Manuals / Toro / Lawn and Garden / Lawn Mower

Toro 3000D manual Cartridge Valves, Cartridge Installation, Hydraulic System 5 32 Rev. a

Models: 3000 3000D

1 242

Download 242 pages 19.97 Kb

Page 102

Cartridge Valves

1.Clean valve block to prevent contamination when valve cartridge is removed.

2.Remove cartridge valve:

A.Remove nut from solenoid.

B.Remove solenoid coil and o–ring at each end of solenoid coil.

C.Use a deep socket to remove cartridge valve. NOTE: Use care when handling valve cartridges, because slight bending or distortion of stem tube can cause binding and malfunction.

3.Visually inspect port in block for damage to sealing areas, damaged threads or contamination.

4.Visually inspect cartridge for damaged seals and con tamination.

A.O–rings and backup rings must be arranged properly on the valve for proper operation and seal ing. Replace any damaged seals.

B.Contamination may cause valves to stick or hang up. Contamination can become lodged in small valve orifices or seal areas on poppet type valves causing malfunction.

C.If cartridge valve seals appear pitted or dam aged, the hydraulic system may be overheating or there may be water in the system.

5.Clean and check for proper valve operation:

A.Use clean mineral spirits to clean cartridge valve. Submerge the valve in clean mineral spirits and use a brass or plastic probe to push the internal spool in and out 20 to 30 times to flush out contamination. Mineral spirits does not affect the o–ring material. Particles as fine as talcum powder can affect the op eration of high pressure hydraulic valves.

Cartridge Installation

1.Lubricate all o–rings with clean hydraulic oil.

2.Carefully thread cartridge into the port by hand. Valve cartridge should go in easily without binding.

3.Use a torque wrench and deep socket to tighten car tridge valves to a torque of 35 ft–lb (5 Kgm). Excessive torque may cause the spool to bind and malfunction.

NOTE: Use care when handling solenoid valve car tridges because slight bending or distortion of stem tube can cause binding and malfunction.

4.Install solenoid coil. Make sure there is an o–ring at each end of the coil. Apply “Loctite 242” or equivalent to threads of stem tube before installing nut. Tighten nut to a torque of 15 in–lb (17 Kg–cm).

5.If problem still exists, remove valve and clean again or replace valve.

Figure 41

Hydraulic System

Page 5 – 32 Rev. A

Groundsmaster 3000/3000–D

Image 102

Toro 3000D manual Cartridge Valves, Cartridge Installation, Hydraulic System 5 32 Rev. a

