Page 1: Service Manual
The Toro Company reserves the right to change product specifications or this publication without notice. IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- vent damage to systems or components on the machine.
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Page 3: Table Of Contents
Table Of Contents Chapter 1 - - Safety Chapter 5 - - Electrical System General Safety Instructions ....1 -- 1 Electrical Schematics and Diagrams .
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Page 5: General Safety Instructions
..... General Safety Instructions The GROUNDSMASTER 3505--D was tested and certi- fied by TORO for compliance with existing standards WARNING and specifications as identified in the Operator’s Manu- al.
Page 6: While Operating
4. Since fuel is highly flammable, handle it carefully: D. Fill fuel tank outdoors and only to within an inch of the top of the tank, not the filler neck. Do not overfill. A. Store fuel in containers specifically designed for this purpose.
Page 7 Toro replacement parts and ping the engine and then using all of the hydraulic accessories. Replacement parts and accessories made...
Page 8: Jacking Instructions
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 lev- el 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 ma- chine.
Page 9: Product Records
Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......Standard Torque for Dry, Zinc Plated and Steel Fas- MAINTENANCE .
Page 10: Equivalents And Conversions
Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 - - 2 Groundsmaster 3505--D Rev. A...
Page 11: Torque Specifications
For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
Page 12 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
Page 13 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws and Studs with Class 10.9 Bolts, Screws and Studs with Thread Size Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...
Page 14 Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 -- 20 UNF 65 + 10 ft--lb 88 + 14 N--m Grade 5 1/4 -- 20 UNC 140 + 20 in--lb...
Page 15: Introduction 3
Chapter 3 Kubota Diesel Engine Table of Contents INTRODUCTION ......Radiator .
Page 16: Introduction
3505--D. Refer to the Traction Unit Operator’s Manual utor with the Toro equipment model and serial numbers for engine maintenance information. as well as the Kubota engine model and serial numbers.
Page 17: Specifications
Specifications Item Description Make / Designation Kubota D1105T, 3 Cylinder, Liquid Cooled, Turbocharged, Diesel Engine Horse Power 32 HP @ 2800 RPM Bore mm (in.) 78.0 (3.07) Stroke mm (in.) 78.4 (3.09) Total Displacement cc (cu. in.) 1123 (68.53) Firing Order 1--2--3 Combustion Chamber Spherical Type...
Page 18: Service And Repairs
Service and Repairs Muffler and Air Cleaner Assembly Figure 1 1. Air inlet hose (upper) 9. Air cleaner assembly 17. Exhaust guard (if used) 2. Air inlet hose (lower) 10. Flange head screw 18. Hose clamp 3. Flange nut 11. Hex nut (4 used) 19.
Page 19: Muffler Removal
Muffler Removal (Fig. 1) CAUTION The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and ex- haust system to cool before working on the muf- fler. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch.
Page 20: Air Cleaner Assembly Removal
Air Cleaner Assembly Removal (Fig. 1) NOTE: See Traction Unit Operator’s Manual for air cleaner maintenance procedures and intervals. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. Unlatch and raise hood. 2.
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Page 22: Fuel System
Fuel System 9 22 Figure 4 1. Cap screw (2 used) 16. Flat washer (2 used) 31. Flat washer (2 used) 2. Fuel tank 17. Tee fitting 32. Fuel hose 3. Fuel hose strap 18. Barb fitting 33. Fuel hose 4.
Page 23: Check Fuel Lines And Connections
Fuel Tank Installation (Fig. 4) DANGER 1. Position fuel tank to the machine. 2. Connect both fuel hoses to the tank and secure with Because diesel fuel is highly flammable, use cau- tion when storing or handling it. Do not smoke hose clamps and fuel hose strap.
Page 24: Radiator
Radiator 24 25 Figure 6 1. Draincock valve 14. Reservoir bracket 27. Hydraulic tube 2. Flange head screw (11 used) 15. Wire form latch (2 used) 28. Oil cooler hose 3. Flange nut (4 used) 16. Oil cooler bracket (2 used) 29.
Page 25: Removal
Removal (Fig. 6) Installation (Fig. 6) 1. Park machine on a level surface, lower cutting units, 1. Remove any plugs placed in radiator and coolant stop engine, engage parking brake and remove key hose openings during the removal procedure. from the ignition switch. 2.
Page 26: Removal
Engine 30 16 Figure 7 1. Kubota engine 15. Engine mounting bracket (RH) 29. Lock washer 2. Engine mount (2 used) 16. Cap screw (4 used) 30. Flat washer 3. Engine mount 17. Pulley 31. Flange head screw (2 used) 4.
Page 27: Chapter 4-- Hydraulic System)
7. Remove coolant expansion tank and bracket from the upper fan shroud. Remove upper fan shroud from the radiator (see Radiator Removal in this section). 8. Disconnect electrical wires from engine: A. Negative battery cable, wire harness ground and fuel stop solenoid (Fig. 8). B.
Page 28: Installation
16.Separate hydrostat and pump mount plate from the engine as follows: A. Remove traction belt from the engine flywheel and hydrostat pulleys (see Traction Unit Operator’s Manual). B. Support hydraulic pump assembly to prevent it from falling during removal. C. Remove five (5) cap screws, four (4) washers and five (5) spacers securing the pump mount plate to the engine (Fig.
Page 29 6. Secure wire harness to the front lift tab and the en- 12.Connect coolant hoses to the water pump and en- gine with cable ties. gine block. Close radiator drain cock valve. Fill radiator with coolant (see Traction Unit Operator’s Manual). 7.
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Page 31: General Information 4
Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......SERVICE AND REPAIRS .
Page 32: Specifications
Specifications Item Description Piston Pump (Hydrostat) (P3) Variable displacement piston pump Charge Pressure 100 to 150 PSI (6.9 to 10.3 bar) Traction Circuit Relief Pressure (Forward Only) 3000 PSI (207 bar) Gear Pump (P1 and P2) Dual section, positive displacement, gear pump Section P1 Displacement .946 in /rev.
Page 33: General Information
