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3000, 3000D
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Equivalents and Conversions
Product Records and Maintenance
Page 2 – 2
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)