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Page 3 - Table Of Contents; Chapter 2 -- Product Records and Maintenance
Groundsmaster 3505--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. B Groundsmaster 3505--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 15
Groundsmaster 3505--D Page 1 -- 2 Safety 4. Since fuel is highly flammable, handle it carefully: A. Store fuel in containers specifically designed for this purpose. B. Do not remove machine fuel tank cap while en- gine is hot or running. C. Do not smoke while handling fuel. D. Fill fuel tank outdoor...
Page 7 - Maintenance and Service
Groundsmaster 3505--D Page 1 -- 3 Safety Maintenance and Service 1. Before servicing or making adjustments, lower cut- ting decks, stop engine, set parking brake and remove key from the switch. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 3. Never ...
Page 9 - Chapter 2; Product Records and Maintenance; Product
Groundsmaster 3505--D Page 2 -- 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS 1 . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS 2 ...
Page 10 - Equivalents and Conversions
0.09375 Rev. A Groundsmaster 3505--D Page 2 -- 2 Product Records and Maintenance Equivalents and Conversions
Page 11 - Torque Specifications; reduced by 25% for lubricated fasteners; Fastener Identification
Groundsmaster 3505--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 clearly iden...
Page 14 - Other Torque Specifications; Grade 5; Conversion Factors
Groundsmaster 3505--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 15 - Chapter 3; Kubota Diesel Engine; Kubota
Groundsmaster 3505--D Page 3 -- 1 Kubota Diesel Engine Chapter 3 Kubota Diesel Engine Table of Contents INTRODUCTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS 4 . . . . . . . . . . . . ...
Page 16 - Introduction
Groundsmaster 3505--D Page 3 -- 2 Kubota Diesel Engine Introduction This Chapter gives information about specifications, troubleshooting, testing and repair of the Kubota D1105T diesel engine used in the Groundsmaster 3505--D. Refer to the Traction Unit Operator’s Manual for engine maintenance infor...
Page 17 - Specifications
Groundsmaster 3505--D Page 3 -- 3 Kubota Diesel Engine Specifications Item Description Make / Designation Kubota D1105T, 3 Cylinder, Liquid Cooled, Turbocharged, 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....
Page 18 - Service and Repairs; Muffler and Air Cleaner Assembly; Figure 1
Groundsmaster 3505--D Page 3 -- 4 Kubota Diesel Engine Service and Repairs Muffler and Air Cleaner Assembly Figure 1 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 assembly 10. Flange...
Page 19 - CAUTION
Groundsmaster 3505--D Page 3 -- 5 Kubota Diesel Engine Muffler Removal (Fig. 1) 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 engin...
Page 22 - Fuel System; Figure 4
Groundsmaster 3505--D Page 3 -- 8 Kubota Diesel Engine Fuel System Figure 4 1. Cap screw (2 used) 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 (2 used) 14. Flange hex ...
Page 23 - DANGER
Groundsmaster 3505--D Page 3 -- 9 Kubota Diesel Engine 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 ta...
Page 24 - Radiator; Figure 6
Groundsmaster 3505--D Page 3 -- 10 Kubota Diesel Engine Radiator Figure 6 1. Draincock valve 2. Flange head screw (11 used) 3. Flange nut (4 used) 4. Carriage bolt (4 used) 5. Radiator 6. Upper fan shroud 7. Lower fan shroud 8. Flange head screw (4 used) 9. Hose clamp 10. Radiator frame 11. Radiator...
Page 25 - Do not open radiator cap or drain coolant if the
Groundsmaster 3505--D Page 3 -- 11 Kubota Diesel Engine Removal (Fig. 6) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Open and remove hood from the machine (see Trac- tion Unit Operator’s Manual). CAUTION Do no...
Page 26 - Engine
Groundsmaster 3505--D Page 3 -- 12 Kubota Diesel Engine Engine Figure 7 1. Kubota engine 2. Engine mount (2 used) 3. Engine mount 4. Flange nut (6 used) 5. Cap screw (3 used) 6. Flange head screw (6 used) 7. External lock washer 8. Lock nut (3 used) 9. Hardened washer (3 used) 10. Machine screw 11. ...
Page 31 - Chapter 4; Hydraulic System; Hydraulic System
Rev. B Groundsmaster 3505--D Hydraulic System Page 4 -- 1 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Hydraulic Hoses 3 . . . . . . . . . . . . . . . . . . . . ...
Page 33 - General Information; Hydraulic Hoses; WARNING; Hydraulic Fitting Installation
Groundsmaster 3505--D Hydraulic System Page 4 -- 3 General Information 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 or maintena...
