Toro 3505D User Manual

PART NO. 05145SL (Rev. B)

Service Manual

Groundsmaster

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 3505--D.

REFER TO THE OPERATOR’S MANUAL FOR OPERATING, 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.

3505--D

This safety symbol means DANGER, WARNING or CAUTION, PERSONAL SAFETY INSTRUCTION. 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 -- 2005, 2007, 2009

This page is intentionally blank.

Groundsmaster 3505--D

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.......................

Chapter 3 -- Kubota Diesel Engine

Introduction 3 -- 2................................

Specifications 3 -- 3..............................

Service and Repairs 3 -- 4........................

KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,

05 SERIES

Chapter 4 -- Hydraulic System

Specifications 4 -- 2..............................

General Information 4 -- 3........................

Hydraulic Schematic 4 -- 7........................

Hydraulic Flow Diagrams 4 -- 8....................

Special Tools 4 -- 18.............................

Troubleshooting 4 -- 22...........................

Testing 4 - - 25...................................

Adjustments 4 -- 50..............................

Service and Repairs 4 -- 51.......................

ROSS TORQMOTOR

RIES SERVICE PROCEDURE

EATON MEDIUM DUTY PISTON PUMP REPAIR IN-

FORMATION MODEL 70160 VARIABLE DISPLACEMENT PISTON PUMP

SAUER/DANFOSS STEERING UNIT TYPE OSPM

SERVICE MANUAL

MG, MF, ME, AND MJ SE-

Chapter 5 -- Electrical System

Electrical Schematics and Diagrams 5 -- 1..........

Special Tools 5 -- 2..............................

Troubleshooting 5 -- 4............................

Electrical System Quick Checks 5 -- 7..............

Component Testing 5 -- 9.........................

Service and Repairs 5 -- 22.......................

Chapter 6 -- Chassis

Specifications 6 -- 2..............................

Special Tools 6 -- 3..............................

Adjustments 6 -- 4...............................

Service and Repairs 6 -- 6........................

Chapter 7 -- Cutting Units

Specifications 7 -- 2..............................

Special Tools 7 -- 3..............................

Troubleshooting 7 -- 4............................

Adjustments 7 -- 5...............................

Service and Repairs 7 -- 6........................

Chapter 8 -- Electrical Diagrams

Electrical Schematic 8 -- 3........................

Circuit Diagrams 8 -- 4...........................

Wire Harness Drawings 8 -- 8.....................

SafetyProduct Records

Kubota

Hydraulic

Electrical

ChassisCutting

and Maintenance

Diesel Engine

System

Groundsmaster 3505--D

Electrical

Units

Diagrams

This page is intentionally blank.

Groundsmaster 3505--D

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 3505--D was tested and certified by TORO for compliance with existing standards and specifications as identified in the Operator’s Manual. 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 personnel 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.

Chapter 1

Safety

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 mow-

ing site completely to determine which hills can be

Before Operating

1. Read and understand the contents of the Operator’s Manual before starting and operating the machine. Become familiar with the controls and know how to stop the machine and engine quickly. Copies of the Operator’s Manual are available on the internet at www.Toro.com.

2. Keep all shields, safety devices and decals in place. If a shield, safety device or decal is defective, illegible or damaged, repair or replace it before operating the machine. Also tighten any loose nuts, bolts or screws to ensure machine is in safe operating condition.

operated on safely. When performing this site survey, always use common sense and take into consideration the turf condition and the rollover risk. To perform a site survey, follow the procedure outlined in the Traction Unit Operator’s Manual. THE MAXIMUM SIDE HILL

ANGLE SHOULD NOT BE GREATER THAN 15 DEGREES.

3. Assure that operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate the machine unless these items are functioning properly.

Groundsmaster 3505--D Page 1 -- 1 Safety

Rev. B

4. Since fuel is highly flammable, handle it carefully:

A. Store fuel in containers specifically designed for this purpose.

B. Do not remove machine fuel tank cap while engine is hot or running.

C. Do not smoke while handling fuel.

While Operating

D. Fill fuel tank outdoors and only to within an inch of the top of the tank, not the filler neck. Do not overfill.

E. Replace fuel tank and fuel container caps securely after refueling machine.

F. If fuel is spilled, do not attempt to start the engine but move the machine away from the area of the spillage. Avoid creating any source of ignition until fuel vapors have dissipated. Clean up any spilled fuel.

