Preface, Toro Company 1997, 1998, 2003 | Toro 3000D instruction

Part No. 96890SL Rev. C

Service Manual

GroundsmasterR 3000/3000–D

Preface

The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Groundsmaster 3000 and 3000–D.

REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUC- TIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine. Replacement Operator’s Manuals are available by sending complete Model and Serial Num- ber to:

The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420

The Toro Company reserves the right to change product specifications or this publication without notice.

This safety symbol means DANGER, WARN- ING, 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 re- pair of the machine.

IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- vent damage to systems or components on the machine.

EThe Toro Company – 1997, 1998, 2003, 2004

Image 1

Toro 3000D manual Preface, Toro Company 1997, 1998, 2003

Contents

Toro Company 1997, 1998, 2003 Preface Groundsmaster 3000/3000-D Table Of Contents Groundsmaster 3000/3000-D 84I Cutting Units 72I Cutting Units Contour 82I Cutting Unit Electrical Diagrams Groundsmaster 3000/3000-D Chapter Safety InstructionsBefore Operating While Operating Safety Groundsmaster 3000/3000-D Maintenance Safety 1 4 Rev. a Groundsmaster 3000/3000-D Safety and Instruction Decals GroundsmasterOn Control Panel Groundsmaster 3000/3000-D 1 5 Rev. a Safety Safety and Instruction Decals Groundsmaster 3000-D Safety 1 6 Rev. a Safety and Instruction Decals 84I Cutting Units On Rear of Deck On Front of Deck On Rear Of Deck 1 7 Rev. a SafetyOn Each Castor Arm On Each Castor Arm On Deck Channels, Under Covers On Top of Rear Castor Chambers 2 Safety and Instruction Decals Contour 82I Cutting Unit On Front Deck Hanger Groundsmaster 3000/3000-D Safety Deck On Each Corner On Right Rear Top of Deck Under Cover On Gearbox Base On Front of Deck On Front of Deck On Rear Of Deck Safety Groundsmaster 3000/3000-D Product Records Product Records and Maintenance Equivalents and Conversions Product Records and Maintenance Groundsmaster 3000/3000-D Torque Specifications Product Records and Maintenance 2 4 Rev. a Traction Unit Lubrication Cutting Units Contour 82I Cutting Unit Rear Discharge 84I Cutting UnitPage Equipment Operation and Service History Report Annual Recommendations GroundsmasterR3000 Maintenance Schedule Maintenance Daily Maintenance Check For Week Check Item b GroundsmasterR3000 Daily Maintenance Check List B Service Required Service RequiredRecords Groundsmasterr 3000-D Product Records and Maintenance 2 14 Rev. B GroundsmasterR3000-D Maintenance Schedule GroundsmasterR3000-D Daily Maintenance Check List C, and D Service Required Service every 100 hoursService 2 16 Rev. a Groundsmaster Ford VSG-411 Engine Ford VSG-411 Engine Ford VSG-411 Engine 3 2 Rev. a Groundsmaster General Information Specifications Belt Adjustments AdjustmentsAlternator Belt Cooling & Governor Fan Belts Ford VSG-411 Engine Groundsmaster Governor Adjustment Outside Temperature Service and RepairsCheck Engine Oil Single Viscosity Oils Change Engine Oil and Filter Check Coolant Maintaining Cooling System Capacity Cooling System Service Service Air Cleaner General Air Cleaner ServiceWashing Method Compressed Air Method Fuel Tank Fuel System ServiceFuel Lines and Connections Check Governor Oil Level Replacing Spark Plugs Servicing Spark Arrestor Muffler Peugeot TUD5 Engine Peugeot TUD5 Engine Peugeot TUD5 Engine Groundsmaster 3000-D Special Tools Air Filter Element Cleaner TOR277220Compression Test Kit TOR3003A Valve Spring Compression Tool TOR4024T Injection Nozzle Tester TOR463610 Peugeot TUD5 Diesel Engine Service Tool Kit TOR4080Digital Belt Tension Tool TOR4075 Order separately Injector Socket TOR4082 Valve Guide Seal Remover TOR4081Torque Angle Gauge TOR4083 Rear Main Seal Installer TOR4086 Camshaft Pinion Setting Tool TOR4084Timing Pin Set TOR4085 Camshaft Seal Installer