Toro Groundmaster 3500-D Rotary Mower Service & Repair Manual

PART NO. 01088SL (Rev. F) Service Manual Groundsmaster R 3500--D Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Groundsmaster 3500--D. REFER TO THE OPERATOR’S MANUAL FOR OPER- ATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. For reference, insert a copy of the Operator’s Manual and Parts Catalog for your machine into Chapter 2 of this service manual. Additional copies of the Operator’s Manual and Parts Catalog are available on the internet at www.Toro.com. The Toro Company reserves the right to change product specifications or this publication without notice. This safety symbol means DANGER, WARNING, or CAUTION, PERSONAL SAFETY INSTRUC- TION. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions may result in personal injury. NOTE: A NOTE will give general information about the correct operation, maintenance, service, testing, or repair of the machine. IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the machine. E The Toro Company -- 2001, 2002, 2003, 2004, 2005, 2007, 2009 Downloaded from www.Manualslib.com manuals search engine

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Rev. E Groundsmaster 3500--D Table Of Contents Chapter 1 -- Safety General Safety Instructions 1--1 .................. Jacking Instructions 1--4 ......................... Chapter 2 -- Product Records and Maintenance Product Records 2--1 ........................... Maintenance 2--1 ............................... Equivalents and Conversions 2--2 ................ Torque Specifications 2--3 ....................... Lubrication 2--7 ................................ Preparation for Seasonal Storage 2 -- 11 ............ Chapter 3 -- Kubota Diesel Engine Introduction 3--2 ................................ Specifications 3--3 .............................. General Information 3--4 ........................ Adjustments 3--6 ............................... Service and Repairs 3--8 ........................ KUBOTA WORKSHOP MANUAL, DIESEL ENGINE, 05 SERIES Chapter 4 -- Hydraulic System Specifications 4--2 .............................. General Information 4--3 ........................ Hydraulic Schematic 4--9 ........................ Hydraulic Flow Diagrams 4 -- 10 ................... Special Tools 4 -- 22 ............................. Troubleshooting 4 -- 26 ........................... Testing 4 -- 28 ................................... Adjustments 4 -- 54 .............................. Service and Repairs 4 -- 56 ....................... ROSS TORQMOTOR TM MG, MF, ME, AND MJ SE- RIES SERVICE PROCEDURE EATON MEDIUM DUTY PISTON PUMP REPAIR IN- FORMATION MODEL 70160 VARIABLE DISPLACE- MENT PISTON PUMP ROSS HYDRAGUIDE TM HYDROSTATIC STEERING SYSTEM HGF SERIES SERVICE PROCEDURE SAUER/DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Chapter 5 -- Electrical System Electrical Schematics and Diagrams 5--2 .......... Special Tools 5--3 .............................. Troubleshooting 5--4 ............................ Electrical System Quick Checks 5--7 .............. Component Testing 5--9 ......................... Service and Repairs 5 -- 24 ....................... Chapter 6 -- Wheels, Brakes, and Chassis Specifications 6--2 .............................. Special Tools 6--2 .............................. Adjustments 6--3 ............................... Service and Repairs 6--8 ........................ Chapter 7 -- Cutting Units Specifications 7--2 .............................. Troubleshooting 7--3 ............................ Special Tools 7--4 .............................. Adjustments 7--5 ............................... Service and Repairs 7--8 ........................ Chapter 8 -- Electrical Diagrams Electrical Schematics and Diagrams 8--3 .......... Safety Product Records and Maintenance Kubota Diesel Engine Hydraulic System Electrical System Wheels, Brakes, and Chassis Cutting Units Electrical Diagrams Downloaded from www.Manualslib.com manuals search engine

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Rev. F Groundsmaster 3500--D Page1 -- 1 Safety Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS 1 ............ Supervisor’s Responsibilities 1 ................. Before Operating 1 ............................ While Operating 2 ............................. Maintenance and Service 3 .................... JACKING INSTRUCTIONS 4 ..................... General Safety Instructions The GROUNDSMASTER 3500--D was tested and certi- fied by TORO for compliance with existing standards and specifications as identified in the Operator’s Manu- al. Although hazard control and accident prevention are dependent partially upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the per- sonnel involved in the operation, transport, maintenance, and storage of the machine. Improper use or maintenance by the operator or owner of the machine can result in injury. To reduce the potential for any injury, comply with the following safety instructions. WARNING To reduce the potential for injury or death, comply with the following safety instructions. Supervisor’s Responsibilities 1. Make sure operators are thoroughly trained and familiar with the Operator’s Manual, Operator’s Video, and all the operating and safety decals on the machine. 2. Be sure to establish your own special procedures and work rules for unusual operating conditions (e.g. slopes too steep for machine operation). Survey mowing site completely to determine which hills can be operated on safely. When performing this site survey, always use common sense and take into consideration the turf condition and the rollover risk. To determine which hills or slopes may be safely operated on, use the inclinometer provided with each machine. To perform a site survey, lay a 4 foot long, 2 by 4 inch piece of wood on the slope surface and measure the angle of the slope. The piece of wood will average the slope but will not take into consideration dips or holes. THE MAXIMUM SIDE HILL ANGLE SHOULD NOT BE GREATER THAN 25 DEGREES. Before Operating 1. Operate machine only after reading and understand- ing the contents of the Operator’s Manual and viewing the Operator’s Video. Copies of the Operator’s Manual are available on the internet at www.Toro.com. 2. Only trained operators who are skilled in slope operation and who have read the Operator’s Manual and viewed the Operator’s Video should operate the machine. Never allow children to operate the machine or 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 everyone, especially children and pets, away from the areas of operation. Safety Downloaded from www.Manualslib.com manuals search engine