1. Sit on the seat when starting and operating the machine.

2. Before starting the engine:

A. Engage the parking brake.

B. Make sure traction pedal is in neutral and the P.T.O. switch is OFF (disengaged).

C. After engine is started, release parking brake and keep foot off traction pedal. Machine must not move. If movement is evident, the traction pedal linkage is adjusted incorrectly; therefore, shut engine off and adjust traction pedal linkage until machine does not move when traction pedal is released (see Traction Unit Operator’s Manual).

3. Do not run engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could possibly be deadly.

4. 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), tire pressure and operator experience. At side hill angles of 10 degrees or less, the risk of a rollover is low. As the slope angle increases to a recommended maximum limit of 15 degrees, the risk of a rollover increases to a moderate level. DO NOT EXCEED A 15

DEGREE SIDE HILL ANGLE BECAUSE THE RISK OF A ROLLOVER AND SERIOUS INJURY OR DEATH IS VERY HIGH.

5. Do not touch engine, radiator or exhaust system while engine is running or soon after it is stopped. These areas could be hot enough to cause burns.

6. Before getting off the seat:

A. Ensure that traction pedal is in neutral.

B. Lower and disengage cutting decks and wait for all movement to stop.

C. Set parking brake.

D. Stop engine and remove key from ignition switch.

7. Anytime the machine is parked (short or long term), the cutting decks should be lowered to the ground. This relieves pressure from the lift circuit and eliminates the risk of a cutting deck accidentally lowering to the ground.

8. Do not park on slopes unless wheels are chocked or blocked.

Groundsmaster 3505--DPage 1 -- 2Safety

Maintenance and Service

1. Before servicing or making adjustments, lower cutting decks, stop engine, set parking brake and remove key from the switch.

2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight.

3. Never store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace.

4. Make sure all hydraulic line c onnectors are tight, and all hydraulic hoses and lines are in good condition before applying pressure to the hydraulic system.

5. Keep body and hands away from pin hole leaks in hydraulic lines that eject high pressure hydraulic fluid. Use cardboard or paper to find hydraulic leaks. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Fluid accidentally injected into the skin 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 the system must be relieved by lowering the cutting decks to the ground, stopping the engine and then using all of the hydraulic controls (depressing the traction pedal, turning the steering wheel in both directions and energizing the deck solenoid with the engine not running).

7. If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor.

8. Use care when checking or servicing the cutting deck. Wear gloves and use caution when servicing it.

9. To reduce potential fire hazard, keep engine area free of excessive grease, grass, leaves and dirt. Clean protective screen on machine frequently.

10.If engine must be running to perform maintenance or to make an adjustment, keep hands, feet, clothing and other parts of the body away from the cutting decks and other moving parts. Keep bystanders away.

11. Do not overspeed the engine by changing governor setting. To assure safety and accuracy,check maximum engine speed with a tachometer.

12.Shut engine off before checking or adding oil to the crankcase.

13.Disconnect battery before servicing the machine. Disconnect negative battery cable first and positive cable last. If battery voltage is required for troubleshooting or test procedures, temporarily connect the battery. Reconnect positive cable first and negative cable last.

14.Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes and clothing. Protect your face, eyes and clothing when working with a battery.

15.Battery gases can explode. Keep cigarettes, sparks and flames away from the battery.

16.If welding on the machine is necessary, disconnect the negative battery cable to prevent electrical system damage.

17.At the time of manufacture, the machine conformed to the safety standards for riding mowers. To assure optimum performance and continued safety certification of the machine, use genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers may result in non-conformance with the safety standards, and the warranty may be voided.

18.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 the machine, remove any attachments that may interfere 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 supported by blocks or jack stands, the machine may move or fall, which may result in personal injury (see Jacking Instructions in this chapter).

Safety

Groundsmaster 3505--D Page 1 -- 3 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 thatmay interfere 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 supported by blocks or jack stands, the machine may move or fall, which may result in personal injury.

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

Figure 1

1. Square tube 2. Side plate

1. The preferred method for removing the rear fork or the rear wheel 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 machine.

B. Place jack s ecurely under the rear casting as close to the fork as possible (Fig. 3). Jack rear tire off the g round.

C. Use jack stands or blocks under the frame to support the machine.

Figure 2

1. Rear tire 2. Rear casting

Figure 3

1. Frame

2. Rear casting

3. Rear fork

Groundsmaster 3505--DPage 1 -- 4Safety

Product Records and Maintenance

Table of Contents

Chapter 2

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.......................

Product Records

Insert a copy of the Operator’s Manual and Parts Catalog for your Groundsmaster 3505--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 intervals for the Groundsmaster 3505--D are covered in the Operator’s Manual. Refer to that publication when performing regular equipment maintenance.