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure WARNING to weather, sun, chemicals, very warm storage condi- tions or mishandling during operation or maintenance. Before disconnecting or performing any work These conditions can cause damage or premature dete- on hydraulic system, relieve all pressure in rioration.
Page 34 SAE Straight Thread O- -Ring Port - - Non- -adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches or any foreign material. 2. Always replace the o--ring seal when this type of fit- ting shows signs of leakage. O- -Ring 3.
Page 35: Towing Traction Unit
Towing Traction Unit In case of emergency, the Groundsmaster 3505--D can be towed (or pushed) for a very short distance. Howev- er, Toro does not recommend this as a standard proce- dure. 1. Locate by--pass valve on hydrostat pump (Fig. 6) and rotate it 90 to open the by--pass valve.
Page 36: Traction Circuit (Closed Loop) Component Failure
Traction Circuit (Closed Loop) Component Failure The Groundsmaster 3505--D traction circuit is a closed Once the filter has been placed in the traction circuit, loop system that includes the hydrostat and two (2) place the machine on jack stands and operate the trac- wheel motors.
Page 37: Hydraulic Schematic
Hydraulic Schematic Groundsmaster 3505--D Page 4 - - 7 Hydraulic System...
Page 38: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams Hydraulic System Page 4 - - 8 Groundsmaster 3505--D...
Page 39: Traction Circuits
Traction Circuits Forward A two section gear pump is directly coupled to the the hy- drostat. Gear pump section (P2) supplies hydraulic flow The traction circuit of the hydraulic system consists of a for maintaining 100 to 150 PSI (6.9 to 10.3 bar) to the low hydrostat connected in a closed loop circuit to two orbital pressure side of the traction circuit (charge), raising and rotor wheel motors.
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Page 41: Cutting Unit Circuit
Cutting Unit Circuit Cutting Unit Blade Braking A two section gear pump is directly coupled to the the hy- When the solenoid valve (R1) is de--energized as the drostat which is driven by the engine. Gear pump sec- PTO switch is DISENGAGED, brake relief cartridge tion (P1) supplies oil flow to the cutting unit circuit (BV) shifts to its closed position, blocking return flow through the manifold block and to the cutting unit mo-...
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Page 43: Lift Circuit (Raise)
Lift Circuit (Raise) A two section gear pump is directly coupled to the the hy- When the cutting units are to be raised, the lift control drostat which is driven by the engine. Gear pump sec- valve is positioned by moving the lift control lever to tion (P2) supplies hydraulic flow for raising and lowering RAISE.
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Page 45: Lift Circuit (Lower)
Lift Circuit (Lower) Circuit operation for lowering the cutting units is similar When the lift control lever is released, spring action re- to raising them. However, pressure is relieved from the turns the valve to its original position and by--passes lift cylinders and this action allows the cutting units to flow back to the hydrostat (charge).
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Page 47: Steering Circuit
Steering Circuit A two section gear pump is directly coupled to the the hy- Left Turn drostat which is driven by the engine. Gear pump sec- When a left turn is made with the engine running, the tion (P2) supplies hydraulic flow for operating the turning of the steering wheel positions the steering con- steering system, raising and lowering the cutting units trol valve so that flow goes through the top of the valve.
Page 48: Special Tools
Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Toro Part Number: TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.
Page 49: Hydraulic Test Fitting Kit
Hydraulic Test Fitting Kit Toro Part Number: TOR4079 This kit includes a variety of O--ring Face Seal fittings to enable the connection of test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings.
Page 50: O--Ring Kit
O- -Ring Kit Toro Part Number: 16- -3799 The kit includes o--rings in a variety of sizes for face seal and port seal hydraulic connections. It is recommended that o--rings be replaced whenever a hydraulic connec- tion is loosened. Figure 13...
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Page 52: Troubleshooting
Troubleshooting The chart that follows contains information to assist in Refer to the Testing section of this Chapter for precau- troubleshooting. There may possibly be more than one tions and specific hydraulic test procedures. cause for a machine malfunction. Problem Possible Cause Hydraulic oil leaks from system.
Page 53 Problem Possible Cause Wheel motor will not turn. Brakes are binding. Key on wheel motor shaft is sheared or missing. Internal parts in wheel motor are damaged. Wheel motor will not hold load in Make up fluid from charge pump is not available. neutral.
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Page 55: Testing
Testing The most effective method for isolating problems in the 3. All hydraulic tests should be made with the hydraulic hydraulic system is by using hydraulic test equipment oil at normal operating temperature. such as pressure gauges and flow meters in the circuits during various operational checks (See the Special WARNING Tools section in this Chapter).
Page 56: Traction Circuit Working Pressure Test
Traction Circuit Working Pressure Test (Using Pressure Gauge) TRACTION WHEEL MOTORS PRESSURE GAUGE BI--PASS LOWER UPPER VALVE PORT PORT 3000 psi TRACTION RELIEF 100 to 150 psi CHARGE FROM HYDRAULIC RELIEF MANIFOLD (CHARGE) PORT PISTON PUMP (HYDROSTAT) Working Pressure TO GEAR PUMP SUCTION Low Pressure (Charge) THROUGH CASE DRAIN Return or Suction...
Page 57 Procedure for Traction Circuit Working Pressure Test: 1. Make sure hydraulic oil is at normal operating tem- perature. Park machine on a level surface with the cut- ting units lowered and off. Make sure engine is off. 2. Read Precautions for Hydraulic Testing. 3.
Page 58: Charge Relief Valve Pressure Test
Charge Relief Valve Pressure Test (Using Pressure Gauge) TRACTION WHEEL MOTORS BI--PASS LOWER UPPER VALVE PORT PORT TO HYDRAULIC MANIFOLD (P1) PORT 3000 psi TRACTION RELIEF PRESSURE GAUGE FROM HYDRAULIC MANIFOLD (CHG) PORT 100 to 150 psi CHARGE RELIEF TO STEERING CONTROL VALVE (IN) PORT ENGINE HYDROSTAT...
