Part No. 96890SL Rev. C Service Manual GroundsmasterR 3000/3000–D Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Groundsmaster 3000 and 3000–D. REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine.
Groundsmaster 3000/3000–D
Chapter 5 – Hydraulic System and Transaxle Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 3 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . 5 – 6 Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . 5 – 8 Special Tools . . .
Groundsmaster 3000/3000–D
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 2 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 3 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 9 – 7 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 – 2 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 – 3 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . .
Groundsmaster 3000/3000–D
Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . . 3 SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 4 Safety Instructions The GROUNDSMASTERR 3000 and 3000-D was tested and certified by TORO for compliance with the B71.
7. Check interlock switches daily for proper operation. Do not rely entirely on safety switches -shut off engine before getting off seat. If a switch fails, replace it before operating the machine. The interlock system is for your protection, so do not bypass it. Replace all interlock switches every two years. Interlock switches should be adjusted so: A. Engine cannot be started unless traction pedal is released (neutral position). B. Engine stops if operator gets off seat when traction pedal is depressed.
25. Lower the cutting unit or other attached implement to the ground and remove key from switch whenever machine is left unattended. 26. Before getting off the seat: A. Move traction pedal to neutral position and re move foot from pedal. B. Set the parking brake and disengage the PTO. C. Shut the engine off and remove key from igni tion switch. Wait for all movement to stop before getting off the seat. Maintenance 27.
Safety and Instruction Decals (Groundsmaster 3000) The following safety and instruction decals are mounted on the traction unit. If any decal becomes damaged or illeg ible, install a new decal. Part numbers are listed below or in your parts catalog. On Side of Tool Box (Part No. 67–1710) Next to Right Side of Seat (Part No. 93–5935) In Compartment Behind Control panel (Part No. 93–5933) ON FAN SHROUD (Part No. 77–3100) On Hood (Part No. 93–6328) On Right Side Of Center Shroud (Part No.
Safety and Instruction Decals (Groundsmaster 3000–D) Safety The following safety and instruction decals are mounted on the traction unit. If any decal becomes damaged or illeg ible, install a new decal. Part numbers are listed below or in your parts catalog. On Side of Tool Box (Part No. 67–1710) Next to Right Side of Seat (Part No. 93–5934) In Compartment Behind Control panel (Part No. 93–5932) ON FAN SHROUD (Part No. 77–3100) On Radiator Near Inlet (Part No.
Safety and Instruction Decals (84I Cutting Units) The following safety and instruction decals are mounted on the cutting unit. If any decal becomes damaged or illegible, install a new decal. Part numbers are listed below or in your parts catalog. On Each Corner Of Cutting Unit (Part No. 43–8480) On Gearbox Base (Part No. 93–6697) On Front of Cutting Unit (Part No. 68–8340) On Right & Left Covers (Part No. 93–0299) On Front of Deck (Part No. 88–1270) On Deck Channels, Under Covers (Part No.
Safety On Rear of Deck (Part No. 66–6380) On Front of Deck (Part No. 66–1340) On Rear Of Deck (Part No. 93–7828) Replaces Decal Part No. 66–6380 for CE On Front Of Deck (Part No. 93–7824) On Each Castor Arm (Part No. 93–4894) Replaces Decal Part No. 66–1340 for CE On Each Castor Arm (Part No. 93–4690) Groundsmaster 3000/3000–D On Deck Channels, Under Covers (Part No. 93–7814) Replaces Decal Part No. 85–6410 for CE Page 1 – 7 Rev.
Safety and Instruction Decals (Contour 82I Cutting Unit) The following safety and instruction decals are mounted on the cutting unit. If any decal becomes damaged or illegible, install a new decal. Part numbers are listed below or in your parts catalog. On Sides of Right & Left Chambers (Part No. 43–8480) On Top of Chamber 2 (Part No. 88–1270) On Right & Left Chambers (Part No. 93–0299) On Top of Chamber 3 (Part No. 93–7818) Replaces Decal Part No. 68–8340 for CE On Top of Chamber 3 (Part No.
Safety and Instruction Decals (Guardian 72I Recycler Cutting Unit) Safety The following safety and instruction decals are mounted on the cutting unit. If any decal becomes damaged or illegible, install a new decal. Part numbers are listed below or in your parts catalog. On Each Corner Of Cutting Unit (Part No. 43–8480) On Front of Cutting Unit (Part No. 68–8340) On Left Caster Arm (Part No. 93–0299) On Gearbox Base (Part No. 93–6697) On Front of Cutting Unit (Part No.
Safety and Instruction Decals (Rear Discharge 72I Cutting Unit) The following safety and instruction decals are mounted on the cutting unit. If any decal becomes damaged or illegible, install a new decal. Part numbers are listed below or in your parts catalog. On Gearbox Base (Part No. 93–6697) On Front of Deck (Part No. 68–8340) On Front of Deck (Part No. 93–7818) Replaces Decal Part No. 68–8340 for CE On Each Corner Of Deck (Part No. 43–8480) On Each Corner Of Deck (Part No.
On Front of Deck (Part No. 66–6380) On Rear Of Deck (Part No. 93–7828) Replaces Decal Part No. 66–6380 for CE On Rear Of Deck (Part No. 93–4977) On Front of Deck (Part No. 66–1340) On Front Of Deck (Part No. 93–7824) On Deck Channels, Under Covers (Part No. 85–6410) Replaces Decal Part No. 66–1340 for CE On Right Rear Top of Deck (Part No. 94–3392) Groundsmaster 3000/3000–D On left Rear Top of Deck (Part No. 93–4691) Page 1 – 11 On Front of Deck (Part No.
Safety Page 1 – 12 Groundsmaster 3000/3000–D
Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Capscrew Markings and Torque Values – U.S. . . Capscrew Markings and Torque Values – Metric . QUICK REFERENCE MAINTENANCE AID . . . . . . .
Equivalents and Conversions Product Records and Maintenance Page 2 – 2 Groundsmaster 3000/3000–D
Product Records and Maintenance Torque Specifications Groundsmaster 3000/3000–D Page 2 – 3 Product Records and Maintenance
Product Records and Maintenance Page 2 – 4 Rev.
Lubrication Traction Unit CAUTION Product Records and Maintenance Before servicing or making adjustments to the machine, stop engine and remove key from the switch. The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation or immediately after every washing.
Cutting Units If machine is operated under normal conditions, lubri cate castor bearings and bushings with No. 2 general purpose lithium base grease or molybdenum base grease, after every 8 hours of operation or daily, which ever comes first. Lubricate fittings immediately after ev ery washing, regardless of the interval listed. CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch.
Product Records and Maintenance Rear Discharge 84I Cutting Unit Figure 8 Contour 82I Cutting Unit Figure 9 Groundsmaster 3000/3000–D Page 2 – 7 Product Records and Maintenance
Guardian 72I Recycler Cutting Unit Figure 10 Rear Discharge 72I Cutting Unit Figure 11 Product Records and Maintenance Page 2 – 8 Groundsmaster 3000/3000–D
Product Records and Maintenance EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for GROUNDSMASTERR 3000 TORO Model and Serial Number: ______________–______________ Engine Numbers: _____________________________ Transmission Numbers: _____________________________ Drive Axle(s) Numbers: _____________________________ Date Purchased: _____________________________ Warranty Expires____________ Purchased From: _____________________________ _____________________________ _____________________________ Conta
GroundsmasterR3000 Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Lubricate All Grease Fittings Inspect Air Filter Check Battery Level/Cable Connections Check Cutting Unit Gearbox Oil Level Clean Under Cutting Unit Belt Covers Check Cutting Unit Drive Belt Adjustment Maintenance Interval & Service Every 100hrs Every 50hrs Every 200hrs Every 400hrs Every 800hrs A Level Service } Change Engine Oil and Filter Inspect Cooling System Hoses B Level Service { Check F
GroundsmasterR3000 Daily Maintenance Check List Unit Designation: ____________ TORO ID #: ________–________ Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator’s Manual for fluid specifications MON n Safety Interlock Operation n Brake Operation n Engine Oil & Fuel Level n Cooling System Fluid Level n Radiator & Screen for Debris n Unusual Engine Noises n Unusual Operating Noises n Hydraulic System Oil Level n Hydraulic Hoses for Damage n Fluid Leaks
Product Records and Maintenance Page 2 – 12 Groundsmaster 3000/3000–D R A B C D E Other Service to perform (circle): __________________–__________________ TORO I.D.
Product Records and Maintenance EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for GROUNDSMASTERR 3000–D TORO Model and Serial Number: ______________–______________ Engine Numbers: _____________________________ Transmission Numbers: _____________________________ Drive Axle(s) Numbers: _____________________________ Date Purchased: _____________________________ Warranty Expires____________ Purchased From: _____________________________ _____________________________ _____________________________ Con
GroundsmasterR3000–D Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Lubricate All Grease Fittings Inspect Air Filter Check Battery Level/Cable Connections Check Cutting Unit Gearbox Oil Level Clean Under Cutting Unit Belt Covers Check Cutting Unit Drive Belt Adjustment Every 50hrs Every 100hrs Every 200hrs Every 400hrs Every 800 hrs A Level Service } Change Engine Oil and Filter Inspect Cooling System Hoses B Level Service { Ch
GroundsmasterR3000–D Daily Maintenance Check List Unit Designation: ____________ TORO ID #: ________–________ Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator’s Manual for fluid specifications MON n Safety Interlock Operation n Brake Operation n Engine Oil & Fuel Level n Cooling System Fluid Level TUES WED THURS FRI SAT SUN Drain Water/Fuel Separator n Radiator & Screen for Debris n Unusual Engine Noises1 n Unusual Operating Noises n Hydraulic S
Product Records and Maintenance Page 2 – 16 Rev. A Groundsmaster 3000/3000–D R A B C D E Other Service to perform (circle): __________________–__________________ TORO I.D. #: _______________________________ _______________________________ ________________________________ ________________________________ Pack 2WD Rear Axle Bearings Check Rear Wheel Toe–In Hyd. Oil (see note on Maint. Sched.) Hyd. Filter (see note on Maint. Sched.
