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Part No. 96890SL Rev. C
Service Manua
Groundsmaster
3000/3000DPreface
The purpose of this publication is to provide the servicetechnician with information for troubleshooting, testing,
and repair of major systems and components on theGroundsmaster 3000 and 3000D.
REFER TO THE TRACTION UNIT AND CUTTINGUNIT OPERATORS MANUALS FOR OPERATING,MAINTENANCE AND ADJUSTMENT INSTRUC-TIONS. Space is provided in Chapter 2 of this book toinsert the Operators Manuals and Parts Catalogs foryour machine. Replacement Operators Manuals are
available by sending complete Model and Serial Number to:
The Toro Company8111 Lyndale Avenue SouthBloomington, MN 55420
The Toro Company reserves the right to change productspecifications or this publication without notice.
ING, or CAUTION, PERSONAL SAFETYThis safety symbol means DANGER, WARN-
INSTRUCTION. When you see this symbol,carefully read the instructions that follow.Failure to obey the instructions may result inpersonal injury.
NOTE: A NOTE will give general information about thcorrect operation, maintenance, service, testing or re
pair of the machine.
IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on thmachine.
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Table Of Contents
Chapter 1 Safety
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 4
Chapter 2 Product Records and Maintenance
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1Equivalents and Conversions . . . . . . . . . . . . . . . . 2 2Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 3
Maintenance Quick Reference Aid . . . . . . . . . . . . 2 4
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5Equipment Operationand Service History Reports . . . . . . . . . . . . . . . . 2 9
Chapter 3 Ford Gasoline Engine
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2General Information . . . . . . . . . . . . . . . . . . . . . . . . . 3 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 4FORD VSG411/413 ENGINE SERVICE MANUAL
Chapter 4 Peugeot Diesel Engine
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3
Chapter 5 Hydraulic System and Transaxle
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General Information . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . 5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 2SAUERSUNDSTRAND IHT SERVICE MANUAL
Chapter 6 Electrical System
Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Troubleshooting (GM3000) . . . . . . . . . . . . . . . . . . 6 Troubleshooting (GM3000D) . . . . . . . . . . . . . . . . 6
Electrical System Quick Checks . . . . . . . . . . . . . . 6 Component Identification and Testing . . . . . . . . . . 6
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 6 3
Chapter 7 Rear Axle (2WD)
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 7
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Table of Contents (continued)
Chapter 9 84Cutting Units
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Chapter 10 Contour 82Cutting Unit
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . 10 7
Chapter 11 72Cutting Units
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 12 Electrical Diagrams
Groundsmaster 3000 . . . . . . . . . . . . . . . . . . . . . . 12 Groundsmaster 3000D . . . . . . . . . . . . . . . . . . 12 1
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Chapter 1
SafetyTable of Contents
SAFETYINSTRUCTIONS ...................... 1BeforeOperating ............................ 1WhileOperating ............................. 2
Safety Instructions
The GROUNDSMASTERR 3000 and 3000-D wastestedandcertifiedbyTOROforcompliancewiththeB71.41990 specificationsof theAmericanNationalStandardsInstitute.Althoughhazardcontrolandaccidentpreventionpartiallyaredependentuponthedesignandconfigurationofthemachine,thesefactorsarealsodependentupontheawareness,concern,andpropertrainingofthepersonnelinvolvedintheoperation,transport,maintenance,andstorageofthemachine.Improperuseormaintenanceofthemachinecanresultininjuryordeath.Toreducethepotentialforinjuryordeath,complywiththefollowingsafetyinstructions.
MaintenanceandService .....................SAFETYANDINSTRUCTIONDECALS..........
CAUTION
TO REDUCE THE POTENTIAL FOR INJURY
OR DEATH, COMPLY WITH THE FOLLOWINGSAFETY INSTRUCTIONS.
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7. Checkinterlockswitchesdailyforproperoperation.Donotrelyentirelyonsafetyswitches-shutoffengine
beforegettingoffseat.Ifaswitchfails,replaceitbefore
operatingthemachine.Theinterlocksystemisforyour
protection,so donotbypass it. Replaceall interlock
switcheseverytwoyears.Interlockswitchesshouldbe
adjustedso:
A. Enginecannotbestartedunlesstractionpedal
isreleased(neutralposition).
B.Enginestops ifoperator getsoffseatwhen
tractionpedalisdepressed.
C.PTOdisengagesifoperatorgetsoffseatwhen
PTOleverisENGAGED(onposition).
8. Fillfueltankwithdieselfuelbeforestartingtheen
gine.Avoidspillinganyfuel.Sincedieselfuelisflammable,handleitcarefully.
A.Useanapprovedfuelcontainer.
B.Donotfillfueltankwhenengineishotor
running.
C.Donotsmokewhilehandlingfuel.
D.Fillfueltankoutdoorsanduptoaboutone
inch(25mm)fromthetopofthetank,not
thefillerneck.E.Wipeupanyspilledfuel.
9. Sitontheseatwhenstartingtheengineandoperatingthemachine.
10. Always use seat beltand ROPS together. Make
sureseatislatched.
11. Beforestartingtheengine:
A.Engageparkingbrake.B.Makesuretractionpedalisinneutral.
C.Afterengineisstarted,releaseparkingbrake
andkeepfootofftractionpedal.Machinemustnot
move.Ifmovementisevident,theneutralreturnmechanismisadjustedincorrectly.Shutengine
offandadjustuntilmachinedoesnotmovewhen
tractionpedalisreleased.
12. Donotruntheengineinaconfinedareawithoutadequateventilation.Exhaustfumesarehazardousand
couldpossiblybedeadly.
13. Maximumseatingcapacityisoneperson.Therefore,nevercarrypassengers.
14. Thistractionunitisintendedtobeusedwithanim
plement. Refer to implement operators manual for
soundandvibrationinformationandrearweightrequire
ments.15. Check carefully for overhead clearances before
drivingunderanyobjects.
While Operating
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24. Donottouchengine,muffler,orradiatorwhileengineisrunningorsoonafterithasstopped.Theseareas
couldbehotenoughtocauseaburn.
25. Lowerthecuttingunitorotherattachedimplement
tothegroundandremovekeyfromswitchwhenever
machineisleftunattended.
26. Beforegettingofftheseat:
A. Movetractionpedaltoneutralpositionandremovefootfrompedal.
B.SettheparkingbrakeanddisengagethePTO
C.Shuttheengineoffandremovekeyfromigni
tionswitch.Waitforallmovementtostopbefogettingofftheseat.
Maintenance
27. Removekeyfromignitionswitchtopreventaccidentalstartingoftheenginewhenservicing,adjusting,
orstoringthemachine.
28. Ifmajorrepairsareeverneededorassistanceisde
sired,contactanAuthorizedTORODistributor.
29. Toreducepotentialfirehazard,keeptheenginefree
ofexcessivegrease,grass,leaves,andaccumulations
ofdirt.Neverwashawarmengineorelectricalconnec
tionswithwater.
30. Ifthecuttingunitdischargeareaeverplugs,disengagePTOandshutengineoffbeforeremovingtheob
struction.
31. Makesuremachineisinsafeoperatingconditionby
keepingnuts,bolts,andscrewstight.Checkattachmentmountinghardwareandallcuttingunitblademounting
boltsfrequentlytoassuretheyaretorquedtoproper
specifications.
32 Periodically inspect the roll bar and roll bar mount
Hydraulicfluidescapingunderpressurecanhavesufficientforcetopenetrateskinanddoseriousdamage.
fluidisejectedintotheskin,itmustbesurgicallyre
movedwithinafewhoursbyadoctorfamiliarwithth
formofinjuryorgangrenemayresult.
35. Beforedisconnectingorperforminganyworkonthhydraulicsystem,allpressureinsystemmustbere
lievedbystoppingengineandloweringimplementtoth
ground.
36. Iftheenginemustberunningtoperformmainte
nanceoranadjustment,keepclearofPTOshaft,cuttingunitblades,andothermovingparts.
37. Donotoverspeedtheenginebychangingthegovernorsettings.Toensuresafetyandaccuracy,haveaAuthorizedTORODistributorcheckmaximumengin
speedwithatachometer.
38. Enginemustbeshutoffbeforecheckingoilorad
dingoiltothecrankcase.
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Safety and Instruction Decals (Groundsmaster 3000)
ible,installanewdecal.Partnumbersarelistedbeloworinyourpartscatalog.
(Part No. 671710)
Thefollowingsafetyandinstructiondecalsaremountedonthetractionunit.Ifanydecalbecomesdamagedorilleg
On Side of Tool Box
Next to Right Side of Seat In Compartment Behind Control panel
(Part No. 935935) (Part No. 935933)
(Part No. 773100)
On Hood
ON FAN SHROUD
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Safety and Instruction Decals (Groundsmaster 3000D)
Thefollowingsafetyandinstructiondecalsaremountedonthetractionunit.Ifanydecalbecomesdamagedorilleg
ible,installanewdecal.Partnumbersarelistedbeloworinyourpartscatalog.
(Part No. 671710)
In Compartment Behind Control panel
On Side of Tool Box
Next to Right Side of Seat (Part No. 935932)
(Part No. 773100)
(Part No. 935934)
ON FAN SHROUD
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Safety and Instruction Decals (84ICutting Units)
Thefollowingsafetyandinstructiondecalsaremountedonthecuttingunit.Ifanydecalbecomesdamagedorillegible,
installanewdecal.Partnumbersarelistedbeloworinyourpartscatalog.
On Each Corner OfOn Front of Cutting Unit
Cutting Unit On Right & Left Covers (Part No. 688340)(Part No. 930299)(Part No. 438480)
On Gearbox BaseOn Front of Deck(Part No. 881270)
(Part No. 936697) On Deck Channels, Under Covers(Part No. 856410)
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On Front of Deck(Part No. 661340)
On Front Of Deck(Part No. 937824)
Replaces Decal Part No.
661340 for CE
On Rear of Deck(Part No. 666380)
On Rear Of Deck(Part No. 937828)
Replaces Decal Part No.
666380 for CE
On Each Castor Arm(Part No. 934894)
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Safety and Instruction Decals (Guardian 72IRecycler Cutting Unit)
Thefollowingsafetyandinstructiondecalsaremountedonthecuttingunit.Ifanydecalbecomesdamagedorillegible
installanewdecal.Partnumbersarelistedbeloworinyourpartscatalog.