Page 35 - Towing Traction Unit; er than 2 to 3 mph because the drive system may be; Relieving Hydraulic System Pressure
Groundsmaster 3505--D Hydraulic System Page 4 -- 5 Towing Traction Unit In case of emergency, the Groundsmaster 3505--D can be towed (or pushed) for a very short distance. Howev- er, Toro does not recommend this as a standard proce- dure. 1. Locate by--pass valve on hydrostat pump (Fig. 6) and rotat...
Page 36 - Traction Circuit (Closed Loop) Component Failure
Groundsmaster 3505--D Hydraulic System Page 4 -- 6 Traction Circuit (Closed Loop) Component Failure The Groundsmaster 3505--D traction circuit is a closed loop system that includes the hydrostat and two (2) wheel motors. If a component in the traction circuit should fail, debris and contamination fr...
Page 37 - Hydraulic Schematic; Hydraulic; Groundsmaster
Groundsmaster 3505--D Hydraulic System Page 4 -- 7 Hydraulic Schematic Hydraulic Schematic Groundsmaster 3505 --D All solenoids are shown as de --energized AU X (E) OUT (T) IN (P ) Hydraulic System
Page 38 - Hydraulic Flow Diagrams; action; Groundmaster
Groundsmaster 3505--D Hydraulic System Page 4 -- 8 Hydraulic Flow Diagrams G2 1000 psi POW E R STEER IN G VA LV E IN OUT B A R EAR RIGHT LEFT ST CR CF CHG LC 1 LV T1 MA NI FO LD BLOC K M2 T2 3000 psi TR AC TION W H EEL FOR W ARD OIL COOLER STR A IN ER 100 --150 psi INTE RNA L C A S E DRA IN U PPER P...
Page 39 - Traction Circuits; Forward
Groundsmaster 3505--D Hydraulic System Page 4 -- 9 Traction Circuits Forward The traction circuit of the hydraulic system consists of a hydrostat connected in a closed loop circuit to two orbital rotor wheel motors. The engine drives traction pump (P3) indirectly through pulleys and a V--belt. The t...
Page 41 - Cutting Unit Circuit; Mow
Rev. B Groundsmaster 3505--D Hydraulic System Page 4 -- 11 Cutting Unit Circuit Mow A two section gear pump is directly coupled to the the hy- drostat which is driven by the engine. Gear pump sec- tion (P1) supplies oil flow to the cutting unit circuit through the manifold block and to the cutting u...
Page 47 - Steering Circuit; Right Turn
Groundsmaster 3505--D Hydraulic System Page 4 -- 17 Steering Circuit A two section gear pump is directly coupled to the the hy- drostat which is driven by the engine. Gear pump sec- tion (P2) supplies hydraulic flow for operating the steering system, raising and lowering the cutting units and mainta...
Page 48 - Special Tools; Hydraulic Pressure Test Kit
Rev. B Groundsmaster 3505--D Hydraulic System Page 4 -- 18 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 mati...
Page 49 - Hydraulic Test Fitting Kit
Rev. B Groundsmaster 3505--D Hydraulic System Page 4 -- 19 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 fitt...
Page 50 - Wheel Hub Puller
Groundsmaster 3505--D Hydraulic System Page 4 -- 20 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 13 Wheel Hub...
Page 52 - Troubleshooting; Problem
Groundsmaster 3505--D Hydraulic System Page 4 -- 22 Troubleshooting The chart that follows contains information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the Testing section of this Chapter for precau- tions and specific hydraulic tes...
Page 56 - Traction Circuit Working Pressure Test (Using Pressure Gauge); FOR
Groundsmaster 3505--D Hydraulic System Page 4 -- 26 Traction Circuit Working Pressure Test (Using Pressure Gauge) Working PressureLow Pressure (Charge)Return or Suction Flow M4 M5 BI--PASS VALVE P3 PISTON PUMP LOWER PORT UPPERPORT TO GEAR PUMP SUCTION FOR W ARD TRACTION WHEEL MOTORS FROM HYDRAULIC M...
Page 58 - Charge Relief Valve Pressure Test (Using Pressure Gauge)
Groundsmaster 3505--D Hydraulic System Page 4 -- 28 Charge Relief Valve Pressure Test (Using Pressure Gauge) Working PressureLow Pressure (Charge)Return or Suction Flow M4 M5 BI--PASS VALVE P3 HYDROSTAT P1 P2 ENGINE RPM GEAR PUMP LOWER PORT UPPER PORT INTERNAL CASE DRAIN STRAINER FOR W ARD TRACTION ...