Chapter 3 Ford VSG–411 Engine GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information The engine used in the Groundsmaster 3000 is manufa cutured by Ford Motor Company. Order service and re pair parts for Ford engines from you local Ford Power Products Dealer. See the Ford VSG–411/413 Engine Service Manual for engine identification information.
Adjustments Belt Adjustments Check condition and tension of belts after every 100 hours of operation. Replace belts as required. Alternator Belt The alternator belt should be tensioned so when it is pressed firmly with thumb, midway between pulleys, it deflects .25 inch (6.4 mm). 1 2. Rotate alternator away from engine. 3. Hold alternator in position after proper belt tension setting is achieved and tighten alternator and brace bolts to secure adjustment. Figure 1 1. Cooling Fan Belt 2.
Governor Adjustment 1. With engine shut off, move throttle control to FAST position and open hood. Check between the throttle arm and the stop on the carburetor base to make sure there is 1/32” (0.8 mm). If gap is not correct, adjust throttle rod by turning ball joint ends until gap is 1/32” (0.8 mm). If gap is correct, proceed to step 2. 9. Bump the throttle lever with your hand so engine speeds up momentarily.
Service and Repairs Check Engine Oil Crankcase capacity is 3–1/2 U.S. qt. (3.3 liter) with filter. 1. Park machine on a level surface. Rotate hood latch fully counterclockwise and open hood. 2. Remove dipstick and wipe it with a clean rag. Insert dipstick into tube and make sure it is fully seated. Re move dipstick and check level of oil. If level of oil is low, add enough oil to raise level to notch in dipstick. DO NOT OVERFILL. 1 5.
Change Engine Oil and Filter Change oil and filter initially after the first 50 hours of op eration, thereafter change oil and filter every 100 hours. 1. Remove drain plug (Fig. 7) and let oil flow into drain pan. When oil stops, install drain plug. 2. Remove oil filter (Fig. 8). Apply a light coat of clean oil to the new filter seal before screwing it on. DO NOT OVER–TIGHTEN. 3. Add oil to crankcase. Capacity is 3.5 U.S. quarts (3.3 liters) with filter. Refer to Check Engine Oil. 1 Figure 7 1.
Check Coolant Capacity of system is 9 U.S. qt. (8.5 liters). Clean debris off screen, oil cooler and radiator daily, hourly if conditions are extremely dusty and dirty; refer to Cleaning Radiator and Screen. 1 The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti–freeze. Check level of coolant at beginning of each day before starting the engine. 2. Check coolant level. Coolant should be up to COLD line on reserve tank, when engine is cold. HOT COLD Figure 9 1.
Cooling System Service 1. Removing Debris – Remove debris from rear screen, oil cooler and radiator daily, clean more fre quently in dirty conditions. IMPORTANT: Never spray water onto a hot engine as damage to engine may occur. A. Turn engine off and clean hood screen thor oughly. B. Release hood latch and raise hood. Clean engine area thoroughly of all debris. C. Clean both sides of oil cooler and radiator area thoroughly with compressed air. Do not use water. D. Close hood and secure latch.
General Air Cleaner Service 1. Inspect air cleaner after every 50 hours of operation. More frequent in dusty or dirty conditions. 2. Check air cleaner body for damage which could possibly cause an air leak. Replace a damaged air cleaner body. 3. Service the air cleaner filter every 400 hours (more frequently in extreme dusty or dirty conditions). Do not over service air filter.
Fuel System Service Fuel Tank Drain and clean fuel tank every 800 hours of operation or yearly, whichever comes first. Also, drain and clean tank if fuel system becomes contaminated or if machine is to be stored for an extended period. Use clean fuel to flush out the tank. Fuel Lines and Connections Check lines and connections every 400 hours or yearly, whichever comes first. Inspect for deterioration, dam age, or loose connections.
Replacing Spark Plugs Change spark plugs after every 400 operating hours to assure proper engine performance and reduce exhaust emission level. 3. Check condition of side electrode, center electrode, and center electrode insulator to assure there is no dam age. Correct spark plug to use is a Motorcraft–AGSF22C or AGRF22 or equivalent. IMPORTANT: A cracked, fouled, dirty or otherwise malfunctioning spark plug must be replaced.
Servicing Spark Arrestor Muffler Every 200 hours operation, clear the muffler of carbon buildup. 1. Remove pipe plug from clean–out port at lower side of muffler. CAUTION Be careful while working around muffler as it may be hot and could cause injury. 2. Start engine. Plug the normal muffler exit with block of wood or metal plate so exhaust flow will be forced out of the clean–out port. Continue to block exit until carbon deposits cease coming out port.
Chapter 4 Peugeot TUD5 Engine Table of Contents Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . Priming Fuel System . . . . . . . . . . . . . . . . . . . . . . . . Frame, Fuel Tank and Battery . . . . . . . . . . . . . . . . Muffler and Rear Bumper . . . . . . . . . . . . . . . . . . . . Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Bracket and Degasser . . . . . . . . . . . . . . . . . . Center Shroud and Air Cleaner . . . . . . . . . . . . . . .
Specifications Item Specification Make / Designation Peugeot TUD5 4 cycle, in–line, overhead cam, liquid cooled diesel engine Governor Adjustment High idle 2650 + 50 RPM Low Idle 1500 + 100 R{M Oil SAE 15W–40 CE Oil capacity 4.75 U.S. qt. with filter (4.5 liters) Coolant 50/50 mixture water and Peugeot recommended antifreeze (Toro Part No. 93–7213) Coolant capacity 11.5 U.S. qt. (10.
Special Tools Compression Test Kit (TOR3003A) 0–1000 PSI Gauge allows testing of diesel engines to check general operating condition of engine. Kit contains: – Case – Gauge with hose – Glow plug hole adapters Figure 3 Valve Spring Compression Tool (TOR4024T) Peugeot Diesel Engine Use for removing valve springs. Figure 4 Air Filter Element Cleaner (TOR277220) A solution of filter cleaner and water may be used to wash the air filter element of the Donaldson 3–stage air cleaners.
Injection Nozzle Tester (TOR463610) When used along with the adapter, TOR437580, injec tion nozzles may be examined by performing the follow ing tests: – Injection pressure test. – Chattering test. – Nozzle leakage test. – Spray test. Figure 6 Digital Belt Tension Tool (TOR4075) Tool is used to accurately adjust the cam drive belt ten sion. NOTE: This tool is not included in TOR4080 kit. Order separately.
Valve Guide Seal Remover (TOR4081) Use to remove old valve guide seals. Figure 9 Injector Socket (TOR4082) Peugeot Diesel Engine A special deep socket to remove and install injectors. Figure 10 Torque Angle Gauge (TOR4083) Provides a method to tighten the fastener a specified number of degrees after torque loads are applied. Cali brated in degrees in large easy to read increments. 1/2 inch square drive.
Camshaft Pinion Setting Tool (TOR4084) Tool is used to hold the camshaft gear and / or injector pump gear while tightening the fasteners. Figure 12 Timing Pin Set (TOR4085) Tool set is used to set injection pump engine timing. Figure 13 Rear Main Seal Installer (TOR4086) Tool is used to install the crankshaft rear main seal.
Front Seal Installer (TOR4087) Tool is used to install the crankshaft front seal. Figure 15 Camshaft Seal Installer (TOR4088) Peugeot Diesel Engine Tool is used to install the camshaft seal.
Adjustments CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. Engine Belts Check condition and tension of belts after every 100 hours of operation (Fig. 17). Replace belts as required. Alternator Belt 1. Proper tension will allow 1/8 in. (3.2 mm) deflection on the belt midway between the pulleys, when pressed firmly with thumb. 1 2. If deflection exceeds 1/8 in. (3.2 mm), loosen alter nator mounting bolts.
Service and Repairs CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. Check Engine Oil Crankcase capacity is 4.75 U.S. qt. (4.5 liters) with filter. 1. Park machine on a level surface. Rotate hood latch fully counterclockwise and open hood. 2. Remove dipstick and wipe it with a clean rag. Insert dipstick into tube and make sure it is fully seated. Re move dipstick and check level of oil.
Change Engine Oil and Filter Change oil and filter initially after the first 50 hours of op eration, thereafter change oil and filter every 100 hours. 1. Remove drain plug (Fig. 20) and let oil flow into drain pan. When oil stops, install drain plug and new plug seal, Part No. 74–7850. 2. Remove oil filter (Fig. 21). Apply a light coat of clean oil to the new filter seal before screwing it on. DO NOT OVER–TIGHTEN. 3. Add 15W–40 CE oil to crankcase. Capacity is 4.75 quarts with filter. 1 Figure 20 1.
Check Cooling System Capacity of system is 11.5 qts. (10.9 l). Check cooling system if low water level light illuminates. 1. Park machine on a level surface. Release hood latch and open hood. 2. Remove degasser tank cap and check coolant lev el. Coolant level should be up to or above tabs In degasser tank, when engine is cold. 1 CAUTION If engine has been running, pressurized hot coolant can escape and cause burns if degasser cap is removed.
Cooling System Service 1. Removing Debris – Remove debris from rear screen, oil cooler and radiator daily, clean more fre quently in dirty conditions. IMPORTANT: Never spray water onto a hot engine as damage to engine may occur. A. Turn engine off and clean hood screen thor oughly. B. Release hood latch and raise hood. Clean engine area thoroughly of all debris. C. Clean both sides of oil cooler and radiator area thoroughly with compressed air. Do not use water. D. Close hood and secure latch.
General Air Cleaner Maintenance 1. Inspect air cleaner after every 50 hours of operation. More frequent in dusty or dirty conditions. 2. Check air cleaner body for damage which could possibly cause an air leak. Replace a damaged air cleaner body. 3. Service the air cleaner filter every 400 hours (more frequently in extreme dusty or dirty conditions). Do not over service air filter.
Fuel System Service Fuel Tank Drain and clean fuel tank every 800 hours of operation or yearly, whichever comes first. Also, drain and clean tank if fuel system becomes contaminated or if machine is to be stored for an extended period. Use clean fuel to flush out the tank. 1 3 DANGER Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area.
