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PART NO. 14209SL
Service Manual
Groundsmaster 3500
R
Models 30807 and 30809
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 (Model 30807) and 3500- G
(Model 30809).
REFER TO THE OPERATOR’S MANUAL FOR
OPERATING, MAINTENANCE AND ADJUSTMENT
INSTRUCTIONS. For reference, insert a copy of the
Operator’s Manual and Parts Catalog for your machine
into Chapter 2 of this service manual. Additional copies
of the Operator’s Manual and Parts Catalog are
available on the internet at www.Toro.com.
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 important instructions which must be followed to prevent damage to systems or components on the
machine.
The Toro Company reserves the right to change product
specifications or this publication without notice.
EThe
Toro Company - 2014
This page is intentionally blank.
Groundsmaster 3500
Chapter 6 - Electrical System
General Safety Instructions . . . . . . . . . . . . . . . . . . 1 - 1
Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
General Information . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6
Electrical System Quick Checks . . . . . . . . . . . . . 6 - 10
Standard Control Module (SCM) . . . . . . . . . . . . . 6 - 12
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 6 - 14
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 6 - 31
Chapter 4 - Kubota Gasoline Engine
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6
KUBOTA WORKSHOP MANUAL, GASOLINE ENGINE, WG972- G- E3F SERIES
KUBOTA DIAGNOSTIC MANUAL, GASOLINE ENGINE, WG972- G- E3F SERIES
Chapter 5 - Hydraulic System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . 5 - 14
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . 5 - 16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 30
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 34
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 66
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 - 70
PARKER TORQMOTOR TC, TB, TE, TJ, TF, TG, TH
and TL SERIES SERVICE PROCEDURE
EATON MEDIUM DUTY PISTON PUMP REPAIR INFORMATION MODEL 70160 VARIABLE DISPLACEMENT PISTON PUMP
SAUER/DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
Groundsmaster 3500
7777-
2
2
3
8
888888-
2
3
4
5
6
8
Chapter 8 - Cutting Units
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 9 - Foldout Drawings
Electrical Drawing Designation . . . . . . . . . . . . . . . 9 - 2
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . 9 - 3
Electrical Schematics and Diagrams . . . . . . . . . . 9 - 5
Kubota
Gasoline Engine
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
05 SERIES
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic
System
Chapter 3 - Kubota Diesel Engine
Chapter 7 - Wheels, Brakes, and Chassis
Electrical
System
1
1
2
3
Wheels, Brakes,
and Chassis
2222-
Cutting Decks
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions . . . . . . . . . . . . . . . .
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . .
Foldout
Drawings
Chapter 2 - Product Records and Maintenance
Kubota
Diesel Engine
Chapter 1 - Safety
Product Records
and Maintenance
Safety
Table Of Contents
This page is intentionally blank.
Groundsmaster 3500
Safety
Table of Contents
GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . .
Supervisor’s Responsibilities . . . . . . . . . . . . . . . . .
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . .
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Service . . . . . . . . . . . . . . . . . . . .
JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
3
4
General Safety Instructions
The GROUNDSMASTER 3500 was tested and certified
by TORO for compliance with existing standards and
specifications as identified in the Operator’s Manual. Although hazard control and accident prevention are dependent partially upon the design and configuration of
the machine, these factors are also dependent upon the
awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance,
and storage of the machine. Improper use or maintenance by the operator or owner of the machine can re-
sult in injury. To reduce the potential for any injury,
comply with the following safety instructions.
WARNING
To reduce the potential for injury or death, comply with the following safety instructions.
Supervisor’s Responsibilities
1. Make sure operators are thoroughly trained and familiar with the Operator’s Manual, Operator’s Video,
and all the operating and safety decals on the machine.
2. Be sure to establish your own special procedures
and work rules for unusual operating conditions (e.g.
slopes too steep for machine operation). Survey mowing site completely to determine which hills can be
operated on safely. When performing this site survey,
always use common sense and take into consideration
the turf condition and the rollover risk. To determine
which hills or slopes may be safely operated on, use the
inclinometer provided with each machine. To perform a
site survey, lay a 4 foot long, 2 by 4 inch piece of wood
on the slope surface and measure the angle of the slope.
The piece of wood will average the slope but will not take
into consideration dips or holes. THE MAXIMUM SIDE
HILL ANGLE SHOULD NOT BE GREATER THAN 25
DEGREES.
Before Operating
1. Operate machine only after reading and understanding the contents of the Operator’s Manual and viewing
the Operator’s Video. Copies of the Operator’s Manual
are available on the internet at www.Toro.com.
adults to operate it without proper instructions.
2. Only trained operators who are skilled in slope operation and who have read the Operator’s Manual and
viewed the Operator’s Video should operate the machine. Never allow children to operate the machine or
4. Do not carry passengers on the machine. Keep everyone, especially children and pets, away from the
areas of operation.
Groundsmaster 3500
3. Become familiar with the controls and know how to
stop the machine and engine quickly.
Page 1 − 1
Safety
Safety
Chapter 1
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.
9. Fill fuel tank with diesel fuel before starting engine.
Avoid spilling any fuel. Since fuel is highly flammable,
handle it carefully.
A. Use an approved fuel container.
6. Always wear substantial shoes. Do not operate machine while wearing sandals, tennis shoes or sneakers.
Do not wear loose fitting clothing because it could get
caught in moving parts and possibly cause personal injury.
7. Wearing safety glasses, safety shoes, long pants
and a helmet is advisable and required by some local ordinances and insurance regulations.
B. Do not remove cap from fuel tank when engine is
hot or running.
C. Do not smoke while handling diesel fuel.
D. Fill fuel tank outdoors and not over one inch from
the top of the tank (bottom of the filler neck). Do not
overfill.
8. Make sure the work area is clear of objects which
might be picked up and thrown by the blades.
While Operating
1. Always wear your seat belt.
2. Do not run the engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and
could be deadly.
3. Sit on the seat when starting and operating the machine.
4. Check interlock switches daily for proper operation
(see Chapter 5 − Electrical System). Do not rely entirely
on safety switches: shut off engine before getting off
seat. If a switch fails, replace it before operating the machine. The interlock system is for your protection, so do
not bypass it.
5. Operator must be skilled and trained in how to drive
on hillsides. Failure to use caution on slopes or hills may
cause vehicle to tip or roll, possibly resulting in personal
injury or death.
6. This triplex mower has a unique drive system for superior traction on hills. The uphill wheel will not spin out
and limit traction like conventional triplexes. If operated
on a side hill that is too steep, rollover may occur before
losing traction.
7. Before backing up, look to the rear and assure no
one is behind the machine. Watch out for traffic when
near or crossing roads. Always yield the right of way.
8. Keep hands, feet and clothing away from moving
parts and the deck discharge area.
angle increases to a Toro recommended maximum limit
of 25 degrees, the risk of a rollover increases to a moderate level. DO NOT EXCEED A 25 DEGREE SIDE HILL
ANGLE BECAUSE THE RISK OF A ROLLOVER AND
SERIOUS INJURY OR DEATH IS VERY HIGH. The
Groundsmaster 3500−D is equipped with an angle indicator, mounted on the steering tube, which indicates the
side hill angle the machine is operating on and identifies
the recommended maximum limit of 25 degrees.
Stay alert for holes in terrain and other hidden hazards
which can cause a sudden change in side hill angle. Use
extreme caution when operating close to sand traps,
ditches, creeks, steep hillsides, or other hazards. Reduce speed when making sharp turns. Do not turn on
hills. Avoid sudden stops and starts. Use reverse pedal
for braking. Cutting units must be lowered when going
down slopes for steering control.
10.When starting the engine:
A. Engage parking brake.
B. Be sure traction pedal is in neutral and blade drive
is in disengage position.
C. After engine starts, release parking brake and
keep foot off traction pedal. Machine must not move.
If movement is evident, the neutral control linkage is
incorrectly adjusted: therefore, shut engine off and
adjust until machine does not move when traction
pedal is released (see Adjust Traction Drive for Neutral in the Adjustments section of Chapter 4 − Hydraulic System).
9. The slope angle at which the machine will tip is dependent on many factors. Among these are mowing
11. This product may exceed noise levels of 85 dB(A) at
conditions such as wet or undulating turf, speed (espethe operator position. Ear protectors are recommended
cially in turns), position of the cutting units, tire pressure,
for prolonged exposure to reduce the potential of perand operator experience. At side hill slope angles of 20
manent hearing damage.
degrees or less the risk of a rollover is low. As the slope
Safety
Page 1 − 2
Groundsmaster 3500
12.Raise the cutting units when driving from one work
area to another.
15.Before getting off the seat:
Safety
A. Move traction pedal to neutral.
13.Do not touch engine, muffler, exhaust pipe or hydraulic tank while engine is running or soon after it has
stopped because these areas could be hot enough to
cause burns.
B. Set the parking brake.
C. Disengage the cutting units and wait for the
blades to stop spinning.
14.If a cutting unit strikes a solid object or vibrates abnormally, stop immediately. Turn engine off, wait for all
motion to stop and inspect for damage.
D. Stop the engine and remove key from the ignition
switch.
16.Whenever machine is left unattended, make sure
key is removed from ignition switch and parking brake
is set.
Maintenance and Service
1. Before servicing or making adjustments to the machine, stop the engine and remove key from switch to
prevent accidental starting of the engine.
2. Check performance of all interlock switches daily. Do
not disable or bypass interlock system components.
The interlock system is for your protection.
3. To ensure entire machine is in good operating condition, frequently check and keep all nuts, bolts, screws
and hydraulic fittings tight.
4. Make sure all hydraulic line connectors are tight, and
all hydraulic hoses and lines are in good condition before applying pressure to the system.
5. Keep body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pressure.
Use paper or cardboard, not hands, to search for leaks.
Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and do serious damage. lf
fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this
form of injury or gangrene may result.
7. If major repairs are ever needed, or if assistance is
desired, contact an Authorized Toro Distributor.
8. To reduce potential fire hazard, keep the engine area
free of excessive grease, grass, leaves and accumulation of dirt.
9. If the engine must be running to perform a maintenance adjustment, keep hands, feet, clothing, and any
other parts of the body away from the cutting units and
any moving parts. Keep everyone away.
10.Do not overspeed the engine by changing governor
settings. To assure safety and accuracy, have an Authorized Toro Distributor check maximum engine speed
with a tachometer.
11. Engine must be shut off before checking oil or adding
oil to the crankcase.
12.To insure optimum performance and safety, use genuine Toro replacement parts and accessories. Replacement parts and accessories made by other
manufacturers could be dangerous, and such use could
void the product warranty of The Toro Company.
6. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be relieved by stopping engine and lowering cutting units to
the ground.
Groundsmaster 3500
Page 1 − 3
Safety
Jacking Instructions
CAUTION
1
When changing attachments, tires, or performing
other service, use correct blocks, hoists, and
jacks. Make sure machine is parked on a solid level floor such as a concrete floor. Prior to raising
machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack
stands or solid wood blocks to support the raised
machine. If the machine is not properly supported by blocks or jack stands, the machine may
move or fall, which may result in personal injury.
2
Figure 1
1. Square tube
2. Side plate
Use the following positions when jacking up the machine:
Jacking the Front End
2
1. If the front wheel motor is to be removed, position
jack securely under the square tube of the lower frame
as closely to the side plate as possible (Fig. 1).
1
2. If the front tire is to be removed, position the jack securely under the front wheel motor.
3. Use jack stands or hardwood blocks under the
square tube or wheel motors to support the machine.
Figure 2
Jacking the Rear End
1. Rear tire
2. Rear casting
1. The preferred method for removing the rear fork, the
rear wheel, or the rear wheel motor is to lift the rear end
of the machine from above:
3
A. Secure a chain fall or hoist to the rear casting (Fig
2).
B. Chock both front tires. Lift rear tire off the ground.
1
C. Use jack stands or hardwood blocks under the
frame to support the machine (Fig. 3).
2
2. If the rear of the machine cannot be lifted from above:
A. Chock both front tires.
Figure 3
IMPORTANT: Make sure jack is as close to the rear
fork as possible when jacking the rear wheel.
1. Frame
2. Rear wheel motor
3. Rear fork
B. Place jack securely under the rear wheel motor
as close to the fork as possible (Fig. 3). Jack rear tire
off the ground.
C. Use jack stands or blocks under the frame to support the machine.
Safety
Page 1 − 4
Groundsmaster 3500
Product Records
and Maintenance
Product Records and Maintenance
Table of Contents
1
1
2
2
2
3
3
4
5
6
6
Kubota
Diesel Engine
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . .
Decimal and Millimeter Equivalents . . . . . . . . . . . .
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . .
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Standard Torque (Inch Series) . . . . . . . . . . . . . . . .
Standard Torque (Metric Fasteners) . . . . . . . . . . .
Other Torque Specifications . . . . . . . . . . . . . . . . . .
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . .
Safety
Chapter 2
Hydraulic
Systems
Product Records
Electrical
System
Insert a copy of the Operator’s Manual and Parts Catalog for your Groundsmaster 3500 at the end of this chapter. Additionally, if any optional equipment or
accessories have been installed to your Groundsmaster, insert the Installation Instructions, Operator’s Manuals and Parts Catalogs for those options at the end of
this chapter.
Wheels, Brakes,
and Chassis
Maintenance
Maintenance procedures and recommended service intervals for the Groundsmaster 3500 are covered in the
Operator’s Manual. Refer to that publication when performing regular equipment maintenance.
Groundsmaster 3500
Page 2 − 1
Product Records and Maintenance
Equivalents and Conversions
0.09375
Product Records and Maintenance
Page 2 − 2
Groundsmaster 3500
The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Hydraulic
Systems
Fastener Identification
Product Records
and Maintenance
These Torque Specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in this Service Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (Loctite), degree of lubrication on the
fastener, presence of a prevailing torque feature, hardness of the surface underneath the fastener’s head, or
similar condition which affects the installation.
As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread engagement, etc.
Kubota
Diesel Engine
Recommended fastener torque values are listed in the
following tables. For critical applications, as determined
by Toro, either the recommended torque or a torque that
is unique to the application is clearly identified and specified in this Service Manual.
Safety
Torque Specifications
Grade 5
Grade 8
Class 8.8
Metric Bolts and Screws
Wheels, Brakes,
and Chassis
Inch Series Bolts and Screws
Class 10.9
Electrical
System
Grade 1
Groundsmaster 3500
Page 2 − 3
Product Records and Maintenance
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Thread Size
Grade 1, 5, &
8 with Thin
Height Nuts
SAE Grade 1 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
in−lb
in−lb
N−cm
10 + 2
13 + 2
147 + 23
# 6 − 32 UNC
# 6 − 40 UNF
# 8 − 32 UNC
13 + 2
25 + 5
# 10 − 24 UNC
30 + 5
SAE Grade 8 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
in−lb
N−cm
in−lb
N−cm
15 + 2
170 + 20
23 + 2
260 + 20
17 + 2
190 + 20
25 + 2
280 + 20
29 + 3
330 + 30
41 + 4
460 + 45
31 + 3
350 + 30
43 + 4
485 + 45
42 + 4
475 + 45
60 + 6
675 + 70
48 + 4
540 + 45
68 + 6
765 + 70
282 + 30
# 8 − 36 UNF
18 + 2
SAE Grade 5 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
339 + 56
# 10 − 32 UNF
1/4 − 20 UNC
48 + 7
53 + 7
599 + 79
100 + 10
1125 + 100
140 + 15
1580 + 170
1/4 − 28 UNF
53 + 7
65 + 10
734 + 113
115 + 10
1300 + 100
160 + 15
1800 + 170
5/16 − 18 UNC
115 + 15
105 + 17
1186 + 169
200 + 25
2250 + 280
300 + 30
3390 + 340
5/16 − 24 UNF
138 + 17
128 + 17
1446 + 192
225 + 25
2540 + 280
325 + 30
3670 + 340
ft−lb
ft−lb
N−m
ft−lb
N−m
ft−lb
N−m
3/8 − 16 UNC
16 + 2
16 + 2
22 + 3
30 + 3
41 + 4
43 + 4
58 + 5
3/8 − 24 UNF
17 + 2
18 + 2
24 + 3
35 + 3
47 + 4
50 + 4
68 + 5
7/16 − 14 UNC
27 + 3
27 + 3
37 + 4
50 + 5
68 + 7
70 + 7
95 + 9
7/16 − 20 UNF
29 + 3
29 + 3
39 + 4
55 + 5
75 + 7
77 + 7
104 + 9
1/2 − 13 UNC
30 + 3
48 + 7
65 + 9
75 + 8
102 + 11
105 + 10
142 + 14
1/2 − 20 UNF
32 + 3
53 + 7
72 + 9
85 + 8
115 + 11
120 + 10
163 + 14
5/8 − 11 UNC
65 + 10
88 + 12
119 + 16
150 + 15
203 + 20
210 + 20
285 + 27
5/8 − 18 UNF
75 + 10
95 + 15
129 + 20
170 + 15
230 + 20
240 + 20
325 + 27
3/4 − 10 UNC
93 + 12
140 + 20
190 + 27
265 + 25
359 + 34
375 + 35
508 + 47
3/4 − 16 UNF
115 + 15
165 + 25
224 + 34
300 + 25
407 + 34
420 + 35
569 + 47
7/8 − 9 UNC
140 + 20
225 + 25
305 + 34
430 + 45
583 + 61
600 + 60
813 + 81
7/8 − 14 UNF
155 + 25
260 + 30
353 + 41
475 + 45
644 + 61
660 + 60
895 + 81
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
Product Records and Maintenance
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.
Page 2 − 4
Groundsmaster 3500
M5 X 0.8
57 + 5 in−lb
640 + 60 N−cm
78 + 7 in−lb
885 + 80 N−cm
M6 X 1.0
96 + 9 in−lb
1018 + 100 N−cm
133 + 13 in−lb
1500 + 150 N−cm
M8 X 1.25
19 + 2 ft−lb
26 + 3 N−m
27 + 2 ft−lb
36 + 3 N−m
M10 X 1.5
38 + 4 ft−lb
52 + 5 N−m
53 + 5 ft−lb
72 + 7 N−m
M12 X 1.75
66 + 7 ft−lb
90 + 10 N−m
92 + 9 ft−lb
125 + 12 N−m
M16 X 2.0
166 + 15 ft−lb
225 + 20 N−m
229 + 22 ft−lb
310 + 30 N−m
M20 X 2.5
325 + 33 ft−lb
440 + 45 N−m
450 + 37 ft−lb
610 + 50 N−m
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately + 10% of the
nominal torque value.
Wheels, Brakes,
and Chassis
Electrical
System
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Product Records
and Maintenance
Class 10.9 Bolts, Screws, and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)
Kubota
Diesel Engine
Class 8.8 Bolts, Screws, and Studs with
Regular Height Nuts
(Class 8 or Stronger Nuts)
Hydraulic
Systems
Thread Size
Safety
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
Groundsmaster 3500
Page 2 − 5
Product Records and Maintenance
Other Torque Specifications
SAE Grade 8 Steel Set Screws
Wheel Bolts and Lug Nuts
Recommended Torque
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 + 10 ft−lb
18 + 3 ft−lb
1/2 − 13 UNC
75 + 15 ft−lb
50 + 10 ft−lb
7/16 − 20 UNF
Grade 5
65 + 10 ft−lb
88 + 14 N−m
1/2 − 20 UNF
Grade 5
80 + 10 ft−lb
108 + 14 N−m
M12 X 1.25
Class 8.8
80 + 10 ft−lb
108 + 14 N−m
M12 X 1.5
Class 8.8
80 + 10 ft−lb
108 + 14 N−m
* For steel wheels and non−lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23, or Type F
Thread Size
Baseline Torque*
No. 6 − 32 UNC
20 + 5 in−lb
No. 8 − 32 UNC
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
Threads per Inch
Baseline Torque**
Type A
Type B
No. 6
18
20
20 + 5 in−lb
30 + 5 in−lb
No. 8
15
18
30 + 5 in−lb
No. 10 − 24 UNC
38 + 7 in−lb
No. 10
12
16
38 + 7 in−lb
1/4 − 20 UNC
85 + 15 in−lb
No. 12
11
14
85 + 15 in−lb
5/16 − 18 UNC
110 + 20 in−lb
3/8 − 16 UNC
200 + 100 in−lb
** Hole size, material strength, material thickness & finish must be considered when determining specific
torque values. All torque values are based on non−lubricated fasteners.
Conversion Factors
in−lb X 11.2985 = N−cm
ft−lb X 1.3558 = N−m
Product Records and Maintenance
N−cm X 0.08851 = in−lb
N−m X 0.7376 = ft−lb
Page 2 − 6
Groundsmaster 3500
Kubota Diesel Engine
Safety
Chapter 3
3
4
4
4
4
6
6
7
7
7
8
Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . 9
Clean Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . 9
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
05 SERIES
Wheels, Brakes,
Electrical
Hydraulic
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator’s Manuals . . . . . . . . . . . . . . . . . . . . . . . . .
Kubota Workshop Manual . . . . . . . . . . . . . . . . . . . .
Kubota Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner and Muffler . . . . . . . . . . . . . . . . . . . . . .
Check Air Filter, Dust Cup, & Burp Valve . . . . . .
Muffler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Muffler Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kubota
Diesel Engine
Table of Contents
Product Records
Model 30807
Groundsmaster 3500- D
Page 3 - 1
Kubota Diesel Engine
This page is intentionally left blank.
Kubota Diesel Engine
Page 3 − 2
Groundsmaster 3500−D
Item
Description
Kubota D1105- E3B or D1105- E4B, 4- Stroke,
Liquid Cooled, OHV Diesel
Number of Cylinders
3
Bore in. (mm)
3.07 (78.0)
Stroke in. (mm.)
3.09 (78.4)
68.53 (1123)
Firing Order
1 (fan end) - 2 - 3 (flywheel end)
Combustion Chamber
Spherical Type
Fuel
No. 2 Diesel Fuel (ASTM D975)
Fuel Injection Pump
Bosch MD Type Mini Pump
Governor
Centrifugal Mechanical
Low Idle (no load)
1400 + 50 RPM
High Idle (no load)
3220 + 50 RPM
Injection Nozzles
API classification CH- 4, CI- 4 or Higher
(see Traction Unit Operator’s Manual for viscosity recommendations)
Oil Pump
Gear Driven Trochoid Type
Crankcase Oil Capacity U.S. Qt. (liters)
4 (3.8) with Filter
Starter
12 VDC, 1.4 KW
Alternator/Regulator
12 VDC, 40 AMP
Dry Weight U.S. Lbs (kilograms)
205.0 (93.0)
Coolant Capacity U.S. qt. (liters)
5.5 (5.2)
Groundsmaster 3500- D
Page 3 - 3
Kubota Diesel Engine
Wheels, Brakes,
Engine Oil
Mini Nozzle (DNOPD)
Hydraulic
14 (53)
Electrical
Fuel Capacity gallons (liters)
Kubota
Diesel Engine
Total Displacement cu. In. (cc)
Product Records
Make / Designation
Safety
Specifications
Introduction
This Chapter gives information about specifications,
maintenance, troubleshooting, testing, and repair of the
diesel engine used in the Groundsmaster 3500- D
(Model 30807).
Service and repair parts for Kubota gasoline engines
are supplied through your local Toro Distributor. If a
parts list is not available, be sure to provide your distributor with the Toro model and serial number.
Most repairs and adjustments require tools which are
commonly available in many service shops. The use of
some specialized test equipment is explained in the engine service manual included at the end of this chapter.
However, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be
done at an engine repair facility.
Operator’s Manuals
The Traction Unit Operator’s Manual provides information regarding the operation, general maintenance and
maintenance intervals for the Kubota diesel engine that
powers your Groundsmaster 3500- D. Refer to this publication for additional information when servicing the
machine.
Kubota Workshop Manual
The engine that powers your Groundsmaster machine
is a Kubota model D1105. The Kubota Workshop Manual is available for these engines. Make sure that the correct engine manual is used when servicing the engine
on your Groundsmaster 3500- D.
Kubota Diesel Engine
The Kubota D1105 engine used in your Groundsmaster
3500- D is a naturally aspirated diesel engine that complies with either EPA emission regulations Tier 4i (model
D1105- E3B) or Tier 4 (model D1105- E4B) depending
on manufacture date. The engine includes a Bosch inline injection pump.
Figure 1
Kubota Diesel Engine
Page 3 - 4
Groundsmaster 3500- D
Safety
Product Records
Kubota
Diesel Engine
Hydraulic
Wheels, Brakes,
Electrical
This page is intentionally left blank.
Groundsmaster 3500−D
Page 3 − 5
Kubota Diesel Engine
Service and Repairs
Air Cleaner and Muffler
10
11
12
14
19
16
21
15
4
13
18
3
12
17
20
12
7
8
1
5
9
2
6
4
5
Figure 2
1.
2.
3.
4.
5.
6.
7.
Exhaust guard
Cap screw
Muffler
Flange head screw
Flange nut
Muffler bracket
Hex nut
Kubota Diesel Engine
8.
9.
10.
11.
12.
13.
14.
Lock washer
Exhaust gasket
Hose clamp
Air inlet hose (upper)
Hose clamp
Air cleaner body
Filter cover
Page 3 − 6
15.
16.
17.
18.
19.
20.
21.
Burp (Actuator) valve
Mounting band assembly
Shoulder bolt
Compression spring
Lock nut
Air inlet hose (lower)
Air filter mount
Groundsmaster 3500−D
Check Air Filter, Dust Cup, & Burp Valve
Safety
The air cleaner body, air filter, dust cup, and burp valve
should be checked daily, prior to operation.
IMPORTANT: Any leaks in the air cleaner system
will cause serious engine damage. Make sure that
all air cleaner components are in good condition
and are properly secured during operation.
4
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch. Unlatch and raise hood.
1
4. Make sure air hoses connecting the air cleaner to the
engine and radiator are secured tightly and free of possible air leaks.
Figure 4
1. Flange head nut
2. Flange head screw
3. Muffler plate
4. Muffler bracket
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
2. Open engine hood to gain access to engine.
3. Remove exhaust guard.
Product Records
Kubota
Diesel Engine
3. Check burp valve and dust cup for damage.
3
Hydraulic
2. Check air cleaner body for damage that could cause
possible air leaks. Make sure dust cup seals completely
to the air cleaner body (Fig. 3).
2
6. Remove exhaust gasket. Replace gasket if damaged or torn.
2
Muffler Installation
NOTE: Make sure muffler flange and exhaust manifold
sealing surfaces are free of debris or damage that may
prevent a tight seal.
3
1. Place exhaust gasket on the exhaust manifold.
IMPORTANT: Finger tighten all fasteners before securing the muffler plate to the muffler bracket so
there is no preload on the exhaust manifold.
Figure 3
1. Latch
2. Dust cup
3. Burp valve
2. Position muffler flange to the exhaust manifold with
four lock washers and hex nuts.
Muffler Removal
3. Position muffler plate to the muffler bracket with both
flange head screws and nuts (Fig. 4).
CAUTION
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the engine and exhaust system to cool before working on the muffler.
4. Tighten muffler flange hex nuts and then muffler
plate screws and nuts.
5. Install exhaust guard.
6. Close and latch engine hood.
Groundsmaster 3500−D
Page 3 − 7
Kubota Diesel Engine
Wheels, Brakes,
5. Remove four hex nuts and lock washers from the exhaust manifold studs. Separate muffler flange from the
exhaust manifold. Remove muffler from the machine.
Electrical
4. Remove both flange head nuts and screws securing
the muffler plate to the muffler bracket (Fig. 4).
1
Fuel System
6
12
13
11 8
22
9
18
5
17
14
7 16
4
1
10
19
44
3
42
33
41
2
43
15
33
Thread Sealant
40
39
Thread Sealant
38
37 36
16
7
26
25
24
7
27
35
34
28
20
33
23
22
Thread
Sealant
31
21
32
33
17
7
29
30
Figure 5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Cap screw
Fuel tank
Cap screw
Fuel cap
Heat shield
Hex flange head screw
Hose clamp
Stand pipe
Connector fitting
Bushing
Seat support strap
Foam
Cap screw
Flat washer
Spacer
Kubota Diesel Engine
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Fuel hose − tank
Fuel hose − stand pipe
Fuel gauge
Grommet
Hose clamp
Fuel hose − crossover
Insert nut
Trim
Barb fitting − ¼”
Tee fitting
Barb fitting 5/16”
Fuel hose − engine
Barb fitting − 3/16”
Fuel hose
Page 3 − 8
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
R−clamp
Tank support
Fuel pump
Hose clamp
Cap screw
Lock washer
Chassis ground
Spacer
R−clamp
Fuel filter/water separator
Fuel fitting − 5/16”
Fuel fitting
Clamp block
Fuel hose
Grommet
Groundsmaster 3500−D
Fuel Tank Installation (Fig. 5)
DANGER
5. Install crossover fuel hose if removed and fill fuel
tank.
3
2. Remove fuel from the tank into a suitable container.
If necessary, remove crossover fuel hose to drain tank
completely.
4
3. Remove seat and seat support straps from the
frame. Note location of spacers under front of seat support straps. Disconnect seat switch from the electrical
harness (Fig. 6).
5
1
2
4. Remove fuel hose strap and both fuel hoses from the
fuel tank. Remove fuel tank from the machine.
Clean Fuel Tank
Figure 6
1. Seat support strap
2. Hex flange head screw
3. Electrical harness
4. Fuel hose strap
5. Fuel hose
Wheels, Brakes,
Clean the fuel tank every 2 years. Also, clean the fuel
tank if the fuel system becomes contaminated or if the
machine is to be stored for an extended period.
1. Remove fuel tank from the machine (see Fuel Tank
Removal).
2. Flush fuel tank out with clean diesel fuel. Make sure
tank is free of contaminates and debris.
3. Install fuel tank to the machine (see Fuel Tank Installation).
Groundsmaster 3500−D
Product Records
4. Check for correct seat operation and that seat switch
wires and connector are not pinched and do not contact
any moving parts.
Kubota
Diesel Engine
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch. Unlatch and raise hood.
3. Connect seat switch to the electrical harness. Route
seat switch wire under seat support strap. Secure seat
support straps and seat to the frame with hex flange
head screws.
Hydraulic
Fuel Tank Removal (Fig. 5)
2. Connect both fuel hoses to the tank and secure with
hose clamps. Apply anti−seize lubricant to inserts on top
of tank and install fuel hose strap.
Page 3 − 9
Electrical
Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke
while filling the fuel tank. Do not fill fuel tank
while engine is running or hot, or when machine
is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before
starting the engine. Store fuel in a clean, safety−
approved container and keep cap in place. Use
diesel fuel for the engine only; not for any other
purpose.
Safety
1. Position fuel tank to the machine.
Kubota Diesel Engine
Radiator − Radiator/Hydraulic Fluid Cooler
Traction Units Prior to
Serial No 314000001
10
18
17
22
15
28
5 11
9
34
30
6
16
13
32
9
31
8
14
35
25
3
20
29
19
33
21
4
26
28
27
2
12
36
24 25
23
37
1
38
7
Figure 7
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Drain−cock valve
Flange head screw
Flange nut
Carriage bolt
Radiator
Fan shroud (top)
Fan shroud (bottom)
Flange head screw
Hose clamp
Radiator frame
Radiator cap
Radiator foam seal
Flange head screw
Kubota Diesel Engine
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Reservoir bracket
Wire form latch
Hydraulic fluid cooler bracket
Bracket clamp
Screw
Lock nut
Radiator shield (lower)
Magnetic catch
Hydraulic fluid cooler
Radiator hose (upper)
Radiator hose (lower)
Hose clamp
Hydraulic tube
Page 3 − 10
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
Hydraulic tube
Hydraulic fluid cooler hose
Grommet
Foam seal
Expansion tank hose
Expansion tank
Glow plug relay
Thread forming screw
Flange lock nut
Bulkhead nut
Tube assembly
Nut
Groundsmaster 3500−D
9
8
7
6
Safety
Traction Units
Serial No 314000001 & Up
7
5
11
25
4
10
28
27
3
12
26
Kubota
Diesel Engine
13
1
7
25
24
22
9
14
21
15
31
16
23
6
29
13
30
Hydraulic
2
32
Product Records
6
17
18
FRONT
Electrical
20
7
9
19
Figure 8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Expansion tank
Hose clamp
Coolant hose
Flange head screw
Radiator bracket − RH
Carriage bolt
Flange nut
Radiator bracket − top
Flange head screw
Frame casting
Cap screw
Groundsmaster 3500−D
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Radiator
Straight fitting
Drain−cock
Lower radiator shield
Radiator bracket − LH
Elbow fitting
Magnet
Radiator bracket − bottom
Lower fan shroud
Upper fan shroud
Hydraulic tube
Page 3 − 11
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Hydraulic hose
Lower radiator hose
Hose clamp
Hex nut
Relay
Upper radiator hose
Flange nut
Straight fitting
Expansion tank support
Flange head screw
Kubota Diesel Engine
Wheels, Brakes,
RIGHT
Removal
Units prior to serial no. 314000001 use a separate hydraulic oil cooler. The hydraulic oil cooler on later units
is combined with the radiator assembly. It is not necessary to drain the hydraulic system when removing the
radiator on early units prior to serial no. 314000001.
2
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1
3
2. Open and remove engine hood from the machine.
Figure 9
CAUTION
1. Hydraulic filter element
2. Hydraulic filter head
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Ethylene- glycol antifreeze is poisonous. Dispose of coolant
properly, or store it in a properly labeled container away from children and pets.
3. Place a suitable container under the radiator to collect the coolant. Open drain- cock valve, and completely
drain the radiator.
4. Remove glow plug relay from the radiator assembly.
Position relay away from the radiator.
5. Place a suitable container under the hydraulic filter
to collect the hydraulic fluid. The container should have
a 6 gal. (23 Ltr.) minimum capacity. Disconnect the hydraulic hose below the filter head or remove the hydraulic filter element and drain the hydraulic system (Fig. 9).
6. Disconnect following hoses from the radiator or radiator/oil cooler assembly:
A. Upper radiator hose to the water pump.
3. Hydraulic hose
9. Remove expansion tank bracket and both fan
shrouds from radiator assembly.
10.Remove flange head screws securing the top and
bottom of the radiator frame to the radiator. Remove four
carriage bolts and lock nuts securing the radiator to the
radiator frame.
11. Carefully remove radiator from the radiator frame.
12.Plug any openings to prevent contamination.
Installation
1. Remove any plugs used during the removal procedures.
2. Position radiator carefully to the radiator frame.
3. Secure radiator assembly to the radiator frame with
four carriage bolts and lock nuts. Secure top and bottom
of radiator to frame with flange head screws.
4. Secure both fan shrouds to the radiator assembly
with flange head screws.
B. Lower radiator hose to the engine block.
5. Secure expansion tank bracket and tank to the top
fan shroud with both flange head screws and flange
nuts.
C. Coolant hose to the expansion tank.
D. Air hose to the air cleaner.
7. For units serial no. 314000001 & up, disconnect the
following hoses from the oil cooler section of the radiator/oil cooler assembly:
6. For units serial no. 314000001 & up, connect the following hoses to the oil cooler section of the radiator/oil
cooler assembly:
A. Hydraulic tube from top of hydraulic fluid cooler.
A. Hydraulic tube from top of hydraulic fluid cooler.
B. Hydraulic hose from bottom of hydraulic fluid
cooler.
B. Hydraulic hose from bottom of hydraulic fluid
cooler.
8. Remove expansion tank from the fan shroud.
Kubota Diesel Engine
Page 3 - 12
Groundsmaster 3500- D
A. Upper radiator hose to the water pump.
9. Make sure drain- cock valve is closed. Fill radiator
with coolant to the bottom of the filler neck.
10.Install engine hood to the machine. Close and latch
hood.
B. Lower radiator hose to the engine block.
Safety
7. Connect following hoses to the radiator or radiator/oil
cooler assembly:
D. Air hose to the air cleaner.
Wheels, Brakes,
Electrical
Hydraulic
Kubota
Diesel Engine
8. Secure glow plug relay to the radiator assembly with
both thread forming screws.
12.After running engine for a short time on units with serial no. 314000001 & up, stop engine and make sure hydraulic tank is full. Add correct oil if necessary.
Product Records
11. Start engine. Check for fluid leaks and proper engine
operation.
C. Coolant hose to the expansion tank.
Groundsmaster 3500- D
Page 3 - 13
Kubota Diesel Engine
Diesel Engine
1
Thread Sealant
6
8
5
2
6
9
10
7
3
13
11
12
4
26
41
42
15
31
40
30
16
43
36
44
38
14
35
34
37
32
17
18
19
48
47
26
20
23
24
25
27
46
45
28
29
30
21
22
4
31
32
39
39
33
34
Figure 10
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Engine mount bracket − RH
Cap screw
Hardened washer
Engine mount
Lower radiator hose
Hose clamp
Exhaust flange gasket
Coolant temperature switch
Upper radiator hose
Wire Harness − fusible link
Flat washer
Lock washer
Hex nut
Flange nut
Fuel filter bracket
External tooth lock washer
Kubota Diesel Engine
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Engine ground
Flat washer
Cap screw
Throttle cable bracket
Cable clamp
Cap screw
Throttle cable
Swivel clamp
Cable stop
Cap screw
Engine mount bracket − LH
Hardened washer
Cap screw
Flange head screw
Hardened washer
Hex nut
Page 3 − 14
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
Lock washer
Flange nut
Engine mount bracket − front
Engine mount
Hardened washer
Cap screw
Cable tie
Spacer (1)
Spacer (4)
Pump mount plate
Hardened washer
Cap screw
Cap screw
Hardened washer
Flange head screw
Clamp
Groundsmaster 3500−D
Removal
5
2. Open and remove engine hood from the machine.
Slide seat all the way forward.
3. Disconnect both battery cables at the battery (see
Battery Service in Chapter 6 − Electrical System).
5. Remove muffler from the exhaust manifold and muffler bracket (see Muffler Removal in this Chapter).
1
Figure 11
1. Battery ground cable
2. Wire harness ground
3. Throttle cable
4. Support bracket
5. Speed control lever
6. Fuel hose
2
6. Drain radiator from the drain cock valve into a suitable container (see Radiator Removal in this Chapter).
Disconnect coolant hoses from the water pump and engine block.
Kubota
Diesel Engine
4. Disconnect air hose from the air cleaner and radiator.
Remove air cleaner assembly from the engine.
2
6
1
4
3
Hydraulic
7. Remove coolant expansion tank and bracket from
the top fan shroud. Remove top fan shroud from the radiator (see Radiator Removal in this Chapter).
8. Disconnect wire harness and electrical wires from
the following:
Figure 12
1. Glow plug wire
2. Rear injector nozzle
3. Fuel hose
4. Lift tab
Electrical
A. Battery, wire harness and engine grounds (Fig.
11).
Safety
4
3
Product Records
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
B. Glow plug bus (Fig. 12) and fuel stop solenoid.
2
C. High temperature warning switch (Fig. 13).
1
Wheels, Brakes,
D. High temperature shutdown switch, alternator,
and low oil pressure switch (Fig. 14).
9. Disconnect throttle cable from the support and swivel on the speed control lever (Fig. 11).
10.Disconnect fuel hose from the fuel pump (Fig. 11)
and front injector nozzle.
Figure 13
1. Temp. warning switch
11. Remove traction control cable from the neutral arm
assembly on the piston pump. Remove all hydraulic
hoses from the piston and gear pumps (see Piston
Pump Removal in Chapter 5− Hydraulic System).
2. Lift tab
1
12.Remove cable ties securing the wire harness to the
front lift tab and other engine parts. Connect hoist or lift
to the front and rear lift tabs (Fig. 12 and 13).
2
3
Figure 14
1. Temp. shutdown switch
2. Alternator
Groundsmaster 3500−D
Page 3 − 15
3. Low oil press. switch
Kubota Diesel Engine
1
RIGHT
FRONT
2
3
4
5
6
10
9
8
7
Figure 15
1.
2.
3.
4.
Engine mount bracket
Flange nut
Flange screw
Pump mount plate
5. Hardened washer
6. 10 mm cap screw (4)
7. 8 mm cap screw (1)
CAUTION
8. Hardened washer
9. Long spacer (4)
10. Short spacer (1)
CAUTION
Make sure lift or hoist can support the total
weight of the engine before removing the cap
screws from the engine and engine brackets.
One person should operate lift or hoist while the
other person guides the engine out of the machine.
13.Remove hex nuts, cap screws, and washers from the
center of the three engine mounts.
IMPORTANT: Make sure not to damage the engine,
fuel and hydraulic lines, electrical harness, or other
parts while removing the engine.
14.Remove engine slowly from the machine.
Kubota Diesel Engine
Page 3 − 16
Groundsmaster 3500−D
Installation
1. If removed, install engine mounts, front engine
mounting bracket, throttle support bracket and left engine mounting bracket. Also, make sure that all switches
and sensors are installed on engine.
2. Install hydrostat and pump assembly to the engine
as follows (Fig. 15):
A. Secure the pump support to the engine mount
bracket with two flange nuts and cap screws.
B. Secure pump mount plate to the engine with five
spacers, washers, and cap screws.
C. Install traction belt to the engine flywheel and hydrostat pulleys.
3. Connect hoist or lift to the front and rear engine lift
tabs (Fig. 12 and 13).
C. High temperature warning switch (Fig. 13).
D. High temperature shutdown switch, alternator,
and low oil pressure switch (Fig. 14).
11. Secure wire harness to engine with cable ties at locations noted during engine removal.
12.Connect coolant hoses to the water pump and engine block. Make sure drain cock valve is closed. Fill radiator with coolant.
13.Install muffler to the exhaust manifold and muffler
bracket (see Muffler Installation in this Chapter).
14.Connect throttle cable to the support and swivel on
the speed control lever (Fig. 11).
15.Connect both battery cables at the battery (see Battery Service in Chapter 6 − Electrical system).
16.Install air cleaner to the engine. Connect air hose to
air cleaner and radiator.
18.Bleed fuel system.
One person should operate lift or hoist while the
other person guides the engine into the machine.
IMPORTANT: Make sure not to damage the engine,
fuel and hydraulic lines, electrical harness, or other
parts while installing the engine.
4. Position engine slowly into the machine.
5. Secure all three engine mounts to the engine mounting brackets with cap screws, washers, and hex nuts.
6. Secure wire harness to the front lift tab and the engine with cable ties.
7. Install all hydraulic hoses to the piston and gear
pumps. Install traction control cable to the neutral arm
assembly on the piston pump (see Piston Pump Installa-
Safety
B. Glow plug bus (Fig. 12) and fuel stop solenoid.
17.Adjust throttle cable.
CAUTION
Groundsmaster 3500−D
A. Engine grounds to the battery and wire harness
(Fig. 11).
Product Records
16.As necessary, remove engine mounts, front engine
mounting bracket, throttle support bracket and left engine mounting bracket.
10.Connect wire harness and electrical wires to the following:
Kubota
Diesel Engine
C. Remove two cap screws and flange nuts securing the pump support to the engine mount bracket
and remove the hydrostat and pump assembly from
the engine.
9. Install top fan shroud to the radiator. Install expansion tank and bracket to the top fan shroud (see Radiator
Installation in this Chapter).
Hydraulic
B. Remove five cap screws, washers, and spacers
securing the pump mount plate to the engine.
8. Connect fuel hose to the fuel pump (Fig. 11) and front
injector nozzle.
Electrical
A. Remove traction belt from the engine flywheel
and hydrostat pulleys.
tion in Chapter 5− Hydraulic System).
19.Install engine hood to the machine. Close and latch
hood.
20.Check the hydraulic fluid level and fill the hydraulic
fluid tank if necessary.
21.Start the unit and run engine to normal operating
temperature. Use all of the hydraulic controls while the
engine is running to distribute the hydraulic fluid
throughout the system.
22.Stop the engine and check the hydraulic fluid and
coolant levels. Adjust as necessary.
23.Adjust traction drive for neutral.
Page 3 − 17
Kubota Diesel Engine
Wheels, Brakes,
15.Separate hydrostat and pump assembly from the engine as follows (Fig. 15):
This page is intentionally left blank.
Kubota Diesel Engine
Page 3 − 18
Groundsmaster 3500−D
Kubota Gasoline Engine
Safety
Chapter 4
Fuel Evaporative Control System
(Unit Serial No. Prior to 315000001) . . . . . . . . . 10
Carbon Canister Removal . . . . . . . . . . . . . . . . . 11
Carbon Canister Installation . . . . . . . . . . . . . . . . 11
Radiator/Hydraulic Fluid Cooler . . . . . . . . . . . . . . 12
Radiator Removal . . . . . . . . . . . . . . . . . . . . . . . . 13
Radiator Installation . . . . . . . . . . . . . . . . . . . . . . . 13
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . 18
KUBOTA WORKSHOP MANUAL, GASOLINE ENGINE, WG972- G- E3F
KUBOTA DIAGNOSTICS MANUAL, GASOLINE ENGINE, WG972- G- E3F
Kubota
Gasoline Engine
3
4
4
4
4
5
6
6
7
7
7
8
9
9
9
Wheels, Brakes,
Electrical
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operators Manuals . . . . . . . . . . . . . . . . . . . . . . . . . .
Kubota Workshop and Diagnostics Manuals . . . .
Kubota Gasoline Engine . . . . . . . . . . . . . . . . . . . . .
Engine Electronic Control Unit (ECU) . . . . . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner and Muffler . . . . . . . . . . . . . . . . . . . . . .
Check Air Filter, Dust Cup, & Burp Valve . . . . . .
Muffler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Muffler Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic
Table of Contents
Product Records
Model 30809
Groundsmaster 3500- G
Page 4 - 1
Kubota Gasoline Engine
This page is intentionally left blank.
Kubota Gasoline Engine
Page 4 − 2
Groundsmaster 3500−G
Item
Description
Kubota, Vertical, 4−Cycle, 3 Cylinder,
Liquid Cooled, Gasoline Engine
Bore in. (mm)
2.93 (74.5)
Stroke in. (mm)
2.90 (73.6)
Total Displacement cu. In. (cc)
58.68 (962)
9.2:1
Ignition Timing
31_ BTDC @ 3600 rpm
Ignition System
Full Transistor Battery Ignition Type
Firing Order
1−2−3
NGK BKR6E 0.028 to 0.031 (0.7 to 0.8)
Intake & Exhaust Valve Clearance in. (mm)
(check when engine is cold)
0.0065 + 0.0001 (0.165 + 0.02)
Fuel
Unleaded Gasoline (up to 10% ethanol)
Governor
Electronic
Low Idle (no load)
1600 + 30 RPM
High Idle (no load)
3420 + 30 RPM
Direction of Rotation
Counterclockwise (Viewed from Flywheel)
API classification SL or higher
(see Traction Unit Operator’s Manual for viscosity recommendations)
Oil Pump
Trochoid Type
Crankcase Oil Capacity U.S. qt. (liters)
3.6 (3.4) with Filter
Starter
12 VDC, 1.2 KW
Alternator/Regulator
12 VDC, 480W
Dry Weight U.S. lbs (kilograms)
163 (74)
Coolant Capacity U.S. qt. (liters)
Groundsmaster 3500−G
6 (5.7) with 1.0 (0.9) Reservoir
Page 4 − 3
Kubota Gasoline Engine
Electrical
11 (41.7)
Wheels, Brakes,
Fuel Capacity gallons (liters)
Engine Oil
Hydraulic
Spark Plug Type/Gap in. (mm)
Kubota
Gasoline Engine
Compression Ratio
Product Records
Make / Designation
Safety
Specifications
Introduction
This Chapter gives information about specifications,
maintenance, troubleshooting, testing, and repair of the
gasoline engine used in the Groundsmaster 3500−G
(Model 30809).
Service and repair parts for Kubota gasoline engines
are supplied through your local Toro Distributor. If a
parts list is not available, be sure to provide your distributor with the Toro model and serial number.
Most repairs and adjustments require tools which are
commonly available in many service shops. The use of
some specialized test equipment is explained in the engine service manual included at the end of this chapter.
However, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be
done at an engine repair facility.
Traction Unit Operator’s Manuals
The Traction Unit Operator’s Manual provides information regarding the operation, general maintenance and
maintenance intervals for your Groundsmaster
3500−G. Refer to this publication for additional information when servicing the machine.
Kubota Workshop and Diagnostics Manuals
The engine that powers your Groundsmaster 3500−G is
a Kubota model WG972−G−E3F. Both the Kubota
Workshop Manual and Kubota Diagnostics Manual are
available for this engine. Make sure that the correct engine manuals are used when servicing the engine.
Kubota Gasoline Engine
The engine used in your Groundsmaster 3500−G is a
Kubota WG972 Series gasoline engine. Engine features include an electronic control unit (ECU) that controls a common rail fuel injection system with port
injection, electronic throttle valve (ETV), an electronic
governor and a catalytic muffler exhaust system with an
oxygen sensor. The ECU receives information from the
traction unit Standard Control Module (SCM) as well as
numerous engine sensors. The information provided allows the engine ECU to monitor and control engine operation for optimum engine performance.
