Toro Groundsmaster 3500 30807 Service Manual Download Page 46

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Groundsmaster 3500−G

Page 4 − 8

Kubota Gasoline Engine

Fuel System

Figure 6

1. Fuel

tank

2. Hose

clamp

3. Fuel hose − crossover
4. Protective

trim

5. Bushing
6. Elbow

fitting

7. Spacer
8. Flat

washer

9. Cap

screw

10. Seat support strap
11. Pump gasket
12. Fuel pump
13. Fuel pump cap
14. Flange screw
15. Flat washer
16. Heat shield
17. Hose clamp
18. Foam

19. Cap screw
20. Strap
21. Strap
22. Fuel tank cap
23. Fuel gauge
24. Seal
25. Cable tie
26. Fuel Hose
27. Hose clamp

17 18

FRONT

RIGHT

175 to 200 in−lb

(20 to 22 N−m)

Summary of Contents for Groundsmaster 3500 30807

Page 1: ...Form No 14209SL Rev C Groundsmaster 3500 Models 30807 and 30809 Original Instructions EN ...

Page 2: ... the delivery of this document or the disclosure of its content This document shall not be reproduced by a third party without the express written consent of The Toro Company and or the appropriate affiliated company Revision History Revision Date Description 2014 Initial Issue A 03 2018 Added revision history B 03 2019 Updated Electrical chapter C 12 2019 Updated Chapter 1 Safety Statements ...

Page 3: ...blications To do this effectively we encourage user feedback Please comment on the completeness accuracy organization usability and readability of this manual by an e mail to servicemanuals toro com or Mail to Technical Publication Manager Commercial The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 1196 Phone 1 952 887 8495 ...

Page 4: ...NOTES _ ...

Page 5: ... 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 The Toro Company reserves the right to change product specifications or this publication without notice NOTE A NOTE will give general information about the correct operation maintenance ser...

Page 6: ...Groundsmaster 3500 This page is intentionally blank ...

Page 7: ... 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 IN FORMATION MODEL 70160 VARIABLEDISPLACE MENT PISTON PUMP DANFOSS STEERING UNIT ...

Page 8: ...Groundsmaster 3500 This page is intentionally blank ...

Page 9: ... slope op eration and who have read the Operator s Manual and viewed the Operator s Video should operate the ma chine Never allow children to operate the machine or adults to operate it without proper instructions 3 Become familiar with the controls and know how to stop the machine and engine quickly 4 Do not carry passengers on the machine Keep ev eryone especially children and pets away from the...

Page 10: ...erator s Manual 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 Re duce speed when making sharp turns Do not turn on hills Avoid sudden stops and starts Use reverse pedal for braking Cutting units must be lowered when going down slopes f...

Page 11: ...thin a few hours by a doctor familiar with this form of injury or gangrene may result 6 Before disconnecting or performing any work on the hydraulic system all pressure in system must be re lieved by stopping engine and lowering cutting units to the ground 7 If major repairs are ever needed or if assistance is desired contact an Authorized Toro Distributor 8 To reduce potential fire hazard keep th...

Page 12: ...ont tire is to be removed position the jack se curely under the front wheel motor 3 Use jack stands or hardwood blocks under the square tube or wheel motors to support the machine Jacking the Rear End 1 The preferred method for removing the rear fork the rear wheel or the rear wheel motor is to lift the rear end of the machine from above A Secure a chain fall or hoist to the rear casting Fig 2 B C...

Page 13: ...us safety and instruction decals are affixed to the Groundsmaster 3500 If any decal becomes illegible or damaged install a new decal Part numbers for re placement decals are listed in your Parts Catalog Order replacement decals from your Authorized Toro Distribu tor Safety ...

Page 14: ...Page 1 6 Safety Groundsmaster 3500 This page is intentionally blank ...

Page 15: ...f the Operator s Manual and Parts Cata log for your Groundsmaster 3500 at the end of this chap ter Additionally if any optional equipment or accessories have been installed to your Groundsmas ter insert the Installation Instructions Operator s Manu als and Parts Catalogs for those options at the end of this chapter Maintenance Maintenance procedures and recommended service in tervals for the Groun...

Page 16: ...0 09375 Groundsmaster 3500 Page 2 2 Product Records and Maintenance Equivalents and Conversions ...

Page 17: ... 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...

Page 18: ... 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 2...

Page 19: ... 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 Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific to...

Page 20: ...100 in lb Wheel Bolts and Lug Nuts Thread Size Recommended Torque 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 Thread Size Threads per Inch Baseline Torque Type A Type B No 6 18 20 20 5 in...

Page 21: ... SERVICE AND REPAIRS 6 Air Cleaner and Muffler 6 Check Air Filter Dust Cup Burp Valve 7 Muffler Removal 7 Muffler Installation 7 Fuel System 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 Safety Product Records Kubota Diesel Engine Hydraulic Electrical...

Page 22: ...Groundsmaster 3500 D Page 3 2 Kubota Diesel Engine This page is intentionally left blank ...

Page 23: ...ers 14 53 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 Mini Nozzle DNOPD Engine Oil 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 VD...

Page 24: ...e to provide your distribu tor with the Toro model and serial number Operator s Manuals The Traction Unit Operator s Manual provides informa tion regarding the operation general maintenance and maintenance intervals for the Kubota diesel engine that powers your Groundsmaster 3500 D Refer to this pub lication for additional information when servicing the machine Kubota Workshop Manual The engine th...

Page 25: ...Groundsmaster 3500 D Page 3 5 Kubota Diesel Engine This page is intentionally left blank Safety Product Records Kubota Diesel Engine Hydraulic Electrical Wheels Brakes ...

Page 26: ...Flange nut 6 Muffler bracket 7 Hex nut 8 Lock washer 9 Exhaust gasket 10 Hose clamp 11 Air inlet hose upper 12 Hose clamp 13 Air cleaner body 14 Filter cover 15 Burp Actuator valve 16 Mounting band assembly 17 Shoulder bolt 18 Compression spring 19 Lock nut 20 Air inlet hose lower 21 Air filter mount 1 10 11 12 21 13 12 20 12 17 18 15 16 19 14 2 3 4 7 8 5 9 4 5 6 ...

Page 27: ...ead screw 3 Muffler plate 4 Muffler bracket 4 2 1 3 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 4 Remove both flange head nuts and screws securing the muffler plate to the muffler bracket Fig 4 5 Remove four hex nuts and lock washers from the ex haus...

Page 28: ...Fuel hose crossover 22 Insert nut 23 Trim 24 Barb fitting 25 Tee fitting 26 Barb fitting 5 16 27 Fuel hose engine 28 Barb fitting 3 16 29 Fuel hose 30 R clamp 31 Tank support 32 Fuel pump 33 Hose clamp 34 Cap screw 35 Lock washer 36 Chassis ground 37 Spacer 38 R clamp 39 Fuel filter water separator 40 Fuel fitting 5 16 41 Fuel fitting 42 Clamp block 43 Fuel hose 44 Grommet 22 11 8 22 9 7 16 5 1 3 ...

Page 29: ... from the fuel tank Remove fuel tank from the machine Clean Fuel Tank 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 t...

Page 30: ...c fluid cooler bracket 17 Bracket clamp 18 Screw 19 Lock nut 20 Radiator shield lower 21 Magnetic catch 22 Hydraulic fluid cooler 23 Radiator hose upper 24 Radiator hose lower 25 Hose clamp 26 Hydraulic tube 27 Hydraulic tube 28 Hydraulic fluid cooler hose 29 Grommet 30 Foam seal 31 Expansion tank hose 32 Expansion tank 33 Glow plug relay 34 Thread forming screw 35 Flange lock nut 36 Bulkhead nut ...

Page 31: ...racket LH 17 Elbow fitting 18 Magnet 19 Radiator bracket bottom 20 Lower fan shroud 21 Upper fan shroud 22 Hydraulic tube 23 Hydraulic hose 24 Lower radiator hose 25 Hose clamp 26 Hex nut 27 Relay 28 Upper radiator hose 29 Flange nut 30 Straight fitting 31 Expansion tank support 32 Flange head screw 13 1 FRONT RIGHT 2 3 4 5 6 6 6 7 8 7 9 9 10 11 12 7 13 14 15 16 17 18 19 7 20 21 22 23 24 25 26 27 ...

Page 32: ...A Upper radiator hose to the water pump B Lower radiator hose to the engine block C Coolant hose to the expansion tank D Air hose to the air cleaner 7 For units serial no 314000001 up disconnect the following hoses from the oil cooler section of the radiat or oil cooler assembly A Hydraulic tube from top of hydraulic fluid cooler B Hydraulic hose from bottom of hydraulic fluid cooler 8 Remove expa...

Page 33: ...adiator assembly with both thread forming screws 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 11 Start engine Check for fluid leaks and proper engine operation 12 After running engine for a short time on units with se rial no 314000001 up stop engine and make sure hy draulic tank is ful...

Page 34: ...ttle cable bracket 21 Cable clamp 22 Cap screw 23 Throttle cable 24 Swivel clamp 25 Cable stop 26 Cap screw 27 Engine mount bracket LH 28 Hardened washer 29 Cap screw 30 Flange head screw 31 Hardened washer 32 Hex nut 33 Lock washer 34 Flange nut 35 Engine mount bracket front 36 Engine mount 37 Hardened washer 38 Cap screw 39 Cable tie 40 Spacer 1 41 Spacer 4 42 Pump mount plate 43 Hardened washer...

Page 35: ...ttery wire harness and engine grounds Fig 11 B Glow plug bus Fig 12 and fuel stop solenoid C High temperature warning switch Fig 13 D High temperature shutdown switch alternator and low oil pressure switch Fig 14 9 Disconnect throttle cable from the support and swiv el on the speed control lever Fig 11 10 Disconnect fuel hose from the fuel pump Fig 11 and front injector nozzle 11 Remove traction c...

Page 36: ...re lift or hoist can support the total weight of the engine before removing the cap screws from the engine and engine brackets 13 Remove hex nuts cap screws and washers from the center of the three engine mounts CAUTION One person should operate lift or hoist while the other person guides the engine out of the ma chine IMPORTANT Make sure not to damage the engine fuel and hydraulic lines electrica...