Standard Torque for Dry, Zinc Plated and Steel Fas-

teners (Inch Series) 4........................

Standard Torque for Dry, Zinc Plated and Steel Fas-

teners (Metric Fasteners) 5...................

Other Torque Specifications 6..................

Conversion Factors 6..........................

Product Records

and Maintenance

Groundsmaster 3505--D Page 2 -- 1 Product Records and Maintenance

Equivalents and Conversions

0.09375

Rev. A

Groundsmaster 3505--DPage 2 -- 2Product Records and Maintenance

Torque Specifications

Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual.

These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a s pecific requirement identified in this Service Manual. The following factors should be considered when applying torque: cleanliness of the fastener, use of a thread sealant (e.g. Loctite), degree of lubrication on the fastener, presence of a prevailing torque feature (e.g. Nylock nut), hardness of the surface underneath the fastener’shead or similar condition which affects the installation.

Fastener Identification

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 material strength, fastener size, length of thread engagement, etc.

The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut) and mating part, then back off fastener 1/4 of a turn. Measure the torque required to tighten the fastener until the lines match up.

Product Records

and Maintenance

Grade 1 Grade 5 Grade 8

Inch Series Bolts and Screws

Figure 1

Class 8.8 Class 10.9

Metric Bolts and Screws

Figure 2

Groundsmaster 3505--D Page 2 -- 3 Product Records and Maintenance

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Thread Size

# 6 -- 32 UNC

# 6 -- 40 UNF

# 8 -- 32 UNC

# 8 -- 36 UNF

#10--24UNC

#10--32UNF

1/4 -- 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1130 + 11 3 140 + 15 1582 + 169

1/4 -- 28 UNF 53 + 7 65 + 10 734 + 113 115 + 12 1299 + 136 160 + 17 1808 + 192

5/16 -- 18 UNC 115 + 15 105 + 15 1186 + 169 200 + 25 2260 + 282 300 + 30 3390 + 339

5/16 -- 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2542 + 282 325 + 33 3672 + 373

3/8 -- 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 5 58 + 7

Grade 1, 5 &

8withThin

Height Nuts

in--lb in--lb N--cm in --lb N--cm in --lb N--cm

10 + 2 13 + 2 147 + 23

13 + 2 25 + 5 282 + 30

18 + 2 30 + 5 339 + 56

ft--lb ft--lb N--m ft--lb N--m ft--lb N-- m

SAE Grade 1 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

SAE Grade 5 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

15 + 2 169 + 23 23 + 3 262 + 34

17 + 2 192 + 23 25 + 3 282 + 34

29 + 3 328 + 34 41 + 5 463 + 56

31 + 4 350 + 45 43 + 5 486 + 56

42 + 5 475 + 56 60 + 6 678 + 68

48 + 5 542 + 56 68 + 7 768 + 79

SAE Grade 8 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 5 or Stronger Nuts)

3/8 -- 24 UNF 17 + 2 18 + 2 24 + 3 35 + 4 47 + 5 50 + 6 68 + 8

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 + 6 75 + 8 77 + 8 104 + 11

1/2 -- 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 11 142 + 15

1/2 -- 20 UNF 32 + 4 53 + 7 72 + 9 85 + 9 115 + 12 120 + 12 163 + 16

5/8 -- 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 21 285 + 28

5/8 -- 18 UNF 75 + 10 95 + 15 129 + 20 170 + 18 230 + 24 240 + 24 325 + 33

3/4 -- 10 UNC 93 + 12 140 + 20 190 + 27 265 + 27 359 + 37 375 + 38 508 + 52

3/4 -- 16 UNF 115 + 15 165 + 25 224 + 34 300 + 30 407 + 41 420 + 43 569 + 58

7/8 -- 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81

7/8 -- 14 UNF 155 + 25 260 + 30 353 + 41 475 + 48 644 + 65 667 + 66 904 + 89

NOTE: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc.

NOTE: The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is approximately +

10% of the nominal torque value. Thin

height nuts include jam nuts.

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 engine oil or thread sealant such as Loctite.

