Troubleshooting Groundsmaster, Starting Problems | Toro 3000D

Troubleshooting (Groundsmaster 3000)

CAUTION

Remove all jewelry, especially rings and watches, before doing any electrical trouble- shooting or testing. Disconnect the battery cables unless the test requires battery voltage.

For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Wiring Sche matics section of this chapter).

If the machine has any interlock switches by–passed, they must be reconnected for proper troubleshooting and safety.

Starting Problems

Problem	Possible Causes


Starter solenoid clicks, but starter will not crank	Battery charge is low.
(if solenoid clicks, the problem is not with the Ignition	Battery cables are loose or corroded.
module or its inputs).	Battery cables are loose or corroded.
	Battery ground to engine is loose or corroded.
	Wiring at starter is faulty.
	Starter solenoid is faulty.
	Starter mounting bolts are loose or not supplying a
	sufficient ground for solenoid.
	Starter is faulty causing incomplete circuit for solenoid.


Nothing happens when a start attempt is made.	Wiring to start circuits (see Wiring Schematics) is
	loose, corroded, or damaged.
	Battery is dead.
	20 ampere fuse to start relay or 10 ampere fuse to
	ignition switch is blown.
	Neutral switch is faulty or traction pedal is depressed.
	Ignition switch is faulty.
	Start relay is faulty.
	Starter is faulty.


Engine cranks, but does not fire.	Wiring to start circuits (see Wiring Schematics) is
	loose, corroded, or damaged.
	Ignition switch is faulty.
	A high temperature condition exists, high temperature
	switch is shorted, or the high temperature relay is
	faulty.
	Fuel solenoid is faulty.
	Ignition module or components imputing into it are
	faulty (see Chapter 3 – Ford Gasoline Engine).
	Engine or fuel system is malfunctioning (see Chapter 3
	– Ford Gasoline Engine).

Electrical System

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Groundsmaster 3000/3000–D

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Toro 3000D manual Troubleshooting Groundsmaster, Starting Problems, Problem Possible Causes