Priming Fuel System 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. 2 1. Unlatch and raise hood. 2. Insert a 3/16 inch (5 mm) hose over bleed screw and run other end into a container to catch fuel. 3. Loosen fuel filter / water separator bleed screw (Fig. 28) a few turns. Pump priming plunger until a steady stream of fuel comes out of hole in bleed screw.
Frame, Fuel Tank and Battery 6 5 9 4 10 11 12 13 14 15 3 16 2 8 7 42 19 18 20 17 1 43 19 22 41 39 36 38 21 23 24 25 26 37 28 27 35 26 44 34 40 33 32 31 30 30 29 Figure 29 1. Bushing 2. Fuel hose 3. Hose clamp 4. Fitting 5. Lock washer 6. Fuel hose 7. Gasket 8. Fuel sender 9. Screw 10. Fuel cap Peugeot TUD5 Engine 11. Stand pipe 12. Fuel hose 13. Screw 14. Washer 15. Spacer 16. Fuel tank 17. Lock nut 18. Frame 19. Clinch nut 20. Bumper Page 4 – 16 21. Battery cable (+) 22.
Muffler and Bumper 3 2 4 5 6 7 9 8 10 1 11 12 11 15 13 14 Figure 30 1. Lock nut 2. Nut 3. Bumper 4. Screw 5. Bumper cap Groundsmaster 3000–D 6. Nut 7. Clinch nut 8. Rubber hanger 9. Spacer 10. Muffler guard Page 4 – 17 11. Screw 12. Flat washer 13. Muffler 14. Muffler clamp 15.
Hood 7 5 4 6 8 3 2 1 9 20 19 11 18 17 12 14 13 15 16 Figure 31 1. Decal 2. Latch handle 3. Decal 4. Side seal 5. Top seal 6. Rear screen 7. Tinnermann nut Peugeot TUD5 Engine 8. Toro logo plate 9. Pop rivet 10. Flat washer 11. Hair pin cotter 12. Decal 13. Hood 14. Screw Page 4 – 18 15. Foam strip 16. Clinch nut 17. Hood pivot 18. Clevis pin 19. Latch arm 20.
Center Shroud and Air Cleaner 2 3 1 4 5 24 6 26 20 7 8 9 29 10 11 28 15 27 23 30 19 14 13 12 21 18 17 16 Figure 32 1. Center shroud 2. ROPS 3. Foam strip 4. Hose clamp 5. Fuel hose 6. Fuel hose 7. Air cleaner hose 8. Hose clamp 9. Air cleaner 10. Hose clamp Groundsmaster 3000–D 11. Intake spacer 12. Air cleaner hose 13. Screw (Model 30302 only) 14. Washer (Model 30302 only) 15. Bar (Europe) 16. Nut 17. Decal – 4wd (Model 30302 only) 18. Screw 19. Flat washer 20. Screw Page 4 – 19 21.
Fan Bracket and Degasser 1 2 3 2 23 22 5 7 8 9 10 11 6 19 18 21 20 17 12 13 16 14 15 Figure 33 1. Hose 2. Hose clamp 3. Hose clamp 5. Screw 6. Lock nut 7. Screw 8. Lock nut Peugeot TUD5 Engine 9. Idler spacer 10. Idler pulley 11. Nut 12. Lever 13. Fan bracket 14. Screw 15. Carriage screw Page 4 – 20 16. Degasser bracket 17. Screw 18. Degasser hose 19. Hose 20. Nut 21. Radiator cap 22.
Radiator and Cooler 12 10 43 42 41 11 9 Pipe thread sealant 38 4 2 14 13 40 13 8 3 15 7 5 1 20 Pipe thread sealant 18 19 5 36 35 37 4 39 34 Peugeot Diesel Engine 13 44 Fan clearance minimum .18 inch (5 mm) 33 26 25 24 23 22 32 2 27 28 31 30 29 Figure 34 1. Upper radiator hose 2. Hose clamp 3. Hose 4. Hose clamp 5. Decal (Europe) 7. Spacer 8. Rubber grommet 9. Lock nut 10. Upper radiator support 11. Decal – starting fluid (Europe) 12. RH radiator support 13. Screw 14.
Engine 18 17 16 14 36 15 19 50 24 8 9 10 49 11 13 7 12 6 34 44 5 20 4 21 22 32 47 3 28 24 43 29 23 25 28 26 2 1 29 30 27 24 2 4 42 34 45 33 48 42 34 37 41 40 31 41 34 47 38 39 46 3 35 33 7 Figure 35 1. Front engine plate 2. Screw 3. Snubbing washer 4. Engine mount 5. Lower radiator hose 6. R.H. engine mount 7. Lock nut 8. Fuel hose 9. Hose clamp 10. Fuel hose 11. Engine 12. Bearing 13. Retaining ring 14. Screw 15. Fan hub 16. Fan hub 17. V–belt 18. Screw 19. Fan 20.
Peugeot TUD5 Overhaul, Checking Tuning See the Peugeot Citroen Moteurs TUD5 Overhaul, Checking, Tuning manual for detailed service informa tion. See the Toro Parts Catalog for parts indentification. Refer to the Special Tools list starting on Page 4 – 3 of the Toro Groundsmaster 3000/3000–D Service Manual. The tool numbers referred to in the Peugeot manual are Peugeot numbers, which Toro does not use.
Peugeot TUD5 Engine Page 4 – 24 Groundsmaster 3000–D
Chapter 5 Hydraulic System and Transaxle Table of Contents SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . Check Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . Check Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . Change Hydraulic Oil and Filter . . . . . . . . . . . . . . Traction Control Linkage . . . . . . . . . . . . . . . . . . . . . Brake Linkage . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Specification Transaxle Sauer–Sundstrand IHT–M15 Charge Pressure: 80 – 130 PSI (5.5 – 9 Bar) Implement Relief Pressure: 1,000 – 1,100 PSI (69 – 76 Bar) Traction Forward Pressure: 6,200 PSI (428 Bar) maximum Traction reverse pressure: 5,000 PSI (345 Bar) maximum Manifold Block Toro logic cartridge, elec./hyd.
General Information Pushing or Towing Traction Unit In an emergency, the traction unit can be pushed or towed. However, Toro does not recommend this as stan dard procedure. IMPORTANT: Do no push or tow the traction unit faster than 10 mph (16 km/hr). If traction unit must be moved a considerable distance, transport it on a truck or trailer. 1 1. Locate towing lever on right side of axle assembly. 2. Remove cotter pin and clevis pin securing lever to plate on side of axle. 3.
Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as, pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage condi tions or mishandling during operation or maintenance. These conditions can cause damage or premature dete rioration. Some hoses are more susceptible to these conditions than others. Inspect the hoses frequently for signs of deterioration or damage.
SAE Straight Thread O–Ring Port – Non–adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O–ring seal when this type of fitting shows signs of leakage. O–Ring 3. Lubricate the O–ring with a light coating of oil. 4. Install the fitting into the port and tighten it down full length until finger tight. 5. Tighten the fitting to the correct flats from finger tight (F.F.F.T.). Size 4 (1/4 in.
15CC VARIABLE PUMP Hydraulic System PF CHARGE PRESSURE PRIORITY VALVE RESERVOIR INLET FILTER PV CHARGE/ IMPLEMENT PUMP IHT–M15 TRANSAXLE Page 5 – 6 6.1 IN DISPLACEMENT 3 STEERING CONTROL UNIT IMPLEMENT CIRCUIT PRESSURE RELIEF VALVE ”EASY–RIDE” VALVES MV 25CC VARIABLE MOTOR R T T1 STEERING CYLINDER 1.625 BORE 7.00 STROKE .625 ROD L P PB P3 P2 T3 S T2 C3 S2 OFF OFF ON S1 ON OFF OFF SOLENOIDS OIL COOLER OUT S1 N1 G1 LC1 75–220 PSI ADJ ORIFICE STD .187 LIFT CYLINDERS 2.
15CC VARIABLE PUMP PV Groundsmaster 3000/3000–D Page 5 – 7 Rev. A A VARIABLE MOTOR OPTION DETAIL MV 25CC VARIABLE MOTOR SCREW CLOCKWISE TO MAX SETTING WITH HYD. KIT INSTALLED. 25CC FIXED MOTOR P2 T3 S DETAIL P3 R T 1000 PSI 5 PSI Hydraulic System Hydraulic System and Transaxle STEERING CYLINDER 1.625 BORE 7.00 STROKE .
Hydraulic Components Steering cylinder Oil cooler Manifold block Lift cylinder Lift cylinder Steering control unit Hydraulic System Page 5 – 8 Groundsmaster 3000/3000–D
Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may also be available from a local supplier. Hydraulic Pressure Test Kit – TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.
Hydraulic Tester – With Pressure and Flow Capabilities – TOR214678 Figure 10 You must have o–ring face seal (ORFS) adapter fittings for this tester to use it on the Workman vehicle. 1. INLET HOSE: Hose connected from the system cir cuit to the inlet side of the hydraulic tester. 2. LOAD VALVE: If required, upon turning the valve to restrict flow, a simulated working load is created in the circuit. 4.
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks. (See the Special Tools section in this Chapter.) 1. Thoroughly clean the machine before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. 2.
IMPORTANT: Test ports on the transaxle are painted closed. Opening the ports will loosen the paint. Make sure dirt or paint particles do not fall into the open port. Charge Pressure Test NOTE: See Sauer–Sundstrand IHT Service Manual for more information. Use a 500 or 1,000 PSI (35 or 70 Bar) test gauge. Specification: 80 to 130 PSI (5.5 to 9 Bar) 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 1 2.
Forward Traction Test NOTE: See Sauer–Sundstrand IHT Service Manual for more information. Use a 10,000 PSI (700 Bar) gauge. Specification: 6,200 PSI (428 Bar) maximum NOTE: When you move the traction pedal to create pressure, move it a short distance first and wait for a change in sound before moving the pedal further. The change in sound indicates that the easy ride valve has closed. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes.
Implement Relief Pressure Test NOTE: See Sauer–Sundstrand IHT Service Manual for more information. Use a 5,000 PSI (350 Bar) test gauge. 1 Specification:1,000 to 1,100 PSI (69 to 76 Bar) 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Lower cutting unit, engage parking brake and stop the engine. 3. Install a 5,000 PSI (350 Bar) pressure gauge with quick connect adapter on the test port. 4.
