Toro 3000, 3000D

Safety Page 1 – 12 Groundsmaster 3000/3000–D

Contents

Main Service Manual GroundsmasterR 3000/3000D E The Toro Company 1997, 1998, 2003, 2004 Preface Page Page Page Table of Contents (continued) Page Chapter 1 Safety Table of Contents Safety Instructions CAUTION Before Operating While Operating Maintenance Page Page Page Page Page Page Safety and Instruction Decals Page Page Chapter 2 Product Records and Maintenance Table of Contents Product Records Page Page Page Lubrication Traction Unit Cutting Units Page Page Page GroundsmasterR3000 Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service A Level Service B Level Service C Level Service GroundsmasterR3000 Daily Maintenance Check List Unit Designation: ____________ TORO ID #: ________________ Maintenance Check Item b Daily Maintenance Check For Week Of _________________ Notation for areas of concern: Inspection performed by__________________ Date: ________________ A B C D E Other Groundsmaster 3000 Supervisor Maintenance Work Order Other Annual Service & Specials Page GroundsmasterR3000D Maintenance Schedule Minimum Recommended Maintenance Intervals A Level Service B Level Service C Level Service D Level Service E Level Service GroundsmasterR3000D Daily Maintenance Check List Date: ________________ Other Annual Service & Specials A B C D E Other Groundsmaster 3000D Supervisor Maintenance Work Order Ford VSG411 Engine Table of Contents General Information Specifications Belt Adjustments Governor Adjustment WARNING Check Engine Oil Single Viscosity Oils MultiViscosity Oils Change Engine Oil and Filter Check Coolant CAUTION Cooling System Service General Air Cleaner Service CAUTION Service Air Cleaner Fuel System Service DANGER Replacing Spark Plugs Check Governor Oil Level Page Chapter 4 Peugeot TUD5 Engine Table of Contents Figure 1 Figure 2 Peugeot TUD5 Engine Page 4 2 Groundsmaster 3000D Compression Test Kit (TOR3003A) Valve Spring Compression Tool (TOR4024T) Air Filter Element Cleaner (TOR277220) Injection Nozzle Tester (TOR463610) Digital Belt Tension Tool (TOR4075) Peugeot TUD5 Diesel Engine Service Tool Kit (TOR4080) Page Page Page Engine Belts Check Engine Oil Change Engine Oil and Filter Check Cooling System Cooling System Service General Air Cleaner Maintenance Servicing the Air Cleaner Fuel System Service DANGER Priming Fuel System Page 4 16 Peugeot TUD5 Engine Frame, Fuel Tank and Battery Figure 29 Groundsmaster 3000D Page 4 17 Peugeot TUD5 Engine Muffler and Bumper Figure 30 Hood Figure 31 Peugeot TUD5 Engine Page 4 18 Groundsmaster 3000D Groundsmaster 3000D Page 4 19 Peugeot TUD5 Engine Center Shroud and Air Cleaner Figure 32 Fan Bracket and Degasser Figure 33 Peugeot TUD5 Engine Page 4 20 Groundsmaster 3000D Groundsmaster 3000D Page 4 21 Peugeot TUD5 Engine Radiator and Cooler Page 4 22 Peugeot TUD5 Engine Engine NOTE: See the Toro Parts Catalog for more information. Figure 35 Peugeot TUD5 Overhaul, Checking Tuning Page Chapter 5 Hydraulic System and Transaxle Table of Contents Hydraulic System Page 5 2 Rev. A Groundsmaster 3000/3000D General Information Pushing or Towing Traction Unit Hydraulic Hoses Hydraulic Fitting Installation WARNING Page LIFT/LOWER OFF SOLENOIDS HOLD OFF Hydraulic Schematic LOWER/FLOAT Groundsmaster 3000/3000D Page 5 7 Hydraulic System Hydraulic Schematic A IHTM15 TRANSAXLE and Transaxle Rev. A Hydraulic Components TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS) Hydraulic Pressure Test Kit TOR47009 Hydraulic Test Fitting Kit TOR4079 Measuring Container TOR4077 Hydraulic Tester With Pressure and Flow Capabilities TOR214678 Testing Charge Pressure Test Forward Traction Test Reverse Traction Test Implement Relief Pressure Test Counterbalance Pressure Test and Adjustment Steering Circuit Test Auxiliary Hydraulic Pump Efficiency T est Page Page Traction Pedal Linkage Adjustment Service Brake Adjustment Wheel and Tires Lubrication Check Hydraulic Fluid Change Hydraulic Oil and Filter Traction Control Linkage Figure 34 Hydraulic System Page 5 24 Groundsmaster 3000/3000D Groundsmaster 3000/3000D Page 5 25 Hydraulic System Brake Linkage Figure 35 Page 5 26 Driveshafts Figure 36 Lift Arms Figure 37 Groundsmaster 3000/3000D Page 5 27 Hydraulic System and Transaxle Page 5 28 Steering Control Figure 38 Page Removing Hydraulic System Components Manifold Block Figure 40 Groundsmaster 3000/3000D Page 5 31 Hydraulic System and Transaxle Cartridge Valves Lift Cylinder Steering Cylinder Figure 43 Hydraulic System Page 