Groundsmaster 3505--DPage 2 -- 4Product Records and Maintenance

Rev. B

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)

Class 8.8 Bolts, Screws and Studs with

Thread Size Regular Height Nuts

(Class 8 or Stronger Nuts)

M5 X 0.8 57 + 6in--lb 644 + 68 N--cm 78 + 8in--lb 881 + 90 N--cm

M6 X 1.0 96 + 10 in--lb 1085 + 11 3 N - -cm 133 + 14 in--lb 1503 + 158 N--cm

M8 X 1.25 19 + 2ft--lb 26 + 3N--m 28 + 3ft--lb 38 + 4N--m

M10 X 1.5 38 + 4ft--lb 52 + 5N--m 54 + 6ft--lb 73 + 8N--m

M12 X 1.75 66 + 7ft--lb 90 + 10 N--m 93 + 10 ft--lb 126 + 14 N--m

M16 X 2.0 166 + 17 ft--lb 225 + 23 N--m 229 + 23 ft--lb 310 + 31 N--m

M20 X 2.5 325 + 33 ft--lb 440 + 45 N--m 450 + 46 ft--lb 610 + 62 N--m

NOTE: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAE J1199.The tolerance is approximately + nominal torque value.

10% of the

Class 10.9 Bolts, Screws and Studs with

Regular Height Nuts

(Class 10 or Stronger Nuts)

Product Records

and Maintenance

Groundsmaster 3505--D Page 2 -- 5 Product Records and Maintenance

Other Torque Specifications

SAE Grade 8 Steel Set Screws

Recommended Torque

Thread Size

Square Head Hex Socket

1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb

5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb

3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3ft--lb

1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb

Thread Cutting Screws

(Zinc Plated Steel)

Type 1, Type 23 or Type F

Thread Size Baseline Torque*

No. 6 -- 32 UNC 20 + 5in--lb

Wheel Bolts and Lug Nuts

Thread Size

7/16 -- 20 UNF

Grade 5

1/2 -- 20 UNF

Grade 5

M12 X 1.25

Class 8.8

M12 X 1.5

Class 8.8

** For steel wheels and non--lubricated fasteners.

Thread Cutting Screws

(Zinc Plated Steel)

Thread

Size

No. 6 18 20 20 + 5in--lb

Threads per Inch

Type A Type B

Recommended Torque**

65 + 10 ft--lb 88 + 14 N--m

80 + 10 ft--lb 108 + 14 N--m

Baseline Torque

No. 8 -- 32 UNC 30 + 5in--lb

No. 10 -- 24 UNC 38 + 7in--lb

1/4 -- 20 UNC 85 + 15 in--lb

5/16 -- 18 UNC 110 + 20 in--lb

3/8 -- 16 UNC 200 + 100 in--lb

Conversion Factors

in--lb X 11.2985 = N--cm N-- cm X 0.08851 = in--lb

ft--lb X 1.3558 = N--m N--m X 0.7376 = ft--lb

No. 8 15 18 30 + 5in--lb

No. 10 12 16 38 + 7in--lb

No. 12 11 14 85 + 15 in--lb

* Hole size, material strength, material thickness & finish must be considered when determining specific torque values. All torque values are based on non--lubricated fasteners.

Groundsmaster 3505--DPage 2 -- 6Product Records and Maintenance

Table of Contents

INTRODUCTION 2..............................

SPECIFICATIONS 3.............................

SERVICE AND REPAIRS 4......................

Muffler and Air Cleaner Assembly 4.............

Muffler Removal 5...........................

Muffler Installation 5.........................

Air Cleaner Assembly Removal 6..............

Air Cleaner Assembly Installation 6............

Fuel System 8................................

Check Fuel Lines and Connections 9...........

Fuel Tank Removal 9........................

Drain and Clean Fuel Tank 9..................

Fuel Tank Installation 9.......................

Chapter 3

Kubota Diesel Engine

Radiator 10..................................

Removal 11.................................

Installation 11...............................

Engine 12....................................

Removal 12.................................

Installation 14...............................

KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,

05 SERIES

Kubota

Diesel Engine

Groundsmaster 3505--D Page 3 -- 1 Kubota Diesel Engine

Introduction

This Chapter gives information about specifications, troubleshooting, testing and repair of the Kubota D1105T diesel engine used in the Groundsmaster 3505--D. Refer to the Traction Unit Operator’s Manual for engine maintenance information.

Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Kubota Workshop Manual, Diesel Engine, 05 Series included at the end of this chapter. The use of some specialized test equipment is explained. However, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility.

Service and repair parts for Kubota engines are supplied through your Authorized Toro Distributor. If no parts list is available, be prepared to provide yourdistributor with the Toro equipment model and serial numbers as well as the Kubota engine model and serial numbers.