Contents

Preface Toro Company 1997, 1998, 2003 Groundsmaster 3000/3000-D Table Of Contents Groundsmaster 3000/3000-D Contour 82I Cutting Unit Electrical Diagrams 84I Cutting Units 72I Cutting Units Groundsmaster 3000/3000-D Before Operating Safety InstructionsChapter Safety Groundsmaster 3000/3000-D While Operating Maintenance On Control Panel Safety and Instruction Decals GroundsmasterSafety 1 4 Rev. a Groundsmaster 3000/3000-D Safety and Instruction Decals Groundsmaster 3000-D Groundsmaster 3000/3000-D 1 5 Rev. a Safety Safety and Instruction Decals 84I Cutting Units Safety 1 6 Rev. a On 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 Covers Safety and Instruction Decals Contour 82I Cutting Unit On Top of Rear Castor Chambers 2 Groundsmaster 3000/3000-D Safety On Front Deck Hanger On Gearbox Base On Front of Deck Deck On Each Corner On Right Rear Top of Deck Under Cover On Front of Deck On Rear Of Deck Safety Groundsmaster 3000/3000-D Product Records and Maintenance Product Records Product Records and Maintenance Groundsmaster 3000/3000-D Equivalents and Conversions Torque Specifications Product Records and Maintenance 2 4 Rev. a Lubrication Traction Unit Cutting Units Rear Discharge 84I Cutting Unit Contour 82I Cutting UnitPage Equipment Operation and Service History Report GroundsmasterR3000 Maintenance Schedule Annual Recommendations GroundsmasterR3000 Daily Maintenance Check List Maintenance Daily Maintenance Check For Week Check Item b Records Service RequiredB Service Required Groundsmasterr 3000-D GroundsmasterR3000-D Maintenance Schedule Product Records and Maintenance 2 14 Rev. B GroundsmasterR3000-D Daily Maintenance Check List Service Service every 100 hoursC, and D Service Required 2 16 Rev. a Ford VSG-411 Engine Groundsmaster Ford VSG-411 Engine General Information Specifications Ford VSG-411 Engine 3 2 Rev. a Groundsmaster Alternator Belt AdjustmentsBelt Adjustments Cooling & Governor Fan Belts Governor Adjustment Ford VSG-411 Engine Groundsmaster Check Engine Oil Service and RepairsOutside Temperature Single Viscosity Oils Change Engine Oil and Filter Check Coolant Cooling System Service Maintaining Cooling System Capacity Washing Method General Air Cleaner ServiceService Air Cleaner Compressed Air Method Fuel Lines and Connections Fuel System ServiceFuel Tank Replacing Spark Plugs Check Governor Oil Level Servicing Spark Arrestor Muffler Peugeot TUD5 Engine Peugeot TUD5 Engine Peugeot TUD5 Engine Groundsmaster 3000-D Compression Test Kit TOR3003A Air Filter Element Cleaner TOR277220Special Tools Valve Spring Compression Tool TOR4024T Digital Belt Tension Tool TOR4075 Peugeot TUD5 Diesel Engine Service Tool Kit TOR4080Injection Nozzle Tester TOR463610 Order separately Torque Angle Gauge TOR4083 Valve Guide Seal Remover TOR4081Injector Socket TOR4082 Timing Pin Set TOR4085 Camshaft Pinion Setting Tool TOR4084Rear Main Seal Installer TOR4086 Front Seal Installer TOR4087 Camshaft Seal Installer TOR4088 Engine Belts Fan Belt Not Overfill Change Engine Oil and Filter Check Cooling System El. Coolant level should be up to or above tabs In de Rear Screen Oil Cooler Radiator General Air Cleaner Maintenance Servicing the Air Cleaner Draining Fuel Filter / Water Separator Area. Always fill fuel tank outside and wipeUp any spilled diesel fuel before starting Changing Fuel Filter Priming Fuel System Frame, Fuel Tank and Battery Muffler and Bumper Hood Center Shroud and Air Cleaner Rops Fan Bracket and Degasser Radiator and Cooler 4 21 Rev. a Peugeot TUD5 Engine Engine Peugeot TUD5 Overhaul, Checking Tuning Peugeot TUD5 Engine Groundsmaster 3000-D Hydraulic System and Transaxle Hydraulic System Hydraulic System 5 2 Rev. a General Information Pushing or Towing Traction Unit Ring Face Seal Hydraulic Fitting InstallationHydraulic Hoses SAE Straight Thread O-Ring Port Non-adjustable SAE Straight Thread O-Ring Port Adjustable Hydraulic Schematic Lift OFF Hold LOWER/FLOAT 5 7 Rev. a Hydraulic System Hydraulic System Transaxle Hydraulic Components Hydraulic System Groundsmaster 3000/3000-D Measuring Container TOR4077 Hydraulic Pressure Test Kit TOR47009Hydraulic Test Fitting Kit TOR4079 Hydraulic System Groundsmaster 3000/3000-D Testing Charge Pressure Test Charge Pressure Priority Valve Test Forward Traction Test Reverse Traction Test Implement Relief Pressure Test Counterbalance Pressure Test and Adjustment 5 15 Rev. a Hydraulic System Steering Valve Test Steering Circuit TestCylinder Test Hydraulic System 5 16 Rev. a Use a tester with pressure