Page 59 Procedure for Charge Relief Valve Pressure Test: NOTE: If charge pressure is good under no load, but drops below specification when under traction load, the 1. Make sure hydraulic oil is at normal operating tem- piston pump and/or wheel motor(s) should be sus- perature.
Page 60: Pressure Test
Piston Pump (P3) Flow and Traction Relief Pressure Test (Using Tester with Pressure Gauges and Flow Meter) TRACTION WHEEL MOTORS HYDRAULIC TESTER BI--PASS LOWER UPPER VALVE PORT PORT 3000 psi TRACTION RELIEF 100 to 150 psi FROM HYDRAULIC CHARGE MANIFOLD (CHARGE) PORT RELIEF PISTON PUMP (HYDROSTAT)
Page 61 Procedure for Piston Pump (P3) Flow and Traction 11. Slowly push traction pedal fully to forward position. Relief Pressure Test: 12.Verify traction relief valve setting by slowly closing 1. Make sure hydraulic oil is at normal operating tem- flow control valve on tester. System pressure should be perature.
Page 62: Wheel Motor Efficiency Test
Wheel Motor Efficiency Test (Using Tester with Pressure Gauges and Flow Meter) TRACTION WHEEL MOTORS HYDRAULIC TESTER LOWER UPPER DUMP PORT PORT VALVE 3000 psi TRACTION RELIEF 100 to 150 psi CHARGE FROM HYDRAULIC RELIEF MANIFOLD (CHG) PORT PISTON PUMP High Pressure (HYDROSTAT) Low Pressure...
Page 63 Procedure for Wheel Motor Efficiency Test: 12.Motor internal leakage will be shown on flow meter in GPM. Flow should be less than 1.5 GPM for the 1. Make sure hydraulic oil is at normal operating tem- tested wheel motor. perature. Make sure the hydraulic tank is full. 13.If specifications are not met, the tested wheel motor 2.
Page 64: Cutting Deck Circuit Pressure Test
Cutting Deck Circuit Pressure Test (Using Pressure Gauge) FROM DECK MOTOR CASE DRAINS TO LEFT FRONT DECK MOTOR FROM REAR DECK MOTOR TO HYDRAULIC TANK 1500 psi PRESSURE HYDRAULIC GAUGE DECK MANIFOLD ON--OFF (ENERGIZED) BLOCK 3200 psi TO OIL COOLER FROM FRONT LIFT CYLINDER FROM REAR LIFT...
Page 65 Procedure for Cutting Deck Circuit Pressure Test: 1. Make sure hydraulic oil is at normal operating tem- perature. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged.
Page 66: Manifold Relief Valve (R1) Pressure Test (Using Pressure Gauge And Tester With Pres
Manifold Relief Valve (R1) Pressure Test (Using Pressure Gauge and Tester with Pres- sure Gauges and Flow Meter) FROM DECK MOTOR CASE DRAINS TO LEFT FRONT DECK MOTOR HYDRAULIC FROM REAR TESTER DECK MOTOR TO HYDRAULIC TANK 1500 psi PRESSURE HYDRAULIC GAUGE DECK...
Page 67 Procedure for Manifold Relief Valve (R1) Pressure 10.Relieve hydraulic system pressure (See Relieving Test: Hydraulic System Pressure in the General Information section). Disconnect tester from manifold and hose. Re- 1. Make sure hydraulic oil is at normal operating tem- connect hydraulic hose that was disconnected for test perature.
Page 68 Logic (Counterbalance) Valve (LC1) Pressure Test (Using Pressure Gauge) FROM DECK MOTOR CASE DRAINS TO LEFT FRONT DECK MOTOR FROM REAR DECK MOTOR TO HYDRAULIC TANK 1500 psi DECK ON--OFF (NOT ENERGIZED) HYDRAULIC MANIFOLD BLOCK 3200 psi TO OIL COOLER FROM FRONT LIFT CYLINDER FROM REAR LIFT...
Page 69: Logic (Counterbalance) Valve (Lc1)
Procedure for Logic (Counterbalance) Valve (LC1) C. To increase pressure setting, turn the adjust- Pressure Test: ment shaft on the valve in a clockwise direction. A 1/8 turn on the shaft will make a measurable change in NOTE: If the counterbalance system is functioning, the counterbalance pressure.
Page 70: Gear Pump (P1) Flow Test
Gear Pump (P1) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO HYDRAULIC MANIFOLD (P1) PORT HYDRAULIC TESTER TO STEERING CONTROL VALVE (IN) PORT TO TOTO ENGINE GEAR PUMP FROM HYDROSTAT CASE DRAIN FROM OIL FILTER STRAINER Working Pressure Low Pressure Return or Suction Flow...
Page 71 Procedure for Gear Pump (P1) Flow Test: 11. If flow was less than 11.8 GPM or a pressure of 2000 PSI cannot be obtained, check for restriction in the pump NOTE: Over a period of time, the gears and wear plates intake line.
Page 72: Deck Motor Efficiency -- Case Drain Test
Deck Motor Efficiency - - Case Drain Test (Using Tester with Pressure Gauges and Flow Meter) TO HYDRAULIC MANIFOLD PORT (D1) LEFT FROM HYDRAULIC DECK MOTOR MANIFOLD PORT (M1) HYDRAULIC TESTER MEASURING RIGHT CONTAINER DECK MOTOR Working Pressure Low Pressure Return or Suction REAR TO HYDRAULIC...
Page 73 10.After achieving 1200 PSI, place disconnected motor Test: case drain hose into a container graduated in ounces or milliliters (e.g. Toro #TOR4077) and collect hydraulic 1. Make sure hydraulic oil is at normal operating tem- fluid for 15 seconds. After 15 seconds, remove hose end perature.
Page 74: Steering And Lift Relief Pressure Test
Steering and Lift Relief Pressure Test (Using Pressure Gauge) TO HYDRAULIC MANIFOLD (ST) PORT TO LIFT VALVE (IN) PORT IN (P) 1000 psi OUT (T) AUX (E) TO HYDRAULIC POWER MANIFOLD PRESSURE STEERING (P1) PORT GAUGE VALVE GEAR PUMP ENGINE STRAINER Working Pressure FROM...
Page 75 Procedure for Steering and Lift Relief Pressure 12.Relieve hydraulic system pressure (See Relieving Test: Hydraulic System Pressure in the General Information section). Disconnect T--connector with test gauge from 1. Make sure hydraulic oil is at normal operating tem- pump connection and hose. Reconnect hydraulic hose perature.
Page 76: Gear Pump (P2) Flow Test
Gear Pump (P2) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO HYDRAULIC MANIFOLD (P1) PORT HYDRAULIC TESTER TO STEERING CONTROL VALVE (IN) PORT TO TOTO ENGINE GEAR PUMP FROM HYDROSTAT CASE DRAIN FROM OIL FILTER Working Pressure Low Pressure Return or Suction STRAINER...
Page 77 Procedure for Gear Pump (P2) Flow Test: 1. Make sure hydraulic oil is at normal operating tem- perature. RIGHT 2. Park machine on a level surface with the cutting units FRONT lowered and off. Make sure engine is off and the parking brake is engaged.
Page 78: Steering Control Valve Test
Steering Control Valve Test STEERING CYLINDER (Fully Extended) OPEN FITTING PLUG POWER STEERING VALVE (LEFT TURN) High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 - - 48 Groundsmaster 3505--D...
Page 79 Procedure for Steering Control Valve Test: 5. If either of these performance tests indicate a steer- ing problem, determine if the steering cylinder is faulty 1. Make sure hydraulic oil is at normal operating tem- using the following procedure. perature. A.
Page 80: Adjustments