Page 37: ...raulic hoses to the piston and gear pumps Install traction control cable to the neutral arm assembly on the piston pump see Piston Pump Installa tion in Chapter 5 Hydraulic System 8 Connect fuel hose to the fuel pump Fig 11 and front injector nozzle 9 Install top fan shroud to the radiator Install expan sion tank and bracket to the top fan shroud see Radiator Installation in this Chapter 10 Connec...

Page 38: ...Groundsmaster 3500 D Page 3 18 Kubota Diesel Engine This page is intentionally left blank ...

Page 39: ...fler Removal 7 Muffler Installation 7 Fuel System 8 Fuel Tank Removal 9 Cleaning Fuel Tank 9 Fuel Tank Installation 9 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 ...

Page 40: ...Groundsmaster 3500 G Page 4 2 Kubota Gasoline Engine This page is intentionally left blank ...

Page 41: ...065 0 0001 0 165 0 02 check when engine is cold Fuel Unleaded Gasoline up to 10 ethanol Fuel Capacity gallons liters 11 41 7 Governor Electronic Low Idle no load 1600 30 RPM High Idle no load 3420 30 RPM Direction of Rotation Counterclockwise Viewed from Flywheel Engine Oil API classification SL or higher see Traction Unit Operator s Manual for viscosity recommendations Oil Pump Trochoid Type Cran...

Page 42: ...des informa tion regarding the operation general maintenance and maintenance intervals for your Groundsmaster 3500 G Refer to this publication for additional informa tion 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 thi...

Page 43: ...ic Manual should be used to provide assistance in identifying the cause of the problem and any repairs that are neces sary Use the diagnostic cable to connect a PC running the KGST software and Ecom interface driver to the dia gnostic connector above the engine ECU Fig 3 Con tact your Toro distributor for assistance in Kubota engine troubleshooting or to acquire Kubota engine software and hardware...

Page 44: ...2 Lower intake hose 13 Hose clamp 14 Flange head screw 15 Muffler bracket 16 Exhaust clamp 17 Flange nut 18 Exhaust tube 19 Cap screw 20 Heat shield 21 Air cleaner bracket 22 Flange head screw 23 Upper intake hose 24 Air cleaner assembly 25 Burp actuator valve 26 Radiator inlet tube 27 Hose clamp 28 Radiator hose adapter 19 Figure 4 20 9 18 17 16 15 14 12 11 6 10 6 7 25 5 4 3 5 1 2 13 23 13 22 13 ...

Page 45: ... used as inputs for the engine ECU to monitor exhaust system operation The exhaust exits the catalytic muffler through the tailpipe outlet Muffler Removal Fig 4 CAUTION The muffler and exhaust pipe may be hot To avoid burns allow the engine and exhaust sys tem 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...

Page 46: ...r 9 Cap screw 10 Seat support strap 11 Pump gasket 12 Fuel pump 13 Fuel pump cap 14 Flange screw 15 Flat washer 16 Heat shield 17 Hose clamp 18 Foam 19 Cap screw 20 Strap 21 Strap 22 Fuel tank cap 23 Fuel gauge 24 Seal 25 Cable tie 26 Fuel Hose 27 Hose clamp 2 3 24 23 4 4 25 26 27 22 5 17 6 21 19 16 15 14 13 12 11 10 9 8 7 6 5 17 18 19 20 1 26 FRONT RIGHT 175 to 200 in lb 20 to 22 N m ...

Page 47: ...al har ness 5 Remove fuel hose straps and three fuel hoses from the fuel tank Remove fuel tank from the machine Clean Fuel Tank 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 gasoline Make sure tank i...

Page 48: ...7 18 19 Thread Sealant 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 evapora tive 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...

Page 49: ...es for damage or obvious leaks A damaged or leaking cannis ter should be replaced 4 Note hose routing cable tie and anchor clamp loca tions Remove fuel evaporative control system compon ents as needed Fig 7 Carbon Canister Installation 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 ...

Page 50: ...tor 13 Straight fitting 14 Drain cock 15 Lower radiator shield 16 Radiator bracket LH 17 Elbow fitting 18 Magnet 19 Radiator bracket bottom 20 Lower fan shroud 21 Upper fan shroud 22 Hydraulic tube 23 Hydraulic hose 24 Lower radiator hose 25 Hose clamp 26 Hex nut 27 Relay 28 Upper radiator hose 29 Flange nut 30 Straight fitting 31 Expansion tank support 32 Flange head screw 13 1 FRONT RIGHT 2 3 4 ...

Page 51: ...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 10 Plug any openings in the radiator hydraulic fluid cooler and h...

Page 52: ...ulic 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 ...

Page 53: ...Groundsmaster 3500 G Page 4 15 Kubota Gasoline Engine This page is intentionally left blank Safety Product Records Kubota Gasoline Engine Hydraulic Electrical Wheels Brakes ...

Page 54: ...xhaust gasket 14 Flange head screw 15 Hardened washer 16 Cap screw 17 Engine mount 18 Fusible link 19 Flat washer 20 Lock washer 21 Hex nut 22 Mount bracket LH 23 Lock washer 24 Cap screw 25 Cap screw 26 Flat washer 27 Engine ground 28 Lock washer 29 Cable tie 30 Spacer 31 Hardened washer 32 Cap screw 33 Spacer 34 Hardened washer 35 Cap screw 1 8 13 12 11 10 9 FRONT RIGHT 2 3 4 5 6 7 3 14 8 15 16 ...

Page 55: ...ess and electrical wires at the following locations A Positive cable from battery 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 Figure 13 1 Alternator 2 Harness connections 1 2 11 Note the locations and remove any cable ties secur ing the wire harness to the engin...

Page 56: ... Gasoline Engine Figure 14 1 Engine mount bracket 2 Flange nut 3 Flange screw 4 Pump mount plate 5 Hardened washer 6 10 mm cap screw 4 7 8 mm cap screw 1 8 Hardened washer 9 Long spacer 4 10 Short spacer 1 1 2 3 4 5 6 7 8 9 10 FRONT RIGHT ...

Page 57: ...tion engine slowly into the machine 5 Secure all three engine mounts to the engine mount ing 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 Installa tion in Chapter 5 Hydraulic System in this manual 7 Connect fuel hoses from the fuel pump and carbo...

Page 58: ...lic 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 ...

Page 59: ... Test 64 ADJUSTMENTS 66 Blade Braking Valve BV Adjustment Units Prior to Serial No 314000001 66 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 ...

Page 60: ...5 cc rev Mow Circuit Relief Pressure 3200 PSI 221 Bar Cutting Unit Motor Gear motor Cross over Relief Pressure 1813 PSI 125 Bar Displacement 1 16 cu in rev 19 cc rev Steering Control Valve Distributor valve with rotary meter Maximum Displacement 6 10 cu in rev 100 0 cc rev Implement Steering and Lift Relief Valve Pressure 1000 PSI 69 Bar Hydraulic Filter 10 Micron spin on cartridge type Hydraulic ...

Page 61: ...n 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 chap ter into the circuit This filter sho...

Page 62: ...wo wrenches hold the hose straight with one wrench and tighten the hose swivel nut onto the fit ting 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 For additional hydraulic hose information refer to Toro Service Training Bo...

Page 63: ...ch in the Torque Specifica tions section of Chapter 2 Product Records and Main tenance 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 Resist ance F F W R method Fig 2 A Using a wrench tighten the swivel nut onto the fit ting until light wrench resistance is reached approxi mately 30 in lb ...

Page 64: ...ecords and Maintenance to determine necessary con version information 5 If a torque wrench is not available or if space at the port prevents use of a torque wrench an alternate meth od of assembly is the Flats From Finger Tight F F F T method A Install the fitting into the port and tighten it down full length until finger tight B If port material is steel tighten the fitting to the listed F F F T ...

Page 65: ... with a wrench and use a torque wrench to tighten the fitting to the rec ommended 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 lo...

Page 66: ...raulic Tester Pressure and Flow This tester requires O ring Face Seal ORFS adapter fittings for use on this machine see Hydraulic Test Fit ting Kit TOR4079 in this section 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 PRESSURE GAUGE 0 to 5000 PSI ...

Page 67: ... 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 NOTE This tester does not include hoses see Hydrau lic Hose Kit TOR6007 below Figure 10 Hydraulic Hose Kit This kit includes fittings and hoses needed to connect 40 GP...

Page 68: ...t components or after replacing a failed traction circuit component e g piston pump or wheel motor the high flow hydraulic fil ter can be installed in the traction circuit The filter will ensure that contaminates are removed from the closed loop and thus do not cause additional component dam age Toro Part Number TOR6011 NOTE This kit does not include hoses see Hydraulic Hose Kit TOR6007 above NOTE...

Page 69: ...Measuring Container Use this container for doing hydraulic motor efficiency testing motors with case drain lines only Measure effi ciency 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 ...

Page 70: ...ctor for circuit protection 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 NOTE For information on using the remote starter switch to prime t...

Page 71: ...roundsmaster 3500 Hydraulic System Page 5 13 Wheel Hub Puller Toro Part Number TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors Figure 20 Hydraulic System ...

Page 72: ... COOLER FILTER OIL T1 P1 CHG ST CR CF PUMP GEAR P1 P2 STRAINER LV G2 P T E OUT IN LV LC1 S1 3200 psi T2 G1 M2 BV 1500 psi S W BULKHEAD PLATE D1 M1 A B C M1 M2 M3 D LIFT S W VALVE 1000 psi POWER STEERING VALVE STEERING SIDEWINDER L R 250 psi V1 BACK PRESSURE LEFT RIGHT REAR DECK DECK DECK REAR FRONT LIFT 200 300 psi 3500 psi 100 150 psi UPPER PORT LOWER PORT HYDROSTAT BY PASS VALVE P3 G2 G1 NOTE A ...