Page 60 - Gauges and Flow Meter)
Groundsmaster 3505--D Hydraulic System Page 4 -- 30 Piston Pump (P3) Flow and Traction Relief Pressure Test (Using Tester with Pressure Gauges and Flow Meter) Working PressureLow PressureReturn or Suction Flow M4 M5 BI--PASS VALVE P3 PISTON PUMP LOWER PORT UPPER PORT TO GEAR PUMP SUCTION 100 to 150 ...
Page 64 - Cutting Deck Circuit Pressure Test (Using Pressure Gauge)
Groundsmaster 3505--D Hydraulic System Page 4 -- 34 Cutting Deck Circuit Pressure Test (Using Pressure Gauge) 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...
Page 66 - sure Gauges and Flow Meter)
Groundsmaster 3505--D Hydraulic System Page 4 -- 36 Manifold Relief Valve (R1) Pressure Test (Using Pressure Gauge and Tester with Pres- sure Gauges and Flow Meter) 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 ...
Page 70 - TO TOTO
Groundsmaster 3505--D Hydraulic System Page 4 -- 40 Gear Pump (P1) Flow Test (Using Tester with Pressure Gauges and Flow Meter) Working PressureLow PressureReturn or Suction Flow P1 P2 ENGINE RPM GEAR PUMP STRAINER TO TOTO TO STEERING CONTROL VALVE (IN) PORT TO HYDRAULIC MANIFOLD (P1) PORT FROM HYDR...
Page 74 - Steering and Lift Relief Pressure Test (Using Pressure Gauge); STEERING
Groundsmaster 3505--D Hydraulic System Page 4 -- 44 Steering and Lift Relief Pressure Test (Using Pressure Gauge) P1 P2 ENGINE RPM GEAR PUMP L R V1 STRAINER STEERING POWER STEERING VALVE IN (P) OUT (T) AUX (E) 1000 psi FROM HYDROSTAT INTERNAL CASE DRAIN TO HYDRAULIC MANIFOLD TO HYDRAULIC MANIFOLD (S...
Page 78 - Steering Control Valve Test; IN
Groundsmaster 3505--D Hydraulic System Page 4 -- 48 Steering Control Valve Test L R V1 STEERING POWER STEERING VALVE (LEFT TURN) IN (P) OUT (T) AUX (E) 1000 psi PLUG High PressureLow PressureReturn or Suction Flow CYLINDER OPEN FITTING (Fully Extended)
Page 80 - Adjustments; Braking Valve Adjustment; decrease
Groundsmaster 3505--D Hydraulic System Page 4 -- 50 Adjustments 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 ...
Page 81 - Check Hydraulic Lines and Hoses
Groundsmaster 3505--D Hydraulic System Page 4 -- 51 Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- tem, park machine on a level surface, engage parking bra...
Page 82 - Flush Hydraulic System
Rev. B Groundsmaster 3505--D Hydraulic System Page 4 -- 52 Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or if the system is contaminated (oil appears milky, black or con- tains metal particles). IMPORTANT: Flush hydraulic system when chang...
Page 83 - Charge Hydraulic System
Rev. B Groundsmaster 3505--D Hydraulic System Page 4 -- 53 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 sys...
Page 84 - Hydraulic Tank; FRONT
Groundsmaster 3505--D Hydraulic System Page 4 -- 54 Hydraulic Tank 1. Grommet (4 used) 2. Flange head screw (4 used) 3. Barb fitting 4. Check fitting 5. Flat washer (4 used) 6. Hydraulic tank 7. O--ring 8. Hose clamp 9. Barb fitting (straight) 10. Flange head screw (2 used) 11. Elbow fitting 12. O--...
Page 86 - Oil Cooler
Groundsmaster 3505--D Hydraulic System Page 4 -- 56 Oil Cooler Removal 1. Thoroughly clean hydraulic hose ends and fittings on oil cooler to prevent hydraulic system contamination. CAUTION The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool b...
Page 88 - Wheel Motors
Groundsmaster 3505--D Hydraulic System Page 4 -- 58 Wheel Motors 1. Lock nut (4 per motor) 2. Spacer (4 per motor) 3. Socket head screw (4 per motor) 4. Hydraulic wheel motor (LH shown) 5. Frame 6. Hydraulic tube 7. Hydraulic tube 8. O--ring 9. Hydraulic fitting 10. O--ring Figure 36 FRONT RIGHT 5 3...
