Toro Groundsmaster 3500-D (Model 30821, 30839, 30843) Service Repair Manual

Table of Content – Groundsmaster 3500-D (Model 30821, 30839, 30843)

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
Lubrication
Preparation for Seasonal Storage
3 – Kubota Diesel Engine
Introduction
Specifications
Adjustments
Adjust Throttle Cable
Service and Repairs
Replace Traction Belt
Bleed Fuel System
Bleed Air from Fuel Injectors
Muffler and Air Cleaner
Fuel System
Radiator (SN Below 313999999)
Radiator and Oil Cooler Assembly (SN Above 314000000)
Engine
Kubota 05 Series Workshop Manual (S.N Below 250000000)
Kubota 05 E2B Series Workshop Manual (S.N 250000001-270999999)
Kubota 05 E3B Series Workshop Manual (S.N 280000001 & up)
4 – Hydraulic System
Specifications
General Information
Traction Unit Operator’s Manual
Check Hydraulic Fluid
Towing Traction Unit
Hydraulic Hoses
Hydraulic Hose and Tube Installation
Hydraulic Fitting Installation
Relieving Hydraulic System Pressure
Traction Circuit (Closed Loop) Component Failure
Hydraulic Schematics
SN Below 240000600
SN 240000601 to 313999999
SN Above 314000000
Hydraulic Flow Diagrams
Traction Circuits
Cutting Unit Circuit
Lift Circuit (Up)
Lift Circuit (Down)
Sidewinder Circuit
Steering Circuit
Special Tools
Troubleshooting
Testing
Before Performing Hydraulic Tests
Traction Circuit Working Pressure Test (Using Pressure Gauge)
Piston Pump (P3) Flow and Traction Relief Pressure Test (Using Tester with Pressure
Charge Relief Valve Pressure Test
Gear Pump (P2) Flow Test (Using Tester with Pressure Gauges and Flow Meter)
Wheel Motor Efficiency Test (Using Tester with Pressure Gauges and Flow Meter)
Cutting Deck Circuit Pressure Test
Gear Pump (P1) Flow Test (Using Tester with Pressure Gauges and Flow Meter)
Manifold Relief Valve (R1) Pressure Test
Logic (Counterbalance) Valve (LC1) Pressure Test
Deck Motor Efficiency – Case Drain Test (Using Tester with Pressure Gauges and Flow)
Lift and Steering Control Valve Relief Pressure Test
Steering Control Valve Test
Adjustments
Adjust Traction Drive for Neutral
Braking Valve Adjustment
Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Change Hydraulic Fluid
Replace Hydraulic Oil Filter
Replace Traction Belt
Check Hydraulic Lines and Hoses
Flush Hydraulic System
Filtering Closed- Loop Traction Circuit
Charge Hydraulic System
Hydraulic Tank and Hydraulic Oil Filter
Oil Cooler
Front Wheel Motors
Rear Wheel Motor
Wheel Motor Service
Rotary Cutting Motors
Rotary Cutting Motor Service (Haldex)
Rotary Cutting Motor Service (Casappa)
Hydraulic Manifold
Hydraulic Manifold Service (Serial Number Below 240000600)
Hydraulic Manifold Service (Serial Number 240000601 to 313999999)
Hydraulic Manifold Service (Serial Numbers Above 314000000)
Control Valve
Control Valve Service
Piston Pump
Piston Pump Service
Gear Pump
Gear Pump Service (Serial Number Below 260000400)
Gear Pump Service (Serial Numbers Above 260000400)
Steering Control Valve
Steering Control Valve Service (Serial Numbers Below 240000000)
Steering Control Valve Service (Serial Numbers Above 240000000)
Sidewinder
Front Lift Cylinder
Rear Lift Cylinder
Lift Cylinder Service
Steering Cylinder
Steering Cylinder Service
Ross Torqmotor Wheel Motor Service Repair Manual
Eaton Piston Pump Repair Information
Ross Hydraguide Steering Control Servcie Manual
Danfoss Steering Control Service Repair Manual
5 – Electrical System
Electrical Schematics and Diagrams
Special Tools
Troubleshooting
Electrical System Quick Check
Battery Test (Open Circuit Test)
Charging System Test
Glow Plug System Test
Check Operation of Interlock Switches
Component Testing
Ignition Switch
Glow Relay
Interlock, Neutral, Seat, and High Temperature Shutdown Relays
Hour Meter
SRV Valve Solenoid
Diode Assemblies
Warning Light Cluster (Serial Numbers Below 240000000)
Indicator Lights (Serial Numbers Above 240000000)
Cutting Unit Drive Switch (Serial Number Below 314000000)
Cutting Unit Drive Switch (Serial Number Above 314000000)
Neutral Switch
Seat Switch
Parking Brake and Transport, Mow Switches
Fusible Link Harness
High Temperature Warning and Shutdown Switches
Fuel Pump
Fuel Stop Solenoid (Solenoid With 3 Wire Connector)
Fuel Stop Solenoid (Solenoid With 2 Wire Connector)
Glow Controller
Standard Control Module
Service and Repairs
Battery Storage
Battery Care
Battery Service
Solenoid Valve Coil
6 – Wheels, Brakes and Chassis
Specifications
Special Tools
Adjustments
Adjust Brake Lever
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
Hood Removal
7 – Cutting Units
Specifications
Troubleshooting
Special Tools
Adjustments
Height Of Cut Adjustment
Adjust Roller Scraper
Blade Plane Inspection and Adjustment
Service and Repairs
Blade Stopping Time
Cutting Unit Removal and Installation
Cutting Blade Removal and Installation
Inspecting and Sharpening Blade
Rear Roller
Rear Roller Service (Non-Greasable Bearings)
Rear Roller Service (Greasable Bearings)
Rear Roller Service (Greasable Bearings with Bearing Nut)
Front Roller Service
Blade Spindle Service
Carrier Frame
8 – Electrical Diagrams
Serial No 90101 to 230999999)
Schematic
Glow Circuits
Crank Circuits
Run Circuits (Transport)
Run Circuits (Mow)
Harness Diagram (SN 90101 to 230999999)
Harness Drawing (SN 90101 to 230999999)
Serial No 240000001 to 314000000)
Schematic
(Serial Numbers 314000001 to 403440000)
(Serial Numbers Above 403440001)
Harness Diagram (SN 240000001 to 313999999)
Harness Drawing (SN 240000001 to 313999999)
Harness Diagram (SN 314000001 to 403440000)
Harness Drawing (SN 314000001 to 403440000)
Harness Diagram(Serial Numbers Above 403440001)
Wire Harness Diagram(Serial Numbers Above 403430001)