Counterbalance Pressure Test and Adjustment Use a 500 or 1,000 PSI (35 or 70 Bar) test gauge. Recommend counterbalance pressure: 84 inch decks: 220 PSI (15 Bar) 72 inch decks: 220 PSI (15 Bar) Contour 82 deck: 100 – 150 PSI (7 – 10 Bar) Brush: 225 PSI (16 Bar) Blower: 70 – 80 PSI (5 – 6 Bar) 2 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 1 2. Lower cutting unit, engage parking brake and stop the engine. Figure 17 1. Test Port 2.
Steering Circuit Test The steering and implement lift circuits are connected in series. If the implement lift operates correctly, the steer ing valve has adequate flow and pressure. 2. Lower cutting unit, engage parking brake and stop the engine. 3. Disconnect the tee from the cylinder. Install a cap on the cylinder and a plug on the open tee port. Cylinder Test This test checks the steering cylinder for internal bypass, and assumes that the steering valve is working correctly.
Auxiliary Hydraulic Pump Efficiency Test (Model 30726 Hydraulic Kit) A worn or damaged pump will by–pass oil and make the pump less efficient. Eventually, enough by–passing will occur to cause the cutting units to to stall in heavy cutting conditions. Continued operation with a worn, inefficient pump can generate a lot of heat and cause damage to seals and other components in the hydraulic system. 8 2 4 1 Use a tester with pressure and flow capabilities. 3 Specification: Minimum 12 GPM (45 liter/min.
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Adjustments Traction Pedal Linkage Adjustment Traction pedal to reach full stroke prior to contact with stop. 1. Park machine on a level surface, shut engine off and lower cutting unit to the floor. 2. Check pedal stop adjustment. Distance from top of stand to top of stop must be 1.25 in. (32 mm). Loosen jam nuts and adjust stop if required. 3. Loosen jam nut securing hub to rod. 4. Remove hair pin cotter and washer securing trac tion rod hub to lever rod on side of axle assembly. 5.
Service and Repairs Wheel and Tires Check Tire Pressure Check Wheel Nut Torque The tires are over–inflated for shipping. Therefore, re lease some of the air to reduce the pressure. Correct air pressure in the front and rear tires is 15 psi (1 Bar). IMPORTANT: Maintain even pressure in all tires to as sure a good quality–of–cut and proper machine perfor mance. DO NOT UNDER INFLATE.
Check Hydraulic Fluid The hydraulic system is designed to operate on anti– wear hydraulic fluid. The machines reservoir is filled at the factory with approximately 12 U.S. quarts (11.4 liters) of Mobil 424 hydraulic fluid. Check level of hydraulic fluid before engine is first started and daily thereafter. 1 1. Position machine on a level surface, raise the imple ment, and stop the engine. 2. Unscrew dipstick cap from the filler neck and wipe it with a clean rag.
Change Hydraulic Oil and Filter The hydraulic system oil and filter must be changed ini tially at 200 hours and thereafter every 800 hours of op eration or seasonally, whichever comes first. NOTE: Change oil and filters every 400 hours if equipped with Model 30726 Hydraulic Kit. The hydraulic system is de signed to operate on anti–wear hydraulic fluid. The ma chines reservoir is filled at the factory with approximately 12 U.S. quarts (11.
Traction Control Linkage 1 2 26 3 4 5 7 6 8 9 10 11 12 22 13 21 25 14 24 20 23 15 16 19 18 17 Figure 34 1. Carriage bolt 2. Traction lever 3. Rod end bearing 4. Jam nut 5. Control tube 6. Flat washer 7. Hair pin cotter 8. Hub 9. Rubber bushing Hydraulic System 10. Hub post 11. Lever 12. Lock nut 13. Lock nut 14. Screw 15. Pedal abrasive 16. Pedal abrasive 17. Traction pedal 18. Nut Page 5 – 24 19. Screw 20. Screw 21. Flange bushing 22. Pedal bracket 23. Grease fitting 24. Nut 25.
Brake Linkage 9 8 12 11 13 2 14 1 17 8 15 34 10 7 3 16 6 4 5 33 21 20 22 29 23 32 13 19 7 18 24 31 34 1 30 27 Hydraulic System and Transaxle 28 25 26 Figure 35 1. Control rod 2. Cotter pin 3. Carriage screw 4. Clevis pin 5. Jam nut 6. Clevis 7. Hair pin cotter 8. Bellcrank 9. Extension spring 10. Screw 11. R.H. pedal 12. Foot pad Groundsmaster 3000/3000–D 13. Lock nut 14. Foot pad 15. L.H. pedal 16. Screw 17. Nylon bushing 18. Retaining ring 19. Thrust washer 20.
Driveshafts 9 8 7 6 5 4 3 2 10 1 11 21 20 19 16 12 15 13 18 17 Never–seez 14 13 Figure 36 1. Screw 2. Cross and bearing kit 3. Slip yoke 4. Grease fitting 5. Yoke and shaft 6. Screw 7. Lock washer Hydraulic System 8. Flange yoke 9. Engine adapter plate 10. Lock nut (Model 30302) 11. Screw (Model 30302) 12. Clamp yoke (Model 30302) 13. Grease fitting (Model 30302) 14. Yoke and sleeve (Model 30302) Page 5 – 26 15. Yoke and shaft (Model 30302) 16. Cross & bearing kit (Model 30302) 17.
Lift Arms 11 9 6 8 66 ft–lb (9 Kgm) 12 7 20 5 13 4 3 250 ft–lb (35 Kgm) 2 Hydraulic System and Transaxle 19 1 Figure 37 1. Lift arm (L.H. shown) 2. Flange bushing 3. Nut 4. Grease fitting 5. Hydraulic cylinder 6. Bushing Groundsmaster 3000/3000–D 7. Cylinder spacer 8. Screw 9. Pin 11. Lock nut 12. Screw 13. Screw Page 5 – 27 14. Screw 19. Pivot spacer 20.
Steering Control 30 31 13 8 7 9 10 14 35 – 45 ft–lb (5 – 6 Kgm) 15 3 11 2 4 5 6 16 17 12 18 20 1 19 21 28 27 22 29 23 3 24 25 6 26 Figure 38 1. Tower housing 2. Tower decal 3. Screw 4. Screw 5. Spacer 6. Clinch nut 7. Tower decal 8. Steering column 9. Flange bushing 10. Washer Hydraulic System 11. Knob 12. Tower cover 13. Steering wheel 14. Nut 15. Flat washer 16. Foam collar 17. Steering seal 18. Retaining ring 19. Steering shaft 20. Vinyl cap Page 5 – 28 21.
#4 Tube ÄÄ ÅÅÅ ÉÉÉÉÉ ÄÄ ÅÅÅ ÉÉÉÉÉ ÁÁÁÁÁÁ ÀÀÀ ÄÄ ÅÅÅ ÉÉÉÉÉ ÁÁÁÁÁÁ ÀÀÀ ÄÄ ÅÅÅ ÉÉÉÉÉ ÁÁÁÁÁÁ ÀÀÀ ÄÄ ÅÅÅ ÉÉÉÉÉ ÁÁÁÁÁÁ ÀÀÀ ÄÄ ÅÅÅ ÉÉÉÉÉ ÁÁÁÁÁÁ ÀÀÀ ÉÉÉÉÉ ÄÄ ÅÅÅ ÁÁÁÁÁÁ ÀÀÀ ÅÅÅ ÉÉÉÉÉ ÄÄ ÁÁÁÁÁÁ ÀÀÀ ÄÄ ÅÅÅ ÀÀÀ ÀÀÀ #3 Tube #2 Tube #5 Tube #1 Tube #3 #5 #1 #2 Hydraulic System and Transaxle #4 Figure 39 Groundsmaster 3000/3000–D Page 5 – 29 Hydraulic System
Removing Hydraulic System Components 1. Thoroughly clean the machine before disconnecting, removing or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. 2. Put caps or plugs on any hydraulic lines or fittings left open or exposed. 3. Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed. 2. After repairs, check control linkage for proper adjust ment, binding or broken parts. 3.
Manifold Block 7 8 11 12 10 6 13 3 9 11 2 28 5 4 2 3 24 2 23 22 16 3 12 17 1 Torque to 35 ft–lb 15 (5 Kgm) Torque to 15 in–lb (17 Kg–cm) Apply Loctite 242 to threads 14 14 15 18 26 19 27 26 Hydraulic System and Transaxle 25 15 20 14 21 Figure 40 1. Body 2. O–ring 3. O–ring 4. Needle valve 5. Wheel 6. Set screw 7. Knob 8. Logic valve 9. Orifice plug (.187 dia.) 10. Cartridge – N.C. poppet 11. O–ring 12. Solenoid coil 13. Nut 14. Plug 15. O–ring 16. Nut 17. Cartridge – N.O.
Cartridge Valves 1. Clean valve block to prevent contamination when valve cartridge is removed. Cartridge Installation 1. Lubricate all o–rings with clean hydraulic oil. 2. Remove cartridge valve: 2. Carefully thread cartridge into the port by hand. Valve cartridge should go in easily without binding. A. Remove nut from solenoid. B. Remove solenoid coil and o–ring at each end of solenoid coil. C. Use a deep socket to remove cartridge valve.
Lift Cylinder 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Hydraulic System and Transaxle 15 Figure 42 1. Tube 2. Lock nut 3. Piston seal 4. Piston 5. Wear ring 6. O–ring 7. Rod 8. Bushing 9. O–ring 10. Backup washer 11. Head 12. Wiper 13. Retaining ring 14. Spacer 15. Retaining ring NOTE: Assembly kits are available for servicing this component. See the Parts Catalog for more information.
Steering Cylinder 1 2 3 4 5 6 7 8 9 10 11 12 19 13 14 15 16 18 17 Figure 43 1. Rod wiper 2. Threaded cap 3. Head 4. U–cup 5. Backup ring 6. Rod 7. O–ring 8. O–ring 9. Piston ring 10. O–ring 11. Piston 12. Wear ring 13. Lock nut 14. Barrel 15. Roll pin 16. Slotted nut 17. Tie rod end 18. Jam nut 19. Set screw NOTE: Assembly kits are available for servicing this component. See the Parts Catalog for more information.