Adjustments Braking Valve Adjustment The braking valve (BV) on the hydraulic manifold con- trols the stopping time for the cutting deck blades. The braking valve is adjustable. If adjustment of the braking valve is correct, the cutting deck blades should come to a complete stop within 7 seconds after the PTO switch is disengaged.
Page 81: Service And Repairs
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- 1. Check oil level in the hydraulic reservoir and add cor- tem, park machine on a level surface, engage parking rect oil if necessary.
Page 82: Flush Hydraulic System
NOTE: Use only hydraulic fluids specified in Traction Ing from petroleum base hydraulic fluid to a biode- Unit Operator’s Manual. Other fluids may cause system gradable fluid such as Toro Biodegradable damage. Hydraulic Fluid. 8. Fill hydraulic tank with new hydraulic fluid (see Trac- IMPORTANT: If a component failure occurred in the tion Unit Operator’s Manual).
Page 83: Charge Hydraulic System
Charge Hydraulic System NOTE: When initially starting the hydraulic system with 10.Make sure traction pedal and lift control lever are in new or rebuilt components such as motors, pumps or lift neutral. Start engine and run at low idle speed (1400 + cylinders, it is important that the hydraulic system be 50 RPM).
Page 84: Hydraulic Tank
Hydraulic Tank RIGHT Antiseize lubricant FRONT 30 to 60 in- -lb (3.4 to 6.8 N- -m) Figure 33 1. Grommet (4 used) 11. Elbow fitting 21. Tee fitting 2. Flange head screw (4 used) 12. O- -ring 22. Hydraulic hose 3.
Page 85 Hydraulic Tank Removal (Fig. 33) 3. Attach fittings with new o--rings and hoses to hydrau- lic tank using Figure 33 as a guide. 1. Drain hydraulic oil from Hydraulic tank (see Traction Unit Operator’s Manual). 4. Thread suction strainer into hydraulic tank. 2.
Page 86: Oil Cooler
Oil Cooler Removal 1. Thoroughly clean hydraulic hose ends and fittings on oil cooler to prevent hydraulic system contamination. CAUTION The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before working on the oil cooler. 2.
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Page 88: Wheel Motors
Wheel Motors RIGHT FRONT Figure 36 1. Lock nut (4 per motor) 5. Frame 8. O- -ring 2. Spacer (4 per motor) 6. Hydraulic tube 9. Hydraulic fitting 3. Socket head screw (4 per motor) 7. Hydraulic tube 10. O- -ring 4.
Page 89 Removal (Fig. 36) WARNING 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved.
Page 90: Wheel Motor Service
Wheel Motor Service 45 to 55 ft- -lb (60 to 76 N- -m) Figure 37 1. Coupling shaft 9. Commutator ring 17. Back- -up washer 2. Thrust bearing 10. Manifold 18. Inner seal 3. Drive link 11. Stator 19. Woodruff key 4.
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Page 92 Cutting Deck Motors RIGHT FRONT Figure 38 1. Hydraulic motor 8. Hydraulic fitting 15. O- -ring 2. O- -ring 9. Hydraulic hose 16. O- -ring 3. O- -ring 10. Hydraulic T- -fitting 17. O- -ring 4. Hydraulic elbow 11. Hydraulic hose 18.
Page 93: Cutting Deck Motors
Removal (Fig. 38) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Thoroughly clean hydraulic hose ends and fittings on deck motor to prevent hydraulic system contamination. WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the...
Page 94: Cutting Deck Motor Service
Cutting Deck Motor Service 33 ft- -lb (45 N- -m) 26 ft- -lb (35 N- -m) 26 ft- -lb (35 N- -m) Figure 40 1. Socket head screw (4 used) 8. Rear wear plate 14. Front wear plate 2. Washer (4 used) 9.
Page 95 IMPORTANT: Note position of the open and closed B. Face of wear plates that are in contact with gears side of the wear plates before removing. Also, iden- should be free of wear, roughness or scoring. tify wear plates (front and rear) for proper re- C.
Page 96 8. Lubricate the idler gear shaft with clean hydraulic oil. 14.Apply a light coating of petroleum jelly to the exposed Install idler gear shaft into the remaining position in the side of the back plate. front wear plate. Apply a light coating of clean hydraulic 15.Place back plate on assembly.
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Page 98: Hydraulic Manifold
Hydraulic Manifold RIGHT FRONT Figure 43 1. Hose clamp 10. Straight hydraulic fitting 18. Hydraulic hose 2. O- -ring 11. O- -ring 19. Hydraulic manifold 3. Barb fitting 12. Hydraulic hose 20. O- -ring 4. Stud (2 used) 13. Hydraulic hose 21.
Page 99 Removal (Fig. 43) Installation (Fig. 43) 1. Park machine on a level surface, lower cutting units, 1. Install hydraulic manifold to the frame using Figure stop engine, engage parking brake and remove key 43 as guide. Use labels and marks made during the re- from the ignition switch.
Page 100: Hydraulic Manifold Service
Hydraulic Manifold Service 60 in- -lb (6.8 N- -m) 35 ft- -lb (47 N- -m) 25 ft- -lb (34 N- -m) 45 to 50 ft- -lb (61 to 68 N- -m) 120 in- -lb (13.6 N- -m) RIGHT FRONT Figure 44 1.
Page 101 Cartridge Valve Service (Fig. 44) 7. Reinstall the cartridge valve into the manifold block: 1. Make sure the manifold is clean before removing the A. Lubricate new seal kit components with clean hy- valve. draulic oil and install on valve. The o--rings, sealing rings and backup rings must be arranged properly on 2.
Page 102: Lift Control Valve
Lift Control Valve RIGHT FRONT Figure 46 1. Knob 8. O- -ring 15. Hydraulic 90 fitting 2. Lever assembly 9. Hydraulic adapter 16. Hydraulic hose 3. Flange nut (2 used) 10. O- -ring 17. Flange nut (2 used) 4. Control panel 11.
Page 103 Removal (Fig. 46) 1. Thoroughly clean hydraulic hose ends and fittings on lift cylinder to prevent hydraulic system contamination. WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hy- draulic System Pressure in the General Infor- mation section.
Page 104: Lift Control Valve Service
Lift Control Valve Service 10 to 12 ft- -lb 30 to 42 ft- -lb (14 to 16 N- -m) (41 to 57 N- -m) 30 to 35 ft- -lb (41 to 48 N- -m) 30 to 35 ft- -lb (41 to 48 N- -m) 20 to 25 ft- -lb (27 to 34 N- -m) Figure 48...
Page 105 Figure 49 1. Check poppet 10. Spool cap 19. Detent plug 2. Plunger 11. Valve body 20. O- -ring 3. Spacer 12. O- -ring 21. O- -ring 4. Spool 13. Retaining ring 22. Detent plunger 5. Seat 14. Washer 23. Spring 6.
Page 106 Disassembly (Figs. 48 and 49) Assembly (Figs. 48 and 49) 1. Plug all ports and clean the outside of the valve thor- IMPORTANT: Do not wipe parts dry with paper tow- oughly. els or rags. Lint free cloth must be used to prevent lint from causing damage to the hydraulic system.
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Page 108: Neutral Arm Assembly