TOR4088 Front Seal Installer TOR4087 Fan Belt Engine Belts Not Overfill Change Engine Oil and Filter El. Coolant level should be up to or above tabs In de Check Cooling System Rear Screen Oil Cooler Radiator Servicing the Air Cleaner General Air Cleaner Maintenance Up any spilled diesel fuel before starting Area. Always fill fuel tank outside and wipeDraining Fuel Filter / Water Separator Changing Fuel Filter Priming Fuel System Frame, Fuel Tank and Battery Muffler and Bumper Hood Rops Center Shroud and Air Cleaner Fan Bracket and Degasser 4 21 Rev. a Peugeot TUD5 Engine Radiator and Cooler Engine Peugeot TUD5 Overhaul, Checking Tuning Peugeot TUD5 Engine Groundsmaster 3000-D Hydraulic System Hydraulic System and Transaxle Hydraulic System 5 2 Rev. a Pushing or Towing Traction Unit General Information Hydraulic Hoses Hydraulic Fitting InstallationRing Face Seal SAE Straight Thread O-Ring Port Adjustable SAE Straight Thread O-Ring Port Non-adjustable Lift OFF Hold LOWER/FLOAT Hydraulic Schematic Hydraulic System Transaxle 5 7 Rev. a Hydraulic System Hydraulic System Groundsmaster 3000/3000-D Hydraulic Components Hydraulic Test Fitting Kit TOR4079 Hydraulic Pressure Test Kit TOR47009Measuring Container TOR4077 Hydraulic System Groundsmaster 3000/3000-D Testing Charge Pressure Priority Valve Test Charge Pressure Test Reverse Traction Test Forward Traction Test Implement Relief Pressure Test 5 15 Rev. a Hydraulic System Counterbalance Pressure Test and Adjustment Cylinder Test Steering Circuit TestSteering Valve Test Hydraulic System 5 16 Rev. a Use a tester with pressure and flow capabilities This page is blank Hydraulic System Service Brake Adjustment Traction Pedal Linkage Adjustment Lubrication Wheel and TiresCheck Tire Pressure 5 21 Rev. a Hydraulic System BP HYD TF Check Hydraulic Fluid Change Hydraulic Oil and Filter Traction Control Linkage Brake Linkage Driveshafts Lift Arms Steering Control ÁÁÁÁÁÁÀÀÀ#1ÄÄÉÉÉÉÉÅÅÅ Removing Hydraulic System Components After Repair or Replacement of Components Manifold Block Cartridge Valves Cartridge InstallationHydraulic System 5 32 Rev. a Lift Cylinder Steering Cylinder 5 35 Rev. a Hydraulic System Auxiliary Hydraulic Pump Model 30726 Hydraulic Kit Transaxle Service Electrical System Electrical System Groundsmaster 3000/3000-D Electrical Schematics, Wiring Diagrams, and Harness Drawings Skin-Over Grease Multimeter Starting Problems Troubleshooting GroundsmasterProblem Possible Causes Cutting Unit Operating Problems Groundsmaster General Run and Transport Problems Groundsmaster6 5 Rev. a Electrical System Troubleshooting Groundsmaster 3000-D Cutting Unit Operating Problems GM 3000-D General Run and Transport Problems GM 3000-D6 7 Rev. a Electrical System Voltage Measured Battery Charge Level Battery Test Open Circuit TestElectrical System Quick Checks Glow Plug System Test GM 3000-D Ignition Switch Component Identification and Testing Diode Circuit Boards Seat Switch Neutral Switch6 11 Rev. a Electrical System Hour Meter Hydraulic Valve SolenoidsElectrical System 6 12 Rev. a PTO Clutch Coil Cruise Control Coil Optional6 13 Rev. a Electrical System Fuel Gauge Fuel SenderElectrical System 6 14 Rev. a Fuse Testing Relay TestingRelays and Fuses Electrical System 6 16 Rev. a Ampere Thermal Breaker GM 3000-D Live testing Place TestingFuel Stop Solenoid GM 3000-D 6 17 Rev. a Electrical System Electrical System 6 18 Rev. a Injection Advance Solenoid GM 3000-D Alternator GM 3000-D Testing for DC Current Output FigTest Equipment 6 19 Rev. a Electrical System Electrical System 6 20 Rev. a Temperature Sender GM 3000-D Oil Pressure Switch GM 3000-D Temperature Gauge GM 3000-DTesting with the Engine Off Testing with the Engine On Electrical System 6 22 Rev. a Temperature Sending Unit GM 3000-D Glow Plugs GM 3000-D Transport Solenoid GM 3000-D6 23 Rev. a Electrical System H2O in Fuel Sensor GM 3000-D Coolant Level Sensor GM 3000-D Disconnect connector from the sensor. Unscrew