Auxiliary Hydraulic Pump (Model 30726 Hydraulic Kit) 16 15:1 15 15:2 2 3 4 5 1 7 8:2 6 8 8:1 14 17 8:2 8 18 8:1 19 13 12:2 12 12:1 11:1 11 10 Hydraulic System and Transaxle 9 9:1 Figure 44 1. Hydraulic pump 2. Adapter 3. O–ring 4. Splined coupler 5. Internal snap ring 6. Screw 7. Lock nut Groundsmaster 3000/3000–D 8. Hydraulic fitting 9. Hydraulic fitting 10. Flush face fitting 11. Elbow fitting 12. Adapter 13. Hydraulic coupler 14. Hose Page 5 – 35 Rev. A 15. Hydraulic fitting 16.
Transaxle Service Some of the components shown in the Sauer–Sundstrand IHT Service Manual may not be used on the Toro application. See your Toro Parts Catalog for more information. Toro recommended fluids and maintenance intervals may be different than those listed in the Sauer–Sundstrand IHT Service Manual. When doing maintenance or service on the transaxle, use the Toro recommended fluids and maintenance intervals.
Chapter 6 Electrical System Table of Contents 50 Ampere Thermal Breaker (GM 3000–D) . . . . 16 Fuel Stop Solenoid (GM 3000–D) . . . . . . . . . . . . 17 Injection Advance Solenoid (GM 3000–D) . . . . . 18 Alternator (GM 3000–D) . . . . . . . . . . . . . . . . . . . . 19 Temperature Sender (GM 3000–D) . . . . . . . . . . . 20 Temperature Gauge (GM 3000–D) . . . . . . . . . . . 21 Oil Pressure Switch (GM 3000–D) . . . . . . . . . . . . 21 Temperature Sending Unit (GM 3000–D) . . . . . .
Electrical Schematics, Wiring Diagrams, and Harness Drawings All electrical schematics, diagrams, and drawings for both the Groundsmaster 3000 and Groundsmaster 3000–D are located in Chapter 14 – Electrical Dia grams.
Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may also be available from a local supplier. Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: Toro recommends the use of a DIGITAL Volt– Ohm–Amp multimeter when testing electrical circuits.
Troubleshooting (Groundsmaster 3000) For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Wiring Sche matics section of this chapter). CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage.
General Run and Transport Problems (Groundsmaster 3000) Problem Possible Causes Engine kills when the traction pedal is positioned to either forward or reverse. Operator is sitting too far forward on the seat (seat switch not depressed). Wiring to seat and shutdown delay circuits (see Wiring Schematics) is loose, corroded, or damaged. 2 ampere fuse, seat switch, or seat relay is faulty. Diode (D1) or shutdown delay relay is faulty. 20 ampere fuse to seat relay is blown. Battery does not charge.
Troubleshooting (Groundsmaster 3000–D) For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Wiring Sche matics section of this chapter). CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage.
General Run and Transport Problems (GM 3000–D) Problem Possible Causes Engine kills when the traction pedal is positioned to either forward or reverse. Operator is sitting too far forward on the seat (seat switch not depressed). Wiring to seat and shutdown delay circuits (see Wiring Schematics) is loose, corroded, or damaged. 7.5 ampere fuse, seat switch, or seat relay is faulty. Diode (D1) or shutdown delay relay is faulty. 20 ampere fuse to seat relay is open. Battery does not charge.
Electrical System Quick Checks Battery Test (Open Circuit Test) Note: This test provides a relative condition of the bat tery. Load testing of the battery will provide additional and more accurate information. 1. The battery temperature should be from 60_ to 100_ F. The ignition key should be off and all accessories turned off. 2. Set multimeter to the DC volts setting. Voltage Measured Battery Charge Level 12.68 V (or higher) Fully charged (100%) 12.45 V 75% charged 12.24 V 50% charged 12.
Component Identification and Testing For accurate resistance and/or continuity checks, elec trically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check). CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected. Ignition Switch A B S TORO The ignition (key) switch has three positions (OFF, START and RUN).
Diode Circuit Boards Each circuit board contains four diodes. The diodes are used for circuit protection from inductive voltage spikes, battery charging indication, and for safety circuit logic. Diodes D4 and D8 are not used. D2 On the GM 3000 wiring diagram, the diode circuit cards a designated P3 and P5. On the GM 3000–D wiring diagrams, the diode circuit cards are designated P7 and P5.
Neutral Switch This switch is closed when the traction pedal is in the neutral position. The switch and its electrical connector are located under the seat on the side of the transaxle. SWITCH 1. Make sure the engine is off. 2. Disconnect electrical connector from the switch. 3. Check the continuity of the switch by connecting a multimeter (ohms setting) across the connector termi nals. 4. With the traction pedal in the neutral position, there should be continuity between the terminals. Figure 9 5.
Hydraulic Valve Solenoids The hydraulic valve solenoids are located below the seat and on the hydraulic manifold block. 1 Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The me ter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal re sistance of the meter and test leads. Subtract this value from from the measured value of the component you are testing. 2 1. Make sure engine is off.
Cruise Control Coil (Optional) The cruise control coil is located below the seat. Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The me ter will display a small resistance value (usually 0.5 ohms or less). Subtract internal resistance of the meter and test leads from the measured value of the compo nent you are testing. 1. Make sure engine is off. Disconnect blue and violet wires to the coil. CRUISE CONTROL COIL 2.
Fuel Sender The sender is located on top of the fuel tank inside the center shroud area. GROUND WIRE 1. Remove blue wire and black ground wire from the sender. 2. Remove remaining screws and lock washers from the sender and fuel tank. 3. Remove sender and gasket from the fuel tank. Clean any fuel from the sender. BLUE WIRE Note: Before taking small resistance readings with a digital multimeter, short test leads together. The meter will display a small resistance value.
Relays and Fuses Relay Testing 87A 86 87 1. Verify coil resistance between terminals 86 and 85 with a multimeter (ohms setting). Resistance should be from 75 to 95 ohms. There should be continuity between terminals 87A and 30. 2. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as 12 VDC is ap plied and removed from terminal 85.
50 Ampere Thermal Breaker (GM 3000–D) This device operates as a thermal overload. After the device trips, time should be allowed for it to cool and re set. It is located near the starter. 1. Verify continuity between the two terminals. Conti nuity should be less than 1 ohm. THERMAL BREAKER Figure 23 Figure 24 Electrical System Page 6 – 16 Rev.
Fuel Stop Solenoid (GM 3000–D) The fuel stop solenoid is located on the front end of the injection pump, which is on the right side of the engine. Its has a black wire connected to it that leads to a con nector with a white and orange wire. The solenoid is powered from the white wire (Fig. 25). In Place Testing Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The me ter will display a small resistance value (usually 0.5 ohms or less).
Injection Advance Solenoid (GM 3000–D) The injection advance solenoid is located on top of the injector pump, which is on the right side of the engine. Its has two black wires connected to it. One wire leads to a connector with orange and white wires. The other wire is grounded to the injector pump. The solenoid is powered from the orange (top) wire (Fig. 52). In Place Testing CONNECTOR Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together.
Alternator (GM 3000–D) The alternator is belt driven with a internal regulator. It is located on the bottom right end of the engine. If either the alternator or the regulator is damaged, the entire unit must be replaced (Fig. 28). Note: Prior to testing the charging system, make sure the poly V–belt to the alternator is in good operation condition and adjusted properly (see Belt Adjustment in Chapter 4 – Peugeot Diesel Engine). Test Equipment Use a shunt capable of handling at least 70 ampere.
Temperature Sender (GM 3000–D) The temperature sender is located on the top right side of the water outlet box. It has a green connector with blue and black wires. The sender supplies a signal to the glow control unit (Fig. 31). TEMP SENDER CAUTION Make sure engine is cool and coolant system is depressurized before removing the thermistor. 1. Lower the coolant level in the engine and remove the thermistor from the water pump. Figure 31 2.
Temperature Gauge (GM 3000–D) The temperature gauge can be tested using a new gauge as a substitute or by the use of a DC voltage source and a variable resistance box. 150_F 220_F 1. Connect the temperature gauge to the variable re sistance and DC voltage source (Fig. 34). 2. Adjust resistance until the gauge needle points to following test points on the gauge (Fig. 34): A. At 220_F the resistance setting should be from 125.2 to 138.4 ohms. I VARIABLE RESISTANCE + B.
Temperature Sending Unit (GM 3000–D) The temperature sending unit is located on the top right side of the water outlet box, which is located on the front end of the engine block. It has a blue connector with gray and violet wires. The violet wire supplies a signal to the high coolant temperature relay from the switch compo nent of the sending unit. The gray wire supplies a signal to the temperature gauge from the thermistor compo nent of the sending unit (Fig. 36).
Transport Solenoid (GM 3000–D) The transport solenoid is located below the seat and on the front right side of the hydraulic housing. TO CONNECTOR Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The me ter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal re sistance of the meter and test leads. Subtract this value from from the measured value of the component you are testing. SOLENOID 1.
H2O in Fuel Sensor (GM 3000–D) The sensor is located on the fuel filter assembly, which is inside the center shroud area to the left side of the en gine. It energizes a red warning light when too much wa ter has collected in the fuel filter bowl (Fig. 42). FILTER ASSEMBLY 1. Make sure engine is OFF. Remove start relay from the control center. SENSOR 2. Disconnect connector from the sensor. Verify cir cuitry to the sensor at the connector using a multimeter and the following steps: A.
Coolant Level Sensor (GM 3000–D) The sensor is located on the degassing box, which is on the upper left end of the engine. It energizes a red warn ing light when coolant level in the degassing box and ra diator is to low (Fig. 44). PRESSURE PLUG CONNECTOR 1. Make sure engine is OFF. Remove start relay from the control center. DEGASSING BOX SENSOR DANGER Make sure engine and cooling system have cooled down prior to checking coolant system levels.
