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Toro 3000D manual Troubleshooting Groundsmaster 3000-D

Models: 3000 3000D

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Troubleshooting (Groundsmaster 3000–D)

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 frame 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 stop solenoid is faulty.
	Preheating unit or components inputing into it are
	faulty.
	Engine or fuel system is malfunctioning (see Chapter 4
	– Peugeot Diesel Engine).

Electrical System

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Groundsmaster 3000/3000–D

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Toro 3000D manual Troubleshooting Groundsmaster 3000-D

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 Chapter Safety InstructionsBefore Operating Safety Groundsmaster 3000/3000-D While OperatingMaintenance Safety 1 4 Rev. a Groundsmaster 3000/3000-D Safety and Instruction Decals GroundsmasterOn 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. a1 7 Rev. a Safety On Rear of Deck On Front of Deck On Rear Of DeckOn Each Castor Arm 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 bB Service Required Service RequiredRecords Groundsmasterr 3000-D GroundsmasterR3000-D Maintenance Schedule Product Records and Maintenance 2 14 Rev. BGroundsmasterR3000-D Daily Maintenance Check List Service every 100 hours C, and D Service RequiredService 2 16 Rev. aFord VSG-411 Engine Groundsmaster Ford VSG-411 EngineGeneral Information Specifications Ford VSG-411 Engine 3 2 Rev. a GroundsmasterAdjustments Belt AdjustmentsAlternator Belt Cooling & Governor Fan BeltsGovernor Adjustment Ford VSG-411 Engine GroundsmasterService and Repairs Outside TemperatureCheck Engine Oil Single Viscosity OilsChange Engine Oil and Filter Check Coolant Cooling System Service Maintaining Cooling System CapacityGeneral Air Cleaner Service Service Air CleanerWashing Method Compressed Air MethodFuel Tank Fuel System ServiceFuel Lines and Connections Replacing Spark Plugs Check Governor Oil LevelServicing Spark Arrestor Muffler Peugeot TUD5 Engine Peugeot TUD5 EnginePeugeot TUD5 Engine Groundsmaster 3000-D Air Filter Element Cleaner TOR277220 Special ToolsCompression Test Kit TOR3003A Valve Spring Compression Tool TOR4024TPeugeot TUD5 Diesel Engine Service Tool Kit TOR4080 Injection Nozzle Tester TOR463610Digital Belt Tension Tool TOR4075 Order separatelyInjector Socket TOR4082 Valve Guide Seal Remover TOR4081Torque Angle Gauge TOR4083 Rear Main Seal Installer TOR4086 Camshaft Pinion Setting Tool TOR4084Timing 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 CleanerArea. Always fill fuel tank outside and wipe Up any spilled diesel fuel before startingDraining Fuel Filter / Water Separator 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 Hoses Hydraulic Fitting InstallationRing 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 Test Fitting Kit TOR4079 Hydraulic Pressure Test Kit TOR47009Measuring 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 Circuit Test Cylinder TestSteering Valve 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 AdjustmentWheel and Tires LubricationCheck Tire Pressure 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 Valves Cartridge InstallationHydraulic 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 GreaseStarting 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 Battery Test Open Circuit Test Voltage Measured Battery Charge LevelElectrical System Quick Checks Glow Plug System Test GM 3000-DComponent Identification and Testing Ignition SwitchDiode 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 Ampere Thermal Breaker GM 3000-D Electrical System 6 16 Rev. aPlace Testing Live testingFuel Stop Solenoid GM 3000-D 6 17 Rev. a Electrical SystemInjection Advance Solenoid GM 3000-D Electrical System 6 18 Rev. aTesting for DC Current Output Fig Alternator GM 3000-DTest Equipment 6 19 Rev. a Electrical SystemTemperature Sender GM 3000-D Electrical System 6 20 Rev. aTemperature Gauge GM 3000-D Oil Pressure Switch GM 3000-DTesting with the Engine Off Testing with the Engine OnTemperature Sending Unit GM 3000-D Electrical System 6 22 Rev. aGlow Plugs GM 3000-D Transport Solenoid 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 Temperature Gauge GM Thermistor GMHandle the hot oil with extreme care to prevent 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 Battery Service Inspection, Maintenance, and TestingImportant Before cleaning the battery, tape or Caps are on tightlyMinimum Battery Electrolyte Battery Charge Specific Open Circuit BatteryCharging 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-DAnti-Scalp Roller Adjustment Skid 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 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 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 Assembly Important When greasing spindles, greaseBearing cavity of the housing. If grease does not 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