Service and Repairs, 8 3 Rev. a | Toro 3000D manual

Service and Repairs

Wheel and Tire Service

Check Tire Pressure

The tires are over–inflated for shipping. Therefore, re lease some of the air to reduce the pressure. Correct air pressure in the front and rear tires is 15 psi (1 Bar).

IMPORTANT: Maintain even pressure in all tires to as sure a good quality–of–cut and proper machine perfor mance. DO NOT UNDER INFLATE.

Check Wheel Nut Torque

WARNING	1

Torque wheel nuts to 70–80 ft–lb (10–11 Kgm) after 1-4 hours of operation and again after 10 hours of operation and every 200 hours thereafter. Failure to maintain proper torque could result in failure or loss of wheel and may result in personal injury.

Figure 2

1. Rear wheel and tire

Lubrication

The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If machine is operated under normal condi tions, lubricate all bearings and bushings after every 50 hours of operation or immediately after every washing.

Steering cylinder ball joints, Rear axle tie rod (2), Rear axle pivot (1) and Double Cardan joints (2 ea. side).

Figure 3

4WD Rear Axle

Groundsmaster 3000/3000–D

Page 8 – 3 Rev. A

4WD Rear Axle

Image 155

Toro 3000D manual Service and Repairs, 8 3 Rev. a

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 Before Operating Safety InstructionsChapter While Operating Safety Groundsmaster 3000/3000-D Maintenance On Control Panel Safety and Instruction Decals GroundsmasterSafety 1 4 Rev. a Groundsmaster 3000/3000-D 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 Each Castor Arm On Deck Channels, Under Covers 1 7 Rev. a SafetyOn Rear of Deck On Front of Deck On Rear Of Deck On Each Castor Arm 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 Records Service RequiredB Service Required Groundsmasterr 3000-D Product Records and Maintenance 2 14 Rev. B GroundsmasterR3000-D Maintenance Schedule GroundsmasterR3000-D Daily Maintenance Check List 2 16 Rev. a Service every 100 hoursC, and D Service Required Service Groundsmaster Ford VSG-411 Engine Ford VSG-411 Engine Ford VSG-411 Engine 3 2 Rev. a Groundsmaster General Information Specifications Cooling & Governor Fan Belts AdjustmentsBelt Adjustments Alternator Belt Ford VSG-411 Engine Groundsmaster Governor Adjustment Single Viscosity Oils Service and RepairsOutside Temperature Check Engine Oil Change Engine Oil and Filter Check Coolant Maintaining Cooling System Capacity Cooling System Service Compressed Air Method General Air Cleaner ServiceService Air Cleaner Washing Method Fuel Lines and Connections Fuel System ServiceFuel Tank Check Governor Oil Level Replacing Spark Plugs Servicing Spark Arrestor Muffler Peugeot TUD5 Engine Peugeot TUD5 Engine Peugeot TUD5 Engine Groundsmaster 3000-D Valve Spring Compression Tool TOR4024T Air Filter Element Cleaner TOR277220Special Tools Compression Test Kit TOR3003A Order separately Peugeot TUD5 Diesel Engine Service Tool Kit TOR4080Injection Nozzle Tester TOR463610 Digital Belt Tension Tool TOR4075 Torque Angle Gauge TOR4083 Valve Guide Seal Remover TOR4081Injector Socket TOR4082 Timing Pin Set TOR4085 Camshaft Pinion Setting Tool TOR4084Rear Main Seal Installer TOR4086 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 Changing Fuel Filter Area. Always fill fuel tank outside and wipeUp any spilled diesel fuel before starting Draining Fuel Filter / Water Separator 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 Ring Face Seal Hydraulic Fitting InstallationHydraulic Hoses 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 Measuring Container TOR4077 Hydraulic Pressure Test Kit TOR47009Hydraulic Test Fitting Kit TOR4079 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 Hydraulic System 5 16 Rev. a Steering Circuit TestCylinder Test Steering Valve Test Use a tester with pressure and flow capabilities This page is blank Hydraulic System Service Brake Adjustment Traction Pedal Linkage Adjustment 5 21 Rev. a Hydraulic System Wheel and TiresLubrication Check Tire Pressure 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 Hydraulic System 5 32 Rev. a Cartridge InstallationCartridge Valves 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 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 Glow Plug System Test GM 3000-D Battery Test Open Circuit TestVoltage Measured Battery Charge Level Electrical System Quick Checks Ignition Switch Component Identification and Testing 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 Electrical System 6 16 Rev. a Ampere Thermal Breaker GM 3000-D 6 17 Rev. a Electrical System Place TestingLive testing Fuel Stop Solenoid GM 3000-D Electrical System 6 18 Rev. a Injection Advance Solenoid GM 3000-D 6 19 Rev. a Electrical System Testing for DC Current Output FigAlternator GM 3000-D Test Equipment Electrical System 6 20 Rev. a Temperature Sender GM 3000-D Testing with the Engine On Temperature Gauge GM 3000-DOil Pressure Switch GM 3000-D Testing with the Engine Off Electrical System 6 22 Rev. a Temperature Sending Unit GM 3000-D 6 23 Rev. a Electrical System Transport Solenoid GM 3000-DGlow Plugs GM 3000-D 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 Personal injury or fire Temperature Gauge GMThermistor GM Handle the hot oil with extreme care to prevent Oil Pressure Switch GM High Temperature Switch Anti-Dieseling Valve Solenoid GM Indicator Lights and Circuits GM Verify Interlock System Operation Battery Maintenance Caps are on tightly Battery ServiceInspection, Maintenance, and Testing Important Before cleaning the battery, tape or Minimum Battery Electrolyte Gravity Voltage Battery Charge Specific Open CircuitBattery Charging 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 Bolt Skid AdjustmentAnti-Scalp Roller Adjustment 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 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 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 Passes into the center of the shaft and out to fill AssemblyImportant When greasing spindles, grease Bearing cavity of the housing. If grease does not 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