Page 73: ... CHG ST CR CF PUMP GEAR P1 P2 STRAINER LV G2 OUT IN LV LC1 T2 M2 S W BULKHEAD PLATE D1 M1 A B C M1 M2 M3 D LIFT S W VALVE 1000 psi POWER STEERING VALVE STEERING SIDEWINDER L R 250 psi V1 BACK PRESSURE LEFT RIGHT REAR DECK DECK DECK REAR FRONT LIFT S 3200 G1 RV 1500 LC2 psi psi P T E 200 300 psi 3500 psi 100 150 psi UPPER PORT LOWER PORT HYDROSTAT BY PASS VALVE P3 G2 G1 NOTE A larger hydraulic sche...

Page 74: ...WHEEL MOTORS FORWARD TOP PORT 100 150 psi INTERNAL CASE DRAIN UPPER PORT LOWER PORT HYDROSTAT BY PASS VALVE M6 M5 M4 MANIFOLD BLOCK OIL COOLER FILTER OIL T1 P1 CHG ST CR CF PUMP GEAR P1 P2 STRAINER LV G2 OUT IN LV LC1 T2 M2 S W BULKHEAD PLATE D1 M1 A B C M1 M2 M3 D LIFT S W VALVE 1000 psi POWER STEERING VALVE STEERING SIDEWINDER L R 250 psi P3 V1 BACK PRESSURE LEFT RIGHT REAR DECK DECK DECK REAR F...

Page 75: ...stat upper port Fluid flow out of the upper port goes to the rear wheel motor where an internal check valve allows the hydraul ic fluid to bypass the motor Fluid flow out of the rear 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 NO...

Page 76: ...AL CASE DRAIN M6 M5 M4 MANIFOLD BLOCK OIL COOLER FILTER OIL T1 P1 CHG ST CR CF PUMP GEAR P1 P2 STRAINER LV G2 OUT IN LV LC1 S1 3200 psi T2 G1 M2 BV 1500 psi S W BULKHEAD PLATE D1 M1 LEFT RIGHT REAR REAR FRONT A B C M1 M2 M3 D LIFT S W VALVE 1000 psi POWER STEERING VALVE STEERING SIDEWINDER L R 250 psi V1 BACK PRESSURE DECK DECK DECK LIFT P T E 200 300 psi 3500 psi 100 150 psi UPPER PORT LOWER PORT...

Page 77: ...5 M4 MANIFOLD BLOCK OIL COOLER FILTER OIL T1 P1 CHG ST CR CF PUMP GEAR P1 P2 STRAINER LV G2 OUT IN LV LC1 T2 M2 S W BULKHEAD PLATE D1 M1 LEFT RIGHT REAR REAR FRONT A B C M1 M2 M3 D LIFT S W VALVE 1000 psi POWER STEERING VALVE STEERING SIDEWINDER L R 250 psi V1 BACK PRESSURE DECK DECK DECK LIFT S 3200 G1 RV 1500 LC2 psi psi ENERGIZED P T E 200 300 psi 3500 psi 100 150 psi UPPER PORT LOWER PORT HYDR...

Page 78: ...t 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 im balance that shifts the logic cartridge to allow oil flow from the deck motors to pass through the ...

Page 79: ...f 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 re turn pressure drops below 1500 PSI 104 bar the relief valve reseats blocking flow through the orifice in the lo gic cartridge The los...

Page 80: ...MOTORS FORWARD TOP PORT INTERNAL CASE DRAIN M6 M5 M4 MANIFOLD BLOCK OIL COOLER FILTER OIL T1 P1 CHG ST CR CF PUMP GEAR P1 P2 STRAINER LV G2 OUT IN LV LC1 T2 M2 S W BULKHEAD PLATE D1 M1 A B C M1 M2 M3 D LIFT S W VALVE 1000 psi POWER STEERING VALVE STEERING SIDEWINDER L R 250 psi V1 BACK PRESSURE LEFT RIGHT REAR DECK DECK DECK REAR FRONT LIFT S 3200 G1 RV 1500 LC2 psi psi P T E NOTE Hydraulic Schema...

Page 81: ...ic 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 cylin ders Hydraulic pressure against the cylinder pistons moves their shafts causing the cutting units to raise ...

Page 82: ...ON WHEEL MOTORS FORWARD TOP PORT INTERNAL CASE DRAIN M6 M5 M4 MANIFOLD BLOCK OIL COOLER FILTER OIL T1 P1 CHG ST CR CF PUMP GEAR P1 P2 STRAINER LV G2 OUT IN LV LC1 T2 M2 S W BULKHEAD PLATE D1 M1 A B C M1 M2 M3 D LIFT S W VALVE 1000 psi POWER STEERING VALVE STEERING SIDEWINDER L R 250 psi V1 BACK PRESSURE LEFT RIGHT REAR DECK DECK DECK REAR FRONT LIFT S 3200 G1 RV 1500 LC2 psi psi P T E NOTE Hydraul...

Page 83: ...en 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 t...

Page 84: ...R FILTER OIL T1 P1 CHG ST CR CF PUMP GEAR P1 P2 STRAINER LV G2 OUT IN LV LC1 T2 M2 S W BULKHEAD PLATE D1 M1 A B C M1 M2 M3 D LIFT S W VALVE 1000 psi POWER STEERING VALVE STEERING SIDEWINDER L R 250 psi V1 BACK PRESSURE LEFT RIGHT REAR DECK DECK DECK REAR FRONT LIFT S 3200 G1 RV 1500 LC2 psi psi P T E 200 300 psi 3500 psi 100 150 psi UPPER PORT LOWER PORT HYDROSTAT BY PASS VALVE P3 G2 G1 NOTE Hydra...

Page 85: ... At the same time the piston pushes the hydraulic fluid out of the cylinder back through the spool valve and hydraulic manifold and to the hydrostat When the cutting unit shift lever is released spring ac tion returns the valve to its original position and by passes flow back to the hydrostat and stopping cylinder movement The cylinder position is locked in place since there is no complete circuit...

Page 86: ...PORT INTERNAL CASE DRAIN M6 M5 M4 MANIFOLD BLOCK OIL COOLER FILTER OIL T1 P1 CHG ST CR CF PUMP GEAR P1 P2 STRAINER LV G2 OUT IN LV LC1 T2 M2 S W BULKHEAD PLATE D1 M1 A B C M1 M2 M3 D LIFT S W VALVE 1000 psi POWER STEERING VALVE STEERING SIDEWINDER L R 250 psi V1 BACK PRESSURE LEFT RIGHT REAR DECK DECK DECK REAR FRONT LIFT S 3200 G1 RV 1500 LC2 psi psi P T E 200 300 psi 3500 psi 100 150 psi UPPER P...

Page 87: ...nder 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 cylin der is proportional to the amount of steering wheel rota tion Fluid leaving the cylinder flows back through the steering control spool valve and through the T port Re turn flow passes through the hydraulic manifold hydro sta...

Page 92: ... rating as listed in test procedures could result in damage to the gauge and possible personal injury from leaking hot hydraulic fluid CAUTION All testing should be performed by two 2 people One person should be in the seat to oper ate the machine and the other should read and record test results 1 Clean machine thoroughly before disconnecting or disassembling any hydraulic components Always keep ...

Page 93: ... full 9 Check control linkages for improper adjustment binding or broken parts 10 All hydraulic tests should be made with the hydraulic fluid at normal operating temperature Hydraulic Test Selection Before beginning any hydraulic test identify if the prob lem is related to the traction circuit cutting mow circuit or steering and lift sidewinder circuit Once the faulty system has been identified pe...

Page 94: ...HYDROSTAT P1 P2 ENGINE RPM GEAR PUMP LOWER PORT UPPER PORT M6 INTERNAL CASE DRAIN 100 to 150 psi STRAINER TOP PORT FORWARD TRACTION WHEEL MOTORS 3500 psi TO HYDRAULIC FROM HYDRAULIC MANIFOLD MANIFOLD P1 PORT CHG PORT TO STEERING CONTROL VALVE IN PORT CHARGE RELIEF FROM OIL FILTER TEE CONNECTOR PRESSURE GUAGE AND 200 300 psi TESTER WITH PRESSURE GUAGE AND FLOW METER ...

Page 95: ... machine from moving during testing 9 Chock the wheels to prevent wheel rotation during testing 10 Start engine Move throttle to full speed Diesel en gine 3220 50 RPM Gas engine 3420 30 RPM 11 Make sure hydraulic fluid is at normal operating tem perature by operating the machine for approximately 10 minutes 12 Verify with a phototach that the pump speed is ap proximately 2850 RPM 1 Hydraulic fitti...

Page 96: ...T PISTON PUMP HYDROSTAT M4 M5 UPPER PORT M6 FORWARD FRONT WHEEL MOTORS REAR WHEEL MOTOR TEST TESTER WITH PRESSURE GAUGES AND FLOW METER REAR WHEEL MOTOR PISTON PUMP HYDROSTAT LOWER PORT PISTON PUMP HYDROSTAT TOP PORT M4 M5 BY PASS VALVE P3 PISTON PUMP LOWER PORT UPPER PORT M6 TO GEAR PUMP 100 to 150 psi FORWARD FRONT WHEEL MOTORS 3500 psi FROM HYDROSTAT TRACTION RELIEF FRONT WHEEL MOTOR TEST toget...

Page 97: ...d the parking brake engaged 2 Read Precautions for Hydraulic Testing in this chapter 3 Make sure that traction pedal is adjusted to the neu tral 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 th...

Page 98: ...ne 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 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 Rear Wheel Motor Test Hydraulic fluid flows through both front whe...

Page 99: ...e pres sure gauge Flow meter should read less than 1 5 GPM 5 7 LPM 8 Release traction pedal shut engine off and record test results 9 Rotate rear wheel 120 degrees and retest Repeat this procedure until wheel motor has been tested in three 3 different positions 10 If specifications are not met repair or replace worn wheel motor Hydraulic System ...

Page 100: ...gh Pressure Low Pressure Return or Suction Flow FROM HYDRAULIC MANIFOLD CHARGE PORT M4 M5 P3 PISTON PUMP M6 TO GEAR PUMP SUCTION 100 to 150 psi TOP PORT FORWARD TRACTION WHEEL MOTORS 3500 psi THROUGH CASE DRAIN HYDROSTAT TRACTION RELIEF BY PASS VALVE LOWER PORT UPPER PORT TESTER WITH PRESSURE GAUGES AND FLOW METER 200 to 300 psi ...