Indicator Lights and Circuits GM 3000-D Glow Plug Indicator Light Ford Engine VSG-411 Electrical Component Locations GM3000 Electrical System Thermistor GM Temperature Gauge GMHandle the hot oil with extreme care to prevent Personal injury or fire Oil Pressure Switch GM High Temperature Switch Anti-Dieseling Valve Solenoid GM Indicator Lights and Circuits GM Verify Interlock System Operation Battery Maintenance Inspection, Maintenance, and Testing Battery ServiceImportant Before cleaning the battery, tape or Caps are on tightly Minimum Battery Electrolyte Battery Battery Charge Specific Open CircuitCharging Gravity Voltage Electrical System Groundsmaster 3000/3000-D 7 1 Rev. a 2WD Rear Axle 2WD Rear Axle Groundsmaster 3000/3000-D Rear Wheel Toe-In 7 3 Rev. a Wheel and Tire Service Wheel Bearing Service Rear Axle 2WD Rear Axle Groundsmaster 3000/3000-D 8 1 Rev. a 4WD Rear Axle 4WD Rear Axle Groundsmaster 3000/3000-D 8 3 Rev. a Change Rear Axle Lubricant Check Rear Axle Lubricant 4WD Axle Spindle flange Differential shim kit 4WD Rear Axle Groundsmaster 3000/3000-D Inch Cutting Units Cutting Units Specifications Transport Latch Adjustment Inch Cutting Units Groundsmaster 3000/3000-D Height of Cut Adjustment Anti-Scalp Roller Adjustment Skid AdjustmentBolt Deck Pitch Adjustment Replace Gear Box Lubricant Check Gear Box Lubricant Lubricate Bearings, Bushings and Gear Box Disconnect Cutting Unit From Traction Unit Connect Cutting Unit to Traction Unit Drive Belt Replacement Install Lift Arm Ball Joints9 11 Rev. a Inch Cutting Units Front Castor Fork Bushing Service Castor Wheel and Bearing Service Cutter Blade Removal and Installation Inspecting and Sharpening Blade Removing Spindle Housing Assembly Blade Spindle ServiceDisassembly 9 17 Rev. a Inch Cutting Units Installing Spindle, Bearings Seals Into Spindle Housing Correcting Cutting Unit Mismatch Gearbox Shaft End Play Adjustment Drive Shaft Inch Cutting Units Groundsmaster 3000/3000-D 10 1 Rev. C Contour 82 Cutting Unit Contour 82I Cutting Unit Specifications Front Castor Wheels Contour 82 Cutting Unit Groundsmaster 3000/3000-D Rear Castor Wheels Rear Deck Chain Deck Pitch Adjustment Grease Bearings and Bushings Needle Valve Latch Cover Connect Cutting Unit to Traction Unit Castor arm tube Bushing 60 80 ft-lb 11 Kgm Castor wheel Bearing Front Caster Fork Cutting Blade Removal and Installation Inspecting and Sharpening Blade Correcting Cutting Unit Mismatch Cutting Unit Contour Chamber Pivot Service Contour 82 Cutting Unit 10 16 Rev. a Inch 6 mm Front Part Of Blade Lift Arm Ball Joint Installation 10 19 Rev. C Contour 82 Cutting Unit Hydraulic Motor and Blade Contour 82 Cutting Unit 10 20 Rev. C Important When greasing spindles, grease AssemblyBearing cavity of the housing. If grease does not Passes into the center of the shaft and out to fill Contour 82 Cutting Unit 10 22 Rev. C Hydraulic Assembly 72I Cutting Units Specifications Guardian Recycler Height of Cut Adjustment Skid Flange nut Gage Wheel Adjustment Rear Discharge Cutting Unit Deck Pitch Adjustment After 50 hours of operation Grease Bearings, Bushings and Gear Box Disconnect Cutting Unit From Traction Unit 11 11 Rev. a Inch Cutting Units Gear Box Plate Capscrews & Nuts Wavey Washer 60 80 ft-lb 8 11 Kgm Bearing Spacer Cutter Blade Removal Inspecting and Sharpening Blade 85 110 ft-lb 12 15 Kgm Inch Cutting Units 11 18 Rev. a Correcting Cutting Unit Mismatch 170 190 in-lb 196 219 Kgcm Shaft End Play Adjustment Drive Shaft Electrical Diagrams Electrical Diagrams Groundsmaster 3000/3000-D Optional Electrical Schematic Start Circuits Temp Gauge Run Circuits Wiring Diagram Rear Section Gauge Hour Ignition Switch Hold SW PTO Switch Override Wiring Diagram Front Section Harness Drawing Rear Section Harness Drawing Front Section All relays and solenoids are shown as de-energized Crank Circuits Optional Cruise Control Wiring Diagram Rear Section Wiring Diagram Front Section Switch Ground Sender Input Power