Page 90 - Wheel Motor Service; The two wheel motors used on the Ground-; IMPORTANT: If a wheel motor failure occurred, refer; For repair of the wheel motors, see the Ross; vice Procedure at the end of this chapter.
Groundsmaster 3505--D Hydraulic System Page 4 -- 60 Wheel Motor Service 1. Coupling shaft 2. Thrust bearing 3. Drive link 4. Cap screw (7 used) 5. End cover 6. Commutator seal 7. Seal ring 8. Commutator 9. Commutator ring 10. Manifold 11. Stator 12. Vane (7 used) 13. Rotor 14. Wear plate 15. Dirt an...
Page 92 - Cutting Deck Motors
Groundsmaster 3505--D Hydraulic System Page 4 -- 62 Cutting Deck 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 hose 13. O--ri...
Page 93 - Before disconnecting or performing any work
Groundsmaster 3505--D Hydraulic System Page 4 -- 63 Removal (Fig. 38) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Thoroughly clean hydraulic hose ends and fittings on deck motor to prevent hydraulic system con...
Page 94 - Cutting Deck Motor Service; diagonal
Groundsmaster 3505--D Hydraulic System Page 4 -- 64 Cutting Deck Motor Service 1. Socket head screw (4 used) 2. Washer (4 used) 3. Back plate 4. Anti--cavitation valve 5. Relief valve 6. Pressure seal 7. Back up gasket 8. Rear wear plate 9. O--ring 10. Dowel pin (4 used) 11. Body 12. Idler gear 13. ...
Page 98 - Hydraulic Manifold
Groundsmaster 3505--D Hydraulic System Page 4 -- 68 Hydraulic Manifold 1. Hose clamp 2. O--ring 3. Barb fitting 4. Stud (2 used) 5. Straight hydraulic fitting 6. O--ring 7. Flange head nut (2 used) 8. O--ring 9. O--ring 10. Straight hydraulic fitting 11. O--ring 12. Hydraulic hose 13. Hydraulic hose...
Page 100 - Hydraulic Manifold Service
Groundsmaster 3505--D Hydraulic System Page 4 -- 70 Hydraulic Manifold Service 1. Manifold body 2. NWD #4 plug 3. Logic cartridge valve (LC1) 4. Nut 5. Solenoid coil 6. Solenoid cartridge valve (R1) 7. Braking cartridge valve (BV) Figure 44 FRONT RIGHT 1 4 25 ft--lb (34 N--m) 60 in--lb (6.8 N--m) 6 ...
Page 102 - Lift Control Valve
Groundsmaster 3505--D Hydraulic System Page 4 -- 72 Lift Control Valve 1. Knob 2. Lever assembly 3. Flange nut (2 used) 4. Control panel 5. Shoulder bolt (2 used) 6. Hydraulic tube 7. Carriage screw (2 used) 8. O--ring 9. Hydraulic adapter 10. O--ring 11. Hydraulic adapter 12. Hydraulic 90 o fitting...
Page 104 - Lift Control Valve Service
Groundsmaster 3505--D Hydraulic System Page 4 -- 74 Lift Control Valve Service 3 4 6 8 10 16 17 18 19 2 22 23 11 12 13 14 7 5 1 15 20 24 21 25 26 12 9 27 1. Check poppet 2. Plunger 3. Spacer 4. Spool 5. Seat 6. Plug (solid) 7. Seat retaining plug 8. Bushing 9. Check spring 10. Spool cap 11. Valve bo...
Page 108 - Neutral Arm Assembly; stop engine, engage parking brake and remove key; The extension spring is under tension and may; ing the neutral bracket to the pump mount plate.
Groundsmaster 3505--D Hydraulic System Page 4 -- 78 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 (3 used) 8. Neutral arm 9. Flange bushing 10. Thrust washer 11. 90 o grease fitting 12. Lock nut (2 used) 13...
Page 110 - Piston Pump
Groundsmaster 3505--D Hydraulic System Page 4 -- 80 Piston Pump 1. Piston pump 2. Straight hydraulic fitting 3. Cap screw (2 used) 4. Lock nut (2 used) 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 (3 used...
Page 114 - Piston Pump Service; For repair of the piston pump, see the Eaton; fer to Traction Circuit (Closed Loop) Component
Rev. A Groundsmaster 3505--D Hydraulic System Page 4 -- 84 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 17...
Page 116 - Gear Pump
Groundsmaster 3505--D Hydraulic System Page 4 -- 86 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. O--ring 12...