Figure 1
Kubota Gasoline Engine
Page 4 − 4
Groundsmaster 3500−G
Product Records
1
2
Hydraulic
If the engine ECU identifies that an engine problem exists, the check engine light on the Operator’s Control
Panel will illuminate. The engine speed may be reduced
or the engine might stop. The Kubota Gasoline Service
Tool (KGST) software, the Ecom interface driver and
diagnostic cable, and the Kubota Diagnostic Manual
should be used to provide assistance in identifying the
cause of the problem and any repairs that are necessary. Use the diagnostic cable to connect a PC running
the KGST software and Ecom interface driver to the diagnostic connector above the engine ECU (Fig. 3). Contact your Toro distributor for assistance in Kubota engine
troubleshooting, or to acquire Kubota engine software
and hardware.
Kubota
Gasoline Engine
The engine electrical components (e.g. ECU, O2
sensor, throttle control, power relay, ETV relay) are identified and matched in the engine ECU program. If engine
electrical components are replaced on the engine, the
Kubota electronic tool must be used to update the ECU
program which will ensure correct engine operation.
Figure 2
1. Engine (Model 30809)
2. Engine ECU
Wheels, Brakes,
IMPORTANT: Two (2) communication connectors
are located near the engine ECU. The connector
along side of the ECU (near the middle of the engine)
is not used for service diagnostics.
Do not plug or unplug the engine ECU for a period
of thirty (30) seconds after the machine key switch
is turned OFF. The ECU may remain energized even
though the ignition switch is OFF.
If the engine ECU is to be disconnected for any reason,
make sure that the ignition switch is in the OFF position
with the key removed before disconnecting the engine
ECU. Also, to prevent possible ECU damage when
welding on the machine, disconnect and remove the engine ECU from the machine before welding.
Figure 3
Diagnostic connector
Groundsmaster 3500−G
Page 4 − 5
Electrical
The Kubota gasoline engine that powers your Groundsmaster 3500−G uses an electronic control unit (ECU)
for engine management. All wire harness electrical connectors should be plugged into the ECU before the machine ignition switch is moved from the OFF position to
either the ON or START position.
Safety
Kubota Gasoline Engine Electronic Control Unit (ECU)
Kubota Gasoline Engine
Service and Repairs
Air Cleaner and Muffler
5
1
22 − 28 ft−lbs
(30 − 38 N−m)
13
3
4
2
25
5
6
7
24
23
13
8
10
22 − 28 ft−lbs
(30 − 38 N−m)
5
22
6
13
11 12
9
21
14
30 to 44 ft−lb
(41 to 59 N−m)
15
28
16
27
13
20
26
19
18
17
Figure 4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Muffler flange cover
Muffler cover
Muffler
Exhaust gasket
Flange nut
Flange head screw
Muffler bracket
Muffler mount tube
Oxygen (O2) sensor
Flange head screw
Kubota Gasoline Engine
11.
12.
13.
14.
15.
16.
17.
18.
19.
Exhaust gasket
Lower intake hose
Hose clamp
Flange head screw
Muffler bracket
Exhaust clamp
Flange nut
Exhaust tube
Cap screw
Page 4 − 6
20.
21.
22.
23.
24.
25.
26.
27.
28.
Heat shield
Air cleaner bracket
Flange head screw
Upper intake hose
Air cleaner assembly
Burp (actuator) valve
Radiator inlet tube
Hose clamp
Radiator hose adapter
Groundsmaster 3500−G
Muffler Removal (Fig. 4)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch. Unlatch and raise hood.
2. Check air cleaner body for damage that could cause
possible air leaks. Make sure dust cup seals completely
to the air cleaner body (Fig. 5).
3. Check burp valve and dust cup for damage.
4. Make sure air hoses connecting the air cleaner to the
engine and radiator are secured tightly and free of possible air leaks.
Safety
IMPORTANT: Any leaks in the air cleaner system
will cause serious engine damage. Make sure that
all air cleaner components are in good condition
and are properly secured during operation.
CAUTION
The muffler and exhaust pipe may be hot. To
avoid burns, allow the engine and exhaust system to cool before working on the muffler.
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
2. Open engine hood to gain access to engine.
Product Records
The air cleaner body, air filter, dust cup, and burp valve
should be checked daily, prior to operation.
take place. These chemical reactions reduce the
amount of CO, HC and NOx in the exhaust. Two (2) oxygen sensors are included in the exhaust system and are
used as inputs for the engine ECU to monitor exhaust
system operation. The exhaust exits the catalytic
muffler through the tailpipe outlet.
Kubota
Gasoline Engine
Check Air Filter, Dust Cup, & Burp Valve
4. Remove both flange head nuts and screws securing
the muffler bracket to the hydraulic pump support.
2
5. Remove four flange head nuts and screws securing
the muffler flange to the muffler mount tube. Separate
muffler flange from the mount tube. Remove muffler assembly from the machine.
6. Remove exhaust gasket. Replace gasket if damaged or torn.
Electrical
1
Hydraulic
3. Remove exhaust guard from frame.
NOTE: Make sure muffler flange and muffler mount
tube sealing surfaces are free of debris or damage that
may prevent a tight seal.
3
1. Hold the exhaust gasket on the muffler flange and
position the muffler assembly to the muffler mount tube
with four flange head screws and nuts.
IMPORTANT: Finger tighten all fasteners before securing the muffler bracket to the pump support so
there is no preload on the muffler mount tube.
Figure 5
1. Latch
2. Dust cup
3. Burp valve
2. Position muffler bracket to the hydraulic pump support with both flange head screws and nuts.
Muffler
To meet gasoline engine emission requirements, the
Kubota engine used on your Groundsmaster has a catalytic muffler. In addition to providing sound damping and
spark arresting, the muffler also includes a three way
catalyst to treat the exhaust gases which are created
from the combustion process. The three-way catalyst
consists of a honeycomb core coated with a mixture of
precious metals. The hot exhaust gases flow through
the catalyst where oxidation and reduction reactions
Groundsmaster 3500−G
3. Torque muffler flange nuts from 22 to 28 ft−lb (30 to
38 N−m and then muffler bracket screws and nuts.
NOTE: If oxygen sensor was removed, torque sensor
from 30 to 44 ft−lb (41 to 59 N−m).
4. Install exhaust guard to frame.
5. Close and latch engine hood.
Page 4 − 7
Kubota Gasoline Engine
Wheels, Brakes,
Muffler Installation (Fig. 4)
Fuel System
175 to 200 in−lb
(20 to 22 N−m)
13
26
RIGHT
12
FRONT
14
15
16
11
10
9
8
7
19
20
17 18
22
21
6
17
6
1
19
5
5
27
26
25
23
24
4
2
3
4
Figure 6
1.
2.
3.
4.
5.
6.
7.
8.
9.
Fuel tank
Hose clamp
Fuel hose − crossover
Protective trim
Bushing
Elbow fitting
Spacer
Flat washer
Cap screw
Kubota Gasoline Engine
10.
11.
12.
13.
14.
15.
16.
17.
18.
Seat support strap
Pump gasket
Fuel pump
Fuel pump cap
Flange screw
Flat washer
Heat shield
Hose clamp
Foam
Page 4 − 8
19.
20.
21.
22.
23.
24.
25.
26.
27.
Cap screw
Strap
Strap
Fuel tank cap
Fuel gauge
Seal
Cable tie
Fuel Hose
Hose clamp
Groundsmaster 3500−G
3. Install fuel tank to the machine (see Fuel Tank Installation).
Fuel Tank Removal (Fig. 6)
Fuel Tank Installation (Fig. 6)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch. Unlatch and raise hood.
1. Position fuel tank to the machine.
2. Remove fuel from the tank into a suitable container.
If necessary, remove crossover fuel hose to drain tank
completely.
2. Connect three fuel hoses to the tank and secure with
hose clamps. Apply anti−seize lubricant to inserts on top
of tank and install fuel hose straps.
3. Connect fuel pump to electrical harness.
3. Remove seat and seat support straps from the
frame. Note location of spacers under front of seat support straps. Disconnect seat switch from the electrical
harness.
4. Connect seat switch to the electrical harness. Route
seat switch wire under seat support strap. Secure seat
support straps and seat to the frame with hex flange
head screws.
4. Disconnect the fuel pump from the electrical harness.
5. Check for correct seat operation and that seat switch
wires and connector are not pinched and do not contact
any moving parts.
6. Install crossover fuel hose if removed and fill fuel
tank.
Wheels, Brakes,
5. Remove fuel hose straps and three fuel hoses from
the fuel tank. Remove fuel tank from the machine.
Kubota
Gasoline Engine
2. Flush fuel tank out with clean gasoline. Make sure
tank is free of contaminates and debris.
Product Records
1. Remove fuel tank from the machine (see Fuel Tank
Removal).
Hydraulic
Because gasoline is highly flammable, use caution when storing or handling it. Do not smoke
while filling the fuel tank. Do not fill fuel tank
while engine is running or hot, or when machine
is in an enclosed area. Always fill fuel tank outside and wipe up any spilled gasoline before
starting the engine. Store fuel in a clean, safety−
approved container and keep cap in place. Use
gasoline for the engine only; not for any other
purpose.
Clean the fuel tank every 2 years. Also, clean the fuel
tank if the fuel system becomes contaminated or if the
machine is to be stored for an extended period.
Electrical
DANGER
Safety
Clean Fuel Tank
Groundsmaster 3500−G
Page 4 − 9
Kubota Gasoline Engine
Fuel Evaporative Control System (Unit Serial No. Prior to 315000001)
19
10
7 9
1
RIGHT
1
12
11 1
7
8
FRONT
7
1
6
5
4
3
Thread Sealant
2
13
1
1
5
1
1
14
1
15
16
1
17
18
7
7
Figure 7
1.
2.
3.
4.
5.
6.
7.
Hose clamp
Fuel hose
Elbow fitting
Tee fitting
Straight barb fitting
Anchor clamp
Cap screw
8.
9.
10.
11.
12.
13.
Fuel hose
Anchor clamp
Vent tube
Anchor clamp
Vacuum check valve
Anchor clamp
The function of the fuel evaporative control system is to
collect and store evaporative emissions from the fuel
tank and engine. A carbon canister that is mounted to
the left side of the frame is used to collect these evaporative emissions. Fuel vapors from the engine and fuel
tank are vented to the canister when the engine is not
running. Vapors from the canister are consumed when
the engine is running.
Kubota Gasoline Engine
14.
15.
16.
17.
18.
19.
Fuel hose
Fuel hose
Carbon canister
Canister clamp
Canister support
Fuel hose
NOTE: If there is restriction in the canister breather, the
carbon canister or the vacuum check valve, the fuel tank
may distort due to venting issues. If the fuel tank returns
to it’s normal shape when the fuel cap is removed, restriction in the evaporative control system is likely.
Page 4 − 10
Groundsmaster 3500−G
Carbon Canister Removal
Safety
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
1
2
VIEW FROM ABOVE
Figure 8
1. Vacuum check valve
2. Cable tie
3. Inspect carbon cannister and attached hoses for
damage or obvious leaks. A damaged or leaking cannister should be replaced.
3. Lower intake hose
CARBON CANISTER CONNECTIONS
4. Note hose routing, cable tie and anchor clamp locations. Remove fuel evaporative control system components as needed (Fig. 7).
TO VACUUM
CHECK VALVE
TO FUEL TANK
VENT TUBE
Carbon Canister Installation
CANISTER
BREATHER
Wheels, Brakes,
1. Install all removed EVAP components. Make sure
that fuel hoses are not kinked after installation. Secure
all hoses with hose clamps, anchor clamps and cable
ties as shown (Fig. 7 and 8). If hoses were removed from
the carbon canister, check hose connections for correct
system operation (Fig. 9).
2. After all evaporative control system components are
installed, close and secure hood.
Figure 9
Groundsmaster 3500−G
Page 4 − 11
Electrical
Gasoline is flammable. Use caution when storing
or handling it. Do not smoke while filling the fuel
tank. Do not fill fuel tank while engine is running
or in an enclosed area. Always fill fuel tank outside and wipe up any spilled fuel before starting
the engine. Store fuel in a clean, safety−approved container and keep the cap in place. Use
gasoline for the engine only; not for any other
purpose.
Kubota
Gasoline Engine
DANGER
Hydraulic
3
2
Product Records
2. Raise and support hood.
Kubota Gasoline Engine
Radiator/Hydraulic Fluid Cooler
RIGHT
9
8
7
6
FRONT
6
7
5
11
25
4
10
28
27
3
2
12
26
13
1
32
7
25
24
22
9
14
21
15
31
16
23
6
29
13
30
17
18
20
7
9
19
Figure 10
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Expansion tank
Hose clamp
Coolant hose
Flange head screw
Radiator bracket − RH
Carriage bolt
Flange nut
Radiator bracket − top
Flange head screw
Frame casting
Cap screw
Kubota Gasoline Engine
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Radiator
Straight fitting
Drain−cock
Lower radiator shield
Radiator bracket − LH
Elbow fitting
Magnet
Radiator bracket − bottom
Lower fan shroud
Upper fan shroud
Hydraulic tube
Page 4 − 12
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Hydraulic hose
Lower radiator hose
Hose clamp
Hex nut
Relay
Upper radiator hose
Flange nut
Straight fitting
Expansion tank support
Flange head screw
Groundsmaster 3500−G
Radiator Removal
Safety
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
CAUTION
1
3
5. Disconnect following hoses from the radiator/hydraulic fluid cooler:
A. Upper radiator hose to the water pump.
B. Lower radiator hose to the coolant inlet tube at
engine.
C. Coolant hose to the expansion tank.
1. Remove any plugs from the radiator/hydraulic fluid
cooler and hydraulic system used during the removal
procedure.
2. Position radiator carefully to the radiator frame.
3. Secure radiator assembly to the radiator frame with
four carriage bolts and lock nuts. Secure top and bottom
of radiator to frame with flange head screws.
4. Secure both fan shrouds to the radiator assembly
with flange head screws, and to each other with flange
head screws and nuts.
5. Secure expansion tank to bracket on fan shroud.
6. Connect following hoses to the radiator:
A. Upper radiator hose to the water pump.
D. Air hose to the air cleaner.
E. Hydraulic tube from top of hydraulic fluid cooler.
F. Hydraulic hose from bottom of hydraulic fluid
cooler.
6. Remove expansion tank from bracket on fan shroud.
7. Remove both fan shrouds from radiator assembly.
8. Remove flange head screws securing the top and
bottom of the radiator frame to the radiator. Remove four
carriage bolts and lock nuts securing the radiator to the
radiator frame.
9. Carefully remove radiator/hydraulic fluid cooler from
the radiator frame.
B. Lower radiator hose to the coolant inlet tube at
engine.
C. Coolant hose to the expansion tank.
D. Air hose to the air cleaner.
E. Hydraulic tube from top of hydraulic fluid cooler.
F. Hydraulic hose from bottom of hydraulic fluid
cooler.
7. Make sure drain−cock valve is closed. Fill radiator
with coolant to the bottom of the filler neck.
8. Fill the hydraulic fluid tank.
10.Plug any openings in the radiator/hydraulic fluid
cooler and hydraulic system to prevent contamination.
Groundsmaster 3500−G
Kubota
Gasoline Engine
Radiator Installation
Hydraulic
4. Place a suitable container under the hydraulic filter
to collect the hydraulic fluid. The container should have
a 6 gal. (23 Ltr.) minimum capacity. Disconnect the hydraulic hose below the filter head or remove the hydraulic filter element and drain the hydraulic system (Fig. 11).
3. Hydraulic hose
Electrical
3. Place a suitable container under the radiator/hydraulic fluid cooler to collect the coolant. The container
should have a 2 gal. (8 Ltr.) minimum capacity. Open
drain−cock valve, and completely drain the radiator.
Figure 11
1. Hydraulic filter element
2. Hydraulic filter head
Page 4 − 13
Kubota Gasoline Engine
Wheels, Brakes,
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Ethylene−glycol antifreeze is poisonous. Dispose of coolant
properly, or store it in a properly labeled container away from children and pets.
Product Records
2
2. Open and remove engine hood from the machine.
9. Prime the hydraulic pumps (see Prime the Hydraulic
Pumps in Chapter 5− Hydraulic System in this manual).
10.Start the unit and run engine to normal operating
temperature. Use all of the hydraulic controls while the
engine is running to distribute the hydraulic fluid
throughout the system. Stop the engine and check the
fluid levels. Adjust as necessary.
11. Install engine hood to the machine. Close and latch
hood.
Kubota Gasoline Engine
Page 4 − 14
Groundsmaster 3500−G
Safety
Product Records
Kubota
Gasoline Engine
Hydraulic
Wheels, Brakes,
Electrical
This page is intentionally left blank.
Groundsmaster 3500−G
Page 4 − 15
Kubota Gasoline Engine
Engine
3
8
9
RIGHT
10
FRONT
11
7
13
12
6
18
5
20
21
4
14
3
3
8
1
2
26
15
11
28
16
27
22
25
5
8
24
30
32
19
9
31
17
11
10
12
12
33
34
35
23
29
10
Figure 12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Pump mount plate
Mount bracket − front
Cap screw
Wire harness bracket
Hardened washer
Cap screw
Mount bracket − RH
Flange head screw
Engine mount
Flange nut
Hardened washer
Lock nut
Kubota Gasoline Engine
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Exhaust gasket
Flange head screw
Hardened washer
Cap screw
Engine mount
Fusible link
Flat washer
Lock washer
Hex nut
Mount bracket − LH
Lock washer
Cap screw
Page 4 − 16
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Cap screw
Flat washer
Engine ground
Lock washer
Cable tie
Spacer
Hardened washer
Cap screw
Spacer
Hardened washer
Cap screw
Groundsmaster 3500−G
Engine Removal
2
Safety
1
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
6. Place a suitable container under the radiator/hydraulic fluid cooler to collect the coolant. Open drain−
cock valve, and completely drain the radiator.
7. Disconnect following hoses from the radiator/hydraulic fluid cooler:
Figure 13
1. Alternator
2. Harness connections
11. Note the locations and remove any cable ties securing the wire harness to the engine. Connect hoist or lift
to the front and rear lift tabs.
12.Disconnect fuel hoses at engine from fuel pump and
from carbon canister.
A. Upper radiator hose to the water pump.
B. Lower radiator hose to the coolant inlet tube at
engine.
C. Coolant hose to the expansion tank.
8. Remove expansion tank from bracket on fan shroud.
13.Remove traction control cable from the neutral arm
assembly on the piston pump. Remove all hydraulic
hoses from the piston and gear pumps (see Piston
Pump Removal in Chapter 5− Hydraulic System in this
manual).
9. Remove both fan shrouds from radiator assembly.
10.Disconnect wire harness and electrical wires at the
following locations:
A. Positive (+) cable from battery
CAUTION
Make sure lift or hoist can support the total
weight of the engine before removing the cap
screws from the engine and engine brackets.
B. Fusible link harness at starter
C. Connector at battery B+ terminal
14.Remove hex nuts, cap screws, and washers from the
center of the three engine mounts.
D. Wire harness and frame grounds
CAUTION
E. O2 sensor
F. Two connections at alternator
G. Engine electronic control unit (ECU)
Groundsmaster 3500−G
One person should operate lift or hoist while the
other person guides the engine out of the machine.
Page 4 − 17
Kubota Gasoline Engine
Hydraulic
5. Remove muffler assembly (see Muffler Removal in
this chapter).
Electrical
4. Disconnect both battery cables at the battery.
Wheels, Brakes,
3. Disconnect air hose from the air cleaner and radiator.
Remove air cleaner from the engine.
Kubota
Gasoline Engine
Product Records
2. Open and remove engine hood from the machine.
Slide seat all the way forward.
RIGHT
FRONT
1
2
3
4
5
6
10
9
8
7
Figure 14
1.
2.
3.
4.
Engine mount bracket
Flange nut
Flange screw
Pump mount plate
Kubota Gasoline Engine
5. Hardened washer
6. 10 mm cap screw (4)
7. 8 mm cap screw (1)
Page 4 − 18
8. Hardened washer
9. Long spacer (4)
10. Short spacer (1)
Groundsmaster 3500−G
8. Connect wire harness and electrical wires at the following locations:
A. Positive (+) cable from battery
B. Remove five cap screws, washers, and spacers
securing the pump mount plate to the engine.
C. Remove two cap screws and flange nuts securing the pump support to the engine mount bracket
and remove the hydrostat and pump assembly from
the engine.
17.As necessary, remove engine mounts, front engine
mounting bracket and left engine mounting bracket.
Engine Installation
B. Fusible link harness at starter
C. Connector at battery B+ terminal
D. Wire harness and frame grounds
E. O2 sensor
F. Two connections at alternator
G. Engine electronic control unit (ECU)
9. Secure wire harness to the engine at locations previously noted with cable ties.
1. If removed, install engine mounts, front engine
mounting bracket and left engine mounting bracket.
10.Secure both fan shrouds to the radiator assembly
with flange head screws, and to each other with flange
head screws and nuts.
2. Install hydrostat and pump assembly to the engine
as follows (Fig. 14):
11. Secure expansion tank to bracket on fan shroud.
A. Secure the pump support to the engine mount
bracket with two flange nuts and cap screws.
12.Connect following hoses to the radiator:
A. Upper radiator hose to the water pump.
B. Secure pump mount plate to the engine with five
spacers, washers, and cap screws.
B. Lower radiator hose to the coolant inlet tube at
engine.
C. Install traction belt to the engine flywheel and hydrostat pulleys.
C. Coolant hose to the expansion tank.
3. Connect hoist or lift to the front and rear engine lift
tabs.
13.Make sure drain−cock valve is closed. Fill radiator
with coolant.
14.Install muffler assembly (see Muffler Installation in
this chapter).
CAUTION
One person should operate lift or hoist while the
other person guides the engine into the machine.
IMPORTANT: Make sure not to damage the engine,
fuel and hydraulic lines, electrical harness, or other
parts while installing the engine.
15.Connect both battery cables at the battery (see Battery Service in Chapter 6 − Electrical system in this
manual).
16.Install air cleaner to the engine. Connect air hose to
air cleaner and radiator.
17.Install engine hood to the machine. Close and latch
hood.
4. Position engine slowly into the machine.
18.Fill the hydraulic fluid reservoir.
5. Secure all three engine mounts to the engine mounting brackets with cap screws, washers, and hex nuts.
6. Install all hydraulic hoses to the piston and gear
pumps. Install traction control cable to the neutral arm
assembly on the piston pump (see Piston Pump InstallaGroundsmaster 3500−G
Hydraulic
A. Remove traction belt from the engine flywheel
and hydrostat pulleys.
Page 4 − 19
Kubota Gasoline Engine
Electrical
16.Separate hydrostat and pump assembly from the engine as follows (Fig. 14):
Product Records
15.Remove engine slowly from the machine.
Kubota
Gasoline Engine
7. Connect fuel hoses from the fuel pump and carbon
canister to engine.
Safety
tion in Chapter 5− Hydraulic System in this manual).
Wheels, Brakes,
IMPORTANT: Make sure not to damage the engine,
fuel and hydraulic lines, electrical harness, or other
parts while removing the engine.
19.Prime the hydraulic pumps (see Prime the Hydraulic
Pumps in Chapter 5− Hydraulic System in this manual).
20.Start the unit and run engine to normal operating
temperature. Use all of the hydraulic controls while the
engine is running to distribute the hydraulic fluid
throughout the system.
21.Stop the engine and check the hydraulic fluid and
coolant levels. Adjust as necessary.
22.Adjust traction drive for neutral.
Kubota Gasoline Engine
Page 4 − 20
Groundsmaster 3500−G
Chapter 5
Hydraulic System
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Relieving Hydraulic System Pressure . . . . . . . . . . . 3
Traction Circuit Component Failure . . . . . . . . . . . . . 3
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Hose and Tube Installation
(O−Ring Face Seal Fitting) . . . . . . . . . . . . . . . . . 5
Hydraulic Fitting Installation
(SAE Straight Thread O−Ring Fitting into
Component Port) . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . 14
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . 16
Traction Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cutting Unit Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lift Circuit (Up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Lift Circuit (Down) & Counterbalance . . . . . . . . . . 24
Sidewinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 30
General Hydraulic System Problems . . . . . . . . . . 30
Traction Circuit Problems . . . . . . . . . . . . . . . . . . . . 31
Lift Circuit Problems . . . . . . . . . . . . . . . . . . . . . . . . . 32
Steering Circuit Problems . . . . . . . . . . . . . . . . . . . . 33
Mow Circuit Problems . . . . . . . . . . . . . . . . . . . . . . . 33
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Traction Circuit Testing . . . . . . . . . . . . . . . . . . . . . . 36
Charge Pressure Test . . . . . . . . . . . . . . . . . . . . . . 36
Wheel Motor Efficiency Tests . . . . . . . . . . . . . . . . 38
Piston Pump/Hydrostat (P3) Flow & Relief
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cutting Deck Circuit Testing . . . . . . . . . . . . . . . . . . 46
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Deck Motor Efficiency/Case Drain Test . . . . . . . . 50
Manifold Relief Valve Pressure Test . . . . . . . . . . 54
Gear Pump (P1) Flow Test . . . . . . . . . . . . . . . . . . 56
Steering/Lift/Sidewinder Circuit Testing . . . . . . . . 58
Gear Pump (P2) Flow Test . . . . . . . . . . . . . . . . . . 58
Relief Valve Pressure Test . . . . . . . . . . . . . . . . . . . 62
Steering Control Valve and
Steering Cylinder Test . . . . . . . . . . . . . . . . . . . . . 64
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Blade Braking Valve (BV) Adjustment
(Units Prior to Serial No. 314000001) . . . . . . . 66
Groundsmaster 3500
Blade Braking Relief Valve (RV) Adjustment
(Unit Serial No. 314000001 & Up) . . . . . . . . . . 67
Counterbalance Logic Valve (LC1)
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 70
General Precautions for Removing and
Installing Hydraulic System Components . . . 70
Check Hydraulic Lines and Hoses . . . . . . . . . . . . . 71
Priming Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . 71
Flush Hydraulic System . . . . . . . . . . . . . . . . . . . . . . 72
Filtering Closed Loop Traction Circuit . . . . . . . . . . 73
Charge Hydraulic System . . . . . . . . . . . . . . . . . . . . 74
Hydraulic Tank and Hydraulic Fluid Filter . . . . . . . 76
Hydraulic Fluid Cooler . . . . . . . . . . . . . . . . . . . . . . . 78
Piston Pump/Hydrostat Assembly . . . . . . . . . . . . . 80
Piston Pump/Hydrostat Service . . . . . . . . . . . . . . . 88
Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Gear Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . 94
Front Wheel Motors . . . . . . . . . . . . . . . . . . . . . . . . . 96
Rear Wheel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Wheel Motor Service . . . . . . . . . . . . . . . . . . . . . . . 100
Hydraulic Manifold
(Units Prior to Serial No. 314000001) . . . . . . . 102
Hydraulic Manifold
(Unit Serial No 314000001 & Up) . . . . . . . . . . . 103
Hydraulic Manifold Service . . . . . . . . . . . . . . . . . . 106
Cutting Deck Motors . . . . . . . . . . . . . . . . . . . . . . . 109
Cutting Deck Motor Service . . . . . . . . . . . . . . . . . 110
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . 114
Steering Control Valve Service . . . . . . . . . . . . . . 116
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Steering Cylinder Service . . . . . . . . . . . . . . . . . . . 120
Lift/Sidewinder Control Valve . . . . . . . . . . . . . . . . 122
Lift/Sidewinder Control Valve Service . . . . . . . . . 124
Front Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Rear Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Lift Cylinder Service . . . . . . . . . . . . . . . . . . . . . . . . 132
Sidewinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
PARKER TORQMOTORt TC, TB, TE, TJ, TF, TG,
TH and TL SERIES SERVICE PROCEDURE
EATON MEDIUM DUTY PISTON PUMP REPAIR INFORMATION MODEL 70160 VARIABLE DISPLACEMENT PISTON PUMP
SAUER/DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
Page 5 − 1
Hydraulic System
Hydraulic
System
Table of Contents
Specifications
Item
Description
Piston Pump (Hydrostat)
Charge Relief Pressure
Traction Circuit Relief Pressure (Forward Only)
Maximum Displacement
Variable displacement piston pump
100 to 150 PSI (6.9 to 10 Bar)
3500 PSI (241.3 Bar)
1.44 cu. in./rev (23.6 cc/rev)
Gear Pump
Displacement Section 1 (P1)
Displacement Section 2 (P2)
2 stage fixed displacement gear type pump
0.95 cu. In./rev (15.65 cc/rev)
0.33 cu. in./rev (5.34 cc/rev)
Wheel Motors (see note)
Front Wheel Motor Displacement
Rear Wheel Motor Displacement
Orbital geroller motor
12 cu. in./rev (195 cc/rev)
24.7 cu. in./rev (405 cc/rev)
Mow Circuit Relief Pressure
3200 PSI (221 Bar)
Cutting Unit Motor
Cross−over Relief Pressure
Displacement
Gear motor
1813 PSI (125 Bar)
1.16 cu. in./rev (19 cc/rev)
Steering Control Valve
Maximum Displacement
Implement (Steering and Lift) Relief Valve Pressure
Distributor valve with rotary meter
6.10 cu. in./rev (100.0 cc/rev)
1000 PSI (69 Bar)
Hydraulic Filter
10 Micron, spin−on cartridge type
Hydraulic Fluid
See Hydraulic System Fluid in this Chapter
Hydraulic Tank
6 Gal. U.S. (22.6 L)
NOTE: The three wheel motors are similar in construction with only minor differences. The right front wheel motor and rear wheel motor have a
reverse timed manifold, and the front left wheel motor does not. The end cover of the rear motor has a check valve consisting of a ball and spring,
and both front motors lack this feature.
Hydraulic System
Page 5 − 2
Groundsmaster 3500
General Information
Operator’s Manual
The Traction Unit and Cutting Unit Operator’s Manuals
provide information regarding the operation, general
maintenance and maintenance intervals for your
Groundsmaster machine. Refer to these publications
for additional information when servicing the machine.
Before disconnecting or performing any work on the
Groundsmaster 3500 hydraulic system, all pressure in
the hydraulic system must be relieved. Park machine on
a level surface with the cutting units lowered and the
PTO switch off. Turn key switch to OFF and allow engine
to stop.
To relieve cutting unit system pressure, turn key switch
to ON (engine not running). Move PTO switch to engage
which will energize the solenoid valve on hydraulic manifold to relieve circuit pressure. Move PTO switch to disengage, return key switch to OFF and remove key from
the ignition switch.
To relieve hydraulic pressure in traction circuit, move
traction lever to both forward and reverse directions. To
relieve hydraulic pressure in steering and lift circuits, rotate steering wheel in both directions.
NOTE: Moving steering wheel with engine off may unseat implement relief valve. If steering or lift circuits appear weak or inoperative after machine is returned to
service, repeat relieving hydraulic system pressure procedure.
Traction Circuit Component Failure
The Groundsmaster 3500 traction circuit is a closed
loop system that includes the hydrostat and three (3)
wheel motors. If a component in the traction circuit
should fail, debris and contamination from the failed
component will circulate throughout the traction circuit.
This contamination can damage other components in
the circuit so it must be removed to prevent additional
component failure.
The recommended method of removing traction circuit
contamination would be to temporarily install the Toro
high flow hydraulic filter (see Special Tools in this chapter) into the circuit. This filter should be used when connecting hydraulic test gauges in order to test traction
circuit components or after replacing a failed traction circuit component (e.g. traction (piston) pump or wheel
motor). The filter will ensure that contaminates are removed from the closed loop and thus, do not cause additional component damage.
Groundsmaster 3500
Once the Toro high flow hydraulic filter kit has been
placed in the circuit, raise and support the machine with
all wheels off the ground. Then, operate the traction circuit to allow fluid flow throughout the circuit. The filter will
remove contamination from the traction circuit during
operation. Because the Toro high flow filter is bi−directional, the traction circuit can be operated in both the forward and reverse direction. The filter should be
removed from the machine after contamination has
been removed from the traction circuit. See Filtering
Closed−Loop Traction Circuit in the Service and Repairs
section of this chapter for additional information on using the Toro high flow hydraulic filter.
The alternative to using the Toro high flow hydraulic filter
kit after a traction circuit component failure would be to
disassemble, drain and thoroughly clean all components, hydraulic tubes and hydraulic hoses in the traction circuit. If any debris remains in the traction circuit
and the machine is operated, the debris can cause additional circuit component failure.
Page 5 − 3
Hydraulic System
Hydraulic
System
Relieving Hydraulic System Pressure
Hydraulic Hoses
Hydraulic hoses are subject to extreme conditions such
as pressure differentials during operation and exposure
to weather, sun, chemicals, very warm storage conditions or mishandling during operation and maintenance.
These conditions can cause hose damage and deterioration. Some hoses are more susceptible to these
conditions than others. Inspect all machine hydraulic
hoses frequently for signs of deterioration or damage:
Hard, cracked, cut, abraded, charred, leaking or
otherwise damaged hose.
Kinked, crushed, flattened or twisted hose.
Blistered, soft, degraded or loose hose cover.
Cracked, damaged or badly corroded hose fittings.
When replacing a hydraulic hose, be sure that the hose
is straight (not twisted) before tightening the fittings.
This can be done by observing the imprint (layline) on
the hose. Use two wrenches; hold the hose straight with
one wrench and tighten the hose swivel nut onto the fitting with the other wrench (See Hydraulic Hose and
Tube Installation in this section in this chapter). If the
hose has an elbow at one end, tighten the swivel nut on
that end before tightening the nut on the straight end of
the hose.
WARNING
Before disconnecting or performing any work
on hydraulic system, relieve all pressure in
system. Stop engine; lower or support cutting
units and/or other attachment(s).
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands,
to search for leaks. Hydraulic fluid escaping
under pressure can have sufficient force to
penetrate the skin and cause serious injury. If
fluid is injected into the skin, it must be surgically removed within a few hours by a doctor
familiar with this type of injury. Gangrene may
result from such an injury.
For additional hydraulic hose information, refer to Toro
Service Training Book, Hydraulic Hose Servicing (Part
Number 94813SL).
Hydraulic System
Page 5 − 4
Groundsmaster 3500
Hydraulic Hose and Tube Installation (O−Ring Face Seal Fitting)
C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The
markings on the nut and fitting body will verify that the
connection has been properly tightened.
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 leakage, it is recommended that the face seal O−ring be replaced any
time the connection is opened. Make sure the O−ring is
installed and properly seated in the fitting groove. Lightly
lubricate the O−ring with clean hydraulic oil.
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
3. Place the hose/tube against the fitting body so that
the flat face of the hose/tube sleeve fully contacts the O−
ring in the fitting.
F.F.W.R.
1/2 to 3/4
1/2 to 3/4
1/2 to 3/4
1/2 to 3/4
1/3 to 1/2
1/3 to 1/2
Swivel Nut
Fitting Body
O−ring
4. Thread the swivel nut onto the fitting by hand. While
holding the hose/tube with a wrench, use a torque
wrench to tighten the swivel nut to the recommended
installation torque shown in Figure 3. This tightening
process will require the use of an offset wrench (e.g.
crowfoot wrench). Use of an offset wrench will affect
torque wrench calibration due to the effective length
change of the torque wrench. Tightening torque when
using a torque wrench with an offset wrench will be lower
than the listed installation torque (see Using a Torque
Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 − Product Records and Maintenance).
Tube or Hose
5. If a torque wrench is not available or if space at the
swivel nut prevents use of a torque wrench, an alternate
method of assembly is the Flats From Wrench Resistance (F.F.W.R.) method (Fig. 2).
A. Using a wrench, tighten the swivel nut onto the fitting until light wrench resistance is reached (approximately 30 in−lb).
Mark Nut
and Fitting
Body
Hydraulic
System
Figure 1
Final
Position
Initial
Position
Extend Line
AT WRENCH RESISTANCE
B. Mark the swivel nut and fitting body. Hold the
hose/tube with a wrench to prevent it from turning.
AFTER TIGHTENING
Figure 2
Fitting Dash Size
Hose/Tube Side Thread Size
Installation Torque
4
9/16 − 18
18 to 22 ft−lb (25 to 29 N−m)
6
11/16 − 16
27 to 33 ft−lb (37 to 44 N−m)
8
13/16 − 16
37 to 47 ft−lb (51 to 63 N−m)
10
1 − 14
60 to 74 ft−lb (82 to 100 N−m)
12
1 3/16 − 12
85 to 105 ft−lb (116 to 142 N−m)
16
1 7/16 − 12
110 to 136 ft−lb (150 to 184 N−m)
20
1 11/16 − 12
140 to 172 ft−lb (190 to 233 N−m)
Figure 3
Groundsmaster 3500
Page 5 − 5
Hydraulic System
Hydraulic Fitting Installation (SAE Straight Thread O−Ring Fitting into Component Port)
Non−Adjustable Fitting (Fig. 4)
1. Make sure all threads and sealing surfaces of fitting
and component port are free of burrs, nicks, scratches
or any foreign material.
5. If a torque wrench is not available, or if space at the
port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.)
method.
2. As a preventative measure against leakage, it is recommended that the O−ring be replaced any time the
connection is opened.
3. Lightly lubricate the O−ring with clean hydraulic oil.
Fitting threads should be clean with no lubricant applied.
IMPORTANT: Before installing fitting into port, determine port material. If fitting is to be installed into
an aluminum port, installation torque is reduced.
4. Install the fitting into the port. Then, use a torque
wrench and socket to tighten the fitting to the recommended installation torque shown in Figure 5.
A. Install the fitting into the port and tighten it down
full length until finger tight.
B. If port material is steel, tighten the fitting to the
listed F.F.F.T. If port material is aluminum, tighten fitting to 60% of listed F.F.F.T.
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
NOTE: Use of an offset wrench (e.g. crowfoot wrench)
will affect torque wrench calibration due to the effective
length change of the torque wrench. Tightening torque
when using a torque wrench with an offset wrench will
be less than the recommended installation torque. See
Using a Torque Wrench with an Offset Wrench in the
Torque Specifications section of Chapter 2 − Product
Records and Maintenance to determine necessary conversion information.
F.F.F.T.
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
Fitting
O−ring
Figure 4
Fitting
Dash Size
Fitting Port Side
Thread Size
Installation Torque Into
Steel Port
Installation Torque Into
Aluminum Port
4
7/16 − 20
15 to 19 ft−lb (21 to 25 N−m)
9 to 11 ft−lb (13 to 15 N−m)
5
1/2 − 20
18 to 22 ft−lb (25 to 29 N−m)
11 to 15 ft−lb (15 to 20 N−m)
6
9/16 − 18
34 to 42 ft−lb (47 to 56 N−m)
20 to 26 ft−lb (28 to 35 N−m)
8
3/4 − 16
58 to 72 ft−lb (79 to 97 N−m)
35 to 43 ft−lb (48 to 58 N−m)
10
7/8 − 14
99 to 121 ft−lb (135 to 164 N−m)
60 to 74 ft−lb (82 to 100 N−m)
12
1 1/16 − 12
134 to 164 ft−lb (182 to 222 N−m)
81 to 99 ft−lb (110 to 134 N−m)
14
1 3/16 − 12
160 to 196 ft−lb (217 to 265 N−m)
96 to 118 ft−lb (131 to 160 N−m)
16
1 5/16 − 12
202 to 248 ft−lb (274 to 336 N−m)
121 to 149 ft−lb (165 to 202 N−m)
20
1 5/8 − 12
247 to 303 ft−lb (335 to 410 N−m)
149 to 183 ft−lb (202 to 248 N−m)
Figure 5
Hydraulic System
Page 5 − 6
Groundsmaster 3500
Adjustable Fitting (Fig. 6)
1. Make sure all threads and sealing surfaces of fitting
and component port are free of burrs, nicks, scratches
or any foreign material.
2. As a preventative measure against leakage, it is recommended that the O−ring be replaced any time the
connection is opened.
Lock Nut
3. Lightly lubricate the O−ring with clean hydraulic oil.
Fitting threads should be clean with no lubricant applied.
Back−up Washer
4. Turn back the lock nut as far as possible. Make sure
the back up washer is not loose and is pushed up as far
as possible (Step 1 in Figure 7).
O−ring
Figure 6
5. Install the fitting into the port and tighten finger tight
until the washer contacts the face of the port (Step 2).
6. To put the fitting in the desired position, unscrew it by
the required amount, but no more than one full turn
(Step 3).
7. Hold the fitting in the desired position with a wrench
and use a torque wrench to tighten the fitting to the recommended installation torque shown in Figure 5. This
tightening process will require the use of an offset
wrench (e.g. crowfoot wrench). Use of an offset wrench
will affect torque wrench calibration due to the effective
length change of the torque wrench. Tightening torque
when using a torque wrench with an offset wrench will
be lower than the listed installation torque (see Using a
Torque Wrench with an Offset Wrench in the Torque
Specifications section of Chapter 2 − Product Records
and Maintenance).
Step 1
Step 3
Step 2
Step 4
Hydraulic
System
IMPORTANT: Before installing fitting into port, determine port material. If fitting is to be installed into
an aluminum port, installation torque is reduced.
Figure 7
8. If a torque wrench is not available, or if space at the
port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.)
method. Hold the fitting in the desired position with a
wrench and, if port material is steel, tighten the lock nut
with a second wrench to the listed F.F.F.T (Step 4). If port
material is aluminum, tighten fitting to 60% of listed
F.F.F.T.
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
Groundsmaster 3500
F.F.F.T.
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
Page 5 − 7
Hydraulic System
Special Tools
Hydraulic Pressure Test Kit
Use to take various pressure readings for diagnostic
tests. Quick disconnect fittings provided attach directly
to mating fittings on machine test ports without tools. A
high pressure hose is provided for remote readings.
Contains one each: 1000 PSI (70 Bar), 5000 PSI (350
Bar) and 10000 PSI (700 Bar) gauges. Use gauges as
recommended in Testing section of this chapter.
Toro Part Number: TOR47009
Figure 8
15 GPM Hydraulic Tester (Pressure and Flow)
This tester requires O−ring Face Seal (ORFS) adapter
fittings for use on this machine (see Hydraulic Test Fitting Kit (TOR4079) in this section).
1. INLET HOSE: Hose connected from the system circuit to the inlet side of the hydraulic tester.
2. LOAD VALVE: A simulated working load is created
in the circuit by turning the valve to restrict flow.
3. PRESSURE GAUGE: 0 to 5000 PSI gauge to provide operating circuit pressure.
4. FLOW METER: This meter measures actual fluid
flow in the operating circuit with a gauge rated at 15
GPM.
Figure 9
5. OUTLET HOSE: A hose from the outlet side of the
hydraulic tester connects to the hydraulic system circuit.
Toro Part Number: TOR214678
Hydraulic System
Page 5 − 8
Groundsmaster 3500
40 GPM Hydraulic Tester (Pressure and Flow)
Use to test hydraulic circuits and components for flow
and pressure capacities as recommended in the Testing
section of this chapter. This tester includes the following:
1. LOAD VALVE: A simulated working load is created
in the circuit by turning the valve to restrict flow.
2. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI
gauge to provide operating circuit pressure.
3. FLOW METER: This meter measures actual fluid
flow in the operating circuit with a gauge rated from 4 to
40 GPM (20 to 150 LPM).
Toro Part Number: AT40002
Figure 10
NOTE: This tester does not include hoses (see Hydraulic Hose Kit TOR6007 below).
Hydraulic Hose Kit
This kit includes fittings and hoses needed to connect 40
GPM hydraulic tester (AT40002) or high flow hydraulic
filter kit (TOR6011) to machine hydraulic traction system
components.
Hydraulic
System
Toro Part Number: TOR6007
Figure 11
Groundsmaster 3500
Page 5 − 9
Hydraulic System
High Flow Hydraulic Filter Kit
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−directional filtration which prevents filtered debris from being
allowed back into the circuit regardless of flow direction.
If a component failure occurs in the closed loop traction
circuit, contamination from the failed part will remain in
the circuit until removed. When connecting hydraulic
test gauges in order to test traction circuit components
or after replacing a failed traction circuit component (e.g.
piston pump or wheel motor), the high flow hydraulic filter can be installed in the traction circuit. The filter will
ensure that contaminates are removed from the closed
loop and thus, do not cause additional component damage.
Figure 12
Toro Part Number: TOR6011
NOTE: This kit does not include hoses (see Hydraulic
Hose Kit TOR6007 above).
NOTE: Replacement filter element is Toro part number
TOR6012. Filter element cannister tightening torque is
25 ft−lb (34 N−m).
O−Ring Kit
The O−ring kit includes O−rings in a variety of sizes for
face seal and port seal hydraulic connections. It is recommended that O−rings be replaced whenever a hydraulic connection is loosened.
Toro Part Number: 117−2727
Figure 13
Hydraulic System
Page 5 − 10
Groundsmaster 3500
Hydraulic Test Fitting Kit
This kit includes a variety of O−ring Face Seal fittings to
enable you to connect test gauges into the system.
The kit includes: tee’s, unions, reducers, plugs, caps
and male test fittings.
Toro Part Number: TOR4079
Figure 14
Measuring Container
Use this container for doing hydraulic motor efficiency
testing (motors with case drain lines only). Measure efficiency of a hydraulic motor by restricting the outlet flow
from the motor and measuring leakage from the case
drain line while the motor is pressurized by the hydraulic
system.
The table in Figure 16 provides gallons per minute
(GPM) conversion for measured milliliter or ounce motor
case drain leakage.
Hydraulic
System
Toro Part Number: TOR4077
Figure 15
Figure 16
Groundsmaster 3500
Page 5 − 11
Hydraulic System
Remote Starter Switch
After flushing the hydraulic system or replacing a hydraulic component (e.g. gear pump, piston pump, wheel
motor), it is necessary to prime the hydraulic pumps. A
remote starter switch (Fig. 17) can be used for this purpose. Obtain a remote starter switch locally.
IMPORTANT: When using a remote starter switch, it
is highly recommended to include a 20 amp in−line
fuse between the battery and switch connector for
circuit protection.
Figure 17
A remote stater switch can also be constructed using
Toro switch #106−2027, a length of 14 gauge wire, a 20
amp in−line fuse, two (2) alligator clips and necessary
connectors. Connecting the wire to switch terminals 1
and 2 will allow the momentary switch contacts to be
used for the remote starter switch (Fig. 18).
MACHINE
BATTERY
NOTE: For information on using the remote starter
switch to prime the hydraulic pumps, see Flush Hydraulic System in the Service and Repairs section of this
chapter.
TORO SWITCH
(#106−2027)
20 AMP
FUSE
STARTER
SOLENOID
MACHINE
STARTER
Figure 18
2
3
1
Figure 19
1. Starter motor
2. Starter solenoid
Hydraulic System
Page 5 − 12
3. B+ terminal
Groundsmaster 3500
Wheel Hub Puller
Toro Part Number: TOR4097
The wheel hub puller allows safe removal of the wheel
hub from the shaft of wheel motors.
Hydraulic
System
Figure 20
Groundsmaster 3500
Page 5 − 13
Hydraulic System
Page 5 − 14
G2
LOWER
PORT
P3
200−300 psi
100−150 psi
3500 psi
G1
UPPER
PORT
HYDROSTAT
M6
TOP PORT
INTERNAL CASE DRAIN
BY−PASS
VALVE
M4
M5
TRACTION WHEEL MOTORS
All solenoids are shown as
de−energized
FORWARD
Hydraulic System
OIL
FILTER
OIL
COOLER
P1
STRAINER
GEAR
PUMP
P1
M1
P2
CHG
ST
S1
3200 psi
1500 psi
LC1
BV
CR
M2
CF
LV
G2
250 psi
BACK
PRESSURE
OUT
S.W.
BULKHEAD
PLATE
IN
NOTE: A larger hydraulic schematic is included
in Chapter 9 − Foldout Drawings
T1
MANIFOLD
BLOCK
G1
T2
D1
A
REAR
DECK
B
RIGHT
DECK
LEFT
DECK
E
T
P
V1
C
D
POWER STEERING VALVE
1000 psi
LIFT/S.W. VALVE
M3
M2
M1
LIFT
REAR
FRONT
R
L
SIDEWINDER
STEERING
Groundsmaster 3500
Hydraulic Schematic (Units Prior to Serial No. 314000001)
Hydraulic Schematics
Groundsmaster 3500
Page 5 − 15
G2
LOWER
PORT
FORWARD
P3
G1
UPPER
PORT
HYDROSTAT
M6
TOP PORT
INTERNAL CASE DRAIN
200−300 psi
100−150 psi
3500 psi
BY−PASS
VALVE
M4
M5
TRACTION WHEEL MOTORS
All solenoids are shown as
de−energized
OIL
FILTER
OIL
COOLER
P1
STRAINER
GEAR
PUMP
P1
RV
P2
CHG
3200
psi
1500
psi
M1
ST
S
M2
CR
LC1
LC2
CF
LV
G2
250 psi
BACK
PRESSURE
OUT
S.W.
BULKHEAD
PLATE
IN
Hydraulic System
Hydraulic
System
NOTE: A larger hydraulic schematic is included
in Chapter 9 − Foldout Drawings
T1
MANIFOLD
BLOCK
G1
T2
D1
Groundsmaster 3500
Hydraulic Schematic (Unit Serial No. 314000001 & Up)
A
REAR
DECK
B
RIGHT
DECK
LEFT
DECK
E
T
P
V1
C
D
POWER STEERING VALVE
1000 psi
LIFT/S.W. VALVE
M3
M2
M1
LIFT
REAR
FRONT
R
L
SIDEWINDER
STEERING
Groundsmaster 3500
Page 5 − 16
G2
LOWER
PORT
FORWARD
Hydraulic System
P3
G1
UPPER
PORT
HYDROSTAT
M6
TOP PORT
INTERNAL CASE DRAIN
200−300 psi
100−150 psi
3500 psi
BY−PASS
VALVE
M4
M5
TRACTION WHEEL MOTORS
High Pressure
Low Pressure (Charge)
Return or Suction
Flow Direction
OIL
FILTER
OIL
COOLER
P1
STRAINER
GEAR
PUMP
P1
RV
P2
CHG
3200
psi
1500
psi
M1
ST
S
M2
CR
LC1
LC2
CF
LV
G2
250 psi
BACK
PRESSURE
OUT
S.W.