Indicator Lights and Circuits (GM 3000–D) Note: Individual light bulbs can be tested by removing them from the lighting cluster and applying 12 VDC to their wiring terminals (Fig 46). LOW OIL PRESSURE (RED) LOW WATER LEVEL (RED) Low Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running. Also, it should light with the engine running when the oil pressure drops below 7 PSI (0.48 Bar). BATT (AMBER) 1.
Glow Plug Indicator Light BACK OF GAUGE This light comes on when the glow control relay supplies power to the glow plugs. 1. Disconnect wire clip and pin connector (pins 1 to 7) from the pre/post heat relay. A F B E 2. Jumper from post # 8 (brass) on the glow control relay to female receptor # 5 (green wire) on the pin con nector. 3. The light should come on. Remove jumper from relay post and pin connector. 4. Connect pin connector and wire clip to the glow con trol relay.
Ford Engine (VSG–411) Electrical Component Locations (GM3000) Note: See the Ford VSG–411/413 Engine Service Manual for component testing information. The starter is located on the front end and lower right side of the engine block (Fig. 49). Figure 49 The alternator is located on the lower right side of the engine block and just forward of the radiator (Fig. 50).
The engine coolant temperature (ECT) sensor is lo cated on the bottom of the intake manifold, which is lo cated on the left side of the engine. It has a connector with green/white and gray/white wires (Fig. 52). Figure 52 The universal electronic spark control is located in side the black center shroud in the upper left corner (Fig. 53). Figure 53 Electrical System The variable reluctance sensor (VRS) is located on the front right end of the engine block behind the fly wheel and front engine plate.
Temperature Gauge (GM 3000) The temperature gauge can be tested using a new gauge as a substitute or by the use of a DC voltage source and a variable resistance box. 150_F 1. Connect the temperature gauge to the variable re sistance and DC voltage source (Fig. 34). 180_F ÄÄ ÄÄ 2. Adjust resistance until the gauge needle points to following test points on the gauge (Fig. NO TAG): G A. At 150_F the resistance setting should be from 113 to 123 ohms. S 240_F I B.
Oil Pressure Switch (GM 3000) The switch is located on the left side of the engine block above the oil filter. It is a normally closed switch when the engine is not running and opens with increasing oil pres sure. Testing with the Engine Off 1. Turn the ignition switch to ON. The oil pressure lamp should be on. 2. If the lamp does not come on in step 1 above no, dis connect the gray wire from the switch and ground it to the engine block. A. If the lamp comes on the switch is bad. Figure 58 B.
High Temperature Switch The high temperature switch is located on the top right side of the water pump, which is located on the rear end of the engine block. It has a connector which a gray wire (Fig. 59). CAUTION Make sure engine is cool before removing the temperature switch. 1. Lower the coolant level in the engine and remove the high temperature switch. Figure 59 2. Put the switch in a container of oil with a thermome ter and slowly heat the oil (Fig. 60).
Anti–Dieseling Valve Solenoid (GM 3000) The anti–dieseling valve solenoid is located on the right side of the carburetor, which is on the top rear end of the engine. Its has two white wires (Fig. 61 and 62). SOLENOID In Place Testing Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The me ter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal re sistance of the meter and test leads.
Indicator Lights and Circuits (GM 3000) Note: Individual light bulbs can be tested by removing them from the lighting cluster and applying 12 VDC to their wiring terminals (Fig 63). LOW OIL PRESSURE (RED) LOW WATER LEVEL (RED) Low Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running. Also, it should light with the engine running when the oil pressure drops below 7 PSI (0.48 Bar). 1.
Service and Repairs NOTE: See the Peugeot TUD5 Repair Manual or Ford VSG–411/413 Engine Service Manual for more compo nent repair information. Verify Interlock System Operation The machine has interlock switches in the electrical sys tem. These switches are designed to stop the engine when operator gets off the seat when traction pedal is depressed. However, operator may get off the seat while engine is running.
Battery Maintenance Check battery condition weekly or after every 50 hours of operation. Keep terminals and entire battery case clean because a dirty battery will discharge slowly. To clean the battery, wash the entire case with solution of baking soda and water. Rinse with clear water. Coat the battery posts and cable connectors with Grafo 112X (skin–over) grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion.
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extend. Additionally, battery and electrical component failure can be prevented. 6 7 3 4 WARNING When working with batteries, use extreme caution to avoid slashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries. 2 2 Electrolyte Specific Gravity Fully charged: 1.
E. Connect a battery load tester to the battery ter minals following the manufacturer’s instructions. Connect a digital multimeter to the battery terminals. 2. Conduct a hydrometer test of the battery electrolyte. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. A. Measure the specific gravity of each cell with a hydrometer. Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm– up the hydrometer.
6. Apply a light coat of grease on all battery posts and cable connectors to reduce corrosion after connections are made. 7. Connect a digital multimeter (set to amps) between the negative battery post and the negative (ground) cable connector. The reading should be less than 0.1 amp. If the reading is 0.1 amp or more, the unit’s electri cal system should be tested and repaired. 8. Connect the negative (ground) cable connector to the negative battery post.
Electrical System Page 6 – 40 Groundsmaster 3000/3000–D
Chapter 7 2WD Rear Axle Table of Contents 2 2 3 3 Wheel Lug Nut Torque . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Bearing Service . . . . . . . . . . . . . . . . . . . . . . . Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 4 5 2WD Rear Axle ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wheel Toe–in . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments Rear Wheel Toe–In After every 800 operating hours or annually, check rear wheel toe–in. 1. Measure center–to–center distance (at axle height) at front and rear of steering tires. Front measurement must be 1/8 in. (3 mm) less than rear measurement. 2. To adjust toe–in: A. Remove cotter pins and nuts securing ball joints to steering arms. Separate ball joint from arm. B. Loosen clamps at both ends of tie rod. 2 1 2 Figure 1 C. Rotate ball joints to move front of tire inward or outward. 1.
Service and Repairs Wheel and Tire Service Check Tire Pressure The tires are over–inflated for shipping. Therefore, re lease some of the air to reduce the pressure. Correct air pressure in the front and rear tires is 15 psi (1 Bar). IMPORTANT: Maintain even pressure in all tires to as sure a good quality–of–cut and proper machine perfor mance. DO NOT UNDER INFLATE.
Wheel Bearing Service Disassemble, clean, repack and adjust the rear wheel bearings after each 800 hours of operation. Use No. 2 general purpose lithium base grease containing E.P. ad ditive. If operating conditions are extremely dusty and dirty, it may be necessary to perform this maintenance more often. 10. Adjust preload on the wheel bearings. A. Tighten the jam nut to 75 – 80 in–lb (86 – 270 Kg– cm) while turning the hub to seat the bearings and remove all end play. B.
Rear Axle 9 49 7 1 2 3 4 5 6 8 34.5 in. (876 mm) installed 50 11 12 13 150 ft–lb (21 Kgm) 14 15 45 20 51 44 43 46 150 ft–lb (21 Kgm) 48 16 47 42 18 41 4 19 17 20 5 40 15 inch (38 mm) compressed length 8 21 22 23 24 25 26 39 27 28 29 30 38 37 36 35 34 33 70 – 80 ft–lb (10 – 11 Kgm) 31 32 1. Nut 2. R.H. spindle 3. Seal 4. Rod end 5. Grease fitting 6. Lock nut 7. Screw 8. Cotter pin 9. Screw 10. Axle pivot pin 11. Grease fitting 12. Spring pin 13. Axle pivot 14.
2WD Rear Axle Page 7 – 6 Groundsmaster 3000/3000–D
Chapter 8 4WD Rear Axle Table of Contents 2 2 3 3 3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Rear Axle Lubricant . . . . . . . . . . . . . . . . . . . Replace Rear Axle Lubricant . . . . . . . . . . . . . . . . . . Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4 4 5 4WD Rear Axle ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wheel Toe–in . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments Rear Wheel Toe–In After every 800 operating hours or annually, check rear wheel toe–in. 1. Measure center–to–center distance (at axle height) at front and rear of steering tires. Front measurement must be 1/8 in. (3 mm) less than rear measurement. 2. To adjust toe–in: A. Remove cotter pins and nuts securing ball joints to steering arms. Separate ball joint from arm. B. Loosen clamps at both ends of tie rod. 2 1 2 Figure 1 C. Rotate ball joints to move front of tire inward or outward. 1.
Service and Repairs Wheel and Tire Service Check Tire Pressure The tires are over–inflated for shipping. Therefore, re lease some of the air to reduce the pressure. Correct air pressure in the front and rear tires is 15 psi (1 Bar). IMPORTANT: Maintain even pressure in all tires to as sure a good quality–of–cut and proper machine perfor mance. DO NOT UNDER INFLATE.
Check Rear Axle Lubricant The rear axle reservoir uses Mobil 424 hydraulic fluid. Although the axle is shipped with lubricant from the factory, check the level before operating the machine. 1 1. Position the machine on a level surface. 2. Remove check plug from axle and make sure lubricant is up to bottom of hole. If level is low, add enough lubricant to bring the level up to the bottom of the check hole (Fig. 4). 2 Figure 4 1. Check Plug 2.
4WD Axle 11 8 9 10 34.5 in. (876 mm) installed 12 7 150 ft–lb (21 Kgm) 1 16 6 5 4 3 2 1 19 20 13 14 1 17 90 – 110 ft–lb (12 – 15 Kgm) 18 15 16 3 2 29 1 16 28 21 4 22 27 15 inch (38 mm) compressed length 26 23 25 24 70 – 80 ft–lb (10 – 11 Kgm) Figure 6 1. Nut 2. Seal 3. Rod end 4. Grease fitting 5. Screw 6. Flat washer 7. Lock nut 8. Screw 9. Axle pivot 10. Axle pivot pin 11. Grease fitting 12. Spring pin 13. Screw 14. Clamp and tube assy 15. Lock nut 16. Cotter pin 17.