and flow capabilities This page is blank Hydraulic System Traction Pedal Linkage Adjustment Service Brake Adjustment Check Tire Pressure Wheel and TiresLubrication 5 21 Rev. a Hydraulic System Check Hydraulic Fluid BP HYD TF Change 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 Components Manifold Block Hydraulic System 5 32 Rev. a Cartridge InstallationCartridge Valves Lift Cylinder Steering Cylinder Auxiliary Hydraulic Pump Model 30726 Hydraulic Kit 5 35 Rev. a Hydraulic System Transaxle Service Electrical System Electrical Schematics, Wiring Diagrams, and Harness Drawings Electrical System Groundsmaster 3000/3000-D Multimeter Skin-Over Grease Problem Possible Causes Troubleshooting GroundsmasterStarting Problems 6 5 Rev. a Electrical System General Run and Transport Problems GroundsmasterCutting Unit Operating Problems Groundsmaster Troubleshooting Groundsmaster 3000-D 6 7 Rev. a Electrical System General Run and Transport Problems GM 3000-DCutting Unit Operating Problems GM 3000-D Electrical System Quick Checks Battery Test Open Circuit TestVoltage Measured Battery Charge Level Glow Plug System Test GM 3000-D Component Identification and Testing Ignition Switch Diode Circuit Boards 6 11 Rev. a Electrical System Neutral SwitchSeat Switch Electrical System 6 12 Rev. a Hydraulic Valve SolenoidsHour Meter 6 13 Rev. a Electrical System Cruise Control Coil OptionalPTO Clutch Coil Electrical System 6 14 Rev. a Fuel SenderFuel Gauge Relays and Fuses Relay TestingFuse Testing Ampere Thermal Breaker GM 3000-D Electrical System 6 16 Rev. a Fuel Stop Solenoid GM 3000-D Place TestingLive testing 6 17 Rev. a Electrical System Injection Advance Solenoid GM 3000-D Electrical System 6 18 Rev. a Test Equipment Testing for DC Current Output FigAlternator GM 3000-D 6 19 Rev. a Electrical System Temperature Sender GM 3000-D Electrical System 6 20 Rev. a Testing with the Engine Off Temperature Gauge GM 3000-DOil Pressure Switch GM 3000-D Testing with the Engine On Temperature Sending Unit GM 3000-D Electrical System 6 22 Rev. a 6 23 Rev. a Electrical System Transport Solenoid GM 3000-DGlow Plugs GM 3000-D H2O in Fuel Sensor GM 3000-D Disconnect connector from the sensor. Unscrew Coolant Level Sensor GM 3000-D Indicator 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 fire Oil 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 tightly Minimum Battery Electrolyte Charging Battery Charge Specific Open CircuitBattery Gravity Voltage Electrical System Groundsmaster 3000/3000-D 2WD Rear Axle 7 1 Rev. a Rear Wheel Toe-In 2WD Rear Axle Groundsmaster 3000/3000-D Wheel and Tire Service 7 3 Rev. a Wheel Bearing Service Rear Axle 2WD Rear Axle Groundsmaster 3000/3000-D 4WD Rear Axle 8 1 Rev. a 4WD Rear Axle Groundsmaster 3000/3000-D 8 3 Rev. a Check Rear Axle Lubricant Change Rear Axle Lubricant 4WD Axle Spindle flange Differential shim kit 4WD Rear Axle Groundsmaster 3000/3000-D Cutting Units Inch Cutting Units Specifications Transport Latch Adjustment Height of Cut Adjustment Inch Cutting Units Groundsmaster 3000/3000-D Bolt Skid AdjustmentAnti-Scalp Roller Adjustment Deck Pitch Adjustment Check Gear Box Lubricant Replace Gear Box Lubricant Lubricate Bearings, Bushings and Gear Box Disconnect Cutting Unit From Traction Unit Connect Cutting Unit to Traction Unit 9 11 Rev. a Inch Cutting Units Install Lift Arm Ball JointsDrive Belt Replacement Front Castor Fork Bushing Service Castor Wheel and Bearing Service Cutter Blade Removal and Installation Inspecting and Sharpening Blade Disassembly Blade Spindle ServiceRemoving Spindle Housing Assembly Installing Spindle, Bearings Seals Into Spindle Housing 9 17 Rev. a Inch Cutting Units Correcting 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 Unit Specifications Front Castor Wheels Rear Castor Wheels Contour 82 Cutting Unit Groundsmaster 3000/3000-D 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 Chamber Pivot Service Cutting Unit Contour Contour 82 Cutting Unit 10 16 Rev. a Front Part Of Blade Inch 6 mm Lift Arm Ball Joint Installation Hydraulic Motor and Blade 10 19 Rev. C Contour 82 Cutting Unit Contour 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 fill Hydraulic Assembly Contour 82 Cutting Unit 10 22 Rev. C 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 Electrical Schematic Optional Start Circuits Run Circuits Temp Gauge Wiring Diagram Rear Section Wiring Diagram Front Section Gauge Hour Ignition Switch Hold SW PTO Switch Override 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