Toro Groundsmaster 3500-D, 3500-G (Model 30807, 30809) Service Repair Manual

Table of Content – Groundsmaster 3500-D, 3500-G (Model 30807, 30809)

Title Page
Revision History
Reader Comments
Preface
1 – Safety
General Safety Instructions
Before Operating
While Operating
Maintenance and Service
Jacking Instructions
Safety and Instruction Decals
2 – Product Records and Maintenance
Product Records
Maintenance
Equivalents and Conversions
Torque Specifications
Fastener Identification
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
Other Torque Specifications
Conversion Factors
3 – Kubota Diesel Engine (Model 30807)
Specifications
Introduction
Operator’s Manuals
Kubota Workshop Manual
Kubota Diesel Engine
Service and Repairs
Air Cleaner and Muffler
Fuel System
Radiator – Radiator, Hydraulic Fluid Cooler
Diesel Engine
Kubota Workshop Manual, Diesel Engine, 05−E3B Series (S.N Below 314000000)
Kubota Workshop Manual, Diesel Engine, 05-E4B Series (S.N Above 314000000)
4 – Kubota Gasoline Engine (Model 30809)
Specifications
Introduction
Traction Unit Operator’s Manuals
Kubota Workshop and Diagnostics Manuals
Kubota Gasoline Engine
Kubota Gasoline Engine Electronic Control Unit (ECU)
Service and Repairs
Air Cleaner and Muffler
Fuel System
Fuel Evaporative Control System (Unit Serial No. Prior to 315000001)
Radiator, Hydraulic Fluid Cooler
Engine
Kubota Workshop Manual, Gasoline Engine, WG972−G−E3F
Kubota Diagnostics Manual, Gasoline Engine, WG972−G−E3F
5 – Hydraulic System
Specifications
General Information
Operator’s Manual
Relieving Hydraulic System Pressure
Traction Circuit Component Failure
Hydraulic Hoses
Hydraulic Hose and Tube Installation (O-Ring Face Seal Fitting)
Hydraulic Fitting Installation (SAE Straight Thread O-Ring Fitting into Component Port)
Special Tools
Hydraulic Schematics
Units Prior to Serial No. 314000001
Unit Serial No. 314000001 & Up
Hydraulic Flow Diagrams
Traction Circuit
Cutting Unit Circuit
Lift Circuit (Up)
Lift Circuit (Down) & Counterbalance
Sidewinder Circuit
Steering Circuit
Troubleshooting
General Hydraulic System Problems
Traction Circuit Problems
Lift Circuit Problems
Steering Circuit Problems
Mow Circuit Problems
Testing
Traction Circuit Testing – Charge Pressure Test
Traction Unit Testing – Wheel Motor Efficiency Tests
Traction Circuit Testing – Piston Pump, Hydrostat (P3) Flow and Relief Pressure Test
Cutting Deck Circuit Testing – Pressure Test
Cutting Deck Circuit Testing – Deck Motor Efficiency, Case Drain Test
Cutting Deck Circuit Testing – Manifold Relief Valve Pressure Test
Cutting Deck Circuit Testing – Gear Pump (P1) Flow Test
Steering, Lift, Sidewinder Circuit Testing – Gear Pump (P2) Flow Test
Steering, Lift, Sidewinder Circuit Testing – Relief Valve Pressure Test
Steering, Lift, Sidewinder Circuit Testing – Steering Control Valve and Steering Cylinder Test
Adjustments
Blade Braking Valve (BV) Adjustment (Traction Units Prior to No 314000001)
Blade Braking Relief Valve (RV) Adjustment (Traction Units No 314000001 & Up)
Counterbalance Logic Valve (LC1) Adjustment
Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Check Hydraulic Lines and Hoses
Priming Hydraulic Pumps
Flush Hydraulic System
Filtering Closed-Loop Traction Circuit
Charge Hydraulic System
Hydraulic Tank and Hydraulic Fluid Filter
Hydraulic Fluid Cooler
Piston Pump, Hydrostat Assembly
Piston Pump, Hydrostat Service
Gear Pump Service
Front Wheel Motors
Rear Wheel Motor
Wheel Motor Service
Hydraulic Manifold
Hydraulic Manifold Service