5 34 Groundsmaster 3000/3000D Groundsmaster 3000/3000D Page 5 35 Hydraulic System Auxiliary Hydraulic Pump Figure 44 Transaxle Service Chapter 6 Electrical System Table of Contents Page TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PROD- UCTS) Multimeter SkinOver Grease T roubleshooting CAUTION Starting Problems General Run and T ransport Problems Cutting Unit Operating Problems T roubleshooting CAUTION Starting Problems General Run and T ransport Problems Cutting Unit Operating Problems Electrical System Quick Checks Battery Test (Open Circuit Test) Glow Plug System T est Component Identification and Testing CAUTION Ignition Switch T OOR Diode Circuit Boards Neutral Switch Seat Switch Hydraulic Valve Solenoids Hour Meter Cruise Control Coil (Optional) PTO (Clutch) Coil Fuel Sender Fuel Gauge Relays and Fuses 50 Ampere Thermal Breaker Fuel Stop Solenoid Injection Advance Solenoid Alternator T emperature Sender CAUTION T emperature Gauge Oil Pressure Switch T emperature Sending Unit CAUTION T ransport Solenoid Glow Plugs H2O in Fuel Sensor (GM 3000D) Coolant Level Sensor DANGER Indicator Lights and Circuits Page Ford Engine (VSG41 1) Electrical Component Locations Page T emperature Gauge Thermistor CAUTION Oil Pressure Switch High Temperature Switch CAUTION AntiDieseling V alve Solenoid Indicator Lights and Circuits Verify Interlock System Operation Battery Maintenance Battery Service Page Page Page Page Rear Wheel ToeIn A. Wheel and Tire Service Lubrication Wheel Bearing Service Groundsmaster 3000/3000D Page 7 5 2WD Rear Axle Rear Axle 2WD Rear Axle Figure 5 Page 4WD Rear Axle Rear Wheel ToeIn A. Wheel and Tire Service Lubrication Check Rear Axle Lubricant Change Rear Axle Lubricant Groundsmaster 3000/3000D Page 8 5 4WD Rear Axle 4WD Axle 4WD Rear Axle4WD Rear Axle Figure 6 Page 8 6 4WD Rear Axle Figure 7 4WD Rear Axle Groundsmaster 3000/3000D Page 8 7 4WD Rear Axle Figure 8 4WD Rear Axle Page Chapter 9 84" Cutting Units Table of Contents Page Transport Latch Adjustment Page Skid Adjustment AntiScalp Roller Adjustment Page Check Gear Box Lubricant Replace Gear Box Lubricant Lubricate Bearings, Bushings and Gear Box Disconnect Cutting Unit From Traction Unit Page Install Lift Arm Ball Joints Drive Belt Replacement Page Page Cutter Blade Removal and Installation Inspecting and Sharpening Blade Page Page Page Groundsmaster 3000/3000D Page 9 19 84 inch Cutting Units Gearbox Figure 31 84 inch Cutting Units Page Drive Shaft Page Chapter 10 Contour 82 Cutting Unit Table of Contents Page Page Page Page Page Grease Bearings and Bushings Disconnect Cutting Unit from Traction Unit Page Page Page Cutting Blade Removal and Installation Inspecting and Sharpening Blade Page Chamber Pivot Service Page Page Lift Arm Ball Joint Installation Hydraulic Motor and Blade Page Page Hydraulic Assembly Figure 34 Contour 82 Cutting Unit Page 10 22 Rev. C Groundsmaster 3000/3000D NOTE: See Chapter 5 Hydraulic System for hydraulic test information. Chapter 11 72I Cutting Units Table of Contents Page Transport Latch Adjustment Page Skid Adjustment Gage Wheel Adjustment Antiscalp Roller Adjustment Page Check Gear Box Lubricant Replace Gear Box Lubricant Grease Bearings, Bushings and Gear Box Disconnect Cutting Unit From Traction Unit Connect Cutting Unit to Traction Unit Install Lift Arm Ball Joints Drive Belt Replacement Page Page Cutter Blade Removal Inspecting and Sharpening Blade Page Page Page Page 11 20 72 inch Cutting Units Gearbox Figure 32 Page Drive Shaft Chapter 12 Electrical Diagrams Table of Contents Page OPTIONAL Electrical Schematic CRUISE CONTROL Page 12 3 Groundsmaster 3000 All relays and solenoids are shown as deenergized. All ground wires are black. Start Circuits Groundsmaster 3000 Page 12 4 Run Circuits Groundsmaster 3000 Page 12 5 Groundsmaster 3000 Wiring Diagram (Rear Section) Page 12 6 P7 P8 WIRE IDENTIFICATION LIGHT CLUSTER ENGINE SHUTDOWN Wiring Diagram (Front Section) Page 12 7 Page 12 8 Harness Drawing (Front Section) Groundsmaster 3000 Page 12 9 OPTIONAL Electrical Schematic CRUISE CONTROL Page 12 10 Groundsmaster 3000D All relays and solenoids are shown as deenergized. All ground wires are black. Crank Circuits Groundsmaster 3000D Page 12 11 Run Circuits Groundsmaster 3000D Page 12 12 WIRE IDENTIFICATION Groundsmaster 3000D Wiring Diagram (Rear Section) Page 12 13 WIRE IDENTIFICATION WIRE IDENTIFICATION (Cont.) Groundsmaster 3000D Wiring Diagram (Front Section) Page 12 14 Page 12 15 Harness Drawing (Front Section)