BULKHEAD
PLATE
IN
A
NOTE: Hydraulic Schematic for Unit Serial No. 413000001 & Up shown
T1
MANIFOLD
BLOCK
G1
T2
D1
REAR
DECK
B
RIGHT
DECK
LEFT
DECK
E
T
P
V1
C
D
POWER STEERING VALVE
1000 psi
LIFT/S.W. VALVE
M3
M2
M1
LIFT
REAR FRONT
R
L
SIDEWINDER
STEERING
Groundmaster 3500
Traction Circuit (Forward)
Hydraulic Flow Diagrams
Groundsmaster 3500
Traction Circuit
The mow/transport slide control on Groundsmaster
3500 machines has positions for mow and transport.
The mow position allows traction pedal inputs that are
appropriate for mow speeds by limiting the movement of
the traction pedal and the piston pump swash plate. The
transport position allows full movement of the traction
pedal so complete pump swash rotation is possible.
Forward
The engine drives traction pump (P3) indirectly through
pulleys and a V−belt. The traction pump is a variable displacement piston pump/hydrostat. The traction pedal
connects through a cable to the trunnion shaft and
swash plate of the pump. With the engine running and
the traction pedal in the neutral position, traction pump
(P3) supplies no flow to the wheel motors. When the
traction pedal is pressed to the forward position, the
cable from the pedal positions the swash plate in the
traction pump so fluid flows out of the hydrostat lower
port. Fluid flow out of the lower port goes to the front
wheel motors first, turning them in the forward direction.
Fluid flowing out of the front wheel motors flows to the
rear wheel motor, turning it in a forward direction. Fluid
flowing out of the rear wheel motor returns to the upper
port of the hydrostat and is continuously pumped out of
the lower port.
Operating pressure in the closed traction circuit is determined by the amount of load developed by the wheel
motors. As the load increases, circuit pressure can increase to the relief valve setting of 3500 psi (241.3 bar).
In forward operation, fluid flows through the internal hydrostat relief valve to the low pressure side of the traction circuit when circuit pressure exceeds the relief
setting.
Reverse
The traction circuit operates essentially the same in reverse as it does in forward. However, there are a few differences in operation.
When the reverse traction pedal is depressed, the cable
from the pedal positions the swash plate in the traction
pump (P3) so fluid flows out of the hydrostat upper port.
Fluid flow out of the upper port goes to the rear wheel
motor where an internal check valve allows the hydraulic fluid to bypass the motor. Fluid flow out of the rear
Groundsmaster 3500
wheel motor flows to the front wheel motors, turning
them in the reverse direction. Fluid flow out of the front
wheel motors returns to the lower port of the hydrostat
and is continuously pumped out of the upper port.
NOTE: The rear wheel motor does not help propel the
traction unit in reverse.
Charge Circuit
The traction pump uses a small amount of hydraulic fluid
for internal lubrication. Fluid is designed to leak across
internal pump parts into the case drain. This leakage results in the loss of hydraulic fluid from the closed loop circuit that must be replenished via the charge circuit.
The gear pump (P2) is directly coupled to the hydrostat
through gear pump (P1) and driven by the engine. Gear
pump (P2) supplies hydraulic pressure for operating the
power steering system, raising and lowering the cutting
units, and operating the sidewinder unit. Gear pump
(P2) may also be referred to as the charge pump as flow
from the gear pump also replenishes the closed loop
traction circuit. Hydraulic fluid exits the lift/sidewinder
valve, passes through the hydraulic manifold where it
actuates logic cartridge (LC1), and continues on to the
hydrostat. A relief valve located in the hydrostat
provides sufficient resistance so that flow is guided to
the low pressure side of the traction circuit through one
of two check valves (charge circuit). Pump flow in excess of charge circuit requirements is relieved through
the relief valve back to the gear pump inlet and hydraulic
tank.
Traction Circuit Cooling
The traction circuit is cooled by a bleed off circuit in the
piston pump. The piston pump includes an internal
bleed valve which allows a small amount of hydraulic oil
to pass from the return side of the pump while operating
the traction unit in the forward direction. The charge circuit replenishes oil that is bled from the traction circuit by
the bleed valve.
When operating the traction circuit in the reverse direction, the bleed valve closes once reverse pressure
reaches 200 to 300 PSI (13.8 to 20.6) to allow normal
reverse operation.
NOTE: The bleed valve threads into the piston pump
back plate. Access to the bleed valve requires removal
of the back plate from the piston pump.
Page 5 − 17
Hydraulic System
Hydraulic
System
The traction circuit of the hydraulic system consists of a
hydrostat connected in a closed loop circuit to three orbital geroller wheel motors.
Page 5 − 18
G2
LOWER
PORT
FORWARD
P3
G1
UPPER
PORT
HYDROSTAT
M6
TOP PORT
INTERNAL CASE DRAIN
200−300 psi
100−150 psi
3500 psi
BY−PASS
VALVE
M4
M5
TRACTION WHEEL MOTORS
High Pressure
Low Pressure (Charge)
Return or Suction
Flow Direction
OIL
FILTER
OIL
COOLER
T1
MANIFOLD
BLOCK
G1
T2
P1
P1
M1
STRAINER
GEAR
PUMP
D1
Groundmaster 3500
Cutting Unit Circuit (Units Prior to Serial No. 314000001)
P2
CHG
ST
S1
3200 psi
1500 psi
LC1
BV
CR
M2
CF
LV
G2
250 psi
BACK
PRESSURE
OUT
S.W.
BULKHEAD
PLATE
IN
A
REAR
DECK
RIGHT
DECK
LEFT
DECK
B
E
T
P
V1
C
D
POWER STEERING VALVE
1000 psi
LIFT/S.W. VALVE
M3
M2
M1
LIFT
REAR
FRONT
R
L
SIDEWINDER
STEERING
Hydraulic System
Groundsmaster 3500
Page 5 − 19
G2
LOWER
PORT
FORWARD
P3
G1
UPPER
PORT
HYDROSTAT
M6
TOP PORT
INTERNAL CASE DRAIN
200−300 psi
100−150 psi
3500 psi
BY−PASS
VALVE
M4
M5
TRACTION WHEEL MOTORS
High Pressure
Low Pressure (Charge)
Return or Suction
Flow Direction
OIL
FILTER
OIL
COOLER
T1
MANIFOLD
BLOCK
GEAR
PUMP
P1
P1
P2
ST
M2
Hydraulic
System
CHG
S
ENERGIZED
RV
3200
psi
1500
psi
M1
STRAINER
G1
T2
D1
Groundmaster 3500
Cutting Unit Circuit (Unit Serial No. 314000001 & Up)
CR
LC1
LC2
CF
LV
G2
250 psi
BACK
PRESSURE
OUT
S.W.
BULKHEAD
PLATE
IN
A
REAR
DECK
RIGHT
DECK
LEFT
DECK
B
E
T
P
V1
C
D
POWER STEERING VALVE
1000 psi
LIFT/S.W. VALVE
M3
M2
M1
LIFT
REAR
FRONT
R
L
SIDEWINDER
STEERING
Groundsmaster 3500
Hydraulic System
Cutting Unit Circuit
Cutting Unit Blade Braking (Units Prior to Serial No.
314000001)
Mow
The gear pump (P1) is directly coupled to the the hydrostat which is driven by the engine. Taking its suction directly from the hydraulic tank, the gear pump (P1)
supplies fluid flow to the manifold block and to the cutting
unit motors.
Solenoid valve (S or S1) is de−energized with the engine
running when either the PTO switch is in DISENGAGE,
or the transport/mow slide is in TRANSPORT. When
solenoid valve (S or S1) is de−energized, flow by−
passes the cutting deck motors through the solenoid
valve (S or S1) and moves on to the fluid cooler, filter,
and gear pump inlet.
Solenoid valve (S or S1) is energized with the engine
running when the PTO switch is in ENGAGE, and the
transport/mow slide is in MOW. When energized, solenoid valve (S or S1) allows flow out manifold block port
M1 to the cutting unit motors.
When the solenoid valve (S1) is de−energized, the
blade relief cartridge (BV) shifts to its closed position,
blocking return flow from the deck motors and slowing
the cutting blades. The inertia of the rotating cutting
blades, however, effectively turns the deck motors into
pumps causing an increase in pressure as the flow from
the motors comes up against the closed blade relief cartridge (BV). When this pressure builds to 1500 PSI (103
bar), blade relief cartridge (BV) opens which allows hydraulic flow to return to tank and reduces return pressure. When return pressure drops below 1500 PSI (103
bar), blade relief cartridge (BV) reseats to further slow
the cutting blades. This action repeats several times in
a very short period as the blades finally come to a stop.
Once the blades have stopped, blade relief cartridge
(BV) remains closed to keep the deck motors from rotating.
Fluid flows through the left, right, and then rear cutting
unit motors before returning to the manifold block port
(M2). When solenoid valve (S or S1) is energized, fluid
pressure shifts return circuit components in the hydraulic manifold as follows:
Units Prior to Serial No 314000001: When solenoid valve (S1) is energized, fluid pressure shifts
blade relief valve (BV) which allows flow returning
from the deck motors to pass through the manifold.
Returning fluid continues on to the fluid cooler, filter,
and gear pump inlet.
Unit Serial No. 314000001 & Up: When solenoid
valve (S) is energized, fluid pressure shifts relief
valve (RV) which allows a small amount of hydraulic
flow returning from the deck motors past the relief
valve. This returning flow is restricted by the orifice
in the logic cartridge (LC2) creating a pressure imbalance that shifts the logic cartridge to allow oil flow
from the deck motors to pass through the manifold.
Returning fluid continues on to the fluid cooler, filter,
and gear pump inlet.
If cutting unit circuit pressure exceeds relief pressure of
3200 PSI (221 bar) during deck motor operation, solenoid valve (S or S1) shifts to allow circuit pressure relief.
Hydraulic System
Page 5 − 20
Groundsmaster 3500
Cutting Unit Blade Braking (Unit Serial No.
314000001 & Up)
TO DECK
MOTORS
When the solenoid valve (S) is de−energized, the flow
to the cutting deck motors and the relief valve (RV) is removed allowing relief valve (RV) to shift. The shifted relief valve removes flow from the orifice at the logic
cartridge (LC2), causing a balanced pressure condition
which shifts the logic cartridge, blocking the return oil
path from the deck motors (Fig. 21).
FROM DECK
MOTORS
ORIFICE
RV
1500
LC2
psi
The inertia of the rotating cutting blades, however, effectively turns the deck motors into pumps immediately
causing an increase in return pressure against the
closed relief valve (RV) and logic cartridge (LC2). When
this pressure builds to approximately 1500 PSI (104
bar), the relief valve (RV) opens which allows a small
amount of hydraulic flow past the relief valve (Fig. 22).
This returning flow is restricted by the orifice in the logic
cartridge (LC2) creating a pressure imbalance that
shifts the logic cartridge to allow oil flow from the deck
motors to pass through the manifold (Fig. 23). When return pressure drops below 1500 PSI (104 bar), the relief
valve reseats blocking flow through the orifice in the logic cartridge. The loss of flow causes the logic cartridge
to close again, stopping the cutting blades. Once the
blades have stopped, the logic cartridge remains in the
closed position to keep the deck motors from rotating.
S
3200
psi
FROM
GEAR PUMP (P1)
TO
FLUID COOLER
Figure 22
TO DECK
MOTORS
FROM DECK
MOTORS
FROM DECK
MOTORS
ORIFICE
PRESSURE
IMBALANCE
1500
psi
RV
1500
LC2
LC2
RV
S
BLANCED
PRESSURE
3200
psi
psi
S
3200
psi
FROM
GEAR PUMP (P1)
TO
FLUID COOLER
Figure 23
FROM
GEAR PUMP (P1)
TO
FLUID COOLER
Figure 21
Groundsmaster 3500
Page 5 − 21
Hydraulic System
Hydraulic
System
ORIFICE
TO DECK
MOTORS
Page 5 - 22
G2
LOWER
PORT
FORWARD
P3
M6
INTERNAL CASE DRAIN
G1
UPPER
PORT
TOP PORT
HYDROSTAT
200- 300 psi
100- 150 psi
3500 psi
BY- PASS
VALVE
M4
M5
TRACTION WHEEL MOTORS
High Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundmaster 3500
Lift Circuit (Up)
OIL
FILTER
OIL
COOLER
T1
MANIFOLD
BLOCK
GEAR
PUMP
P1
P1
RV
ST
S
M2
CR
LC1
LC2
CF
LV
G2
250 psi
BACK
PRESSURE
OUT
S.W.
BULKHEAD
PLATE
IN
A
REAR
DECK
B
RIGHT
DECK
LEFT
DECK
E
T
P
V1
C
D
POWER STEERING VALVE
1000 psi
LIFT/S.W. VALVE
M3
M2
NOTE: Hydraulic Schematic for Unit Serial No. 314000001 & Up Shown
P2
CHG
3200
psi
1500
psi
M1
STRAINER
G1
T2
D1
M1
LIFT
REAR FRONT
R
L
SIDEWINDER
STEERING
Hydraulic System
Groundsmaster 3500
Lift Circuit (Up)
Raise Cutting Units
The gear pump (P2) is directly coupled to the hydrostat
through gear pump (P1) and driven by the engine. It supplies hydraulic pressure for operating the power steering system, raising and lowering the cutting units,
operating the sidewinder unit, and replenishing the
closed loop traction circuit (charge pressure). The pump
takes its suction directly from the hydraulic tank.
When the cutting unit shift lever is released, spring action returns the valve to its original position and bypasses flow back to the hydrostat stopping lift cylinder
movement. The cylinder position is locked in place by
the load holding checks in the lift control valve.
Hydraulic
System
During conditions of not lifting or lowering cutting units,
flow from the gear pump (P2) is by- passed through the
power steering valve, 2- spool lift/sidewinder valve, and
hydraulic manifold directly to the hydrostat and the
charge relief valve. Flow then returns to the gear pump
inlet and hydraulic tank.
When the cutting units are to be raised, the 2- spool
valve is positioned by moving the cutting unit shift lever
to RAISE. Flow is directed to cap ends of the lift cylinders. Hydraulic pressure against the cylinder pistons
moves their shafts causing the cutting units to raise. At
the same time, the pistons push the hydraulic fluid out
of the lift cylinders and back through the hydraulic manifold to the hydrostat.
Groundsmaster 3500
Page 5 - 23
Hydraulic System
Page 5 - 24
G2
LOWER
PORT
FORWARD
P3
200- 300 psi
100- 150 psi
3500 psi
G1
UPPER
PORT
HYDROSTAT
M6
TOP PORT
INTERNAL CASE DRAIN
BY- PASS
VALVE
M4
M5
TRACTION WHEEL MOTORS
High Pressure
Low Pressure (Charge)
Return or Suction
Flow
OIL
FILTER
T1
P1
GEAR
PUMP
D1
P1
RV
ST
S
M2
CR
LC1
LC2
CF
LV
G2
250 psi
BACK
PRESSURE
OUT
S.W.
BULKHEAD
PLATE
IN
A
REAR
DECK
B
RIGHT
DECK
LEFT
DECK
E
T
P
V1
C
D
POWER STEERING VALVE
1000 psi
LIFT/S.W. VALVE
M3
M2
M1
NOTE: Hydraulic Schematic for Unit Serial No. 314000001 & Up Shown
P2
CHG
3200
psi
1500
psi
M1
STRAINER
G1
T2
MANIFOLD
BLOCK
OIL
COOLER
Groundmaster 3500
Lift Circuit (Down) & Counterbalance
LIFT
REAR FRONT
R
L
SIDEWINDER
STEERING
Hydraulic System
Groundsmaster 3500
Lift Circuit (Down) & Counterbalance
Lower Cutting Units
The gear pump (P2) is directly coupled to the hydrostat
through gear pump (P1) and driven by the engine. It supplies hydraulic pressure for operating the power steering system, raising and lowering the cutting units,
operating the sidewinder unit, and replenishing the
closed loop traction circuit (charge pressure). The pump
takes its suction directly from the hydraulic tank.
During conditions of not lifting or not lowering cutting
units, flow from the gear pump (P2) is by- passed
through the power steering valve, 2- spool lift/sidewinder valve, and hydraulic manifold directly to the hydrostat
and the charge relief valve. Flow then returns to the gear
pump inlet and hydraulic tank.
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.
When the cutting unit shift lever is released, spring action returns and detents the valve into the float position
while by- passing flow back to the hydrostat. The pilot
valve remains shifted to allow the lift cylinders to float until the lift control valve is moved to the raise position.
Counterbalance
The logic cartridge valve (LC1) in the manifold block
maintains 250 PSI (17.2 bar) back pressure on the lift
cylinders. This back pressure (counterbalance) transfers cutting unit weight to the machine to improve traction and minimize turf marking by the cutting decks.
Hydraulic
System
When the cutting units are to be lowered, the 2- spool
valve is positioned by moving the cutting unit shift lever
to LOWER. Pressure from gear pump (P2) is used to
shift the pilot valve in the 2- spool valve. This shifting of
the pilot valve allows hydraulic pressure to relieve from
the cap end of the lift cylinders. Flow from the cap end
of the lift cylinders causes the cutting units to lower. At
the same time, the fluid relieved from the cap end of the
lift cylinders goes into the rod end of the cylinders and
back through the hydraulic manifold to the hydrostat.
Groundsmaster 3500
Page 5 - 25
Hydraulic System
Page 5 - 26
G2
LOWER
PORT
FORWARD
P3
G1
UPPER
PORT
HYDROSTAT
M6
TOP PORT
INTERNAL CASE DRAIN
200- 300 psi
100- 150 psi
3500 psi
BY- PASS
VALVE
M4
M5
TRACTION WHEEL MOTORS
High Pressure
Low Pressure (Charge)
Return or Suction
Flow
OIL
COOLER
OIL
FILTER
GEAR
PUMP
P1
P1
RV
P2
CHG
3200
psi
1500
psi
M1
ST
S
M2
CR
LC1
LC2
CF
LV
G2
250 psi
BACK
PRESSURE
OUT
S.W.
BULKHEAD
PLATE
IN
A
REAR
DECK
B
RIGHT
DECK
LEFT
DECK
E
T
P
V1
C
D
POWER STEERING VALVE
1000 psi
LIFT/S.W. VALVE
M3
M2
M1
NOTE: Hydraulic Schematic for Unit Serial No. 314000001 & Up Shown
T1
D1
STRAINER
G1
T2
MANIFOLD
BLOCK
Groundmaster 3500
Sidewinder Circuit (Move Right - Extend)
LIFT
REAR FRONT
R
L
SIDEWINDER
STEERING
Hydraulic System
Groundsmaster 3500
Sidewinder Circuit
The gear pump (P2) is directly coupled to the hydrostat
through gear pump (P1) and driven by the engine. It supplies hydraulic pressure for operating the power steering system, raising and lowering the cutting units,
operating the sidewinder unit, and replenishing the
closed loop traction circuit (charge pressure). The pump
takes its suction directly from the hydraulic tank.
spool valve and hydraulic manifold, and to the hydrostat.
When the cutting unit shift lever is released, spring action returns the valve to its original position and bypasses flow back to the hydrostat and stopping cylinder
movement. The cylinder position is locked in place since
there is no complete circuit of flow to or from the sidewinder cylinder when the lever is released.
During conditions of not lifting or not lowering cutting
units, flow from the gear pump (P2) is by- passed
through the power steering valve, 2- spool lift/sidewinder valve, and hydraulic manifold directly to the hydrostat
and the charge relief valve. Flow then returns to the gear
pump inlet and hydraulic tank.
Move Left (Retract)
Move Right (Extend)
Hydraulic
System
When the sidewinder is to be shifted right, the 2- spool
valve is positioned by moving the cutting unit shift lever
to RIGHT. Flow is directed to the cap end of the sidewinder cylinder. Hydraulic pressure against the cylinder
piston moves the rod causing the sidewinder cylinder to
extend (move right). At the same time, the piston pushes
the hydraulic fluid out of the cylinder, back through the
When the sidewinder is to be shifted left, the 2- spool
valve is positioned by moving the cutting unit shift lever
to LEFT. Flow is directed to the rod end of the sidewinder
cylinder. Hydraulic pressure against the cylinder piston
moves the rod causing the cylinder to retract (move left).
At the same time, the piston pushes the hydraulic fluid
out of the cylinder, back through the spool valve, hydraulic manifold, and to the hydrostat. When the cutting unit
shift lever is released, spring action returns the valve to
its original position and by- passes flow back to the hydrostat stopping cylinder movement. The cylinder position is locked in place since there is no complete circuit
of flow to or from the sidewinder cylinder when the lever
is released.
Groundsmaster 3500
Page 5 - 27
Hydraulic System
Page 5 - 28
G2
LOWER
PORT
FORWARD
P3
M6
INTERNAL CASE DRAIN
G1
UPPER
PORT
TOP PORT
HYDROSTAT
200- 300 psi
100- 150 psi
3500 psi
BY- PASS
VALVE
M4
M5
TRACTION WHEEL MOTORS
High Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundmaster 3500
Steering Circuit (Right Turn)
OIL
FILTER
OIL
COOLER
T1
MANIFOLD
BLOCK
GEAR
PUMP
P1
P1
RV
ST
S
M2
CR
LC1
LC2
CF
LV
G2
250 psi
BACK
PRESSURE
OUT
S.W.
BULKHEAD
PLATE
IN
A
REAR
DECK
B
RIGHT
DECK
LEFT
DECK
E
T
P
V1
C
D
POWER STEERING VALVE
1000 psi
LIFT/S.W. VALVE
M3
M2
NOTE: Hydraulic Schematic for Unit Serial No. 314000001 & Up Shown
P2
CHG
3200
psi
1500
psi
M1
STRAINER
G1
T2
D1
M1
LIFT
REAR FRONT
R
L
SIDEWINDER
STEERING
Hydraulic System
Groundsmaster 3500
Steering Circuit
With the steering wheel in the neutral position, the engine running, and the lift/sidewinder spool valve in the
center position, flow enters the steering control valve at
the P port and goes through the valve, by−passing the
rotary meter (V1) and steering cylinder. Flow leaves the
steering control valve through the E port, passes
through the lift/sidewinder valve, hydraulic manifold, hydrostat and charge relief valve, and continues on to the
gear pump inlet and hydraulic tank.
Right Turn
When a right turn is made with the engine running, the
turning of the steering wheel positions the steering control spool valve so that flow goes through the bottom of
the spool. Flow entering the steering control valve at the
P port goes through the spool and is routed to two
places. First, most of the flow through the steering control valve is by−passed out the E port back through the
lift/sidewinder valve, hydraulic manifold, hydrostat and
charge relief valve, and continues on to the gear pump
inlet and hydraulic tank. Second, the remainder of the
flow is drawn through the rotary meter (V1) and out port
(R). Pressure retracts the piston for a right turn. The
rotary meter (V1) ensures that the fluid flow to the cylinder is proportional to the amount of steering wheel rota-
Groundsmaster 3500
tion. Fluid leaving the cylinder flows back through the
steering control spool valve and through the T port. Return flow passes through the hydraulic manifold, hydrostat and charge relief valve, and continues on to the gear
pump inlet and hydraulic tank.
The steering control valve returns to the neutral position
when turning is complete.
Left Turn
When a left turn is made with the engine running, the
turning of the steering wheel positions the steering control spool valve so that flow goes through the top of the
spool. Flow entering the steering control valve at the P
port goes through the spool and is routed to two places.
Most of the flow through the steering control valve is by−
passed out the E port back through the lift/sidewinder
valve, hydraulic manifold, hydrostat and charge relief
valve, and continues on to the gear pump inlet and hydraulic tank (as in a right turn). The remainder of the flow
is drawn through rotary meter (V1) but during a left turn
the flow goes out port (L). Pressure extends the piston
for a left turn. The rotary meter (V1) ensures that the fluid
flow to the cylinder is proportional to the amount of steering wheel rotation. Fluid leaving the cylinder flows back
through the spool valve then through the T port. Return
flow passes through the hydraulic manifold, hydrostat
and charge relief valve, and continues on to the gear
pump inlet and hydraulic tank.
The steering control valve returns to the neutral position
when turning is complete.
Page 5 − 29
Hydraulic System
Hydraulic
System
The gear pump (P2) is directly coupled to the hydrostat
through gear pump (P1) and driven by the engine. It supplies hydraulic pressure for operating the power steering system, raising and lowering the cutting units,
operating the sidewinder unit, and maintaining 100 to
150 PSI (6.9 to 10.0 bar) to the low pressure side of the
closed loop traction circuit (charge pressure). The pump
takes its suction directly from the hydraulic tank.
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 precautions and specific hydraulic test procedures.
Review the hydraulic schematic and information on hydraulic system operation in the Hydraulic Flow Diagrams section of this Chapter. This information will be
useful during the hydraulic troubleshooting process.
General Hydraulic System Problems
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Problem
Possible Cause
Hydraulic oil leaks from system.
Hydraulic fitting(s), hose(s) or tube(s) are loose or damaged.
O−ring(s) or seal(s) are missing or damaged.
Hydraulic fluid foams.
Oil level in hydraulic tank is low.
Hydraulic system has wrong type of hydraulic oil.
The pump suction line has an air leak.
Incompatible hydraulic oils are mixed in the hydraulic system.
Water contamination is in the hydraulic system.
Hydraulic system operates hot
(above 200F (93C).
Traction pressure is high due to excessive load or brake applied.
Oil level in hydraulic tank is low, or inlet filter is loose or clogged
(NOTE: Other hydraulic systems are affected as well).
Hydraulic oil is contaminated or oil viscosity is too light.
Oil cooler is damaged or plugged.
Bypass valve in traction pump/hydrostat is open or defective.
Charge pressure is low.
Wheel motor(s) or cutting unit motor(s) are worn or damaged.
Traction pump/hydrostat is worn or damaged.
Hydraulic System
Page 5 − 30
Groundsmaster 3500
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
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Traction Circuit Problems
Problem
Possible Cause
Neutral is difficult to find or machine
operates in one direction only.
External control linkage is misadjusted, disconnected, binding or
damaged.
Traction pump/hydrostat is worn or damaged.
Traction response is sluggish.
Bypass valve in traction pump/hydrostat is open or defective.
Brake is not released.
Hydraulic oil is very cold.
Traction charge pressure is low.
Traction pump/hydrostat or wheel motor(s) are worn or damaged.
No traction exists in either direction.
Brake is not released.
Oil level in hydraulic tank is low
(NOTE: Other hydraulic systems are affected as well).
Bypass valve in traction pump/hydrostat is open or defective.
Traction pump/hydrostat drive belt is loose or broken.
Traction charge pressure is low.
Traction pump/hydrostat or wheel motor(s) are worn or damaged.
Wheel will not turn.
Brakes are binding.
Key on wheel motor shaft is sheared or missing.
Internal parts in wheel motor are damaged.
Unit rolls when stopped on an incline
− Engine Running (up to 10% grade
and parking brake disengaged).
Make up fluid from charge pump is not available.
Unit rolls when stopped on an incline
− Engine Not Running (up to 10%
grade, wheels straight and parking
brake disengaged).
Wheel motor(s) are worn or damaged (see Testing in this Chapter).
Groundsmaster 3500
Hydrostat check valves are damaged.
NOTE: If unit rolls away straight, both front wheel motors are worn.
If the unit turns to one side as it rolls away, the wheel motor on the
outside of the turn is worn.
Page 5 − 31
Hydraulic System
Hydraulic
System
Traction relief valve is damaged − open.
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Lift Circuit Problems
Problem
Possible Cause
Cutting units will not lift or lift slowly.
Engine speed is too low.
Hydraulic tank oil level is low
(NOTE: Other hydraulic systems are affected as well).
Lift arm bushings are binding.
Implement relief valve (in steering control valve) is stuck open.
Lift cylinders leak internally.
Gear pump (P2) is worn or damaged
(NOTE: Steering and traction charge systems are affected as well).
Cutting units raise, but will not stay
up as the traction units travels
between adjacent fairways or fields.
Lift circuit hydraulic lines or fittings are leaking.
Lift control valve detent pin is worn or has failed.
Lift control valve check valve (in pilot valve) leaks.
Lift cylinders leak internally.
Cutting units will not lower.
Lift arm pivots are binding.
Lift control valve is faulty.
Lift cylinder(s) for affected cutting unit(s) is damaged.
Hydraulic System
Page 5 − 32
Groundsmaster 3500
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Steering Circuit Problems
Problem
Possible Cause
Steering inoperative or sluggish
Oil level in hydraulic reservoir is low
(NOTE: Other hydraulic systems are affected as well).
Steering components (e.g. steering fork assembly, steering cylinder
ends) are worn or binding.
Relief valve in steering control valve is damaged − open.
Steering cylinder leaks internally.
Steering control valve is worn or damaged (see Troubleshooting
Guide in the Sauer/Danfoss Steering Unit Type OSPM Service
Manual.).
Tandem gear pump rear section is worn or damaged
(NOTE: The lift/lower and traction charge circuits are affected as
well).
Hoses to the steering cylinder are reversed.
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Mow Circuit Problems
Problem
Possible Cause
Gear pump is noisy (cavitation).
Hydraulic tank oil level is low
(NOTE: Other hydraulic systems are affected as well).
Suction line is restricted.
Suction line has an air leak.
None of the cutting reels will turn.
Solenoid valve (S) or (S1) is stuck open.
NOTE: To engage the mow circuit,
the seat must be occupied, the cutting units must be fully lowered, the
transport/mow switch must be in the
MOW position and the enable/disable switch must be in the ENABLE
position.
An electrical problem exists that prevents the solenoid valve (S) or
(S1) in the manifold from being energized (See Chapter 6 − Electrical System in this manual).
Poor after−cut appearance (cutting
blades(s) turn too slowly).
Cutting unit spindle bearing(s) is (are) damaged.
Gear pump (P1) is worn or damaged.
Cutting unit motor has internal leakage (see Testing in this
chapter).
Gear pump (P1) is inefficient (see Testing in this chapter).
Groundsmaster 3500
Page 5 − 33
Hydraulic System
Hydraulic
System
Turning steering wheel turns machine in the wrong direction.
Testing
The most effective method for isolating problems in the
hydraulic system is by using hydraulic test equipment
such as pressure gauges and flow meters in the various
hydraulic circuits to perform various operational checks
(See the Special Tools section in this chapter).
Remember that pressure specifications that appear on
hydraulic schematics are the design specifications for
the specific component. Actual system pressure will
vary depending on oil temperature, the location of the
test port, and the specific components used in the hydraulic circuit.
IMPORTANT: The hydraulic test procedures listed
in this manual represent actual performance for this
machine. To correctly measure product or component performance, be sure to follow the test procedures provided.
CAUTION
All testing should be performed by two (2)
people. One person should be in the seat to operate the machine, and the other should read and
record test results.
1. Clean machine thoroughly before disconnecting or
disassembling any hydraulic components. Always keep
in mind the need for cleanliness when working on hydraulic equipment. Hydraulic fluid contamination will
cause excessive wear of components.
2. Put metal caps or plugs on any hydraulic lines left
open or exposed during testing or while hydraulic components are removed.
Before Performing Hydraulic Tests
All obvious areas such as fluid supply, filter, binding linkages, loose fasteners, or improper adjustments must be
checked before assuming that a hydraulic component is
the source of the problem.
Precautions for Hydraulic Testing
WARNING
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Do not use hands to search for
leaks; use paper or cardboard. Hydraulic fluid
escaping under pressure can have sufficient
force to penetrate the skin and cause serious
injury. If fluid is injected into the skin, it must
be surgically removed within a few hours by a
doctor familiar with this type of injury. Gangrene may result from such an injury.
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved. See Relieving Hydraulic System Pressure in the General Information section.
3. The engine must be in good operating condition. Use
a phototach (non−contact tachometer) when performing
a hydraulic test. Engine speed can affect the accuracy
of the test readings. Monitor engine RPM during hydraulic testing. Use the information below when performing hydraulic system tests. If engine RPM is above
or below the specified speed during a test, you will need
to adjust the expected hydraulic performance parameters (aprox. 3% per 100 engine rpm at full throttle)
IMPORTANT: Hydraulic component output volume
relates directly to engine RPM. For every 100 engine
rpm the following component output volumes will
change by the volume listed.
Hydrostat: 100 engine RPM = 0.55 GPM or 70.6 oz.
(2077 cc) of hydraulic fluid displaced per minute
CAUTION
Failure to use gauges with recommended pressure (psi) rating as listed in test procedures
could result in damage to the gauge and possible
personal injury from leaking hot hydraulic fluid.
Hydraulic System
Page 5 − 34
Gear Pump (P1): 100 engine RPM = 0.36 GPM or
46.6 oz. (1377 cc) of hydraulic fluid displaced per
minute.
Gear Pump (P2): 100 engine RPM = 0.12 GPM or
15.9 oz. (469 cc) of hydraulic fluid displaced per
minute
Groundsmaster 3500
NOTE: Engine−to−Pump ratio is 1:0.88 for diesel units
and 1:0.83 for gasoline units. In other words, 1 engine
RPM = 0.88 pump RPM for a diesel powered unit.
4. The inlet and the outlet hoses must be properly connected and not reversed (hydraulic tester with pressure
and flow capabilities) to prevent damage to the hydraulic
tester or components.
5. When using a hydraulic tester with pressure and flow
capabilities, open load valve completely in the hydraulic
tester to minimize the possibility of damaging components.
6. Install fittings finger tight and far enough to make
sure that they are not cross−threaded before tightening
them with a wrench.
7. Position hydraulic tester hoses to prevent moving
machine parts from contacting and damaging the hoses
or tester.
8. Check fluid level in the hydraulic tank. After connecting test equipment, make sure tank is full.
Hydraulic Test Selection
Before beginning any hydraulic test, identify if the problem is related to the traction circuit, cutting (mow) circuit
or steering and lift/sidewinder circuit. Once the faulty
system has been identified, perform tests that relate to
that circuit.
If a traction circuit problem exists, consider performing
one or more of the following tests: Charge Pressure
Test, Wheel Motor Efficiency Test, and/or Piston Pump/
Hydrostat (P3) Flow and Relief Valve Tests.
If a cutting (mow) circuit problem exists, consider performing one or more of the following tests: Circuit Pressure Test, Deck Motor Efficiency/Case Drain Test,
Manifold Relief Pressure Test, and/or Gear Pump (P1)
Flow Test.
If a steering or lift/sidewinder circuit problem exists, consider performing one or more of the following tests: Gear
Pump (P2) Flow Test, Relief Valve Pressure Test, and/or
Steering Control Valve and Steering Cylinder Test.
9. Check control linkages for improper adjustment,
binding, or broken parts.
Hydraulic
System
10.All hydraulic tests should be made with the hydraulic
fluid at normal operating temperature.
Groundsmaster 3500
Page 5 − 35
Hydraulic System
Traction Circuit Testing − Charge Pressure Test
M5
TRACTION WHEEL MOTORS
M4
FORWARD
TOP PORT
M6
TESTER WITH
PRESSURE GUAGE
AND FLOW METER
LOWER
PORT
BY−PASS
VALVE
UPPER
PORT
TO HYDRAULIC
MANIFOLD (P1) PORT
TEE CONNECTOR
AND
PRESSURE GUAGE
3500 psi
FROM HYDRAULIC MANIFOLD
(CHG) PORT
100 to 150 psi
CHARGE RELIEF
200−300 psi
TO STEERING CONTROL
VALVE (IN) PORT
ENGINE
P1
P2
RPM
P3
FROM OIL
FILTER
GEAR PUMP
HYDROSTAT
STRAINER
INTERNAL CASE DRAIN
High Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System
Page 5 − 36
Groundsmaster 3500
Traction Circuit Testing − Charge Pressure Test:
2
The charge pressure test is the first in a series of tests
recommended to determine traction circuit performance. A charge pressure drop of more than 20% indicates an internal leak in the piston pump/hydrostat.
Continued unit operation can generate excessive heat,
cause damage to seals and other components in the hydraulic system, and affect overall machine performance.
1
Special Equipment Required:
Figure 24
S Pressure Gauge
S Flow Meter with Pressure Gauge that has at least
an 18 GPM (68 LPM) capacity.
1.
Hydraulic fitting
2.
Piston pump
S Phototach (non−contact tachometer).
1. Park machine on a level surface with the cutting units
lowered and PTO switch off. Make sure engine is off and
the parking brake is engaged.
2
2. Read Precautions for Hydraulic Testing in this
chapter.
1
3. Make sure that traction pedal is adjusted to the neutral position.
5. Install a T−connector and pressure gauge between
the fitting and disconnected hose.
6. Disconnect hose from the lower hydraulic fitting on
the engine side of the hydrostat (Fig. 25).
7. Install tester in series with the pump and the disconnected hose. Make sure the tester flow control valve is
fully open.
8. Attach a heavy chain to the rear of the machine frame
and an immovable object to prevent the machine from
moving during testing.
9. Chock the wheels to prevent wheel rotation during
testing.
10.Start engine. Move throttle to full speed (Diesel engine = 3220 + 50 RPM, Gas engine = 3420 + 30 RPM).
11. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes.
12.Verify with a phototach that the pump speed is approximately 2850 RPM.
Lower hydraulic fitting
2.
Piston pump
13.Record reading on pressure gauge from CHG manifold port. Charge pressure (without load) should read
from 150 to 200 PSI (10.3 to13.8 Bar). If charge relief
pressure specification is not met, consider the following:
A. Gear pump (P2) is faulty (steering/lift/sidewinder
circuit performance will also be affected). Test gear
pump (P2) flow (see Gear Pump (P2) Flow Test in
this chapter).
B. The piston pump charge relief valve is faulty. Repair or replace the piston pump charge relief valve
(see Piston Pump Service in this chapter).
14.Sit in the operator’s seat, release the parking brake,
and slowly depress the forward traction pedal until 1000
to 1500 PSI (68.9 to 103.4 Bar) is reached on the flow
meter pressure gauge.
15.Record reading on pressure gauge from CHG manifold port (under load). Charge pressure (under load)
should not drop more than 20% when compared to
charge pressure (without load) recorded in step 13.
If specifications are not met, perform Piston Pump/Hydrostat (P3) Flow and Traction Relief Pressure Test as
outlined in this chapter.
16.Release traction pedal, move throttle to low speed
and turn the engine off.
Groundsmaster 3500
Page 5 − 37
Hydraulic System
Hydraulic
System
4. Disconnect hose to the rear hydraulic fitting on the
piston pump coming from the hydraulic manifold port
(CHG) (Fig. 24).
Figure 25
1.
Traction Unit Testing − Wheel Motor Efficiency Tests
FRONT WHEEL MOTORS
FRONT WHEEL MOTORS
M4
M4
TESTER
WITH
PRESSURE
GAUGES
AND
FLOW
METER
LOWER
PORT
FORWARD
FRONT WHEEL MOTOR TEST
(individually)
M5
FORWARD
FRONT WHEEL MOTOR TEST
(together)
M5
TESTER
WITH
PRESSURE
GAUGES
AND
FLOW
METER
M6
REAR
WHEEL
MOTOR
BY−PASS
VALVE
M6
REAR
WHEEL
MOTOR
UPPER
PORT
PISTON PUMP
(HYDROSTAT)
LOWER PORT
3500 psi
TRACTION
RELIEF
PISTON PUMP
(HYDROSTAT)
UPPER PORT
REAR WHEEL MOTOR TEST
M5
FROM
HYDRAULIC
MANIFOLD
(CHG) PORT
FRONT WHEEL MOTORS
M4
100 to 150 psi
TESTER
WITH
PRESSURE
GAUGES
AND
FLOW
METER
FORWARD
200 to 300 psi
P3
TOP PORT
M6
REAR
WHEEL
MOTOR
PISTON PUMP
(HYDROSTAT)
TO GEAR PUMP
SUCTION
THROUGH
CASE DRAIN
High Pressure
Low Pressure
Return or Suction
Flow
PISTON PUMP
(HYDROSTAT)
LOWER PORT
PISTON PUMP
(HYDROSTAT)
UPPER PORT
Figure 26
Hydraulic System
Page 5 − 38
Groundsmaster 3500
Traction Circuit Testing − Wheel Motor Efficiency
Test:
There are moments during wheel motor operation (geroller position) when fluid flow through the motor is less
restricted. If a wheel motor is tested in this position, the
test results will be higher should not be used to determine wheel motor efficiency. Test wheel motors in three
(3) different wheel positions to obtain accurate test results. Record test readings for all three (3) wheel positions.
Hydraulic fluid flows through both front wheel motors (in
parallel) before passing through the rear wheel motor (in
series). In this configuration, the rear wheel motor can
mask front wheel motor performance issues, and the
front wheel motors can mask rear wheel motor performance issues. Start by testing both front wheel motors together, then individually if necessary. Finish by testing
the rear wheel motor.
1
Figure 27
1. Lower hydraulic fitting
2. Piston pump
1. Disconnect hose from the lower hydraulic fitting on
the bottom of the hydrostat (Fig. 27).
NOTE: An alternate testing location would be at the hydraulic hose from the hydrostat and the hydraulic tube
supplying the front wheel motors under the left floor
plate.
2. Install flow tester between the hydrostat and the disconnected hose. Make sure the tester flow control valve
is fully open.
3. Disconnect both hydraulic lines from the rear wheel
motor, then reconnect the lines to each other. Plug ports
in wheel motor to prevent contamination.
4. Chock front wheels to prevent wheel rotation.
5. Start engine. Move throttle to full speed (Diesel engine = 3220 + 50 RPM, Gas engine = 3420 + 30 RPM).
Special Equipment Required:
S Pressure Gauge
S Flow Meter with Pressure Gauge that has at least
an 18 GPM (68 LPM) capacity.
S Phototach (non−contact tachometer).
1. Park machine on a level surface with the cutting units
lowered and the PTO switch off. The engine should be
off and the parking brake engaged.
2. Read Precautions for Hydraulic Testing in this
chapter.
3. Make sure that traction pedal is adjusted to the neutral position.
4. Attach a heavy chain to the rear of the machine frame
and an immovable object to prevent the machine from
moving during testing.
Front Wheel Motor Test:s
Hydraulic fluid flows through both front wheel motors (in
parallel) before passing through the rear wheel motor (in
series). To accurately test the front wheel motors, the
rear wheel motor must be removed from the traction circuit.
Groundsmaster 3500
2
6. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
7. Verify with a phototach that the pump speed is approximately 2850 RPM.
CAUTION
Use extreme caution when performing wheel motor tests. The wheel motors will be trying to move
the machine forward.
8. Sit in the operators seat, release the parking brake,
and set the Transport/Mow slide to the transport position.
9. Slowly depress forward traction pedal until 1000 to
1500 PSI (68.9 to 103.4 Bar) is displayed on the pressure gauge.
Flow meter should read less than 1.5 GPM (5.7
LPM).
Page 5 − 39
Hydraulic System
Hydraulic
System
Wheel motor efficiency is the second in a series of tests
recommended to determine traction circuit performance. Hydraulic fluid flow of 1.5 GPM (5.7 LPM) or more
through a stationary wheel motor under load indicates
an internal leak in the wheel motor. A worn wheel motor
is less efficient. Eventually, enough fluid by−pass will
cause the wheel motor to stall under heavy load conditions. Continued operation can generate excessive
heat, cause damage to seals and other components in
the hydraulic system, and affect overall machine performance.
10.Release traction pedal, shut engine off, and record
test results.
11. Rotate each front wheel 120 degrees and retest. Repeat this procedure until each wheel motor has been
tested in three (3) different positions.
Proceed to testing rear wheel motor If test results are
within specification. If specifications are not met, test
front wheel motors individually as follows:
Rear Wheel Motor Test:
Hydraulic fluid flows through both front wheel motors (in
parallel) before passing through the rear wheel motor (in
series). To accurately test the rear wheel motor, the front
wheel motors must be allowed to rotate.
1. Disconnect hose from the upper hydraulic fitting of
the rear wheel motor (Fig. 28).
12.Disconnect hydraulic lines from front wheel motor
that is not being tested. Cap disconnected hydraulic
lines and plug ports in wheel motor to prevent contamination.
2
13.Chock front wheel being tested to prevent wheel rotation.
RIGHT
FRONT
14.Start engine. Move throttle to full speed.
CAUTION
1
Use extreme caution when performing wheel motor tests. The wheel motors will be trying to move
the machine forward.
Figure 28
1. Rear wheel motor
15.Sit in the operators seat, release the parking brake,
and set the Transport/Mow slide to the transport position.
2. Install flow tester between the disconnected hydraulic hose and the rear wheel motor. Make sure the tester
flow control valve is fully open.
16.Slowly depress forward traction pedal until 1000 to
1500 PSI (68.9 to 103.4 Bar) is displayed on the pressure gauge.
Flow meter should read less than 1.5 GPM (5.7
LPM).
17.Release traction pedal, shut engine off, and record
test results.
18.Rotate front wheel 120 degrees and retest. Repeat
this procedure until wheel motor has been tested in
three (3) different positions.
WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 − Safety.
3. Raise off the floor and support both front wheels.
4. Chock rear wheel to prevent wheel rotation.
5. Start engine. Move throttle to full speed.
19.Reconnect hydraulic lines to front wheel motor and
repeat procedure for remaining front wheel motor.
20.If specifications are not met, repair or replace worn
wheel motor.
2. Upper fitting
CAUTION
Use extreme caution when performing wheel motor tests. The wheel motors will be trying to move
the machine forward.
6. Sit in the operators seat, release the parking brake,
and set the Transport/Mow slide to the transport position.
Hydraulic System
Page 5 − 40
Groundsmaster 3500
7. Slowly depress forward traction pedal until 1000 to
1500 PSI (68.9 to 103.4 Bar) is displayed on the pressure gauge.
9. Rotate rear wheel 120 degrees and retest. Repeat
this procedure until wheel motor has been tested in
three (3) different positions.
Flow meter should read less than 1.5 GPM (5.7
LPM).
10.If specifications are not met, repair or replace worn
wheel motor.
Hydraulic
System
8. Release traction pedal, shut engine off, and record
test results.
Groundsmaster 3500
Page 5 − 41
Hydraulic System
Traction Circuit Testing − Piston Pump/Hydrostat (P3) Flow and Relief Pressure Test
M5
FORWARD
TRACTION WHEEL MOTORS
M4
TOP PORT
TESTER
WITH PRESSURE GAUGES
AND FLOW METER
LOWER
PORT
M6
BY−PASS
VALVE
UPPER
PORT
3500 psi
TRACTION
RELIEF
100 to 150 psi
FROM HYDRAULIC
MANIFOLD
(CHARGE) PORT
200 to 300 psi
P3
PISTON PUMP
(HYDROSTAT)
Low Pressure
Return or Suction
TO GEAR PUMP SUCTION
THROUGH CASE DRAIN
Hydraulic System
High Pressure
Flow
Page 5 − 42
Groundsmaster 3500
Traction Circuit Testing − Piston Pump/Hydrostat
(P3) Flow and Relief Pressure Test:
The hydrostat flow test is the third in a series of tests recommended to determine traction circuit performance.
The final traction circuit test is verifying the hydrostat relief valve operation. This test compares fluid flow at No
Load with fluid flow Under Load. A drop in flow under
load of more than 12% indicates an internal leak or malfunctioning relief valve in the piston pump/hydrostat. A
worn hydrostat or malfunctioning relief valve is less efficient. Eventually, enough fluid by−pass will cause the
unit to stall under heavy load conditions. Continued operation can generate excessive heat, cause damage to
seals and other components in the hydraulic system,
and affect overall machine performance.
Special Equipment Required:
2
1
Figure 29
1.
Lower hydraulic fitting
2.
Piston pump
10.Sit in the operator’s seat, release the parking brake,
and set the Transport/Mow slide to the transport position.
S Pressure Gauge
S Flow Meter with Pressure Gauge that has at least
an 18 GPM (68 LPM) capacity.
1. Park machine on a level surface with the cutting units
lowered and the PTO switch off. The engine should be
off and the parking brake engaged.
2. Read Precautions for Hydraulic Testing in this
chapter.
3. Make sure that traction pedal is adjusted to the neutral position.
WARNING
Use extreme caution when performing hydrostat
flow tests. The traction unit wheels will be rotating during the test .
11. Verify pump flow at No Load as follows:
A. Slowly depress forward traction pedal to full forward position.
B. Record tester pressure and flow readings. Unrestricted pump output should be approximately 16
GPM (60.5 LPM) at 650 PSI (44.8 Bar).
12. Verify pump flow Under Load as follows:
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 − Safety.
4. Raise off the floor and support both front wheels and
the rear wheel.
5. Disconnect hose from the lower hydraulic fitting on
the engine side of the hydrostat (Fig. 29).
6. Install tester in series with the pump and the disconnected hose. Make sure the tester flow control valve is
fully open.