Groundsmaster 3505--DPage 3 -- 2Kubota Diesel Engine

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

Fuel No. 2 Diesel Fuel (ASTM D975)

Fuel Capacity liters (gallons) 41.6 (11)

Fuel Injection Pump Bosch MD Type Mini Pump

Governor Centrifugal Mechanical

Low Idle (no load) 1400 + 50 RPM

High Idle (no load) 3050 + 50 RPM

Kubota

Diesel Engine

Direction of Rotation Counterclockwise (Viewed from Flywheel)

Compression Ratio 23:1

Injection Nozzles Mini Nozzle (DNOPD)

Engine Oil See Traction Unit Operator’s Manual

Oil Pump Trochoid Type

Crankcase Oil Capacity liters (U.S. qt.) 3.8 (4.0) with Filter

Starter 12 VDC, 1.4 KW

Alternator/Regulator 12 VDC, 40 AMP

Dry Weight kilograms (U.S. lbs) 98.0 (216.0)

Coolant Capacity liters (U.S. qt.) 5.7 (6.0) with 0.9 (1.0) Reservoir

Groundsmaster 3505--D Page 3 -- 3 Kubota Diesel Engine

Service and Repairs

Muffler and Air Cleaner Assembly

1. Air inlet hose (upper)

2. Air inlet hose (lower)

3. Flange nut

4. Flange head screw

5. Flat washer

6. Cap screw

7. Air filter mount

8. Hose clamp

Figure 1

9. Air cleaner assembly

10. Flange head screw

11. Hex nut (4 used)

12. Lock washer (4 used)

13. Mounting band assembly

14. Muffler

15. Muffler bracket

16. Cap screw (4 used)

17. Exhaust guard (if used)

18. Hose clamp

19. Plug

20. Lock nut

21. Compression spring

22. Bolt

23. Vacuator valve

Groundsmaster 3505--DPage 3 -- 4Kubota Diesel Engine

Muffler Removal (Fig. 1)

CAUTION

The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system 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 from the ignition switch.

2. Open hood to gain access to engine.

3. Remove exhaust guard (if equipped) from frame.

4. Remove both flange head nuts and screws securing the muffler plate to the muffler bracket (Fig. 2).

5. Remove four hex nuts and lock washers from the exhaust manifold studs. Separate muffler flange from the exhaust manifold. Remove muffler from the machine.

6. Remove exhaust gasket. Replace gasket if damaged or torn.

Muffler Installation (Fig. 1)

NOTE: Make sure muffler flange and exhaust manifold

sealing surfaces are free of debris or damage that may prevent a tight seal.

1. Place exhaust gasket on the exhaust manifold.

1. Flange head nut

2. Flange head screw

Figure 2

3. Muffler plate

4. Muffler bracket

Kubota

Diesel Engine

IMPORTANT: Finger tighten all fasteners before securing the muffler plate to the muffler bracket so there is no preload on the exhaust manifold.

2. Position muffler flange to the exhaust manifold with four lock washers and hex nuts.

3. Position muffler plate to the muffler bracket with both flange head screws and nuts (Fig. 2).

4. Tighten muffler flange hex nuts and then muffler plate screws and nuts.

5. If equipped, install exhaust guard to frame.

6. Close and latch hood.

Groundsmaster 3505--D Page 3 -- 5 Kubota Diesel Engine

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. Remove air cleaner components as needed using Figure 1 as a guide.

3. Check air cleaner body for damage that could cause possible air leaks. Make sure that dust cup seals completely to the air cleaner body.

Air Cleaner Assembly Installation (Fig. 1)

IMPORTANT: Any leaks in the air filter system will allow dirt into engine and will cause serious engine damage. Make sure that all air cleaner components are in good condition and are properly secured during assembly.

1. Assemble air cleaner system using Figure 1 as a guide. Make sure that vacuator valve is pointed down after assembly (Fig. 3).

1. Latch

2. Dust cup

Figure 3

3. Vacuator valve

2. Close and latch hood.

Groundsmaster 3505--DPage 3 -- 6Kubota Diesel Engine

This page is intentionally blank.

Kubota

Diesel Engine

Groundsmaster 3505--D Page 3 -- 7 Kubota Diesel Engine

Fuel System

14 16

36 22

1. Cap screw (2 used)

2. Fuel tank

3. Fuel hose strap

4. Cap screw

5. Fuel cap

6. Tank support

7. Fuel gauge

8. Grommet

9. Connector fitting

10. Stand pipe

11. R--clamp

12. Barb fitting

13. Cap screw (2 used)

14. Flange hex nut (2 used)

15. Heat shield

Figure 4

16. Flat washer (2 used)

17. Tee fitting

18. Barb fitting

19. Barb fitting

20. Bushing

21. Spacer (2 used)

22. Hose clamp

23. Fuel prefilter

24. Fuel/water separator

25. Fuel fitting

26. Flange head screw (2 used)

27. Flange nut (2 used)

28. Seat support strap (2 used)

29. Foam (2 used)

30. Hex flange head screw (2 used)

31. Flat washer (2 used)

32. Fuel hose

33. Fuel hose

34. Fuel hose

35. Fuel hose

36. Fuel hose

37. Fuel hose

38. Fuel hose

39. R--clamp

40. Fuel pump

41. Spacer (2 used)

42. Cap screw (2 used)

43. Crossover fuel hose

44. Hose clamp

Groundsmaster 3505--DPage 3 -- 8Kubota Diesel Engine

Fuel Tank Installation (Fig. 4)

