5. Grease fitting plug 6. Jam nut 7. Rear fork 8. Cap screw 9. Lock washer 10. Thrust washer 11. Tire 12. Hex socket head screw...
Page 212 - Brake Lever Linkages
Groundsmaster 3500--D Page 6 -- 14 Wheels, Brakes, and Chassis Brake Lever Linkages 1. Pop rivet 2. Control panel cover 3. Cover bracket 4. Flange nut 5. Hex flange head screw 6. Magnet support 7. Hex washer head screw 8. Strike bracket 9. Magnetic catch 10. Flat washer 11. Lock nut 12. Cotter pin 1...
Page 214 - Steering Column
Rev. E Groundsmaster 3500--D Page 6 -- 16 Wheels, Brakes, and Chassis Steering Column 1. Steering arm 2. Flange nut 3. Flange head screw 4. Steering control valve bracket 5. Cap screw 6. Pivot hub 7. Steering cover 8. Cap screw 9. Toro decal 10. Ball knob 11. Steering tilt lever 12. Steering control...
Page 216 - Front Lift Arms
Groundsmaster 3500--D Page 6 -- 18 Wheels, Brakes, and Chassis Front Lift Arms 1. 90 o hydraulic fitting 2. Hydraulic cylinder 3. Sidewinder carrier assembly 4. Flange nut 5. Flange head screw 6. Hydraulic hose 7. Centering wire 8. Hydraulic hose 9. Hydraulic hose 10. Hydraulic hose 11. Slide bracke...
Page 218 - Rear Lift Arm
Groundsmaster 3500--D Page 6 -- 20 Wheels, Brakes, and Chassis Rear Lift Arm 1. Hydraulic tube 2. Bulkhead locknut 3. Hydraulic T--fitting 4. Hydraulic hose 5. 90 o hydraulic fitting 6. Hydraulic hose 7. Hydraulic tube 8. Straight hydraulic fitting 9. Castor bushing 10. Hydraulic lift cylinder 11. T...
Page 220 - Sidewinder Carrier; Disassembly
Groundsmaster 3500--D Page 6 -- 22 Wheels, Brakes, and Chassis Sidewinder Carrier 1. Lower frame 2. Sidewinder carrier assembly 3. Slide bracket 4. Plastic slide 5. Flange head screw 6. Flange nut 7. Cap screw 8. Thrust washer 9. Slide support bar 10. Bearing cap 11. Lock nut 12. Liftarm (RH shown) ...
Page 221 - Hood Removal; stop engine, engage parking brake, and remove key
Groundsmaster 3500--D Page 6 -- 23 Wheels, Brakes,and Chassis Hood Removal 1. Flange screw 2. Trim--seal 3. Locknut 4. Hood screen 5. Hood 6. Pivot bracket 7. Flat washer 8. Flex draw latch 9. Rivet 10. Pop rivet 11. Washer 12. Hair pin 13. Cap screw 14. Lock bracket 15. Cap screw 16. Flat washer 17...
Page 223 - Chapter 7; Cutting Units
Rev. E Groundsmaster 3500--D Page 7 -- 1 Cutting Units (Rev. D) Chapter 7 Cutting Units Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 3 . . . . . . . . . . . . . . . . . . . . . . . . . Factors That Can Affect Quality of Cut 3 . . . . . ...
Page 225 - Factors That Can Affect Quality of Cut; Factor
Groundsmaster 3500--D Page 7 -- 3 Cutting Units (Rev. 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 m...
Page 226 - Cutting Unit Tool Kit - TOR4070
Rev. E Groundsmaster 3500--D Page 7 -- 4 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 ...
Page 228 - Adjust Roller Scraper; EARLY STYLE; LATER STYLE
Groundsmaster 3500--D Page 7 -- 6 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 ...
Page 229 - Blade Plane Inspection and Adjustment; Blade Plane Inspection
Groundsmaster 3500--D Page 7 -- 7 Cutting Units (Rev. 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). ...
Page 230 - Never install or work on the cutting units or lift; Blade Stopping Time
Rev. E Groundsmaster 3500--D Page 7 -- 8 Cutting Units (Rev. D) 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...
Page 231 - Cutting Unit Removal and Installation
Rev. E Groundsmaster 3500--D Page 7 -- 9 Cutting Units (Rev. 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. Remove two cap screws that secure hydraulic...
Page 232 - Do not try to straighten a blade that is bent.
Groundsmaster 3500--D Page 7 -- 10 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 if the blade is bent. Always use genuine TORO replacement blades to be sure of safety and optimum performance....