On Front of Cutting UnitOn Each Corner Of On Left Caster Arm (Part No. 688340)Cutting Unit (Part No. 930299)(Part No. 438480)
On Gearbox Base
(Part No. 936697) On Deck Channels, Under Covers(Part No. 856410)
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Safety and Instruction Decals (Rear Discharge 72ICutting Unit)
Thefollowingsafetyandinstructiondecalsaremountedonthecuttingunit.Ifanydecalbecomesdamagedorillegible,
installanewdecal.Partnumbersarelistedbeloworinyourpartscatalog.
On Gearbox Base(Part No. 936697)
On Front of Deck(Part No. 688340)
On Front of Deck(Part No. 937818)
Replaces Decal Part No.
688340 for CE On Front Deck Hanger(Part No. 934690)
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On Rear Of Deck(Part No. 937828)
Replaces Decal Part No.
666380 for CE
On Rear Of Deck(Part No. 934977)
On Front of Deck(Part No. 666380)
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Chapter 2
Product Records and MaintenanceTable of Contents
PRODUCTRECORDS......................... 1EQUIVALENTSANDCONVERSIONS ........... 2
DecimalandMillimeterEquivalents ............ 2U.S.toMetricConversions ................... 2
TORQUESPECIFICATIONS ................... 3CapscrewMarkingsandTorqueValuesU.S. .. 3
CapscrewMarkingsandTorqueValuesMetric . 3QUICKREFERENCEMAINTENANCEAID....... 4
Product Records
RecordinformationaboutyourGroundsmaster3000or
3000DontheOPERATIONANDSERVICEHISTORYREPORTform.Usethisinformationwhenreferringtoyourmachine.
LUBRICATION ................................TractionUnit ................................CuttingUnits ................................
OPERATIONANDSERVICEHISTORYREPORTS
InsertOperatorsManualsandPartsCatalogsforyou
Groundsmaster3000or3000Dattheendofthissection.
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Equivalents and Conversions
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Torque Specifications
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800 800
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Lubrication
Traction Unit
CAUTION
Before servicing or making adjustments to the
machine, stop engine and remove key from the
switch.
Themachinehasgreasefittingsthatmustbelubricatedregularly with No. 2 General Purpose Lithium Base
Grease. Ifmachine isoperatedundernormal condi-tions,lubricateallbearingsandbushingsafterevery50hoursofoperationorimmediatelyaftereverywashing.
Thegreasefittinglocationsandquantitiesare:
2 Wheel Drive Models onlySteeringcylinderballjoint,Rearaxletierod(2),Rearaxlepivot(1)RearSpindleShafts(2)(Fig.1).
4 Wheel Drive Models onlySteering cylinder balljoints,Rearaxletierod(2),Rearaxlepivot(1),DoubleCardanjoints(2ea.side)(Fig.2)andRearDrIveShaft(3)(Fig.3)
All Models Intermediate Drive Shaft (3) (Fig 4); Pedal
Figure3
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Cutting Units
Ifmachineisoperatedundernormalconditions,lubri
catecastorbearingsandbushingswithNo.2generalpurpose lithium base grease or molybdenum base
grease,afterevery8hoursofoperationordaily,whichevercomesfirst.Lubricatefittingsimmediatelyaftereverywashing,regardlessoftheintervallisted.
Guardian 84IRecyler Cutting Unit
CAUTION
Before servicing or making adjustments to the
machine, stop engine and remove key from the
switch.
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Rear Discharge 84ICutting Unit
Figure8
Contour 82ICutting Unit
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Guardian 72IRecycler Cutting Unit
Figure10
Rear Discharge 72ICutting Unit
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EQUIPMENTOPERATIONANDSERVICEHISTORYREPORTfor
GROUNDSMASTERR3000
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GroundsmasterR3000 Maintenance Schedule
Minimum Recommended Maintenance Intervals
LubricateAllGreaseFittings
InspectAirFilter
CheckBatteryLevel/CableConnections
CheckCuttingUnitGearboxOilLevel
CleanUnderCuttingUnitBeltCovers
CheckCuttingUnitDriveBeltAdjustment
} ChangeEngineOilandFilter
InspectCoolingSystemHoses
{
{
CheckGovernorOilLevel
ServiceAirFilter
ChangeFuelFilter
Maintenance Procedure
Every50hrs
Every100hrs
Every200hrs
Every800hrs
Maintenance Interval & Service
Every400hrs
A LevelService
B LevelService
C LevelService
CheckFan,GovernorandAlternatorBeltTension
TorqueWheelLugNuts
ServiceSparkArresterMuffler
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GroundsmasterR3000 Daily Maintenance Check List
UnitDesignation:__________
TOROID#:_____________
DailyMaintenance:(duplicatethispageforroutineuse)CheckpropersectionofOperatorsManualforfluidspecifications
MaintenanceCheck Itemb
Daily Maintenance Check For Week Of _________________
MON TUES WED THURS FRI SAT SUN
n SafetyInterlockOperation
n BrakeOperation
n EngineOil&FuelLevel
n CoolingSystemFluidLevel
n Radiator&ScreenforDebris
n UnusualEngineNoises
n UnusualOperatingNoises
n HydraulicSystemOilLevel
n HydraulicHosesforDamage
n
FluidLeaksn TirePressure
n InstrumentOperation
LubricateAllGreaseFittings1
TouchupDamagedPaint
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_____________
_______
_____________
_______
__________________________
________________________________
_____________
_______
_____________
_______
_____________
_______
_____________
_______
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_____________
_______
_____________
_______
Date:______
__________
every100hou
rs)
CService(every20
0hours)
(every800ho
urs)
eOilandFilter
gSystemHoses
aulicOil
aulicFilter
DServiceReq
uired
CheckGovernorOilLev
el
nceWorkO
rder
nofalldrivebelts
equired
TorqueWheelLugNuts
ServiceSparkArrestorM
uffler
AandBServiceRequired
O
therAnnualService&Specials
anFuelTank
eBearings
WheelToeIn
ReplaceMovingHoses
ReplaceSafetySwitches
CoolingSystemFlush/ReplaceFluid
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EQUIPMENTOPERATIONANDSERVICEHISTORYREPORTfor
GROUNDSMASTERR3000D
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GroundsmasterR3000D Daily Maintenance Check List
UnitDesignation:__________
TOROID#:_____________
DailyMaintenance:(duplicatethispageforroutineuse)CheckpropersectionofOperatorsManualforfluidspecifications
MaintenanceCheck Itemb
Daily Maintenance Check For Week Of _________________
MON TUES WED THURS FRI SAT SUN
n SafetyInterlockOperation
n BrakeOperation
n EngineOil&FuelLevel
n
CoolingSystemFluidLevel
DrainWater/FuelSeparator
n Radiator&ScreenforDebris
n UnusualEngineNoises1
n UnusualOperatingNoises
n HydraulicSystemOilLevel
n HydraulicHosesforDamage
n FluidLeaks
n TirePressure
n InstrumentOperation
LubricateAllGreaseFittings2
_
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____________________
____________________
___________________
_____________
___________________
_____________
_______________________________
____________________
____________________
____________________
____________________
_____________
_______
_______________________________
_______________________________
_______________________________
Date:______
__________
DServiceRequired
every100hou
rs)
CService(every20
0hours)
(every600ho
urs)
eOilandFilter
gSystemHose
s
iceRequired
ReplaceMovingHoses
ReplaceSafetySwitches
CoolingSystemFlush/ReplaceFluid
noteonMaint.S
ched.)
enoteonMaint.Sched.)
nanceWorkOrder
dAlternatorBeltTension
TorqueWheelLugNuts
AandBServiceRequired
gBelt
anFuelTank
arAxleBearing
s
WheelToeIn
O
therAnnualService&Specials
TimingBelt(seenoteo
nMaint.Sched.)
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General Information
TheengineusedintheGroundsmaster3000ismanufacuturedbyFordMotorCompany.OrderserviceandrepairpartsforFordenginesfromyoulocalFordPowerProductsDealer.SeetheFordVSG411/413EngineServiceManualforengineidentificationinformation.
Specifications
Item Specification
Make/Designation FordModelVSG411
FiringOrder 1243
IgnitionTiming DistributorlessIgnitionSystem(DIS)TimingcontrolledbyUniversalElectronicSparkControl(UESC)
SparkPlug MotorcraftAGSF22CorAGRF22orequivalent
SparkPlugGap 0.040in.(1.0mm)
CrankcaseOilCapacity 3.5U.S.qt.(3.25liter)includingfilter
OilServiceClassification APISG
OilViscosity Ambient temperature (single viscosity oil)10to+60_F SAE10+10_to+90_F SAE20Above+32_F SAE30Above+50_F SAE40
Ambient temperature (multiviscosity oil)Below+60_F SAE5W30
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Adjustments
Belt Adjustments
Checkconditionandtensionofbeltsafterevery100hoursofoperation. Replacebeltsasrequired.
Alternator Belt
Thealternatorbeltshouldbetensionedsowhenitispressedfirmlywiththumb,midwaybetweenpulleys,it
deflects.25inch(6.4mm).
1. Toadjustbelttension,loosenboltsecuringbraceto
engine,boltsecuringalternatortobraceandalternator
mountingbolt.
2. Rotatealternatorawayfromengine.
3. Holdalternatorinpositionafterproperbelttension
setting is achieved and tighten alternator and braceboltstosecureadjustment. Figure1
2
1
Cooling & Governor Fan Belts1. Cooling Fan Belt2. Governor Fan Belt
Thecoolingandgovernorfanbeltsbeltshouldbeten
sionedsowhentheyarepressedfirmlywiththumb,midwaybetweenpulleys,theydeflect.38inch(9.7mm).
1. Toadjustbelttension,loosenupperandlowernuts
securingidlerarmtofrontenginemount.
2. Pullout on idler armuntildesired belt tension is
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Governor Adjustment
1. Withengineshutoff,movethrottlecontroltoFASTpositionandopenhood.Checkbetweenthethrottlearmandthestoponthecarburetorbasetomakesurethere
is1/32(0.8mm).Ifgapisnotcorrect,adjustthrottlerodbyturningballjointendsuntilgapis1/32(0.8mm).Ifgapiscorrect,proceedtostep2.
Engine must be running so final adjust-
ment of the governor can be performed.guard against possible personal
hands, feet, face and other parts of the
body away from fan or other moving
parts.