A. Slowly depress forward traction pedal to full forward position.
B. Apply an additional load of 1000 to 1500 PSI
(68.9 to 103.4 Bar) by slowly closing the flow meter.
The flow meter pressure gauge should read 1700 to
2100 PSI (117.2 to 144.8 Bar).
C. Record tester pressure and flow readings.
13.Verify traction relief valve operation as follows:
A. Return the traction pedal to neutral.
7. Start engine. Move throttle to full speed (Diesel engine = 3220 + 50 RPM, Gas engine = 3420 + 30 RPM).
B. Fully close the flow meter flow control valve.
8. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes.
C. Slowly set traction pedal to full forward position.
9. Verify with a phototach that the pump speed is approximately 2850 RPM.
System pressure should reach 3600 to 3650 PSI
(248 to 251 Bar) before the relief valve opens.
Groundsmaster 3500
D. Record tester pressure reading.
Page 5 − 43
Hydraulic System
Hydraulic
System
S Phototach (non−contact tachometer).
CAUTION
NOTE: The relief valve setting is 3500 PSI (241
Bar). An additional 100 to 150 PSI (6.9 to10.3 Bar)
is necessary to overcome system charge pressure
before the relief valve opens.
E. Release traction pedal, open flow control valve
fully, move throttle to low speed and turn the engine
off.
14.If relief pressure can not be met or is greater than
specified, the traction relief valve is faulty and should be
replaced.
Hydraulic System
15.The Under Load test flow reading (step 12.) should
not drop more than 12% when compared to the No
Load test flow reading (step 11.). A difference of more
than 12% may indicate:
A. The traction belt is worn and/or slipping.
B. The piston pump/hydrostat (P3) is worn and
should be repaired or replaced.
16.Disconnect tester and reconnect hose to pump.
Page 5 − 44
Groundsmaster 3500
Hydraulic
System
This page is intentionally blank.
Groundsmaster 3500
Page 5 − 45
Hydraulic System
Cutting Deck Circuit Testing − Pressure Test
FROM DECK MOTOR
CASE DRAINS
TO LEFT FRONT
DECK MOTOR
D1
M1
FROM REAR
DECK MOTOR
M2
TO HYDRAULIC
TANK
T2
1500 psi
RV
LC2
1500
psi
G1
TEST
GAUGE
3200
psi
TO OIL
COOLER
HYDRAULIC
MANIFOLD
BLOCK
S
T1
LC1
G2
LV
P1
CHG
ST
TO HYDROSTAT
CHARGE CIRCUIT
CR
CF
FROM LIFT VALVE
(OUT) PORT
FROM FRONT LIFT
CYLINDER
FROM REAR LIFT
CYLINDER
ENGINE
RPM
TO STEERING CONTROL
VALVE (IN) PORT
FROM STEERING CONTROL
VALVE (OUT) PORT
P1 P2
FROM HYDROSTAT
INTERNAL CASE DRAIN
GEAR PUMP
High Pressure
Low Pressure
STRAINER
FROM OIL FILTER
Return or Suction
Flow
NOTE: Hydraulic Schematic for Unit Serial No. 413000001 & Up shown
Hydraulic System
Page 5 − 46
Groundsmaster 3500
Cutting Deck Circuit Testing − Pressure Test:
Cutting deck circuit pressure is the first in a series of
tests recommended to check cutting deck circuit performance. The results from this test will help determine
which component(s) are the cause of cutting deck performance issues.
Unit Serial No.
Prior to 314000001
1
Special Equipment Required:
NOTE: If available, connecting a flow meter with pressure gauge that has at least a 12 GPM (45 LPM) capacity at the hydraulic manifold (M1) port instead of
connecting a pressure gauge at manifold port (G1) as
described in this test, will allow performing the pressure
test and manifold relief valve test with the same test configuration (see Cutting Deck Circuit Testing − Manifold
Relief Valve Pressure Test in this chapter).
2
Figure 30
1.
S Pressure Gauge with extension hose
S Test fitting and cover Toro p/n 354−77 and
354−79
Hydraulic manifold
2.
Manifold port (G1)
Unit Serial No.
314000001 & Up
1. Park machine on a level surface with the cutting units
lowered and off. Make sure engine is off and the parking
brake is disengaged.
1
2. Read Precautions for Hydraulic Testing in this
chapter.
Hydraulic
System
2
3. Remove plug from hydraulic manifold port (G1) and
install a test fitting and cover (Fig. 30 and 31).
4. Install test gauge with hydraulic hose to manifold port
(G1).
Figure 31
CAUTION
1.
Keep away from decks during test to prevent personal injury from the cutting blades.
5. Sit in the Operator’s seat, start the engine, and move
throttle to full speed (Diesel engine = 3220 + 50 RPM,
Gas engine = 3420 + 30 RPM).
6. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes.
7. Engage the cutting units.
When engaged, the cutting circuit pressure should exceed manifold relief valve pressure setting of 3200 PSI
(220.6 Bar) momentarily opening the relief valve. Circuit
pressure should then stabilize at approximately 1000
PSI (68.9 Bar) with standard combination sail blades installed.
Groundsmaster 3500
Hydraulic manifold
2.
Manifold port (G1)
8. Safely secure the test pressure gauge and operate
the machine under your specific mowing conditions.
Monitor test gauge while mowing. Cutting deck circuit
pressure should be approximately 1500 to 2000 PSI
(103.4 to 137.9 Bar) under low load conditions, and can
reach a maximum pressure equal to the manifold relief
valve setting of 3200 PSI (220.6 Bar).
9. Disengage cutting decks, move throttle to low speed
and shut off engine.
10.If pressure readings are within specifications and
cutting deck performance is still in question, test cutting
deck motors individually (see Cutting Deck Circuit −
Deck Motor Efficiency/Case Drain Test).
Page 5 − 47
Hydraulic System
11. If pressure specifications are not met, consider the
following:
A. Manifold relief valve is faulty (see Cutting Deck
Circuit − Manifold Relief Valve Pressure Test in this
chapter)
B. Gear pump (P1) is faulty (see Cutting Deck Circuit − Gear Pump (P1) Flow Under Load Test in this
chapter)
Hydraulic System
C. The blade braking valve (BV − Unit Serial No. Prior to 31400000) or the blade braking relief valve and/
or logic cartridge (RV and LC2 − Unit Serial No.
314000001 & Up) is faulty. Adjust, repair, or replace
the necessary components (see Adjustments −
Blade Braking Valve/Relief Valve in this chapter).
12.Disconnect test equipment from hydraulic manifold.
Page 5 − 48
Groundsmaster 3500
Hydraulic
System
This page is intentionally blank.
Groundsmaster 3500
Page 5 − 49
Hydraulic System
Cutting Deck Circuit Testing − Deck Motor Efficiency/Case Drain Test
TO HYDRAULIC
MANIFOLD PORT (D1)
FROM HYDRAULIC
MANIFOLD PORT (M1)
LEFT
DECK MOTOR
TESTER WITH
PRESSURE GAUGE
AND FLOW METER
MEASURING
CONTAINER
RIGHT
DECK MOTOR
High Pressure
Low Pressure
TO HYDRAULIC
MANIFOLD PORT (M2)
REAR
DECK MOTOR
Return or Suction
Flow
Toro # TOR4077
Hydraulic System
Page 5 − 50
Groundsmaster 3500
Cutting Deck Circuit Testing − Deck Motor Efficiency/Case Drain Test
1
The deck motor efficiency/case drain test is the second
in a series of tests recommended to check cutting deck
circuit performance. Over a period of time, a deck motor
can wear internally. This test measures case drain
volume while restricting flow across the motor ports.
Case drain volume under load of more than 9% of total
motor flow indicates the gears and wear plates in the
motor have worn. A worn motor may by−pass hydraulic
fluid to its case drain causing the motor to be less efficient. Eventually, enough fluid loss will cause the deck
motor to stall under heavy cutting conditions. Continued
operation with a worn, inefficient motor can generate excessive heat, cause damage to seals and other components in the hydraulic system, and affect quality of cut.
2
33 to 36 ft−lb (3.7 to 4.0 N−m)
Figure 32
1.
Deck motor
Special Equipment Required:
2.
Motor mounting screws
2
3
S Flow Meter with Pressure Gauge that has at least
a 12 GPM (45 LPM) capacity.
S Phototach (non−contact tachometer).
7
1. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
2. Park the machine on a level surface with the cutting
units lowered and PTO switch off. Make sure engine is
off, transport/mow switch in in the MOW position, and
the parking brake is disengaged.
1
6
Hydraulic
System
5
3. Read Precautions for Hydraulic Testing in this
chapter.
NOTE: The deck motors are connected in series. If a
faulty deck motor is not obvious (based on quality of cut
issues) you may have to test all three motors in the circuit. If testing all cutting deck motors, start with the first
motor in the series (front left).
5. Remove the deck motors from all cutting decks (Fig.
32).
RIGHT
4
4. Make sure that traction pedal is adjusted to the neutral position.
FRONT
1
8
Figure 33
1.
2.
3.
4.
Deck motor
Rear case drain hose
Rear T−fitting
Front left
case drain hose
5. Front right
case drain hose
6. Front T−fitting
7. Rear return hose
8. Front left return hose
6. Disconnect the return hose from the motor. The return hose is the first hose counterclockwise of the smaller (center) case drain hose (Fig. 33).
9. Two people are required to complete the following
steps. One person should sit in the operator’s seat and
operate the machine while another person reads the
tester and measures deck motor case drain volume.
7. Install hydraulic tester between the motor and the
disconnected return hose. Make sure the tester flow
control valve is fully open.
Start the engine and move throttle to full speed (Diesel
engine = 3220 + 50 RPM, Gas engine = 3420 + 30
RPM). Engage the cutting units.
8. Disconnect hose from deck motor case drain at the
bulkhead T−fitting (Fig. 33). Plug the T−fitting to prevent
system contamination. Place open end of disconnected
case drain hose into a drain pan.
10.Verify with a phototach that the pump speed is approximately 2850 RPM.
Groundsmaster 3500
11. Engage cutting decks and slowly close tester flow
control valve until a pressure of 2000 PSI (138 Bar) is
obtained.
Page 5 − 51
Hydraulic System
12.Hold disconnected motor case drain hose into a container graduated in ounces or milliliters (e.g. Toro
#TOR4077) and collect hydraulic fluid for 30 seconds.
After 30 seconds, remove hose end from container.
16.Remove tester and reconnect hydraulic hoses.
13.Record amount of fluid collected in the container.
18.Repeat test with remaining deck motors as needed.
14.Disengage cutting decks, set throttle to low speed
and stop engine.
19.Install deck motors after testing is completed. (see
Cutting Deck Operator’s Manual). Tighten mounting
screws from 33 to 36 ft−lb (3.7 to 4.0 N−m).
17.Check hydraulic fluid level (see Traction Unit Operator’s Manual).
15.If volume is more than 80 oz (2366 milliliters), repair
or replace the tested deck motor.
Hydraulic System
Page 5 − 52
Groundsmaster 3500
Hydraulic
System
This page is intentionally blank.
Groundsmaster 3500
Page 5 − 53
Hydraulic System
Cutting Deck Circuit Testing − Manifold Relief Valve Pressure Test
FROM DECK MOTOR
CASE DRAINS
TESTER
WITH PRESSURE GAUGES
AND FLOW METER
D1
M1
TO LEFT FRONT
DECK MOTOR
FROM REAR
DECK MOTOR
M2
TO HYDRAULIC
TANK
T2
1500 psi
RV
LC2
1500
psi
G1
3200
psi
TO OIL
COOLER
HYDRAULIC
MANIFOLD
BLOCK
S
T1
LC1
G2
LV
P1
CHG
ST
TO HYDROSTAT
CHARGE CIRCUIT
CR
CF
FROM LIFT VALVE
(OUT) PORT
FROM FRONT LIFT
CYLINDER
FROM REAR LIFT
CYLINDER
ENGINE
RPM
TO STEERING CONTROL
VALVE (IN) PORT
FROM STEERING CONTROL
VALVE (OUT) PORT
P1 P2
FROM HYDROSTAT
INTERNAL CASE DRAIN
GEAR PUMP
High Pressure
Low Pressure
STRAINER
FROM OIL FILTER
Return or Suction
Flow
NOTE: Hydraulic Schematic for Unit Serial No. 413000001 & Up shown
Hydraulic System
Page 5 − 54
Groundsmaster 3500
Cutting Deck Circuit Testing − Manifold Relief Valve
Pressure Test:
Unit Serial No.
Prior to 314000001
Test the performance of the manifold relief valve (S or
S1) to make sure that the maximum amount of fluid is
available to the cutting deck motors up to the set relief
pressure. This test also ensures that pump (P1) is capable of generating enough pressure to open a properly
functioning manifold relief valve. The manifold relief
valve is part of the cutting deck solenoid valve.
3
1
2
Special Equipment Required:
S Flow Meter with Pressure Gauge that has at least
a 12 GPM (45 LPM) capacity.
1. Park machine on a level surface with the cutting units
lowered and PTO switch off. Engine should be off and
the parking brake disengaged.
2. Read Precautions for Hydraulic Testing in this
chapter.
Figure 34
1.
2.
Hydraulic manifold
Manifold port (M1)
3.
Relief valve (S1)
Unit Serial No.
314000001 & Up
3. Disconnect the hose from hydraulic fitting at manifold port (M1) (Fig. 34 and 35).
NOTE: An alternative to using manifold port (M1) would
be to disconnect the inlet hydraulic hose to the front left
deck motor. The inlet hose is the first hose clockwise of
the smaller (center) case drain hose. (Fig. 36).
3
1
CAUTION
Hydraulic
System
4. Install tester between the hose and hydraulic fitting.
Make sure the flow control valve on tester is fully open.
2
Keep away from decks during test to prevent personal injury from the cutting blades.
Figure 35
1.
2.
Hydraulic manifold
Manifold port (M1)
3.
5. Start the engine and move throttle to full speed (Diesel engine = 3220 + 50 RPM, Gas engine = 3420 + 30
RPM).
Relief valve (S)
4
6. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes.
7. Engage the cutting units.
2
8. Watch pressure gauge carefully while slowly closing
the flow control valve.
1
9. System pressure should reach 3100 to 3330 PSI
(213.7 to 227.5 Bar) before the relief valve opens.
Figure 36
10.Set throttle to low speed and shut off engine.
1. Deck motor
2. Inlet hose
11. If specification is met, test pump (P1) flow (see Cutting Deck Circuit Testing − Gear Pump (P1) Flow Test in
this chapter) If specification is not met, clean or replace
relief valve (S or S1) (see Hydraulic Manifold Service in
this chapter) and retest.
Groundsmaster 3500
3. Case drain hose
12.Disconnect tester and reconnect hydraulic hose.
Page 5 − 55
Hydraulic System
Cutting Deck Circuit Testing − Gear Pump (P1) Flow Test
TO HYDRAULIC MANIFOLD
(P1) PORT
TESTER
WITH PRESSURE GAUGES
AND FLOW METER
TO STEERING CONTROL
VALVE (IN) PORT
TO TOTO
ENGINE
P1
P2
RPM
GEAR PUMP
FROM HYDROSTAT
CASE DRAIN
FROM OIL FILTER
STRAINER
High Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System
Page 5 − 56
Groundsmaster 3500
Cutting Deck Circuit Testing − Gear Pump (P1) Flow
Test:
2
The gear pump (P1) flow test is the last in a series of
tests recommended to determine cutting deck circuit
performance. This test compares fluid flow at No Load
with fluid flow Under Load. A drop in flow under load of
more than 15% indicates the gears and wear plates in
the pump have worn. A worn pump will by−pass hydraulic fluid and make the pump less efficient. Eventually,
enough fluid loss will occur to cause the cutting unit motors to stall under heavy cutting conditions. Continued
operation with a worn, inefficient pump can generate excessive heat and cause damage to the seals and other
components in the hydraulic system.
RIGHT
FRONT
1
P2
P1
Special Equipment Required:
Figure 37
S Flow Meter with Pressure Gauge that has at least
a 12 GPM (45 LPM) capacity.
1.
S Phototach (non−contact tachometer).
9. Verify pump flow Under Load as follows:
Gear pump assembly
1. Park machine on a level surface with the cutting units
lowered and PTO switch off. Make sure engine is off and
the parking brake is engaged.
3. Disconnect hose connection on the gear pump (P1)
leading to port (P1) on the hydraulic manifold (Fig. 37).
4. Install tester between the gear pump and the disconnected hose.
5. Make sure the flow control valve on the tester is fully
open.
6. Sit in the Operator’s seat, start the engine, and move
throttle to full speed (Diesel engine = 3220 + 50 RPM,
Gas engine = 3420 + 30 RPM). Do not engage the cutting units.
To hydraulic manifold
CAUTION
Do not close tester valve fully when performing this test. In this test, the hydraulic tester is
positioned before the manifold relief valve.
Pump damage can occur if the fluid flow is fully
restricted by fully closing the tester flow control valve.
A. Watch flow meter pressure gauge carefully while
slowly closing the flow control valve until 2000 PSI
(137.9 Bar) is obtained on gauge.
B. Record tester pressure and flow readings under
load.
10.Set throttle to low speed and shut off engine.
7. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes.
Use a phototach to verify that the pump speed is approximately 2850 RPM.
8. Verify pump flow at No Load as follows:
11. The under load test flow reading (step 9.B) should
not drop more than 15% when compared to no load test
flow reading (step 8.A). A difference in flow of more than
15%, or the inability to achieve specified pressure may
indicate:
A. A restriction in the pump intake line
Record tester pressure and flow reading at no load.
Unrestricted pump output should be approximately
11.1 GPM (42.1 LPM).
B. A Worn and/or slipping traction belt
C. The gear pump (P1) is worn and should be repaired or replaced
12.Disconnect tester and reconnect hose to pump.
Groundsmaster 3500
Page 5 − 57
Hydraulic System
Hydraulic
System
2. Read Precautions for Hydraulic Testing in this
chapter.
2.
Steering/Lift/Sidewinder Circuit Testing − Gear Pump (P2) Flow Test
TO HYDRAULIC MANIFOLD
(P1) PORT
TESTER
WITH PRESSURE GAUGES
AND FLOW METER
TO STEERING CONTROL
TO TOTO
VALVE (IN) PORT
ENGINE
P1
P2
RPM
GEAR PUMP
FROM HYDROSTAT
CASE DRAIN
FROM OIL FILTER
High Pressure
Low Pressure
STRAINER
Return or Suction
Flow
Hydraulic System
Page 5 − 58
Groundsmaster 3500
Steering/Lift/Sidewinder Circuit Testing − Gear
Pump (P2) Flow Test:
2
Gear pump (P2) is designed to satisfy both steering cylinder and lift/sidewinder cylinder needs simultaneously
(at full speed throttle). The Gear Pump (P2) Flow Test
compares fluid flow at No Load with fluid flow Under
Load. A drop in flow under load of more than 15% indicates the gears and wear plates in the pump have worn.
Continued operation with a worn pump can generate excessive heat and cause damage to the seals and other
components in the hydraulic system.
RIGHT
FRONT
P2
P1
1
If unit steering is sluggish or otherwise performs poorly,
see Steering/Lift/Sidewinder Circuit − Steering Control
Valve and Steering Cylinder Test in this chapter.
If cutting deck lift or sidewinder operation is unsatisfactory, check lift/sidewinder control valve and/or lift and
sidewinder cylinders. Additional information on these
components is available in this chapter.
If both steering and lift operations perform poorly, perform the gear pump (P2) flow test and circuit relief valve
pressure test (see Steering/Lift/Sidewinder Circuit − Relief Valve Pressure Test in this chapter).
Figure 38
1.
Gear pump assembly
2.
To steering control valve
8. Verify pump flow at No Load as follows:
Record tester pressure and flow readings at no load.
Unrestricted pump output should be approximately
3.8 GPM (14.4 LPM).
9. Verify pump flow Under Load as follows:
Special Equipment Required:
S Flow Meter with Pressure Gauge that has at least
a 5 GPM (16 LPM) capacity.
S Phototach (non−contact tachometer).
1. Park machine on a level surface with the cutting units
lowered and PTO switch off. The engine should be off
and the parking brake engaged.
2. Read Precautions for Hydraulic Testing in this
chapter.
3. Disconnect hose connection on the gear pump (P2)
leading to the steering control valve (Fig. 38).
4. Install tester between gear pump and the disconnected hose.
5. Make sure the flow control valve on the tester is fully
open.
6. Start engine and move throttle to full speed (Diesel
engine = 3220 + 50 RPM, Gas engine = 3420 + 30
RPM).
7. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes.
Use a phototach to verify that the pump speed is approximately 2850 RPM.
Do not close tester valve fully when performing this test. In this test, the hydraulic tester is
positioned before the manifold relief valve.
Pump damage can occur if the fluid flow is fully
restricted by fully closing the tester flow control valve.
A. Watch pressure gauge carefully while slowly
closing the flow control valve until 800 PSI (55.2 Bar)
is obtained on gauge.
B. Record tester pressure and flow readings under
load.
10.Set throttle to low speed and shut off engine.
11. The under load test flow reading (step 9.B) should
not drop more than 15% when compared to the no load
test flow reading (step 8.A). A difference in flow of more
than 15%, or the inability to achieve specified pressure
may indicate:
A. A restriction in the pump intake line
B. A Worn and/or slipping drive belt
C. The gear pump (P1) is worn and should be repaired or replaced
Groundsmaster 3500
Page 5 − 59
Hydraulic System
Hydraulic
System
CAUTION
12.Disconnect tester and reconnect hose to pump.
NOTE: If necessary, circuit relief valve pressure test
can be conducted with tester in the same location as for
this test (see Steering/Lift/Sidewinder Circuit − Relief
Valve Pressure Test in this chapter).
Hydraulic System
Page 5 − 60
Groundsmaster 3500
Hydraulic
System
This page is intentionally blank
Groundsmaster 3500
Page 5 − 61
Hydraulic System
Steering/Lift/Sidewinder Circuit Testing − Relief Valve Pressure Test
TO HYDRAULIC
MANIFOLD
(ST) PORT
TO LIFT VALVE
(IN) PORT
L
V1
T
1000 psi
STEERING
P
R
E
POWER
STEERING
VALVE
TEST
GAUGE
TO HYDRAULIC
MANIFOLD
(P1) PORT
GEAR PUMP
ENGINE
RPM
P1
P2
STRAINER
FROM
OIL FILTER
High Pressure
Low Pressure
Return or Suction
FROM HYDROSTAT
INTERNAL CASE DRAIN
Hydraulic System
Flow
Page 5 − 62
Groundsmaster 3500
Steering/Lift/Sidewinder Circuit Testing − Relief
Valve Pressure Test:
2
The relief valve for the steering, lift, and sidewinder circuits is integrated into the steering control valve. If both
steering and lift operations perform poorly, perform the
relief valve pressure test and gear pump (P2) flow test
(see Steering/Lift/Sidewinder Circuit − Gear Pump (P2)
Flow Test in this chapter).
RIGHT
FRONT
P2
P1
NOTE: If available, using a flow meter with pressure
gauge that has at least a 5 GPM (16 LPM) capacity instead of a pressure gauge (as described in this test) will
allow performing the relief valve test and the pump (P2)
flow test with the same test configuration (see Steering/
Lift/Sidewinder Circuit − Gear Pump (P2) Flow Test in
this chapter.
1
Figure 39
2. Read Precautions for Hydraulic Testing in this
chapter.
3. Disconnect hose connection on gear pump (P2)
leading to the steering control valve (Fig. 39).
4. Install T−connector with test gauge between the
gear pump and the disconnected hose.
1.
Gear pump assembly
2.
To steering control valve
9. System pressure should reach 940 to 1015 PSI (65
to 70 Bar) as the relief valve opens.
10.Return steering wheel to the center position and shut
off engine.
11. If specification is not met, repair or replace steering
control valve.
12.Disconnect T−connector with test gauge and reconnect hydraulic hose to gear pump.
5. Make sure steering wheel is positioned so the rear
wheel points directly ahead.
6. Start engine and move throttle to full speed (Diesel
engine = 3220 + 50 RPM, Gas engine = 3420 + 30
RPM).
7. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes.
8. Watch pressure gauge carefully while turning the
steering wheel completely in one direction and holding.
CAUTION
Do not allow pressure to exceed 1500 PSI. Hold
steering wheel at full lock only long enough to
get a system pressure reading. Holding the
steering wheel against the stop for an extended period may damage the steering control valve.
Groundsmaster 3500
Page 5 − 63
Hydraulic System
Hydraulic
System
1. Park machine on a level surface with the cutting units
lowered and PTO switch off. Make sure engine is off and
the parking brake is engaged.
Steering/Lift/Sidewinder Circuit Testing − Steering Control Valve and Steering Cylinder
Test
STEERING
CYLINDER
OPEN FITTING
PLUG
E
T
P
1000 psi
V1
L
R
POWER
STEERING
VALVE (LEFT TURN)
High Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System
Page 5 − 64
Groundsmaster 3500
Unit steering performance will be affected by incorrect
rear tire pressure, binding in the hydraulic steering cylinder, extra weight on the vehicle, and/or binding of the
steering fork assembly. Make sure that these conditions
are checked and functioning properly before proceeding
with any steering system hydraulic testing.
1. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes.
2. Drive machine slowly in a figure eight on a flat level
surface.
A. There should be no shaking or vibration in the
steering wheel or rear wheel.
B. Steering wheel movements should be followed
immediately by a corresponding rear wheel movement without the steering wheel continuing to turn.
3. Stop unit with the engine running. Turn steering
wheel with small quick movements in both directions.
Let go of the steering wheel after each movement.
A. The steering control valve should respond to
each steering wheel movement.
B. When steering wheel is released, steering control
should return to the neutral position with no additional turning.
Groundsmaster 3500
4. If either of these performance tests indicate a steering problem, determine if the steering cylinder is faulty
using the following procedure.
A. Park machine on a level surface with the cutting
units lowered, PTO switch off, and the parking brake
engaged.
B. With the engine running, turn the steering wheel
to the left (counterclockwise) until the steering cylinder rod is fully extended and turn the engine off.
C. Read Precautions for Hydraulic Testing in this
chapter.
D. Remove hydraulic hose from the fitting on the rod
end of the steering cylinder. Plug the end of the hose
removed.
E. With the engine off, continue turning the steering
wheel to the left (counterclockwise) with the steering
cylinder fully extended. Observe the open fitting on
the steering cylinder as the wheel is turned. If hydraulic fluid comes out of the fitting while turning the
steering wheel to the left, the steering cylinder has internal leakage and must be repaired or replaced.
F. Remove plug from the hydraulic hose and reconnect the hose.
5. If steering problem exists and steering cylinder
passed test, perform the Gear Pump (P2) Flow Test and
Circuit Relief Valve Pressure Test (see specific test procedures in this chapter) to make sure the steering control valve and cylinder are receiving adequate fluid flow
and pressure. Based on the results of these tests, repair
or replace steering control valve as necessary (see
Steering Control Valve and Steering Control Valve Service in this chapter).
Page 5 − 65
Hydraulic System
Hydraulic
System
Steering/Lift/Sidewinder Circuit Testing − Steering
Control Valve and Steering Cylinder Test:
Adjustments
Blade Braking Valve (BV) Adjustment (Traction Units Prior to No 314000001)
The blade braking valve (BV) on the hydraulic manifold
controls the stopping time for the cutting deck blades.
The braking valve is adjustable. If adjustment of the
braking valve is correct, the cutting deck blades should
come to a complete stop within 7 seconds after the PTO
switch is disengaged.
3
If blade stopping time is incorrect, adjustment of the
braking valve (BV) can be performed as follows:
1
2
NOTE: Do not remove the braking valve from the hydraulic manifold for adjustment.
1. Loosen lock nut on braking valve (Fig. 40).
2. To decrease blade stopping time, turn the adjustment shaft on the valve in a counterclockwise direction.
3. To increase blade stopping time, turn the adjustment
shaft on the valve in a clockwise direction.
Figure 40
1.
2.
4. Tighten lock nut to secure adjustment.
Hydraulic manifold
Blade braking valve
3.
Lock nut
5. Check blade stopping time and readjust braking
valve as needed.
Hydraulic System
Page 5 − 66
Groundsmaster 3500
Blade Braking Relief Valve (RV) Adjustment (Traction Units No 314000001 & Up)
The blade braking relief valve (RV) on the hydraulic
manifold works in conjunction with logic cartridge valve
(LC2) to control the stopping time for the cutting deck
blades. The relief valve is adjustable. If adjustment of
the relief valve is correct, the cutting deck blades should
come to a complete stop within 7 seconds after the PTO
switch is disengaged.
1
2
If blade stopping time is incorrect, adjustment of the relief valve (RV) can be performed as follows:
3
NOTE: Do not remove the relief valve from the hydraulic manifold for adjustment.
1. Remove cap on relief valve with an allen wrench.
2. To increase pressure setting, turn the adjustment
socket on the valve in a clockwise direction. A 1/8 turn
on the socket will make a measurable change in relief
pressure.
3. To decrease pressure setting, turn the adjustment
socket on the valve in a counterclockwise direction. A
1/8 turn on the socket will make a measurable change
in relief pressure.
Figure 41
1.
2.
Hydraulic manifold
Relief valve (RV)
3.
Logic valve (LC2)
5. Check blade stopping time and readjust relief valve
as needed.
1
2
Figure 42
1. Relief valve cap
Groundsmaster 3500
Page 5 − 67
2.
Adjustment socket
Hydraulic System
Hydraulic
System
4. Install and tighten cap on relief valve.
Counterbalance Logic Valve (LC1) Adjustment
FROM DECK MOTOR
CASE DRAINS
TO LEFT FRONT
DECK MOTOR
D1
TO HYDRAULIC
TANK
M1
FROM REAR
DECK MOTOR
M2
T2
RV
1500
psi
LC2
S
3200
psi
HYDRAULIC
MANIFOLD
BLOCK
G1
LC1
TO OIL
COOLER
G2
T1
TEST
GAUGE
LV
P1
CHG
ST
TO HYDROSTAT
CHARGE CIRCUIT
CR
CF
FROM LIFT VALVE
(OUT) PORT
FROM FRONT LIFT
CYLINDER
FROM REAR LIFT
CYLINDER
ENGINE
RPM
TO STEERING CONTROL
VALVE (IN) PORT
FROM STEERING CONTROL
VALVE (OUT) PORT
P1 P2
GEAR PUMP
FROM HYDROSTAT
INTERNAL CASE DRAIN
High Pressure
STRAINER
FROM OIL FILTER
NOTE: Hydraulic Schematic for Unit Serial No. 413000001 & Up shown
Hydraulic System
Page 5 − 68
Low Pressure
Return or Suction
Flow
Groundsmaster 3500
Counterbalance Logic Valve (LC1) Adjustment:
Unit Serial No. Prior to 314000001
The counterbalance system helps distribute the overall
unit weight across the drive wheels and cutting decks for
improved traction and reduced turf marking. The system
is functioning properly if the machine settles slightly
when the engine is started while the cutting decks are in
the fully lowered position.
4
3
1
1. Park machine on a level surface with the cutting units
lowered and PTO switch off. Make sure engine is off and
the parking brake is engaged.
2. Read Precautions for Hydraulic Testing in this
chapter.
3. Remove cap from test fitting at manifold port (G2)
(Fig. 43 and 44).
4. Install test gauge with hydraulic hose attached to
port (G2).
5. Start engine and move throttle to full speed (Diesel
engine = 3220 + 50 RPM, Gas engine = 3420 + 30
RPM).
2
Figure 43
1.
2.
Hydraulic manifold
Manifold port (G2)
3.
4.
Logic valve
Hex cap
Unit Serial No. 314000001 & Up
4
6. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes.
3
1
Hydraulic
System
The standard counterbalance pressure should be 250
PSI (17 Bar) with a range of 180 to 300 psi (12.4 to 20.7
Bar). A lower counterbalance pressure is more desirable for flat terrain, while a higher counterbalance pressure will improve performance in hilly terrain. Adjust the
Logic Valve (LC1) as necessary.
7. Adjust the Logic Valve (LC1) with the engine running
as follows:
A. Remove hex cap from logic valve (Fig. 43 and
44).
2
Figure 44
B. Loosen locknut.
1.
2.
C. To increase pressure setting, turn the adjustment
shaft on the valve in a clockwise direction. A 1/8 turn
on the shaft will make a measurable change in counterbalance pressure.
D. To decrease pressure setting, turn the adjustment shaft on the valve in a counterclockwise direction. A 1/8 turn on the shaft will make a measurable
change in counterbalance pressure.
Hydraulic manifold
Manifold port (G2)
3.
4.
Logic valve
Hex cap
8. Shut off engine.
9. Disconnect test gauge and install cap on test fitting
at manifold port (G2).
E. Tighten locknut. Check counterbalance pressure
and readjust as needed.
F. Replace hex cap to Logic valve (LC1).
Groundsmaster 3500
Page 5 − 69
Hydraulic System
Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Before Repair or Replacement of Components
After Repair or Replacement of Components
1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking
brake, lower cutting units or attachments, and stop engine. Remove key from the ignition switch.
1. Check fluid level in the hydraulic tank and add correct
hydraulic fluid if necessary. Drain and refill hydraulic
tank, and change fluid filter if component failure was severe or system is contaminated (see Flush Hydraulic
System in this chapter).
2. Clean machine before disconnecting, removing, or
disassembling any hydraulic components. Make sure
hydraulic components, hoses, connections, and fittings
are cleaned thoroughly. Always keep in mind the need
for cleanliness when working on hydraulic components.
CAUTION
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hydraulic fluid. Controls must be operated with the
ignition switch in RUN and the engine OFF. Make
sure all electrically operated control valves are
actuated. Return ignition switch to OFF when
pressure has been relieved. Remove key from
the ignition switch.
3. Put caps or plugs on any hydraulic lines, hydraulic fittings, and components left open or exposed to prevent
contamination.
2. Lubricate O–rings and seals with clean hydraulic fluid before installing hydraulic components.
3. Make sure caps or plugs are removed from the hydraulic tubes, hydraulic fittings, and components before
reconnecting.
4. Use proper tightening methods when installing hydraulic hoses and fittings (see Hydraulic Fitting Installation in this chapter).
5. After repairs, check control linkages or cables for
proper adjustment, binding, or broken parts.
6. After disconnecting or replacing any hydraulic components, operate machine functions slowly until air is
out of system (see Charge Hydraulic System in this
chapter).
7. Check for hydraulic fluid leaks. Shut off engine and
correct leaks if necessary. Check fluid level in hydraulic
reservoir and add correct hydraulic fluid if necessary.
4. Put labels on disconnected hydraulic lines and
hoses for proper installation after repairs are completed.
5. Note the position of hydraulic fittings (especially elbow fittings) on hydraulic components before removal.
Mark parts if necessary to make sure they will be aligned
properly when reinstalling hydraulic hoses and tubes.
Hydraulic System
Page 5 − 70
Groundsmaster 3500
Check Hydraulic Lines and Hoses
IMPORTANT: Check hydraulic lines and hoses daily
for leaks, kinked lines, loose mounting supports,
wear, loose fittings or deterioration. Make all necessary repairs before operating the machine.
WARNING
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands, to
search for leaks. Hydraulic fluid escaping under
pressure can have sufficient force to penetrate
the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar
with this type of injury. Gangrene may result from
such an injury.
Priming Hydraulic Pumps
Whenever the hydraulic system is flushed, the hydraulic
system is charged or hydraulic components are removed, it is important to properly prime the hydraulic
pumps. Hydraulic pump priming ensures that the gear
pump and piston (traction) pump have adequate oil during initial start−up and running. The pumps can be
primed by using a remote starter switch (see Special
Tools in this chapter) to crank engine which allows the
pumps to prime.
3
Hydraulic
System
2
1
Use the following procedure to prime the hydraulic
pumps:
1. Make sure that ignition switch is in the OFF position
and key is removed from switch.
2. Check hydraulic reservoir oil level and adjust if necessary.
NOTE: It may not be necessary to remove the wire from
the starter solenoid B+ terminal when connecting a remote starter switch.
3. Connect remote starter switch electrical leads to the
starter motor solenoid B+ terminal (Fig. 45) and the positive (+) terminal at the starter or battery.
Figure 45
1. Starter motor
2. Starter solenoid
3. B+ terminal
5. Disconnect remote starter switch leads from starter
motor solenoid terminal and positive post of the battery.
4. Engage remote starter switch and crank starter for
thirty (30) seconds to prime hydraulic pumps. Wait thirty
(30) seconds to allow the starter motor and starter
solenoid to cool. Repeat cranking procedure a second
time.
Groundsmaster 3500
Page 5 − 71
Hydraulic System
Flush Hydraulic System
IMPORTANT: Flush the hydraulic system any time
there is a severe component failure or if the system
is contaminated (fluid appears milky, black, or contains metal particles).
IMPORTANT: Flush hydraulic system when changIng from petroleum base hydraulic fluid to a biodegradable fluid such as Toro Biodegradable
Hydraulic Fluid. Operate machine under normal operating conditions for at least four (4) hours before
draining.
IMPORTANT: If a component failure occurred in the
traction circuit, refer to Traction Circuit (Closed
Loop) Component Failure in this chapter for information regarding the importance of removing contamination from the traction circuit.
1. Park machine on a level surface. Lower cutting units,
disengage PTO switch. stop engine, and engage parking brake. Remove key from the ignition switch.
IMPORTANT: Follow all local codes and regulations
when recycling or disposing hydraulic fluid and filters.
6. Reconnect all hydraulic hoses, lines, and components that were disconnected while draining system.
NOTE: Use only hydraulic fluids specified (see Traction
Unit Owner’s Manual). Other fluids may cause system
damage.
7. Fill hydraulic tank with new hydraulic fluid.
8. Prime hydraulic pumps (see Priming Hydraulic
Pumps in this chapter).
9. Start engine and let it idle at low speed for a minimum
of 2 minutes. Increase engine speed to high speed for
a minimum of 1 minute under no load.
10.Raise and lower cutting units several times. Turn
steering wheel fully left and right several times.
11. Move PTO switch to ON to engage cutting units and
let them run for several minutes. Move PTO switch to
OFF.
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved. See Relieving Hydraulic System Pressure in this chapter.
IMPORTANT: Make sure to clean around any hydraulic connections that will be disassembled.
2. Drain hydraulic tank.
3. Drain hydraulic system. Drain all hoses, tubes, and
components while the system is warm.
12.Shut off engine and check for hydraulic fluid leaks.
Check fluid level in hydraulic tank and add correct
amount of hydraulic fluid if necessary.
13.Operate the machine for 2 hours under normal operating conditions.
14.Check condition of hydraulic fluid. If the new fluid
shows any signs of contamination, repeat steps 1
through 13 again until fluid is clean. If changing to biodegradable fluid, repeat steps 1 through 13 again at least
once and until the fluid is clean.
15.Assume normal operation and follow recommended
maintenance intervals.
4. Change and replace hydraulic fluid filter.
5. Inspect and clean hydraulic fluid tank (see Hydraulic
Tank Inspection in this chapter).
Hydraulic System
Page 5 − 72
Groundsmaster 3500
Filtering Closed−Loop Traction Circuit
1. Park machine on a level surface, stop engine and remove key from ignition switch.
WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 − Safety.
2. Raise and support machine so all wheels are off the
ground.
NOTE: If a wheel motor was replaced, install high flow
filter to the inlet (when traveling forward) of new wheel
motor instead of to the inlet (when traveling forward) of
the traction pump. This will prevent system contamination from entering and damaging the new motor.
3. Thoroughly clean junction of hydraulic hose and
lower fitting on rear wheel motor (Fig. 46). Disconnect
hose from lower fitting on wheel motor.
4. Connect Toro high flow hydraulic filter in series between wheel motor fitting and disconnected hose. Use
hydraulic hose kit (see Special Tools in this chapter) to
connect filter to machine. Make sure that fitting and hose
connections are properly tightened.
7. With engine running at low idle speed, slowly depress the forward traction pedal to the full forward position to allow flow through the traction circuit and high
flow filter. Keep traction circuit engaged for five (5) minutes while gradually increasing both forward pressure
on traction pedal and engine speed. Monitor filter indicator to make sure that green color is showing during operation.
8. With engine running at high idle speed and traction
pedal moved to the forward direction, periodically apply
brakes to increase pressure in traction circuit. While
monitoring filter indicator, continue this process for an
additional five (5) minutes.
IMPORTANT: If using a filter that is not the bi−directional Toro high flow filter, do not press the traction
pedal in the reverse direction. If flow is reversed
when using a filter that is not bi−directional, debris
from the filter will re−enter the traction circuit.
9. With engine running at high idle speed, alternately
move traction pedal from forward to reverse. While monitoring filter indicator, continue this process for an additional five (5) minutes.
10.Shut engine off and remove key from ignition switch.
11. Remove high flow hydraulic filter and hydraulic hose
kit from machine. Reconnect hydraulic hose to rear
wheel motor fitting. Make sure to properly tighten hose
(see Hydraulic Hose and Tube Installation in the General Information section of this chapter).
12.Lower machine to ground.
13.Check oil level in hydraulic reservoir and add correct
oil if necessary.
IMPORTANT: Use only hydraulic fluids specified in
Operator’s Manual. Other fluids could cause system
damage.
1
5. After installing high flow filter to machine, check and
fill hydraulic reservoir with new hydraulic oil as required.
6. Sit in the operator’s seat and start engine. Run engine at low idle speed and check for any hydraulic leakage from filter and hose connections. Correct any leaks
before proceeding.
IMPORTANT: While engaging the traction circuit,
monitor the high flow hydraulic filter indicator. If the
indicator should show red, either reduce traction
pedal setting or reduce engine speed to decrease
1.
hydraulic flow through the filter.
Groundsmaster 3500
Page 5 − 73
RIGHT
2
FRONT
Figure 46
Rear wheel motor
2. Lower fitting
Hydraulic System
Hydraulic
System
Filtering of a closed−loop hydraulic system after a major
component failure (e.g. traction (piston) pump or wheel
motor) is a requirement to prevent debris from transmitting throughout the system. If a closed−loop hydraulic
system filtering tool is not used (to ensure system cleanliness) repeat failures and subsequent damage to other
hydraulic components in the system will occur. To effectively remove contamination from closed−loop traction
circuit, use of the Toro high flow hydraulic filter and hydraulic hose kit are recommended (see Special Tools in
this chapter).
Charge Hydraulic System
NOTE: When initially starting the hydraulic system with
new or rebuilt components such as motors, pumps, or
lift cylinders, it is important that the hydraulic system be
charged properly. Air must be purged from the system
and its components to reduce the chance of damage.
IMPORTANT: Change hydraulic fluid filter whenever hydraulic components are repaired or replaced.
8. After the hydraulic system starts to show signs of fill,
actuate lift control switch until the lift cylinders move in
and out several times. If the cylinders do not move after
15 seconds or the pump emits abnormal sounds, shut
the engine off immediately and determine cause or
problem. Inspect for the following:
A. Loose filter or suction lines.
1. Park machine on a level surface. Lower cutting units,
disengage PTO switch. stop engine, and engage parking brake. Remove key from the ignition switch.
B. Incorrect hydraulic hose routing.
2. Make sure all hydraulic connections, lines, and components are secured tightly.
D. Faulty charge relief valve in traction pump.
3. If component failure was severe or the system is contaminated, flush and refill hydraulic system and tank
(see Flush Hydraulic System in this chapter).
4. Make sure hydraulic tank is full. Add correct hydraulic fluid if necessary.
5. Prime hydraulic pumps (see Priming Hydraulic
Pumps in this chapter).
E. Faulty gear pump.
9. Operate the traction pedal in the forward and reverse
directions. The wheels should rotate in the proper direction. If the wheels rotate in the wrong direction, stop engine, remove lines from rear of hydrostat pump, and
reverse the connections.
10.Make sure that traction pedal returns to the neutral
position when released from the forward or reverse direction.
11. Check operation of the traction interlock switches
(see Check Operation of Interlock Switches in Chapter
− 6, Electrical Systems in this manual).
WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 − Safety.
6. Raise all 3 wheels off the floor and safely support, the
traction unit.
IMPORTANT: During initial operation, check hydraulic reservoir oil level frequently and add oil as
necessary.
7. Make sure traction pedal is in neutral. Sit in the operator’s seat and start engine and let it idle at low speed.
The hydraulic pumps should pick up hydraulic fluid and
fill the hydraulic system. If there is no indication of fill in
30 seconds, stop the engine and determine the cause.
Hydraulic System
C. Blocked suction line.
12.Stop the engine, remove blocks from wheels and
lower machine.
13.If the traction (traction) pump or a wheel motor was
replaced or rebuilt, run the traction unit so all wheels turn
slowly for 10 minutes.
14.Operate traction unit by gradually increasing its work
load to full over a 10 minute period.
15.Stop the machine. Check hydraulic tank and fill if
necessary. Check hydraulic components for leaks and
tighten any loose connections.
Page 5 − 74
Groundsmaster 3500
Hydraulic
System
This page is intentionally blank.
Groundsmaster 3500
Page 5 − 75
Hydraulic System
Hydraulic Tank and Hydraulic Fluid Filter
14
18
16
6
80 to 87 ft−lbs
(108.4 to 117.9 N−m)
30
9
12
15
27
26
28
25
24
4
23
8
11
19
22
29
7
17
8
10
13
3
20
21
22
1
5
2
Anti−seize
lubricant
30 to 60 in−lb
(3.4 to 6.8 N−m)
Figure 47
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Grommet
Flange head screw
Barb fitting
Check fitting
Flat washer
Hydraulic tank
O–ring
Hose clamp
Barb fitting (straight)
Flange head screw
Hydraulic System
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Elbow fitting
O–ring
Fluid filter element
Shoulder screw
Suction strainer
Dipstick
Filter head
Hydraulic tank cap
Hose clamp
Hydraulic hose
Page 5 − 76
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Tee fitting
Hydraulic hose
O–ring
O–ring
O–ring
O–ring
Hydraulic hose (suction)
Hydraulic tube (from fluid cooler)
Hydraulic hose (from manifold)
O–ring
Groundsmaster 3500
Hydraulic Tank Removal
Hydraulic Tank Installation
1. Drain hydraulic fluid from Hydraulic tank.
2. Remove hydraulic tank (Fig. 47). Discard and replace any O–rings that are removed.
1. Apply anti−seize lubricant or equivalent to the four
(4) flange head screws that secure the hydraulic tank.
Tighten the tank mounting screws from 30 to 60 in−lb
(3.4 to 6.8 N−m). Install tank (Fig 47).
Hydraulic Tank Inspection (Fig. 47)
2. Lubricate and install new O−ring on suction strainer.
1. Clean hydraulic tank and suction strainer with solvent.
3. Thread suction strainer into hydraulic tank. Torque
strainer into tank port from 80 to 87 ft−lb (109 to 117
N−m).
4. Fill hydraulic tank with new hydraulic fluid.
Hydraulic
System
2. Inspect hydraulic tank for leaks, cracks, or other
damage.
Groundsmaster 3500
Page 5 − 77
Hydraulic System
Hydraulic Fluid Cooler
CAUTION
The radiator and hydraulic fluid cooler may be
hot. To avoid possible burns, allow the engine
and cooling systems to cool before working on
the hydraulic fluid cooler.
2
Removal (Diesel Engine)
1
Traction Unit Serial No. Prior to 314000001, remove hydraulic fluid cooler (Fig. 48 and 49).
Traction Unit Serial No. 314000001 & Up, remove radiator/hydraulic fluid cooler assembly (see Radiator/Hydraulic Fluid Cooler Removal in Chapter 3 − Kubota
Diesel Engine).
Figure 48
1.
Fluid cooler
Removal (Gasoline Engine)
2.
Latch
RIGHT
Remove radiator/hydraulic fluid cooler assembly (see
Radiator/Hydraulic Fluid Cooler Removal in Chapter 4
− Kubota Gasoline Engine).
1
FRONT
Inspection
2
CAUTION
4
Use eye protection such as goggles when using
compressed air.
1. Back flush fluid cooler with cleaning solvent. After
cooler is clean, make sure all solvent is drained from the
cooler.
2. Dry inside of fluid cooler using compressed air in the
opposite direction of the fluid flow.
3. Plug both ends of hydraulic fluid cooler. Clean exterior of cooler. Make sure fluid cooler fins are clear of dirt
and debris.
4. The fluid cooler should be free of corrosion, cracked
tubes, or excessive pitting of tubes.
Installation (Diesel Engine)
1. Traction Unit Serial No. Prior to 314000001, install
hydraulic fluid cooler (Fig. 48 and 49).
6
5
3
Traction Units Prior to
Serial No 314000001
Figure 49
1.
2.
3.
Fluid cooler
Barb fitting
Hydraulic hose
4.
5.
6.
Hose clamp
Flow to fluid filter
Flow from manifold
Installation (Gasoline Engine)
1. Install radiator/hydraulic fluid cooler assembly (see
Radiator/Hydraulic Fluid Cooler Installation in Chapter
4 − Kubota Gasoline Engine).
2. Make sure hydraulic tank is full. Add hydraulic fluid
if necessary.
1. Install radiator/hydraulic fluid cooler assembly (see
Radiator/Hydraulic Fluid Cooler Installation in Chapter
3 − Kubota Diesel Engine).
2. Make sure hydraulic tank is full. Add hydraulic fluid
if necessary.
Hydraulic System
Page 5 − 78
Groundsmaster 3500
Hydraulic
System
This page is intentionally blank.