Page 118 - Plug pump ports and clean the outside of the pump; line across the; IMPORTANT: Avoid using excessive clamping; MARKER LINE
Rev. B Groundsmaster 3505--D Hydraulic System Page 4 -- 88 Gear Pump Service (Below Serial Number 260000400) 1. Front plate 2. Back plate 3. Front body 4. Rear body 5. Drive gear 6. Front idler gear 7. Rear idler gear 8. Back--up gasket 9. Rear wear plate 10. Pressure seal 11. Front wear plate 12. O...
Page 124 - Steering Control Valve
Rev. A Groundsmaster 3505--D Hydraulic System Page 4 -- 92 Steering Control Valve 1. Steering arm 2. Flange nut 3. Flange head screw 4. Steering valve bracket 5. Cap screw (2 used) 6. Pivot hub (2 used) 7. Steering cover 8. Cap screw 9. Flange nut (2 used) 10. Ball knob 11. Steering tilt lever 12. S...
Page 126 - Steering Control Valve Service; For service of the steering control valve, see the
Groundsmaster 3505--D Hydraulic System Page 4 -- 94 Steering Control Valve Service 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. Distribution plate 15. Inner gearwheel 16. Outer...
Page 128 - Front Lift Cylinder
Groundsmaster 3505--D Hydraulic System Page 4 -- 96 Front Lift Cylinder 1. 90 o hydraulic fitting (2 used) 2. Hydraulic cylinder 3. Carrier assembly 4. RH actuator 5. Actuator bracket 6. Hydraulic hose 7. LH actuator 8. Hydraulic hose 9. Hydraulic hose 10. Hydraulic hose 11. Clamp bracket 12. Flange...
Page 130 - Rear Lift Cylinder
Groundsmaster 3505--D Hydraulic System Page 4 -- 98 Rear Lift Cylinder 1. Rear lift arm 2. Cap screw 3. Washer 4. Cap screw 5. Retaining ring (3 used) 6. Pin 7. Hydraulic lift cylinder 8. Flange nut (4 used) 9. Cap screw (2 used) 10. Washer 11. Jam nut 12. Cap screw (2 used) 13. Guard 14. Thrust was...
Page 132 - Lift Cylinder Service
Groundsmaster 3505--D Hydraulic System Page 4 -- 100 Lift Cylinder Service 1. Grease fitting 2. Barrel with clevis 3. Lock 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. Jam nut 15. Clevis Figure 66 1 2 3 4 5 6 7...
Page 134 - Steering Cylinder
Groundsmaster 3505--D Hydraulic System Page 4 -- 102 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 nut 10. Frame 11. Rear fork 12. Rear casting Figure 68 8 9 12 11 9 1 8 5 7 2 3 4 5 6 3 7 4...
Page 136 - Steering Cylinder Service
Groundsmaster 3505--D Hydraulic System Page 4 -- 104 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 71 1 2 3 4 5 6 7 8 9 10 12 11 2 3 4 5 8 ...
Page 139 - Chapter 5; Electrical System; Electrical System
Groundsmaster 3505--D Page 5 -- 1 Electrical System Chapter 5 Electrical System Table of Contents ELECTRICAL SCHEMATICS AND DIAGRAMS 1 . . . SPECIAL TOOLS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 4 . . . . . . . . . . . . . . . . . . . . . . . . . Starting Problems...
Page 140 - Multimeter
Rev. A Groundsmaster 3505--D Page 5 -- 2 Electrical System Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The multimeter can test electrical components and cir- cuits for current, resistance or voltage. NOTE: Toro reco...
Page 141 - Battery Hydrometer; Use the Battery Hydrometer when measuring specific
Groundsmaster 3505--D Page 5 -- 3 Electrical System Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally. Figure 4 Electrical System
Page 142 - Starting Problems
Groundsmaster 3505--D Page 5 -- 4 Electrical System Troubleshooting CAUTION Remove all jewelry, especially rings and watches, before doing any electrical trouble- shooting or testing. Disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting and repairs, y...
Page 143 - General Run and Transport Problems
Groundsmaster 3505--D Page 5 -- 5 Electrical System Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Wiring in the crank circuit is loose, corroded or damaged (see Electrical Diagrams -- Chapter 8). Engine run solenoid or circuit wiring is faulty. Engine fuel ...
Page 144 - Cutting Deck Operating Problems
Groundsmaster 3505--D Page 5 -- 6 Electrical System Cutting Deck Operating Problems The cutting units will not run with the mow/transport slide in MOW and the PTO switch in ENGAGE. Wiring to the cutting unit drive circuit (see Electrical Diagrams -- Chapter 8) is loose, corroded or damaged. The sole...