WARNING
To
injury, engage parking brake and keep
2. StartengineandmovethrottletoSLOWposition.Allowenginetowarmuptonormaloperatingtemperature.
3. Rotatethrottlearmcloseduntilitcontactsstop.
4. Checkidlespeedandadjustcarburetoridlespeedscrew if necessary to attain 1350 + 50 rpm
9. Bumpthethrottleleverwithyourhandsoenginespeedsupmomentarily.Ifgovernorisworkingproperly,enginespeedshouldreturntonormalwithinoneortwo
surgesofthegovernor.Morethantwosurgesofthegovernorusuallyindicatesthantheantisurgescrewmustbeturnedinslightlymorethanitis.Whenadjustmentiscorrect,lockjamnutagainstgovernorbody.
10. Checklowandhighidlespeedtobesurethereisnochangefromtheinitialsetting.Ifhighidlespeedhasincreased,antisurgehasbeenturnedintothegovernortoofaranditmustbebackedout.Thenrepeattheentireadjustmentprocedure.
Note:IfthethrottlecontrolontheinstrumentpanelwillnotstayintheFASTpositionduringoperation,removethepanelcoverandtightenthenutatbaseofthrottleleverassembly.
1
23
4
5
S i d R i
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Service and Repairs
Check Engine Oil
Crankcasecapacityis31/2U.S.qt.(3.3liter)withfilter.1. Parkmachineonalevelsurface.Rotatehoodlatchfullycounterclockwiseandopenhood.
2. Removedipstickandwipeitwithacleanrag.Insert
dipstickintotubeandmakesureitisfullyseated.Re
movedipstickandchecklevelofoil.Iflevelofoilislow,
addenoughoiltoraiseleveltonotchindipstick.DONOTOVERFILL.
3. Installdipstickintotube.4. Ifoillevelislow,cleanareaaroundoilfillcap,re
movecapandaddoiluntillevelreachesFULLmarkon
dipstick.DONOTOVERFILL.
1
5. Theengineusesanyhighqualitydetergentoilhav- Figure 4
ing the American Petroleum InstituteAPIservice 1. Hood Latch
classificationSG.Oilviscosityweight mustbe se
lectedaccordingtoambienttemperature.Temperature/
viscosityrecommendationsare:
Single Viscosity Oils
Outside Temperature
10_Fto+60_F SAE10W
+10_Fto+90_F SAE20W20
1
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Change Engine Oil and Filter
Changeoilandfilterinitiallyafterthefirst50hoursofop
eration,thereafterchangeoilandfilterevery100hours.
1. Removedrainplug(Fig.7)andletoilflowintodrain
pan.Whenoilstops,installdrainplug.
2. Removeoilfilter(Fig.8).Applyalightcoatofcleanoiltothenewfiltersealbeforescrewingiton.DONOT
OVERTIGHTEN.
3. Addoiltocrankcase.Capacityis3.5U.S.quarts
(3.3liters)withfilter.RefertoCheckEngineOil.1
Figure 71. Drain Plug
1
Figure 81. Oil Filter
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Check Coolant
Capacityofsystemis9U.S.qt.(8.5liters).
Cleandebrisoffscreen, oilcoolerandradiatordaily,
hourlyifconditionsareextremelydustyanddirty;refer
toCleaningRadiatorandScreen.
Thecoolingsystemisfilledwitha50/50solutionofwaterandpermanentethyleneglycolantifreeze.Checklevel
ofcoolantatbeginningofeachdaybeforestartingthe
engine.
1. Parkmachineonalevelsurface.Rotatehoodlatch
fullycounterclockwiseandopenhood.
2. Checkcoolantlevel.CoolantshouldbeuptoCOLD
lineonreservetank,whenengineiscold.
1
COLD
HOT
CAUTION
If engine has been running, pressurized
if radiator cap is removed. Allow engineto cool at least 15 minutes or until the
radiator cap is cool enough to touch
hot coolant can escape and cause burns
without burning hand.
Figure 91. Reserve Tank
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Cooling System Service
1. Removing Debris Remove debris from rear
screen,oilcoolerand radiatordaily, cleanmore fre
quentlyindirtyconditions.
IMPORTANT: Never spray water onto a hot engine asdamage to engine may occur.
A. Turnengineoff and cleanhoodscreen thor
oughly.
B.Releasehoodlatchandraisehood.Cleanengine
areathoroughlyofalldebris.
C. Cleanbothsidesofoilcoolerandradiatorarea
thoroughlywithcompressedair.Do not use water.
1
D. Closehoodandsecurelatch. Figure 101. Rear Screen
Note:Donotusewatertocleanengineorelectrical
components,asdamagemayoccur.
2. Maintaining Cooling System Capacity of the
systemis9quarts(8.5liters). Alwaysprotectcooling
systemwitha50/50solutionofwaterandpermanent
ethylene glycol antifreeze. DO NOT USE WATER
ONLYINCOOLINGSYSTEM.
A. Afterevery100operatinghours, inspectandtightenhoseconnections.Replaceanydeteriorated
hoses.
2
1
Figure 11B. Afterevery2years,drainandflushthecooling
1. Oil Coolersystem.Addantifreeze (refer toCheck Cooling 2. RadiatorSystem)
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Fuel System Service
Fuel Tank
Drainandcleanfueltankevery800hoursofoperationor
yearly,whichevercomesfirst.Also,drainandcleantank
iffuelsystembecomescontaminatedorifmachineistobestoredforanextendedperiod.Usecleanfueltoflush
outthetank.
Fuel Lines and Connections
Checklinesandconnectionsevery400hoursoryearly,
whichevercomesfirst.Inspectfordeterioration,dam
age,orlooseconnections.
DANGER
Because gasoline is flammable, caution mustbe used when storing or handling it. Do not fill
fuel tank while engine is running, hot, or when
filling the fuel tank to prevent the possibility of
an explosion. Always fill fuel tank outside andwipe up any spilled gasoline before starting
engine. Use a funnel or spout to prevent spil-
ling gasoline and fill tank to about 1 inch (25
machine is in an enclosed area. Vapors may
build up and be ignited by a spark or flame
source many feet away. DO NOT SMOKE while
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Replacing Spark Plugs
Changesparkplugsafterevery400operatinghoursto
assureproperengineperformanceandreduceexhaust
emissionlevel.
CorrectsparkplugtouseisaMotorcraftAGSF22CorAGRF22orequivalent.
Recommendedairgapis.040(1.016mm).
Note:Thesparkplugusuallylastsalongtime;however,theplugshouldberemovedandcheckedwheneverthe
enginemalfunctions.
1. Cleanareaaroundsparkplugssoforeignmatter
cannotfallintocylinderwhensparkplugisremoved.
2. Pullsparkplugwiresoffsparkplugsandremove
plugsfromcylinderhead.
3. Checkconditionofsideelectrode,centerelectrode
andcenterelectrodeinsulatortoassurethereisnodam
age.
IMPORTANT: A cracked, fouled, dirty or otherwismalfunctioning spark plug must be replaced. Do no
sand blast, scrape, or clean electrodes by using wire brush because grit may eventually releas
from the plug and fall into the cylinder. The result i
usually a damaged engine.
4. Setairgapbetweencenterandsideofelectrodesa
.040(1.016mm).Installcorrectlygappedsparkplu
andtightenplugto1115ftlb.Iftorquewrenchisno
used,tightenplugfirmly.
5. Installsparkplugwires.
Check Governor Oil Level
Thegovernorisshippedwithoilinit,butthelevelofoilmustbecheckedafterevery250hoursofoperation.
1. Positionmachineonlevelsurfaceandshutengineoff.
2. Disengagehoodlatchandopenthehood.
3. Cleanareaaroundcheckplugongovernor.
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Servicing Spark Arrestor Muffler
Every200hoursoperation,clearthemufflerofcarbon
buildup.
1. Removepipeplugfromcleanoutportatlowerside
ofmuffler.
CAUTION
Be careful while working around muffler as it
may be hot and could cause injury.
2. Startengine.Plugthenormalmufflerexitwithblock
ofwoodormetalplatesoexhaustflowwillbeforcedout
ofthecleanoutport.Continuetoblockexituntilcarbon
depositsceasecomingoutport.
CAUTION
Do not stand in line with the cleanout
port. Always wear safety glasses.
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Chapter 4
Peugeot TUD5 Engine
Table of Contents
SPECIFICATIONS 2............................ FuelSystemService ........................ 1SPECIALTOOLS 3............................. PrimingFuelSystem........................ 1ADJUSTMENTS 8.............................. Frame,FuelTankandBattery ................ 1
BeltAdjustments 8............................ MufflerandRearBumper .................... 1SERVICEANDREPAIRS 9...................... Hood ..................................... 1
CheckEngineOil 9............................ FanBracketandDegasser .................. 1ChangeEngineOilandFilter 10................. CenterShroudandAirCleaner............... 2CheckCoolingSystem .......................11 RadiatorandCooler ........................ 2CoolingSystemService 12..................... Engine .................................... 2GeneralAirCleanerService 13................. PeugeotTUD5Overhaul,Checking,Tuning.... 2ServicingAirCleaner 13.......................
Specifications
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Specifications
Item Specification
Make/Designation PeugeotTUD54cycle,inline,overheadcam,
liquidcooleddieselengineGovernorAdjustment Highidle2650+50RPM
LowIdle1500+100R{M
Oil SAE15W40CE
Oilcapacity 4.75U.S.qt.withfilter(4.5liters)
Coolant 50/50mixturewaterandPeugeotrecommendedantifreeze
(ToroPartNo.937213)
Coolantcapacity 11.5U.S.qt.(10.9liters)
Special Tools
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Special Tools
Compression Test Kit (TOR3003A)
01000PSIGaugeallowstestingofdieselenginestocheckgeneraloperatingconditionofengine.
Kitcontains:
CaseGaugewithhoseGlowplugholeadapters
Figure3
Valve Spring Compression Tool (TOR4024T)
Useforremovingvalvesprings.
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Injection Nozzle Tester (TOR463610)
Whenusedalongwiththeadapter,TOR437580,injec
tionnozzlesmaybeexaminedbyperformingthefollowingtests:
Injectionpressuretest.Chatteringtest.
Nozzleleakagetest.Spraytest.
Figure6
Digital Belt Tension Tool (TOR4075)
Toolisusedtoaccuratelyadjustthecamdrivebelttension.NOTE: This tool is not included in TOR4080 kit.
Order separately.
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C h f Pi i S i T l (TOR4084)
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Camshaft Pinion Setting Tool (TOR4084)
Toolisusedtoholdthecamshaftgearand/orinjector
pumpgearwhiletighteningthefasteners.