1 2 3 9 8 4 5 6 7 10 11 12 13 14 15 19 16 18 17 23 10 9 24 8 27 26 8 25 24 22 21 23 20 Figure 7 1. Inboard yoke shaft 2. Cross and bearing kit 3. Double pivot yoke 4. Outboard yoke shaft 5. Washer 6. Retaining ring 7. Tapered bearaing 8. Screw 9. Kingpin cover 10. Kingpin trunnion 11. Belleville washer 12. L.H. spindle flange 13. Wheel hub 14. Washer 15. Nut 16. Dust cap 17. Wheel stud 18. Nut 19. Screw 20. Retaining ring 21. Lip seal 22. Journal bearing 23. Bearing cone 24.
13 11 14 12 15 16 16 15 11 10 9 8 7 14 17 6 17 5 4 3 2 1 21 20 19 18 22 Figure 8 1. Clutch housing 2. O–ring 3. Lip seal 4. Internal retaining ring 5. Thrust washer 6. Clutch 7. Clutch race 8. Needle bearing 9. Retaining ring 10. Ball bearing 11. Bushing 12. Breather vent 13. Axle housing 14. Plug 15. Bearing cup 16. Bearing cone 17. Differential 18. Screw 19. Side cover 20. O–ring 21. Differential shim kit 22.
4WD Rear Axle Page 8 – 8 Groundsmaster 3000/3000–D
84" Cutting Units Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport Latch Adjustment . . . . . . . . . . . . . . . . . . . Height of Cut Adjustment . . . . . . . . . . . . . . . . . . . . . Skid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti–Scalp Roller Adjustment . . . . . . . . . . . . . . . . . Deck Pitch Adjustment . . . . . . . . . . . . . . . . . . . . .
Specifications Type: 84 inch (2.1 m) width of cut, 5 blades, 3 blade cen ter section, and 2 one blade wings. Toro Recycler technology on Guardian Recycler. Mowing Rate: Mows up to 4.7 acres/hr (1.9 hectares/ hr) at 5.5 mph (8.8 km/hr). Trimming Ability: Deck is centered on tractor with 15 inches (38 mm) of over hang on each side. Uncut circle is 24.0 inches (610 mm) on both left and right with no brakes. Height Of Cut: 1–5 inches (25 to 127 mm) adjustable in 1/2 inch (13 mm) increments.
Adjustments 84 inch Cutting Units Transport Latch Adjustment 1. Start tractor and raise deck to highest possible posi tion and turn off engine. 2. Loosen (2) flange head capscrews securing latch plate to side of gearbox. 2 3. Rotate latch rod downward from front of traction unit. 1 4. Insert latch rod into rear hole (transport position) in latch plate. 5. Tighten flange head capscrews securing latch plate to gearbox. 6.
Height of Cut Adjustment The height–of–cut is adjustable from 1 to 5 inches (25 to 127 mm) in 1/2 inch (13 mm) increments. 1. Start engine and raise cutting unit. Stop engine after cutting unit is raised. 1 2. Remove front snapper pins from castor arms and slide castor wheel assembly up or down. 3. Insert snapper pin into castor arm and through groove in castor shaft to get desired height–of–cut. 4. Remove hair pin cotter and clevis pin securing height–of–cut chain to rear of deck. 5.
Skid Adjustment 84 inch Cutting Units Skids should be located in upper holes for 1 (25 mm) and 1–1/2 inch (38 mm) heights–of–cut and lower holes for 2 (51 mm) to 5 inch (127 mm) heights–of–cut. 1. Adjust skids by removing flange nuts, positioning as desired and re–installing flange nuts. 1 Figure 6 1. Skid Anti–Scalp Roller Adjustment Anti–scalp rollers should be located in upper holes for 1 (25 mm) and 1–1/2 inch (38 mm) heights–of–cut and lower holes for 2 (51 mm) to 5 inch (127 mm) heights– of–cut.
Deck Pitch Adjustment Deck pitch is the difference in height–of–cut from the front of the blade plane to the back of the blade plane. TORO recommends a blade pitch of .25 inches (6 mm). That is the back of the blade plane is .25 inches (6 mm) higher than the front. 2 1. Position machine on a level surface on shop floor. 2. Set deck to the desired height–of–cut. 1 3. Rotate one blade so it points straight forward. 4. Using a short ruler, measure from floor to front tip of blade.
Service and Repairs 84 inch Cutting Units 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 operating the cutting unit. 1. Position the machine and cutting unit on a level sur face. 2.
Lubricate Bearings, Bushings and Gear Box The cutting unit must be lubricated regularly. If machine is operated under normal conditions, lubricate castor bearings and bushings with No. 2 general purpose lithi um base grease or molybdenum base grease, after ev ery 8 hours of operation or daily, whichever comes first. Lubricate fittings immediately after every washing, re gardless of the interval listed. 1.
Disconnect Cutting Unit From Traction Unit 84 inch Cutting Units Note: Implements are heavy and may require two people to handle. 1. Start tractor and raise deck to highest possible position and turn off engine. 2. Remove hair pin cotter and clevis pin securing height–of–cut chains to rear height–of–cut brackets. 1 3. Rotate ignition key to run position and move lift lever forward to lower cutting unit. 4. Raise seat and open needle valve. This allows lift arms to float freely. 5.
Connect Cutting Unit to Traction Unit 1. Center traction unit in front of cutting unit on any flat hard surface. 2. Raise seat and open needle valve. This allows lift arms to float freely. 3. Adjust lift arms heights making sure that the machined surface on top of each traction unit lift arm is parallel to ground. (Raise or lower lift arm casting by pushing up or down from behind the front tires or using wrench in front of tractor) 1 4. Check for dirt and debris on mating parts and clean as required. 5.
Install Lift Arm Ball Joints 140 ft–lb (19 Kgm) then continue tightening until slot in nut aligns with cotter pin hole 1 84 inch Cutting Units 1. Adjust ball joint in each lift arm assembly until a dimension of 2.75 inches (70 mm) from end of lift arm to center of ball joint is attained. 2.75 in. (70 mm) 2 Figure 18 1. Ball Joint 2. Lift Arm Drive Belt Replacement The blade drive consists of three belts, one main drive belt and two wing belts.
Front Castor Fork Bushing Service The castor forks have bushings pressed into the top and bottom of the casting and after many hours of operation, the bushings will wear. To check the bushings, move castor fork back and forth and from side to side. If castor spindle is loose around the bushings, bushings are worn and must be replaced. 5 6 1. Start tractor and raise deck to highest possible posi tion and turn off engine. 2.
The castor wheel rotates on a high–quality roller bear ing. Even after many hours of use, provided that the bearing was kept well–lubricated, bearing wear will be minimal. However, failure to keep bearing lubricated will cause rapid wear. A wobbly castor wheel usually indi cates a worn bearing. 84 inch Cutting Units Castor Wheel and Bearing Service 60 – 80 ft–lb (8 – 11 Kgm) 1. Remove locknut from capscrew holding castor wheel assembly between castor fork.
Cutter Blade Removal and Installation The blade must be replaced if a solid object is hit, the blade is out–of–balance or if the blade is bent. Always use genuine TORO replacement blades to be sure of safety and optimum performance. Never use replace ment blades made by other manufacturers because they could be dangerous. 1. Raise cutting unit to highest position, shut the en gine off and engage the parking brake. 2 2.
Inspecting and Sharpening Blade 84 inch Cutting Units 1. Raise cutting unit to highest position, shut the en gine off and engage the parking brake. 2. Remove hair pin cotters and clevis pins securing height–of–cut straps to rear of deck. 3. Rotate front of deck upward and insert latch rod into front hole (service position) in latch plate. 4. Examine cutting ends of the blade carefully, espe cially where the flat and curved parts of the blade meet (Fig. 24–A).
Blade Spindle Service Removing Spindle Housing Assembly 1 1. Lower the cutting unit, shut the engine off and engage the parking brake. 85 – 110 ft–lb (12 – 15 Kgm) 2. Remove deck covers from top of cutting unit. Release belt tension. Remove belt from spindle to be serviced. Install seal with lip facing IN 2 3 4 6 3. Start the engine and raise the cutting unit. Turn the engine OFF and remove the key from the key switch. Block up the cutting unit so it cannot fall accidentally. 7 8 5 4.
IMPORTANT: If a new spindle housing is being used, new bearings and matched snap ring set must be installed; see step 1 below. Never use old bearings, spacer, and snap ring with a new spindle housing. If installing bearings into a used spindle housing that still has a snap ring installed, use only new bearings with cups and spacer – not the large snap ring because it is not required; see step 2 below. 11. Slide pulley end of spindle assembly through hole in cutting unit.
Correcting Cutting Unit Mismatch If there is mismatch between the blades, the grass will appear streaked when it is cut. This problem can be cor rected by making sure the blades are straight and all blades are cutting on the same plane. 1. Position machine on a level surface on the shop floor. 2. Release belt tension on belts. 3. Raise deck to transport position and lock transport latch. 4.
2 8 4 3 12 15 5 1 6 7 9:3 8 9:2 9 10 13 11 12 14 22 21 17 16 20 19 19:1 170 – 190 in–lb (196 – 219 Kgcm) Figure 31 1. Gearbox 2. Shroud 3. Lock nut 4. Drive shaft 5. Roll pin 6. Screw 7. Lock nut 8. Flat washer Groundsmaster 3000/3000–D 9. Gearbox mount 9:2. Lube decal 9:3. Threaded insert 10. Rubber mount 11. Screw 12. Screw 13. Rubber bumper 14. Rivet Page 9 – 19 15. Latch plate 16. Screw 17. Woodruff key 19. Taper lock bushing 19:1. Set screw 20. Gearbox pulley 21. Pop rivet 22.
4 15 14 13 2 16 12 1 17 9 4 11 5 3 5 2 18 20 21 7 19 8 10 6 22 23 2 Figure 32 1. Housing 2. Capscrew 3. Cap 4. Bearing cone 5. Bearing cup 6. R.H. gear 7. Bearing cup 8. Bearing cone 9. Spacer 10. Lower shaft 11. Upper seal 12. Cap 13. Gasket (.015) 14. Gasket (.005) 15. Gasket (.003) 16. Upper shaft 17. L.H. gear 18. Plug 19. Lower seal 20. Bearing cone 21. Bearing cup 22. Cap 23. Washer Shaft End Play Adjustment The lower shaft (Fig.