Page 233 - Rear Roller
Rev. E Groundsmaster 3500--D Page 7 -- 11 Cutting Units (Rev. 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 design has grease fittings in the roller shaft ends. The...
Page 235 - Rear Roller Service (Greasable Bearings with Retaining Ring); IMPORTANT: If ball bearing has a seal on one side,
Rev. E Groundsmaster 3500--D Page 7 -- 13 Cutting Units (Rev. D) 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 ...
Page 236 - Rear Roller Service (Greasable Bearings with Bearing Nut); IMPORTANT: During assembly process, frequently
Rev. E Groundsmaster 3500--D Page 7 -- 14 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 out...
Page 238 - Front Roller Service
Rev. E Groundsmaster 3500--D Page 7 -- 16 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 altern...
Page 240 - Blade Spindle Service
Rev. E Groundsmaster 3500--D Page 7 -- 18 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 ...
Page 242 - Carrier Frame; Front Carrier Frame
Rev. E Groundsmaster 3500--D Page 7 -- 20 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 mounte...
Page 243 - Chapter 8; Electrical Diagrams
Rev. G Groundsmaster 3500- D Electrical Diagrams Page 8 - 1 Chapter 8 Electrical Diagrams Table of Contents ELECTRICAL SCHEMATICS AND DIAGRAMS 3 . . . Electrical Schematic (Serial Numbers 90101 to 230999999) 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow Circuits 4 . . . . . . . . . ...
Page 245 - Electrical Schematic
Rev. E Page 8 -- 3 OPTIONAL LIGHT (NOT SUPPLIED) F2 15 A F1 D2 1 2 OR BU OR OR R R PK BU Y 5 A F4 STOP -- -- -- -- NONE ON/PREHEAT -- -- -- -- B+I+A; X+Y START -- -- -- B+I+S I X S Y Y OR BK IGNITION F3 5 A B FRAME BATTERY (+) (-- ) A VIO VIO PK PK VIO 30 87 86 85 PK PK R GLOW RELAY 4 5 6 1 2 3 KUBO...
Page 246 - Glow Circuits; (Schematic from machine with Serial
Rev. E Page 8 -- 4 OPTIONAL LIGHT (NOT SUPPLIED) F2 15 A F1 D2 1 2 OR BU OR OR R R PK BU Y 5 A F4 STOP -- -- -- -- NONE ON/PREHEAT -- -- -- -- B+I+A; X+Y START -- -- -- B+I+S I X S Y Y OR BK IGNITION F3 5 A B FRAME BATTERY (+) (-- ) A VIO VIO PK PK VIO 30 87 86 85 PK PK R GLOW RELAY 4 5 6 1 2 3 KUBO...
Page 247 - Crank Circuits
Rev. E Page 8 -- 5 OPTIONAL LIGHT (NOT SUPPLIED) F2 15 A F1 D2 1 2 OR BU OR OR R R PK BU Y 5 A F4 STOP -- -- -- -- NONE START -- -- -- B+I+S I X S Y Y OR BK IGNITION F3 5 A B FRAME BATTERY (+) (-- ) A VIO VIO PK PK VIO 30 87 86 85 PK PK R GLOW RELAY 4 5 6 1 2 3 KUBOTA GLOW PLUGCONTROLER VIO BU OR PK...
Page 250 - Harness Diagram
Page 8 -- 8 30 1 2 85 SHUT DOWN HIGH TEMP DIODE D2 P9 J17 J16 VIOLET BLACK ORANGE ORANGE BLACK SP2 VIOLET P22 HOUR METER J3 ENGINE GROUND P10 87A INTERLOCK RELAY P11 CLUSTER GAUGE HIGH TEMP GLOW BATTERY OIL PRESS 6 4 5 3 2 1 PINK ORANGE WHITE YELLOW 2 1 YELLOW BLUE GROUND (+) 85 30 GRAY PINK C B A B...
Page 251 - Harness Drawing
Page 8 -- 9 J1 P1 J2 J4 P8 J7 P23 P19 P20 J12 J3 P2 J5 J6 P4 P5 P18 P7 P6 P21 J8 J9 P8 P9 P10 P22 J10 J11 P12 P13 P14 J18 P11 P15 P16 J13 P17 D2 D3 D1 FUEL PUMP SEAT SWITCH TRANSPORT/MOW SWITCH DECK UP/DOWN SWITCH OVERTEMP RELAY DECK ON/OFF SWITCH GLOWCONTROLLER IGNITIONSWITCH ALTERNATOR GLOW RELAY ...