Figure12
Timing Pin Set (TOR4085)
Toolsetisusedtosetinjectionpumpenginetiming.
F t S l I t ll (TOR4087)
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Front Seal Installer (TOR4087)
Toolisusedtoinstallthecrankshaftfrontseal.
Figure15
Camshaft Seal Installer (TOR4088)
Toolisusedtoinstallthecamshaftseal.
Adjustments
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j
CAUTION
Before servicing or making adjustments to the
machine, stop engine and remove key from the
switch.
Engine Belts
Checkconditionandtensionofbeltsafterevery100hoursofoperation(Fig.17).Replacebeltsasrequired.
Alternator Belt
1. Propertensionwillallow1/8in.(3.2mm)deflection
onthebeltmidwaybetweenthepulleys,whenpressed
firmlywiththumb.
2. Ifdeflectionexceeds1/8in.(3.2mm),loosenalter
nator mountingbolts. Adjust belttensionandtighten
mountingbolts.Checkdeflectionofbeltagaintoassure
tensioniscorrect.
Fan Belt 2
1
1. Propertensionwillallow3/8in.(9.5mm)deflection Figure17onthebeltmidwaybetweenthepulleys,whenpressed
1. Fan Beltfirmlywiththumb. 2. Alternator belt
2 If deflection exceeds 3/8 in (9 5 mm) loosen pulley
Service and Repairs
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CAUTION
Before servicing or making adjustments to the
machine, stop engine and remove key from the
switch.
Check Engine Oil
Crankcasecapacityis4.75U.S.qt.(4.5liters)withfilter.
1. Parkmachineonalevelsurface.Rotatehoodlatch
fullycounterclockwiseandopenhood.
2. Removedipstickandwipeitwithacleanrag.Insert
dipstickintotubeandmakesureitisfullyseated.Re
movedipstickandchecklevelofoil.Iflevelofoilislow,
addenoughoiltoraiseleveltonotchindipstick.DONOTOVERFILL.
3. Ifoillevelislow,cleanareaaroundoilfillcap,re
movecapandaddSAE15W40CEoiluntillevelreach
esFULLmarkondipstick.DONOTOVERFILL.4. Installoilfillcap.
1
5. Closehoodandsecurelatch. Figure181. Hood Latch
Change Engine Oil and Filter
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Change Engine Oil and Filter
Changeoilandfilterinitiallyafterthefirst50hoursofop
eration,thereafterchangeoilandfilterevery100hours.
1. Removedrainplug(Fig.20)andletoilflowintodrain
pan.Whenoilstops,installdrainplugandnewplugseal,PartNo.747850.
2. Removeoilfilter(Fig.21).Applyalightcoatofclean
oiltothenewfiltersealbeforescrewingiton.DONOT
OVERTIGHTEN.
3. Add15W40CEoiltocrankcase.Capacityis4.75
quartswithfilter.
1
Figure201. Drain Plug
Check Cooling System
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Check Cooling System
Checkcoolingsystemiflowwaterlevellightilluminates.
1. Park machine ona level surface.Release hood
latchandopenhood.
2. Removedegassertankcapandcheckcoolantlev
el.Coolant level should be up to or above tabs In de-
gasser tank, when engine is cold.
If engine has been running, pressurized
if degasser cap is removed. Allow engine
to cool at least 15 minutes or until thedegasser cap is cool enough to touch
CAUTION
Figure22
1
Capacityofsystemis11.5qts.(10.9l).
hot coolant can escape and cause burns
without burning hand.
1. Degasser Tank
3. Ifcoolantislow,removedegassertankcapandadda50/50mixtureofwaterandPeugeotrecommended
antifreeze(ToroPartNo.937213).DO NOT USE WA-
TER ONLY OR ALCOHOL/METHANOL BASE COOL-
ANTS.
4 I ll d k
Cooling System Service
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Cooling System Service
1. Removing Debris Remove debris from rear
screen,oilcoolerand radiatordaily, cleanmore fre
quentlyindirtyconditions.
IMPORTANT: Never spray water onto a hot engine asdamage to engine may occur.
A. Turnengineoff and cleanhoodscreen thor
oughly.
B.Releasehoodlatchandraisehood.Cleanengine
areathoroughlyofalldebris.
C. Cleanbothsidesofoilcoolerandradiatorarea
thoroughlywithcompressedair.Do not use water.
D. Closehoodandsecurelatch.Note:Donotusewatertocleanengineorelectrical
components,asdamagemayoccur.
1
2. Maintaining Cooling System Capacity of the Figure23
systemis11.5quarts.Alwaysprotectcoolingsystem1. Rear Screen
with a 50/50 solution of water and Peugeot recom
mendedantifreeze(PartNo.937213).DONOTUSE
WATERONLYINCOOLINGSYSTEM.
A. Afterevery100operatinghours, inspectandtightenhoseconnections.Replaceanydeteriorated
hoses.
B. Afterevery2years,drainandflushthecooling
system. Addantifreeze(refertoCheckCooling
System)
2
1
General Air Cleaner Maintenance
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General Air Cleaner Maintenance
1. Inspectaircleanerafterevery50hoursofoperation.
Morefrequentindustyordirtyconditions.
2. Checkaircleanerbodyfor damagewhichcould
possibly cause an air leak. Replace a damaged aircleanerbody.
3. Servicetheaircleanerfilterevery400hours(more
frequentlyinextremedustyordirtyconditions).Donot
overserviceairfilter.
4. Besurecoverissealingaroundaircleanerbody.
CAUTION
cleaner assembly in place and latched proper-
ly or a damaged air cleaner Debris entering en-
gine can cause engine failure.
Never operate machine without complete air
Servicing the Air Cleaner
1. Releaselatchessecuringaircleanercovertoair
cleanerbody.Separatecoverfrombody.Cleaninsideof
aircleanercover.
2. Gentlyslidefilter(Fig.26)outofaircleanerbodyto
reducetheamountofdustdislodged.Avoidknockingfil
teragainstaircleanerbody.
3. Inspectfilteranddiscardifdamaged.Donotwashorreuseadamagedfilter.
Washing Method
A. Prepareasolutionoffiltercleanerandwater
andsoakfilterelementabout15minutes.Referto
di ti filt l t f l t i 2
1
Fuel System Service
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Fuel System Service
Drainandcleanfueltankevery800hoursofoperationor
iffuelsystembecomescontaminatedorifmachineistobestoredforanextendedperiod.Usecleanfueltoflush
outthetank.
DANGER
Because diesel fuel is highly flammable,
Do not smoke while filling the fuel tank. Donot fill fuel tank while engine is running,
hot, or when machine is in an enclosed
area. Always fill fuel tank outside and wipeup any spilled diesel fuel before starting
the engine. Store fuel in a clean, safety
approved container and keep cap in
place. Use diesel fuel for the engine only;
not for any other purpose.
Figure27
1. Fuel Filter2. Drain Screw3. Primer plunger
3
2
1
Fuel Tank
yearly,whichevercomesfirst.Also,drainandcleantank
use caution when storing or handling it.
Fuel Lines and Connections
Checklinesandconnectionsevery400hoursoryearly,
whichevercomesfirst.Inspectfordeterioration,dam
age,orlooseconnections.
Priming Fuel System
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g y
IMPORTANT: The fuel system may need to be
primed when a new engine is started for the first
time, if it runs out of fuel or if maintenance is
performed on the fuel system.
1. Unlatchandraisehood.
2. Inserta3/16inch (5mm)hoseoverbleedscrew
andrunotherendintoacontainertocatchfuel.
3. Loosenfuelfilter/waterseparatorbleedscrew(Fig.
28)afewturns.Pumpprimingplungeruntilasteadystreamoffuelcomesoutofholeinbleedscrew.When
fuelstopsfoaming,tightenthebleedscrewduringthe
downstrokeoftheprimingplunger.Wipeupanyspilled
1
2
fuel. Figure28
4. Pumpprimingplungeruntilresistanceisfelt.Tryto 1. Primer Plunger 2. Bleed Screw
startengine.Ifenginedoesnotstartrepeatstep3.
Frame, Fuel Tank and Battery
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, y
36
37
38
39
1
2
3
4
56
78
910
16
17
18
21
22
23 24 25 26
27
11 1213
1415
44
28
19
35
2019
41
42
43
26
Muffler and Bumper
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p
1 2
3
4 5
7
8
9
6
10
11
12
1
Hood
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2
4
3
67
8
9
12
1314
17
19
18
1
5
11
20
Center Shroud and Air Cleaner
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1
2
3 4 5
6
7
8
9
10
11
1213
20
1415
21
25
23
24
28
27
26
29
30
Fan Bracket and Degasser
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1 2 3
5
6
7 89
10
16
17
18
19
11
12
13
14
20
22
21
2 23
Radiator and Cooler
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33
1
23
4
5
7
8
9
10
18 19
20
5
2223242526
1112
13
4
34
35
36 37
38
39
13
40
4143
42 14
15
13
44
Fan clearanceminimum .18 inch (5 mm)
Pipe threadsealant
Pipe threadsealant
Engine
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1
2
3
4
5
6
7
8 9 11
17 18
19
20
21
22
2324
25
26
27
2829
30
12
49
1415
16
2
4
41
34
3134
33
24
42
43
10
44
42
34
3624
47
13
50
32
2928
Peugeot TUD5 Overhaul, Checking Tuning
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See the Peugeot Citroen Moteurs TUD5 Overhaul,
Checking,Tuningmanualfordetailedserviceinformation.SeetheToroPartsCatalogforpartsindentification.
RefertotheSpecial ToolsliststartingonPage43oftheToroGroundsmaster3000/3000DServiceManual.
ThetoolnumbersreferredtointhePeugeotmanualarePeugeotnumbers,whichTorodoesnotuse.
UsetheTOROlubrication,maintenanceandfluidrecommendationsiftheyaredifferentfromtheinformation
inthePeugeotmanual.