Rev. F Groundsmaster 3500--D Page1 -- 2 Safety 5. Keep all shields, safety devices, and decals in place. Repair or replace damaged, malfunctioning, or illegible shields, safety devices, or decals before operating the machine. 6. Always wear substantial shoes. Do not operate machine while wearing sandals, tennis shoes or sneakers. Do not wear loose fitting clothing because it could get caught in moving parts and possibly cause personal injury. 7. Wearing safety glasses, safety shoes, long pants and a helmet is advisable and required by some local or- dinances and insurance regulations. 8. Make sure the work area is clear of objects which might be picked up and thrown by the blades. 9. Fill fuel tank with diesel fuel before starting engine. Avoid spilling any fuel. Since fuel is highly flammable, handle it carefully. A. Use an approved fuel container. B. Do not remove cap from fuel tank when engine is hot or running. C. Do not smoke while handling diesel fuel. D. Fill fuel tank outdoors and not over one inch from the top of the tank (bottom of the filler neck). Do not overfill. While Operating 1. Always wear your seatbelt. 2. Do not run the engine in a confined area without ade- quate ventilation. Exhaust fumes are hazardous and could be deadly. 3. Sit on the seat when starting and operating the machine. 4. Check interlock switches daily for proper operation (see Chapter 5 -- Electrical System). Do not rely entirely on safety switches: shut off engine before getting off seat. If a switch fails, replace it before operating the machine. The interlock system is for your protection, so do not bypass it. 5. Operator must be skilled and trained in how to drive on hillsides. Failure to use caution on slopes or hills may cause vehicle to tip or roll, possibly resulting in personal injury or death. 6. This triplex mower has a unique drive system for su- perior traction on hills. The uphill wheel will not spin out and limit traction like conventional triplexes. If operated on a side hill that is too steep, rollover may occur before losing traction. 7. Before backing up, look to the rear and assure no one is behind the machine. Watch out for traffic when near or crossing roads. Always yield the right of way. 8. Keep hands, feet and clothing away from moving parts and the deck discharge area. 9. The slope angle at which the machine will tip is dependent on many factors. Among these are mowing conditions such as wet or undulating turf, speed (especially in turns), position of the cutting units, tire pressure, and operator experience. At side hill slope angles of 20 degrees or less the risk of a rollover is low. As the slope angle increases to a Toro recommended maximum limit of 25 degrees, the risk of a rollover increases to a moder- ate level. DO NOT EXCEED A 25 DEGREE SIDE HILL ANGLE BECAUSE THE RISK OF A ROLLOVER AND SERIOUS INJURY OR DEATH IS VERY HIGH. The Groundsmaster 3500--D is equipped with an angle indi- cator, mounted on the steering tube, which indicates the side hill angle the machine is operating on and identifies the recommended maximum limit of 25 degrees. Stay alert for holes in terrain and other hidden hazards which can cause a sudden change in side hill angle. Use extreme caution when operating close to sand traps, ditches, creeks, steep hillsides, or other hazards. 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 for steering control. 10.When starting the engine: A. Engage parking brake. B. Be sure traction pedal is in neutral and blade drive is in disengage position. C. After engine starts, release parking brake and keep foot off traction pedal. Machine must not move. If movement is evident, the neutral control linkage is incorrectly adjusted: therefore, shut engine off and adjust until machine does not move when traction pedal is released (see Adjust Traction Drive for Neu- tral in the Adjustments section of Chapter 4 -- Hy- draulic System). 11. This product may exceed noise levels of 85 dB(A) at the operator position. Ear protectors are recommended for prolonged exposure to reduce the potential of per- manent hearing damage. Downloaded from www.Manualslib.com manuals search engine