Page 145 - Electrical System Quick Checks; Voltage Measured; Charging System Test; At least 0.50 volt over initial battery voltage.; Glow Plug System Test
Groundsmaster 3505--D Page 5 -- 7 Electrical System Electrical System Quick Checks 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 38 o C...
Page 146 - Check Operation of Interlock Switches; Do not disconnect safety switches. They are for
Rev. A Groundsmaster 3505--D Page 5 -- 8 Electrical System Check Operation of Interlock Switches CAUTION Do not disconnect safety switches. They are for the operator’s protection. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before op-...
Page 147 - Component Testing; When testing electrical components for continu-; Ignition Switch; Testing
Groundsmaster 3505--D Page 5 -- 9 Electrical System 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 engine co...
Page 148 - Glow Relay
Groundsmaster 3505--D Page 5 -- 10 Electrical System Glow Relay The glow relay used on the Groundsmaster 3505--D al- lows electrical current to the engine glow plugs when en- ergized. The glow relay is attached to the radiator assembly. Testing 1. Make sure ignition switch is in the OFF position. Un...
Page 149 - Hour Meter; Hobbs; Solenoid Valve Coil
Groundsmaster 3505--D Page 5 -- 11 Electrical System 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 move 1/10 ...
Page 150 - Indicator Lights
Groundsmaster 3505--D Page 5 -- 12 Electrical System Indicator Lights 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 en...
Page 152 - Neutral Switch; Seat Switch
Groundsmaster 3505--D Page 5 -- 14 Electrical System 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 (Fig. 15). The Standard Control Module mon...
Page 153 - Parking Brake and Transport/Mow Switches; Fusible Link Harness
Groundsmaster 3505--D Page 5 -- 15 Electrical System 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 opens when the parking brake lever is engaged. The switch is located under the dash ...
Page 154 - High Temperature Warning Switch; Make sure engine is cool before removing the; Handle the hot oil with extreme care to prevent
Groundsmaster 3505--D Page 5 -- 16 Electrical System High Temperature Warning Switch The high temperature warning switch is located on the water pump housing on the rear of the engine block (Fig. 20). The high temperature warning switch has a gray wire connected to it. The Standard Control Module mo...
Page 155 - High Temperature Shutdown Switch
Groundsmaster 3505--D Page 5 -- 17 Electrical System High Temperature Shutdown Switch The high temperature shutdown switch is located on the water pump housing on the rear of the engine block (Fig. 20). The shutdown switch has a blue/white wire con- nected to it. The Standard Control Module monitors...
Page 156 - Fuel Pump; Operational Test; Fuel Pump Specifications
Rev. B Groundsmaster 3505--D Page 5 -- 18 Electrical System Fuel Pump The fuel pump is attached to the frame just outboard of the fuel injection pump. The Standard Control Module Run output LED will be il- luminated when the fuel pump is energized. Operational Test 1. Park machine on a level surface...
Page 157 - Fuel Stop Solenoid; In Place Testing
Groundsmaster 3505--D Page 5 -- 19 Electrical System Fuel Stop Solenoid 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. 25). The fuel stop solenoid includes two coils for oper...
Page 158 - Glow Controller; Controller Operation
Groundsmaster 3505--D Page 5 -- 20 Electrical System Glow Controller The controller is located under the right, lower corner of the instrument panel. NOTE: Refer to Chapter 8 -- Electrical Diagrams when troubleshooting the glow controller. Controller Operation 1. When the ignition switch is placed i...
Page 160 - Battery Storage
Groundsmaster 3505--D Page 5 -- 22 Electrical System 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. Make sure ignition switch is in the OFF...
Page 161 - Battery Service
Groundsmaster 3505--D Page 5 -- 23 Electrical System 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 ext...
Page 164 - Removal
Groundsmaster 3505--D Page 5 -- 26 Electrical System Solenoid Valve Coil The solenoid valve coil on the hydraulic control manifold (Fig. 32) can be replaced without opening the hydraulic system. Removal 1. Park machine on a level surface, lower cutting decks, engage parking brake, stop engine and re...