Page 101: ... hydraulic fitting on the engine side of the hydrostat Fig 29 6 Install tester in series with the pump and the discon nected hose Make sure the tester flow control valve is fully open 7 Start engine Move throttle to full speed Diesel en gine 3220 50 RPM Gas engine 3420 30 RPM 8 Make sure hydraulic fluid is at normal operating tem perature by operating the machine for approximately 10 minutes 9 Ver...

Page 102: ...ow 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 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 ...

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Page 104: ... FRONT DECK MOTOR TO HYDRAULIC TANK TO OIL COOLER TO HYDROSTAT CHARGE CIRCUIT FROM HYDROSTAT INTERNAL CASE DRAIN DECK MOTOR FROM STEERING CONTROL VALVE OUT PORT TO STEERING CONTROL VALVE IN PORT OUT PORT FROM REAR LIFT CYLINDER FROM FRONT LIFT CYLINDER HYDRAULIC High Pressure Low Pressure Return or Suction Flow FROM OIL FILTER TEST GAUGE LC1 1500 psi S 3200 RV 1500 LC2 psi psi NOTE Hydraulic Schem...

Page 105: ...decks during test to prevent per sonal 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 tem perature by operating the machine for approximately 10 minutes 7 Engage the cutting units When engaged the cutting circuit pressure should ex ceed m...

Page 106: ...pump P1 is faulty see Cutting Deck Cir cuit Gear Pump P1 Flow Under Load Test in this chapter C The blade braking valve BV Unit Serial No Pri or 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 equ...

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Page 108: ...ficiency Case Drain Test TO HYDRAULIC FROM HYDRAULIC TO HYDRAULIC LEFT RIGHT REAR DECK MOTOR DECK MOTOR DECK MOTOR MANIFOLD PORT D1 MANIFOLD PORT M1 MANIFOLD PORT M2 MEASURING CONTAINER High Pressure Low Pressure Return or Suction Flow Toro TOR4077 TESTER WITH PRESSURE GAUGE AND FLOW METER ...

Page 109: ...l is adjusted to the neu tral position 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 cir cuit 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 6 Disconnect the return hose from the motor The re ...

Page 110: ... in the container 14 Disengage cutting decks set throttle to low speed and stop engine 15 If volume is more than 80 oz 2366 milliliters repair or replace the tested deck motor 16 Remove tester and reconnect hydraulic hoses 17 Check hydraulic fluid level see Traction Unit Operat or s Manual 18 Repeat test with remaining deck motors as needed 19 Install deck motors after testing is completed see Cut...

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Page 112: ...T DECK MOTOR TO HYDRAULIC TANK TO OIL COOLER TO HYDROSTAT CHARGE CIRCUIT FROM HYDROSTAT INTERNAL CASE DRAIN DECK MOTOR FROM STEERING CONTROL VALVE OUT PORT TO STEERING CONTROL VALVE IN PORT OUT PORT FROM REAR LIFT CYLINDER FROM FRONT LIFT CYLINDER HYDRAULIC High Pressure Low Pressure Return or Suction Flow FROM OIL FILTER LC1 1500 psi S 3200 RV 1500 LC2 psi psi NOTE Hydraulic Schematic for Unit Se...

Page 113: ...hose Fig 36 4 Install tester between the hose and hydraulic fitting Make sure the flow control valve on tester is fully open CAUTION Keep away from decks during test to prevent per sonal injury from the cutting blades 5 Start the engine and move throttle to full speed Dies el engine 3220 50 RPM Gas engine 3420 30 RPM 6 Make sure hydraulic fluid is at normal operating tem perature by operating the ...

Page 114: ...sting Gear Pump P1 Flow Test High Pressure Low Pressure Return or Suction Flow P1 P2 ENGINE RPM GEAR PUMP STRAINER TO TOTO TO STEERING CONTROL VALVE IN PORT TO HYDRAULIC MANIFOLD P1 PORT FROM HYDROSTAT CASE DRAIN FROM OIL FILTER TESTER WITH PRESSURE GAUGES AND FLOW METER ...

Page 115: ... start the engine and move throttle to full speed Diesel engine 3220 50 RPM Gas engine 3420 30 RPM Do not engage the cut ting units 7 Make sure hydraulic fluid is at normal operating tem perature by operating the machine for approximately 10 minutes Use a phototach to verify that the pump speed is ap proximately 2850 RPM 8 Verify pump flow at No Load as follows Record tester pressure and flow read...

Page 116: ...uit Testing Gear Pump P2 Flow Test P1 P2 ENGINE RPM GEAR PUMP STRAINER TO TOTO TO STEERING CONTROL VALVE IN PORT TO HYDRAULIC MANIFOLD P1 PORT FROM HYDROSTAT CASE DRAIN High Pressure Low Pressure Return or Suction Flow FROM OIL FILTER TESTER WITH PRESSURE GAUGES AND FLOW METER ...

Page 117: ... 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 discon nected 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 tem perature by o...

Page 118: ...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 ...

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Page 120: ...ve Pressure Test P1 P2 ENGINE RPM GEAR PUMP L R V1 STRAINER STEERING POWER STEERING VALVE P T E 1000 psi FROM HYDROSTAT INTERNAL CASE DRAIN TO HYDRAULIC MANIFOLD TO HYDRAULIC MANIFOLD ST PORT TO LIFT VALVE IN PORT High Pressure Low Pressure Return or Suction Flow P1 PORT FROM OIL FILTER TEST GAUGE ...

Page 121: ...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 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 tem perature by operating the mac...

Page 122: ...age 5 64 Steering Lift Sidewinder Circuit Testing Steering Control Valve and Steering Cylinder Test L R V1 STEERING POWER STEERING VALVE LEFT TURN P T E 1000 psi PLUG High Pressure Low Pressure Return or Suction Flow CYLINDER OPEN FITTING ...

Page 123: ...ests indicate a steer ing 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 cylin der rod is fully extended and turn the engine off C Read Precautions for Hydr...

Page 124: ... disengaged If blade stopping time is incorrect adjustment of the braking valve BV can be performed as follows NOTE Do not remove the braking valve from the hy draulic manifold for adjustment 1 Loosen lock nut on braking valve Fig 40 2 To decrease blade stopping time turn the adjust ment shaft on the valve in a counterclockwise direction 3 To increase blade stopping time turn the adjustment shaft ...

Page 125: ...e performed as follows NOTE Do not remove the relief valve from the hydrau lic 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 c...

Page 126: ...R CASE DRAINS FROM REAR TO LEFT FRONT DECK MOTOR TO HYDRAULIC TANK TO OIL COOLER TO HYDROSTAT CHARGE CIRCUIT FROM HYDROSTAT INTERNAL CASE DRAIN DECK MOTOR FROM STEERING CONTROL VALVE OUT PORT TO STEERING CONTROL VALVE IN PORT OUT PORT FROM REAR LIFT CYLINDER FROM FRONT LIFT CYLINDER HYDRAULIC High Pressure Low Pressure Return or Suction Flow FROM OIL FILTER TEST GAUGE LC1 NOTE Hydraulic Schematic ...

Page 127: ... PSI 17 Bar with a range of 180 to 300 psi 12 4 to 20 7 Bar A lower counterbalance pressure is more desir able for flat terrain while a higher counterbalance pres sure 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 B Loosen locknut C To increase pressur...

Page 128: ...aulic lines and hoses for proper installation after repairs are completed 5 Note the position of hydraulic fittings especially el bow fittings on hydraulic components before removal Mark parts if necessary to make sure they will be aligned properly when reinstalling hydraulic hoses and tubes After Repair or Replacement of Components 1 Check fluid level in the hydraulic tank and add correct hydraul...

Page 129: ...ures that the gear pump and piston traction pump have adequate oil dur ing 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 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 hydra...

Page 130: ...e and replace hydraulic fluid filter 5 Inspect and clean hydraulic fluid tank see Hydraulic Tank Inspection in this chapter IMPORTANT Follow all local codes and regulations when recycling or disposing hydraulic fluid and fil ters 6 Reconnect all hydraulic hoses lines and compo nents that were disconnected while draining system NOTE Use only hydraulic fluids specified see Traction Unit Owner s Manu...

Page 131: ... operator s seat and start engine Run en gine at low idle speed and check for any hydraulic leak age from filter and hose connections Correct any leaks before proceeding IMPORTANT While engaging the traction circuit monitor the high flow hydraulic filter indicator If the indicator should show red either reduce traction pedal setting or reduce engine speed to decrease hydraulic flow through the fil...

Page 132: ...raulic 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 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 o...

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Page 134: ...er element 14 Shoulder screw 15 Suction strainer 16 Dipstick 17 Filter head 18 Hydraulic tank cap 19 Hose clamp 20 Hydraulic hose 21 Tee fitting 22 Hydraulic hose 23 O ring 24 O ring 25 O ring 26 O ring 27 Hydraulic hose suction 28 Hydraulic tube from fluid cooler 29 Hydraulic hose from manifold 30 O ring Figure 47 14 18 16 6 19 9 4 8 15 1 5 2 13 17 3 8 20 10 11 21 22 22 24 23 26 25 7 30 12 29 28 ...

Page 135: ...draulic tank for leaks cracks or other damage Hydraulic Tank Installation 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 2 Lubricate and install new O ring on suction strainer 3 Thread suction strainer into hydraulic tank Torque strainer into tank port...

Page 136: ...inside of fluid cooler using compressed air in the opposite direction of the fluid flow 3 Plug both ends of hydraulic fluid cooler Clean exteri or 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...

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Page 138: ...r 30 Cap screw 31 Flat washer 32 Spacer 33 Pump mount plate 34 Pump mount spacer 35 Pulley 36 Cap screw 37 Lock washer 38 Taper lock bushing 39 V belt 40 O ring 41 O ring 42 O ring 43 O ring 44 O ring 45 O ring 46 Flat washer 47 O ring 48 Hydraulic hose 49 Hydraulic hose 50 Hydraulic hose 51 Hydraulic hose 52 Bushing 53 Gear pump 54 O ring 55 Flat washer 56 Socket head screw 57 Idler arm spacer 58...