Neutral Arm Assembly Figure 50 1. Pump assembly 12. Lock nut (2 used) 23. Flange head screw (2 used) 2. Hose 13. Spacer 24. Cable support bracket 3. Extension spring 14. Traction stud 25. Ball bearing 4. Pump mount plate 15.
Page 109 5. Remove cap screw (item 19) and flat washer (item 4. Position three (3) flat washers (items 16 and 17) to 20) that secure the pump lever (item 29) and hub (item traction control cable end. Secure traction control cable 21) assembly to the piston pump trunnion.
Page 110: Piston Pump
Piston Pump RIGHT FRONT 77 to 93 ft- -lb (105 to 127 N- -m) 27 to 31 ft- -lb (37 to 42 N- -m) 90 to 120 in- -lb (10.2 to 13.6 N- -m) Figure 51 1. Piston pump 23. Idler arm 44.
Page 111 Piston Pump Removal (Fig. 51) 11. If hydraulic fittings are to be removed from piston pump, mark fitting orientation to allow correct assembly. 1. Park machine on a level surface, lower cutting units, Remove hydraulic fittings and o--rings from the piston stop engine, engage parking brake and remove key pump as needed.
Page 112 2. Remove plugs from piston pump openings that were 10.Using a straight edge across the lower face of the placed during disassembly. Install hydraulic fittings with pump pulley, verify traction belt alignment across engine new o--rings to their original positions on the piston and pump pulleys.
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Page 114: Piston Pump Service
Piston Pump Service 40 41 Figure 54 1. Key 17. O- -ring 33. Washer 2. Drive shaft 18. Plug 34. Shaft seal 3. Bearing 19. Spring 35. Retaining ring 4. Cap screw (3 used per plate) 20. Seat 36. Retaining ring 5.
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Page 116: Gear Pump
Gear Pump 27 to 31 ft- -lb (37 to 42 N- -m) RIGHT FRONT Figure 55 1. Piston pump 8. O- -ring 15. Cap screw (2 used) 2. Gear pump 9. O- -ring 16. Flat washer (2 used) 3. Hydraulic hose (tank suction) 10.
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Page 118: Gear Pump Service
Gear Pump Service (Below Serial Number 260000400) 38 to 43 ft- -lb (51 to 58 N- -m) Figure 56 1. Front plate 8. Back- -up gasket 14. Dowel 2. Back plate 9. Rear wear plate 15. Coupler 3. Front body 10.
Page 119 3. Clamp mounting flange of pump in a vise with the CAUTION shaft end down. 4. Loosen cap screws from the back plate. Use eye protection such as goggles when using 5. Remove pump from the vise. Turn pump so that the compressed air.
Page 120 5. Inspect wear plates for the following: 8. Install rear wear plate with pressure seal side up and open side of the pressure seal pointing to the suction A. Bearing areas should not have excessive wear or side of the pump. scoring.
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Page 122: Gear Pump Service
Gear Pump Service (Serial Numbers Above 260000400) 33 ft- -lb (45 N- -m) Figure 33 Front cover Dowel pin 15. Front thrust plate Pressure seal Seal 16. Idler gear Back- -up gasket 10. Body 17. Drive gear Front thrust plate 11.
Page 123 IMPORTANT: Use caution when clamping gear 8. Clean all pump parts. Check all components for pump in a vise to avoid distorting any pump compo- burrs, scoring, nicks and other damage. nents. 9. Replace the entire pump assembly if parts are ex- 3.
Page 124: Steering Control Valve
Steering Control Valve 20 to 26 ft- -lb (28 to 35 N- -m) Figure 59 1. Steering arm 12. Steering control valve 23. Hydraulic hose 2. Flange nut 13. Tilt bracket 24. Hydraulic hose 3. Flange head screw 14. Cap screw 25.
Page 125 Removal (Fig. 59) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Thoroughly clean hydraulic hose ends and fittings on steering control valve to prevent hydraulic system con- tamination.
Page 126: Steering Control Valve Service
Steering Control Valve Service 20 to 24 ft- -lb (27 to 33 N- -m) Figure 62 1. Sleeve 9. Dust seal ring 16. Outer gearwheel 2. Cross pin 10. Housing 17. End cover 3. Ring 11. Cardan shaft 18. O- -ring (5 used) 4.
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Page 128: Front Lift Cylinder
Front Lift Cylinder RIGHT 8 35 1 FRONT 55 to 65 ft- -lb (75 to 88 N- -m) Figure 63 1. 90 hydraulic fitting (2 used) 20. Clamp (4 used) 39. Cap screw (2 used) 2. Hydraulic cylinder 21. Jam nut (4 used) 40.
Page 129 Removal (Fig. 63) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Thoroughly clean hydraulic hose ends and fittings on lift cylinder to prevent hydraulic system contamination. WARNING Before disconnecting or performing any work Figure 64...
Page 130: Rear Lift Cylinder
Rear Lift Cylinder RIGHT FRONT 200 to 250 ft- -lb (271 to 339 N- -m) Figure 65 1. Rear lift arm 10. Washer 18. Flange screw 2. Cap screw 11. Jam nut 19. Grease fitting 3. Washer 12. Cap screw (2 used) 20.
Page 131 Removal (Fig. 65) Installation (Fig. 65) 1. Park machine on a level surface, lower cutting units, 1. If fittings were removed, install fittings to lift cylinder stop engine, engage parking brake and remove key using marks made during the removal process to prop- from the ignition switch.
Page 132: Lift Cylinder Service
Lift Cylinder Service 24 to 30 ft- -lb (33 to 41 N- -m) Figure 66 1. Grease fitting 6. O- -ring 11. Internal collar 2. Barrel with clevis 7. O- -ring 12. Dust seal 3. Lock nut 8. Back- -up ring 13.
Page 133 Disassembly (Fig. 66) IMPORTANT: Prevent damage when clamping the hydraulic cylinder into a vise; clamp on the clevis 1. Remove oil from lift cylinder into a drain pan by slowly ONLY. pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder.
Page 134: Steering Cylinder
Steering Cylinder RIGHT 65 to 85 ft- -lb (88 to 115 N- -m) FRONT 65 to 85 ft- -lb (88 to 115 N- -m) Figure 68 1. Hydraulic hose 5. O- -ring 9. Jam nut 2. Hydraulic hose 6. Steering cylinder 10.
Page 135 Removal (Fig. 68) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. NOTE: The rear tire must be removed to allow sufficient clearance to remove the steering cylinder from the ma- chine.
Page 136: Steering Cylinder Service
Steering Cylinder Service 24 to 30 ft- -lb (33 to 41 N- -m) Figure 71 1. Barrel with clevis 5. O- -ring 9. O- -ring 2. Lock nut 6. Piston rod 10. Back- -up ring 3. Piston 7. Rod seal 11.
Page 137 Disassembly (Fig. 71) Assembly (Fig. 71) 1. Remove oil from the steering cylinder into a drain pan 1. Make sure all parts are clean before reassembly. by slowly pumping the cylinder shaft. Plug both ports 2. Coat new o--rings, Uni--ring, rod seal and back--up and clean the outside of the cylinder.