Page 165 - Chapter 6; Chassis; Chassis
Groundsmaster 3505--D Page 6 -- 1 Chassis Chapter 6 Chassis Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 167 - Order special tools from your Toro Distributor.; The wheel hub puller allows safe removal of the wheel
Rev. A Groundsmaster 3505--D Page 6 -- 3 Chassis Special Tools Order special tools from your Toro Distributor. Wheel Hub Puller Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors. Figure 1 Chassis
Page 168 - Adjust Brakes; Before and after adjusting the brakes, always; Before jacking up the machine, review and follow
Groundsmaster 3505--D Page 6 -- 4 Chassis Adjustments 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 surface, lower cutt...
Page 170 - Operator Seat
Groundsmaster 3505--D Page 6 -- 6 Chassis Service and Repairs Operator Seat 1. Seat 2. Cap screw 3. Armrest bracket (LH shown) 4. Armrest 5. Screw 6. Flange head screw (3 used per side) 7. Flat washer 8. Flange nut 9. Spacer 10. Seat belt 11. Lock washer 12. Cap screw 13. Flange head screw (2 used) ...
Page 172 - Front Wheels and Brakes
Groundsmaster 3505--D Page 6 -- 8 Chassis Front Wheels and Brakes 1. Lug nut (4 used per wheel) 2. Drive stud (4 used per wheel) 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 (4 used...
Page 174 - Rear Fork and Wheel; Figure 7
Groundsmaster 3505--D Page 6 -- 10 Chassis Rear Fork and Wheel 1. Cap screw 2. Thrust washer 3. Lock washer 4. Flange bushing 5. Grease fitting 6. Rear casting 7. Rear fork 8. Socket head screw (4 used) 9. Grease fitting plug 10. Ball joint 11. Retaining ring 12. Lock nut (4 used) 13. Hub 14. Seal 1...
Page 175 - Support rear fork to prevent its falling during re-
Groundsmaster 3505--D Page 6 -- 11 Chassis Disassembly (Fig. 7) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove hood from the machine (see Traction Unit Operator’s Manual). WARNING Before jacking up the mac...
Page 176 - Brake Lever Linkages; Figure 8
Groundsmaster 3505--D Page 6 -- 12 Chassis Brake Lever Linkages 1. Pop rivet (4 used) 2. Control panel cover 3. Cover bracket 4. Flange nut (2 used) 5. Flange head screw (2 used) 6. Magnet support 7. Hex washer head screw (4 used) 8. Strike bracket 9. Magnetic catch 10. Flat washer 11. Lock nut (2 u...
Page 178 - Steering Column; Figure 9
Rev. A Groundsmaster 3505--D Page 6 -- 14 Chassis Steering Column 1. Steering arm 2. Flange nut 3. Flange head screw 4. Steering control valve bracket 5. Cap screw (2 used) 6. Pivot hub (2 used) 7. Steering cover 8. Washer head screw 9. Flange nut 10. Ball knob 11. Steering tilt lever 12. Steering c...
Page 180 - Front Lift Arms
Groundsmaster 3505--D Page 6 -- 16 Chassis Front Lift Arms 1. 90 o hydraulic fitting (2 used) 2. Hydraulic cylinder 3. Carrier assembly 4. RH actuator 5. Actuator bracket (2 used) 6. Hydraulic hose 7. LH actuator 8. Hydraulic hose 9. Hydraulic hose 10. Hydraulic hose 11. Clamp bracket 12. Flange nut...
Page 182 - Rear Lift Arm
Groundsmaster 3505--D Page 6 -- 18 Chassis Rear Lift Arm 1. Rear lift arm 2. Cap screw 3. Washer 4. Cap screw 5. Retaining ring (3 used) 6. Pin 7. Hydraulic lift cylinder 8. Flange nut (4 used) 9. Cap screw (2 used) 10. Washer 11. Jam nut 12. Cap screw (2 used) 13. Guard 14. Thrust washer 15. Grease...
Page 185 - Chapter 7; Cutting Units; Cutting Units
Rev. A Groundsmaster 3505--D Page 7 -- 1 Cutting Units Chapter 7 Cutting Units Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 4 . . . . . . . . . . . . . . . . . . ...
Page 187 - Cutting Unit Tool Kit - TOR4070
Rev. A Groundsmaster 3505--D Page 7 -- 3 Cutting Units 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 ...
Page 188 - Factors That Can Affect Quality of Cut; Factor
Groundsmaster 3505--D Page 7 -- 4 Cutting Units Troubleshooting There are a number of factors that can contribute to un- satisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not al...
Page 189 - Never adjust or work on the cutting units or lift; Blade Stopping Time
Groundsmaster 3505--D Page 7 -- 5 Cutting Units Adjustments CAUTION Never adjust or work on the cutting units or lift arms with the engine running. Always stop en- gine and remove key first. Refer to the Cutting Unit Operator’s Manual regarding adjustment procedures for Groundsmaster 3505--D cut- ti...
