Service and Repairs, After 50 hours of operation | Toro 3000D

Service and Repairs

CAUTION

To prevent accidental starting of the engine, while performing maintenance, shut engine off and remove key from ignition switch.

Check Gear Box Lubricant

The gear box is designed to operate with SAE 80–90 wt. gear lube. Although the gear box is shipped with lubri

cant from the factory, check the level before operating1 the cutting unit. Change lubricant in gear box initially

after 50 hours of operation.

1.Position the machine and cutting unit on a level sur face.

2.Remove check plug from side of gear box and make sure lubricant is up to bottom of hole. If level of lubricant is low, remove fill plug on top of gear case and add enough lubricant to bring it up to bottom of hole in side.

2

Figure 12

1.Filler Plug

2.Check Plug

Replace Gear Box Lubricant

The gear box lubricant must be changed initially, after the first 400 hours of operation, and thereafter every 1600 hours of operation.

1.Position the machine and cutting unit on a level sur face.

2.Loosen fixed idler pulley locking nut.

3.Loosen spring tensioning nut as required and re move belt.

4.Remove (4) locknuts securing gearbox mount to deck.

5.Remove belt from pulley.

6.Remove check plug from side of gear box and tip gear box assembly allowing lubricant to drain from gear box.

7.Reinstall belt to pulley.

8.Reinstall gear box assembly to deck

9.Remove fill plug on top of gear case and add SAE 80–90 wt. gear lube until level is up to bottom of hole in side.

10.Reinstall check plug to side of gear box and fill plug to top of gear case.

11.Re–tension belt. Refer to Replacing Drive Belts.

2

1

3

Figure 13

1.Gear Box Mount

2.Filler Plug

3.Check Plug

72 inch Cutting Units

Page 11 – 8

Groundsmaster 3000/3000–D

Image 212

Toro 3000D manual Service and Repairs, After 50 hours of operation

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 1 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 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 every 100 hours C, and D Service RequiredService 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 Adjustments Belt AdjustmentsAlternator Belt Cooling & Governor Fan Belts Governor Adjustment Ford VSG-411 Engine Groundsmaster Service and Repairs Outside TemperatureCheck Engine Oil Single Viscosity Oils Change Engine Oil and Filter Check Coolant Cooling System Service Maintaining Cooling System Capacity General Air Cleaner Service Service Air CleanerWashing Method 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 Air Filter Element Cleaner TOR277220 Special ToolsCompression Test Kit TOR3003A Valve Spring Compression Tool TOR4024T Peugeot TUD5 Diesel Engine Service Tool Kit TOR4080 Injection Nozzle Tester TOR463610Digital Belt Tension Tool TOR4075 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 Area. Always fill fuel tank outside and wipe Up any spilled diesel fuel before startingDraining Fuel Filter / Water Separator 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 Circuit Test Cylinder TestSteering Valve 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 Wheel and Tires LubricationCheck Tire Pressure 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 Battery Test Open Circuit Test Voltage Measured Battery Charge LevelElectrical System Quick Checks 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 Place Testing Live testingFuel Stop Solenoid GM 3000-D 6 17 Rev. a Electrical System Injection Advance Solenoid GM 3000-D Electrical System 6 18 Rev. a Testing for DC Current Output Fig Alternator GM 3000-DTest Equipment 6 19 Rev. a Electrical System Temperature Sender GM 3000-D Electrical System 6 20 Rev. a Temperature Gauge GM 3000-D Oil Pressure Switch GM 3000-DTesting with the Engine Off 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 Temperature Gauge GM Thermistor GMHandle the hot oil with extreme care to prevent 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 Battery Service Inspection, Maintenance, and TestingImportant Before cleaning the battery, tape or Caps are on tightly Minimum Battery Electrolyte Battery Charge Specific Open Circuit BatteryCharging 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 Assembly Important When greasing spindles, greaseBearing cavity of the housing. If grease does not 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