Page 139: ...onents as needed Drive Belt Installation Fig 50 1 Install all removed drive belt idler components Make sure that idler pulley and idler arm rotate freely after as sembly 2 Install drive belt onto pulleys Position idler pulley to ward the pump drive belt 3 Using a straight edge across the lower face of the pump pulley verify pump drive belt alignment across en gine and pump pulleys If pulleys are n...

Page 140: ...tting 12 Lock nut 13 Spacer 14 Traction stud 15 Traction control cable 16 Flat washer 17 Ball joint 18 Lock nut 19 Cap screw 20 Flat washer 21 Hub assembly 22 Flange nut 23 Flange head screw 24 Cable support bracket 25 Ball bearing 26 Flat washer 27 Lock nut 28 Cap screw 29 Pump lever 30 Cap screw 31 Flat washer 32 Cap screw 33 Mount Figure 52 21 6 5 7 9 12 8 10 14 12 13 25 27 20 19 22 7 24 23 17 ...

Page 141: ...assembly to the piston pump trun nion 7 Separate pump lever and hub assembly from pump trunnion and neutral bracket from mount plate Locate and retrieve key from trunnion Neutral Arm Installation Fig 52 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 Secure pump lever and hub assembly to the piston pump trunnio...

Page 142: ...ood WARNING Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydraulic Sys tem Pressure in the General Information section of this chapter 3 Remove pump drive belt see Drive Belt Removal in this chapter 4 Remove neutral arm assembly see Neutral Arm Re moval in this chapter 5 Thoroughly clean hydraulic hose ends and fittin...

Page 143: ...n 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 1 Piston pump hydrostat case drain 2 Gear pump suction port Figure 54 Remove plugs before installing gear pump to piston pump 2 1 16 Remove both c...

Page 144: ... drive belt alignment across en gine and pump pulleys Slide pulley and taper lock bush ing on pump shaft so that drive belt and straight edge are aligned indicating correct position of pump pulley Se cure taper lock bushing in position with set screw IMPORTANT When tightening taper lock bushing cap screws tighten in three 3 equal steps and in a circular pattern 11 Secure taper lock bushing and pum...

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Page 146: ...rew 23 O ring 24 Shaft seal 25 Cover plate 26 Washer 3 used per plate 27 Coupler 28 Housing 29 Retaining ring 30 Thrust washer 31 Thrust bearing 32 Washer 33 Shaft seal 34 Retaining ring 35 Cam plate insert 36 Retaining ring 37 Washer 38 Charge relief spring 39 Charge relief poppet 40 Charge relief housing 41 O ring 42 Cartridge 43 O ring 44 Bleed off spring 45 Bleed off valve poppet 46 Bearing cu...

Page 147: ...s 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 re placed See Piston Pump Crush Ring Replacement in this chapter in conjunction with the Eaton service manual at the end of this chapter for additional in formation NOTE For repair of the piston pump see the Eaton Medium Duty Pisto...

Page 148: ...te 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 cov er plate see Eaton Medium Duty Piston Pump Repair Information Model 70160 Variable Displacement Piston Pump at the end of this chapter 5 Install washers and cap screws to the cover plate and housing Torque cap screws to 29 ft lbs 39 N m 6 ...

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Page 150: ...e ends and fittings on gear pump to prevent hydraulic system contamination 4 Drain hydraulic oil from hydraulic tank by disconnect ing the suction hose from the barbed fitting in the bottom of the gear pump Drain tank into a suitable container 5 Label hydraulic hoses and fittings on gear pump for assembly purposes 6 Disconnect hydraulic hoses connected to the hy draulic fittings on the gear pump A...

Page 151: ...g gear pump to piston pump fill piston pump housing with clean hydraulic oil through case drain hole 4 Remove plugs that were placed in piston pump case drain and gear pump suction port Fill piston pump hous ing with clean hydraulic oil through case drain hole IMPORTANT The gear pump suction fitting must be on the same side as the trunnion of the piston pump 5 Align gear teeth and slide gear pump ...

Page 152: ...asher 4 used 21 Cap screw 4 used Figure 60 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 8 3 2 14 13 21 33 ft lb 45 N m 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 1 Plug pump ports and thoroughly clean exterior of p...

Page 153: ...ye 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 8 Clean all pump parts Check all components for burrs scoring nicks and other damage 9 Replace the entire pump assembly if parts are ex cessively worn or scored Assembly Fig 60 1 Apply...

Page 154: ...System Page 5 96 Front Wheel Motors 1 Lock nut 2 Spacer 3 Socket head screw 4 Hydraulic wheel motor 5 Frame 6 Hydraulic tube 7 Hydraulic tube 8 O ring 9 Hydraulic fitting 10 O ring Figure 62 FRONT RIGHT 5 3 6 8 9 10 7 8 9 4 2 1 10 ...

Page 155: ...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 Installation Fig 62 1 If adapters were removed from wheel motor lubri cate and place new ...

Page 156: ...cking 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 4 Remove rear wheel motor with wheel hub attached from the rear fork 5 Secure wheel hub in a vise Loosen but do not re move lock nut that secures wheel hub to wheel motor IMPORTANT DO NOT hit wheel hub wheel hub puller or w...

Page 157: ...e with lock nut Torque lock nut from 300 to 400 ft lb 407 to 542 N m Remove wheel motor and hub from vise 4 Install wheel motor to the rear fork Fig 63 5 Install tire and rim assembly to machine 6 Lower the machine to the ground 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 ...

Page 158: ...he rear motor The three wheel motors are identical in construc tion 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 displace ment The right front and rear wheel motors have re verse timed manifolds and the front left motor does not The end cover of the rear motor has a check valve con sisting of a ball ...

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Page 160: ...ing 14 Hydraulic hose P1 15 Hydraulic tube T1 16 Hydraulic hose CHG 17 Straight hydraulic fitting 18 O ring 19 O ring 20 Hydraulic hose CF 21 Hydraulic hose D1 22 Hydraulic hose CR 23 O ring 24 Straight hydraulic fitting 25 O ring 26 Hydraulic hose M1 27 Hydraulic hose M2 28 Hydraulic manifold Figure 65 Traction Units Prior to Serial No 314000001 FRONT RIGHT 8 7 LV 2 3 1 4 9 5 6 ST T2 28 10 11 12 ...

Page 161: ...c hose P1 15 Hydraulic tube T1 16 Hydraulic hose CHG 17 Straight hydraulic fitting 18 O ring 19 O ring 20 Hydraulic hose CF 21 Hydraulic hose D1 22 Hydraulic hose CR 23 O ring 24 Straight hydraulic fitting 25 O ring 26 Hydraulic hose M1 27 Hydraulic hose M2 28 Hydraulic manifold Figure 66 FRONT RIGHT 8 7 LV 2 3 1 4 9 5 6 ST T2 28 10 11 12 13 14 15 16 17 18 19 11 19 11 18 20 T1 P1 CHG 21 22 23 23 2...

Page 162: ...NING Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in 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 Installation Fig 65 and 66 1 If hydraulic fittings were removed fr...

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Page 164: ... 4 Zero leak plug 4 Logic cartridge valve LC1 5 Nut 6 Solenoid coil 7 Solenoid cartridge valve S1 8 Braking cartridge valve BV Figure 67 1 5 25 ft lb 34 N m 60 in lb 6 8 N m 7 2 8 4 6 25 ft lbs 34 N m 50 ft lbs 68 N m 20 ft lbs 27 1 N m Traction Units Prior to Serial No 314000001 FRONT RIGHT 3 25 ft lbs 24 N m ...

Page 165: ... LC1 5 Logic cartridge valve LC2 6 Relief valve RV 7 Solenoid cartridge valve S 8 Solenoid coil 9 Nut Figure 68 25 ft lb 34 N m 60 in lb 6 8 N m 2 8 4 25 ft lbs 34 N m 20 ft lbs 27 1 N m Traction Units Serial No 314000001 Up FRONT RIGHT 3 25 ft lbs 34 N m 25 ft lbs 34 N m 20 ft lbs 27 1 N m 1 3 3 5 6 7 9 Hydraulic System ...

Page 166: ...or damage to the sealing surfaces damaged threads or contamina tion 5 Visually inspect cartridge valve for damaged sealing surfaces and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in small valve orifices or seal areas causing malfunction B If valve sealing surfaces appear pitted or dam aged the hydraulic system may be overheating or there may ...

Page 167: ... from deck mo tor mark fitting orientation to allow correct assembly Remove fittings from motor and discard O rings 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 pro cess to properly orientate fittings Tighten fittings see Hydraulic Fitting Installation in the General Infor...

Page 168: ... 10 8 14 13 2 12 10 12 7 6 16 17 18 19 45 N m 33 ft lb 35 N m 26 ft lb 35 N m 26 ft lb 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 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 int...

Page 169: ...efully 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 CAUTION Use goggles or other appropriate eye protection when using compressed air for drying parts 2 Clean all parts with solvent Dry all parts with com pressed air 3 Inspect drive gears and idler gears for t...

Page 170: ...tion in the front wear plate Apply a light coating of clean hy draulic fluid to gear faces 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 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 ...

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Page 172: ...teering wheel nut 21 Toro decal 22 Hydraulic hose 23 Hydraulic hose 24 Hydraulic hose 25 Hydraulic hose 26 Hydraulic hose 27 Tilt steering boss 28 Friction disc 29 Friction disc 30 Flat washer 31 Jam nut 32 Flange screw 33 Steering shield 34 O ring 35 O ring 36 O ring 37 O ring 38 Philips head screw 39 Steering wheel cap 40 Flat washer 41 Flange nut 42 Slope indicator 43 Decal 44 Lock nut 45 Cap s...

Page 173: ... the steering valve bracket and remove the valve from the bracket Fig 76 Installation Fig 75 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 2 Apply blue Loctite 242 to flange hd screws and in stall steering control valve to the steering va...

Page 174: ...ring 14 Distribution plate 15 Inner gearwheel 16 Outer gearwheel 17 End cover 18 O ring 5 used 19 Screw fitting ports L R T 20 Screw fitting ports P and E 21 P port check ball 22 Spring set Figure 77 1 2 3 11 13 17 12 14 16 15 4 5 6 8 9 10 7 13 13 18 19 20 21 22 20 to 24 ft lb 27 to 33 N m NOTE For service of the steering control valve see the Sauer Danfoss Steering Unit Type OSPM Service Manual a...