Page 190 - Never install or work on the cutting units or lift; Rear Roller
Rev. A Groundsmaster 3505--D Page 7 -- 6 Cutting Units 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. Rear Roller 1. Cutting deck 2. Flange head screw (4 used) 3. Cap screw 4. Roller mount 5. Ski...
Page 192 - Rear Roller Service (Greasable Bearings with Retaining Ring)
Rev. A Groundsmaster 3505--D Page 7 -- 8 Cutting Units Rear Roller Service (Greasable Bearings with Retaining Ring) 1. Roller shaft 2. Outer seal 3. Retaining ring 4. Outer oil seal 5. Grease fitting 6. Washer 7. Inner seal 8. Ball bearing 9. Inner oil seal 10. Roller tube Figure 6 6 3 5 4 2 1 7 8 9...
Page 194 - Rear Roller Service (Greasable Bearings with Bearing Nut); IMPORTANT: During assembly process, frequently
Rev. A Groundsmaster 3505--D Page 7 -- 10 Cutting Units Rear Roller Service (Greasable Bearings with Bearing Nut) Disassembly (Fig. 7) 1. Remove bearing lock nut from each end of roller shaft. 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals a...
Page 196 - Blade Spindle
Rev. A Groundsmaster 3505--D Page 7 -- 12 Cutting Units Blade Spindle 1. Socket head screw (2 per motor) 2. Flat washer (2 per motor) 3. Hydraulic deck motor 4. O--ring 5. Flange nut (6 used) 6. Spindle plate 7. Cutting deck 8. Spindle assembly 9. Cap screw (6 used) 10. Cutting blade 11. Anti--scalp...
Page 198 - Blade Spindle Service
Rev. A Groundsmaster 3505--D Page 7 -- 14 Cutting Units Blade Spindle Service Disassembly (Fig. 15) 1. Loosen and remove spindle nut from top of spindle shaft. 2. Press the spindle shaft out of the spindle housing us- ing an arbor press. The shaft spacer remains on the spindle shaft as the shaft is ...
Page 201 - Chapter 8; Electrical Diagrams; Electrical Diagrams
Groundsmaster 3505--D Electrical Diagrams Page 8 -- 1 Chapter 8 Electrical Diagrams Table of Contents ELECTRICAL SCHEMATIC 3 . . . . . . . . . . . . . . . . . . . . . Electrical Schematic 3 . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAMS 4 . . . . . . . . . . . . . . . . . . . . ....
Page 203 - Electrical Schematic
Page 8 -- 3 Electrical Schematic Groundsmaster 3505--D All relays and solenoids are shown as de-- energized.All ground wires are black. LIMIT SWITCH JUMPER DECK ON--OFF SOLENOID
Page 204 - Glow Circuits
Page 8 -- 4 Glow Circuits Power CurrentControl CurrentIndication Current Groundsmaster 3505--D (E NE RG IZ E D ) (OCCUPIED) (IN NEUTRAL) (OFF) (IN TRANSPORT) (BRAKE APPLIED) LIMIT SWITCH JUMPER DECK ON--OFF SOLENOID
Page 205 - Crank Circuits
Page 8 -- 5 Crank Circuits Power CurrentControl CurrentIndication Current Groundsmaster 3505--D (E NE RG IZ E D ) (OCCUPIED) (IN NEUTRAL) (OFF) (IN TRANSPORT) (BRAKE APPLIED) LIMIT SWITCH JUMPER DECK ON--OFF SOLENOID
Page 208 - Wire Harness Drawing
Rev. B Page 8 -- 8 Wire Harness Drawing Groundsmaster 3505--D DECK ON-- OFF SOLENOID (SERIAL NUMBERS ABOVE 280000000) (SERIAL NUMBERS BELOW 280000000) (SERIAL NUMBERS ABOVE 260000400)
Page 209 - Wire Harness Diagram
Rev. B Page 8 -- 9 Wire Harness Diagram Groundsmaster 3505--D TAN PIN K BLUE WHITE BLUE PINK ORANGE YELLOW WHITE PINK GREEN PINK PINK PIN K GRAY RED/BLACK RE D/ B LA CK G R EEN BL U E BL AC K GREEN BLACK BLACK BLUE/WHITE BLACK ORANGE BLACK BLACK BL AC K BL AC K VIOLET BLACK YELLOW GREEN ORANGE BLACK...