Contents

Preface Toro Company 1997, 1998, 2003Groundsmaster 3000/3000-D Table Of Contents Groundsmaster 3000/3000-D Contour 82I Cutting Unit Electrical Diagrams 84I Cutting Units 72I Cutting UnitsGroundsmaster 3000/3000-D Safety Instructions ChapterBefore Operating Safety Groundsmaster 3000/3000-D While OperatingMaintenance Safety and Instruction Decals Groundsmaster Safety 1 4 Rev. a Groundsmaster 3000/3000-DOn Control Panel Safety and Instruction Decals Groundsmaster 3000-D Groundsmaster 3000/3000-D 1 5 Rev. a SafetySafety and Instruction Decals 84I Cutting Units Safety 1 6 Rev. aOn Each Castor Arm 1 7 Rev. a SafetyOn Rear of Deck On Front of Deck On Rear Of Deck On Each Castor Arm On Deck Channels, Under CoversSafety and Instruction Decals Contour 82I Cutting Unit On Top of Rear Castor Chambers 2Groundsmaster 3000/3000-D Safety On Front Deck HangerOn Gearbox Base On Front of Deck Deck On Each Corner On Right Rear Top of Deck Under CoverOn Front of Deck On Rear Of Deck Safety Groundsmaster 3000/3000-D Product Records and Maintenance Product RecordsProduct Records and Maintenance Groundsmaster 3000/3000-D Equivalents and ConversionsTorque Specifications Product Records and Maintenance 2 4 Rev. a Lubrication Traction UnitCutting Units Rear Discharge 84I Cutting Unit Contour 82I Cutting UnitPage Equipment Operation and Service History Report GroundsmasterR3000 Maintenance Schedule Annual RecommendationsGroundsmasterR3000 Daily Maintenance Check List Maintenance Daily Maintenance Check For Week Check Item bService Required B Service RequiredRecords Groundsmasterr 3000-D GroundsmasterR3000-D Maintenance Schedule Product Records and Maintenance 2 14 Rev. BGroundsmasterR3000-D Daily Maintenance Check List Service Service every 100 hoursC, and D Service Required 2 16 Rev. aFord VSG-411 Engine Groundsmaster Ford VSG-411 EngineGeneral Information Specifications Ford VSG-411 Engine 3 2 Rev. a GroundsmasterAlternator Belt AdjustmentsBelt Adjustments Cooling & Governor Fan BeltsGovernor Adjustment Ford VSG-411 Engine GroundsmasterCheck Engine Oil Service and RepairsOutside Temperature Single Viscosity OilsChange Engine Oil and Filter Check Coolant Cooling System Service Maintaining Cooling System CapacityWashing Method General Air Cleaner ServiceService Air Cleaner Compressed Air MethodFuel System Service Fuel TankFuel Lines and Connections Replacing Spark Plugs Check Governor Oil LevelServicing Spark Arrestor Muffler Peugeot TUD5 Engine Peugeot TUD5 EnginePeugeot TUD5 Engine Groundsmaster 3000-D Compression Test Kit TOR3003A Air Filter Element Cleaner TOR277220Special Tools Valve Spring Compression Tool TOR4024TDigital Belt Tension Tool TOR4075 Peugeot TUD5 Diesel Engine Service Tool Kit TOR4080Injection Nozzle Tester TOR463610 Order separatelyValve Guide Seal Remover TOR4081 Injector Socket TOR4082Torque Angle Gauge TOR4083 Camshaft Pinion Setting Tool TOR4084 Rear Main Seal Installer TOR4086Timing Pin Set TOR4085 Front Seal Installer TOR4087 Camshaft Seal Installer TOR4088Engine Belts Fan BeltNot Overfill Change Engine Oil and Filter Check Cooling System El. Coolant level should be up to or above tabs In deRear Screen Oil Cooler Radiator General Air Cleaner Maintenance Servicing the Air CleanerDraining Fuel Filter / Water Separator Area. Always fill fuel tank outside and wipeUp any spilled diesel fuel before starting Changing Fuel FilterPriming Fuel System Frame, Fuel Tank and Battery Muffler and Bumper Hood Center Shroud and Air Cleaner RopsFan Bracket and Degasser Radiator and Cooler 4 21 Rev. a Peugeot TUD5 EngineEngine Peugeot TUD5 Overhaul, Checking Tuning Peugeot TUD5 Engine Groundsmaster 3000-D Hydraulic System and Transaxle Hydraulic SystemHydraulic System 5 2 Rev. a General Information Pushing or Towing Traction UnitHydraulic Fitting Installation Hydraulic HosesRing Face Seal SAE Straight Thread O-Ring Port Non-adjustable SAE Straight Thread O-Ring Port AdjustableHydraulic Schematic Lift OFF Hold LOWER/FLOAT5 7 Rev. a Hydraulic System Hydraulic System TransaxleHydraulic Components Hydraulic System Groundsmaster 3000/3000-DHydraulic Pressure Test Kit TOR47009 Hydraulic Test Fitting Kit TOR4079Measuring Container TOR4077 Hydraulic System Groundsmaster 3000/3000-D Testing Charge Pressure Test Charge Pressure Priority Valve TestForward Traction Test Reverse Traction TestImplement Relief Pressure Test Counterbalance Pressure Test and Adjustment 5 15 Rev. a Hydraulic SystemSteering Valve Test Steering Circuit TestCylinder Test Hydraulic System 5 16 Rev. aUse a tester with pressure and flow capabilities This page is blank Hydraulic System Traction Pedal Linkage Adjustment Service Brake AdjustmentCheck Tire Pressure Wheel and TiresLubrication 5 21 Rev. a Hydraulic SystemCheck Hydraulic Fluid BP HYD TFChange Hydraulic Oil and Filter Traction Control Linkage Brake Linkage Driveshafts