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Page 176: ... 3 O ring 4 Hydraulic fitting 5 O ring 6 Steering cylinder 7 Ball joint 8 Retaining ring 9 Jam nuts 10 Frame 11 Rear fork 12 Rear casting Figure 78 8 9 12 11 9 1 8 5 7 2 3 4 5 6 3 7 4 10 No 2 General Purpose Grease No 2 General Purpose Grease 65 to 85 ft lb 88 to 115 N m 65 to 85 ft lb 88 to 115 N m ...

Page 177: ...ylinder from the frame and rear fork Fig 79 and 80 6 If hydraulic fittings are to be removed from steering cylinder note and mark fitting orientation to allow correct assembly Installation 1 If hydraulic fittings were removed from steering cylin der install fittings to cylinder using marks made during the removal process to properly orientate fittings 2 Install steering cylinder to the frame and r...

Page 178: ...g Cylinder Service 1 Barrel with clevis 2 Lock nut 3 Piston 4 Uni ring 5 O ring 6 Piston rod 7 Rod seal 8 Cylinder gland 9 O ring 10 Back up ring 11 Retaining ring 12 Dust seal Figure 81 1 2 3 4 5 6 7 8 9 10 12 11 2 3 4 5 8 9 10 11 1 6 7 12 40 ft lb 54 N m ...

Page 179: ...or straightness excessive scoring and pit ting or wear Inspect piston and head for evidence of ex cessive scoring and pitting or wear Replace entire cylinder assembly if necessary Assembly 1 Make sure all parts are clean before reassembly 2 Coat new O rings Uni ring rod seal and back up ring with with clean hydraulic fluid A Install Uni ring and O ring to the piston B Install O rings back up ring ...

Page 180: ...Valve actuator bracket 9 Shoulder bolt 10 Cotter pin 11 Valve lever 12 Valve actuator trunnion 13 Shoulder bolt 14 Link 15 Bolt 16 Lock nut 17 Push nut 18 Hydraulic fitting 19 Carriage screw 20 O ring 21 O ring 22 Hydraulic tube 23 Hydraulic tube 24 Hydraulic hose 25 O ring 26 Hydraulic hose 27 Hydraulic tube Figure 82 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 21 22 23 24 25 26 27 11 12 13 14 15 14 17 2...

Page 181: ...c fittings are to be removed from control valve note and mark fitting orientation to allow correct assembly Installation 1 If hydraulic fittings were removed from control valve install fittings to valve using marks made during the re moval process to properly orientate fittings 2 Install control valve to the frame 3 Reinstall operator s control panel cover 4 Make sure hydraulic tank is full Add co...

Page 182: ...eat retaining plug 16 Spool spring 17 Disc 18 Plug 19 Detent plug 20 Wiper seal 21 Plunger 22 Plunger detent 23 Detent spring 24 O ring 25 O ring 26 Back up washer 27 O ring 28 O ring 29 O ring 30 Back up washer Figure 84 1 2 3 4 5 6 15 8 9 10 16 17 18 19 20 21 22 23 11 12 13 14 7 5 1 30 29 24 28 25 26 27 25 26 12 9 27 27 5 1 7 30 29 9 10 4 20 to 25 ft lb 30 to 35 ft lb 30 to 35 ft lb 41 to 48 N m...

Page 183: ... 11 Valve body 12 O ring 13 Retaining ring 14 Washer 15 Seat retaining plug 16 Spool spring 17 Disc 18 Plug 19 Detent plug 20 Wiper seal 21 Plunger 22 Plunger detent 23 Detent spring 24 O ring 25 O ring 26 Back up washer 27 O ring 28 O ring 29 O ring 30 Back up washer Figure 85 20 12 8 3 13 16 14 12 4 18 28 22 24 23 15 9 26 25 27 30 5 1 27 29 21 19 17 5 1 6 26 25 1 9 7 Hydraulic System ...

Page 184: ...embly IMPORTANT Do not wipe parts with dry paper tow els or rags Lint may cause damage to the hydraulic system 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 ...

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Page 186: ...lkhead nut 32 Carrier stop bracket 33 Nut 34 Flange nut 35 O ring 36 O ring 37 RH lift arm 38 LH lift arm 39 Cap screw 40 Shaft 41 Thrust washer 42 Lynch pin 43 Rod 44 Cap screw 45 Cap screw 46 Torsion spring 47 Grease fitting 48 Hair pin 49 RH deck stop 50 LH deck stop 51 Rivet 52 Rubber bumper 53 Flange nut 54 Flange head screw 55 RH pivot bracket 56 LH pivot bracket 57 Front carrier frame 58 Fl...

Page 187: ...aulic fittings were removed from lift cylinder install fittings to cylinder using marks made during the removal process to properly orientate fittings IMPORTANT With lift arms raised fully hydraulic hoses should be routed as shown 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...

Page 188: ...mp 21 O ring 22 Cap screw 23 Lock nut 24 Rear pivot shaft 25 Jam nut 26 Washer 27 Lift arm assembly 28 Flange head screw 29 Thrust washer 30 Grease fitting 31 Cutting unit pivot shaft 32 Cap screw 33 Cap screw 34 Rebound washer 35 Thrust washer 36 Lynch pin 37 Pop rivet 38 Wear strip 39 Rear cutting unit frame 40 Grease fitting 41 O ring 42 Guard 43 Cap screw 44 Cap screw 45 Lock nut 46 External r...

Page 189: ...m the frame and lift arm 2 If hydraulic fittings are to be removed from lift cylin der note and mark fitting orientation to allow correct as sembly 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 2 Install rear lift cylinder to the frame and lift arm 3 Make sure hydraulic ta...

Page 190: ...Grease fitting 2 Barrel with clevis 3 Nut 4 Uni ring 5 Piston 6 O ring 7 O ring 8 Back up ring 9 Rod seal 10 Head 11 Internal collar 12 Dust seal 13 Shaft 14 Nut 15 Clevis Figure 89 1 2 3 4 5 6 7 8 9 10 1 11 12 13 14 15 1 2 9 12 13 3 5 4 6 7 8 10 11 14 15 1 40 ft lb 54 N m ...

Page 191: ...ly 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 IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surface before mount ing in a vice 3 Mount shaft securely in a vise by ...

Page 192: ...ew 15 Lock nut 16 Spacer 17 Hydraulic tube 18 Hydraulic tube 19 90o hydraulic fitting 20 Bulkhead lock nut 21 Straight hydraulic fitting 22 Hydraulic hose 23 90o hydraulic fitting 24 Hydraulic hose 25 Scissor link 26 O ring 27 O ring 28 O ring 29 Retaining ring 30 Lower frame 31 Frame 32 Pinch point decal Figure 91 14 1 7 1 13 14 18 4 25 5 6 8 19 19 13 11 17 9 1 12 10 10 12 1 9 16 21 22 24 23 15 2...

Page 193: ...on 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 3 Make sure hydraulic tank is full Add correct hydraul ic fluid if necessary 4 Adjust scissors mount as follows A Shift sidewinder fully to the left fully retract cylin der B Loosen four cap screws an...

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Page 195: ...ogic 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 Diode Assemblies 17 CAN bus Termination Resistor Gasoline Engines Only 17 Indicator Lights 18 PTO Switch 19 Neutral Switch 20 Seat Switch 21 Parking Brake Switch 22 Transport Mow Switch 22 Fuses 22 Fusible Links 23 H...

Page 196: ...oundsmaster 3500 machines with are equipped with a Standard Control Module SCM to monitor and control electrical components required for safe opera tion The SCM can be used to check operation of ma chine 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 Ground...

Page 197: ...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 di...

Page 198: ...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 un sealed connection terminals To ensure complete coat ing of terminals liberally apply gel to both component and wire harness connector plug connector to compo nent unplug connector reapply gel to both surfaces and reconnect harness connector to...

Page 199: ...ray that should be used on battery terminals ring terminals and fork terminals to reduce corrosion problems Apply battery terminal protector to the con nection after the battery cable ring terminal or fork ter minal has been secured Toro Part Number 107 0392 Figure 6 Electrical System ...

Page 200: ...oline 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 ne cessary Contact your Toro distributor for assistance in Kubota engine troubleshooting 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 Op...

Page 201: ...lty The engine and or fuel may be too cold The fuel filter may be plugged Gasoline Engines Only The Electronic Throttle Valve ETV relay or ETV relay circuit wiring is faulty 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 ...

Page 202: ...maged 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 Alte...

Page 203: ...ch 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 ...

Page 204: ...n the condition of the battery charge and battery temperature the charging system voltage will increase at different rates as the battery charges Start the engine and run at high idle Allow the battery to charge for at least 3 minutes Record the battery volt age After running the engine for at least 3 minutes battery voltage should be at least 0 50 volt higher than initial bat tery voltage Example...

Page 205: ...ng the parking brake The traction pedal is depressed with the parking brake engaged Use the Standard Control Module SCM to check oper ation of the interlocks 1 Remove the cover over the instrument panel to ex pose the Standard Control Module SCM Fig 8 2 Turn the ignition switch to the on RUN position 1 Standard Control Module Figure 8 1 3 Sit in the operators seat and the In Seat LED on the SCM sh...

Page 206: ...itting in the seat Diesel Engines Only The Over Temperature Shut down 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 Gasoline Engines Only The Over Temperature Warn ing input LED should be illuminated when the engine coolant tempe...

Page 207: ...ed OUTPUTS PTO Engine Run Backlap Engine Start NA NA NA NA NA In Seat High Temperature Shutdown OUTPUTS PTO Engine Run Backlap Engine Start High Temperature Warning Engine Start No Operator in Start High Temperature Warning Gasoline Engine ONLY NA NA Gasoline Engine ONLY IMPORTANT Diesel Engine Units The console temperature warning light illuminates when engine coolant temperature exceeds 221F 105...

Page 208: ...for continu ity 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 ex...