Traction Units Prior to Serial No 314000001
Traction Units Serial No 314000001 & Up
Cutting Deck Motor
Cutting Deck Motor Service
Steering Control Valve
Steering Control Valve Service
Steering Cylinder
Steering Cylinder Service
Lift, Sidewinder Control Valve
Lift, Sidewinder Control Valve Service
Front Lift Cylinder
Rear Lift Cylinder
Lift Cylinder Service
Sidewinder
Parker Torqmotor TC, TB, TE, TJ, TF, TG,TH and TL Series Service Procedure
Eaton Piston Pump Repair Information Model 70160
Danfoss Steering Unit Type OSPM Service Repair Manual
6 – Electrical System
General Information
Operator’s Manual
Electrical Drawings
Standard Control Module (SCM)
Kubota Diesel Engine – Electrical Components
Kubota Gasoline Engine – Electrical Components
Special Tools
Troubleshooting
Starting Problems
General Run and Transport Problems
Cutting Deck Operating Problems
Electrical System Quick Check
Battery Test (Open Circuit Test)
Charging System Test
Glow Plug System Test (Diesel Engines Only)
Check Operation of Interlock Switches
Standard Control Module (SCM)
Standard Control Module (SCM) Logic Chart
Component Testing
Ignition Switch
Glow Controller (Diesel Engines Only)
Glow Relay (Diesel Engine Only)
Start, PWR, ETV Relays (Gasoline Engine Only)
Hour Meter
Diode Assemblies
CAN-bus Termination Resistor (Gasoline Engines Only)
Indicator Lights
PTO Switch
Neutral Switch
Seat Switch
Parking Brake and Transport, Mow Switches
Fuses
Fusible Links
High Temperature Warning and Shutdown Switches (Diesel Engines Only)
Oil Pressure Switch
Fuel Pump (Diesel Engine Only)
Fuel Pump (Gasoline Engine Only)
Fuel Stop Solenoid (Diesel Engine Only)
Electronic Throttle Control (Gasoline Engine Only)
Hydraulic Cartridge Solenoid Valve Coils
Service and Repairs
Battery Care
Battery Service
Hydraulic Cartridge Solenoid Valve Coil
7 – Wheels, Brakes, and Chassis
Specifications
Special Tools
Adjustments
Adjust Brakes
Adjust Front Lift Arms
Adjust Front Lift Arm Carrier Stop Bracket Assembly
Adjust Rear Lift Arm
Service and Repairs
Standard Seat
Deluxe Seat
Front Wheel and Brake
Rear Fork and Wheel
Brake Lever Linkages
Steering Column
Front Lift Arms
Rear Lift Arm
Sidewinder Carrier
8 – Cutting Decks
Specifications
General Information
Operator’s Manual
Troubleshooting
Factors That Can Affect Quality of Cut
Special Tools
Adjustments
Blade Stopping Time
Service and Repairs
Blade Spindle Assembly
Blade Spindle Service
Rear Roller
Rear Roller Service
Front Roller Service
Cutting Deck Carrier Frame
9 – Foldout Drawings
Electrical Drawing Designations
Groundsmaster 3500−D Hydraulic Schematic
(Units Prior to Serial No. 314000001)
Groundsmaster 3500−D Hydraulic Schematic
(Unit Serial No. 314000001 & Up)
Groundsmaster 3500−D Electrical Schematic (Serial Numbers Below 403440000)
Groundsmaster 3500–DElectrical Schematic(Serial Numbers Above 403440001)
Groundsmaster 3500−D Harness Diagram (Serial Numbers Below 403440000)
Groundsmaster 3500−D Harness Drawing (Serial Numbers Below 403440000)
Groundsmaster 3500–DHarness Diagram(Serial Numbers Above 403440001)
Groundsmaster 3500–DWire Harness Diagram(Serial Numbers Above 403440001)
Groundsmaster 3500−G Electrical Schematic (sheet 1 of 2)
Groundsmaster 3500-G Electrical Schematic (sheet 2 of 2)
Groundsmaster 3500−G Harness Diagram (Serial Numbers Below 402700000)
Groundsmaster 3500−G Harness Drawing (Serial Numbers Below 402700000)
Groundsmaster 3500–GHarness Drawing(Serial Numbers Above 402700001)
Groundsmaster 3500–GWire Harness Drawing(Serial Numbers Above 402700001)