Lift Arms Steering Control ÁÁÁÁÁÁÀÀÀ#1ÄÄÉÉÉÉÉÅÅÅ After Repair or Replacement of Components Removing Hydraulic System ComponentsManifold Block Cartridge Installation Cartridge ValvesHydraulic System 5 32 Rev. a Lift Cylinder Steering Cylinder Auxiliary Hydraulic Pump Model 30726 Hydraulic Kit 5 35 Rev. a Hydraulic SystemTransaxle Service Electrical System Electrical Schematics, Wiring Diagrams, and Harness Drawings Electrical System Groundsmaster 3000/3000-DMultimeter Skin-Over GreaseTroubleshooting Groundsmaster Starting ProblemsProblem Possible Causes General Run and Transport Problems Groundsmaster Cutting Unit Operating Problems Groundsmaster6 5 Rev. a Electrical System Troubleshooting Groundsmaster 3000-D General Run and Transport Problems GM 3000-D Cutting Unit Operating Problems GM 3000-D6 7 Rev. a Electrical System Electrical System Quick Checks Battery Test Open Circuit TestVoltage Measured Battery Charge Level Glow Plug System Test GM 3000-DComponent Identification and Testing Ignition SwitchDiode Circuit Boards Neutral Switch Seat Switch6 11 Rev. a Electrical System Hydraulic Valve Solenoids Hour MeterElectrical System 6 12 Rev. a Cruise Control Coil Optional PTO Clutch Coil6 13 Rev. a Electrical System Fuel Sender Fuel GaugeElectrical System 6 14 Rev. a Relay Testing Fuse TestingRelays and Fuses Ampere Thermal Breaker GM 3000-D Electrical System 6 16 Rev. aFuel Stop Solenoid GM 3000-D Place TestingLive testing 6 17 Rev. a Electrical SystemInjection Advance Solenoid GM 3000-D Electrical System 6 18 Rev. aTest Equipment Testing for DC Current Output FigAlternator GM 3000-D 6 19 Rev. a Electrical SystemTemperature Sender GM 3000-D Electrical System 6 20 Rev. aTesting with the Engine Off Temperature Gauge GM 3000-DOil Pressure Switch GM 3000-D Testing with the Engine OnTemperature Sending Unit GM 3000-D Electrical System 6 22 Rev. aTransport Solenoid GM 3000-D Glow Plugs GM 3000-D6 23 Rev. a Electrical System H2O in Fuel Sensor GM 3000-D Disconnect connector from the sensor. Unscrew Coolant Level Sensor GM 3000-DIndicator Lights and Circuits GM 3000-D Glow Plug Indicator Light Ford Engine VSG-411 Electrical Component Locations GM3000 Electrical System Handle the hot oil with extreme care to prevent Temperature Gauge GMThermistor GM Personal injury or fireOil Pressure Switch GM High Temperature Switch Anti-Dieseling Valve Solenoid GM Indicator Lights and Circuits GM Verify Interlock System Operation Battery Maintenance Important Before cleaning the battery, tape or Battery ServiceInspection, Maintenance, and Testing Caps are on tightlyMinimum Battery Electrolyte Charging Battery Charge Specific Open CircuitBattery Gravity VoltageElectrical System Groundsmaster 3000/3000-D 2WD Rear Axle 7 1 Rev. aRear Wheel Toe-In 2WD Rear Axle Groundsmaster 3000/3000-DWheel and Tire Service 7 3 Rev. aWheel Bearing Service Rear Axle 2WD Rear Axle Groundsmaster 3000/3000-D 4WD Rear Axle 8 1 Rev. a4WD Rear Axle Groundsmaster 3000/3000-D 8 3 Rev. a Check Rear Axle Lubricant Change Rear Axle Lubricant4WD Axle Spindle flange Differential shim kit 4WD Rear Axle Groundsmaster 3000/3000-D Cutting Units Inch Cutting UnitsSpecifications Transport Latch Adjustment Height of Cut Adjustment Inch Cutting Units Groundsmaster 3000/3000-DSkid Adjustment Anti-Scalp Roller AdjustmentBolt Deck Pitch Adjustment Check Gear Box Lubricant Replace Gear Box LubricantLubricate Bearings, Bushings and Gear Box Disconnect Cutting Unit From Traction Unit Connect Cutting Unit to Traction Unit Install Lift Arm Ball Joints Drive Belt Replacement9 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 Blade Spindle Service Removing Spindle Housing AssemblyDisassembly Installing Spindle, Bearings Seals Into Spindle Housing 9 17 Rev. a Inch Cutting UnitsCorrecting Cutting Unit Mismatch Gearbox Shaft End Play Adjustment Drive Shaft Inch Cutting Units Groundsmaster 3000/3000-D Contour 82I Cutting Unit 10 1 Rev. C Contour 82 Cutting UnitSpecifications Front Castor Wheels Rear Castor Wheels Contour 82 Cutting Unit Groundsmaster 3000/3000-DRear 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 Chamber Pivot Service Cutting Unit ContourContour 82 Cutting Unit 10 16 Rev. a Front Part Of Blade Inch 6 mmLift Arm Ball Joint Installation Hydraulic Motor and Blade 10 19 Rev. C Contour 82 Cutting UnitContour 82 Cutting Unit 10 20 Rev. C Bearing cavity of the housing. If grease does not AssemblyImportant When greasing spindles, grease Passes into the center of the shaft and out to fillHydraulic Assembly Contour 82 Cutting Unit 10 22 Rev. C72I 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 Electrical Schematic OptionalStart Circuits Run Circuits Temp GaugeWiring Diagram Rear Section Wiring Diagram Front Section Gauge Hour Ignition Switch Hold SW PTO Switch OverrideHarness 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