Page 209: ... is energized C Glow plugs are energized D Glow indicator lamp goes out and glow plugs de energize after 10 seconds 4 Place ignition switch in the START position Verify the following while in the START position A Glow indicator lamp is out B Glow relay is energized C Glow plugs are energized D Power exists at terminal 1 of the glow controller NOTE If there is no power to terminal 1 of the glow con...

Page 210: ...ed to the control panel support When energized the relays allow electrical current to the specific circuits see Chapter 9 Foldout Drawings in this manual 1 Verify coil resistance between terminals 86 and 85 with a multimeter ohms setting Resistance should be approximately 80 ohms Fig 14 2 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to ter...

Page 211: ... End of diode body 1 2 3 4 Figure 16 CAN bus Termination Resistor Gasoline Engines Only System communication between electrical components on Groundsmaster 3500 G machines is accomplished on a CAN bus communication system Two 2 special ly 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 th...

Page 212: ... wir ing 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 Glow Plug Indicator Light Diesel Engines Only The glow plug light should come on when the ignition switch is placed in the ON positio...

Page 213: ...e 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 1 COM B terminal 2 NO B terminal 3 NC B terminal 4 COM C terminal 5 NO C terminal 6 NC C terminal Figure 20 2 3 1 6 4...

Page 214: ...n pedal in the neutral position there should be continuity between the two switch leads 4 Slowly depress the traction pedal The continuity tes ter should show no continuity as the pedal is moved in either the forward or reverse direction 5 Reconnect switch after testing 1 Neutral switch 2 Floor plate 3 Switch bracket Figure 23 2 1 3 Adjustment The neutral switch should be installed so that the pin...

Page 215: ...Testing is the same for either switch type 1 Make sure the engine is off Remove seat by remov ing four cap screws that secure seat mounting straps to traction unit 2 Disconnect electrical connector from the switch 3 Check the continuity of the switch by connecting a multimeter ohms setting across the switch connector terminals 4 With no pressure on the seat there should be no continuity between th...

Page 216: ... switch connector terminals 4 When the switch plunger is extended there should be continuity between the switch terminals 5 When the switch plunger is depressed there should be no continuity between the switch terminals 6 Reconnect switch connector 1 Parking brake switch 2 Parking brake lever Figure 25 1 2 1 Transport Mow switch Figure 26 1 Fuses Four fuses are held in a fuse block located below t...

Page 217: ...and unplug fusible link connector from machine wire harness B Use a multimeter to make sure that continuity ex ists 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 4 For fusible link integrated into wire harness A Locate an...

Page 218: ... heat the oil Fig 32 CAUTION Handle the hot oil with extreme care to prevent personal injury or fire 3 Check continuity of the switch with a multimeter ohms setting A The high temperature warning switch is normally open and should close between 216 to 226F 102 to 108C B The high temperature shutdown switch is normal ly open and should close between 225 to 235F 107 to 113C 4 Allow oil to cool while...

Page 219: ...he 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 4 With the ignition switch in the RUN position ground the disconnected wire to the engine block Figure 33 1 Engine temp...

Page 220: ...nto a graduated cylin der with at least a 1 quart 0 95 liter capacity IMPORTANT When testing the fuel pump DO NOT turn ignition switch to START 6 Collect fuel in the graduated cylinder by turning igni tion switch to the RUN position Allow pump to run for time listed below then return switch to OFF The amount of fuel collected in the graduated cylinder should be approximately 21 to 37 fl oz 0 62 to...

Page 221: ... hood 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 2 Disconnect fuel supply hose from engine fuel rail 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 c...

Page 222: ...unger 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 Testi...

Page 223: ...e operator panel as an input to determine the appropriate signal output for the throttle control valve at the engine to set the engine speed 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 Dia gnostic Manual for WG972 engines to test t...

Page 224: ...g small resistance readings with a digital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from the measured value of the component you are test ing 2 Measure resistance between the two connector ter minals on the solenoid coil The re...

Page 225: ...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 A Clean battery by washing entire case with a solu tion of baking soda and water Rinse with clear water B Coat battery posts and cable connectors with bat tery terminal protector Toro Part No 107 0392 or...

Page 226: ... Be careful not to damage terminal posts or cable connectors when removing the bat tery cables 1 Remove battery cover from the frame Loosen bat tery retainer securing the back of the battery to the bat tery support 2 Loosen and remove negative cable from battery After negative cable is removed loosen and remove positive cable from battery 3 Carefully remove battery from machine 4 Install battery i...

Page 227: ...uals 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 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 bat tery Charge at the recommended rate and time giv en in Battery Charging in this section or u...

Page 228: ...mps 15 hrs 3 amps 81 to 125 5 3 hrs 4 amps 10 5 hrs 4 amps 15 8 hrs 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 10 amps 12 hrs 10 amps 18 hrs 10 amps 24 hrs 10 amps CAUTION Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm...

Page 229: ... the solenoid valve coil 3 Remove the nut from the spool assembly 4 Slide the coil assembly from the solenoid valve stem Discard the coil 5 Clean any corrosion or dirt from the valve stem Installation 1 Slide new coil assembly onto the solenoid valve stem 2 Install the nut onto the spool assembly and torque nut 60 in lb 6 8 N m do not over tighten 3 Connect the wire harness electrical connector to...

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Page 231: ...NTS 3 Adjust Brakes 3 Adjust Front Lift Arms 4 Adjust Front Lift Arm Carrier Stop Bracket Assembly 5 Adjust Rear Lift Arm 6 SERVICE AND REPAIRS 8 Standard Seat 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 ...

Page 232: ... Tire pressure 14 to 18 PSI 97 to 124 kPa Wheel lug nut torque 70 to 90 ft lb 95 to 122 N m Special Tools Order special tools from your Toro Distributor Wheel Hub Puller Part Number TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors Figure 1 ...

Page 233: ... hub lock nut to identify the break away torque at each front wheel The mini mum break away torque with the parking applied should be 300 ft lb 407 N m 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 de crease shoe pressure on the brake drum...

Page 234: ...earance between the lift arm and the floor plate bracket Fig 5 B Adjust front hydraulic cylinder by backing off jam nut on the cylinder removing the pin from the clevis and rotating the clevis Fig 6 C Install pin to clevis Fully raise front lift arms and check clearance Repeat steps A and B if necessary D Tighten jam nut on the hydraulic cylinder when clearance is correct IMPORTANT The lack of cle...

Page 235: ...tem 3 loosen carriage screws and flange nuts that secure actuator mount brackets to lift arms 5 Simultaneously move both actuators against back of the carrier stop bracket and pivot brackets Secure actu ators items 2 and 8 to actuator mount brackets with carriage screws and flange nuts 6 With pivot brackets tipped forward slide actuator mount brackets down so that the actuators just contact the pi...

Page 236: ...earance is not in this range attain proper clearance by adjusting the rear hydraulic cylinder as fol lows Fig 9 A Lower cutting units turn engine off and remove key from the ignition switch B Back off jam nut from the rear hydraulic cylinder clevis IMPORTANT Use a protective covering around the hydraulic cylinder rod when rotating the rod to pre vent damage to the rod C Grasp cylinder rod near the...

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Page 238: ... 11 12 13 14 14 15 16 17 18 19 20 20 22 21 22 23 Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove 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...

Page 239: ...5 16 21 5 22 23 23 Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove 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 4 Remove seat parts as nece...

Page 240: ...3 Hex flange nut Figure 12 FRONT RIGHT 250 to 275 ft lb 339 to 373 N m 70 to 90 ft lb 95 to 122 N m Anti seize Lubricant 10 28 31 30 32 29 2 6 4 1 13 24 12 27 26 25 11 15 21 5 19 20 17 7 23 22 33 8 16 3 17 14 18 9 Blue Loctite 242 Removal Fig 12 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 t...

Page 241: ...ke 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 E Position both brake shoes on the backing plate so that the concave heels attach to the anchor pin F Insert both return springs into the holes of both brake shoes Make sure shoes fit snuggly against the anchor pin and cam ...

Page 242: ... hose 20 Hydraulic hose 21 Lug nut 22 Clamp 23 Spacer 24 Clamp 25 Hydraulic fitting 26 Rear casting 27 Hex flange head screw 28 Bushing 29 Cap screw 30 Lock nut 31 O ring 32 O ring 33 O ring 34 O ring 35 Hose assembly 36 Hose assembly 37 Valve stem 38 Wheel rim 39 Woodruff key Figure 14 31 32 33 34 35 36 37 38 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 11 12 13 14 15 25 4 28...

Page 243: ...ort rear fork to prevent its falling during re moval and installation Personal injury or dam age to the fork may result from improper han dling 7 Remove cap screw thrust washer and lock washer from the rear fork shaft 8 Lower rear fork from machine 9 Check bushings for wear and damage Replace if necessary Installation 1 Position rear fork through the frame 2 Install lock washer thrust washer and c...

Page 244: ...w 15 Parking brake link 16 Clevis pin 17 Clevis pin 18 Lever assembly 19 Parking brake spacer 20 Slotted hex head screw 21 Frame 22 Switch 23 Flat washer 24 Lock nut 25 Cap screw 26 Brake pivot shaft 27 Clevis pin 28 Flange bushing 29 Brake pivot bracket 30 Hex flange head screw 31 Cotter pin 32 Brake cam shaft 33 Brake lever 34 Retainer clip 35 Adjustable clevis 36 Jam nut 37 Adjustment rod Figur...

Page 245: ...he machine IMPORTANT When removing the adjustable clevis adjustment rod or the brake lever make sure to mark both parts Marking both parts will make reas sembly and brake adjustment easier 3 Remove and replace parts as necessary to repair brake linkages 4 Install control panel cover to the machine IMPORTANT Always check and adjust brakes any time brake linkages are disassembled or repaired Wheels ...

Page 246: ...Steering wheel nut 21 Toro decal 22 Hydraulic hose 23 Hydraulic hose 24 Hydraulic hose 25 Hydraulic hose 26 Hydraulic hose 27 Tilt steering boss 28 Friction disc 29 Friction disc 30 Flat washer 31 Jam nut 32 Flange screw 33 Steering shield 34 O ring 35 O ring 36 O ring 37 O ring 38 Philips head screw 39 Steering wheel cap 40 Flat washer 41 Flange nut 42 Slope indicator 43 Decal 44 Lock nut 45 Cap ...