Groundsmaster 3500
Page 5 − 79
Hydraulic System
Piston Pump/Hydrostat Assembly
10
26
27
25
28
58
25
45
50
7
44
49
48
43
47
42
8
5
29
12
54
1
24
45
53
40
32
9
13
77 to 93 ft−lb
(105 to 127 N−m)
27
3
33
30
40
38
55
6
56
34
40
51
4
46
1018
37
41
31
30
21 20
36
27 to 31 ft−lb
(37 to 42 N−m)
11
41
2
RIGHT
35
57
22
23
90 to 120 in−lb
(10.2 to 13.6 N−m)
52
17 16
39
FRONT
19
15
(tighten in 3 equal steps)
14
Blue Loctite
Figure 50
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Piston pump
Straight hydraulic fitting
Cap screw
Lock nut
90o hydraulic fitting
90o hydraulic fitting
Tee fitting
90o hydraulic fitting
90o hydraulic fitting
Washer
Hydraulic hose
Suction hose
Flange nut
Idler pivot pin
Grease fitting
Flange nut
Retaining ring
Cap screw
Thrust washer
Idler pulley
Hydraulic System
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Spacer
Torsion spring
Idler arm
Hose clamp
Flange nut
Cap screw
Flange head screw
Pump support
Spacer
Cap screw
Flat washer
Spacer
Pump mount plate
Pump mount spacer
Pulley
Cap screw
Lock washer
Taper lock bushing
V−belt
Page 5 − 80
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
O–ring
O–ring
O–ring
O–ring
O–ring
O–ring
Flat washer
O–ring
Hydraulic hose
Hydraulic hose
Hydraulic hose
Hydraulic hose
Bushing
Gear pump
O–ring
Flat washer
Socket head screw
Idler arm spacer
Hydraulic hose
Groundsmaster 3500
Drive Belt Removal (Fig. 50)
1. Park machine on a level surface. Lower cutting units,
stop engine and engage parking brake. Remove key
from the ignition switch.
2. Raise and support hood.
CAUTION
CAUTION
Use caution when installing torsion spring end
onto the pump mount plate. Applying tension to
the spring may cause personal injury during installation.
4. Apply pump drive belt tension with torsion spring on
idler arm (Fig. 51).
The torsion spring that tensions the idler assembly is under tension and may cause personal
injury during removal. Use caution when removing spring end from the pump mount plate.
3. Remove pump drive belt tension from torsion spring
on idler arm (Fig. 51).
A. Insert nut driver or small piece of pipe onto the
end of the torsion spring that is secured on the pump
mount plate tab.
A. Insert nut driver or small piece of pipe onto the
end of the torsion spring.
B. Push down on the spring end and then hook the
spring under the tab on the pump mount plate.
5. Lubricate grease fitting on end of idler pivot shaft.
6. Lower and secure hood.
3
B. Push down and forward on the spring end to unhook the spring from the tab on the pump mount
plate.
5
4
4. Rotate idler pulley away from pump drive belt and remove drive belt from pulleys. Make sure that drive belt
is in good condition if it is to be re−installed. Replace
drive belt if worn or damaged.
Hydraulic
System
2
5. Remove drive belt idler components as needed.
1
Drive Belt Installation (Fig. 50)
1. Install all removed drive belt idler components. Make
sure that idler pulley and idler arm rotate freely after assembly.
2. Install drive belt onto pulleys. Position idler pulley toward the pump drive belt.
3. Using a straight edge across the lower face of the
pump pulley, verify pump drive belt alignment across engine and pump pulleys. If pulleys are not in alignment,
adjust location of pump pulley on pump shaft so alignment is correct (see Piston Pump/Hydrostat in this chapter).
Groundsmaster 3500
Figure 51
1. Pump drive belt
2. Idler pulley
3. Torsion spring end
Page 5 − 81
4. Spring end
5. Pump mount plate tab
Hydraulic System
Neutral Arm Assembly
1
4
23
24 7
22
18
21
19 20
6
5
7
9
12
8
9
10
14
12
3
2
11
32
33
29
16
17
15
16
31
13
26
25
27
30
28
Figure 52
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Pump assembly
Hose
Extension spring
Pump mount plate
Neutral bracket
Flange nut
Flange head screw
Neutral arm
Flange bushing
Thrust washer
90o grease fitting
Hydraulic System
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Lock nut
Spacer
Traction stud
Traction control cable
Flat washer
Ball joint
Lock nut
Cap screw
Flat washer
Hub assembly
Flange nut
Page 5 − 82
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Flange head screw
Cable support bracket
Ball bearing
Flat washer
Lock nut
Cap screw
Pump lever
Cap screw
Flat washer
Cap screw
Mount
Groundsmaster 3500
Neutral Arm Removal (Fig. 52)
Neutral Arm Installation (Fig. 52)
1. Park machine on a level surface. Lower cutting units,
stop engine and engage parking brake. Remove key
from the ignition switch.
1. Install key into trunnion slot. Position neutral bracket
to the mount plate and the pump lever and hub assembly
to the pump trunnion.
2. Raise and support hood.
2. Secure pump lever and hub assembly to the piston
pump trunnion with flat washer and cap screw.
3. Secure neutral bracket to the pump mount plate with
flange head screw and flange nut. Secure neutral bracket to the piston pump with both flange head screws.
The extension spring is under tension and may
cause personal injury during removal. Use caution when removing spring from the pump lever.
4. Position three (3) flat washers to traction control
cable end. Secure traction control cable to the pump lever with cap screw and lock nut.
3. Remove extension spring from the cable support
bracket and neutral arm.
4. Disconnect traction control cable from the pump
lever. Locate and retrieve three (3) flat washers and note
their position for assembly purposes.
5. Remove both flange head screws securing the neutral bracket to the piston pump. Remove flange nut and
flange head screw securing the neutral bracket to the
pump mount plate.
6. Remove cap screw and flat washer that secure the
pump lever and hub assembly to the piston pump trunnion.
CAUTION
The extension spring is under tension and may
cause personal injury during installation. Use
caution when installing the spring to the pump
lever.
5. Install extension spring to the cable support bracket
and neutral arm.
6. Adjust traction drive for neutral.
Hydraulic
System
CAUTION
7. Lower and secure hood.
7. Separate pump lever and hub assembly from pump
trunnion and neutral bracket from mount plate. Locate
and retrieve key from trunnion.
Groundsmaster 3500
Page 5 − 83
Hydraulic System
Piston Pump/Hydrostat
1
RIGHT
FRONT
2
3
4
5
6
10
9
8
7
Figure 53
1.
2.
3.
4.
Engine mount bracket
Flange nut
Flange screw
Pump mount plate
5. Hardened washer
6. 10 mm cap screw (4)
7. 8 mm cap screw (1)
Piston Pump/Hydrostat Removal (Fig. 50 and 53)
1. Park machine on a level surface. Lower cutting units,
stop engine and engage parking brake. Remove key
from the ignition switch.
2. Raise and support hood.
3. Remove pump drive belt (see Drive Belt Removal in
this chapter).
4. Remove neutral arm assembly (see Neutral Arm Removal in this chapter).
5. Thoroughly clean hydraulic hose ends and fittings on
piston pump/hydrostat and gear pumps to prevent hydraulic system contamination.
WARNING
Before disconnecting or performing any work on
the hydraulic system, all pressure in the system
must be relieved. See Relieving Hydraulic System Pressure in the General Information section
of this chapter.
Hydraulic System
8. Hardened washer
9. Long spacer (4)
10. Short spacer (1)
6. Disconnect the suction hose from the barbed fitting
on the bottom of the gear pump and drain hydraulic tank
into a suitable container.
7. Label all hydraulic hoses and fittings for assembly
purposes.
Page 5 − 84
Groundsmaster 3500
8. Disconnect all hydraulic hoses connected to the hydraulic fittings on the piston pump/hydrostat and gear
pump. Allow hoses to drain into a suitable container.
Plug hose and fitting openings to prevent contamination.
Remove plugs before installing
gear pump to piston pump
1
CAUTION
Support pump assembly during removal to prevent them from falling and causing personal injury or component damage.
2
9. Support hydraulic pump assembly to prevent it from
shifting.
10.Remove both flange head screws and flange nuts
that secure pump support to engine mount.
12.Carefully remove pump mount plate with pumps,
pulley, pump support and idler assembly from the machine.
NOTE: A case drain exists in the piston pump/hydrostat
and a suction port is near the input shaft of the gear
pump (Fig. 54). When the gear pump is removed from
the piston pump/hydrostat, plug both case drain holes to
prevent draining the pumps.
13.Remove both cap screws and flat washers securing
gear pump to the piston pump. Separate gear pump
from the piston pump. Locate and retrieve O−ring. Plug
openings of gear pump to prevent contamination.
14.Remove pump pulley from the taper lock bushing on
the piston pump shaft:
A. Remove three (3) cap screws and lock washers
securing pulley to the taper lock bushing.
IMPORTANT: Excessive or unequal pressure on
the cap screws can break the bushing flange.
B. Insert cap screws into threaded removal holes of
the pulley. Tighten screws progressively and evenly
until the pulley is loose on the bushing. Remove
pulley from the bushing.
15.Loosen set screw that secures taper lock bushing to
piston pump shaft. Remove bushing from the pump
shaft. Locate and retrieve key from pump shaft.
2. Gear pump suction port
16.Remove both cap screws and washers that secure
piston pump to pump support. Locate and retrieve
spacers.
17.Remove lock nuts, flat washers and cap screws that
secure the piston pump to the pump mount plate. Remove pump from plate.
18.If hydraulic fittings are to be removed from piston
pump, mark fitting orientation to allow correct assembly.
Remove hydraulic fittings and O−rings from the piston
pump as needed. Discard removed O−rings.
Piston Pump Installation (Fig. 50 and 53)
1. Position and secure piston pump to the pump mount
plate with cap screws, flat washers and lock nuts.
2. Lubricate and place new O−rings onto all removed
pump fittings. Install fittings into pump openings using
marks made during the removal process to properly
orientate fittings. Tighten fittings (see Hydraulic Fitting
Installation in this chapter).
IMPORTANT: A case drain exists in the piston
pump/hydrostat and a suction port is near the input
shaft of the gear pump (Fig. 54). Before the gear
pump is installed to the piston pump, make sure that
plugs placed in either of these ports are removed.
Failure to remove plugs will cause excessive pressure in the piston pump and damage seals. Also, before installing gear pump to piston pump, fill piston
pump housing with clean hydraulic oil through case
drain hole.
3. Install and secure gear pump to the piston pump (see
Gear Pump in this chapter).
Groundsmaster 3500
Page 5 − 85
Hydraulic System
Hydraulic
System
11. Remove fasteners and spacers securing the pump
mount plate to the engine (Fig. 53). Note location of cap
screws, washers and spacers for assembly purposes.
Figure 54
1. Piston pump/hydrostat
case drain
4. Place key into piston pump shaft slot. Slide taper lock
bushing onto the piston pump shaft with bushing flange
toward pump housing.
IMPORTANT: When tightening taper lock bushing
cap screws, tighten in three (3) equal steps and in a
circular pattern.
5. Make sure that tapered surfaces of pump pulley and
taper lock bushing are thoroughly clean (no oil, grease,
dirt, rust, etc.).
11. Secure taper lock bushing and pump pulley by tightening three (3) cap screws to a torque from 90 to 120
in−lb (10.2 to 13.6 N−m) in three (3) equal steps and in
a circular pattern.
6. Position pump pulley to taper lock bushing and align
non−threaded holes of pulley with threaded holes of
bushing. Loosely install three (3) cap screws with lock
washers to bushing and pulley.
CAUTION
Support pump assembly during installation to
prevent them from falling and causing personal
injury or component damage.
12.Check that pump drive belt alignment is still correct.
If needed, loosen and re−adjust pulley and taper lock
bushing location on pump shaft to allow for correct belt
alignment.
13.Remove caps and plugs from all fittings and hydraulic hoses. Using labels placed during pump removal,
properly connect hydraulic lines to pump assembly (see
Hydraulic Hose and Tube Installation in this chapter).
14.Install neutral arm assembly to the piston pump (see
Neutral Arm Installation in this chapter).
7. Position pump assembly to the machine. Install fasteners and spacers securing the pump mount plate to
the engine and pump support (Fig. 53). Tighten fasteners securely.
15.Fill hydraulic tank with new hydraulic fluid.
8. Position and secure pump support to pump mount
plate, piston pump and engine mount with removed fasteners and spacers.
17.Adjust traction drive for neutral (see Traction Unit
Operator’s Manual).
16.Properly charge hydraulic system (see Charge Hydraulic System in this chapter)
18.Lower and secure hood.
9. Install pump drive belt (see Drive Belt Installation in
this chapter).
10.Using a straight edge across the lower face of the
pump pulley, verify pump drive belt alignment across engine and pump pulleys. Slide pulley and taper lock bushing on pump shaft so that drive belt and straight edge are
aligned indicating correct position of pump pulley. Secure taper lock bushing in position with set screw.
Hydraulic System
Page 5 − 86
Groundsmaster 3500
Hydraulic
System
This page is intentionally blank.
Groundsmaster 3500
Page 5 − 87
Hydraulic System
Piston Pump/Hydrostat Service
21
22
41
40
39
19
38
17
37
27
16
15
36
14
17
20
15
4
26
15
25
42
24
7
43
44
45
8
46
10
6 18
13
11
12
35
9
6
28
3
2
1
33
32
29
30
31
30
29
46
8
5
26
4
23
18
34
Figure 55
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Key
Drive shaft
Bearing
Cap screw (3 used per plate)
Cover plate
O–ring
Shim kit
Bearing cone
Key
Swashplate
Rotating kit
Gasket
Valve plate
Bearing
Dowel pin
Back plate
Hydraulic System
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
O–ring
Plug
Relief valve asm.
Check valve asm.
Bypass valve asm.
Cap screw
O–ring
Shaft seal
Cover plate
Washer (3 used per plate)
Coupler
Housing
Retaining ring
Thrust washer
Thrust bearing
Page 5 − 88
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
Washer
Shaft seal
Retaining ring
Cam plate insert
Retaining ring
Washer
Charge relief spring
Charge relief poppet
Charge relief housing
O–ring
Cartridge
O–ring
Bleed−off spring
Bleed−off valve poppet
Bearing cup
Groundsmaster 3500
IMPORTANT: If a piston pump failure occurred, refer to Traction Circuit (Closed Loop) Component
Failure in this chapter for information regarding the
importance of removing contamination from the
traction circuit.
CHARGE RELIEF
VALVE
4
NOTE: The traction circuit charge relief valve and the
bleed off valve for traction circuit cooling are attached to
the piston pump back plate assembly (Fig. 56). The
back plate assembly must be removed from the piston
pump/hydrostat to service either the relief valve or the
bleed off valve.
5
7
6
8
1
9
2
IMPORTANT: The shim kit is used to replace the
original crush ring (not shown) in the cover plate. If
the swash plate, cover plate or housing is replaced
during servicing, the old crush ring must be replaced. See Piston Pump Crush Ring Replacement
in this chapter in conjunction with the Eaton service
manual at the end of this chapter for additional information.
BLEED OFF
VALVE
10
11
12
3
13
Groundsmaster 3500
Figure 56
1.
2.
3.
4.
5.
6.
7.
Page 5 − 89
Back plate assembly
Charge relief valve
Bleed off valve
O−ring
Housing
Poppet
Spring
8.
9.
10.
11.
12.
13.
Washer
Retaining ring
Bleed off valve
Spring
O−ring
Cartridge
Hydraulic
System
NOTE: For repair of the piston pump, see the Eaton
Medium Duty Piston Pump Repair Information Model
70160 Variable Displacement Piston Pump at the end of
this chapter.
Hydraulic System
Piston Pump/Hydrostat Crush Ring Replacement
4
5
29 ft−lb
(39 N−m)
8
7
2
3
v
9
10
6
1
Figure 57
1.
2.
3.
4.
Crush ring
Shims
Cover plate
Housing
5. Camplate (control shaft)
6. Bearing cone
7. Bearing cup
Piston Pump Crush Ring Replacement (Fig. 57)
5. Install washers and cap screws to the cover plate
and housing. Torque cap screws to 29 ft−lbs (39 N−m).
NOTE: The shims replace the crush ring in the cover
plate. If the camplate, cover plate or housing is replaced
during servicing of the pump, the old crush ring can not
be used to make sure of proper preload.
1. Remove crush ring from the cover plate. Measure
thickness of crush ring.
2. Stack shims to the thickness of the crush ring.
3. Insert shims into the cover plate in the same location
that the crush ring was removed from.
4. Assemble housing sub assembly consisting of the
housing, camplate, bearing cone, bearing cup and cover plate (see Eaton, Medium Duty Piston Pump, Repair
Information, Model 70160 Variable Displacement Piston
Pump at the end of this chapter).
Hydraulic System
8. O−ring
9. Washer (3)
10. Cap screw (3)
6. Check torque required to rotate control shaft. Torque
should be from 15 to 25 in−lbs (1.7 to 2.8 N−m).
A. If torque is too low, add additional shims and repeat steps 3 through 6 until the specified torque is
achieved.
B. If torque is too high, remove shims and repeat
steps 3 through 6 until the specified torque is
achieved.
7. Complete assembly of the pump (see Eaton, Medium Duty Piston Pump, Repair Information, Model
70160 Variable Displacement Piston Pump at the end of
this chapter).
Page 5 − 90
Groundsmaster 3500
Hydraulic
System
This page is intentionally blank.
Groundsmaster 3500
Page 5 − 91
Hydraulic System
Gear Pump
9
5
10
4
12
11
13
14
2
1
RIGHT
15
FRONT
17
16
8
7
3
6
Figure 58
1.
2.
3.
4.
5.
6.
Piston pump
Gear pump
Hydraulic hose (tank suction)
Hydraulic hose (hydraulic manifold)
Hydraulic hose (steering valve)
Hose clamp
7.
8.
9.
10.
11.
12.
Hydraulic barb fitting
O–ring
O–ring
90o hydraulic fitting
O–ring
O–ring
13.
14.
15.
16.
17.
90o hydraulic fitting
O–ring
Cap screw
Flat washer
O–ring
5. Label hydraulic hoses and fittings on gear pump for
assembly purposes.
Removal (Fig. 58)
1. Park machine on a level surface. Lower cutting units,
stop engine and engage parking brake. Remove key
from the ignition switch. Raise and support hood.
2. Remove muffler from the engine to gain access to
the gear pump (see Exhaust System in Chapter 3 − Kubota Diesel Engine in this manual).
WARNING
6. Disconnect hydraulic hoses connected to the hydraulic fittings on the gear pump. Allow hoses to drain
into a suitable container. Plug hose openings to prevent
contamination.
NOTE: A case drain exists in the piston pump/hydrostat
and a suction port is near the input shaft of the gear
pump (Fig. 59). When the gear pump is removed from
the piston pump, plug piston pump case drain hole to
prevent draining the piston pump.
Before disconnecting or performing any work on
the hydraulic system, all pressure in the system
must be relieved. See Relieving Hydraulic System Pressure in this chapter.
7. Remove both cap screws and flat washers securing
gear pump to the piston pump. Separate gear pump
from the piston pump. Locate and retrieve O−ring. Plug
openings of gear pump to prevent contamination.
3. Thoroughly clean hydraulic hose ends and fittings on
gear pump to prevent hydraulic system contamination.
8. If hydraulic fittings are to be removed from gear
pump, mark fitting orientation to allow correct assembly.
Remove hydraulic fittings and O−rings from the gear
pump as needed. Discard removed O−rings.
4. Drain hydraulic oil from hydraulic tank by disconnecting the suction hose from the barbed fitting in the bottom
of the gear pump. Drain tank into a suitable container.
Hydraulic System
Page 5 − 92
Groundsmaster 3500
Installation (Fig. 58)
Remove plugs before installing
gear pump to piston pump
1. If fittings were removed from gear pump, lubricate
and place new O−rings onto fittings. Install fittings into
pump openings using marks made during the removal
process to properly orientate fittings. Tighten fittings
(see Hydraulic Fitting Installation in the General Information section of this chapter).
1
2. Make sure mounting and O−ring sealing surfaces on
the gear pump and piston pump are clean.
2
3. Apply clean hydraulic oil to gear pump flange O−ring.
Place O−ring on the gear pump.
4. Remove plugs that were placed in piston pump case
drain and gear pump suction port. Fill piston pump housing with clean hydraulic oil through case drain hole.
Figure 59
1. Piston pump/hydrostat
case drain
2. Gear pump suction port
6. Remove caps and plugs from gear pump fittings and
hoses. Using labels placed during gear pump removal,
properly connect hydraulic lines to pump (see Hydraulic
Hose and Tube Installation in this chapter).
7. Fill hydraulic tank with new hydraulic fluid.
IMPORTANT: The gear pump suction fitting must be
on the same side as the trunnion of the piston pump.
8. Install muffler to the engine (see Exhaust System in
Chapter 3 − Kubota Diesel Engine in this manual).
5. Align gear teeth and slide gear pump input shaft into
piston pump coupler. Secure gear pump to piston pump
with two (2) cap screws and flat washers.
9. Properly fill hydraulic system (see Charge Hydraulic
System in this chapter).
Groundsmaster 3500
10.Lower and secure hood.
Page 5 − 93
Hydraulic System
Hydraulic
System
IMPORTANT: A case drain exists in the piston
pump/hydrostat and a suction port is near the input
shaft of the gear pump (Fig. 59). Before the gear
pump is installed to the piston pump, make sure that
plugs placed in either of these ports are removed.
Failure to remove plugs will cause excessive pressure in the piston pump and damage seals. Also, before installing gear pump to piston pump, fill piston
pump housing with clean hydraulic oil through case
drain hole.
Gear Pump Service
19
14
18
17
11
10
12
2
8
3
6
1
3
2
20
16
21
13
15
13
14
33 ft−lb
(45 N−m)
9
8
7
5
4
Figure 60
1.
2.
3.
4.
5.
6.
7.
Front cover
Pressure seal
Back−up gasket
Front thrust plate
Idler gear
Drive shaft
Rear thrust plate
8.
9.
10.
11.
12.
13.
14.
Dowel pin
Seal
Body
Seal
Splined connecting shaft
Pressure seal
Back−up gasket
15.
16.
17.
18.
19.
20.
21.
Front thrust plate
Idler gear
Drive gear
Rear thrust plate
Rear cover
Washer (4 used)
Cap screw (4 used)
Disassembly (Fig. 60)
NOTE: The gear pump must be replaced as a complete
assembly. Individual gears, housings and thrust plates
are not available separately. Disassemble gear pump
for cleaning, inspection and seal replacement only.
DIAGONAL LINE
1. Plug pump ports and thoroughly clean exterior of
pump with cleaning solvent. Make sure work area is
clean.
2. Use a marker to make a diagonal line across the
gear pump for assembly purposes (Fig. 61).
Figure 61
Hydraulic System
Page 5 − 94
Groundsmaster 3500
IMPORTANT: Use caution when clamping gear
pump in a vise to avoid distorting any pump components.
3. Secure the front cover of the pump in a vise with the
drive shaft pointing down.
8. Clean all pump parts. Check all components for
burrs, scoring, nicks and other damage.
9. Replace the entire pump assembly if parts are excessively worn or scored.
Assembly (Fig. 60)
4. Loosen the four (4) cap screws that secure pump assembly.
1. Apply clean hydraulic fluid to all parts before assembling.
5. Remove pump from vise and remove fasteners.
6. Support the pump assembly and gently tap the pump
case with a soft face hammer to loosen the pump sections. Be careful to not drop parts or disengage gear
mesh.
IMPORTANT: Mark the relative positions of the gear
teeth and the thrust plates so they can be reassembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear
finish.
2. Assemble pump sections starting at front cover end.
Apply grease or petroleum jelly to new section seals to
hold them in position during gear pump assembly.
3. After pump has been assembled, tighten cap screws
by hand. Rotate the drive shaft to check for binding. Protect the shaft if using a pliers to rotate shaft.
4. Tighten the four (4) cap screws evenly in a crossing
pattern to a torque of 33 ft−lb (45 N−m).
Hydraulic
System
7. Remove the thrust plates and seals from each pump
section. Before removing each gear set, apply marking
dye to mating teeth to retain ”timing”. Pump efficiency
may be affected if the teeth are not installed in the same
position during assembly. Keep the parts for each pump
section together; do not mix parts between sections.
NOTE: Pressure seals and back−up gaskets fit in
grooves machined into thrust plates. Body seals fit in
grooves machined in body faces.
Groundsmaster 3500
Page 5 − 95
Hydraulic System
Front Wheel Motors
5
7
3
8
9
10
6
4
RIGHT
8
FRONT
9
10
2
1
1.
2.
3.
4.
Lock nut
Spacer
Socket head screw
Hydraulic wheel motor
Hydraulic System
Figure 62
5. Frame
6. Hydraulic tube
7. Hydraulic tube
Page 5 − 96
8. O–ring
9. Hydraulic fitting
10. O–ring
Groundsmaster 3500
Removal (Fig. 62)
Installation (Fig. 62)
1. Park machine on a level surface. Lower cutting units,
stop engine and engage parking brake. Remove key
from the ignition switch.
1. If adapters were removed from wheel motor, lubricate and place new O−rings onto fittings. Install adapters into motor openings and tighten fittings (see
Hydraulic Fitting Installation in the General Information
section of this chapter).
WARNING
2. Install wheel motor and brake bracket to frame using
four (4) socket head screws, spacers and lock nuts.
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 − Safety.
2. Jack up front of machine enough to allow the removal
of the front wheel. Support machine with appropriate
jackstands.
IMPORTANT: DO NOT hit wheel hub, wheel hub
puller or wheel motor with a hammer during removal
or installation. Hammering may cause damage to
the wheel motor.
3. Remove wheel assembly, wheel hub and brake drum
from the hydraulic motor. Remove brake assembly from
the brake bracket (see Front Wheel and Brake Removal
in Chapter 7 − Wheels, Brakes, and Miscellaneous in
this manual).
4. Install brake assembly to the brake bracket. Install
brake drum, wheel hub and wheel assembly to the hydraulic motor (see Front Wheel and Brake Installation in
the Chapter 7 − Wheels, Brakes, and Miscellaneous in
this manual).
5. Lower the machine to the ground.
6. Make sure that lock nut is torqued from 250 to 275
ft−lb (339 to 372 N−m). Also, make sure that wheel lug
nuts are torqued from 45 to 65 ft−lb (61 to 88 N−m).
7. Make sure hydraulic tank is full. Add correct oil if necessary.
Hydraulic
System
4. Thoroughly clean hydraulic line ends and wheel motor fittings to prevent hydraulic system contamination.
3. Remove caps and plugs from wheel motor fittings
and hoses. Using labels placed during motor removal,
properly connect hydraulic lines to motor (see Hydraulic
Hose and Tube Installation in this chapter).
WARNING
Before disconnecting or performing any work on
the hydraulic system, all pressure in the system
must be relieved. See Relieving Hydraulic System Pressure in the General Information section
of this chapter.
5. Disconnect hydraulic tubes from adapters on wheel
motors. Plug hose openings to prevent contamination.
6. Remove four (4) socket head screws and lock nuts
that secure brake bracket and wheel motor to frame.
Located and retrieve spacers. Remove brake bracket
and wheel motor from machine.
7. If necessary, remove hydraulic adapters and
O−rings from the wheel motor. Discard removed
O−rings.
Groundsmaster 3500
Page 5 − 97
Hydraulic System
Rear Wheel Motor
1
70 to 90 ft−lb
(95 to 122 N−m)
2
5
7
8
13
15
6
3
7
4
300 to 400 ft−lb
(407 to 542 N−m)
8
12
14
13
9
11
10
Figure 63
1.
2.
3.
4.
5.
Lug nut
Drive stud
Tire and rim assembly
Wheel hub
Hydraulic hose
6.
7.
8.
9.
10.
Hydraulic hose
O–ring
45o hydraulic fitting
Lock nut
Socket head screw
Removal (Fig. 63)
11.
12.
13.
14.
15.
Hydraulic motor
Rear fork
O–ring
Woodruff key
Lock nut
5. Secure wheel hub in a vise. Loosen but do not remove lock nut that secures wheel hub to wheel motor.
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 − Safety.
2. Raise and safely support rear of machine enough to
allow the removal of the rear wheel.
3. Remove rear tire and rim assembly from machine.
IMPORTANT: DO NOT hit wheel hub, wheel hub
puller or wheel motor with a hammer during wheel
hub removal or installation. Hammering may cause
damage to the wheel motor.
6. Using hub puller (see Special Tools), loosen wheel
hub from wheel motor.
7. Remove wheel hub and motor from vise. Remove
lock nut and hub from motor shaft. Locate and retrieve
woodruff key.
8. If hydraulic fittings are to be removed from wheel motor, mark fitting orientation to allow correct assembly.
4. Remove rear wheel motor with wheel hub attached
from the rear fork.
Hydraulic System
Page 5 − 98
Groundsmaster 3500
Installation (Fig. 63)
5. Install tire and rim assembly to machine.
1. If hydraulic fittings were removed from wheel motor,
install fittings to motor using marks made during the removal process to properly orientate fittings.
6. Lower the machine to the ground.
2. Thoroughly clean wheel motor shaft and wheel hub
taper.
3. Lock wheel hub in a vise. Install woodruff key into the
wheel motor shaft. Slide motor shaft into hub and secure
with lock nut. Torque lock nut from 300 to 400 ft−lb (407
to 542 N−m). Remove wheel motor and hub from vise.
7. Torque wheel lug nuts in a crossing pattern from 70
to 90 ft−lb (95 to 122 N−m).
IMPORTANT: If a wheel motor failure occurred, refer
to Traction Circuit Component Failure in this
chapter for information regarding the importance of
removing contamination from the traction circuit.
8. Charge hydraulic system (see Charge Hydraulic
System in this chapter).
Hydraulic
System
4. Install wheel motor to the rear fork (Fig. 63).
Groundsmaster 3500
Page 5 − 99
Hydraulic System
Wheel Motor Service
13
12
45 to 55 ft−lb
(60 to 76 N−m)
11
10
3
1
4
5
6
7
8
9 8
14
27
2
15
16
17
28
26
25
24
28
27
23
22
21
20
19
18
Figure 64
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Dirt seal
Bearing
Housing
Back−up washer
Seal rings
Back−up washer
Inner seal
Thrust washer
Thrust bearing
Bearing
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Coupling shaft
Thrust bearing
Drive link
Cap screw
Commutator seal
Commutator
Woodruff key
Wear plate
Rotor
NOTE: The wheel motor illustrated (Fig. 64) is the rear
motor. The three wheel motors are identical in construction except for some minor differences. The front wheel
motors have a 12 cu. In (195 cc) displacement while the
rear wheel motor has a 24.7 cu. In. (405 cc) displacement. The right front and rear wheel motors have reverse timed manifolds, and the front left motor does not.
The end cover of the rear motor has a check valve consisting of a ball and spring, and both front motors lack
this feature.
Vane
Stator
Manifold
Commutator ring
End cover
Ball
Spring
Plug
O–ring
NOTE: For repair of the wheel motors, see the Parker
Torqmotort TC, TB, TE, TJ, TF, TG, TH and TL Series
Service Procedure at the end of this chapter.
IMPORTANT: If a wheel motor failure occurred, refer
to Traction Circuit (Closed Loop) Component Failure in this chapter for information regarding the importance of removing contamination from the
traction circuit.
Hydraulic System
Page 5 − 100
Groundsmaster 3500
Hydraulic
System
This page is intentionally blank.
Groundsmaster 3500
Page 5 − 101
Hydraulic System
Hydraulic Manifold
21
CF
CR
17
18
18
11
M1
22
M2
CHG
16
20
D1
15
11
19
T1
19
P1
26
14
25
24
27
13
12
23
25
11
24
10
T2
23
28
4
1
9
3
5
RIGHT
2
6
LV
FRONT
ST
8
Traction Units Prior to
Serial No 314000001
7
Figure 65
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Hose clamp
90o hydraulic fitting
Barb fitting
Hydraulic hose − T2
O–ring
Hydraulic hose − ST
Flange head nut
Stud
Hydraulic tube − LV
O–ring
Hydraulic System
11.
12.
13.
14.
15.
16.
17.
18.
19.
Straight hydraulic fitting
Straight hydraulic fitting
O–ring
Hydraulic hose − P1
Hydraulic tube − T1
Hydraulic hose − CHG
Straight hydraulic fitting
O–ring
O–ring
Page 5 − 102
20.
21.
22.
23.
24.
25.
26.
27.
28.
Hydraulic hose − CF
Hydraulic hose − D1
Hydraulic hose − CR
O–ring
Straight hydraulic fitting
O–ring
Hydraulic hose − M1
Hydraulic hose − M2
Hydraulic manifold
Groundsmaster 3500
21
CF
CR
18
22
M2
T1
17
11
M1
CHG
16
20
D1
18
19
15
11
P1
19
26
14
25
13
24
27
12
23
25
10
24
11
T2
23
28
4
1
9
3
5
RIGHT
2
6
LV
Hydraulic
System
FRONT
ST
8
Traction Units
Serial No 314000001 & Up
7
Figure 66
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Hose clamp
90o hydraulic fitting
Barb fitting
Hydraulic hose − T2
O–ring
Hydraulic hose − ST
Flange head nut
Stud
Hydraulic tube − LV
O–ring
Groundsmaster 3500
11.
12.
13.
14.
15.
16.
17.
18.
19.
Straight hydraulic fitting
Straight hydraulic fitting
O–ring
Hydraulic hose − P1
Hydraulic tube − T1
Hydraulic hose − CHG
Straight hydraulic fitting
O–ring
O–ring
Page 5 − 103
20.
21.
22.
23.
24.
25.
26.
27.
28.
Hydraulic hose − CF
Hydraulic hose − D1
Hydraulic hose − CR
O–ring
Straight hydraulic fitting
O–ring
Hydraulic hose − M1
Hydraulic hose − M2
Hydraulic manifold
Hydraulic System
Removal (Fig. 65 and 66)
Installation (Fig. 65 and 66)
NOTE: The ports on the manifold are marked for easy
identification of components. Example: port LV connects the the lift valve circuit and port P1 connects the
gear pump (P1). See Hydraulic Schematics in this
chapter to identify the function of the hydraulic lines and
cartridge valves at each port location.
1. If hydraulic fittings were removed from manifold,
install fittings to manifold using notes or marks made
during the removal process to properly orientate fittings.
1. Clean hydraulic manifold before doing any disassembly.
2. Install hydraulic manifold to the frame.
3. Make sure hydraulic tank is full. Add hydraulic fluid
if necessary.
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved. See Relieving Hydraulic System Pressure in this chapter.
2. Remove hydraulic manifold from the machine.
3. If hydraulic fittings are to be removed from manifold,
note or mark fitting orientation to allow correct assembly.
Hydraulic System
Page 5 − 104
Groundsmaster 3500
Hydraulic
System
This page is intentionally blank.
Groundsmaster 3500
Page 5 − 105
Hydraulic System
Hydraulic Manifold Service
5
Traction Units Prior to
Serial No 314000001
60 in−lb
(6.8 N−m)
6
25 ft−lbs
(34 N−m)
25 ft−lb
(34 N−m)
7
4
50 ft−lbs
(68 N−m)
8
20 ft−lbs
(27.1 N−m)
1
25 ft−lbs
(24 N−m)
2
RIGHT
3
FRONT
Figure 67
1. Manifold body
2. #4 Hex head plug
3. #4 Zero leak plug
Hydraulic System
4. Logic cartridge valve (LC1)
5. Nut
6. Solenoid coil
Page 5 − 106
7. Solenoid cartridge valve (S1)
8. Braking cartridge valve (BV)
Groundsmaster 3500
Traction Units
Serial No 314000001 & Up
25 ft−lbs
(34 N−m)
4
20 ft−lbs
(27.1 N−m)
5
25 ft−lbs
(34 N−m)
6
25 ft−lb
(34 N−m)
3
3
25 ft−lbs
(34 N−m)
1
7
8
2
20 ft−lbs
(27.1 N−m)
FRONT
3
RIGHT
60 in−lb
(6.8 N−m)
Figure 68
1. Manifold body
2. #4 Hex hd plug
3. #4 Zero leak plug
Groundsmaster 3500
4. Logic cartridge valve (LC1)
5. Logic cartridge valve (LC2)
6. Relief valve (RV)
Page 5 − 107
7. Solenoid cartridge valve (S)
8. Solenoid coil
9. Nut
Hydraulic System
Hydraulic
System
9
Cartridge Valve Service (Fig. 67 and 68)
NOTE: The ports on the manifold are marked for easy
identification of components. Example: port LV connects the the lift valve circuit and port P1 connects the
gear pump (P1). See Hydraulic Schematics in this
chapter to identify the function of the hydraulic lines and
cartridge valves at each port location.
NOTE: The Groundsmaster 3500 hydraulic manifold
uses several zero leak plugs. These plugs have a tapered sealing surface on the plug head that is designed
to resist vibration induced plug loosening. The zero leak
plugs also have an O–ring as a secondary seal. If zero
leak plug removal is necessary, lightly rap the plug head
using a punch and hammer before using an allen
wrench to remove the plug: the impact will allow plug removal with less chance of damage to the socket head of
the plug.
1. Make sure the manifold is clean before removing the
valve.
2. If cartridge is solenoid operated, remove nut securing solenoid to the cartridge valve. Carefully slide solenoid coil off the valve.
IMPORTANT: Use care when handling the cartridge
valve. Slight bending or distortion of the stem tube
can cause binding and malfunction.
3. Remove cartridge valve with a deep socket wrench.
Note correct location for O–rings, sealing rings and
backup rings. Remove and discard seal kit.
4. Visually inspect the port in the manifold for damage
to the sealing surfaces, damaged threads or contamination.
CAUTION
Use eye protection such as goggles when using
compressed air.
6. Clean cartridge valve using clean mineral spirits.
Submerge valve in clean mineral spirits to flush out contamination. Particles as fine as talcum powder can affect
the operation of high pressure hydraulic valves. Be extremely careful not to damage cartridge. Use compressed air for cleaning.
7. Reinstall the cartridge valve into the manifold block:
A. Lubricate new seal kit components with clean hydraulic fluid and install on valve. The O–rings, sealing rings and backup rings must be arranged
properly on the cartridge valve for proper operation
and sealing.
IMPORTANT: Use care when handling the valve
cartridge. Slight bending or distortion of the
stem tube can cause binding and malfunction.
B. Thread cartridge valve carefully into manifold
port. The valve should go in easily without binding.
C. Torque cartridge valve using a deep socket to value identified in manifold illustrations (Fig. 67 and 68).
D. If cartridge is solenoid operated, carefully install
solenoid coil to the cartridge valve. Torque solenoid
nut to 60 in−lbs (6.8 N−m).
8. If problems still exist, remove valve and clean again
or replace valve.
5. Visually inspect cartridge valve for damaged sealing
surfaces and contamination.
A. Contamination may cause valves to stick or hang
up. Contamination can become lodged in small valve
orifices or seal areas causing malfunction.
B. If valve sealing surfaces appear pitted or damaged, the hydraulic system may be overheating or
there may be water in the system.
Hydraulic System
Page 5 − 108
Groundsmaster 3500
Cutting Deck Motor
The hydraulic motors used on all cutting decks are the
same.
2
Removal
1. Park machine on a level surface, lower cutting
decks, stop engine, engage parking brake and remove
key from the ignition switch.
1
2. Read the General Precautions for Removing and
Installing Hydraulic System Components in this chapter.
3. To prevent contamination of hydraulic system during
deck motor removal, thoroughly clean exterior of motor.
4. Disconnect hydraulic lines from deck motor. Put
caps or plugs on fittings and hoses to prevent contamination of hydraulic system. Label hydraulic lines for
proper assembly.
1
Figure 69
1. Socket head screw
2. Hydraulic motor
5. Remove two (2) socket head screws and flat washers that secure hydraulic motor to cutting deck (Fig. 69).
Rotation Direction
6. Lift hydraulic motor from cutting deck.
8. If hydraulic fittings are to be removed from deck motor, mark fitting orientation to allow correct assembly.
Remove fittings from motor and discard O–rings.
1
2
Installation
1. If fittings were removed from deck motor, lubricate
and place new O–rings onto fittings. Install fittings into
motor ports using marks made during the removal process to properly orientate fittings. Tighten fittings (see
Hydraulic Fitting Installation in the General Information
section of this chapter).
3
Figure 70
1. Flow IN
2. Flow OUT
2. Remove cover from deck spindle opening.
3. Case drain
3. Align splines on motor shaft and spindle shaft. Position hydraulic motor to the cutting deck.
4. Secure motor to cutting deck with two (2) socket
head screws and flat washers (Fig. 69).
5. Remove caps or plugs from hydraulic fittings and
hoses. Connect hydraulic hoses to deck motor (see Hydraulic Hose and Tube Installation in the General Information section of this chapter).
6. After assembly is completed, verify that hydraulic
hoses and fittings are not contacted by any moving components.
Groundsmaster 3500
Page 5 − 109
Hydraulic System
Hydraulic
System
7. Place cover on deck spindle opening to prevent contamination.
Cutting Deck Motor Service
33 ft−lb
(45 N−m)
26 ft−lb
(35 N−m)
19
18
16
13
9
8
5
6
3
1
17
15
10
14
7
12
6
11
2
4
12
26 ft−lb
(35 N−m)
7
10
Figure 71
1.
2.
3.
4.
5.
6.
7.
Dust seal (2 used)
Retaining ring
Flange washer
Shaft seal
Front flange
Pressure seal
Backup gasket
8.
9.
10.
11.
12.
13.
Front wear plate
Drive gear
Dowel pin (4 used)
Idler gear
O–ring
Body
14.
15.
16.
17.
18.
19.
Rear wear plate
Rear cover
Anti−cavitation valve
Relief valve
Cap screw (4 used)
Washer (4 used)
Disassembly (Fig. 71)
1. Plug motor ports and clean the outside of the motor
thoroughly. After cleaning, remove plugs and drain any
fluid out of the motor.
MARKER
LINE
2. Use a marker to make a diagonal line across the
front flange, body and rear cover for assembly purposes
(Fig. 72).
IMPORTANT: Prevent damage when clamping the
motor into a vise; clamp on the front flange only.
Also, use a vise with soft jaws.
3. Clamp front flange of motor in a vise with soft jaws
with the shaft end down.
Figure 72
4. Loosen cap screws from the rear cover.
Hydraulic System
Page 5 − 110
Groundsmaster 3500
5. Remove motor from the vise. Turn motor so that the
shaft end is facing down. Remove cap screws.
6. Separate rear cover from body. Lift rear cover from
motor.
7. Carefully remove body. Lift body straight up to remove. Make sure the rear wear plate remains on the
drive and idler gear shafts. Remove and discard
O–rings from the body. Locate and retrieve dowel pins.
IMPORTANT: Note position of the open and closed
side of the wear plates before removing. Identify
wear plates (front and rear, drive gear and idler gear)
with a marker for proper assembly.
IMPORTANT: Mark the relative positions of the gear
teeth so they can be reassembled in the same
(mated) position. Do not touch the gear surfaces as
residue on hands may be corrosive to gear finish.
B. Gear teeth should be free of excessive scoring
and wear. Any broken or nicked gear teeth must be
replaced.
C. Inspect gear face edge for sharpness. Sharp
edges of gears will mill into wear plates and, thus,
must be replaced.
4. Inspect wear plates for the following:
A. Bearing areas should not have excessive wear or
scoring.
B. Face of wear plates that are in contact with gears
should be free of wear, roughness or scoring.
C. Thickness of wear plates should be equal.
5. Inspect front flange and rear cover for damage or
wear.
8. Carefully remove rear wear plate, idler gear, drive
gear and front wear plate from the front flange.
1
2
3
4
5
9. Remove and discard back−up gaskets and pressure
seals from wear plates.
10.Turn front flange over, with seal side up.
Hydraulic
System
IMPORTANT: Make sure to not damage the front
flange counter bore when removing the seals from
the front flange.
11. Carefully remove dust seals, retaining ring, flange
washer and shaft seal from the front flange (Fig. 73).
Discard removed seals.
Inspection
1. Remove any nicks and burrs from all parts with
emery cloth.
Figure 73
1. Outer dust seal
2. Inner dust seal
3. Retaining ring
CAUTION
4. Flange washer
5. Shaft seal
2
3
Use goggles or other appropriate eye protection
when using compressed air for drying parts.
4
2. Clean all parts with solvent. Dry all parts with compressed air.
3. Inspect drive gears and idler gears for the following
(Fig. 74):
A. Gear shafts should be free of rough surfaces and
excessive wear at bushing points and sealing areas.
Scoring, rough surfaces or wear on gear shafts indicates need for replacement.
Groundsmaster 3500
1
Figure 74
1. Gear shaft spline
2. Gear shaft
Page 5 − 111
3. Gear teeth
4. Gear face edge
Hydraulic System
Assembly (Fig. 71)
NOTE: When assembling the motor, check the marker
line on each part to make sure the parts are properly
aligned during assembly.
1. Lubricate O–rings, pressure seals, back−up gaskets
and wear plate grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic fluid.
9. Apply a light coating of petroleum jelly to new
O–rings and O–ring grooves in the body. Install new
O–rings to the body.
10.Install locating dowels in body. Align marker line on
the body and front flange.
IMPORTANT: Do not dislodge seals during installation.
11. Gently slide the body onto the assembly. Firm hand
pressure should be sufficient to engage the dowels.
2. Install new seals into front flange (Fig. 73):
A. Press shaft seal into front flange until it reaches
the bottom of the bore.
B. Install flange washer into front flange and then
install retaining ring into the groove of the front
flange.
12.Check to make sure that the surface of the rear wear
plate is slightly below the face of the body. If the wear
plate is not below the body, check assembly for a shifted
pressure seal, backup gasket or O–ring. Correct before
proceeding.
13.Apply a light coating of petroleum jelly to the exposed
side of the rear cover.
C. Install new dust seals into front flange.
3. Place front flange, seal side down, on a flat surface.
4. Install the pressure seals, flat side outward, into the
grooves in the wear plates. Follow by carefully placing
the backup gaskets, flat side outward, between the
pressure seals and the grooves in the wear plate.
5. Apply a light coating of petroleum jelly to the exposed
side of the front flange.
6. Lubricate the drive gear shaft with clean hydraulic
fluid. Insert the drive end of the drive shaft through the
wear plate with the pressure seal side down and the
open side of the pressure seal pointing to the inlet side
of the motor. Carefully install shaft into front flange.
14.Place rear cover on assembly using marker line for
proper location. Firm hand pressure should be sufficient
to engage the dowel pins.
15.Install the four (4) cap screws with washers and hand
tighten screws.
IMPORTANT: Prevent damage when clamping the
motor into a vise; clamp on the front flange only.
Also, use a vise with soft jaws.
16.Place front flange of the motor into a vise with soft
jaws and alternately torque the cap screws 33 ft−lb (45
N−m).
17.Remove motor from vise.
7. Lubricate the idler gear shaft with clean hydraulic fluid. Install idler gear shaft into the remaining position in
the front wear plate. Apply a light coating of clean hydraulic fluid to gear faces.
18.Place a small amount of clean hydraulic fluid in the
inlet of the motor and rotate the drive shaft away from the
inlet one revolution. If any binding is noted, disassemble
the motor and check for assembly problems.
8. Install rear wear plate with pressure seal side up and
open side of the pressure seal pointing to the inlet side
of the motor.
Hydraulic System
Page 5 − 112
Groundsmaster 3500
Hydraulic
System
This page is intentionally blank.
Groundsmaster 3500
Page 5 − 113
Hydraulic System
Steering Control Valve
20 to 26 ft−lb
(28 to 35 N−m)
8
9
11
14 20
27
21
7
38
39
10
17
28
12
Blue
Loctite 242
32
19
2
18
23
4
6
22
24
5
34
36
8
33
37
41
43
45
40
26
25
3
35
40
44
13
30
3
1
15
16
2
31
29
43
Figure 75
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Steering arm
Flange nut
Flange head screw
Steering valve bracket
Cap screw
Pivot hub
Steering cover
Cap screw
Toro decal
Ball knob
Steering tilt lever
Steering control valve
Tilt bracket
Cap screw
Flat washer
Hydraulic System
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Flange nut
Steering wheel
Hydraulic fitting
Hydraulic fitting
Steering wheel nut
Toro decal
Hydraulic hose
Hydraulic hose
Hydraulic hose
Hydraulic hose
Hydraulic hose
Tilt steering boss
Friction disc
Friction disc
Flat washer
Page 5 − 114
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
Jam nut
Flange screw
Steering shield
O–ring
O–ring
O–ring
O–ring
Philips head screw
Steering wheel cap
Flat washer
Flange nut
Slope indicator
Decal
Lock nut
Cap screw
Groundsmaster 3500
Removal (Fig. 75)
3
1
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved. See Relieving Hydraulic System Pressure in the General Information section.
1. Remove Philips head screws and steering wheel cap
from steering wheel.
2
2. Remove the nut securing the steering wheel to the
steering control valve and pull the steering wheel from
the control valve.
3. Remove the steering cover.
Figure 76
5. Disconnect hydraulic lines from steering valve. Put
caps or plugs on fittings and hoses to prevent contamination of hydraulic system. Label hydraulic lines for
proper assembly.