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Page 139: Electrical Schematics And Diagrams
Chapter 5 Electrical System Table of Contents ELECTRICAL SCHEMATICS AND DIAGRAMS . . . PTO Switch ....... SPECIAL TOOLS .
Page 140: Special Tools
Multimeter The multimeter can test electrical components and cir- cuits for current, resistance or voltage. NOTE: Toro recommends the use of a DIGITAL Volt-- Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
Page 141 Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally. Figure 4 Groundsmaster 3505--D Page 5 - - 3 Electrical System...
Page 142: Troubleshooting
Troubleshooting For effective troubleshooting and repairs, you must CAUTION have a good understanding of the electrical circuits and components used on this machine (see Electrical Dia- grams -- Chapter 8). Remove all jewelry, especially rings and If the machine has any interlock switches by--passed, watches, before doing any electrical trouble- shooting or testing.
Page 143 Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Wiring in the crank circuit is loose, corroded or damaged (see Electrical Diagrams -- Chapter 8). Engine run solenoid or circuit wiring is faulty. Engine fuel pump or circuit wiring is faulty. The fuel tank is empty.
Page 144: Chapter 7 - - Cutting Units
Cutting Deck Operating Problems The cutting units will not run with the mow/transport Wiring to the cutting unit drive circuit (see Electrical slide in MOW and the PTO switch in ENGAGE. Diagrams -- Chapter 8) is loose, corroded or damaged. The solenoid coil (R1) on the hydraulic manifold is faulty.
Page 145: Electrical System Quick Checks
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals. 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery 12.45 V 75% charged should be at a temperature of 60...
Page 146: Check Operation Of Interlock Switches
Check Operation of Interlock Switches NOTE: The machine is equipped with an interlock CAUTION switch on the parking brake. The engine will stop if the traction pedal is depressed with the parking brake en- gaged. Do not disconnect safety switches. They are for 1.
Page 147: Component Testing
Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION circuit (e.g. unplug the ignition switch connector before doing a continuity check on the switch). When testing electrical components for continu- NOTE: For engine component testing information, see ity with a multimeter (ohms setting), make sure the Kubota Workshop Manual, Diesel Engine, 05 Se- that power to the circuit has been disconnected.
Page 148: Glow Relay
Glow Relay The glow relay used on the Groundsmaster 3505--D al- lows electrical current to the engine glow plugs when en- ergized. The glow relay is attached to the radiator assembly. Testing 1. Make sure ignition switch is in the OFF position. Un- plug glow relay electrical connector.
Page 149: Hour Meter
Hour Meter 1. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter. Hobbs 2. Connect the negative (--) terminal of the voltage QUARTZ source to the other terminal of the hour meter. 0 0 0 0 HOURS 3.
Page 150: Indicator Lights
Indicator Lights Charge Indicator Light The charge indicator light should come on when the igni- tion switch is in the ON position with the engine not run- ning. Also, it should illuminate with an improperly operating charging circuit while the engine is running. Engine Oil Pressure Light The engine oil pressure light should come on when the ignition switch is in the ON position with the engine not...
Page 151: Pto Switch
PTO Switch The PTO switch is located on the control panel (Fig. 12). This rocker switch allows the decks to be engaged or disengaged. Along with additional switches in the inter- lock system, the PTO switch controls the solenoid valve on the hydraulic manifold.
Page 152: Neutral Switch
Neutral Switch The neutral switch is a proximity type, normally open 5. Reconnect switch after testing. reed switch that closes when the traction pedal is in the 6. Switch adjustment: neutral switch should be neutral position. The neutral switch is located under the installed so that the pin on the traction pedal (neutral floor support plate (Fig.
Page 153: Parking Brake And Transport/Mow Switches
Parking Brake and Transport/Mow Switches The switches used for the parking brake and transport/ mow are the same, normally closed switch. The parking brake switch opens when the parking brake lever is engaged. The switch is located under the dash cover (Fig.
Page 154: Specifications 6
High Temperature Warning Switch The high temperature warning switch is located on the 4. Allow oil to cool while observing temperature. The water pump housing on the rear of the engine block (Fig. high temperature warning switch should open at about 20).
Page 155: High Temperature Shutdown Switch
High Temperature Shutdown Switch The high temperature shutdown switch is located on the 6. Install switch to the engine housing. water pump housing on the rear of the engine block (Fig. 20). The shutdown switch has a blue/white wire con- A.
Page 156: Fuel Pump
Fuel Pump The fuel pump is attached to the frame just outboard of the fuel injection pump. The Standard Control Module Run output LED will be il- luminated when the fuel pump is energized. Operational Test 1. Park machine on a level surface, lower cutting decks, stop engine and engage parking brake.
Page 157: Fuel Stop Solenoid
Fuel Stop Solenoid The fuel stop solenoid used on the Groundsmaster 3505--D must be energized for the diesel engine to run. The solenoid is mounted to the injection pump on the en- gine (Fig. 25). The fuel stop solenoid includes two coils for operation: the pull coil and the hold coil.
Page 158: Chapter 8 - - Electrical Diagrams
Glow Controller The controller is located under the right, lower corner of 5. If any of the conditions in Step 3 are not met or power the instrument panel. to terminal 1 exists and any of the other conditions in Step 4 are not met: NOTE: Refer to Chapter 8 -- Electrical Diagrams when troubleshooting the glow controller.
Page 159: Standard Control Module
Standard Control Module The Groundsmaster 3505--D is equipped with a Stan- Control Module Outputs (Fig. 29) dard Control Module to monitor and control electrical The Start output LED should be illuminated when the components required for safe operation. This Module is ignition key switch is in the START position with the trac- attached to the back of the instrument panel (Fig.