DANGER

Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running or hot or when machine is in an enclosed area. Always fill fuel tank outside and clean up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety-approved container and keep cap in place. Use diesel fuel for the engine only; not for any other purpose.

Check Fuel Lines and Connections

Check fuel lines and connections every 400 hours or yearly, whichever comes first.

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. Check fuel lines for deterioration, damage, leaks or loose connections. Replace hoses, clamps and connections as necessary.

1. Position fuel tank to the machine.

2. Connect both fuel hoses to the tank and secure with hose clamps and fuel hose strap.

3. Connect seat switch to the electrical harness. Route seat switch wire under seat support strap. Secure seat support straps and seat to the frame (see Operator Seat Installation in Chapter 6 -- Chassis).

4. Check for correct seat operation and also that seat switch wires and connector are not pinched and do not contact any moving parts.

5. Fill fuel tank (see Traction Unit Operator’s Manual).

Kubota

Diesel Engine

Fuel Tank Removal (Fig. 4)

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. Remove fuel from the tank into a suitable container. Crossover fuel hose (item 44) removal may assist to drain tank completely.

3. Remove seat and seat support straps from the frame (see Operator Seat Removal in Chapter 6 -- Chassis). Note location of spacers under front of seat support straps. Disconnect seat switch from the electrical harness (Fig. 5).

4. Remove fuel hose strap and both fuel hoses from the fuel tank. Pull tank from the machine (Fig. 5).

Drain and Clean Fuel Tank

Drain and clean the fuel tank every 2 years. Also, drain and clean the fuel tank if the fuel system becomes contaminated or if the machine is to be stored for an extended period.

1. Seat support strap

2. Hex flange head screw

3. Electrical harness

Figure 5

4. Fuel hose strap

5. Fuel hose

1. Remove fuel tank from the machine (see Fuel Tank Removal).

2. Flush fuel tank out with clean diesel fuel. Make sure that tank is free of all contaminates and debris.

3. Install fuel tank to the machine (see Fuel Tank Installation).

Groundsmaster 3505--D Page 3 -- 9 Kubota Diesel Engine

Radiator

1. Draincock valve

2. Flange head screw (11 used)

3. Flange nut (4 used)

4. Carriage bolt (4 used)

5. Radiator

6. Upper fan shroud

7. Lower fan shroud

8. Flange head screw (4 used)

9. Hose clamp

10. Radiator frame

11. Radiator cap

12. Radiator foam seal

13. Flange head screw (2 used)

Figure 6

14. Reservoir bracket

15. Wire form latch (2 used)

16. Oil cooler bracket (2 used)

17. Bracket clamp (2 used)

18. Screw (2 used)

19. Lock nut (2 used)

20. Radiator shield (lower)

21. Magnetic catch

22. Oil cooler

23. Radiator hose (upper)

24. Radiator hose (lower)

25. Hose clamp

26. Hydraulic tube

27. Hydraulic tube

28. Oil 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

37. Tube assembly

38. Flange nut (2 used)

Groundsmaster 3505--DPage 3 -- 10Kubota Diesel Engine

Removal (Fig. 6)

Installation (Fig. 6)

1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch.

2. Open and remove hood from the machine (see Traction Unit Operator’s Manual).

CAUTION

Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Ethylene--glycol antifreeze is poisonous. Dispose of coolant properly or store it in a properly labeled container away from children and pets.

3. Place a suitable container under the radiator to collect the coolant. Open draincock valve and completely drain the radiator.

4. Remove glow plug relay from the radiator assembly. Position relay away from the radiator.

5. Disconnect following hoses from the radiator:

1. Remove any plugs placed in radiator and coolant hose openings during the removal procedure.

2. Carefully position radiator to the radiator frame.

3. Secure radiator to the radiator frame with four (4) carriage bolts and flange nuts. Secure top and bottom of radiator to frame with flange head screws.

4. Secure lower and upper fan shrouds to the radiator assembly with flange head screws.

5. Secure expansion tank bracket and tank to the top fan shroud with flange head screws and flange nuts.

6. Connect following hoses to the radiator:

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. Secure glow plug relay to the radiator assembly.