6. Remove the four (4) flange screws securing the
steering control valve to the steering valve bracket and
remove the valve from the bracket (Fig. 76).
1.
2.
Steering valve
Steering valve bracket
3.
Flange screw (4)
3. Remove caps or plugs from hydraulic fittings and
hoses. Connect hydraulic hoses to steering valve (see
Hydraulic Hose and Tube Installation in the General Information section of this chapter).
4. Install steering wheel to the steering control valve.
Torque steering wheel nut from 20 to 26 ft−lb (28 to 35
N−m).
Installation (Fig. 75)
5. Secure steering wheel cap to the steering wheel with
philips head screws.
1. If fittings were removed from steering valve, lubricate
and place new O–rings onto fittings. Install and tighten
fittings (see Hydraulic Fitting Installation in the General
Information section of this chapter).
6. Operate the unit. Check for leaks and check steering
function. Make sure hydraulic tank is full and add hydraulic fluid if necessary.
2. Apply blue Loctite 242 to flange hd. screws and install steering control valve to the steering valve bracket.
Groundsmaster 3500
7. Install the steering cover.
Page 5 − 115
Hydraulic System
Hydraulic
System
4. To prevent contamination of hydraulic system during
steering valve removal, thoroughly clean exterior of
valve.
Steering Control Valve Service
8
9
7
6
10
5
4
3
2
11
1
12
22
13
14
15
21
13
16
20
13
17
18
20 to 24 ft−lb
(27 to 33 N−m)
19
Figure 77
1.
2.
3.
4.
5.
6.
7.
8.
Sleeve
Cross pin
Ring
Spool
Bearing assembly
Shaft seal
Ball stop
Ball
9.
10.
11.
12.
13.
14.
15.
Dust seal ring
Housing
Cardan shaft
Spacer
O–ring
Distribution plate
Inner gearwheel
16.
17.
18.
19.
20.
21.
22.
Outer gearwheel
End cover
O–ring (5 used)
Screw/fitting (ports L, R, T)
Screw/fitting (ports P and E)
P port check ball
Spring set
NOTE: For service of the steering control valve, see the
Sauer/Danfoss Steering Unit Type OSPM Service
Manual at the end of this chapter.
Hydraulic System
Page 5 − 116
Groundsmaster 3500
Hydraulic
System
This page is intentionally blank.
Groundsmaster 3500
Page 5 − 117
Hydraulic System
Steering Cylinder
8
7
6
5
3
1
4
8
5
No. 2 General
Purpose Grease
2
7
10
3
No. 2 General
Purpose Grease
9
4
65 to 85 ft−lb
(88 to 115 N−m)
12
9
11
65 to 85 ft−lb
(88 to 115 N−m)
Figure 78
1.
2.
3.
4.
Hydraulic hose
Hydraulic hose
O–ring
Hydraulic fitting
Hydraulic System
5.
6.
7.
8.
O–ring
Steering cylinder
Ball joint
Retaining ring
Page 5 − 118
9.
10.
11.
12.
Jam nuts
Frame
Rear fork
Rear casting
Groundsmaster 3500
Removal (Fig. 78)
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 wheel must be removed to allow sufficient clearance to remove the steering cylinder from the
machine.
2. Install steering cylinder to the frame and rear fork using. When securing cylinder ball joints to machine, tighten the first jam nut from 65 to 85 ft−lb (88 to 115 N−m),
then tighten the second jam nut to the same specification.
3. Lubricate ball joint grease fittings with No. 2 general
purpose grease.
4. Mount rear wheel to the machine with four (4) lug
nuts. Lower machine to the ground. Torque wheel lug
nuts in a crossing pattern from 70 to 90 ft−lb (95 to 122
N−m).
WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 − Safety.
5. Make sure hydraulic tank is full. Add correct hydraulic fluid if necessary.
2. Jack or lift rear wheel off the ground.
3. Remove rear wheel from the drive studs and wheel
hub.
2
1
4. Thoroughly clean hydraulic hose ends and fittings on
steering cylinder to prevent hydraulic system contamination.
Figure 79
1. Steering cylinder
2. Jam nuts
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved. See Relieving Hydraulic System Pressure in this chapter.
Hydraulic
System
WARNING
3
5. Remove steering cylinder from the frame and rear
fork (Fig. 79 and 80).
2
6. If hydraulic fittings are to be removed from steering
cylinder, note and mark fitting orientation to allow correct
assembly.
Figure 80
Installation
1. If hydraulic fittings were removed from steering cylinder, install fittings to cylinder using marks made during
the removal process to properly orientate fittings.
Groundsmaster 3500
1
1. Steering cylinder
2. Rear fork
Page 5 − 119
3. Jam nuts
Hydraulic System
Steering Cylinder Service
1
11
12
10
9
8
7
6
5
4
3
2
40 ft−lb
(54 N−m)
2
3
4
1
5
8
6
9
10
11
7
12
Figure 81
1.
2.
3.
4.
Barrel with clevis
Lock nut
Piston
Uni−ring
Hydraulic System
5.
6.
7.
8.
O–ring
Piston rod
Rod seal
Cylinder gland
Page 5 − 120
9.
10.
11.
12.
O–ring
Back−up ring
Retaining ring
Dust seal
Groundsmaster 3500
Disassembly
Assembly
1. Remove hydraulic fluid from the steering cylinder
into a drain pan by slowly pumping the cylinder shaft.
Plug both ports and clean the outside of the cylinder.
1. Make sure all parts are clean before reassembly.
2. Mount clevis end of steering cylinder in a vice. Remove retaining ring.
3. Remove plugs from ports. Extract shaft, cylinder
gland, and piston by carefully twisting and pulling on the
shaft.
IMPORTANT: Do not clamp vise jaws against the
shaft surface. Protect shaft surface before mounting in a vice.
A. Install Uni−ring and O–ring to the piston.
B. Install O–rings, back−up ring, and rod seal to the
cylinder gland.
IMPORTANT: Do not clamp vise jaws against the
shaft surface. Protect shaft surface before mounting in a vice.
3. Mount shaft securely in a vise by clamping on the clevis of the shaft.
A. Coat shaft with a light coat of clean hydraulic fluid.
4. Mount shaft securely in a vise by clamping on the clevis of the shaft. Remove lock nut and piston from the
shaft. Slide cylinder gland off the shaft.
B. Slide cylinder gland assembly onto the shaft.
Install piston and lock nut onto the shaft. Torque nut
from 40 ft−lb (54 N−m).
5. Remove Uni−ring and O–ring from the piston.
C. Remove shaft from the vise.
6. Remove back−up ring, O–rings, and rod seal from
the cylinder gland.
Inspection
4. Mount clevis of the barrel in a vice.
Carefully inspect internal surface of cylinder barrel for
damage (deep scratches, out−of−round, etc.). Inspect
piston rod for straightness, excessive scoring, and pitting or wear. Inspect piston and head for evidence of excessive scoring and pitting or wear. Replace entire
cylinder assembly if necessary.
Groundsmaster 3500
IMPORTANT: Prevent damage when clamping the
hydraulic cylinder into a vise; clamp on the clevis
only.
5. Coat all internal parts with a light coat of clean hydraulic fluid. Slide piston, shaft, and cylinder gland assembly into the barrel being careful not to damage the
seals.
6. Secure head into the barrel with the retaining ring.
Page 5 − 121
Hydraulic System
Hydraulic
System
IMPORTANT: Prevent damage when clamping the
hydraulic cylinder into a vise; clamp on the clevis
only.
2. Coat new O–rings, Uni−ring, rod seal, and back−up
ring with with clean hydraulic fluid.
Lift/Sidewinder Control Valve
13
6
12 14 17
11
17
1
25
9
7
8
21
5
27
15
26
10
25
14
5
5
16
21
7
25
4
21
20
18
2
25
21
21
23
9
24
21
22
3
19
Figure 82
1.
2.
3.
4.
5.
6.
7.
8.
9.
Control valve (2−spool)
Hydraulic fitting (straight)
90o hydraulic fitting
Hydraulic fitting (straight)
Flange nut
Knob
90o hydraulic fitting
Valve actuator bracket
Shoulder bolt
Hydraulic System
10.
11.
12.
13.
14.
15.
16.
17.
18.
Cotter pin
Valve lever
Valve actuator trunnion
Shoulder bolt
Link
Bolt
Lock nut
Push nut
Hydraulic fitting
Page 5 − 122
19.
20.
21.
22.
23.
24.
25.
26.
27.
Carriage screw
O–ring
O–ring
Hydraulic tube
Hydraulic tube
Hydraulic hose
O–ring
Hydraulic hose
Hydraulic tube
Groundsmaster 3500
Removal (Fig. 82)
1
4
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved. See Relieving Hydraulic System Pressure in the General Information section.
1. Remove cover from operator’s control panel.
2. Remove control valve from the frame.
3
3. If hydraulic fittings are to be removed from control
valve, note and mark fitting orientation to allow correct
assembly.
2
Figure 83
Installation
1. If hydraulic fittings were removed from control valve,
install fittings to valve using marks made during the removal process to properly orientate fittings.
1.
2.
3.
Spool valve
Cover support bracket
Flange head screws
4.
Carriage bolt & flange
nut
2. Install control valve to the frame.
3. Reinstall operator’s control panel cover.
Groundsmaster 3500
Page 5 − 123
Hydraulic
System
4. Make sure hydraulic tank is full. Add correct hydraulic fluid if necessary.
Hydraulic System
Lift/Sidewinder Control Valve Service
10 to 12 ft−lb
(14 to 16 N−m)
18
26
28
9
15
25
1
19
4 to 5 ft−lb
(5.4 to 6.8 N−m)
5
27
17
12
20
23
9
22
29
24
30
7
6
4
26
25
4
11
30 to 35 ft−lb
(41 to 48 N−m)
21
27
1
5
10
2
27
5
1
12
14
8
9
16
13
10
3
29
30
20 to 25 ft−lb
(27 to 34 N−m)
7
30 to 35 ft−lb
(41 to 48 N−m)
Figure 84
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Check poppet
Grooved plunger
Spacer
Spool
Seat
Solid plug
Seat retaining plug with port
Bushing
Check spring
Spool cap
Hydraulic System
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Valve body
O–ring
Retaining ring
Washer
Seat retaining plug
Spool spring
Disc
Plug
Detent plug
Wiper seal
Page 5 − 124
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Plunger
Plunger detent
Detent spring
O–ring
O–ring
Back−up washer
O–ring
O–ring
O–ring
Back−up washer
Groundsmaster 3500
6
26
25
1
27
5
1
9
7
15
9
26
25
17
19
18
1
21 27
5
29 30
23
22
24
4
14
12
16
13
20
12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Check poppet
Grooved plunger
Spacer
Spool
Seat
Solid plug
Seat retaining plug with port
Bushing
Check spring
Spool cap
Groundsmaster 3500
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Figure 85
Valve body
O–ring
Retaining ring
Washer
Seat retaining plug
Spool spring
Disc
Plug
Detent plug
Wiper seal
Page 5 − 125
8
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
3
Plunger
Plunger detent
Detent spring
O–ring
O–ring
Back−up washer
O–ring
O–ring
O–ring
Back−up washer
Hydraulic System
Hydraulic
System
28
Disassembly
1. Plug all ports and clean the outside of the valve thoroughly.
IMPORTANT: Match−mark spools to their associated bores before disassembly. Spools must be reinstalled to the bore from which they were removed.
2. Remove both spool caps and slide the spool assemblies from their bores.
3. Remove O–ring and bushing from each spool assembly.
4. Remove wiper seals and O–rings from the spool
bore ends that are opposite the spool caps.
NOTE: Disassemble spool assemblies only if the retaining ring, spacer, spring, or washer need replacing.
5. Remove seat retaining plugs, back−up washers,
O–rings, and check springs from the valve body.
6. Remove check poppets, seats, O–rings, and plungers from the valve body.
7. Remove solid plug, back−up washer, and O–ring
from the opposite end of the plunger.
8. Remove plug and O–ring from the top of the valve
body next to the detent plug.
9. Remove detent plug and O–ring from the valve body.
Remove disc, spring, and detent plunger from the body.
Inspection
1. Inspect spools and spool bores for wear. If wear is
excessive, replace valve with new one.
2. Inspect springs and replace as necessary.
3. Inspect plunger, detent plunger, and check poppet
for wear. Replace as necessary.
4. Inspect seat, spacer, and bushing for wear. Replace
as necessary.
5. Inspect disc and washer. Replace as necessary.
6. Inspect cap and plugs for damaged threads and inspect O–ring sealing surfaces. Replace as necessary.
CAUTION
Use eye protection such as goggles when using
compressed air.
1. Clean all metal parts with solvent and blow dry with
compressed air.
2. Replace check poppets, O–rings, and back−up
washers with new ones.
3. Install new O–rings into the valve body.
4. Slide bushings and new O–rings over the spools.
5. If a spool was disassembled, install washer, spool
spring, spacer, and retaining ring to the spool.
6. Lubricate spools liberally with clean hydraulic fluid
and install into their proper bore.
7. Install spool caps into valve body. Torque caps from
20 to 25 ft−lb (27 to 34 N−m).
8. Lubricate both plungers liberally with clean hydraulic
fluid and install into their proper bore.
9. Install new O–rings, seats, check poppets, and
check springs into the plunger bores.
10.Install O–rings, back−up washers, and seat retaining
plugs into their plunger bores. Torque both plugs from 30
to 35 ft−lb (41 to 48 N−m).
11. Install new O–ring, back−up washer, and solid plug
into the bore with the grooved plunger. Torque plug from
30 to 35 ft−lb (41 to 48 N−m).
12.Install new O–ring, seat, check poppet, check spring,
new O–ring, back−up washer, and seat retaining plug
into the bore with the plunger. Torque plug from 30 to 35
ft−lb (41 to 48 N−m).
13.Install O–ring and plug into the top of the valve body
next to the detent plug bore. Torque plug from 10 to 12
ft−lb (14 to 16 N−m).
14.Lubricate plunger detent, spring, and disc liberally
with clean hydraulic fluid and install into its valve body
bore.
15.Install O–ring and detent plug into its proper bore.
Torque plug from 4 to 5 ft−lb (5.4 to 6.8 N−m).
Assembly
IMPORTANT: Do not wipe parts with dry paper towels or rags. Lint may cause damage to the hydraulic
system.
Hydraulic System
Page 5 − 126
Groundsmaster 3500
Hydraulic
System
This page is intentionally blank.
Groundsmaster 3500
Page 5 − 127
Hydraulic System
Front Lift Cylinder
9
6
4
RIGHT
FRONT
Anti−seize
Lubricant
15
39
41
40
34
57
47
42
55
43
48
31
5
16
21
22
20
66
63
28
26
3
7
28
37
32
29
30
12
23
24
13
33
53
44
58
59
60
62
61
28
26
28
38
33
17
45
33 46
10
18
53 64
56 27
20
25
24
19
65
49
54
50
51
8 35 1
52
36
2
13
11
14
Figure 86
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
90o hydraulic fitting
Hydraulic cylinder
Sidewinder carrier assembly
Flange nut
Flange head screw
Hydraulic hose
Centering wire
Hydraulic hose
Hydraulic hose
Hydraulic hose
Slide bracket
Flange nut
Plastic slide
Flange head screw
LIft arm pivot shaft
Roll pin
Cap screw
Flange head screw
Cap screw
Bearing cap
Jam nut
Cap screw
Hydraulic System
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
Lock nut
Thrust washer
Slide support bar
Pin
Spacer
External retaining ring
Bulkhead nut
Hydraulic tube
Bulkhead nut
Carrier stop bracket
Nut
Flange nut
O–ring
O–ring
RH lift arm
LH lift arm
Cap screw
Shaft
Thrust washer
Lynch pin
Rod
Cap screw
Page 5 − 128
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
Cap screw
Torsion spring
Grease fitting
Hair pin
RH deck stop
LH deck stop
Rivet
Rubber bumper
Flange nut
Flange head screw
RH pivot bracket
LH pivot bracket
Front carrier frame
Flat washer
Latch tube
Latch rod
Rod clip
Rivet
Actuator bracket
Carriage screw
RH actuator
LH actuator
Groundsmaster 3500
Removal (Fig. 86)
2
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved. See Relieving Hydraulic System Pressure in the General Information section.
1
3
1. Remove front lift cylinder from the frame and lift arm.
Figure 87
2. If hydraulic fittings are to be removed from lift cylinder, note and mark fitting orientation to allow correct assembly.
1.
2.
Lift cylinder
Hydraulic hoses
3.
Clearance
Installation
1. If hydraulic fittings were removed from lift cylinder,
install fittings to cylinder using marks made during the
removal process to properly orientate fittings.
Hydraulic
System
IMPORTANT: With lift arms raised fully, hydraulic
hoses should be routed as shown (Fig 87). Make
sure clearance between hydraulic hose and lift arm
is from 0.040 to 0.120 inches (1.0 to 3.0 mm). Do not
loosen hoses for repositioning without relieving
system hydraulic pressure first.
2. Install front lift cylinder to the frame and lift arm.
3. Make sure hydraulic tank is full. Add correct hydraulic fluid if necessary.
4. Adjust front lift arms.
Groundsmaster 3500
Page 5 − 129
Hydraulic System
Rear Lift Cylinder
36
40
35
16 3 12
37
30
15
12
11
28
10
12
13
46
17
13
15
2
21
14
42
2
48
1
49
46
23
39
31
27
41
20
4
32
46
45
7
24
5
18
44
25
9
13
6
22
38
29
33
34
47
12
8
26
RIGHT
43 19
12
2
FRONT
3
12
Figure 88
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Hydraulic tube
Bulkhead locknut
Hydraulic T−fitting
Hydraulic hose
90o hydraulic fitting
Hydraulic hose
Hydraulic tube
Straight hydraulic fitting
Castor bushing
Hydraulic cylinder
Thrust washer
O–ring
Bulkhead locknut
Bulkhead elbow union
Hydraulic hose
Hydraulic hose
Hydraulic tube
Hydraulic System
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Hydraulic tube
Hydraulic tube
Tube clamp
O–ring
Cap screw
Lock nut
Rear pivot shaft
Jam nut
Washer
Lift arm assembly
Flange head screw
Thrust washer
Grease fitting
Cutting unit pivot shaft
Cap screw
Cap screw
Page 5 − 130
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
Rebound washer
Thrust washer
Lynch pin
Pop rivet
Wear strip
Rear cutting unit frame
Grease fitting
O–ring
Guard
Cap screw
Cap screw
Lock nut
External retaining ring
Pin
Flat washer
O–ring
Groundsmaster 3500
Installation
Removal (Fig. 88)
1. If hydraulic fittings were removed from lift cylinder,
install fittings to cylinder using marks made during the
removal process to properly orientate fittings.
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved. See Relieving Hydraulic System Pressure in the General Information section.
2. Install rear lift cylinder to the frame and lift arm.
3. Make sure hydraulic tank is full. Add correct hydraulic fluid if necessary.
4. Adjust rear lift arm.
1. Remove rear lift cylinder from the frame and lift arm.
Hydraulic
System
2. If hydraulic fittings are to be removed from lift cylinder, note and mark fitting orientation to allow correct assembly.
Groundsmaster 3500
Page 5 − 131
Hydraulic System
Lift Cylinder Service
2
3
4
5
1
6
7
8
9
10
11
12
40 ft−lb
(54 N−m)
13
14
15
1
1
2
3
9
12
13
5
4
6
7
8
10
11
14
15
1
Figure 89
1.
2.
3.
4.
5.
Grease fitting
Barrel with clevis
Nut
Uni−ring
Piston
Hydraulic System
6.
7.
8.
9.
10.
O–ring
O–ring
Back−up ring
Rod seal
Head
Page 5 − 132
11.
12.
13.
14.
15.
Internal collar
Dust seal
Shaft
Nut
Clevis
Groundsmaster 3500
Disassembly
1. Remove hydraulic fluid from lift cylinder into a drain
pan by slowly pumping the cylinder shaft. Plug both
ports and clean the outside of the cylinder.
IMPORTANT: Prevent damage when clamping the
hydraulic cylinder into a vise; clamp on the clevis
only.
2. Mount lift cylinder in a vice. Remove internal collar
with a spanner wrench.
3. Remove plugs from ports. Extract shaft, head, and
piston by carefully twisting and pulling on the shaft.
IMPORTANT: Do not clamp vise jaws against the
shaft surface. Protect shaft surface before mounting in a vice.
3. Mount shaft securely in a vise by clamping on the clevis of the shaft.
A. Coat shaft with with clean hydraulic fluid.
B. Slide head onto the shaft. Install rod seal onto
shaft and into head.
C. Install piston and lock nut onto the shaft. Torque
nut from 40 ft−lb (54 N−m)
D. Remove shaft from the vise.
4. Mount shaft securely in a vise by clamping on the clevis of the shaft. Remove lock nut and piston from the
shaft. Slide head off the shaft.
5. Remove Uni−ring and O–ring from the piston. Remove O–ring, back−up ring, rod seal, and dust seal from
the head.
IMPORTANT: Prevent damage when clamping the
hydraulic cylinder into a vise; clamp on the clevis
only.
4. Mount barrel in a vice.
5. Coat all internal parts with a light coat of clean hydraulic fluid. Slide piston, shaft, and head assembly into
the barrel being careful not to damage the seals.
Inspection
6. Secure head in the barrel with internal collar using a
spanner wrench. Tighten collar until snug and the outer
end of the collar is flush with end of the barrel.
Carefully inspect internal surface of cylinder barrel for
damage (deep scratches, out−of−round, etc.). Inspect
piston rod for straightness, excessive scoring, and pitting or wear. Inspect piston and head for evidence of excessive scoring and pitting or wear. Replace entire
cylinder assembly if necessary.
7. If clevis was removed from cylinder shaft, fully retract
cylinder shaft and thread jam nut and clevis onto shaft.
Adjust center to center length to dimension shown before tightening jam nut (Fig. 90).
Assembly
10.250” to 10.625”
(26.04 to 26.98 cm)
1. Make sure all parts are clean before assembly.
2. Coat new O–rings, Uni−ring, rod seal, back−up ring,
and dust seal with with clean hydraulic fluid.
A. Install Uni−ring and O–ring to the piston.
B. Install rod seal, O–ring, back−up ring, and dust
seal to the head.
Figure 90
Groundsmaster 3500
Page 5 − 133
Hydraulic System
Hydraulic
System
IMPORTANT: Do not clamp vise jaws against the
shaft surface. Protect shaft surface before mounting in a vice.
Sidewinder
18
19
17
14
13
26
1
7
1
19
26
14
11
13
9
1
20
12
10
31
25
10
11
12
1
22
RIGHT
5
9
15
16
28
27
32
27
21
FRONT
15
6
24
1
4
23
28
2
3
30
8
29
Figure 91
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Bushing
Scissor link
Scissor mount
Cap screw
Flat washer
Lock nut
Scissor frame
Hydraulic cylinder
Spacer
Flat washer
Cap screw
Hydraulic System
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Lock nut
Welded pin
Flange head screw
Lock nut
Spacer
Hydraulic tube
Hydraulic tube
90o hydraulic fitting
Bulkhead lock nut
Straight hydraulic fitting
Hydraulic hose
Page 5 − 134
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
90o hydraulic fitting
Hydraulic hose
Scissor link
O–ring
O–ring
O–ring
Retaining ring
Lower frame
Frame
Pinch point decal
Groundsmaster 3500
Removal (Fig. 91)
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved. See Relieving Hydraulic System Pressure in the General Information section.
4
3
2
The hydraulic cylinder used in the Groundsmaster 3500
sidewinder assembly is a non−serviceable cylinder. Replace the cylinder if it becomes worn or damaged.
1
Figure 92
1. Remove hydraulic cylinder from the frame.
2. If hydraulic fittings are to be removed from cylinder,
note and mark fitting orientation to allow correct assembly.
1.
2.
Scissor frame
Lower frame
3.
4.
Sidewinder carrier
Gaps
Installation
1. If hydraulic fittings were removed from cylinder,
install fittings to cylinder using marks made during the
removal process to properly orientate fittings.
2. Install hydraulic cylinder to the frame.
Hydraulic
System
3. Make sure hydraulic tank is full. Add correct hydraulic fluid if necessary.
4. Adjust scissors mount as follows:
A. Shift sidewinder fully to the left (fully retract cylinder).
B. Loosen four cap screws and locknuts securing
the scissor mount to lower frame.
C. The gap between the scissor frame and lower
frame and the gap between the scissor frame and
the sidewinder carrier must be equal distances within 0.060 inch (1.5 mm) (Fig. 92).
D. Tighten four cap screws and lock nuts to secure
the scissor mount.
Groundsmaster 3500
Page 5 − 135
Hydraulic System
This page is intentionally blank.
Hydraulic System
Page 5 − 136
Groundsmaster 3500
Chapter 6
Electrical System
Table of Contents
Diode Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . .
CAN−bus Termination Resistor
(Gasoline Engines Only) . . . . . . . . . . . . . . . . . .
Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Neutral Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . .
Transport/Mow Switch . . . . . . . . . . . . . . . . . . . . . .
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fusible Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Temp Warning and Shutdown Switches
(Diesel Engine Only) . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Pressure Switch . . . . . . . . . . . . . . . . . .
Fuel Pump (Diesel Engine Only) . . . . . . . . . . . . .
Fuel Pump (Gasoline Engine Only) . . . . . . . . . . .
Fuel Stop Solenoid (Diesel Engine Only) . . . . . .
Electronic Throttle Control
(Gasoline Engine Only) . . . . . . . . . . . . . . . . . . .
Hydraulic Cartridge Solenoid Valve Coils . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . .
Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Cartridge Solenoid Valve Coils . . . . . .
17
17
18
19
20
21
22
22
22
23
24
25
26
27
28
29
30
31
31
32
35
Electrical
System
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Standard Control Module (SCM) . . . . . . . . . . . . . . 2
Kubota Diesel Engine − Electrical Components . 2
Kubota Gasoline Engine − Electrical Components 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 6
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General Run & Transport Problems . . . . . . . . . . . . 8
Cutting Deck Operating Problems . . . . . . . . . . . . . 9
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . 10
Battery Test (Open Circuit Test) . . . . . . . . . . . . . . 10
Charging System Test . . . . . . . . . . . . . . . . . . . . . . 10
Glow Plug System Test (Diesel Engine Only) . . 10
Check Operation of Interlock Switches . . . . . . . . . 11
STANDARD CONTROL MODULE (SCM) . . . . . . . 12
SCM Logic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . 14
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Glow Controller (Diesel Engine Only) . . . . . . . . . 15
Glow Relay (Diesel Engine Only) . . . . . . . . . . . . . 16
Start/PWR/ETV Relays
(Gasoline Engine Only) . . . . . . . . . . . . . . . . . . . 16
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Groundsmaster 3500
Page 6 − 1
Electrical System
General Information
Operator’s Manual
The traction unit Operator’s Manual provides information regarding the operation, general maintenance and
maintenance intervals for your Groundsmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Electrical Drawings
The electrical schematic and wire harness drawings for
the Groundsmaster 3500−D Model 30807 and the
Groundsmaster 3500−G Model 30809 are located in
Chapter 9 − Foldout Drawings.
Standard Control Module (SCM)
All Groundsmaster 3500 machines with are equipped
with a Standard Control Module (SCM) to monitor and
control electrical components required for safe operation. The SCM can be used to check operation of machine switches by monitoring the SCM LED’s. Detailed
information on the Standard Control Module can be
found later in this chapter.
Kubota Diesel Engine − Electrical Components
The engine used in the Groundsmaster 3500−D incorporates the following electrical components to start and
run properly:
Glow plug controller and relay
Fuel stop Solenoid
High Temp Warning and Shutdown Switches
Oil Pressure Switch
Alternator
Additional information on troubleshooting and servicing
engine electrical components can be found in the appropriate Kubota Workshop Manual.
Figure 1
Electrical System
Page 6 − 2
Groundsmaster 3500
Kubota Gasoline Engine − Electrical Components
The engine used in the Groundsmaster 3500−G features an electronic control unit (ECU) that controls a
common rail fuel injection system, electronic throttle
valve (ETV), and a catalytic muffler exhaust system with
a pre−muffler oxygen (O2) sensor. The ECU receives information from numerous Kubota engine sensors and
the following traction unit inputs:
1
Standard Control Module (SCM)
Electronic Throttle Control
The information provided by the various inputs allows
the engine ECU to monitor and control engine operation
for optimum engine performance.
All wire harness electrical connectors should be
plugged into the ECU before the machine ignition switch
is moved from the OFF position to either the ON or
START position. If the engine ECU is to be disconnected
for any reason, make sure that the ignition switch is in
the OFF position with the key removed before disconnecting the engine ECU. See Chapter 4 − Kubota Gasoline Engine In this manual for additional engine ECU
information.
Figure 2
1. Engine (Model 30809)
2. Engine ECU
Electrical
System
Additional information on troubleshooting and servicing
engine electrical components can be found in the appropriate Kubota Workshop Manual and Diagnostic Manual.
2
Groundsmaster 3500
Page 6 − 3
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 circuits for current (amps), resistance (ohms) or voltage.
Obtain this tool locally.
NOTE: Toro recommends the use of a DIGITAL VoltOhm- Amp multimeter when testing electrical circuits.
The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.
Figure 3
Dielectric Lubricant/Sealant
Dielectric gel should be used to prevent corrosion of unsealed connection terminals. To ensure complete coating of terminals, liberally apply gel to both component
and wire harness connector, plug connector to component, unplug connector, reapply gel to both surfaces and
reconnect harness connector to component. Connectors should be thoroughly packed with gel for effective
results.
Do not use dielectric gel on sealed connection terminals
as the gel can unseat connector seals during assembly.
Figure 4
Toro Part Number: 107- 0342
Battery Hydrometer
Use the battery hydrometer when measuring specific
gravity of battery electrolyte. Obtain this tool locally.
Figure 5
Electrical System
Page 6 - 4
Groundsmaster 3500
Battery Terminal Protector
Aerosol spray that should be used on battery terminals,
ring terminals, and fork terminals to reduce corrosion
problems. Apply battery terminal protector to the connection after the battery cable, ring terminal, or fork terminal has been secured.
Toro Part Number: 107- 0392
Electrical
System
Figure 6
Groundsmaster 3500
Page 6 - 5
Electrical System
Troubleshooting
(SCM) (see Standard Control Module in this chapter). If
the machine has had any interlock switches by−passed,
they must be reconnected for proper troubleshooting
and safety.
CAUTION
Remove all jewelry, especially rings and
watches, before doing any electrical troubleshooting or testing. Disconnect the battery
cables unless the test requires battery voltage.
For effective troubleshooting and repairs, you must
have a good understanding of the electrical circuits and
components used on this machine (see Foldout Drawings − Chapter 9).
Gasoline Engines Only − If the engine ECU identifies
that an engine problem exists (including electrical faults
with the various engine sensors), the check engine light
on the Operator’s Control Panel will illuminate. The
Kubota Gasoline Service Tool and software, and the
Kubota Diagnostics Manual should be used to in identify
the cause of the problem, and any repairs that are necessary. Contact your Toro distributor for assistance in
Kubota engine troubleshooting.
Switch and switch circuit operation can be checked using the LED indicators on the Standard Control Module
Starting Problems
Problem
Possible Causes
Nothing happens when start attempt is made.
The traction pedal is not in neutral position or the
neutral switch is faulty.
Operator seat is unoccupied AND the parking brake is
not applied.
The PTO switch is in the ENGAGE position or faulty.
The battery is dead.
Fuse F1 or F3 is faulty or blown.
Loose or corroded battery or ground cables.
Loose or corroded engine ground.
The fusible link at the engine starter is faulty.
Wiring in the engine crank circuit is loose, corroded, or
damaged.
The ignition switch is faulty.
Starter solenoid wiring loose, corroded or damaged.
Starter solenoid is faulty.
The Standard Control Module (SCM) is faulty.
Diesel Engines Only
The engine coolant temperature is above 230F
(110C) or the over temperature shutdown switch is
faulty (grounded).
Gasoline Engines Only
The main power relay or main power relay circuit
wiring is faulty.
Electrical System
Page 6 − 6
Groundsmaster 3500
Starting Problems (continued)
Problem
Possible Causes
Starter solenoid clicks, but starter will not crank
Low battery charge.
NOTE: If the solenoid clicks, the problem is not in the in- Loose or corroded battery cables.
terlock circuit.
Loose or corroded ground.
Faulty wiring at the starter.
Faulty starter solenoid.
Faulty starter motor.
Engine cranks, but does not start.
The fuel tank is empty.
The fuel pump or fuel pump circuit wiring is faulty.
Wiring in the engine crank circuit is loose, corroded, or
damaged.
Diesel Engines Only
Engine stop solenoid is faulty.
The glow circuit (glow plug controller, glow plug relay,
glow plugs, fuse F4) is faulty.
The engine and/or fuel may be too cold.
The fuel filter may be plugged.
Gasoline Engines Only
Diesel Engines Only − The glow circuit does not
operate properly.
Wiring in the glow circuit is loose, corroded, or
damaged.
Fuse F4 is blown or faulty.
The glow relay or glow plug controller is faulty.
One or more of the engine glow plugs is faulty.
The fusible link at the engine starter is faulty.
Engine cranks (but should not) with the PTO switch in
the ENGAGE position.
The PTO switch or PTO switch circuit wiring is faulty.
The engine starts, but stops when the ignition switch is
released from the START position.
The ignition switch is faulty.
The Standard Control Module (SCM) is faulty.
Diesel Engines Only
The engine stop solenoid (hold coil) or stop solenoid
hold coil circuit wiring is faulty.
Groundsmaster 3500
Page 6 − 7
Electrical System
Electrical
System
The Electronic Throttle Valve (ETV) relay or ETV
relay circuit wiring is faulty.
General Run and Transport Problems
Engine stops running during operation (operator sitting
on seat and unit moving).
Operator not in center of seat (seat switch is not
depressed).
The seat switch is faulty or seat switch circuit wiring is
loose, corroded or damaged.
The parking brake was engaged or the parking brake
switch is faulty or parking brake switch circuit wiring is
loose, corroded or damaged.
Fuel tank is empty or very low and unit is operating on
a slope or grade.
The fuel pump is faulty.
Fuse F1 or F3 is faulty.
Wiring in the run circuit is loose, corroded, or
damaged.
Diesel Engines Only
The engine coolant temperature is above 230F
(110C) or the over temperature shutdown switch is
faulty (grounded).
The stop solenoid is faulty.
Battery does not charge.
Faulty battery.
Faulty alternator.
Alternator belt is loose or damaged.
Wiring in the charging circuit is loose, corroded, or
damaged.
The fusible link at the engine starter is faulty.
Alternator warning lamp is faulty or alternator warning
lamp wiring is loose, corroded or damaged.
Electrical System
Page 6 − 8
Groundsmaster 3500
Cutting Deck Operating Problems
The cutting units will not run during the following
normal operating conditions:
Operator in seat or parking brake engaged
Mow/transport switch in MOW
PTO switch in ENGAGE
Operator in seat − the seat switch is faulty or seat
switch circuit wiring is loose, corroded or damaged.
Parking brake engaged − the parking brake switch is
faulty or parking brake switch circuit wiring is loose,
corroded or damaged.
The reel drive solenoid valve (S) or (S1) is faulty or the
reel drive solenoid valve (S) or (S1) circuit wiring is
loose, corroded, or damaged.
The PTO switch is faulty.
The cutting unit up limit switch is faulty.
Mow/transport switch is faulty.
There is insufficient hydraulic oil pressure to turn the
cutting units (see Chapter 5 − Hydraulic System in this
manual).
The Standard Control Module (SCM) is faulty.
Gasoline Engines Only
The engine temperature is above 220F (105C)
Electrical
System
High temperature warning switch or high temperature
warning switch circuit wiring is loose, corroded, or
damaged.
Groundsmaster 3500
Page 6 − 9
Electrical System
Electrical System Quick Check
Battery Test (Open Circuit Test)
Use a multimeter to measure the voltage between the
battery terminals.
Voltage Measured
Battery Charge Level
12.68V (or higher)
Fully charged (100%)
Set multimeter to the DC volts setting. The battery
should be at a temperature of 60 to 100F (16 to 38C).
The ignition key should be off and all accessories turned
off. Connect the positive (+) meter lead to the positive
battery post and the negative (−) meter lead to the negative battery post.
12.45V
75% charged
12.24V
50% charged
12.06V
25% charged
11.89V
0% charged
NOTE: This test provides a relative condition of the battery. Load testing of the battery will provide additional
and more accurate information.
Charging System Test
This is a simple test used to determine if a charging system is functioning. It will tell you if the charging system
has an output, but not its capacity.
Start the engine and run at high idle. Allow the battery
to charge for at least 3 minutes. Record the battery voltage.
Tool required: Digital multimeter set to DC volts.
After running the engine for at least 3 minutes, battery
voltage should be at least 0.50 volt higher than initial battery voltage.
Test instructions: Connect the positive (+) multimeter
lead to the positive battery post and the negative (−)
multimeter lead to the negative battery post. Keep the
test leads connected to the battery posts and record the
battery voltage.
NOTE: Upon starting the engine, the battery voltage
will drop and then should increase once the engine is
running.
NOTE: Depending upon the condition of the battery
charge and battery temperature, the charging system
voltage will increase at different rates as the battery
charges.
Example of a charging system that is functioning properly:
At least 0.50 volt over initial battery voltage.
Initial Battery Voltage
= 12.30 v
Battery Voltage after 3 Minute Charge
= 12.85 v
Difference
= +0.55 v
Glow Plug System Test (Diesel Engines Only)
This is a fast, simple test that can help to determine the
integrity and operation of the Groundsmaster 3500−D
glow plug system. The test should be run anytime hard
starting (cold engine) is encountered on a diesel engine
equipped with a glow plug system.
Tool(s) required: Digital multimeter and/or inductive
Ammeter (AC/DC Current Transducer).
Test instructions: Properly connect the ammeter to the
digital multimeter (refer to manufacturers’ instructions).
Electrical System
Set the multimeter to the correct scale. With the ignition
switch in the OFF position, place the ammeter pickup
around the main glow plug power supply wire and read
the meter prior to activating the glow plug system. Adjust
the meter to read zero (if applicable). Activate the glow
plug system (see Traction Unit Operator’s Manual) and
record the multimeter results.
The Groundsmaster 3500−D glow plug system should
have a reading of approximately 27 Amps.
Page 6 − 10
Groundsmaster 3500
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 before operating the machine.
1
The machine is equipped with a number of interlock
switches. The engine will not start, or if the engine is running, the engine will stop if one or more of the interlock
conditions are met.
The PTO switch must be in the DISENGAGE position.
The traction pedal must be in neutral (with pedal and
switch properly adjusted)
An operator must be in the seat or the parking brake
must be engaged.
When the engine is running, the engine should stop in
1−3 seconds if:
The operator leaves the seat without engaging the
parking brake.
The traction pedal is depressed with the parking
brake engaged.
3. Sit in the operators seat and the In Seat LED on the
SCM should be on. Remove your weight from the seat
and the In Seat LED on the SCM should be off.
4. The Parking Brake LED on the SCM should be on
when the parking is disengaged and go off when the
parking brake is engaged.
5. The PTO LED on the SCM should be off when the
PTO switch is in the DISENGAGED position and go on
when the PTO switch is in the ENGAGED position.
6. The Neutral LED on the SCM should be on when the
traction pedal in in the neutral position and off when the
traction pedal in the forward or reverse position.
7. Take corrective action immediately if any of the interlocks do not perform as described.
Electrical
System
To start the engine:
Figure 8
1. Standard Control Module
Use the Standard Control Module (SCM) to check operation of the interlocks.
1. Remove the cover over the instrument panel to expose the Standard Control Module (SCM) (Fig. 8).
2. Turn the ignition switch to the on RUN position
Groundsmaster 3500
Page 6 − 11
Electrical System
Standard Control Module (SCM)
Groundsmaster 3500 machines are equipped with a
Standard Control Module to monitor and control electrical components required for safe operation. This Module is attached to the back of the instrument panel.
coolant temperature exceeds 230F(110C) causing the
high temperature warning switch to close. The Over
Temperature Shutdown input LED is not used with gasoline powered units.
Inputs from the neutral, parking brake, PTO, ignition,
seat, and high temperature switches are monitored by
the Module. Output to the PTO (deck drive solenoid), engine starter motor, fuel pump, and engine stop solenoid
(diesel engines) or the power relay (gasoline engine)
are controlled based on the inputs received by the Module.
The Backlap input LED is not used on the Groundsmaster 3500.
The Standard Control Module can be used to check operation of machine switches by monitoring the LEDs of
the module. If a Module LED does not illuminate (e.g. the
in seat input LED does not illuminate with the seat occupied and the ignition switch in the run position), testing
of the switch and circuit wiring would be required.
Refer to the Traction Unit Operator’s Manual for additional Standard Control Module information.
Control Module Inputs (Fig. 9)
The Power input LED should be illuminated when the
ignition key switch is in the RUN or START position.
The Start output LED should be illuminated when the
ignition key switch is in the START position with the traction pedal in neutral, the PTO switch off and either the
seat occupied or parking brake engaged.
The Run output LED should be illuminated when the
ignition key switch is in the ON position and inputs from
the neutral, parking brake, PTO, seat and over temperature switches indicate safe engine operation (e.g. seat
occupied and parking brake disengaged when traction
pedal is depressed).
The PTO output LED should be illuminated when the
ignition key switch is in the ON position, the parking
brake is disengaged, the operator is sitting in the seat,
and the PTO switch is pulled out.
NOTE: For gasoline powered units, if the Over Temperature Warning input LED is illuminated, PTO output LED
will not be illuminated and PTO will not be engaged regardless of PTO, ignition, parking brake, or in seat
switch position.
The Start input LED should be illuminated when the ignition key switch is in the START position.
12
The Neutral input LED should be illuminated when the
traction pedal is in the neutral position.
10
11
The Parking Brake Off input LED should be illuminated
when the parking brake is not engaged.
4
9
3
8
2
7
The PTO Switch input LED should be illuminated when
the PTO switch is engaged.
6
The In Seat input LED should be illuminated when the
operator is sitting in the seat.
Diesel Engines Only − The Over Temperature Shutdown input LED should be illuminated when the engine
coolant temperature exceeds 230F(110C) causing the
high temperature shutdown switch to close. The Over
Temperature Warning input LED is not used with diesel
powered units.
5
N
The Standard Control Module does not connect to an
external computer or hand held device, can not be re−
programmed, and does not record intermittent fault
data.
Control Module Outputs (Fig. 9)
ASSY PN 106−9277
DECAL PN 106−9290
1
Figure 9
1.
2.
3.
4.
5.
6.
7.
8.
Power input LED
Start input LED
Engine run output LED
Start output LED
PTO output LED
Neutral input LED
Park brake off input LED
PTO switch input LED
9. In seat input LED
10. High temp warning input
LED (Gas Engine Only)
11. High temp shutdown
input LED (Diesel Engine
Only)
12. Backlap input (not used)
Gasoline Engines Only − The Over Temperature Warning input LED should be illuminated when the engine
Electrical System
Page 6 − 12
Groundsmaster 3500
Standard Control Module (SCM) Logic Chart
Example: To start the engine the following conditions
must be met: the ignition key is in START, the operator
is in the seat, the traction control pedal is in the neutral
position and the parking brake is applied. When these
conditions are met the Energize to Run (ETR) and Engine Start relays are energized.
−
+
−
Engine Run (Operator in Seat)
−
Engine Run (No Operator in Seat)
−
Mow
−
High Temperature Warning (Gasoline Engine ONLY)
−
High Temperature Shutdown (Diesel Engine ONLY)
−
−
−
−
−
−
−
−
−
Engine Start
Engine Start (No Operator in Start)
−
Engine Run
−
NA
+
+
NA
+
+
NA
+
NA
+
NA
+
NA
+
Backlap
−
High Temperature Shutdown
(Diesel Engine ONLY)
Parking BrakeOff*
+
High Temperature Warning
(Gasoline Engine ONLY)
Neutral
−
In Seat
Start
Engine Start (Operator in Seat)
OUTPUTS
PTO Switch
Power
MACHINE FUNCTION
INPUTS
PTO
Each line of the following chart identifies the necessary
component position (INPUTS) in order for the Standard
Control Module (SCM) to energize the appropriate
OUTPUTS for machine operation.
+
+
NA
* Parking Brake circuit is open to ground when parking brake is ON (applied)
−
LED ON − Circuit closed to ground
+
LED ON − Circuit is energized
LED OFF − Circuit is open to ground or circuit is de−energized
Circuit is not involved with this machine function (LED OFF)
NA
Backlap Input is not used on the Groundsmaster 3500
IMPORTANT (Diesel Engine Units): The console
temperature warning light illuminates when engine
coolant temperature exceeds 221F (105C). The engine shuts down and the console temperature warning light remains illuminated when the engine
coolant temperature exceeds 230F (110C). The engine should be allowed to cool to a temperature below 221_ F (105_ C). The cooling system should be
checked before returning the machine to service.
Groundsmaster 3500
IMPORTANT (Gasoline Engine Units): During machine operation, the PTO shuts down and the console temperature warning light illuminates when the
engine coolant temperature exceeds 230F (110C).
Under this condition the operator should avoid
shutting off the engine, push the PTO switch to OFF
(disengage), slowly drive to a safe flat area, move
the throttle lever to the SLOW position, release the
traction control pedal to the neutral position and engage the parking brake. The engine should be allowed to idle at low speed until it cools to a safe
level. The cooling system should be checked before
returning the machine to service.
Page 6 − 13
Electrical System
Electrical
System
KEY TO CHART
Component Testing
For accurate resistance and/or continuity checks, disconnect the component being tested from its electrical
circuits (e.g. unplug the ignition switch connector before
doing a continuity check on the switch).
NOTE: For additional electrical component testing information, see the Kubota Workshop Manual for 05
Series Diesel Engines, or the Kubota Workshop and
Diagnostics Manuals for WG972 Gasoline Engines.
CAUTION
When testing electrical components for continuity with a multimeter (ohms setting), make sure
that power to the circuit has been disconnected.
Ignition Switch
The ignition (key) switch has three positions (OFF, ON/
PREHEAT, and START). The terminals are marked as
shown. The circuitry of the ignition switch is shown in the
chart below. With the use of a multimeter (ohms setting),
the switch functions may be tested to determine whether
continuity exists between the various terminals for each
position. Verify continuity between switch terminals.
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
OFF
NONE
NONE
ON/PREHEAT
B+A+I
X+Y
START
B+S+I
NONE
Y
3
2
1
4
Figure 11
1. Switch
2. Key
3. Hex nut
4. Lock washer
OFF
45 °
A
ON/PREHEAT
B
45 °
S
START
I
X
Figure 12
Figure 10
Electrical System
Page 6 − 14
Groundsmaster 3500
Glow Controller (Diesel Engines Only)
The controller is located under the instrument panel.
NOTE: Refer to Foldout Drawings − Chapter 9 in this
manual when troubleshooting the glow controller.
Controller Operation
1. When the ignition switch is placed in the RUN position, the controller energizes the glow plug relay and illuminates the glow lamp for 10 seconds.
2. When the ignition switch is held in the START position, the glow plug relay will energize while the switch is
held in START and the glow lamp will not illuminate.
3. When the ignition switch is released from START to
RUN, the glow plug relay will de−energize and the glow
lamp will remain off.
5. If any of the conditions in Step 3 are not met or power
to terminal 1 exists and any of the other conditions in
Step 4 are not met:
A. Verify continuity of the circuitry from the battery to
the glow relay and glow plugs (see Foldout Drawings
− Chapter 9 of this manual).
B. Verify continuity of the circuitry from the battery to
ignition switch, glow controller, glow lamp, glow
relay, and ground (see Foldout Drawings − Chapter 9
in this manual).
C. Replace parts as necessary.
6. Connect electrical connector to the fuel stop solenoid when finished.
Controller Checks
2
1. Make sure there is power from the battery.
2. Disconnect electrical connector to the fuel stop solenoid to prevent the engine from starting.
3. Place ignition switch in the RUN position. Verify the
following while in the RUN position:
3
6
2
5
1
4
A. Glow indicator lamp is on.
B. Glow relay is energized.
1
C. Glow plugs are energized.
4. Place ignition switch in the START position. Verify
the following while in the START position:
Figure 13
1. Glow controller end view
2. Top view
3. Side view
A. Glow indicator lamp is out.
B. Glow relay is energized.
C. Glow plugs are energized.
D. Power exists at terminal 1 of the glow controller.
NOTE: If there is no power to terminal 1 of the glow controller, verify continuity of the circuitry from the ignition
switch to the controller and perform Step 4 again (see
Foldout Drawings − Chapter 9 in this manual).
Groundsmaster 3500
Page 6 − 15
Electrical System
Electrical
System
3
D. Glow indicator lamp goes out and glow plugs de−
energize after 10 seconds.
Glow Relay (Diesel Engine Only)
The glow relay is attached to the radiator assembly.
When energized, the glow relay allows electrical current
to the engine glow plugs.
3. Disconnect voltage and leads from the terminals.
1. Verify coil resistance between terminals 86 and 85
with a multimeter (ohms setting). Resistance should be
approximately 72 ohms (Fig. 14).
86
2. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as +12 VDC is
applied and removed from terminal 85.
85
87
30
85
86
87
30
Figure 14
Start/PWR/ETV Relays (Gasoline Engine Only)
The relays are attached to the control panel support.