Page 160: Service And Repairs
(+) cable first. Coat terminals with battery are explosive, keep open flames and electrical terminal protector (Toro Part No. 107--0392) or a light sparks away from the battery; do not smoke. coat of grease to reduce corrosion after connections are Nausea may result if the gases are inhaled.
Page 161: Battery Service
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes.
Page 162 2. Conduct a hydrometer test of the battery electrolyte. D. Measure the temperature of the center cell. IMPORTANT: Make sure the area around the cells is E. Connect a battery load tester to the battery termi- clean before opening the battery caps. nals following the manufacturer’s instructions.
Page 163 21 hrs nut with two wrenches. 4 amps 4 amps 4 amps 4 amps 8. Apply battery terminal protector (Toro Part No. 107--0392) or a light coat of grease on all battery posts 126 to 5.5 hrs 11 hrs 16.5 hrs...
Page 164: Solenoid Valve Coil
Solenoid Valve Coil The solenoid valve coil on the hydraulic control manifold (Fig. 32) can be replaced without opening the hydraulic system. Removal 1. Park machine on a level surface, lower cutting 60 in- -lb (6.8 N- -m) decks, engage parking brake, stop engine and remove key from the ignition switch.
Page 165: Special Tools 6
Chapter 6 Chassis Table of Contents SPECIFICATIONS ......SPECIAL TOOLS ......ADJUSTMENTS .
Page 166: Specifications
Specifications Item Description Tire pressure 14 to 18 PSI (0.97 to 1.24 bar) Wheel lug nut torque 45 to 65 ft--lb (61 to 88 N--m) Chassis Page 6 - - 2 Groundsmaster 3505--D...
Page 167: Special Tools
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 Groundsmaster 3505--D Page 6 - - 3 Chassis Rev.
Page 168: Adjustments
Adjustments Adjust Brakes C. If brakes can not be adjusted properly, repair or replace brake components as necessary. CAUTION D. After adjustment is complete, install both front wheel assemblies to the machine (see Front Brake Before and after adjusting the brakes, always and Wheel Installation in the Service and Repairs check the brakes in a wide open area that is flat section).
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Page 170: Service And Repairs
Service and Repairs Operator Seat Figure 4 1. Seat 10. Seat belt 19. Seat switch 2. Cap screw 11. Lock washer 20. Spacer (2 used) 3. Armrest bracket (LH shown) 12. Cap screw 21. Foam (2 used) 4. Armrest 13. Flange head screw (2 used) 22.
Page 171 Removal (Fig. 4) Installation (Fig. 4) 1. Park machine on a level surface, lower cutting units, 1. Install any new seat parts using Figure 4 as a guide. stop engine, engage parking brake and remove key 2. Position seat, spacers and support straps to the fuel from the ignition switch.
Page 172: Front Wheels And Brakes
Front Wheels and Brakes Antiseize Lubricant RIGHT FRONT 45 to 65 ft- -lb (61 to 88 N- -m) 250 to 350 ft- -lb (339 to 474 N- -m) Figure 5 1. Lug nut (4 used per wheel) 12. Brake lever 23.
Page 173 IMPORTANT: Do not hit wheel hub or puller with a E. Insert both return springs into the holes of both hammer during removal or installation. Hammering brake shoes. Make sure shoes fit snuggly against may cause damage to the hydraulic wheel motor. the anchor pin and cam shaft.
Page 174: Rear Fork And Wheel
Rear Fork and Wheel 65 to 85 ft- -lb (88 to 115 N- -m) 60 to 80 ft- -lb (81 to 108 N- -m) 45 to 65 ft- -lb (61 to 88 N- -m) RIGHT FRONT 15 to 20 in- -lb (1.7 to 2.3 N- -m) (See text for tightening procedure) Figure 7...
Page 175 Disassembly (Fig. 7) Assembly (Fig. 7) 1. Park machine on a level surface, lower cutting units, 1. Position rear fork through the frame. stop engine, engage parking brake and remove key 2. Install lock washer, thrust washer and cap screw to from the ignition switch.
Page 176: Brake Lever Linkages
Brake Lever Linkages Figure 8 1. Pop rivet (4 used) 14. Socket head screw (2 used) 26. Brake pivot shaft 2. Control panel cover 15. Parking brake link 27. Clevis pin (2 used) 3. Cover bracket 16. Clevis pin 28. Flange bushing (2 used) 4.
Page 177 Disassembly (Fig. 8) Assembly (Fig. 8) 1. Park machine on a level surface, lower cutting units, 1. Assemble components as necessary using Figure 8 stop engine, engage parking brake and remove key as a guide. from the ignition switch. 2. Install control panel cover to the machine. 2.
Page 178: Steering Column
Steering Column 20 to 26 ft- -lb (28 to 35 N- -m) RIGHT FRONT Figure 9 1. Steering arm 12. Steering control valve 23. Hydraulic hose 2. Flange nut 13. Tilt bracket 24. Hydraulic hose 3. Flange head screw 14. Cap screw 25.
Page 179 Disassembly (Fig. 9) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove philips head screw and steering wheel cap from the steering wheel. 3. Remove steering wheel nut from the steering control valve.
Page 180: Front Lift Arms
Front Lift Arms Antiseize Lubricant RIGHT 8 35 1 FRONT 55 to 65 ft- -lb (75 to 88 N- -m) Figure 11 1. 90 hydraulic fitting (2 used) 20. Clamp (4 used) 39. Cap screw (2 used) 2. Hydraulic cylinder 21.
Page 181 Removal (Fig. 11) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove cutting units from the pivot shaft of the front lift arms (see Cutting Unit Operator’s Manual). NOTE: Remove both spacers from the hydraulic cylin- der shaft clevis when removing the right, front lift arm.
Page 182: Rear Lift Arm
Rear Lift Arm Antiseize Lubricant RIGHT FRONT 200 to 250 ft- -lb (271 to 339 N- -m) Figure 14 1. Rear lift arm 10. Washer 18. Flange screw 2. Cap screw 11. Jam nut 19. Grease fitting 3. Washer 12. Cap screw (2 used) 20.
Page 183 Removal (Fig. 14) 3. Secure hydraulic cylinder clevis to the lift cylinder shaft of the rear lift arm with the thrust washer and exter- 1. Park machine on a level surface, lower cutting units, nal retaining ring. stop engine, engage parking brake and remove key from the ignition switch.
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Page 185: Troubleshooting 7
Chapter 7 Cutting Units Table of Contents SPECIFICATIONS ......SERVICE AND REPAIRS .
Page 186: Specifications
Specifications MOUNTING: All cutting units are supported by equal DISCHARGE: Clippings are discharged from the rear of length, independent lift arms and are interchangeable to the cutting deck. Pre--drilled mounting holes allow at- all three cutting unit positions. tachment of optional mulching baffle. CONSTRUCTION: Deck chamber is welded 7, 10 and CUTTING UNIT LIFT: Cutting units are controlled with 12 gauge steel.