Page 247: ...ove and replace parts as necessary to repair steering column Fig 16 and 17 Assembly 1 Make sure lever and friction discs are properly as sembled to the steering control valve bracket Fig 16 and 17 2 Position steering control bracket to the steering con trol valve and steering arm Secure bracket to the steer ing arm with pivot hubs cap screws and hex flange nuts 3 Apply blue Loctite 242 to flange h...

Page 248: ...Bulkhead nut 32 Carrier stop bracket 33 Nut 34 Flange nut 35 O ring 36 O ring 37 RH lift arm 38 LH lift arm 39 Cap screw 40 Shaft 41 Thrust washer 42 Lynch pin 43 Rod 44 Cap screw 45 Cap screw 46 Torsion spring 47 Grease fitting 48 Hair pin 49 RH deck stop 50 LH deck stop 51 Rivet 52 Rubber bumper 53 Flange nut 54 Flange head screw 55 RH pivot bracket 56 LH pivot bracket 57 Front carrier frame 58 ...

Page 249: ... arm A Apply anti seize lubricant to pivot shaft before in serting into lift arm 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 4 Secure hydraulic cylinder to the lift ar...

Page 250: ...nut 24 Rear pivot shaft 25 Jam nut 26 Washer 27 Lift arm assembly 28 Flange head screw 29 Thrust washer 30 Grease fitting 31 Cutting unit pivot shaft 32 Cap screw 33 Cap screw 34 Rebound washer 35 Thrust washer 36 Lynch pin 37 Pop rivet 38 Wear strip 39 Rear cutting unit frame 40 Grease fitting 41 O ring 42 Guard 43 Cap screw 44 Cap screw 45 Lock nut 46 External retaining ring 47 Pin 48 Flat washe...

Page 251: ...que 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 in serting into lift arm B Secure pivot shaft with two 2 cap screws and washer 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 sh...

Page 252: ...13 Nm 1 FRONT RIGHT Disassembly 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove lift arms Fig 18 and 20 see Front and Rear Lift Arms in this chapter 3 Disassemble sidewinder carrier as needed Fig 21 Assembly 1 Assemble sidewinder carrier using Fig 21 A Do not lubricate sidewinder cross tube as bearing caps and ...

Page 253: ...ATION 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 Cutting Decks ...

Page 254: ...iron housing 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 stan dard blade is not ideal DISCHARGE Clippings are discharged from t...

Page 255: ...ways stop en gine and remove key from ignition switch first Operator s Manual The Cutting Deck Operator s Manual provides informa tion 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 Cutting Decks ...

Page 256: ... 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 c...

Page 257: ...tallation Washer Tool 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 bear ings during installation into the front rollers Toro Part Number TOR6018 Figure 2 Spindle Plug The spindle pl...

Page 258: ...he 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 com plete...

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Page 260: ...key from ignition switch first Blade Spindle Assembly 1 Flange nut 6 used 2 Hydraulic deck motor 3 Spindle plate 4 Cutting deck 5 O ring 6 Spindle assembly 7 Drive stud 6 used 8 Cutting blade 9 Anti scalp cup 10 Blade bolt 11 Socket head screw 2 used 12 Flat washer 2 used Figure 4 FRONT RIGHT 85 to 110 ft lb 115 to 149 N m 1 2 3 4 6 7 8 9 10 5 11 12 33 to 36 ft lb 44 7 to 48 8 N m ...

Page 261: ...g 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 as sembly press new drive studs into spindle Make sure that stud heads are fully pressed against spindle sur face 2 Position spindle assembly and spindle plate to cut ting de...

Page 262: ...nts from one deck spindle to another 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 IMPORTANT If new bearings are installed into a used spindle housing it may not be necessary to re place the original large snap ring If the original large snap ring is in good condition with no evi d...

Page 263: ...ft and shaft spacer to make sure there are no burrs or nicks that could possibly dam age 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 9 Carefully slide spindle shaft with spacer up through spindle housing The bottom oil seal and spindle spacer sh...

Page 264: ...ller 1 Deck frame 2 Rear roller assembly 3 Grease fitting 4 Roller shaft screw 5 Roller mount 6 Flange head screw 7 Skid bracket 8 Cap screw Figure 10 8 5 4 1 7 6 3 2 FRONT RIGHT 29 to 35 ft lb 40 to 47 N m 29 to 35 ft lb 40 to 47 N m Blue Loctite 242 ...

Page 265: ...e 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 scrap er rod as...

Page 266: ...embly process frequently check that bearings rotate freely and do not bind If any binding is detected consider component re moval and reinstallation 2 Install new bearing and outer seals into one end of roller tube A Position a new bearing into one end of roller tube Use bearing outer seal tool see Special Tools in this chapter with a soft face hammer to fully seat bearing against roller shoulder ...

Page 267: ...in make sure that shaft and bearings still freely rotate IMPORTANT Make sure that all grease is removed from shaft threads to prevent bearing lock nut loos ening 5 Thoroughly clean threads on both ends of roller shaft NOTE If original bearing lock nut s are being used apply Loctite 242 or equivalent to threads of lock nut s 6 Install bearing lock nut onto each end of the roller shaft Make sure tha...

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Page 269: ... tool ensures that no side load is applied to the bearings during install ation 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 press ing equally on inner and outer races until the inner race comes in contact with the bearing spacer 2 Install roller assembly to de...

Page 270: ...Flange nut 29 Cap screw 30 Flat washer 31 Flange nut 32 Cap screw 33 O Ring Figure 19 FRONT RIGHT 7 17 5 3 6 15 14 10 11 12 13 16 8 1 6 19 18 17 9 22 21 2 4 1 3 3 4 4 5 5 20 23 30 29 31 24 32 25 26 27 28 33 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 ar...

Page 271: ... top of the spindle to prevent contamination 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 Position machine on a level surface and shut engine off 2 Move cutting deck into position near lift arm 3 Slide deck carrier frame onto lift arm pivot pin Se cure with lynch pin Fig 21 4 Install the ...

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Page 273: ...or 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 1 0 Groundsmaster 3500 G Harness Drawing 11 Foldout Drawings ...

Page 274: ... WHITE Y or YE YELLOW Numerous harness wires used on Groundsmaster ma chines 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 harn...

Page 275: ...NIFOLD BLOCK OIL COOLER FILTER OIL T1 P1 CHG ST CR CF PUMP GEAR P1 P2 STRAINER LV G2 P T E OUT IN LV LC1 S1 3200 psi T2 G1 M2 BV 1500 psi S W BULKHEAD PLATE D1 M1 A B C M1 M2 M3 D LIFT S W VALVE 1000 psi POWER STEERING VALVE STEERING SIDEWINDER L R 250 psi V1 BACK PRESSURE LEFT RIGHT REAR DECK DECK DECK REAR FRONT LIFT 200 300 psi 3500 psi 100 150 psi UPPER PORT LOWER PORT HYDROSTAT BY PASS VALVE ...

Page 276: ...D BLOCK OIL COOLER FILTER OIL T1 P1 CHG ST CR CF PUMP GEAR P1 P2 STRAINER LV G2 OUT IN LV LC1 T2 M2 S W BULKHEAD PLATE D1 M1 A B C M1 M2 M3 D LIFT S W VALVE 1000 psi POWER STEERING VALVE STEERING SIDEWINDER L R 250 psi V1 BACK PRESSURE LEFT RIGHT REAR DECK DECK DECK REAR FRONT LIFT S 3200 G1 RV 1500 LC2 psi psi P T E 200 300 psi 3500 psi 100 150 psi UPPER PORT LOWER PORT HYDROSTAT BY PASS VALVE P3...

Page 277: ...2 3 KUBOTA GLOW PLUG CONTROLLER PK HR GY ENGINE GROUND R BK ENGINE OIL PRESSURE GY R BK VIO 12V START PTO SWITCH REEL DRIVE SEAT SWITCH GROUND GLOW TEMP PK REEL UP STOP NONE RUN B I A X Y START B I S Start B FUEL PUMP 110C OVER TEMP SHUTDOWN WARNING 105C OVER TEMP PULL HOLD RUN SOLENOID BATTERY OPTIONAL TRANSPORT MOW GN W BK BU W HOUR METER LIMIT SWITCH GLOW PLUGS 3 B L Y A S I X B OFF RUN START I...

Page 278: ...E LINK BLUE RED BLACK WHITE BLUE GREEN BLACK GREEN BLACK BLACK BLACK BLUE BLACK BLACK BLACK BROWN BLACK BLACK PINK ORANGE RED GRAY ORANGE PINK PINK PINK BROWN PINK RED VIOLET RED BLACK BLACK BLUE WHITE PINK RED BLACK PINK RED BLACK WHITE PINK PINK PINK PINK GREEN YELLOW ORANGE WHITE TAN BLACK SERIAL NUMBER ABOVE 314000001 ...

Page 279: ...Page 9 7 Harness Drawing Groundsmaster 3500 D SERIAL NUMBER ABOVE 314000001 ...

Page 280: ...Page 9 8 ENGINE INTERCONNECT Groundsmaster 3500 G Electrical Schematic sheet 1 of 2 All relays and solenoids are shown as de energized ...

Page 281: ...Page 9 9 Electrical Schematic sheet 2 of 2 Groundsmaster 3500 G All relays and solenoids are shown as de energized ...

Page 282: ...WHITE BLACK BLACK WHITE WHITE BLACK VIOLET BLACK ORANGE BLACK GREEN BLACK BLACK BLACK BLUE BLACK WHITE BLUE BLUE BLACK YELLOW BLACK BLACK ORANGE RED BLACK WHITE RED BLUE YELLOW GREEN GREEN WHITE GREEN BLACK BLACK YELLOW YELLOW BLACK GREEN RED WHITE BLACK WHITE BROWN WHITE RED BLUE BLACK RED BLACK BLUE BLUE BLUE BLACK BLACK BLUE GREEN GREEN BLACK WHITE RED WHITE P37 P36 P15 P18 P08 P27 P45 P25 P13 ...

Page 283: ...Page 9 11 Harness Drawing Groundsmaster 3500 G ...

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