When energized, the relays allow electrical current to
the specific circuits (see Chapter 9 − Foldout Drawings
in this manual).
3. Disconnect voltage and leads from the terminals.
1. Verify coil resistance between terminals 86 and 85
with a multimeter (ohms setting). Resistance should be
approximately 80 ohms (Fig. 15).
2. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as +12 VDC is
applied and removed from terminal 85.
Figure 15
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.
Hobbs
QUARTZ
00001
HOURS
3. The hour meter should move 1/10 of an hour in six
minutes.
4. Disconnect the voltage source from the hour meter.
1
10
+
BACK
Figure 16
Electrical System
Page 6 − 16
Groundsmaster 3500
Diode Assemblies
Groundsmaster 3500 machines use diodes that plug
into the wiring harness (Fig. 16). Location of the diodes
is under the control console.
Multimeter
Red Lead (+)
on Terminal
Multimeter
Black Lead (- )
on Terminal
Continuity
Female
Male
YES
Male
Female
NO
Diode D1 is used on both diesel and gasoline powered
units. Diode D1 is used to protect the PTO solenoid
valve coil from reverse polarity.
Diodes D2 and D3 are used on gasoline powered units
only. Diode D2 is used to protect the circuits from voltage
spikes when the engine starter solenoid is de- energized. Diode D3 protects the engine start relay circuit
from reverse polarity.
4
1
2
The diode assemblies can be identified by a black color
and a diode symbol on the end of the diode assembly
body. Refer to the engine wire harness drawing in Chapter 9 in this manual for additional information on diode
assembly location.
3
Testing
Figure 16
The diodes can be individually tested using a digital
multimeter (diode test or ohms setting) and the table below.
1. Diode
2. Male terminal
3. Female terminal
4. End of diode body
CAN- bus Termination Resistor (Gasoline Engines Only)
The CAN- bus termination resistor plugs into the main
wire harness under the operator’s control panel (see
Chapter 9 - Foldout Drawings in this manual). The resistor can be accessed by removing the control panel
cover. The termination resistor and the wire harness
connector have blue inserts to identify the proper location for the termination resistor. The resistor also has a
center keyway to prevent it from plugging into the wrong
wire harness connector.
Termination
Resistor
A
B
Electrical
System
System communication between electrical components
on Groundsmaster 3500- G machines is accomplished
on a CAN- bus communication system. Two (2) specially designed, twisted cables form the bus for the network
used on the machine. These wires provide the data
pathways between machine components. At the end of
one of the cables is a 120 ohm termination resistor.
Keyway
C
Figure 17
IMPORTANT: The termination resistor is required
for proper electrical system operation.
Termination Resistor Test
Remove the termination resistor from the main wire harness (Fig. 17). Test the resistor using a digital multimeter
(ohms setting). There should be 120 ohms resistance
across terminals A and B of the termination resistor.
Groundsmaster 3500
Page 6 - 17
Electrical System
Indicator Lights
Charge Indicator Light
The charge indicator light should come on when the ignition switch is in the ON position with the engine not running. It should also illuminate while the engine is running
and the charging circuit is malfunctioning.
used to identify the cause of the problem and any repairs
that are necessary. Contact your Toro distributor for assistance in Kubota engine troubleshooting
Testing Indicator Lights
2
Engine Oil Pressure Light
The engine oil pressure light should come on when the
ignition switch is in the ON position with the engine not
running. It should also illuminate while the engine is running and the engine oil pressure drops to an unsafe level.
3
4
1
IMPORTANT: If the oil pressure indicator light is illuminated with the engine running, shut off the engine immediately.
To test the oil pressure light and circuit wiring, ground the
wire attached to oil pressure switch located on the engine near the oil filter. Turn ignition switch to the ON position; the engine oil pressure light should come on
indicating correct operation of the indicator light and circuit wiring.
Figure 19
1. Charge indicator
2. Engine oil pressure
5
2
High Temperature Warning Light
Diesel Engines Only − If the engine coolant temperature
reaches approximately 221F (105C) (diesel powered
units), or approximately 230F (110C) (gasoline powered
units) the high temperature warning light should come
on.
Glow Plug Indicator Light (Diesel Engines Only)
The glow plug light should come on when the ignition
switch is placed in the ON position prior to placing the
ignition switch in START. The light should stay lit for
approximately 6 seconds while the ignition switch is left
in the ON position.
6
4
1B (−)
1A (+)
2B (−)
2A (+)
Figure 20
1. Charge indicator
2. Engine oil pressure
3. High temperature
Check Engine Light (Gasoline Engines Only)
The check engine light should remain off while the engine is running. If the engine ECU identifies that an engine problem exists, the check engine light will
illuminate. The Kubota Gasoline Service Tool and software, and the Kubota Diagnostic Manual should be
3
1
To test the high temperature warning light and circuit wiring on diesel powered units, turn ignition switch to the
ON position and ground the gray wire attached to high
temperature sender located on the engine water pump
housing (see Temperature Sender in this chapter). The
high temperature warning light should illuminate.
Electrical System
3. High temp shutdown
4. Glow plug indicator
4. Glow plug indicator
(diesel units)
Check engine light
(gasoline units)
5. Indicator light front
6. Indicator light back
1. Apply 12 VDC to terminals 1A and 2A (Fig. 20).
2. Ground terminals 1B and 2B (Fig. 20).
3. Both indicator lights should illuminate.
Page 6 − 18
Groundsmaster 3500
PTO Switch
The PTO switch is located on the control panel. Most
Groundsmaster 3500 machines use a pull type switch
(shown in Fig. 20) while early production diesel powered
units use a rocker switch (shown in Fig. 21). The switch
allows the decks to be engaged or disengaged. Along
with additional switches in the interlock system, the PTO
switch controls the solenoid valve on the hydraulic manifold.
The switch terminals are marked as shown in Fig. 20
and 21. The circuitry of the switch is shown in the charts
in the right column. With the use of a multimeter (ohms
setting), the switch functions may be tested to determine
whether continuity exists between the various terminals
for each switch position. Verify continuity between
switch terminals.
PULL SWITCH
BACK OF SWITCH
4
1
2
5
3
6
Figure 20
1. COM B terminal
2. NO B terminal
3. NC B terminal
4. COM C terminal
5. NO C terminal
6. NC C terminal
PULL SWITCH
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
ENGAGE
C COM + C NO
B COM + B NO
DISENGAGE
C COM + C NC
B COM + B NC
ROCKER SWITCH
Electrical
System
BACK OF SWITCH
Figure 21
ROCKER SWITCH
Groundsmaster 3500
Page 6 - 19
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
ENGAGE
2+3
5+6
DISENGAGE
1+2
4+5
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.
2
1
1. Disconnect electrical connector from the neutral
switch.
2. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the switch connector
terminals.
3. With the traction pedal in the neutral position, there
should be continuity between the two switch leads.
4. Slowly depress the traction pedal. The continuity tester should show no continuity as the pedal is moved in
either the forward or reverse direction.
5. Reconnect switch after testing.
3
Figure 23
1. Neutral switch
2. Floor plate
3. Switch bracket
Adjustment
The neutral switch should be installed so that the pin on
the traction pedal (neutral position) is centered with the
switch when the pedal is in the neutral position. The
switch must open with forward or reverse movement of
0.25” to 1.00” (6.3mm to 25.4mm) when measured at
the top of the traction pedal.
Electrical System
Page 6 − 20
Groundsmaster 3500
Seat Switch
The seat switch is normally open and closes when the
operator is on the seat. If the neutral switch is open when
the operator raises out of the seat, the engine will stop.
2
The standard seat uses a switch that is fastened to the
underside of the seat (Fig. 24). The deluxe seat has a
switch that is mounted to the seat base under the cushion. The switch electrical connector for either seat type
is located directly under the seat. Testing is the same for
either switch type:
1
1. Make sure the engine is off. Remove seat by removing four cap screws that secure seat mounting straps to
traction unit.
2. Disconnect electrical connector from the switch.
Figure 24
1. Standard seat switch
2. Electrical connector
3. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the switch connector
terminals.
4. With no pressure on the seat, there should be no
continuity between the seat switch terminals.
5. Press directly onto the seat switch through the seat
cushion. There should be continuity as the seat cushion
approaches the bottom of its travel.
6. Reconnect switch connector. Reinstall seat assembly.
Groundsmaster 3500
Page 6 − 21
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 is located under the dash cover and opens
when the parking brake lever is engaged. The transport/
mow switch is located under the floor plate and opens
when the transport/mow slide is in the transport position.
2
The Standard Control Module monitors the operation of
the parking brake switch. If the ignition switch is in the
ON position and the parking brake is disengaged, the
Parking Brake Off input LED should be illuminated.
1
1. Make sure the engine is off. Locate switch for testing.
Figure 25
1. Parking brake switch
2. Parking brake lever
2. Disconnect electrical connector from the switch.
3. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the switch connector
terminals.
4. When the switch plunger is extended there should be
continuity between the switch terminals.
1
5. When the switch plunger is depressed, there should
be no continuity between the switch terminals.
6. Reconnect switch connector.
Figure 26
1. Transport/Mow switch
Four fuses are held in a fuse block located below the
control panel. An additional fuse is mounted alongside
the fuse block in a separate fuse holder (Fig. 27).
Testing
Remove fuses from the fuse block for testing. Fuse
should have continuity between fuse terminals.
Gasoline Engines Only − An additional 30 Amp fuse is
located near the battery along the main wire harness in
a separate fuse holder.
1
Identification and Function (Fig. 27)
2
F1 (15A): Main
3
F2 (10A): Lighting (optional)
F3 (10A): System Gauges/Switches/SCM
4
F4 (10A): Diesel Units − Ignition/Glow Controller
Gasoline Units − Ignition
5
F5 (2A): Standard Control Module (SCM)
F6 (30A): Gasoline Units Only − Engine ECU
Figure 27
Electrical System
Page 6 − 22
Groundsmaster 3500
Electrical
System
Fuses
Fusible Links
The Groundsmaster 3500 uses a number of fusible links
for circuit protection. A number of fusible links are located in a harness that connects the starter B+ terminal
to the main wire harness. Power from the alternator,
power to the ignition switch, and in the case of diesel
powered units, power to the glow relay is protected by
the fusible link harness.
FUSIBLE LINK
FUSIBLE LINK
FUSIBLE LINK
Diesel powered units have an additional fusible link integrated into the main wire harness between the starter
G terminal and the stop solenoid pull coil.
Figure 28
If any of these links should fail, current flow in the protected circuit will be interrupted. Refer to wire harness
drawings in Chapter 9 − Foldout Drawings in this manual
for additional information.
1
Testing
1. Make sure that ignition switch is OFF.
2
2. Disconnect negative (−) battery cable from battery
terminal and then disconnect positive (+) cable from battery (see Battery Service in the Service and Repairs section of this chapter).
3. For fusible link harness (Fig. 28):
Figure 29
A. Locate and unplug fusible link connector from
machine wire harness.
1. Fuel stop solenoid
2. Harness connector
2
B. Use a multimeter to make sure that continuity exists between the fusible link terminal on the starter
B+ terminal (terminal J1 on fusible link harness) and
each of the terminals in the link harness connector
P1. If any of the fusible links are open, replace the
fusible link harness.
1
4. For fusible link integrated into wire harness:
A. Locate and unplug machine wire harness connector from the fuel stop solenoid (Fig. 29).
B. Use a multimeter to make sure that continuity exists between the wire harness connector at the starter and the engine fuel stop solenoid connector for the
solenoid pull coil (Fig. 30 − yellow wire).
C. If this fusible link should fail, make sure that the
wire harness is repaired with the correct fusible link.
Do not replace a failed harness fusible link with a regular section of wire.
Groundsmaster 3500
Figure 30
1. Fuel stop solenoid
2. Pull coil terminal
5. When testing is completed, make sure to connect all
disconnected wire harness components. Connect positive (+) battery cable and then negative (−) cable (see
Battery Service in the Service and Repairs section of
this chapter).
Page 6 − 23
Electrical System
High Temperature Warning and Shutdown Switches (Diesel Engines Only)
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 (alternator end) (Fig.
31).
3
1
CAUTION
2
Make sure engine is cool before removing the
temperature switch.
1. Lower coolant level in the engine and remove the
temperature switch.
2. Put switch in a container of oil with a thermometer
and slowly heat the oil (Fig. 32).
Figure 31
1. Temp. warning switch
2. Temp. shutdown switch
3. Water pump housing
CAUTION
VOA
Handle the hot oil with extreme care to prevent
personal injury or fire.
3. Check continuity of the switch with a multimeter
(ohms setting).
A. The high temperature warning switch is normally
open and should close between 216 to 226F (102 to
108C).
Figure 32
B. The high temperature shutdown switch is normally open and should close between 225 to 235F (107
to 113C).
4. Allow oil to cool while observing temperature.
A. The high temperature warning switch should
open at about 208F (98C).
B. The high temperature shutdown switch should
open at about 219F (104C).
5. Replace switch if necessary.
Electrical System
Page 6 − 24
Groundsmaster 3500
Oil Pressure Switch
The engine oil pressure switch is located on the engine
below the alternator (Fig.33). The oil pressure switch is
a normally closed switch that opens with pressure. The
oil pressure switch should open at approximately 8 PSI
(0.56 kg/cm2).
1
If low engine oil pressure allows the oil pressure switch
to close during engine operation, the engine oil pressure
light should illuminate.
2
Testing
3
NOTE: Refer to the Kubota Workshop Manual for information regarding engine lubrication system and testing.
1. Set the ignition switch to the RUN position. The oil
pressure indicator light on the control panel should be
illuminated.
2. If the indicator light is not illuminated, open hood to
gain access to engine.
3. Locate oil pressure switch on engine and disconnect
the harness wire from the switch.
Figure 33
1. Engine temp. sensor
2. Alternator
3. Oil pressure switch
5. If the light comes on, the oil pressure switch is faulty.
6. If the light does not come on after step 4, check the
oil pressure light circuit wiring and indicator light (see Indicator Lights in this section).
7. After testing is completed, connect the harness wire
to the switch. Lower and secure hood.
Electrical
System
4. With the ignition switch in the RUN position, ground
the disconnected wire to the engine block.
Groundsmaster 3500
Page 6 − 25
Electrical System
Fuel Pump (Diesel Engine Only)
The fuel pump is attached to the left frame rail near the
engine.
2
4
Operational Test
1. Park machine on a level surface, lower cutting
decks, stop engine, and engage parking brake. Unlatch
and raise hood.
1
2. Disconnect electrical connector from the fuel stop
solenoid to prevent the engine from starting.
3. Disconnect the fuel hose between the pump and the
filter/separator (pump discharge) at the filter separator.
4. Make sure fuel hoses to and from the fuel pump are
not kinked, damaged, and free of obstructions.
5. Place disconnected fuel hose into a graduated cylinder with at least a 1 quart (0.95 liter) capacity.
3
Figure 34
1. Fuel pump
2. Fuel hose (discharge)
Fuel Pump Specifications
Pump Capacity
IMPORTANT: When testing the fuel pump, DO NOT
turn ignition switch to START.
6. Collect fuel in the graduated cylinder by turning ignition switch to the RUN position. Allow pump to run for
time listed below, then return switch to OFF. The amount
of fuel collected in the graduated cylinder should be
approximately 21 to 37 fl oz (0.62 to 1.1 Ltr) after thirty
(30) seconds.
3. Fuel filter
4. Fuel stop solenoid
42 to 74 fl oz/min
(1.2 to 2.2 Ltr/min)
Pressure
2.3 psi (15.8 kPa)
Max. Current Draw
1.8 amp
7. Replace fuel pump as necessary. Reconnect fuel
hose to the fuel filter/separator.
8. Reconnect electrical connector to the fuel stop solenoid.
9. Bleed fuel system.
Electrical System
Page 6 − 26
Groundsmaster 3500
Fuel Pump (Gasoline Engine Only)
6
175 to 200 in−lb
(20 to 22 N−m)
7
1
4
5
8
1
2
9
4
6
B (−)
3
A (+)
Figure 35
4. Hose clamp
5. Fuel rail
6. Pump electrical connector
The electric fuel pump used on the Groundsmaster
3500−G is a positive displacement in−tank pump that
provides pressurized fuel to the engine fuel rail in a return−less system (Fig. 35). The fuel pump assembly includes a regulator to maintain fuel pressure. Electrical
power for the fuel pump is controlled by the engine ECU
through the PWR relay.
Fuel Pump Test (Fig 35)
1. Park machine on a level surface, lower cutting
decks, stop engine, and engage parking brake. Unlatch
and raise hood.
7. Nut
8. Filter
9. Gasket
3. Install a fuel pressure gauge capable of measuring
50 PSI (350 kPa) to the disconnected hose.
NOTE: If pressure gauge is connected in−line (using a
tee fitting), fuel rail and injectors can be checked for potential leakage while measuring fuel pump pressure.
4. While monitoring pressure gauge, turn ignition
switch to ON so the fuel pump is energized. Fuel pressure displayed on the gauge should rise. Turn ignition
switch to OFF and then back to ON to re-energize the
fuel pump and fully pressurize the fuel line. Fuel pump
pressure should be approximately 43 PSI (300 kPa).
CAUTION
CAUTION
The fuel supply hose will contain pressurized
fuel. Be careful when disconnecting fuel supply
hose. Wipe away any spilled fuel before starting
the engine.
Make sure test wire connections are secure before turning ignition switch to ON to prevent an
explosion or fire from sparks.
2. Disconnect fuel supply hose from engine fuel rail.
Groundsmaster 3500
Page 6 − 27
Electrical System
Electrical
System
1. Fuel pump
2. Fuel hose
3. Cable tie
5. If fuel pump does not operate or pressure is low, test
the pump while supplying power directly, bypassing the
engine ECU and PWR relay.
6. After testing is completed, remove pressure gauge
from fuel supply hose. Connect fuel supply hose to engine fuel rail and secure with hose clamp.
Fuel Pump Specifications
A. Disconnect fuel pump electrical connector.
B. Connect a jumper from the A (+) terminal of the
pump connector (red wire) to the mating A (+) terminal of the wire harness connector.
C. Connect the B (−) terminal at the pump connector
(black wire) to an engine or chassis ground.
Pump Capacity
45 fl oz/min (1.3 Ltr/min)
Pressure
43.5 psi (300 kPa)
Max. Current Draw
4.4 amp
D. Repeat step 4.
If fuel pump pressure is low and power supply to the
pump has been verified, consider a clogged fuel filter or
faulty fuel pump.
Fuel Stop Solenoid (Diesel Engine Only)
The fuel stop solenoid used on the Groundsmaster
3500−D must be energized for the diesel engine to run.
The solenoid is mounted to the injection pump on the engine (Fig. 36).
1
The fuel stop solenoid includes two coils for operation,
the pull coil and the hold coil. When the ignition switch
is turned to START, the solenoid is initially energized
and the pull coil retracts the solenoid plunger. Once the
plunger is retracted, the hold coil will keep it retracted for
continued engine operation. When the solenoid is de−
energized, the plunger extends to shut off fuel supply to
the engine causing the engine to stop running. The fuel
stop solenoid is grounded through the solenoid housing.
NOTE: Refer to Chapter 9 − Foldout Drawings in this
manual when troubleshooting the fuel stop solenoid.
2
Figure 36
1. Fuel stop solenoid
2. Harness connector
Testing
2
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal resistance of the meter and test leads. For accurate test
results, subtract this value from the measured value of
the component you are testing.
1
3
1. Make sure ignition switch is in the OFF position. Disconnect wire harness connector from stop solenoid.
2. Using a digital multimeter, touch one test lead to the
pull coil terminal and the other test lead to the stop solenoid frame (ground) (Fig. 37). The resistance of the pull
coil should be less than 1 ohm (but not zero).
Figure 37
1. Fuel stop solenoid
2. Pull coil terminal
3. Hold coil terminal
3. Using a digital multimeter, touch one test lead to the
hold coil terminal and the other test lead to the fuel stop
solenoid frame (ground) (Fig. 37). The resistance of the
hold coil should be approximately 15.5 ohms.
4. Reconnect solenoid to the wiring harness.
Electrical System
Page 6 − 28
Groundsmaster 3500
Electronic Throttle Control (Gasoline Engine Only)
The engine speed on the Groundsmaster 3500−G is
controlled by an electronic throttle system. The system
includes an electronic throttle control at the operator’s
control panel and a throttle control valve at the Kubota
gasoline engine. The engine ECU uses the position of
the throttle control at the operator panel as an input to
determine the appropriate signal output for the throttle
control valve at the engine to set the engine speed.
1
The electronic throttle control at the operator’s panel is
a rotary hall effect sensor that varies output voltage
based on the sensor position. Use the Kubota Gasoline
Service Tool (KGST) and software, and the Kubota Diagnostic Manual for WG972 engines to test the electronic
throttle control. Contact your Toro distributor for assistance in Kubota engine troubleshooting.
2
Figure 38
2. Rotary hall effect sensor
Electrical
System
1. Throttle control lever
Groundsmaster 3500
Page 6 − 29
Electrical System
Hydraulic Cartridge Solenoid Valve Coils
The hydraulic system on the Groundsmaster 3500 uses
a solenoid valve coil to actuate a cartridge valve on the
hydraulic manifold (Fig. 39). When the solenoid valve
coil is energized, spool shift in the valve will direct hydraulic flow to the cutting decks.
4. If solenoid coil needs replacement, see Hydraulic
Cartridge Valve Coil in the Service and Repairs section
of this chapter.
1
Testing
2
1. Make sure engine is off. Disconnect wire harness
electrical connector from the solenoid valve coil.
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value
from the measured value of the component you are testing.
2. Measure resistance between the two connector terminals on the solenoid coil. The resistance should be
approximately 7.2 ohms.
Figure 39
3. Reconnect electrical connector to the solenoid.
Electrical System
1. Manifold assembly
Page 6 − 30
2. Solenoid valve coil
Groundsmaster 3500
Service and Repairs
NOTE: For additional electrical component service and
repair information, see the Kubota Workshop Manual for
05 Series Diesel Engines, or the Kubota Workshop and
Diagnostics Manuals for WG972 Gasoline Engines.
Battery Care
1. The top of the battery must be kept clean. lf the machine is stored in a location where temperatures are extremely high, the battery will discharge more rapidly
than if the machine is stored in a location where temperatures are cool.
B. Coat battery posts and cable connectors with battery terminal protector (Toro Part No. 107−0392) or
petroleum jelly to prevent corrosion.
3. Battery cables must be tight on terminals to provide
good electrical contact.
WARNING
WARNING
IMPORTANT: Do not remove fill caps (if equipped)
while cleaning the battery.
2. Check battery condition weekly or after every 50
hours of operation. Keep terminals and entire battery
case clean because a dirty battery will discharge slowly.
Connecting battery cables to the wrong battery
post could result in personal injury and/or damage to the electrical system.
4. If corrosion occurs at terminals, disconnect cables.
Always disconnect negative (−) cable first. Clean
clamps and terminals separately. Reconnect cables
with positive (+) cable first. Coat battery posts and cable
connectors with battery terminal protector (Toro Part No.
107−0392) or petroleum jelly to prevent corrosion.
5. If the battery electrolyte is accessible, check electrolyte level every 25 operating hours and every 30 days if
machine is in storage. Maintain cell level with distilled
water. Do not fill cells above the fill line.
Electrical
System
Wear safety goggles and rubber gloves when
working with electrolyte. Charge battery in a
well ventilated place so gasses produced while
charging can dissipate. Since the gases are explosive, keep open flames and electrical sparks
away from the battery; do not smoke. Nausea
may result if the gases are inhaled. Unplug charger from electrical outlet before connecting or
disconnecting charger leads to or from battery
posts.
A. Clean battery by washing entire case with a solution of baking soda and water. Rinse with clear water.
Groundsmaster 3500
Page 6 − 31
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.
1
2
CAUTION
When working with batteries, use extreme caution to avoid splashing or spilling electrolyte.
Electrolyte can destroy clothing and burn skin or
eyes. Always wear safety goggles and a face
shield when working with batteries.
1
Figure 40
Electrolyte Specific Gravity
Fully charged: 1.265 corrected to 80oF (27oC)
Discharged: less than 1.240
1. Knobs
Battery Specifications
BCI Group Size 55:
540 CCA at 0F (−18C)
75 minute reserve capacity at 80F (27C)
2. Battery cover
1
2
Dimensions
(including terminal posts and caps)
Length 9.0 inches (22.8 cm)
Width 6.0 inches (15.2 cm)
Height 8.5 inches (21.6 cm)
Figure 41
Removal and Installation (Fig. 40 and 41)
1. Ground cable
IMPORTANT: Be careful not to damage terminal
posts or cable connectors when removing the battery cables.
1. Remove battery cover from the frame. Loosen battery retainer securing the back of the battery to the battery support.
2. Loosen and remove negative (−) cable from battery.
After negative cable is removed, loosen and remove
positive (+) cable from battery.
2. Positive cable
NOTE: Before connecting the negative (ground) cable,
connect a digital multimeter (set to amps) between the
negative battery post and the negative (ground) cable
connector. The reading should be less than 0.1 amp. If
the reading is 0.1 amp or more, the machine’s electrical
system should be tested for short circuits or faulty components and repaired.
5. Make sure that rubber boot is properly placed over
positive cable end and positive battery post.
3. Carefully remove battery from machine.
4. Install battery in reverse order making sure to connect and tighten positive cable to battery before connecting the negative cable.
Electrical System
Page 6 − 32
Groundsmaster 3500
1. Replace battery if case is cracked or leaking.
2. Check battery terminal posts for corrosion. Use wire
brush to clean corrosion from posts.
IMPORTANT: Before cleaning the battery, tape or
block vent holes to the filler caps and make sure the
caps are on tightly.
3. Check for signs of wetness or leakage on the top of
the battery which might indicate a loose or missing filler
cap, overcharging, loose terminal post or overfilling.
Also, check battery case for dirt and oil. Clean the battery with a solution of baking soda and water, then rinse
it with clean water.
C. If the difference between the highest and lowest
cell specific gravity is 0.050 or greater or the lowest
cell specific gravity is less than 1.225, charge the battery. Charge at the recommended rate and time given in Battery Charging (in this section) or until the
specific gravity for all cells is 1.225 or greater with the
difference in specific gravity between the highest and
lowest cell less than 0.050. If these charging conditions can not be met, replace the battery.
2. Perform a high−discharge test with an adjustable
load tester.
This is one of the most reliable means of testing a battery
as it simulates the cold−cranking test. A commercial battery load tester is required to perform this test.
4. Check that the cover seal is not broken away. Replace the battery if the seal is broken or leaking.
5. Check the electrolyte level in each cell, if possible. If
the level is below the tops of the plates in any cell, fill all
cells with distilled water between the minimum and maximum fill lines. Charge at 15 to 25 amps for fifteen (15)
minutes to allow sufficient mixing of the electrolyte.
Battery Testing
1. Conduct a hydrometer test of the battery electrolyte.
IMPORTANT: Make sure the area around the cells is
clean before opening the battery caps.
A. Measure the specific gravity of each cell with a
hydrometer. Draw electrolyte in and out of the
hydrometer barrel prior to taking a reading to warm−
up the hydrometer. At the same time take the temperature of the cell.
B. Temperature correct each cell reading. For each
10F (5.5C) above 80F (27C) add 0.004 to the specific gravity reading. For each 10F (5.5C) below 80F
(27C) subtract 0.004 from the specific gravity reading.
Example: Cell Temperature
100F
Cell Gravity
1.245
100F minus 80F equals 2F
(38C minus 27C equals 11C)
20F multiply by 0.004/10F equals 0.008
(11C multiply by 0.004/5.5C equals 0.008)
ADD (conversion above)
0.008
Correction to 80F (26.7C)
1.253
Groundsmaster 3500
CAUTION
Follow the battery load tester manufacturer’s
instructions when using a load tester.
A. Check the voltage across the battery terminals
prior to testing the battery. If the voltage is less than
12.4 VDC, recharge the battery.
B. If the battery has been charged, apply a 150 amp
load for fifteen (15) seconds to remove the surface
charge. Use a battery load tester following the
manufacturer’s instructions.
C. Make sure battery terminals are free of corrosion.
D. Measure the temperature of the center battery
cell.
E. Connect a battery load tester to the battery terminals following the load tester manufacturer’s instructions. Connect a digital multimeter to the battery
terminals.
F. Apply a test load of 325 amps (one half the Cranking Performance rating of the battery) for fifteen (15)
seconds.
G. Take a battery voltage reading after the load has
been applied to the battery for fifteen (15) seconds,
then remove the load. Record the voltage reading.
H. Using the table below, determine the minimum
voltage for the cell temperature reading:
Page 6 − 33
Electrical System
Electrical
System
Battery Inspection and Maintenance
Minimum
Voltage
Battery Electrolyte
Temperature
9.6
70F (and up)
21.1C (and up)
9.5
60F
15.6C
9.4
50F
10.0C
9.3
40F
4.4C
9.1
30F
−1.1C
8.9
20F
−6.7C
8.7
10F
−12.2C
8.5
0F
−17.8C
I. If the test voltage is below the minimum, replace
the battery. If the test voltage is at or above the minimum, return the battery to service.
Battery Charging
Battery
Reserve
Capacity
(Minutes)
75%
50%
25%
0%
80 or less
3.8 hrs
@
3 amps
7.5 hrs
@
3 amps
11.3 hrs
@
3 amps
15 hrs
@
3 amps
81 to 125
5.3 hrs
@
4 amps
10.5 hrs 15.8 hrs
@
@
4 amps 4 amps
21 hrs
@
4 amps
126 to
170
5.5 hrs
@
5 amps
11 hrs
@
5 amps
16.5 hrs
@
5 amps
22 hrs
@
5 amps
171 to
250
5.8 hrs
@
6 amps
11.5 hrs
@
6 amps
17.3 hrs
@
6 amps
23 hrs
@
6 amps
above
250
6 hrs
12 hrs
18 hrs
24 hrs
@
@
@
@
10 amps 10 amps 10 amps 10 amps
To minimize possible damage to the battery and allow
the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger
which is available in most locations.
CAUTION
Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to
60oF (16oC) before connecting to a charger.
CAUTION
Follow the battery charger manufacturer’s
instructions when using a battery charger.
NOTE: Using specific gravity of the battery cells is the
most accurate method of determining battery condition.
1. Determine the battery charge level from either its
specific gravity or open circuit voltage.
Battery Charge
Level
Specific
Gravity
Open Circuit
Voltage
100%
1.265
12.68
75%
1.225
12.45
50%
1.190
12.24
25%
1.155
12.06
0%
1.120
11.89
Charge the battery in a well−ventilated place to
dissipate gases produced from charging. These
gases are explosive; keep open flame and electrical spark away from the battery. Do not smoke.
Nausea may result if the gases are inhaled. Unplug the charger from the electrical outlet before
connecting or disconnecting the charger leads
from the battery posts.
3. Following the battery charger manufacturer’s
instructions, connect the charger cables to the battery.
Make sure a good connection is made.
4. Charge the battery following the battery charger
manufacturer’s instructions.
5. Occasionally check the temperature of the battery
electrolyte. If the temperature exceeds 125oF (51.6oC)
or the electrolyte is violently gassing or spewing, the
charging rate must be lowered or temporarily stopped.
2. Determine the charging time and rate using the battery charger manufacturer’s instructions or the following
table.
Electrical System
Battery Charge Level
(Percent of Fully Charged)
6. Three (3) hours prior to the end of the charging, measure the specific gravity of a battery cell once per hour.
The battery is fully charged when the cells are gassing
freely at a low charging rate and there is less than a
0.003 change in specific gravity for three (3) consecutive readings.
Page 6 − 34
Groundsmaster 3500
Hydraulic Cartridge Solenoid Valve Coil
The solenoid valve coil on the hydraulic control manifold
(Fig. 42) can be replaced without opening the hydraulic
system.
1
Removal
1. Park machine on a level surface, lower cutting
decks, engage parking brake, stop engine and remove
key from the ignition switch.
2
3
4
2. Disconnect the wire harness electrical connector
from the solenoid valve coil.
3. Remove the nut from the spool assembly.
4. Slide the coil assembly from the solenoid valve stem.
Discard the coil.
5. Clean any corrosion or dirt from the valve stem.
60 in−lb
(6.8 N−m)
Installation
(manifoldfor unit serial number
314000001 & up shown)
Figure 42
1. Slide new coil assembly onto the solenoid valve
stem.
1. Hydraulic manifold
2. Solenoid valve (R1)
3. Solenoid valve coil
4. Nut
2. Install the nut onto the spool assembly and torque
nut 60 in−lb (6.8 N−m) (do not over tighten).
Electrical
System
3. Connect the wire harness electrical connector to the
solenoid valve coil.
Groundsmaster 3500
Page 6 − 35
Electrical System
This page is intentionally blank.
Electrical System
Page 6 − 36
Groundsmaster 3500
Chapter 7
Wheels, Brakes, and Chassis
Table of Contents
2
2
3
3
4
5
6
8
8
Deluxe Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Front Wheel and Brake . . . . . . . . . . . . . . . . . . . . . 10
Rear Fork and Wheel . . . . . . . . . . . . . . . . . . . . . . . 12
Brake Lever Linkages . . . . . . . . . . . . . . . . . . . . . . 14
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Front Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rear Lift Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Sidewinder Carrier . . . . . . . . . . . . . . . . . . . . . . . . . 22
Wheels, Brakes,
and Chassis
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Front Lift Arms . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Front Lift Arm Carrier Stop Bracket
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Rear Lift Arm . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Standard Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Groundsmaster 3500
Page 7 - 1
Wheels, Brakes,and Chassis
Specifications
Item
Description
Tire pressure
14 to 18 PSI (97 to 124 kPa)
70 to 90 ft- lb (95 to 122 N- m)
Wheel lug nut torque
Special Tools
Order special tools from your Toro Distributor.
Wheel Hub Puller
Part Number: TOR4097
The wheel hub puller allows safe removal of the wheel
hub from the shaft of wheel motors.
Figure 1
Wheels, Brakes, and Chassis
Page 7 - 2
Groundsmaster 3500
Adjustments
Adjust Brakes
C. If brakes can not be adjusted properly, repair or
replace brake components as necessary.
CAUTION
D. After adjustment is complete, install both front
wheel assemblies to the machine (see Front Brake
and Wheel Installation in this section).
Before and after adjusting the brakes, always
check the brakes in a wide open area that is flat
and free of other persons and obstructions.
E. Lower front wheels to the ground.
1. Check brake adjustment as follows:
F. Before starting engine, close by- pass valve on
pump by rotating it 90 degrees (Fig. 2).
A. Park machine on a level surface, lower cutting
units, stop engine, and remove key from the ignition
switch.
B. Rotate by- pass valve on the piston pump 90 degrees to allow front wheels to turn freely (Fig. 2).
1
2
CAUTION
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 - Safety.
Figure 2
1.
Piston pump
2.
D. Apply the parking brake. The force to actuate the
brake lever should be from 30 to 40 lbs (133 to 178
N).
1
5
4
E. With the parking brake applied, use a torque
wrench on the wheel hub lock nut to identify the
break away torque at each front wheel. The minimum break away torque with the parking applied
should be 300 ft- lb (407 N- m).
2
6
3
2. If adjustment is necessary, adjust brakes as follows:
A. Remove both front wheel assemblies from the
machine (see Front Brake and Wheel Removal in
this section).
B. Adjust brakes by turning clevis to increase or decrease shoe pressure on the brake drum (Fig. 3).
Make sure that brake shoes do not drag against
drums with the parking brake lever released.
Groundsmaster 3500
By- pass valve
1. Clevis
2. Adjustment rod
3. Brake lever
Page 7 - 3
Figure 3
4. Brake drum
5. Cotter pin
6. Jam nut
Wheels, Brakes,and Chassis
Wheels, Brakes,
and Chassis
C. Chock rear wheel. Jack up both front wheels and
safely support the machine.
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.
2
1
IMPORTANT: Keep front cutting units on the lift
arms when performing this adjustment.
3
2. Make sure clearance between each lift arm and floor
plate bracket is from 0.18 to 0.32 inch (4.6 to 8.1 mm)
(Fig. 4).
3. If the clearance is not in this range, attain proper
clearance as follows:
A. Lower front lift arms, stop engine, engage parking
brake, and remove key from the ignition switch. Back
off stop bolts if reducing the clearance between the
lift arm and the floor plate bracket (Fig. 5).
Figure 4
1. Lift arm
2. Floor plate bracket
B. Adjust front hydraulic cylinder by backing off jam
nut on the cylinder, removing the pin from the clevis,
and rotating the clevis (Fig. 6).
3. Clearance
1
2
3
C. Install pin to clevis. Fully raise front lift arms and
check clearance. Repeat steps A and B if necessary.
D. Tighten jam nut on the hydraulic cylinder when
clearance is correct.
IMPORTANT: The lack of clearance at the front
stops can damage the lift arms.
4. With the front lift arms fully raised, make sure clearance between each lift arm and stop bolt is from 0.005
to 0.040 inch (0.13 to 1.02 mm). If the clearance is not
in this range, adjust stop bolts as necessary (Fig 5).
Figure 5
1. Stop bolt
2. Lift arm
3. Clearance
2
1
Figure 6
1. Hydraulic cylinder
Wheels, Brakes, and Chassis
Page 7 - 4
2. Jam nut
Groundsmaster 3500
Adjust Front Lift Arm Carrier Stop Bracket Assembly
1. Park machine on a level surface, fully raise cutting
units, stop engine, engage parking brake, and remove
key from the ignition switch.
7
2. Make sure that pivot brackets (items 6 and 9) are not
overtightened. They should pivot and return freely.
8
10
3. To allow horizontal movement of the actuators (items
2 and 8), loosen carriage screws and flange nuts that secure actuators to actuator mount brackets.
4. To allow vertical movement of the actuator mount
brackets (item 3), loosen carriage screws and flange
nuts that secure actuator mount brackets to lift arms.
3
1
4
9
6
5. Simultaneously move both actuators against back of
the carrier stop bracket and pivot brackets. Secure actuators (items 2 and 8) to actuator mount brackets with
carriage screws and flange nuts.
5
3
2
FRONT
11
6. With pivot brackets tipped forward, slide actuator
mount brackets down so that the actuators just contact
the pivot brackets. Secure actuator mount brackets to lift
arms with carriage screws and flange nuts.
Figure 7
LH lift arm
LH actuator
Actuator mount bracket
Horizontal screw
Vertical screw
LH pivot bracket
7.
8.
9.
10.
11.
RH lift arm
RH actuator
RH pivot bracket
Carrier stop bracket
Return spring
Wheels, Brakes,
and Chassis
1.
2.
3.
4.
5.
6.
Groundsmaster 3500
Page 7 - 5
Wheels, Brakes,and Chassis
Adjust Rear Lift Arm
NOTE: If rear lift arm makes clunking noises during
transport, the clearance should be adjusted/reduced.
1. Park machine on a level surface and engage parking
brake.
2
IMPORTANT: This adjustment must be performed
with the rear cutting unit attached to the rear lift arm.
2. Raise lift arms. Make sure clearance between one
end of wear strip and bumper bar on frame is from .020
to .100 inch (0.51 to 2.54 mm) when other end of wear
strip is in contact with bumper bar (Fig. 8).
1
Figure 8
1.
Wear strip
2.
Bumper bar
1
3. If the clearance is not in this range, attain proper
clearance by adjusting the rear hydraulic cylinder as follows (Fig. 9):
2
A. Lower cutting units, turn engine off, and remove
key from the ignition switch.
B. Back off jam nut from the rear hydraulic cylinder
clevis.
IMPORTANT: Use a protective covering around the
hydraulic cylinder rod when rotating the rod to prevent damage to the rod.
C. Grasp cylinder rod near the jam nut and rotate the
rod.
Figure 9
1.
Rear hydraulic cylinder
2.
Jam nut
D. Raise cutting units and check clearance. Repeat
steps A through C as necessary. Tighten jam nut on
hydraulic cylinder rod when clearance is correct.
IMPORTANT: The lack of clearance at the rear wear
strip can damage the rear lift arm.
Wheels, Brakes, and Chassis
Page 7 - 6
Groundsmaster 3500
Wheels, Brakes,
and Chassis
This page is intentionally blank.
Groundsmaster 3500
Page 7 - 7
Wheels, Brakes,and Chassis
Service and Repairs
Standard Seat
1
6
5
2
7
8
9
4
3
2
3
13
4
15
17
19 18
20
22
23
10
14
16
21
12 11
14
22
20
Figure 10
1.
2.
3.
4.
5.
6.
7.
8.
Seat (incl. 4 thru 7, 14, & 15)
Seat belt
Lock washer
Cap screw
Armrest
Cap screw
Flange hex nut
Screw
9.
10.
11.
12.
13.
14.
15.
16.
Hex flange hd screw
Spacer
Armrest bracket
Washer
Hex flange hd screw
Seat support strap
Seat adjuster with latch
Seat adjuster
17.
18.
19.
20.
21.
22.
23.
Seat switch
Hex flange head screw
Hex flange head screw
Flange hex nut
Cap screw
Lock washer
Spacer
Removal
Installation
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. Install any new seat parts (Fig 10).
2. Remove four hex flange head screws securing the
seat support straps to the frame. Note location of
spacers under front of seat support straps.
3. Disconnect electrical connector from the seat switch.
Separate seat from the frame.
2. Position seat, spacers and support straps to the fuel
tank and frame.
3. Connect electrical connector to the seat switch.
4. Secure seat support straps to the frame with four hex
flange head screws.
4. Remove seat parts as necessary to make repairs
(Fig. 10).
Wheels, Brakes, and Chassis
Page 7 - 8
Groundsmaster 3500
Deluxe Seat
8
9
8
2
6
5
3
4
4
3
19
5 6
20
20
1
23
22
12
11
16
15
13
23
18
10
7
17
14
21
Figure 11
Bottom cushion
Back cushion
Seat belt
Flat washer
Flat washer
Cap screw
Bottom cover
Armrest kit
9.
10.
11.
12.
13.
14.
15.
16.
Back cover
Seat switch
Adjusting track - RH
Track - LH
Support strap
Flange nut
Knob kit
Weight indicator
17.
18.
19.
20.
21.
22.
23.
Weight adjust kit
Spring and saddle kit
Shock absorber kit
Knob kit
Chassis assembly
Heat shield
Flange head screw (4)
Removal
Installation
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. Install any new seat parts (Fig. 11) as a guide.
2. Remove heat shield and seat support straps with
seat attached from the frame. Note location of spacers
under front of seat support straps.
3. Disconnect electrical connector from the seat switch
and remove seat assembly.
2. Position seat with support straps attached to the fuel
tank and frame.
3. Attach electrical connector to the seat switch.
4. Secure seat support straps to the frame with four hex
flange head screws.
4. Remove seat parts as necessary to make repairs
(Fig. 11).
Groundsmaster 3500
Page 7 - 9
Wheels, Brakes,and Chassis
Wheels, Brakes,
and Chassis
1.
2.
3.
4.
5.
6.
7.
8.
Front Wheel and Brake
33
31
25
9
22
26
29
30
27
28
11
13
7
32
18
10
23
14
Blue Loctite 242
17
250 to 275 ft- lb
(339 to 373 N- m)
3
24
20
12
4
15
21
17
RIGHT
19
FRONT
16
Anti- seize
Lubricant
8
2
5
70 to 90 ft- lb
(95 to 122 N- m)
1
6
Figure 12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Lug nut
Drive stud
Button head screw
Wheel and tire
Wheel hub
Lock nut
Hydraulic wheel motor
Brake drum
Woodruff key
Cotter pin
Adjustment rod
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Brake lever
Lock nut
Cap screw
Brake bracket
Return spring
Brake shoe
Backing plate
Cam shaft
Retainer clip
Lock nut
Cap screw
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Spacer
Wheel shield
Cotter pin
Clevis pin
Clevis
Jam nut
Flange bushing
Brake pivot bracket
Brake pivot shaft
Hex flange head screw
Hex flange nut
Removal (Fig. 12)
2. Jack up and safely support the front wheel.
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
3. Remove lug nuts. Pull wheel from drive studs and
wheel hub.
WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 - Safety.
Wheels, Brakes, and Chassis
NOTE: The installation torque of the lock nut is from
250 to 275 ft- lb (339 to 373 N- m). Use impact wrench
to loosen, but do not remove, lock nut from the hydraulic
motor shaft.
4. Release parking brake.
Page 7 - 10
Groundsmaster 3500
E. Position both brake shoes on the backing plate so
that the concave heels attach to the anchor pin.
IMPORTANT: DO NOT hit wheel hub, wheel hub
puller or wheel motor with a hammer during wheel
hub removal or installation. Hammering may cause
damage to the wheel motor.
5. Using hub puller (see Special Tools), loosen wheel
hub from wheel motor.
6. Remove lock nut, hub, and brake drum from motor
shaft. Locate and retrieve woodruff key.
7. Remove cotter pin from the adjustment rod. Separate adjustment rod from the brake lever.
NOTE: The brake lever, backing plate, retaining clip,
return springs, brake shoes, and cam shaft can be removed as a complete brake assembly.
8. Remove the brake assembly from the brake bracket
if desired. Remove four cap screws and lock nuts securing the assembly to the bracket.
9. Disassemble brake assembly as follows (Fig. 13):
A. Remove return springs from the brake shoes. Remove brake shoes from the backing plate.
B. Mark brake cam and brake lever to assure proper
alignment during reassembly. Remove retaining clip
from the brake cam. Pull brake lever from the cam
and remove cam from backing plate.
10.The brake bracket and wheel shield can be removed
as follows:
A. Remove lock nuts, spacers, and cap screws securing the brake bracket, wheel shield, and hydraulic
motor to the frame.
B. Separate bracket and shield from the frame.
Installation (Fig. 12)
F. Insert both return springs into the holes of both
brake shoes. Make sure shoes fit snuggly against
the anchor pin and cam.
3. If the brake assembly was not disassembled but was
removed as a complete assembly, secure backing plate
to the brake bracket with four cap screws and lock washers. Tighten fasteners.
4. Attach adjustment rod to the brake lever. Secure adjustment rod with cotter pin.
5. Thoroughly clean wheel motor shaft and wheel hub
taper.
6. Install woodruff key and slide wheel hub and brake
drum assembly onto the shaft.
7. Secure wheel hub and brake drum to the hydraulic
motor shaft with lock nut.
NOTE: For proper brake operation, the brake shoes
and backing plate must be concentrically aligned with
the brake drum.
8. To align brake shoes and drum, apply parking brake.
Then tighten four socket head screws and lock nuts that
secure the brake bracket, shield, and wheel motor to the
frame.
9. Install wheel and tire assembly. Secure with lug nuts
on drive studs.
10.Lower wheel to ground. Torque lug nuts from 70 to
90 ft- lb (95 to 122 N- m) in a criss- cross pattern.
Torque lock nut from 250 to 275 ft- lb (339 to 373
kg- m).
1. If removed, insert four cap screws through the frame,
hydraulic motor, spacers, wheel shield, and brake
bracket. Secure with lock nuts, but do not fully tighten.
6
2
2. Assemble brake assembly as follows (Fig. 13):
5
A. Secure backing plate to the brake bracket with
four cap screws and lock washers.
1
B. Apply antiseize lubricant to cam shaft splines. Insert cam shaft through the backing plate.
C. Attach brake lever to the cam shaft. Make sure
matchmarks are aligned properly. Secure lever to
shaft with retaining clip.
D. Lubricate brake shoe pivot points with a light
coating of grease.
Groundsmaster 3500
4
1.
2.
3.
4.
Page 7 - 11
3
7
Figure 13
Return spring
Brake shoe (toe end)
Brake shoe (heel end)
Backing plate
5. Retaining clip
6. Cam shaft
7. Anchor pin
Wheels, Brakes,and Chassis
Wheels, Brakes,
and Chassis
11. Check and adjust brake.
Rear Fork and Wheel
35 34 25 33
300 to 400 ft- lb
(407 to 542 N- m)
6
4
3
8
27
65 to 85 ft- lb
(88 to 115 N- m)
36
25
29
24
65 to 85 ft- lb
(88 to 115 N- m)
1
70 to 90 ft- lb
(95 to 122 N- m)
21
16
2
60 to 80 ft- lb
(81 to 108 N- m)
10
9
28
4
22
23
26
30
65 to 85 ft- lb
(88 to 115 N- m)
14
6
28
19
17
38
11
20
37
15
32
39
17
13
31
7
18
2
3
12
5
Figure 14
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Hydraulic steering cylinder
Ball joint
External retaining ring
Grease fitting
Grease fitting plug
Jam nut
Rear fork
Cap screw
Lock washer
Thrust washer
Tire
Hex socket head screw
Lock nut
Wheels, Brakes, and Chassis
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Drive stud
Wheel hub
Lock nut
45o hydraulic fitting
Hydraulic motor
Hydraulic hose
Hydraulic hose
Lug nut
Clamp
Spacer
Clamp
Hydraulic fitting
Rear casting
Page 7 - 12
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Hex flange head screw
Bushing
Cap screw
Lock nut
O- ring
O- ring
O- ring
O- ring
Hose assembly
Hose assembly
Valve stem
Wheel rim
Woodruff key
Groundsmaster 3500
Removal
Installation
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. Position rear fork through the frame.