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Chapter 5
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p
Hydraulic System and Transaxle
Table of Contents
SPECIFICATIONS 2............................ SERVICEANDREPAIRS ..................... 2
GENERALINFORMATION 3..................... CheckTirePressure ........................ 2PushingorTowingTractionUnit 3............... CheckWheelNutTorque .................... 2HydraulicHoses 3............................. CheckHydraulicFluid....................... 2HydraulicFittingInstallation 3................... ChangeHydraulicOilandFilter .............. 2
HYDRAULICSCHEMATICS 6.................... TractionControlLinkage..................... 2HYDRAULICCOMPONENTS 8................... BrakeLinkage ............................. 2SPECIALTOOLS 9............................. Driveshafts ................................ 2
TESTING ....................................11 LiftArms .................................. 2ChargePressureTest 12....................... SteeringControl ............................ 2ForwardTractionTest 13....................... RemovingHydraulicSystemComponents ..... 3ReverseTractionTest 13....................... ManifoldBlock ............................. 3ImplementReliefPressureTest 14.............. CartridgeValves............................ 3CounterbalancePressureTest 15............... LiftCylinder................................ 3
SteeringCircuitTest 16........................ SteeringCylinder ........................... 3AuxiliaryHydraulicPumpEfficiencyTest 17....... AuxiliaryHydraulicPump .................... 3
ADJUSTMENTS 20............................. TransaxleService .......................... 3TractionPedalLinkage 20...................... SAUERSUNDSTRANDIHTSERVICEMANUALServiceBrakes 20.............................
Specifications
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Item Specification
Transaxle SauerSundstrandIHTM15ChargePressure: 80130PSI(5.59Bar)
ImplementReliefPressure: 1,0001,100PSI(6976Bar)
TractionForwardPressure:6,200PSI(428Bar)maximumTractionreversepressure:5,000PSI(345Bar)maximum
ManifoldBlock Torologiccartridge,elec./hyd.,solenoidactuatedRecommendedCounterbalancePressure:
84inchdecks: 220PSI(15Bar)72inchdecks: 220PSI(15Bar)
Contour82deck: 100150PSI(710Bar)Brush: 225PSI(16Bar)
Blower: 7080PSI(56Bar)
ImplementReliefPressure(Model30724Hyd.Kit):
1,0001,100PSI(6976Bar)SteeringControl EatonSeries2steeringcontrolunitwithpowerbeyond
HydraulicFluid Mobil424(seeCheck Hydraulic FluidinServiceandRepairs
sectionofthischapterforalternatives)
HydraulicFluidCapacity Approximately12U.S.qts.(11.4liters)
General Information
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Pushing or Towing Traction Unit
Inanemergency,thetractionunitcanbepushedor
towed.However,Torodoesnotrecommendthisasstandardprocedure.
IMPORTANT: Do no push or tow the traction unitfaster than 10 mph (16 km/hr). If traction unit must
be moved a considerable distance, transport it on a
truck or trailer.
1. Locatetowingleveronrightsideofaxleassembly.
2. Removecotterpinandclevispinsecuringlevertoplateonsideofaxle.
3. Pivotleverrearwarduntilholeisalignedwithrear Figure1holeinplate.Securelevertorearholewithcotterpinand 1. Towing Leverclevispinpreviouslyremoved.
1
4. After completion of towing operation, pivot lever
backtooriginalposition andresecure.
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SAE Straight Thread ORing Port Nonadjustable
1.Makesureboththreadsandsealingsurfacesarefreeof burrs nicks scratches or any foreign material
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ofburrs,nicks,scratches,oranyforeignmaterial.
2.AlwaysreplacetheOringsealwhenthistypeoffit-tingshowssignsofleakage.
3.LubricatetheOringwithalightcoatingofoil.
4.Installthefittingintotheportandtightenitdownfulllengthuntilfingertight.
5.Tightenthefittingtothecorrectflatsfromfingertight
(F.F.F.T.). Figure4
Size F.F.F.T.
4(1/4in.nominalhoseortubing) 1.00+.256(3/8in.) 1.50+.258(1/2in.) 1.50+.2510(5/8in.) 1.50+.2512(3/4in.) 1.50+.2516(1in.) 1.50+.25
SAE Straight Thread ORing Port Adjustable
1.Makesureboththreadsandsealingsurfacesarefreeofburrs,nicks,scratches,oranyforeignmaterial.
2.AlwaysreplacetheOringsealwhenthistypeoffit-tingshowssignsofleakage. Lock Nut
ORing
S2
Hydraulic Schematic
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LIFT/LOW
ER
CONTROL
LIFT
SOLENOIDS
S1
S2
ON
OFF
L
P
B
P
RT
STEERIN
GCYLINDER
S
CYL1
CYL2
2.5BORE
3.5STROKE
1ROD
N1
S1
LC1
75220P
SI
P
S
OIL
COOLER
OU
T
LIFT/
COUNTER
BALANCE
MANIFOLD
1.625BO
RE
7.00STR
OKE
.625ROD
HOLD
OFF
OFF
OFF
ON
ADJORIFICE
STD.187
C3
P3
P2
T3
T1
T2
G1
T
LIFTCYLINDERS
LOWER
/FLOAT
Hydraulic Schematic
CK PLER
TRVOI
(with Model 30726 Hyd. Kit and Contour 82 Cutting Unit
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RT
INGCYLINDER
S2
CYL1
CYL2
2.5BORE
3.5STROKE
1ROD
N1
S1
G1
1000PSI
OUT
BORE
TROKE
OD
LC1
75220PSI
P
T2
T1
5PSI
C3
SUNDSTRANDIHT
ID
LE
1650RPM
LOADED1560RPM
QUICK
COUPLER
CCW
INPUT
33CC
ADJORIFICE
STD.187
3625
PSI
1750
PSI
1750
PSI
1750
PSI
1750
PSI
600PSI
OIL
COOLER
18CC
18CC
18CC
18CC
QUIC
COU
QUICK
COUPLER
IH
RESE
LIFT/
COUNTERBALANCE
MANIFOLD
SOLENO
IDS
LIFT/LOWER
CONTROL
A
M1
M2
M3
M4
LIFT
HOLD
ON
OFF
OFF
OFF
OFF
ON
S1
S2
PB
LIFTCYLINDERS
AUXFILTER
BRAKINGVALVE
DECKMOTORS
EDMOTOROPTION
DETAIL
LOWER/FLOAT
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Special Tools
NOTE:OrderspecialtoolsfromtheTORO SPECIAL
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pTOOLS AND APPLICATIONS GUIDE (COMMERCIAL
PRODUCTS).Sometoolsmayalsobeavailablefromalocalsupplier.
Hydraulic Pressure Test Kit TOR47009
Useto takevariouspressurereadingsfor diagnostictests.Quickdisconnectfittingsprovidedattachdirectlytomatingfittingsonmachinetestportswithouttools.Ahigh pressurehose isprovided for remote readings.Containsoneeach:1000PSI(70Bar),5000PSI(350Bar) and10000PSI(700Bar)gauges.Usegaugesas
recommendedinTestingsectionofthischapter.
Figure7
Hydraulic Test Fitting Kit TOR4079
ThiskitincludesavarietyofOringFacesealfittingsto
enableyoutoconnecttestgaugesintothesystem.
Hydraulic Tester With Pressure and Flow Capabilities TOR214678
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Figure10
Testing
Themosteffectivemethodforisolatingproblemsinthe 1.Thoroughlycleanthemachinebeforedisconnectin
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hydraulicsystemisbyusinghydraulictestequipmentsuchaspressuregaugesandflowmetersinthecircuitsduring various operational checks. (See the SpecialToolssectioninthisChapter.)
CAUTION
dures could result in damage to gauge andpossible personal injury from leaking hot oil.
Failure to use gauges with recommended
pressure (psi) rating as listed in test proce-
Before Performing Hydraulic Tests
Allobviousareassuchasoilsupply,filter,bindinglinkage,loosefasteners,orimproperadjustmentsmustbecheckedbeforeassumingthatahydrauliccomponentisthesourceoftheproblembeingexperienced.
Before disconnecting or performing any work
WARNING
on the hydraulic system, all pressure in the
or disassembling any hydraulic components. Alwaykeepinmindtheneedforcleanlinesswhenworkingonhydraulicequipment.
2.Putcapsorplugsonanyhydrauliclinesleftopenoexposedduringtestingorremovalofcomponents.
3.Theenginemustbeingoodoperatingcondition.Usa tachometer when making a hydraulic test.Engin
speedcanaffecttheaccuracyofthetesterreadings.
4.Topreventdamagetotesterorcomponents,theinleandtheoutlethosesmustbeproperlyconnected,an
notreversed(testerwithpressureandflowcapabilities
5.Tominimizethepossibilityofdamagingcomponents
completelyopenloadvalveinhydraulictester(whenuingtesterwithpressureandflowcapabilities).
6.Installfittingsfingertight,farenoughtoinsureththeyarenotcrossthreaded,beforetighteningwith
wrench.
7.Position thetesterhosesso thatrotatingmachinpartswillnotmakecontactwiththemandresultinhosortesterdamage.
8 Check the oil level in the reservoir
IMPORTANT: Test ports on the transaxle are paintedclosed. Opening the ports will loosen the paint.
Make sure dirt or paint particles do not fall into theopen port.
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p p
Charge Pressure Test
NOTE:SeeSauerSundstrandIHTServiceManualformoreinformation.
Usea500or1,000PSI(35or70Bar)testgauge.
Specification:80to130PSI(5.5to9Bar)
1.Makesurehydraulicoilisatnormaloperatingtemper-aturebyoperatingthemachineforapproximately10
minutes.
2.Lowercuttingunit,engageparkingbrakeandstoptheengine.
3.Removetheplugfromthechargepressureportandinstalla500or1,000PSI(35or70Bar)pressuregaugewithextensionhose.
4.Starttheengineandmovethethrottlecontrolallthe
wayforward.Takepressurereadingwithmachinestationary.Alsotakeapressurereadingwhileoperatingthemachineinforwardandreverse.Totestinforwardandreverse,engagethebrakesandpushthetractionpedalforward,thenreverse.
1
Figure11
1. Charge pressure port
Forward Traction Test
NOTE: See SauerSundstrand IHT Service Manual for NOTE: When you move the traction pedal to creat
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NOTE:SeeSauer SundstrandIHTServiceManualfor
moreinformation.
Usea10,000PSI(700Bar)gauge.
Specification:6,200PSI(428Bar)maximum
1.Makesurehydraulicoilisatnormaloperatingtemper-aturebyoperatingthemachineforapproximately10minutes.
2.Lowercuttingunit,engageparkingbrakeandstoptheengine.
3.Removetheplugfromtheforwardtractionpressureportandinstalla10,000PSI(700Bar)pressuregauge
withextensionhose.
4.On4WDmachines,raisetheimplementandengagethetransportswitchsotheIHToperateswithlesstorquetothewheels.Engagetheparkingbrake,andruntheengineatfullspeed.Slowlypushthetractionpedalforward
andlistenforengagementoftheeasyridevalve.Contin
uetopushthetractionpedalandreadthegauge.