Kubota

Diesel Engine

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.

6. Remove expansion tank and bracket from the top fan shroud.

7. Remove upper and lower fan shrouds from radiator assembly.

8. Remove flange head screws securing the top and bottom of the radiator frame to the radiator.Remove four (4) carriage bolts and flange nuts securing the radiator to the radiator frame.

9. Carefully pull radiator from the radiator frame.

10.Plug radiator and hose openings to prevent contamination.

8. Make sure radiator draincock valve is closed. Fill radiator with coolant (see Traction Unit Operator’s Manual).

9. Install hood to the machine (see Traction Unit Operator’s Manual). Close and latch hood.

Groundsmaster 3505--D Page 3 -- 11 Kubota Diesel Engine

Engine

11 2 5 9

22 24

14 6

1. Kubota engine

2. Engine mount (2 used)

3. Engine mount

4. Flange nut (6 used)

5. Cap screw (3 used)

6. Flange head screw (6 used)

7. External lock washer

8. Lock nut (3 used)

9. Hardened washer (3 used)

10. Machine screw

11. Hardened washer (11 used)

12. Cap screw (5 used)

13. Engine mounting bracket (front)

14. Engine mounting bracket (LH)

15. Engine mounting bracket (RH)

16. Cap screw (4 used)

17. Pulley

18. Bolt (3 used)

19. Flange nut (2 used)

20. Flat washer (3 used)

21. Exhaust gasket

22. Throttle swivel

23. Lock nut

24. Slotted hex head screw

25. Throttle cable clamp

26. Cap screw

27. Radiator hose (lower)

28. Lock nut

Removal (Fig. 7)

1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch.

2. Open and remove hood from the machine (see Traction Unit Operator’s Manual). Slide operator seat all the way forward.

3. Disconnect air hose from the air cleaner and radiator. Remove air cleaner from the engine (see Air Cleaner Assembly Removal in this section).

Figure 7

29. Lock washer

30. Flat washer

31. Flange head screw (2 used)

32. Flat washer

33. R--clamp

34. Lock washer

35. Hex nut

36. Wire harness

37. Hose clamp

38. Radiator hose (upper)

39. Wire harness ground

40. Pump mount plate

41. Spacer

42. Throttle support bracket

4. Disconnect both battery cables at the battery (see Battery Service in Chapter 5 -- Electrical System).

5. Remove muffler from the exhaust manifold and muffler bracket (see Muffler Removal in this section).

6. Drain coolant from the radiator into a suitable container (see Radiator Removal in this section). Disconnect r adiator hoses from the water pump and engine block.

Groundsmaster 3505--DPage 3 -- 12Kubota Diesel Engine

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. Glow plug bus (Fig. 9).

C. High temperature w arning switch (Fig. 10).

D. High temperature shutdown switch, alternator and oil pressure switch (Fig. 11).

9. Disconnect throttle cable from the throttle support bracket and swivel on the speed control lever (Fig. 8).

10.Disconnect fuel hoses from the fuel/water separator (Fig. 8). Position disconnected hose from fuel pump to prevent fuel leakage.

11. Remove traction control cable from the neutral arm assembly on the piston pump. Remove all hydraulic hoses from the piston and gear pumps (see Piston Pump Removal in the Service and Repairs section of Chapter 4-- Hydraulic System).

12.Note location of cable ties securing the wire harness to engine. Remove cable ties.

13.Attach a suitable lift or hoist to lift tabs on front (Fig.

10) and rear (on air filter mount) of engine.

1. Negative battery cable

2. Wire harness ground

3. Fuel stop solenoid

1. Glow plug wire

2. Rear injector nozzle

Figure 8

4. Throttle cable

5. Speed control lever

6. Fuel hose

Kubota

Diesel Engine

Figure 9

3. Fuel hose

CAUTION

Make sure lift or hoist can support the total weight of the engine before removing the cap screws from the engine and engine brackets.

14.Remove flange nuts (item 4), flange head screws (item 6) and lock washer (item 7) s ecuring three engine mounts to the engine mounting brackets.

CAUTION

One person should operate lift or hoist while a second person guides the engine out of the machine.

IMPORTANT: Make sure not to damage the engine, fuel hoses, hydraulic lines, electrical harness or other parts while removing the engine.

15.Slowly remove engine from the machine.