2. Remove hood from the machine.
2. Install lock washer, thrust washer, and cap screw to
the rear fork shaft. Torque cap screw from 60 to 80 ft- lb
(81 to 108 N- m). Make sure fork turns freely.
3. Install hydraulic motor to the rear fork. Secure motor
to the fork with four hex socket head screws and lock
nuts.
WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 - Safety.
3. Raise and safely support rear of machine enough to
allow the removal of the rear wheel.
4. Remove lug nuts and remove tire and wheel assembly from hub.
5. Separate hydraulic cylinder from the rear fork as follows:
A. Remove both jam nuts securing the ball joint to
the rear fork.
4. Secure hydraulic cylinder to the rear fork as follows:
A. Swing cylinder to the rear fork.
B. Install ball joint to rear fork.
C. Secure ball joint to the rear fork with both jam
nuts. Tighten the first jam nut from 65 to 85 ft- lb (88
to 115 N- m), then tighten the second jam nut to the
same specification.
5. Lower wheel to ground. Torque lug nuts from 70 to
90 ft- lb (95 to 122 N- m) in a criss- cross pattern.
B. Separate ball joint from the rear fork.
C. Swing cylinder clear of the rear fork.
6. Remove four lock nuts and hex socket head screws
securing the hydraulic motor to the rear fork. Remove
motor from the fork and position it away from the fork.
CAUTION
Support rear fork to prevent its falling during removal and installation. Personal injury or damage to the fork may result from improper handling.
Wheels, Brakes,
and Chassis
7. Remove cap screw, thrust washer, and lock washer
from the rear fork shaft.
8. Lower rear fork from machine.
9. Check bushings for wear and damage. Replace if
necessary.
Groundsmaster 3500
Page 7 - 13
Wheels, Brakes,and Chassis
Brake Lever Linkages
2
1
3
3
9
9
19
24
7
23
25
22
8
5
8
20
6
18
4
7
21
15
10
11
17
15
12
16
12
26
13
27
14
35
12
28
29
30
36
37
31
34
33
32
Figure 15
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Pop rivet
Control panel cover
Cover bracket
Flange nut
Hex flange head screw
Magnet support
Hex washer head screw
Strike bracket
Magnetic catch
Flat washer
Lock nut
Cotter pin
Bumper pad
Wheels, Brakes, and Chassis
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Hex socket flat head screw
Parking brake link
Clevis pin
Clevis pin
Lever assembly
Parking brake spacer
Slotted hex head screw
Frame
Switch
Flat washer
Lock nut
Cap screw
Page 7 - 14
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
Brake pivot shaft
Clevis pin
Flange bushing
Brake pivot bracket
Hex flange head screw
Cotter pin
Brake cam shaft
Brake lever
Retainer clip
Adjustable clevis
Jam nut
Adjustment rod
Groundsmaster 3500
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,
adjustment rod, or the brake lever, make sure to
mark both parts. Marking both parts will make reassembly and brake adjustment easier.
3. Remove and replace parts as necessary to repair
brake linkages.
4. Install control panel cover to the machine.
Wheels, Brakes,
and Chassis
IMPORTANT: Always check and adjust brakes anytime brake linkages are disassembled or repaired.
Groundsmaster 3500
Page 7 - 15
Wheels, Brakes,and Chassis
Steering Column
20 to 26 ft- lb
(28 to 35 N- m)
8
9
11
14 20
27
21
7
38
39
10
12
17
28
Blue
Loctite 242
32
19
2
18
23
4
6
22
24
5
34
36
41
8
33
37
43
45
40
26
25
3
35
40
44
3
43
1
29
30
31
13
15
16
2
Figure 16
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Steering arm
Flange nut
Flange head screw
Steering valve bracket
Cap screw
Pivot hub
Steering cover
Cap screw
Toro decal
Ball knob
Steering tilt lever
Steering control valve
Tilt bracket
Cap screw
Flat washer
Wheels, Brakes, and Chassis
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Flange nut
Steering wheel
Hydraulic fitting
Hydraulic fitting
Steering wheel nut
Toro decal
Hydraulic hose
Hydraulic hose
Hydraulic hose
Hydraulic hose
Hydraulic hose
Tilt steering boss
Friction disc
Friction disc
Flat washer
Page 7 - 16
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
Jam nut
Flange screw
Steering shield
O–ring
O–ring
O–ring
O–ring
Philips head screw
Steering wheel cap
Flat washer
Flange nut
Slope indicator
Decal
Lock nut
Cap screw
Groundsmaster 3500
Disassembly
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
2
2. Remove philips head screws and steering wheel cap
from the steering wheel.
1
3. Remove steering wheel nut from the steering control
valve. Pull steering wheel from the control valve.
6
4. Remove cover from the steering control valve bracket.
3
5. Remove four flange screws securing the steering
control valve to the steering control valve bracket.
6. Remove both hex flange nuts, cap screws, and pivot
hubs securing the steering control valve bracket to the
steering arm. Slide bracket from the steering control
valve and steering arm.
8
7. Remove and replace parts as necessary to repair
steering column (Fig. 16 and 17).
4
5
Assembly
1. Make sure lever and friction discs are properly assembled to the steering control valve bracket (Fig. 16
and 17).
2. Position steering control bracket to the steering control valve and steering arm. Secure bracket to the steering arm with pivot hubs, cap screws, and hex flange
nuts.
3. Apply blue Loctite 242 to flange hd. screws and install steering control valve to the steering valve bracket
7
Figure 17
1.
2.
3.
4.
Tilt bracket
Steering valve bracket
Jam nut
Flat washer
5.
6.
7.
8.
Friction disc
Tilt steering lever
Steering arm
Friction disc
4. Secure cover to the steering control valve bracket
with cap screws.
Wheels, Brakes,
and Chassis
5. Install steering wheel to the steering control valve.
Torque steering wheel nut from 20 to 26 ft- lb (28 to 35
N- m).
6. Secure steering wheel cap to the steering wheel with
six philips head screws.
Groundsmaster 3500
Page 7 - 17
Wheels, Brakes,and Chassis
Front Lift Arms
9
6
4
RIGHT
FRONT
Anti- seize
Lubricant
34
57
47
42
40
15
39
41
55
43
48
44
58
63
28
60
62
61
21
22
20
26
28
26
28
51
23
24
13
38
33
20
25
24
19
65
49
54
3
33
53 64
56 27
17
45
33 46
10
18
5
66
53
59
31
16
28
37
32
29
30
7
12
50
8 35 1
52
36
2
13
11
14
Figure 18
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
90o hydraulic fitting
Hydraulic cylinder
Sidewinder carrier assembly
Flange nut
Flange head screw
Hydraulic hose
Centering wire
Hydraulic hose
Hydraulic hose
Hydraulic hose
Slide bracket
Flange nut
Plastic slide
Flange head screw
LIft arm pivot shaft
Roll pin
Cap screw
Flange head screw
Cap screw
Bearing cap
Jam nut
Cap screw
Wheels, Brakes, and Chassis
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
Lock nut
Thrust washer
Slide support bar
Pin
Spacer
External retaining ring
Bulkhead nut
Hydraulic tube
Bulkhead nut
Carrier stop bracket
Nut
Flange nut
O–ring
O–ring
RH lift arm
LH lift arm
Cap screw
Shaft
Thrust washer
Lynch pin
Rod
Cap screw
Page 7 - 18
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
Cap screw
Torsion spring
Grease fitting
Hair pin
RH deck stop
LH deck stop
Rivet
Rubber bumper
Flange nut
Flange head screw
RH pivot bracket
LH pivot bracket
Front carrier frame
Flat washer
Latch tube
Latch rod
Rod clip
Rivet
Actuator bracket
Carriage screw
RH actuator
LH actuator
Groundsmaster 3500
Removal (Fig. 18)
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 (see Chapter 8 - Cutting Deck
and Carrier Frame in this manual).
NOTE: Remove both spacers from the hydraulic cylinder clevis when removing the right, front lift arm.
3. Disconnect hydraulic cylinder from the front lift arms
by removing external retaining rings and pins.
5. Route hydraulic hoses so they clear the lift arm by
0.040 to 0.120 inch (1.0 to 3.0 mm) when the lift arm is
fully raised (Fig. 19).
6. Adjust lift arms to proper clearance (see Adjust Front
Lift Arms in this chapter).
7. Install cutting unit to the front lift arm pivot shaft (see
Chapter 8 - Cutting Deck and Carrier Frame in this
manual).
8. Grease front lift arm.
1
4. Remove both flange head screws and carrier stop
bracket.
5. Slide lift arm off the pivot shaft.
6. Repair lift arm as necessary.
Installation (Fig. 18)
3
1. If the cutting unit pivot shaft was removed from lift
arm:
A. Apply anti- seize lubricant to pivot shaft before inserting into lift arm.
2
Figure 19
1. Hydraulic hoses
2. Hydraulic cylinder
3. Clearance
B. Secure pivot shaft with cap screw.
2. Slide lift arm onto the lift arm pivot shaft.
3. Secure carrier stop bracket with both flange head
screws to the lift arm pivot shafts.
NOTE: Install both spacers to the hydraulic cylinder
shaft clevis when installing the right, front lift arm.
Wheels, Brakes,
and Chassis
4. Secure hydraulic cylinder to the lift arm with pins and
external retaining rings.
Groundsmaster 3500
Page 7 - 19
Wheels, Brakes,and Chassis
Rear Lift Arm
Blue
Loctite 242
16 3 12
12
15
13
46
17
2
21
14
42
44
11
13
6
22
2
18
1
49
26
35
28
10
12
48
9
7
24
38
29
39
5
31
20
4
27
41
46
45
46
23
25
37
30
15
13
36
40
33
34
32
Anti- seize
Lubricant
47
12
8
RIGHT
43 19
12
FRONT
2
3
200 to 250 ft- lb
(271 to 339 N- m)
12
Figure 20
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Hydraulic tube
Bulkhead locknut
Hydraulic T- fitting
Hydraulic hose
90o hydraulic fitting
Hydraulic hose
Hydraulic tube
Straight hydraulic fitting
Castor bushing
Hydraulic cylinder
Thrust washer
O–ring
Bulkhead locknut
Bulkhead elbow union
Hydraulic hose
Hydraulic hose
Hydraulic tube
Wheels, Brakes, and Chassis
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Hydraulic tube
Hydraulic tube
Tube clamp
O–ring
Cap screw
Lock nut
Rear pivot shaft
Jam nut
Washer
Lift arm assembly
Flange head screw
Thrust washer
Grease fitting
Cutting unit pivot shaft
Cap screw
Cap screw
Page 7 - 20
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
Rebound washer
Thrust washer
Lynch pin
Pop rivet
Wear strip
Rear cutting unit frame
Grease fitting
O–ring
Guard
Cap screw
Cap screw
Lock nut
External retaining ring
Pin
Flat washer
O–ring
Groundsmaster 3500
Removal (Fig. 20)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
2. Remove cutting unit from the pivot shaft of the rear
lift arm (see Chapter 8 - Cutting Deck and Carrier Frame
in this manual).
3. Remove external retaining ring and thrust washer
from the lift cylinder shaft.
4. Remove flange head screw and thrust washer from
the rear pivot shaft.
3. Slide rear lift arm onto rear pivot shaft and through lift
cylinder clevis simultaneously.
4. Apply blue Loctite 242 to cap screw and secure lift
arm to pivot shaft with cap screw and washer.
5. Secure hydraulic cylinder clevis with the thrust washer and external retaining ring.
6. Install cutting unit to the rear lift arm (see Chapter 8
- Cutting Deck and Carrier Frame in this manual).
7. Adjust lift arm to proper clearance (see Adjust Rear
Lift Arm in this chapter).
6. Repair lift arm as necessary.
IMPORTANT: Make sure hoses are free of twists and
sharp bends. Raise cutting units and shift them to
the left. Rear cutting unit hoses must not contact the
traction cable bracket. If required, reposition fittings and hoses.
Installation
8. Grease rear lift arm.
5. Slide rear lift arm from rear pivot shaft and hydraulic
cylinder.
1. If the rear lift arm pivot shaft was removed from
frame:
A. Thoroughly clean tapered surfaces of shaft and
frame.
B. Position pivot shaft to frame and secure with
washer and jam nut. Torque jam nut from 200 to 250
ft- lb (271 to 339 N- m).
2. If the cutting unit pivot shaft was removed from lift
arm:
A. Apply anti- seize lubricant to pivot shaft before inserting into lift arm.
Wheels, Brakes,
and Chassis
B. Secure pivot shaft with two (2) cap screws and
washer.
Groundsmaster 3500
Page 7 - 21
Wheels, Brakes,and Chassis
Sidewinder Carrier
2
6
1
13
12
11
8
10
4
10
RIGHT
9
4
8
FRONT
67 to 83 ft- lb
(91 to 113 Nm)
3
7
5
Figure 21
1.
2.
3.
4.
5.
Lower frame
Sidewinder carrier assembly
Slide bracket
Plastic slide
Flange head screw
6.
7.
8.
9.
Flange nut
Cap screw
Thrust washer
Slide support bar
10.
11.
12.
13.
Bearing cap
Lock nut
Lift arm (RH shown)
Lift arm pivot shaft
Disassembly
Assembly
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. Assemble sidewinder carrier using (Fig. 21).
2. Remove lift arms (Fig. 18 and 20) (see Front and
Rear Lift Arms in this chapter).
3. Disassemble sidewinder carrier as needed (Fig. 21).
Wheels, Brakes, and Chassis
A. Do not lubricate sidewinder cross tube as bearing
caps and slides are self lubricating.
B. Tighten the bearing cap screws from 67 to 83 ft- lb
(91 to 113 Nm).
2. Install lift arms (Fig. 18 and 20) (see Front and Rear
Lift Arms in this chapter).
Page 7 - 22
Groundsmaster 3500
Chapter 8
Cutting Decks
Table of Contents
Cutting Decks
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4
Factors That Can Affect Quality of Cut . . . . . . . . . 4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Blade Stopping Time . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8
Blade Spindle Assembly . . . . . . . . . . . . . . . . . . . . . 8
Blade Spindle Service . . . . . . . . . . . . . . . . . . . . . . 10
Rear Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rear Roller Service . . . . . . . . . . . . . . . . . . . . . . . . 14
Front Roller Service . . . . . . . . . . . . . . . . . . . . . . . . 17
Cutting Deck Carrier Frame . . . . . . . . . . . . . . . . . 18
Groundsmaster 3500
Page 8 − 1
Cutting Decks
Specifications
MOUNTING: All cutting units are supported by equal
length, independent lift arms and are interchangeable to
all three cutting unit positions.
DISCHARGE: Clippings are discharged from the rear of
the mowing decks. Pre−drilled mounting holes allow attachment of optional mulching baffle.
CONSTRUCTION: Deck chamber and frame are
welded steel construction reinforced with channels and
plates.
CUTTING DECK LIFT: Cutting decks are controlled
with one (1) lift lever.
HEIGHT−OF−CUT RANGE: 3/4 to 4 inch (19 to 101
mm) in 1/4 inch (6.4 mm) increments. Height−of−cut adjustment is made by repositioning deck on deck frame.
DECK DRIVE: Closed loop, integrated relief, hydraulic
system operates cutting deck hydraulic motors. Blade
spindles are 1−1/4 inch (31.7 mm) shafts supported by
greaseable, tapered roller bearings in a ductile iron
housing.
SUSPENSION SYSTEM: A fully floating suspension
with hydraulic counterbalance. Main center pivot allows
side−to−side deck oscillation. Individual decks supported with two (2) front rollers and one, full width, rear
roller.
WEIGHT: Individual cutting deck weighs approximately
195 lb (89 kg).
CUTTING BLADE: Each cutting deck equipped with a
27 inch (686 mm) length, 0.250 inch (6.4 mm) thick, heat
treated, steel blade. Anti−scalp cup installed on cutting
blade. The standard blade is optimized for most cutting
applications. Optional high lift, angled sail and Atomic
blades are available for those situations where the standard blade is not ideal.
Cutting Decks
Page 8 − 2
Groundsmaster 3500
General Information
CAUTION
Never install or work on the cutting decks or lift
arms with the engine running. Always stop engine and remove key from ignition switch first.
Operator’s Manual
Cutting Decks
The Cutting Deck Operator’s Manual provides information regarding the operation, general maintenance and
maintenance intervals for the cutting deck on your
Groundsmaster machine. Refer to that publication for
additional information when servicing the cutting deck.
Groundsmaster 3500
Page 8 − 3
Cutting Decks
Troubleshooting
There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf
conditions. Turf conditions such as excessive thatch,
“sponginess”, uneven ground conditions or attempting
to cut off too much grass height may not always be overcome by adjusting the machine. It is important to remember that the lower the height−of−cut, the more
critical these factors are.
Remember that the “effective” or actual height−of−cut
depends on cutting deck weight, counterbalance setting
and turf conditions. Effective height−of−cut will be different than the bench set height−of−cut.
Factors That Can Affect Quality of Cut
Factor
Possible Problem/Correction
1. Maximum governed engine speed.
Check maximum governed engine speed. Adjust
speed to specifications if necessary.
2. Blade speed.
All deck blades should rotate at the same speed.
See items in Troubleshooting Section of Chapter 4 −
Hydraulic System.
3. Tire pressure.
Check air pressure of each tire. Adjust to pressures
specified in Traction Unit Operator’s Manual.
4. Blade condition.
Sharpen blades if their cutting edges are dull or nicked.
Inspect blade sail for wear or damage. Replace blade if
needed.
5. Mower housing condition.
Make sure that cutting chambers are in good condition.
Keep underside of deck clean. Debris buildup will
reduce cutting performance.
6. Height−of−cut.
Make sure all cutting decks are set at the same
height−of−cut. Adjust cutting decks as specified in the
Cutting Deck Operator’s Manual.
Adjust height−of−cut setting to remove only 1 inch (25
mm) or 1/3 of the grass blade when cutting.
7. Cutting deck alignment and ground following.
Check lift arms and cutting deck pivot linkages for
wear, damage or binding. Also inspect for bent or
damaged pivot shafts.
8. Roller condition.
All rollers should rotate freely. Replace bearings if worn
or damaged.
9.Grass Conditions.
Mow when grass is dry for best cutting results.
Cutting Decks
Page 8 − 4
Groundsmaster 3500
Special Tools
Order special tools from your Toro Distributor.
Rear Roller Bearing and Seal Installation Tools
These tools are used to assemble the cutting deck rear
roller.
Toro Part Numbers:
Inner Seal Tool
Bearing/Outer Seal Tool
Bearing Installation Washer
115−0852
115−0853
107−8133
Inner Seal
Tool
Bearing/Outer Seal
Tool
Bearing Installation
Washer
Figure 1
Front Roller Bearing Installation Tool
The front roller bearing installation tool should be used
when installing bearings into the front rollers. This tool
presses equally against both the inner and outer bearing
races to ensure that no side load is applied to the bearings during installation into the front rollers.
Toro Part Number: TOR6018
Figure 2
Spindle Plug
The spindle plug can be used to prevent contaminant
entry into the cutting deck spindle assembly when the
hydraulic motor is removed from the spindle.
Cutting Decks
Toro Part Number: 94−2703
Figure 3
Groundsmaster 3500
Page 8 − 5
Cutting Decks
Adjustments
CAUTION
Never install or work on the cutting decks or lift
arms with the engine running. Always stop engine and remove key from ignition switch first.
See the Cutting Deck Operator’s Manual for adjustment
procedures for cutting decks on the Groundsmaster
3500.
Blade Stopping Time
The blades of the cutting decks are to come to a complete stop in approximately five (5) seconds after the
PTO is disengaged.
NOTE: Make sure the decks are lowered onto a clean
section of turf or hard surface to avoid dust and debris.
To verify this stopping time, have a second person stand
back from the machine at least twenty (20) feet and
watch the blade on one of the cutting decks. Have the
machine operator disengage the PTO and record the
time it takes for the cutting deck blade to come to a complete stop. If this time is greater than seven (7) seconds,
adjust the blade braking valve (BV) on units prior to Serial No. 314000001 or the blade braking relief valve (RV)
on units Serial No. 314000001 & Up (see Chapter 5 −
Hydraulic System in this manual).
Cutting Decks
Page 8 − 6
Groundsmaster 3500
Cutting Decks
This page is intentionally blank.
Groundsmaster 3500
Page 8 − 7
Cutting Decks
Service and Repairs
CAUTION
Never install or work on the cutting decks or lift
arms with the engine running. Always stop engine and remove key from ignition switch first.
Blade Spindle Assembly
11
33 to 36 ft−lb
(44.7 to 48.8 N−m)
2
12
1
3
4
6
5
8
7
RIGHT
85 to 110 ft−lb
(115 to 149 N−m)
FRONT
9
10
Figure 4
1.
2.
3.
4.
Flange nut (6 used)
Hydraulic deck motor
Spindle plate
Cutting deck
Cutting Decks
5.
6.
7.
8.
O−ring
Spindle assembly
Drive stud (6 used)
Cutting blade
Page 8 − 8
9.
10.
11.
12.
Anti−scalp cup
Blade bolt
Socket head screw (2 used)
Flat washer (2 used)
Groundsmaster 3500
Removal (Fig. 4)
1. Park machine on a level surface, lower cutting
decks, stop engine, engage parking brake and remove
key from the ignition switch.
1
2. Remove two (2) socket head screws and flat washers that secure hydraulic motor to the cutting deck (Fig.
5). Remove hydraulic motor and O−ring from deck.
2
3. Cover top of spindle to prevent debris from entering
spindle. A spindle plug (see Special Tools in this chapter) can be used to cover spindle.
1
NOTE: If desired, cutting deck can be removed from
machine for spindle removal from cutting deck.
4. If spindle is to be removed with cutting deck attached
to the machine, start the engine and raise the cutting
deck. Stop engine and remove key from the ignition
switch. Support the cutting deck so it cannot fall accidentally.
Figure 5
1. Socket head screw
2. Hydraulic motor
5. Remove blade bolt, anti−scalp cup and cutting
blade.
6. Remove flange nuts that secure spindle assembly to
cutting deck. Slide spindle assembly out the bottom of
the deck. Remove spindle plate from top of deck.
7. If necessary, press drive studs (item 7) from spindle
assembly.
Installation (Fig. 4)
1. If drive studs (item 7) were removed from spindle assembly, press new drive studs into spindle. Make sure
that stud heads are fully pressed against spindle surface.
2. Position spindle assembly and spindle plate to cutting deck. Notches on cutting deck and spindle plate
should be aligned to front of deck.
3. Secure spindle assembly and spindle plate to cutting
deck with flange nuts. Tighten flange nuts in a star pattern.
Cutting Decks
4. Install cutting blade, anti−scalp cup and bolt. Tighten
blade bolt from 88 to 108 ft−lb (120 to 146 N−m).
5. Remove cover from top of spindle that was placed to
prevent debris from entering spindle.
6. Position O−ring to top of spindle housing. Secure hydraulic motor to the cutting deck with two (2) socket head
screws and flat washers.
7. After assembly, raise and lower the cutting deck to
verify that hydraulic hoses and fittings do not contact
anything.
Groundsmaster 3500
Page 8 − 9
Cutting Decks
Blade Spindle Service
Disassembly (Fig. 6)
1. Remove blade spindle from cutting deck (see Blade
Spindle Removal in this section).
2
6
2. Loosen and remove spindle nut from top of spindle
shaft.
4
131 to 159 ft−lb
(178 to 215 N−m)
3. Remove the spindle shaft from the spindle housing
which may require the use of an arbor press. The spindle
shaft spacer should remain on the spindle shaft as the
shaft is being removed.
11
10
9
12
8
7
4. Carefully remove oil seals from spindle housing noting direction of seal lips.
1
5. Allow the bearing cones, inner bearing spacer and
spacer ring to drop out of the spindle housing.
4
5
6. Using an arbor press, remove both of the bearing
cups and the outer bearing spacer from the housing.
3
7. The large snap ring can remain inside the spindle
housing. Removal of this snap ring is very difficult.
Assembly (Fig. 6)
NOTE: A replacement spindle bearing set contains two
(2) bearings, a spacer ring and a large snap ring (items
1, 2 and 3 in Fig. 7). These parts cannot be purchased
separately. Do not mix bearing set components from
one deck spindle to another.
Figure 6
1.
2.
3.
4.
5.
6.
NOTE: A replacement bearing spacer set includes the
inner spacer and outer spacer (items 4 and 5 in Fig. 7).
Do not mix bearing spacers from one deck spindle to
another.
2. Install outer bearing spacer into top of spindle housing. The spacer should fit against the large snap ring.
Cutting Decks
7.
8.
9.
10.
11.
12.
Grease fitting
Bearing
Spacer ring
Spacer set (2 piece)
Bearing
Large snap ring
1
4
IMPORTANT: If new bearings are installed into a
used spindle housing, it may not be necessary to replace the original large snap ring. If the original
large snap ring is in good condition with no evidence of damage (e.g. spun bearing), leave the snap
ring in the housing and discard the large snap ring
that comes with the new bearings. If the large snap
ring is found to be damaged, replace the snap ring.
1. If large snap ring was removed from spindle housing,
install snap ring into housing groove. Make sure snap
ring is fully seated in groove.
Spindle housing
Spindle plug
Spindle shaft
Oil seal
Shaft spacer
Spindle nut
2
5
3
1
Figure 7
1. Bearing
2. Spacer ring
3. Large snap ring
Page 8 − 10
4. Inner bearing spacer
5. Outer bearing spacer
Groundsmaster 3500
3. Using an arbor press, push the bearing cups into the
top and bottom of the spindle housing. The top bearing
cup must contact the outer bearing spacer previously
installed, and the bottom bearing cup must contact the
large snap ring. Make sure that the assembly is correct
by supporting the first bearing cup and pressing the second cup against it (Fig 8).
PRESS
4
4. Pack the bearing cones with grease. Apply a film of
grease on lips of oil seals.
6
2
5
5. Install lower bearing cone and greased oil seal into
bottom of spindle housing.
NOTE: The bottom seal must have the lip facing out
(down) (Fig. 9). This seal installation allows grease to
purge from the spindle during the lubrication process.
3
1
Figure 8
1. Bearing cup
2. Large snap ring
3. Large spacer
IMPORTANT: If bearings are being replaced, make
sure to use the spacer ring that is included with the
new bearing set (Fig. 7).
4. Arbor press
5. Support
6. Arbor press base
2
6. Slide spacer ring and inner bearing spacer into
spindle housing, then install upper bearing cone and
greased oil seal into top of housing.
NOTE: The upper seal must have the lip facing out (up)
(Fig. 9).
7. Inspect the spindle shaft and shaft spacer to make
sure there are no burrs or nicks that could possibly damage the oil seals. Lubricate the shaft and spacer with
grease.
8. Install spindle shaft spacer onto shaft. Place thin
sleeve or tape on spindle shaft splines to prevent seal
damage during shaft installation.
1
Figure 9
9. Carefully slide spindle shaft with spacer up through
spindle housing. The bottom oil seal and spindle spacer
should fit together when the spindle is fully installed.
1. Bottom seal installation
2. Upper seal installation
10.Thread spindle nut onto shaft and tighten nut from
131 to 159 ft−lb (178 to 215 N−m).
Cutting Decks
IMPORTANT: Pneumatic grease guns can produce
high pressure inside spindle housing that can damage spindle seals. Pneumatic grease guns, therefore, are not recommended to be used for greasing
of spindle housings.
11. Attach a hand pump grease gun to one of the grease
fittings on housing and fill housing cavity with grease until grease starts to come out of lower seal.
12.Rotate spindle shaft to make sure that it turns freely.
13.Install blade spindle assembly to cutting deck (see
Blade Spindle Installation in this section).
Groundsmaster 3500
Page 8 − 11
Cutting Decks
Rear Roller
2
29 to 35 ft−lb
(40 to 47 N−m)
1
3
4
5
6
7
RIGHT
Blue Loctite 242
FRONT
8
29 to 35 ft−lb
(40 to 47 N−m)
Figure 10
1. Deck frame
2. Rear roller assembly
3. Grease fitting
Cutting Decks
4. Roller shaft screw
5. Roller mount
6. Flange head screw
Page 8 − 12
7. Skid bracket
8. Cap screw
Groundsmaster 3500
Removal (Fig. 10)
30 ft−lb
(41 N−m)
1. Park machine on a level surface, lower cutting
decks, stop engine, engage parking brake and remove
key from the ignition switch.
4
2. If cutting deck is equipped with a roller scraper (Fig.
11), remove fasteners securing left and right scraper rod
brackets to roller mounts. Remove scraper rod assembly.
1
3
29 to 35 ft−lb
(40 to 47 N−m)
2
3. Remove four (4) flange head screws securing roller
mounts to rear of deck frame. Remove roller mounts and
rear roller assembly from deck frame.
4. Loosen fasteners securing each end of roller to roller
mounts. Remove mounts and skid brackets from roller.
6
Installation (Fig. 10)
5
1. Slide roller mounts onto roller shaft.
2. Install roller and roller mount assembly into rear of
deck frame. Secure assembly to deck frame with four (4)
flange head screws.
Figure 11
1. Grease fitting
2. Roller shaft screw
3. Scraper plate
4. Cap screw
5. Roller scraper
6. Roller mount
IMPORTANT: During assembly, make sure the
grease groove in each roller mount aligns with the
grease hole in each end of the roller shaft.
3. Align roller shaft grease hole with the roller mount
grease groove. Use alignment mark on end of roller
shaft to assist with alignment.
4. Position skid brackets to roller mounts and install cap
screws to retain brackets in place.
5. If equipped with scraper rod, install and adjust scraper rod assembly to roller mounts (Fig. 11). The gap between the scraper rod and roller should be from 0.020
to 0.040 in (0.5 to 1.0 mm). Torque cap screws 30 ft−lb
(41 N−m).
6. Install and tighten fasteners that secure each end of
roller to roller mounts. Torque roller shaft screws (item
4) and cap screws (item 8) from 29 to 35 ft−lb (40 to 47
N−m).
Groundsmaster 3500
Page 8 − 13
Cutting Decks
7. After assembly, raise and lower the cutting deck to
verify that hydraulic hoses and fittings do not contact
anything.
Cutting Decks
Rear Roller Service
Disassembly (Fig. 12)
2
1. Remove bearing lock nut from each end of roller
shaft.
50 to 60 ft−lb
(68 to 81 N−m)
3
4
2. Loosely secure roller assembly in bench vise and
lightly tap one end of roller shaft until outer seals and
bearing are removed from opposite end of roller tube.
Remove second set of outer seals and bearing from roller tube by tapping on opposite end of shaft. Remove
shaft from roller tube.
5
6
7
1
2
4
3
5
3. Carefully remove inner seal from both ends of roller
tube taking care to not damage tube surfaces.
6
4. Discard removed seals and bearings.
Loctite #242
5. Clean roller shaft and all surfaces on the inside of the
roller tube. Inspect components for wear or damage.
Also, carefully inspect seating surface and threads of
bearing lock nuts. Replace all damaged components.
Assembly (Fig. 12)
1
1. Install inner seals into roller tube making sure that
seal lip (and garter spring) faces end of tube. Use inner
seal tool (see Special Tools in this chapter) and soft face
hammer to fully seat seals against roller shoulder (Fig.
13). Apply a small amount of grease around the lip of
both inner seals after installation.
7
Figure 12
1.
2.
3.
4.
Roller tube
Roller shaft
Inner seal
Bearing
5. Outer seal
6. Bearing lock nut
7. Set screw
1
2
3
IMPORTANT: During assembly process, frequently
check that bearings rotate freely and do not bind. If
any binding is detected, consider component removal and reinstallation.
2. Install new bearing and outer seals into one end of
roller tube:
A. Position a new bearing into one end of roller tube.
Use bearing/outer seal tool (see Special Tools in this
chapter) with a soft face hammer to fully seat bearing
against roller shoulder (Fig. 14). After bearing installation, make sure that it rotates freely with no binding.
Figure 13
1. Roller tube
2. Inner seal
3. Inner seal tool
1
B. Apply a small amount of grease around the lip of
both outer seals.
2
3
4
C. Install first outer seal into roller tube making sure
that seal lip (and garter spring) faces end of tube.
Use bearing/outer seal tool (see Special Tools in this
chapter) and soft face hammer to lightly seat seal
against roller shoulder (Fig. 15). Make sure that
bearing still freely rotates after seal installation.
D. Using the same process, install second outer
seal making sure to not crush the installed outer seal.
Again, make sure that bearing still freely rotates.
Cutting Decks
Figure 14
1. Roller tube
2. Inner seal
Page 8 − 14
3. Bearing
4. Bearing/outer seal tool
Groundsmaster 3500
3. From the roller tube end with only the inner seal
installed, carefully install the roller shaft into the roller
tube. Make sure that seals are not damaged as shaft is
installed.
NOTE: After roller is installed to cutting deck, lubricate
roller grease fittings, rotate roller to properly distribute
grease in bearings and clean excess grease from roller
ends. A properly assembled roller should rotate with
less than 5 in−lbs (0.68 N−m) resistance.
4. Install new bearing and outer seals into second end
of roller tube:
1
3
2
4
5
A. Position a second new bearing to roller shaft and
tube. Position washer (see Special Tools in this
chapter) on bearing to allow pressing on both inner
and outer bearing races simultaneously.
B. Use washer and bearing/outer seal tool (see
Special Tools in this chapter) with a soft face hammer
to fully seat bearing (Fig. 16). After bearing installation, make sure that shaft freely rotates and that no
binding is detected. If necessary, lightly tap bearing
and/or shaft ends to align shaft and bearings. Remove washer from roller.
C. Apply a small amount of grease around the lip of
both outer seals.
Figure 15
1. Roller tube
2. Inner seal
3. Bearing
1
4. Outer seal
5. Bearing/outer seal tool
2
D. Carefully install first outer seal into roller tube
making sure that seal lip (and garter spring) faces
end of tube. Use bearing/outer seal tool (see Special
Tools in this chapter) and soft face hammer to lightly
seat seal (Fig. 17). Make sure that shaft and bearings still freely rotate after seal installation.
E. Using the same process, install second outer
seal making sure to not crush the installed outer seal.
Again, make sure that shaft and bearings still freely
rotate.
4
3
5
6
Figure 16
IMPORTANT: Make sure that all grease is removed
from shaft threads to prevent bearing lock nut loosening.
1. Roller tube
2. Roller shaft
3. Inner seal
5. Thoroughly clean threads on both ends of roller
shaft.
1
4. Bearing
5. Washer
6. Bearing/outer seal tool
2
3
4
5
6
6. Install bearing lock nut onto each end of the roller
shaft. Make sure that outer seals are not damaged during nut installation. Torque lock nuts from 50 to 60 ft−lb
(68 to 81 N−m).
7. If set screw was removed from either end of roller
shaft, apply Loctite #242 (or equivalent) to threads of removed set screw and install into roller shaft. Tighten set
screw until it bottoms in shaft and is recessed in shaft.
Figure 17
1. Roller tube
2. Roller shaft
3. Inner seal
4. Bearing
5. Outer seal
6. Bearing/outer seal tool
IMPORTANT: When roller assembly is installed to
cutting deck, make sure that grease groove in each
roller mount aligns with the grease hole in each end
of roller shaft.
Groundsmaster 3500
Page 8 − 15
Cutting Decks
Cutting Decks
NOTE: If original bearing lock nut(s) are being used,
apply Loctite #242 (or equivalent) to threads of lock
nut(s).
This page is intentionally blank.
Cutting Decks
Page 8 − 16
Groundsmaster 3500
Front Roller Service
Disassembly (Fig. 18)
1. Remove roller mounting bolt.
2. Remove roller assembly from carrier frame.
3. To remove bearings and bearing spacer:
A. Insert punch through end of roller and drive opposite bearing out by alternating taps to opposite side of
inner bearing race. There should be a lip of inner race
exposed for this process.
1
2
B. Remove bearing spacer. Remove second bearing from roller using a press.
3
65 to 95 ft−lb
(89 to 128 N−m)
4. Inspect roller housing, bearings and bearing spacer
for damage or wear. Replace components as needed.
4
2
Assembly (Fig. 18)
Figure 18
1. Install bearings and bearing spacer into roller:
1. Mounting bolt
2. Bearing
3. Bearing spacer
4. Front roller
IMPORTANT: Use Front Roller Bearing Installation
Tool (see Special Tools in this chapter) when installing bearings into roller. This tool ensures that
no side load is applied to the bearings during installation into the front rollers.
A. Press first bearing into housing. Press equally on
inner and outer races during installation.
B. Insert bearing spacer.
C. Press second bearing into roller housing pressing equally on inner and outer races until the inner
race comes in contact with the bearing spacer.
2. Install roller assembly to deck frame.
NOTE: Securing roller assembly with a gap larger than
0.060 inch (1.5 mm) creates a side load on bearings and
can lead to premature bearing failure.
Cutting Decks
3. Verify that there is no more than a 0.060 inch (1.5
mm) gap between roller assembly and the roller mount
brackets of the deck frame. If this gap is larger than
0.060 inch (1.5 mm), shim excess clearance with 5/8”
washers.
4. Insert mounting bolt and tighten to 65 to 95 ft−lb (89
to 128 N−m).
Groundsmaster 3500
Page 8 − 17
Cutting Decks
Cutting Deck Carrier Frame
2
20
9
RIGHT
4
3
21
6
22
FRONT
6
16
1
3
5
4
17
7
5
17
18
19
8
1
25
13
12
11
32
10
3
24
14
26
4
15
5
31
29
30
27
28
23
33
Figure 19
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Front carrier frame
Rear carrier frame
Lynch pin
Thrust washer
Pivot pin
Grease fitting
Front right lift arm
Front left lift arm
Rear lift arm
Latch rod
Latch tube
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Hardened washer
Cap screw
Pop rivet
Rod clip
Cap screw
Cap screw
Rebound washer
Cap screw
Grease fitting
Pop rivet
Wear strip
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Deck motor
Foot guard
Flange bushing
Cap screw
Hardened washer
Flange nut
Cap screw
Flat washer
Flange nut
Cap screw
O−Ring
Each cutting deck is suspended from a carrier frame.
The cutting deck carrier frame is attached to the lift arm
and allows the cutting deck to pivot on the lift arm pivot
shaft.
Carrier frames are secured to the lift arm pivot shaft with
a lynch pin. The front cutting decks are pushed by the
traction unit and have a thrust washer between the carrier frame and the lift arm. The rear cutting deck is pulled
by the traction unit and has a thrust washer between the
carrier frame and the lynch pin.
Cutting Decks
Page 8 − 18
Groundsmaster 3500
Removal and Installation (Fig. 19)
1. Position the machine on a level surface, lower the
cutting decks to the floor, shut the engine off, and engage the parking brake.
IMPORTANT: Support the cutting deck hydraulic
motor when removed from the deck. Do not allow
the hydraulic motor to hang from the hydraulic
hoses.
1
2. Disconnect and remove the hydraulic motor from the
deck (Fig. 20). Cover the top of the spindle to prevent
contamination.
Figure 20
1. Motor mounting screws
3. Remove the lynch pin securing the deck carrier
frame to the lift arm pin (Fig. 21).
4. Roll the cutting deck away from the traction unit.
Installation (Fig. 19)
1
1. Position machine on a level surface and shut engine
off.
2. Move cutting deck into position near lift arm.
2
3. Slide deck carrier frame onto lift arm pivot pin. Secure with lynch pin (Fig. 21).
4. Install the hydraulic motor to the deck (Fig. 20). Make
sure that the O-ring is in position and not damaged.
Figure 21
1. Lynch pin
2. Lift arm pivot pin
Cutting Decks
5. Grease the spindle.
Groundsmaster 3500
Page 8 − 19
Cutting Decks
This page is intentionally blank.
Cutting Decks
Page 8 − 20
Groundsmaster 3500
Chapter 9
Foldout Drawings
Table of Contents
Groundsmaster 3500
Page 9 - 1
Foldout Drawings
Foldout
Drawings
ELECTRICAL DRAWING DESIGNATIONS . . . . . . . 2
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . 3
Groundsmaster 3500- D Hydraulic Schematic
(Units Prior to Serial No. 314000001) . . . . . . . . 3
Groundsmaster 3500- D Hydraulic Schematic
(Unit Serial No. 314000001 & Up) . . . . . . . . . . . 4
ELECTRICAL SCHEMATICS AND DIAGRAMS . . . 5
Groundsmaster 3500- D Electrical Schematic . . 5
Groundsmaster 3500- D Harness Diagram . . . . . 6
Groundsmaster 3500- D Harness Drawing . . . . . . 7
Groundsmaster 3500- G Electrical Schematic . . . 8
Groundsmaster 3500- G Harness Diagram . . . . . 9
Groundsmaster 3500- G Harness Drawing . . . . 10
Electrical Drawing Designations
The following abbreviations are used for wire harness
colors on the electrical schematics and wire harness
drawings in this chapter.
ABBREVIATION
COLOR
BK
BLACK
BR or BN
BROWN
BU
BLUE
GN
GREEN
GY
GRAY
OR
ORANGE
PK
PINK
R or RD
RED
T
TAN
VIO
VIOLET
W or WH
WHITE
Y or YE
YELLOW
Numerous harness wires used on Groundsmaster machines include a line with an alternate color. These wires
are identified with the wire color and line color with either
a / or _ separating the color abbreviations listed above
(e.g. R/BK is a red wire with a black line, OR_BK is an
orange wire with a black line).
NOTE: A splice used in a wire harness will be identified
on the wire harness diagram by SP. The manufacturing
number of the splice is also identified on the wire harness diagram (e.g. SP01 is splice number 1).
Foldout Drawings
Page 9 - 2
Groundsmaster 3500
LEFT
DECK
M2
RIGHT
DECK
D1
M4
M1
M2
S.W.
BULKHEAD
PLATE
T2
REAR
M5
LIFT
TRACTION WHEEL MOTORS
FRONT
M1
BV
1500 psi
REAR
DECK
FORWARD
M3
TOP PORT
G1
M6
S1
A
3200 psi
MANIFOLD
B
C
BLOCK
BY- PASS
UPPER
VALVE
PORT
T1
LC1
PORT
SIDEWINDER
LOWER
G2
G2
G1
OIL
COOLER
LV
3500 psi
P1
CHG
ST
CR
CF
OUT
250 psi
BACK
100- 150 psi
OIL
FILTER
IN
D
LIFT/S.W. VALVE
PRESSURE
GEAR
PUMP
P
200- 300 psi
P1
P2
T
1000 psi
R
STEERING
L
V1
P3
HYDROSTAT
E
STRAINER
INTERNAL CASE DRAIN
POWER STEERING VALVE
Groundsmaster 3500- D
(Units Prior to Serial No. 314000001)
Hydraulic Schematic
All relays and solenoids
are shown as de- energized.
Page 9 - 3
LEFT
DECK
M2
RIGHT
DECK
D1
M4
M2
M1
S.W.
BULKHEAD
PLATE
REAR
M5
LIFT
TRACTION WHEEL MOTORS
FRONT
M1
T2
REAR
RV
DECK
FORWARD
M3
LC2
1500
psi
TOP PORT
S
3200
M6
psi
G1
A
B
C
MANIFOLD
BLOCK
BY- PASS
UPPER
VALVE
PORT
T1
LC1
PORT
SIDEWINDER
LOWER
G2
G2
G1
OIL
COOLER
LV
3500 psi
P1
CHG
ST
CR
CF
OUT
250 psi
BACK
100- 150 psi
OIL
GEAR
FILTER
PUMP
PRESSURE
IN
D
LIFT/S.W. VALVE
P
200- 300 psi
P2
V1
P3
T
1000 psi
L
R
STEERING
P1
HYDROSTAT
E
STRAINER
INTERNAL CASE DRAIN
POWER STEERING VALVE
Groundsmaster 3500- D
(Unit Serial No. 314000001 & Up)
Hydraulic Schematic
All relays and solenoids
are shown as de- energized.
Page 9 - 4
ALTERNATOR
RUN SOLENOID
(HOLD)
B
R/BK
R
L
R
W
(PULL)
W
GY
105C OVER TEMP
WARNING
PK
GN
ENGINE OIL PRESSURE
110C OVER TEMP
SHUTDOWN
BU/W
GN
GY
W
1
4
LAMP
2
5
+ 12V
3
6
OR
PK
R
(+)
TEMP
HR
GLOW
HOUR METER
(- )
GROUND
CLUSTER GAUGE
VIO
START
BN
GLOW
85
K4
GLOW PLUG
CONTROLLER
KUBOTA
86
30
GLOW RELAY
87
PK
OR
OVER TEMP.
PK
OR
ALTERNATOR
GLOW PLUGS (3)
LOW OIL PRESSURE
R/BK
FUEL PUMP
FL
FL
PK
FL
B+ G
Start
FUSIBLE LINK
R/BK
SP
BK
BU
BU
BK
2F
R
BU/W
2A
W/BK
PK
ENGINE
BK
ENGINE GROUND
OR
PARKING BRAKE
GY
SEAT SWITCH
(- )
FRAME GROUND
GN
(+)
NEUTRAL SWITCH
VIO
BATTERY
1
2- A
START
1- A
+12 V
2- B
HIGH TEMP SW.
1- B
PTO COIL
2- C
IGN. SW. ”I”
1- C
RUN
2- D
PARKING BRAKE
1- D
PTO SW.
2- E
BACKLAP
1- E
NOT USED
2- F
SEAT SW.
1- F
GROUND
2- G
NEUTRAL SW.
2- H
IGN. SW. ”S”
PK
BN
R/BK
T
BK
STANDARD CONTROL MODULE
3
OPTIONAL
SEAT SWITCH
VIO
BK
STOP - - - - NONE
RUN - - - - B+I+A; X+Y
START - - - B+I+S
I
B
A
S
Y
X
IGNITION SWITCH
OFF
1F 1
15 A
OR
B
RUN
1
START
1F 3
I
10 A
2
BK
5
A
1F 2
10 A
BU
X
T
VIO
1F 4
Y
TRANSPORT/MOW
SWITCH
2
BU
REEL UP
LIMIT SWITCH
JUMPER
D1
Y
S
GN
REEL DRIVE
SOLENOID
PK
1
3
T
4
6
PTO SWITCH
10 A
W
BU
OPTIONAL LIGHT
SWITCH
OPTIONAL LIGHT
BK
(SERIAL NUMBER
ABOVE 314000001)
Groundsmaster 3500- D
Electrical Schematic
All relays and solenoids
are shown as de- energized.
Page 9 - 5
RED
RED
FUSIBLE LINK
PINK
BLUE
ORANGE
BROWN
PINK
BLACK
RED
PINK
WHITE
BLACK
GRAY
PINK
BLUE
PINK
VIOLET
PINK
PINK
ORANGE
TAN
BROWN
RED/BLACK
TAN
YELLOW
WHITE
BLACK
PINK
BLACK
BLUE
GREEN
WHITE/BLACK
WHITE
PINK
GRAY
VIOLET
PINK
BLACK
PINK
ORANGE
RED/BLACK
BLACK
ORANGE
BLACK
BLACK
BLACK
GREEN
BLUE/WHITE
BLACK
BLACK
YELLOW
(SERIAL NUMBER
ABOVE 314000001)
TAN
BLACK
BLACK
BLUE
BLACK
GREEN
RED/BLACK
GREEN
Groundsmaster 3500- D
Harness Diagram
Page 9 - 6
(SERIAL NUMBER
ABOVE 314000001)
Groundsmaster 3500- D
Harness Drawing
Page 9 - 7
Groundsmaster 3500- G
Electrical Schematic (sheet 1 of 2)
All relays and solenoids
are shown as de- energized.
Page 9 - 8
Groundsmaster 3500- G
Electrical Schematic (sheet 2 of 2)
All relays and solenoids
are shown as de- energized.
Page 9 - 9
P05
P04
BLUE/BLACK
PINK
BLACK/WHITE
TAN
P29
BLACK
GRAY
P03
BLACK/WHITE
J07
ORANGE
P23
ORANGE
P30
BLACK
PINK
BLUE
J19
BLUE/BLACK
P35
P16
PINK
J15
P24
ORANGE
ORANGE
J01
J14
J13
WHITE
PINK
BROWN
RED/BLACK
TAN
BROWN/WHITE
BLACK
BLUE
P14
ORANGE
TAN
P31
BLACK/WHITE
J18
YELLOW
WHITE/BLACK
P32
PINK
P33
VIOLET
WHITE
P34
BLACK
PINK
BROWN/WHITE
PINK
ORANGE
BLACK
GREEN
BLACK
P06
P17
PINK
PINK
P32
BLACK
P13
J02
BLACK
BLACK
BLACK
BLACK
WHITE
YELLOW/BLACK
BLACK/ORANGE
RED/BLACK
BLACK/WHITE
BLUE
BLUE
BLACK
BLUE
RED/BLUE
YELLOW/GREEN
GREEN/WHITE
GREEN/BLACK
BLACK/YELLOW
YELLOW
P02
BLACK
P26
BLUE
GREEN
RED/WHITE
P09
RED/WHITE
BLACK/WHITE
P36
Page 9 - 10
P37
P15
P18
P08
P27
P45
BLUE
BLUE
BROWN/WHITE
BLUE
RED/BLACK
BLACK
BLACK
GREEN
BLACK
GREEN
BLUE
RED/WHITE
BLACK/WHITE
BLACK/WHITE
RED/BLUE
P25
Groundsmaster 3500- G
Harness Diagram
Groundsmaster 3500- G
Harness Drawing
Page 9 - 11

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