NOTE:Whenyou move the tractionpedal tocreat
pressure,moveitashortdistancefirstandwaitforchangeinsoundbeforemovingthepedalfurther.Thchangeinsoundindicatesthattheeasyridevalveha
closed.
1
Figure12
1. Forward traction pressure port
Reverse Traction Test
NOTE: See SauerSundstrand IHT Service Manual for NOTE: When you move the traction pedal to creat
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Counterbalance Pressure Test and Adjustment
Usea500or1,000PSI(35or70Bar)testgauge.
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, ( ) g g
Recommend counterbalance pressure:
84 inch decks: 220PSI(15Bar)
72 inch decks: 220PSI(15Bar)Contour 82 deck: 100150PSI(710Bar)Brush: 225PSI(16Bar)Blower: 7080PSI(56Bar)
1.Makesurehydraulicoilisatnormaloperatingtemper-aturebyoperatingthemachineforapproximately10
minutes.
2.Lowercuttingunit,engageparkingbrakeandstopthe
engine.
1
2
Figure17
3.Installa500or1,000PSI(35or70Bar)pressure 1. Test Port2. Counterbalance valve
gaugewithquickconnectadapteronthetestport.
4.Starttheengineandmovethethrottlecontrolallthewayforward.Readthegauge.Donotraisetheimplementwhentestingcounterbalancepressure.Movethe
liftleverforwardtomakesuretheliftsystemisinthefloatposition.
Steering Circuit Test
Thesteeringandimplementliftcircuitsareconnectedin 2.Lowercuttingunit,engageparkingbrakeandstopthe
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g p
series.Iftheimplementliftoperatescorrectly,thesteeringvalvehasadequateflowandpressure.
Cylinder Test
This test checks the steering cylinder for internalbypass,andassumesthatthesteeringvalveisworkingcorrectly.TheSteeringValveTestwilldetermineifthesteeringvalveisfaulty.
1.Makesurehydraulicoilisatnormaloperatingtemper-aturebyoperatingthemachineforapproximately10minutes.
2.Lowercuttingunit,engageparkingbrakeandstoptheengine.
3.Install ateefittinganda 5,000PSI(350Bar) testgaugeontotherightsidesteeringcylinderfitting.UsepartsfromTOR4079testfittingkitorthefollowingToroparts:
Cap(340117)Plug(340116)Tee(340115)Quickconnectfitting(865480)
4.Starttheengineandmovethethrottlecontrolallthe
g g g p g p
engine.
3.Disconnecttheteefromthecylinder.Installacapon
thecylinderandaplugontheopenteeport.
4.Starttheengineandmovethethrottlecontrolalltheway forward. Gently rotate the steering wheel whileobserving the pressure gauge. If the pressure nowincreasesto1,100PSI(76Bar),thecylinderhasadamagedinternalseal.Repairorreplacethecylinder.Ifthe
pressuredoesnotincreasebyrotatingineitherdirection,repairorreplacethesteeringvalve.
1
Figure18
1. Right side steering cylinder fitting
Auxiliary Hydraulic Pump Efficiency Test (Model 30726 Hydraulic Kit)
Awornordamagedpumpwillbypassoilandmakethe
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pumplessefficient.Eventually,enoughbypassingwilloccurtocausethecuttingunitstotostallinheavycuttingconditions.Continuedoperationwithaworn,inefficient
pumpcangeneratealotofheatandcausedamagetosealsandothercomponentsinthehydraulicsystem.
Useatesterwithpressureandflowcapabilities.
Specification:Minimum12GPM(45liter/min.)at2,500PSI(173Bar)
1.Makesurehydraulicoilisatnormaloperatingtemper-aturebyoperatingthemachineforapproximately10
minutes.
2.Lowercuttingunit,engageparkingbrakeandstoptheengine.
3.Disconnectthelargepressurehosefromthecoupleratthepump.Disconnectthelargereturnhosefromthe
coupleratthereturnfilter.Installthetesterbetweenthepumpoutletandfilterinlet.
IMPORTANT: Make sure the oil flow indicator on theflow meter shows that the oil will flow from thepump, through the tester and into the return filter.Make sure the flow control valve is open beforestarting the engine
Figure201. 45 degree fitting2. Quick coupler nipple3. Pump4. Splined coupler
5. Flush faced coupler6. Pump supply hose7. Hose bracket8. Square Oring
1
3
2
4
5 67
8
Flow
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Service and Repairs
Wheel and Tires
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Check Tire Pressure Check Wheel Nut Torque
Thetiresareoverinflatedforshipping.Therefore,releasesomeoftheairtoreducethepressure.Correctairpressureinthefrontandreartiresis15psi(1Bar).
IMPORTANT: Maintainevenpressureinalltirestoas
sureagoodqualityofcutandpropermachineperformance.DONOTUNDERINFLATE.
Kgm) after 1-4 hours of operation and again
after 10 hours of operation and every 200
WARNING
Torque wheel nuts to 7080 ftlb (1011
hours thereafter. Failure to maintain proper
torque could result in failure or loss of wheel
and may result in personal injury.
Lubrication
Themachinehasgreasefittingsthatmustbelubricatedregularly with No. 2 General Purpose Lithium BaseGrease. Ifmachine isoperatedundernormal conditions,lubricateallbearingsandbushingsafterevery50hours ofoperationorimmediatelyaftereverywashing.
IntermediateDriveShaft(3)(Fig.25),4WDRearDrIveShaft(3)(Fig.26),PedalPivots(5),Tractionpedal(In
t b d fl l t ) (1) (Fi 27) d Lift
Check Hydraulic Fluid
Thehydraulicsystemisdesignedtooperateonanti
wear hydraulic fluid The machines reservoir is filled at
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wearhydraulicfluid.Themachinesreservoirisfilledat
the factory with approximately 12 U.S. quarts (11.4
liters)ofMobil424hydraulicfluid. Check level of hy-
draulic fluid before engine is first started and dailythereafter.
1. Positionmachineonalevelsurface,raisetheimple
ment,andstoptheengine.
2. Unscrewdipstickcapfromthefillerneckandwipeitwithacleanrag.Screwdipstickcapfingertightontofiller
neck.Unscrewthedipstickandchecklevelofoil.Iflevel
isnotuptoFULLmarkondipstick,addenoughoilto
raiseleveltomark.DONOTOVERFILL.
3. Screwdipstickfillercapfingertightontofillerneck.
4. Lowertheimplement.
The following fluids are recommended for use:
ISO type 46/68 antiwear hydraulic fluid
Mobil MobilFluid424
Amoco Amoco1000
InternationalHarvester HyTran
Texaco TDHShell DonaxTD
UnionOIl Hydraulic/TractorFluid
Chevron TractorHydraulicFluid
BP Oil BP HYD TF
1
Figure291. Dipstick cap
Change Hydraulic Oil and Filter
Thehydraulicsystemoilandfiltermustbechangedini
tially at 200 hours and thereafter every 800 hours of op
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tiallyat200hoursandthereafterevery800hoursofop
eration or seasonally, whichevercomes first. NOTE:
Changeoilandfiltersevery400hoursifequippedwith
Model30726HydraulicKit.Thehydraulicsystemisdesignedtooperateonantiwearhydraulicfluid.Themachines reservoir is filled at the factory with
approximately12U.S.quarts(11.4liters)ofMobil424
hydraulicfluid(SeeCheckHydraulicOilinthissection
forrecommendedfluids). Check level of hydraulic
fluid before engine is first started and daily thereaf- Figure31ter. 1. Drain plug
1
1. Startengine,parkmachineonalevelsurface,lower
implementtotheshopfloor,settheparkingbrake,andshutengineoff.
2. Cleanareaarounddipstickcapand remove cap
fromaxlefillertube.
3. Toeaseaccesstoaxlehousingdrainplug,implementmayberemovedfromtractionunit.
4. Removedrainplugfrom axlehousingandallowoil
toflowintodrainpan.
5. Cleanareaaroundhydraulicoilfilterandremovefilter.NOTE:AlsoreplacefilterforModel30726Hydraulic
Kit.
1
Figure326 Lubricate new filter seal and install filter 1 H d li Filt
Traction Control Linkage
1 2 3 4 5 6 726
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1 2 3 4 5 6 7
8
910
1619
20
21
22
23
24
25
11
13
14
15
26
12
Brake Linkage
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1
3
4 5
6
7
89
11
16
17
8
18
19
1
2021
23
24
29
30
31
10
12
13
14
15
2
13
33
32
7
22
34
34
Driveshafts
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23
4
5
6
7
8
9
10
16
1718
11
12
13
14
1
19
15
2021
Neverseez
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Steering Control
30 31
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1
2
3
45 6
78
9 10
16
17
18
19
20
21
22
23
24
25
27
28
11
12
13
14
15
3
29
6
30 31
35 45 ftlb
(5 6 Kgm)
#4Tube
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#1#2
#3
#4
#5
#3Tube
#2Tube
#1Tube
#5Tube
Removing Hydraulic System Components
1.Thoroughlycleanthemachinebeforedisconnecting,
removingordisassemblinganyhydrauliccomponents.
2.Afterrepairs,checkcontrollinkageforproperadjust
ment,bindingorbrokenparts.
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Always keep inmind the need for cleanliness whenworkingonhydraulicequipment.
2.Putcapsorplugsonanyhydrauliclinesorfittingsleftopenorexposed.
3.Putlabelsondisconnectedhydrauliclinesandhosesforproperinstallationafterrepairsarecompleted.
After Repair or Replacement of Components
1.Checkoillevelinhydraulicreservoirandaddcorrect
oilifnecessary.Drainandrefillhydraulicsystemreservoirandchangeoilfilterifcomponentfailurewassevereorsystemiscontaminated.
3.Afterdisconnectingorreplacinganyhydrauliccomponents,operatemachinefunctionsslowlyuntilairis
outofsystem.
4.Checkforhydraulicoilleaks.Shutoffengineandcorrectleaksifnecessary.Checkoillevelinhydraulicreservoirandaddcorrectoilifnecessary.
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Cartridge Valves
1.Clean valve block toprevent contamination when
valvecartridgeisremoved.
Cartridge Installation
1 Lubricate all o rings with clean hydraulic oil
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2.Removecartridgevalve:
A.Removenutfromsolenoid.