Figure 10

1. Temp. warning switch 2. Front lift tab

Figure 11

1. Temp. shutdown switch

2. Alternator

3. Oil pressure switch

Groundsmaster 3505--D Page 3 -- 13 Kubota Diesel Engine

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. 12 and 13). Note location of spacers, washers and cap screws during removal.

D. Remove four (4) cap screws (item 12) and hardened washers (item 11) securing the right engine mounting bracket to the engine.

E. Remove hydrostat, pump mount plate and mounting brackets from engine.

17.As necessary, remove engine mounts (item 3), front engine mounting bracket (item 13), throttle support bracket (item 42) and left engine mounting bracket (item

14).

Installation (Fig. 7)

1. Cap screw (10 mm)

2. Short spacer

3. Torsion spring

Figure 12

4. Pump mount plate

5. Cap screw (8 mm)

6. Long spacer (4 used)

Kubota

Diesel Engine

1. If removed, install engine mounts ( item 3), front engine mounting bracket (item 13), throttle support bracket (item 42) and left engine mounting bracket (item 14). Also, make sure that all switches and sensors are installed on engine.

2. Install h ydrostat, pump mount plate and mounting brackets to the engine as follows:

A. Position hydrostat, pump mount plate and mounting brackets to engine.

B. Secure right engine mounting bracket (with hydrostat attached) to the engine with four (4) hardened washers and cap screws.

NOTE: To prevent the torsion spring from binding, do not install flat washer on cap screw near the spring.

C. Using locations noted during engine removal, secure pump mount plate to the engine with five (5) spacers, four (4) washers and five (5) cap screws (Fig. 12 and 13).

D. Install traction belt to the engine flywheel and hydrostat pulleys (see Traction Unit Operator’s Manual).

3. Connect hoist or lift to the front and rear engine lift tabs (Fig. 9 and 10).

Figure 13

1. Long spacer (4 used)

2. Flat washer (3 used)

3. 8 mm cap screw (4 used)

4. Hardened washer

5. 10 mm cap screw

6. Short spacer

CAUTION

One person should operate lift or hoist while a second person guides the engine into the machine.

IMPORTANT: Make sure not to damage the engine, fuel or hydraulic lines, electrical harness or other parts while installing the engine.

4. Carefully lower engine into the machine.

5. Secure three (3) engine mounts to the engine mounting brackets with cap screws, washers and flange nuts.

Groundsmaster 3505--DPage 3 -- 14Kubota Diesel Engine

6. Secure wire harness to the front lift tab and the engine with cable ties.

7. 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 Installation in Chapter 4-- Hydraulic System).

8. Connect fuel hose to the fuel/water separator (Fig. 8) and front injector nozzle.

9. Install top fan shroud to the radiator. Install expansion tank and bracket to the top fan shroud (see Radiator Installation in this section).

10.Connect electrical wires to engine:

12.Connect coolant hoses to the water pump and engine block. Close radiator drain cock valve. Fill radiator with coolant (see Traction Unit Operator’s Manual).

13.Install muffler to the exhaust manifold and muffler bracket (see Muffler Installation in this section).

14.Connect throttle cable to the support bracket and swivel on the speed control lever (Fig. 8).

15.Connect both battery cables to the battery (see Battery Service in Chapter 5 -- Electrical system).

16.Install air cleaner to the engine (see Air Cleaner Assembly Installation in this section). Connect air hose to air cleaner and radiator.

A. Negative battery cable and wire harness ground (Fig. 8).

B. Glow plug bus (Fig. 9) and fuel stop solenoid.

C. High temperature w arning switch (Fig. 10).

D. High temperature shutdown switch, alternator and oil pressure switch (Fig. 11).

11. Secure wire harness to engine with cable ties at locations noted during engine removal.

17.Adjust throttle cable (see Adjust Throttle Cable).

18.Bleed fuel system (see Traction Unit Operator’s Manual).

19.Install hood to the machine (see TractionUnit Operator’s Manual). Close and latch hood.

20.Check hydraulic oil level (see Traction Unit Operator’s Manual). Adjust as needed.

21.Check traction drive for neutral (see Traction Unit Operator’s Manual). Adjust as needed.

Groundsmaster 3505--D Page 3 -- 15 Kubota Diesel Engine

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Groundsmaster 3505--DPage 3 -- 16Kubota Diesel Engine

+ 180 hidden pages

Toro 3505D User Manual

Preface

Table Of Contents

General Safety Instructions

Before Operating

While Operating

Maintenance and Service

Jacking Instructions

Product Records

Maintenance

Equivalents and Conversions

Torque Specifications

Introduction

Specifications

Service and Repairs

Muffler and Air Cleaner Assembly

Fuel System

Radiator

Engine