Rev. F Groundsmaster 3500--D Page1 -- 3 Safety 12.Raise the cutting units when driving from one work area to another. 13.Do not touch engine, muffler, exhaust pipe or hydraulic tank while engine is running or soon after it has stopped because these areas could be hot enough to cause burns. 14.If a cutting unit strikes a solid object or vibrates ab- normally, stop immediately. Turn engine off, wait for all motion to stop and inspect for damage. 15.Before getting off the seat: A. Move traction pedal to neutral. B. Set the parking brake. C. Disengage the cutting units and wait for the blades to stop spinning. D. Stop the engine and remove key from the ignition switch. 16.Whenever machine is left unattended, make sure key is removed from ignition switch and parking brake is set. Maintenance and Service 1. Before servicing or making adjustments to the machine, stop the engine and remove key from switch to prevent accidental starting of the engine. 2. Check performance of all interlock switches daily. Do not defeat interlock system. It is for your protection. 3. To ensure entire machine is in good operating condition, frequently check and keep all nuts, bolts, screws and hydraulic fittings tight. 4. Make sure all hydraulic line connectors are tight, and all hydraulic hoses and lines are in good condition before applying pressure to the system. 5. Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have suffi- cient force to penetrate skin and do serious damage. lf fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. 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 the engine area free of excessive grease, grass, leaves and accumula- tion of dirt. 9. If the engine must be running to perform a maintenance adjustment, keep hands, feet, clothing, and any other parts of the body away from the cutting units and any moving parts. Keep everyone away. 10.Do not overspeed the engine by changing governor settings. To assure safety and accuracy, have an Autho- rized Toro Distributor check maximum engine speed with a tachometer. 11.Engine must be shut off before checking oil or adding oil to the crankcase. 12.To insure optimum performance and safety, use gen- uine TORO replacement parts and accessories. Re- placement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty of The Toro Company. Safety Downloaded from www.Manualslib.com manuals search engine

Groundsmaster 3500--D Page1 -- 4 Safety Jacking Instructions CAUTION When changing attachments, tires, or performing other service, use correct blocks, hoists, and jacks. Make sure machine is parked on a solid level floor such as a concrete floor. Prior to raising machine, remove any attachments that may inter- fere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands or solid wood blocks to support the raised machine. If the machine is not properly sup- ported by blocks or jack stands, the machine may move or fall, which may result in personal injury. Use the following positions when jacking up the machine: Jacking the Front End 1. If the front wheel motor is to be removed, position jack securely under the square tube of the lower frame as closely to the side plate as possible (Fig. 1). 2. If the front tire is to be removed, position the jack securely under the front wheel motor. 3. Use jack stands or hardwood blocks under the square tube or wheel motors to support the machine. 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. Chock both front tires. Lift rear tire off the ground. C. Use jack stands or hardwood blocks under the frame to support the machine (Fig. 3). 2. If the rear of the machine cannot be lifted from above: A. Chock both front tires. IMPORTANT: Make sure jack is as close to the rear fork as possible when jacking the rear wheel. B. Place jack securely under the rear wheel motor as close to the fork as possible (Fig. 3). Jack rear tire off the ground. C. Use jack stands or blocks under the frame to support the machine. 1. Square tube 2. Side plate Figure 1 2 1 1. Rear tire 2. Rear casting Figure 2 2 1 1. Frame 2. Rear wheel motor 3. Rear fork Figure 3 2 3 1 Downloaded from www.Manualslib.com manuals search engine

Rev. F Groundsmaster 3500--D Page2 -- 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS 1 ......................... MAINTENANCE 1 ............................... EQUIVALENTS AND CONVERSIONS 2 ........... Decimal and Millimeter Equivalents 2 ............ U.S. to Metric Conversions 2 ................... TORQUE SPECIFICATIONS 3 .................... Fastener Identification 3 ....................... Standard Torque (Inch Series) 4 ................ Standard Torque (Metric Fasteners) 5 ........... Other Torque Specifications 6 .................. Conversion Factors 6 .......................... Product Records Insert a copy of the Operator’s Manual and Parts Cata- log for your Groundsmaster 3500--D at the end of this chapter. Additionally, if any optional equipment or accessories have been installed to your Groundsmaster, insert the Installation Instructions, Operator’s Manuals and Parts Catalogs for those options at the end of this chapter. Maintenance Maintenance procedures and recommended service in- tervals for the Groundsmaster 3500--D are covered in the Operator’s Manual. Refer to that publication when performing regular equipment maintenance. Safety Product Records and Maintenance Kubota Diesel Engine Hydraulic Systems Electrical System Wheels, Brakes, and Chassis Downloaded from www.Manualslib.com manuals search engine

0.09375 Rev. E Groundsmaster 3500--D Page2 -- 2 Product Records and Maintenance Equivalents and Conversions Downloaded from www.Manualslib.com manuals search engine

Toro Groundmaster 3500-D Rotary Mower Service & Repair Manual

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