B.Removesolenoidcoilandoringateachendofsolenoidcoil.
C.Useadeepsockettoremovecartridgevalve.
NOTE:Usecarewhenhandlingvalvecartridges,becauseslightbendingordistortionofstemtubecancausebindingandmalfunction.
3.Visuallyinspectportinblockfordamagetosealing
areas,damagedthreadsorcontamination.
4.Visuallyinspectcartridgefordamagedsealsandcontamination.
A.Orings and backup rings must be arrangedproperlyonthevalveforproperoperationandsealing.Replaceanydamagedseals.
B.Contaminationmaycausevalvestostickorhangup. Contamination can become lodged in smallvalveorificesorsealareasonpoppettypevalves
i lf i
1.Lubricatealloringswithcleanhydraulicoil.
2.Carefullythreadcartridgeintotheportbyhand.Valve
cartridgeshouldgoineasilywithoutbinding.
3.Useatorquewrenchanddeepsockettotightencartridgevalvestoatorqueof35ftlb(5Kgm).Excessivetorquemaycausethespooltobindandmalfunction.
NOTE: Use care when handling solenoid valve cartridgesbecauseslightbendingordistortionofstemtubecancausebindingandmalfunction.
4.Installsolenoidcoil.Makesurethereisanoringat
eachendofthecoil.ApplyLoctite242orequivalenttothreadsofstemtubebeforeinstallingnut.Tightennuttoatorqueof15inlb(17Kgcm).
5.Ifproblemstillexists,removevalveandcleanagain
orreplacevalve.
Lift Cylinder
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1
2
3
4
5
9
6
7
8
1011
1312
14
15
Steering Cylinder
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1 23
4
56
78
910
16
19
11
1213
14
15
Auxiliary Hydraulic Pump (Model 30726 Hydraulic Kit)
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1
23
4
5
6
7
8
16
17
18
19
11
12
13
14
15
8
15:215:1
8:1
8:2
12:2
12:1 11:1
8:1
8:2
Transaxle Service
Toro recommended fluids andmaintenance intervals
maybedifferentthanthoselistedintheSauerSunds-trand IHT Service Manual When doing maintenance or
SomeofthecomponentsshownintheSauerSunds-
trandIHTServiceManualmaynotbeusedontheToroapplication See your Toro Parts Catalog for more in-
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trandIHTServiceManual.Whendoingmaintenanceorserviceonthetransaxle,usetheTororecommendedfluidsandmaintenanceintervals.
application.SeeyourToroPartsCatalogformore in-formation.
12
34
5
6
7
8
1516
17
10
11
12
13
14
28
26
27
29
30
9 Brake rotor must be
45 50 ftlb(6 7 Kgm)
free of paint, grease,oil or other contamination
Chapter 6
Electrical System
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Electrical System
Table of Contents
ELECTRICAL SCHEMATICS, WIRING DIAGRAMS,ANDHARNESSDRAWINGS ................. 2
SPECIALTOOLS ............................. 3TROUBLESHOOTING(Groundsmaster3000) .... 4
StartingProblems(GM3000) ................. 4GeneralRun&TransportProblems(GM3000) . 5
CuttingUnitOperatingProblems(GM3000) .... 5TROUBLESHOOTING(Groundsmaster3000D).. 6StartingProblems(GM3000D) .............. 6GeneralRun&TransportProblems(GM3000D)7
CuttingUnitOperatingProblems(GM3000D) . 7ELECTRICALSYSTEMQUICKCHECKS ........ 8
BatteryTest(OpenCircuitTest) ............... 8GlowPlugSystemTest(GM3000D) .......... 8
COMPONENTIDENTIFICATIONANDTESTING.. 9
IgnitionSwitch .............................. 9DiodeCircuitBoards ....................... 10
NeutralSwitch ..............................11SeatSwitch ................................11Hydraulic Valve Solenoids 12
50AmpereThermalBreaker(GM3000D) .... 1FuelStopSolenoid(GM3000D) ............ 1InjectionAdvanceSolenoid(GM3000D) ..... 1Alternator(GM3000D) .................... 1
TemperatureSender(GM3000D) ........... 2TemperatureGauge(GM3000D) ........... 2
OilPressureSwitch(GM3000D) ............ 2TemperatureSendingUnit(GM3000D) ...... 2TransportSolenoid(GM3000D) ............ 2GlowPlugs(GM3000D) ................... 2H2OinFuelSensor(GM3000D) ............ 2CoolantLevelSensor(GM3000D) .......... 2IndicatorLightsandCircuits(GM3000D) .... 2FordEngine(VSG411)ElectricalComponentLoca
tions(GM3000) .......................... 2
TemperatureGauge(GM3000) .............. 3Thermistor(GM3000) ...................... 3
OilPressureSwitch(GM3000) .............. 3HighTemperatureSwitch(GM3000) ......... 3Anti dieseling Valve Solenoid (GM 3000) 3
Electrical Schematics, Wiring Diagrams,and Harness Drawings
Allelectricalschematics,diagrams,anddrawingsforboth the Groundsmaster 3000 and Groundsmaster3000 D l d i Ch 14 El i l Di
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3000D are located in Chapter 14 Electrical Diagrams.
Special Tools
Orderspecialtoolsfromthe TORO SPECIAL TOOLS SometoolsmayalsobeavailablefromalocalsupplierAND APPLICATIONS GUIDE (COMMERCIAL PROD-UCTS).
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Multimeter
Themetercantestelectricalcomponentsandcircuitsforcurrent,resistance,orvoltage.
NOTE:TororecommendstheuseofaDIGITALVoltOhmAmpmultimeterwhentestingelectricalcircuits.Thehighimpedance(internalresistance)ofadigitalmeterinthevoltagemodewillmakesurethatexcesscurrent is not allowed through the meter. This excesscurrentcancausedamagetocircuitsnotdesignedtocarryit.
Figure1
SkinOver Grease
Specialnonconductivegreasewhichformsalightprotectiveskinwhichhelpswaterproofelectricalswitchesandcontacts.
Troubleshooting(Groundsmaster 3000)
CAUTION
For effective troubleshooting and repairs, you musthaveagoodunderstandingoftheelectricalcircuitsandcomponentsusedonthismachine(seeWiringSchematicssectionofthischapter).
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Remove all especially rings andwatches, before doing any electrical trouble-
cables unless the test requires battery voltage.
jewelry,
shooting or testing. Disconnect the battery
Ifthemachinehasanyinterlockswitchesbypassed,
theymustbereconnectedforpropertroubleshootingandsafety.
Starting Problems
Problem Possible Causes
Startersolenoidclicks,butstarterwillnotcrank
(ifsolenoidclicks,theproblemisnotwiththeIgnitionmoduleoritsinputs).
Batterychargeislow.
Batterycablesarelooseorcorroded.
Batterygroundtoengineislooseorcorroded.
Wiringatstarterisfaulty.
Startersolenoidisfaulty.
Startermountingboltsarelooseornotsupplyingasufficientgroundforsolenoid.
Starterisfaultycausingincompletecircuitforsolenoid.
Nothinghappenswhenastartattemptismade. Wiringtostartcircuits(seeWiringSchematics)isloose, corroded, or damaged.
General Run and Transport Problems (Groundsmaster 3000)
Problem Possible Causes
Enginekillswhenthetractionpedalispositionedto Operatorissittingtoofarforwardontheseat(seat
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g p peitherforwardorreverse.
p g (switchnotdepressed).
Wiringtoseatandshutdowndelaycircuits(seeWiringSchematics)isloose,corroded,ordamaged.
2amperefuse,seatswitch,orseatrelayisfaulty.
Diode(D1)orshutdowndelayrelayisfaulty.
20amperefusetoseatrelayisblown.
Batterydoesnotcharge. Wiringtothechargingcircuit(seeWiringSchematics)componentsisloose,corroded,ordamaged.
Voltageregulator/alternatorisfaulty.
50amperefuseisopen.
Batteryisdead.
Cutting Unit Operating Problems (Groundsmaster 3000)
Problem Possible Causes
Cuttingunitdoesnotengage. WiringtoPTOcircuit(seeWiringSchematics)components is loose corroded or damaged
Troubleshooting(Groundsmaster 3000D)
CAUTION
For effective troubleshooting and repairs, you musthaveagoodunderstandingoftheelectricalcircuitsandcomponentsusedonthismachine(seeWiringSchematicssectionofthischapter).
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Remove all especially rings andwatches, before doing any electrical trouble-
cables unless the test requires battery voltage.
jewelry,
shooting or testing. Disconnect the battery
Ifthemachinehasanyinterlockswitchesbypassed,
theymustbereconnectedforpropertroubleshootingandsafety.
Starting Problems
Problem Possible Causes
Startersolenoidclicks,butstarterwillnotcrank
(ifsolenoidclicks,theproblemisnotwiththeIgnitionmoduleoritsinputs).
Batterychargeislow.
Batterycablesarelooseorcorroded.
Batterygroundtoframeislooseorcorroded.
Wiringatstarterisfaulty.
Startersolenoidisfaulty.
Startermountingboltsarelooseornotsupplyingasufficientgroundforsolenoid.
Starterisfaultycausingincompletecircuitforsolenoid.
Nothinghappenswhenastartattemptismade. Wiringtostartcircuits(seeWiringSchematics)isloose,corroded,ordamaged.
General Run and Transport Problems (GM 3000D)
Problem Possible Causes
Enginekillswhenthetractionpedalispositionedtoeither forward or reverse
Operatorissittingtoofarforwardontheseat(seatswitch not depressed)
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eitherforwardorreverse. switchnotdepressed).
Wiringtoseatandshutdowndelaycircuits(seeWiringSchematics)isloose,corroded,ordamaged.
7.5amperefuse,seatswitch,orseatrelayisfaulty.
Diode(D1)orshutdowndelayrelayisfaulty.
20amperefusetoseatrelayisopen.
Batterydoesnotcharge. Wiringtothechargingcircuit(seeWiringSchematics)componentsisloose,corroded,ordamaged.
Voltageregulator/alternatorisfaulty.
80amperefuseisopen.
Batteryisdead.
Cutting Unit Operating Problems (GM 3000D)
Problem Possible Causes
Cuttingunitdonotengage. WiringtoPTOcircuit(seeWiringSchematics)componentsisloose,corroded,ordamaged.
Electrical System Quick Checks
Battery Test (Open Circuit Test)
Note: Thistestprovidesarelativeconditionofthebat Voltage Measured Battery Charge Level
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tery.Loadtestingofthebatterywillprovideadditionalandmoreaccurateinformation.