Page 187: Special Tools
Special Tools Order these special tools from your Toro Distributor. Cutting Unit Tool Kit - TOR4070 This tool kit includes special tools used to assemble the cutting unit rear roller that has greasable bearings with a grease fitting on the ends of the roller shaft.
Page 188: Troubleshooting
Troubleshooting There are a number of factors that can contribute to un- Remember that the “effective” or actual height--of--cut satisfactory quality of cut, some of which may be turf depends on cutting unit weight and turf conditions. Ef- conditions. Turf conditions such as excessive thatch, fective height--of--cut will be different than the bench set “sponginess”...
Page 189: Adjustments
Adjustments CAUTION Never adjust or work on the cutting units or lift arms with the engine running. Always stop en- gine and remove key first. Refer to the Cutting Unit Operator’s Manual regarding adjustment procedures for Groundsmaster 3505--D cut- ting decks. Blade Stopping Time The blades of the cutting decks should come to a com- To verify blade stopping time, have a second person...
Page 190: Service And Repairs
Service and Repairs CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop en- gine and remove key first. Rear Roller 29 to 35 ft- -lb (39 to 47 N- -m) RIGHT 29 to 35 ft- -lb (39 to 47 N- -m) FRONT...
Page 191 Removal (Fig. 4) 30 ft- -lb (41 N- -m) 1. If cutting unit is equipped with rear roller scraper, re- move fasteners securing left and right scraper rod brackets to roller mounts (Fig. 5). Remove scraper rod assembly. 2. Remove four (4) flange head screws that secure roll- er mounts to rear of deck frame.
Page 192: Rear Roller Service (Greasable Bearings With Retaining Ring)
Rear Roller Service (Greasable Bearings with Retaining Ring) Figure 6 Roller shaft Grease fitting Ball bearing Outer seal Washer Inner oil seal Retaining ring Inner seal 10. Roller tube Outer oil seal Rev. A Cutting Units Page 7 - - 8 Groundsmaster 3505--D...
Page 193 Roller Disassembly (Fig. 6) 3. Use tool TOR4068 to install inner seal. 1. Remove retaining ring from both ends of roller. 4. Use tool TOR4069 to install outer seal. 2. Hit end of roller shaft with a soft face hammer to re- 5.
Page 194: Rear Roller Service (Greasable Bearings With Bearing Nut)
Rear Roller Service (Greasable Bearings with Bearing Nut) Disassembly (Fig. 7) 50 to 60 ft- -lb 1. Remove bearing lock nut from each end of roller (68 to 81 N- -m) shaft. 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube.
Page 195 3. From the roller tube end with only the inner seal NOTE: After roller is installed to cutting deck, lubricate installed, carefully install the roller shaft into the roller roller grease fittings, rotate roller to properly distribute tube. Make sure that seals are not damaged as shaft is grease in bearings and clean excess grease from roller installed.
Page 196: Blade Spindle
Lower spindle assembly out 3. Cover top of spindle to prevent contamination. the bottom of the deck. Remove spindle plate from top Spindle plug (Toro Part # 94--2703) can be used to cover of deck. spindle.
Page 197 Installation (Fig. 13) 1. Place spindle plate on cutting deck making sure to align notches in plate and cutting deck. 2. Position spindle housing to underside of cutting deck making sure that grease fitting is toward the front of the deck.
Page 198: Blade Spindle Service
Blade Spindle Service Disassembly (Fig. 15) 1. Loosen and remove spindle nut from top of spindle shaft. 2. Press the spindle shaft out of the spindle housing us- 130 to 160 ft- -lb ing an arbor press. The shaft spacer remains on the (176 to 216 N- -m) spindle shaft as the shaft is being removed.
Page 199 4. Pack the bearing cones with grease. Apply a film of PRESS grease on lips of seals. 5. Install lower bearing and seal into bottom of spindle housing. Note: The bottom seal must have the lip facing out (down) (Fig. 18). 6.
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Page 201: Electrical Schematic
Chapter 8 Electrical Diagrams Table of Contents ELECTRICAL SCHEMATIC ..... Electrical Schematic ......CIRCUIT DIAGRAMS .
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Page 203 DECK ON--OFF LIMIT SWITCH SOLENOID JUMPER Groundsmaster 3505--D Electrical Schematic All relays and solenoids are shown as de- - energized. All ground wires are black. Page 8 - - 3...
Page 204 (BRAKE APPLIED) (OCCUPIED) (IN NEUTRAL) DECK ON--OFF LIMIT SWITCH SOLENOID JUMPER (IN TRANSPORT) Groundsmaster 3505--D (OFF) Glow Circuits Power Current Control Current Indication Current Page 8 - - 4...
Page 205 (BRAKE APPLIED) (OCCUPIED) (IN NEUTRAL) DECK ON--OFF LIMIT SWITCH SOLENOID JUMPER (IN TRANSPORT) Groundsmaster 3505--D (OFF) Crank Circuits Power Current Control Current Indication Current Page 8 - - 5...
Page 206 (BRAKE RELEASED) (OCCUPIED) (NOT IN NEUTRAL) DECK ON--OFF LIMIT SWITCH SOLENOID JUMPER (IN TRANSPORT) Groundsmaster 3505--D (OFF) Run Circuits (Transport) Power Current Control Current Indication Current Page 8 - - 6...
Page 207 (BRAKE RELEASED) (OCCUPIED) (NOT IN NEUTRAL) DECK ON--OFF LIMIT SWITCH SOLENOID JUMPER (ENERGIZED) (IN MOW) Groundsmaster 3505--D (ON) Run Circuits (Mow) Power Current Control Current Indication Current Page 8 - - 7...
Page 208 (SERIAL NUMBERS ABOVE 280000000) (SERIAL NUMBERS BELOW 280000000) DECK ON- -OFF SOLENOID (SERIAL NUMBERS ABOVE 260000400) Groundsmaster 3505--D Wire Harness Drawing Page 8 - - 8 Rev. B...
Page 209 ORANGE BLUE BROWN BLACK PINK BLACK PINK GRAY WHITE VIOLET (SERIAL NUMBERS BELOW 280000000) BLUE ORANGE PINK PINK BROWN RED/BLACK YELLOW BLACK BLACK STANDARD CONTROL MODULE PINK BLUE GREEN WHITE/BLACK WHITE PINK GRAY VIOLET PINK ORANGE BLACK ORANGE RED/BLACK BLACK BLACK BLACK BLUE/WHITE...
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Toro Groundsmaster 3505-D Service Manual

This Page Is Intentionally Blank.

Chapter 1 -- Safety

Chapter 2 -- Product Records and Maintenance

Chapter 3 Kubota Diesel Engine

Chapter 6 -- Chassis

Chapter 4-- Hydraulic System)

Chapter 4 Hydraulic System

Chapter 5 Electrical System

Chapter 7 - - Cutting Units

Chapter 8 - - Electrical Diagrams

Chapter 6 Chassis

Chapter 7 Cutting Units

Quick Links

Service Manual

Chapters

Troubleshooting

Related Manuals for Toro Groundsmaster 3505-D

Summary of Contents for Toro Groundsmaster 3505-D

Table of Contents