1. Thebatterytemperatureshouldbefrom60_to100_
F.The ignitionkeyshouldbeoffand allaccessoriesturnedoff.
2. SetmultimetertotheDCvoltssetting.4. Recordvoltage.
3. Connectpositive(+)meterleadtothepositivebatterypostandnegative()meterleadtothethenegative
batterypost.
g y g
12.68V(orhigher) Fullycharged(100%)
12.45V 75%charged
12.24V 50%charged
12.06V 25%charged
11.89V 0%charged
Glow Plug System Test (GM 3000D)
Thisfast,simpletestcanhelpyoudetermineaglowplugsystemsintegrityandoperation.Runthistestanytimehardstarting(cold)isencounteredonthedieselengine.
Tool(s)required:Digitalmultimeterand/orAC/DC
currenttransducer(HallEffect).
1. Properlyconnectcurrenttransducertothedigital
multimeter.Setmultimeteronthepropervoltsscale(re
GLOWPLUGSGLOWPLUGS
Component Identification and Testing
Foraccurateresistanceand/orcontinuitychecks,electricallydisconnectthecomponentbeingtestedfromthecircuit(e.g.unplugtheignitionswitchconnectorbeforedoingacontinuitycheck).
CAUTION
Wh i l i l f i
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When testing electrical components for continu-ity with a multimeter (ohms setting), make sure
that power to the circuit has been disconnected.
Ignition Switch
The ignition (key) switch has three positions (OFF,STARTandRUN).Theterminalsaremarkedasshown.Thecircuitryoftheignitionswitchisshowninthechart.Withtheuseofacontinuitytester,theswitchfunctions
maybetestedtodeterminewhetherallcircuitsarebeingcompletedwhilethekeyismovedtoeachposition.
T
O
OR
A
B
I
X
S
Y
Figure4
POSITIONCONTINUITYAMONGTERMINALS
OTHERCIRCUITSMADE
Diode Circuit Boards
Eachcircuitboardcontainsfourdiodes.Thediodesare
D2usedforcircuitprotectionfrominductivevoltagespikes,batterychargingindication,andforsafetycircuitlogic.
D4D6
DiodesD4andD8arenotused.
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DIODE
D8OntheGM3000wiringdiagram,thediodecircuitcards D3
adesignatedP3andP5.OntheGM3000Dwiringdia- D7grams,thediodecircuitcardsaredesignatedP7and D1P5.
D5
Diode D1
Directscurrentflowfromthedeckcapacitortothedeckrelaywhentheseatrelayisdeenergizedtoprovidea1seconddelay.
A B C D E F G H
DIAGRAM
Figure6
Diode D2
Providescurrentflowlogicforthechargingcircuitlight.
Diode D3
Prevents a negative spike from damaging the PTOswitchbyallowingagroundpathforthePTOrelayandPTOcoilwhentheydeenergize.
Diode D4
DIODE
P3orP7 P5
CIRCUITBOARDS
Figure7
Thiscomponentisnotused.
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Hydraulic Valve Solenoids
The hydraulicvalve solenoidsare located belowtheseatandonthehydraulicmanifoldblock.
Note: Priortotakingsmallresistancereadingswitha
1
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digitalmultimeter,shortthetestleadstogether.Themeter will display a small resistance value (usually0.5ohmsorless).Thisresistanceisduetotheinternalre
sistanceofthemeterandtestleads.Subtractthisvaluefromfromthemeasuredvalueofthecomponentyouaretesting.
1. Makesureengineisoff.Disconnectsolenoidvalveelectricalconnector.
2
2. Apply12VDCsourcedirectlytothesolenoid.Listen Figure11forsolenoidtoswitchon.Removevoltagesource. 1. Electrical connector 2. Solenoid
3. Measureresistancebetweenthetwoconnectorterminals. The resistance should be approximately 7.2
ohms.
Hour Meter
1. Removeelectricalconnectionsfrommeter.
2. Connect the positive (+) terminal of a 12 VDC
sourcetothepositiveterminalofthehourmeter.
Cruise Control Coil (Optional)
Thecruisecontrolcoilislocatedbelowtheseat.
Note: Priortotakingsmallresistancereadingswithadigitalmultimeter,shortthetestleadstogether.Theme
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ter will display a small resistance value (usually0.5
ohmsorless).Subtractinternalresistanceofthemeterandtestleadsfromthemeasuredvalueofthecompo
nentyouaretesting.
1. Makesureengineisoff.Disconnectblueandvioletwirestothecoil.
2. Apply12VDCsourcedirectlytothecoilwires.Listenforcoiltopullinclutchplate.
CRUISECONTROLCOIL
3. Measureresistancebetweenthetwocoilwires.The Figure13resistanceshouldbefrom3.6to4.0ohms.
PTO (Clutch) Coil
ThePTO(clutch)coilislocatedinsidetheIHTtransmission.Theelectricalconnectortothecoilisbelowtheseat.
Note: Priortotakingsmallresistancereadingswithadigitalmultimeter,shortthetestleadstogether.Theme
ter will display a small resistance value (usually0.5ohmsorless).Subtractinternalresistanceofthemeter
CONNECTORTOPTOCOIL
Fuel Sender
Thesenderislocatedontopofthefueltankinsidethecentershroudarea.
1. Removebluewireandblackgroundwirefromthed
GROUNDWIRE
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sender.
2. Removeremainingscrewsandlockwashersfromthesenderandfueltank.
3. Remove sender and gasket from the fuel tank.Cleananyfuelfromthesender.
Note: Beforetakingsmallresistancereadingswitha
BLUEWIRE
Figure15digitalmultimeter,shorttestleadstogether.Themeterwilldisplayasmallresistancevalue.Thisinternalresis
tanceofthemeterandtestleadsshouldbesubtractfromthemeasuredvalueofthecomponent.
4. Checkresistanceofthesenderwithamultimeter.Resistancewiththefloatinthefullpositionshouldbe27.5to39.5ohms.Resistancewiththefloatintheemptypositionshouldbe240to260ohms.
Figure16
FULLPOSITION
EMPTYPOSITION
Relays and Fuses
Therelaysandfusesandarelocatedinthecompartmentthatisrearofthecontrolpanel(Fig.18).Thereisan80amperefuse(50ampereontheGM3000)locatedbythealternator(Fig.22).
87
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Relay Testing
1. Verifycoilresistancebetweenterminals86and85withamultimeter(ohmssetting).Resistanceshouldbefrom75to95ohms.Thereshouldbecontinuitybetweenterminals87Aand30.
2. Connectmultimeter(ohmssetting) leadstorelay
30
87A
8
6
8
5
30 85 86 87 87A
Figure19terminals30and87.Groundterminal86andapply+12VDCtoterminal85.Therelayshouldmakeandbreak
continuitybetweenterminals30and87as12VDCisappliedandremovedfromterminal85.
3. Disconnectvoltagefromterminal85andmultimeterleadfromterminal87.
4. Connectmultimeter(ohmssetting)leadtorelayter
minal30and87A.Apply+12VDCtoterminal85.Therelayshouldbreakandmakecontinuitybetweentermi
nals30and87Aas12VDCisappliedandremovedfromterminal85.
RelayandFuseLocation(Groundsmaster3000)
Figure20
5. Disconnectvoltageandmultimeterleadsfromrelayterminals
50 Ampere Thermal Breaker (GM 3000D)
Thisdeviceoperatesasa thermaloverload.Afterthedevicetrips,timeshouldbeallowedforittocoolandreset.Itislocatednearthestarter.
1 Verify continuity between the two terminals Conti
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1. Verifycontinuitybetweenthetwoterminals.Continuityshouldbeless than 1 ohm.
THERMAL
BREAKER
Figure23
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Injection Advance Solenoid (GM 3000D)
Theinjectionadvancesolenoidislocatedontopoftheinjectorpump,whichisontherightsideoftheengine.Itshastwoblackwiresconnectedtoit.Onewireleadstoaconnectorwithorangeandwhitewires.Theotherwire is grounded to the injector pump The solenoid is
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wireisgroundedtotheinjectorpump.Thesolenoidispoweredfromtheorange(top)wire(Fig.52).
In Place Testing
Note: Priortotakingsmallresistancereadingswitha
digitalmultimeter,shortthetestleadstogether.Themeter will display a small resistance value (usually0.5ohmsorless).Thisresistanceisduetotheinternalresistanceofthemeterandtestleads.Subtractthisvaluefromfromthemeasuredvalueofthecomponentyouare
testing.
1. Removewireclipfromtheconnectoranddisconnectconnector.
2. Usingadigitalmultimeter,attachoneleadtothelug
ofthegroundwire.Connectotherleadtothepinintheconnector that isattached tothe injectorpump.Theorangewireontheharnessconnectorpowersthesole
noid.
3. Theresistanceshouldbeabout 14.6 ohms.
Live testing
SOLENOID
GROUNDWIRE
CONNECTOR
Alternator (GM 3000D)
Thealternatorisbeltdrivenwithainternalregulator.Itislocatedonthebottomrightendoftheengine.Ifeitherthealternatorortheregulatorisdamaged,theentireunitmustbereplaced(Fig.28).
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Note: Priortotestingthechargingsystem,makesure
thepolyVbelttothealternatorisingoodoperationconditionandadjustedproperly(seeBeltAdjustmentin
Chapter4PeugeotDieselEngine).
Test Equipment
Useashuntcapableofhandlingatleast70ampere.Also,adigitalmultimeterwithahighimpedancemillivoltscale(withatleast300mvrange)canbeusedincon
junctionwiththeshunt(Fig.29).
Testing for DC Current Output (Fig. 30)
Note: Follow the manufacturers instructions whenusingaDCshunt.
1. Makesureengineisoff.
IMPORTANT: To perform this test properly, the bat-
tery must not be fully charged. See Battery Test inthe Electrical Quick Checks section.
2. InstalltheDCshuntonthenegativeterminalofthe
Figure28
Temperature Sender (GM 3000D)
Thetemperaturesenderislocatedonthetoprightsideofthewateroutletbox.Ithasagreenconnectorwithblueandblackwires.Thesendersuppliesasignaltotheglowcontrolunit(Fig.31).
TEMPSENDER
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CAUTION
1. Lowerthecoolantlevelintheengineandremove
thethermistorfromthewaterpump.
Make sure engine is cool and coolant system isdepressurized before removing the thermistor.
Figure312. Putthesen