84 inch Cutting Units Drive Shaft 2 4 8 5 7 3 6 Figure 33 2. Yoke 3. U–joint kit 4. Slip yoke shaft Groundsmaster 3000/3000–D 5. Slip yoke tube 6. Yoke Page 9 – 21 7. Grease fitting 8.
84 inch Cutting Units Page 9 – 22 Groundsmaster 3000/3000–D
Chapter 10 Contour 82 Cutting Unit SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Height of Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Deck Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 7 Grease Bearings and Bushings . . . . . . . . . . . . . . . .
Specifications Deck Configuration: Out front deck with a right hand trim offset. Four individual chambers jointed for articulation. One blade per chamber. Cutting Width: 82 inches (2.1 m). Chamber Housing: 12 GA. steel, 4.5 inch (114 mm) deep, welded construction and reinforced with 10 GA high strength formed plates. Height–of–Cut (HOC): 1 inch (25 mm) to 4 inch (102 mm) by 1/4 inch (6 mm) increments. Blade Size: Four 22 inch (559 mm) long by 2.50 inch (64 mm) wide by .
Adjustments The height–of–cut is adjustable from 1 to 4 inches (25 to 102 mm) in 1/4 inch (6 mm) increments. 2 1. Start the engine and raise the cutting unit so height– of–cut can be changed. Stop engine after cutting unit is raised. 3 Front Castor Wheels 4 Contour 82 Cutting Unit Height of Cut Adjustment 1. Remove H.O.C. cap from spindle shaft and slide spindle out of front castor arm. Slide spacers onto spindle shaft to get desired height–of–cut. 4 2.
Rear Castor Wheels 1 1. Remove hairpin cotter and cotter pin securing rear castor pivot arm to deck bracket. 2. Align the pivot arm holes with selected height–of– cut bracket holes in the deck frame, install cotter pin and secure with hairpin cotter. Figure 4 1.
Rear Deck Chain 1. Remove hair pin cotter and clevis pin securing height–of–cut chain to chamber bracket. 2. Mount height–of–cut chain to desired height–of–cut hole with clevis pin and hair pin cotter. 3. Verify deck pitch on No. 3 chamber. Refer to Adjusting Deck Pitch. Contour 82 Cutting Unit 1 Figure 6 1.
Deck Pitch Adjustment Deck pitch is the difference in height–of–cut from the front of the blade plane to the back of the blade plane. For the Contour 82, TORO recommends a blade pitch of 7/16 inch (11 mm). That is the back of the blade plane is 7/16 inch (11 mm) higher than the front. 1. Position machine on a level surface on shop floor. 2. Set deck to the desired height–of–cut. 3. Rotate No. 3 chamber blade so it points straight forward. 1 4. Using a short ruler, measure from floor to front tip of blade.
Service and Repairs CAUTION Grease Bearings and Bushings The cutting unit must be lubricated regularly. If machine is operated under normal conditions, lubricate castor bearings and bushings with No. 2 general purpose lithium base grease or molybdenum base grease, after every 50 hours of operation. Lubricate fittings immediately after every washing, regardless of the interval listed. 1.
Disconnect Cutting Unit from Traction Unit Note: Implements are heavy and may require two people to handle. 1. Start traction unit and raise deck to highest possible position and turn off engine. 2. Remove hair pin cotter and clevis pin securing height–of–cut chain to rear height–of–cut brackets on chamber 3. 1 3. Rotate ignition key to run position and move lift lever forward to lower cutting unit. 4. Raise seat and open needle valve. This allows lift arms to float freely. 5.
Connect Cutting Unit to Traction Unit 1. Center traction unit in front of cutting unit on any flat hard surface. 3. Adjust lift arms heights making sure that the machined surface on top of each traction unit lift arm is parallel to ground (Fig. 12). (Raise or lower lift arm casting by pushing up or down from behind the front tires or using wrench in front of traction unit) Contour 82 Cutting Unit 2. Raise seat and open needle valve. This allows lift arms to float freely. 1 4.
Front Castor Fork Bushing Service The castor forks have bushings pressed into the top and bottom of the chamber and after many hours of operation, the bushings will wear. To check the bushings, move castor fork back and forth and from side to side. If castor spindle is loose around the bushings, bushings are worn and must be replaced. 1 1. Lock transport levers, raise cutting unit to highest position, shut the engine off and engage the parking brake. 2 2.
Castor Wheel and Bearing Service 1. Lock transport levers, raise cutting unit to highest position, shut the engine off and engage the parking brake. 60 – 80 ft–lb (8 – 11 Kgm) 1 2 Contour 82 Cutting Unit 2. Remove locknut from capscrew holding castor wheel assembly between front castor fork (Fig. 18) or rear castor pivot arm (Fig. 19) Grasp castor wheel and slide capscrew out of fork or pivot arm. 2. Remove bearing from wheel hub and allow bearing spacer to fall out.
Cutting Blade Removal and Installation The blade must be replaced if a solid object is hit, the blade is out–of–balance or if the blade is bent. Always use genuine TORO replacement blades to be sure of safety and optimum performance. Never use replacement blades made by other manufacturers because they could be dangerous. 1. Lock transport levers, raise cutting unit to highest position, shut the engine off and engage the parking brake. 3 2 85 – 110 ft–lb (12 – 15 Kgm) 2.
Inspecting and Sharpening Blade 1. Lock transport levers, raise cutting unit to highest position, shut the engine off and engage the parking brake. Contour 82 Cutting Unit 2. Examine cutting ends of the blade carefully, especially where the flat and curved parts of the blade meet (Fig. 21–A). Since sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check the blade before using the machine. If wear is noticed (Fig.
Correcting Cutting Unit Mismatch If there is mismatch between the blades, the grass will appear streaked when it is cut. This problem can be corrected by making sure the blades are straight and all blades are cutting on the same plane. 1. Raise the height–of–cut to the highest position and lower deck to the floor. 2. Position machine on a level surface on the shop floor. 3. Shut engine off and engage the parking brake. Unlock transport levers. 4.
Chamber Pivot Service If cutting unit chamber pivot assemblies should ever have to be separated for service or repair, use the following procedure. 1 1. Pivot assembly dis–assembly. A. Remove capscrews and nut from pivot casting. Contour 82 Cutting Unit B. Loosen capscrew locking eccentric cam in place. C. Using a 1/2 inch (13 mm) diameter drive pin, drive pilot pin 3/8 inch (10 mm) to 1/2 inch (13 mm) into pivot casting. D. Slide pivot assembly out of chamber housing. 2.
3. Pivot assembly re–assemble. A. Press ball joints into pivot casting. Bottom ball joint first. 3 B. Insert and orientate grease fittings to face upward. C. Install retaining rings on back side of ball joints. D. Clean any debris, oil, or dirt from tapered joints on span casting and tapered sleeve. Any nicks should be filed off. E. Install pivot casting into chamber housing with spacer plate on top and bottom of pivot casting. 2 6 F.
4. Adjustment of Chamber Pivots. A. Set deck to its maximum height of cut: 4 inches (102 mm). 3 B. Place the deck on a level surface with the lock and lift cables in the unlocked position. D. Use two 1–1/4 inch wrenches on the eccentric cam to rotate simultaneously. Verify that identification mark on top of each eccentric cam is facing forward. 2 E. Rotate adjacent blades until cutting edge tips are aligned directly across from each other as shown in figure 27. 6 4 F.
Lift Arm Ball Joint Installation Lift arm ball joints have been adjusted at the factory. The proper setting of left hand ball joint is 1.75 inch (45 mm) from end of lift arm to center of tapered stud (Fig. 28). The proper setting of right hand ball joint is 2.09 inch (53 mm) from end of lift arm to center of tapered stud (Fig. 29). These distances can be adjusted if deck alignment to traction unit is off or if the deck rubs against traction tires.
Hydraulic Motor and Blade 5 1 6 2 Contour 82 Cutting Unit 7 3 4 8 9 10 85 – 110 ft–lb (12 – 15 Kgm) 11 12 Figure 30 1. Motor 2. O–ring 3. Spindle Assy 4. Support plate Groundsmaster 3000/3000–D 5. Screw 6. Washer 7. Locknut 8. Screw Page 10 – 19 Rev. C 9. Blade 10. Anti scalp cup 11. Hardended washer 12.
Blade Spindle Service Disassembly 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 6 131 to 159 ft–lb (178 to 216 N–m) 2 Chamfer side down 2. Remove two cap screws that secure hydraulic motor to the cutting unit. Remove hydraulic motor and O–ring from deck (Fig. 30). 4 8 1 10 3. Start the engine and raise the cutting unit. Stop engine and remove key from the ignition switch.
IMPORTANT: If new bearings will be installed into a used spindle housing that has the original large snap ring installed, discard the snap ring that came with the new bearings because it is not necessary to replace the original snap ring. However, new bearings with their matched spacer set and snap ring must always be installed when the spindle housing is being replaced. Replacement bearings are sold only with a matched snap ring and spacer set. These parts cannot be purchased separately. 1.
Hydraulic Assembly 1 2:1 2 2:2 1:1 3 4 4:1 5 Hydraulic Flow Direction Inlet Outlet Case drain 2 6:2 6 6:1 7 8 12:1 12 11 11:1 11 11:1 11:2 9:2 10 9 9:1 Figure 34 1. Hose 1:1 O–ring 2. Hydraulic fitting 2:1. O–ring 2:2. O–ring 3. Coupler 4. Hose 5. Coupler 6. Hydraulic fitting 6:1. O–ring 6:2. O–ring 7. Hose 8. Hose 9. Hydraulic fitting 10. Hose 11. Tee 11:1. O–ring 11:2. O–ring 12. Hydraulic fitting 12:1. O–ring NOTE: See Chapter 5 – Hydraulic System for hydraulic test information.
Chapter 11 72I Cutting Units SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport Latch Adjustment . . . . . . . . . . . . . . . . . . . Height of Cut Adjustment . . . . . . . . . . . . . . . . . . . . . Skid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti–Scalp Roller Adjustment (Rear Discharge) . . Gage Wheel Adjustment (Guardian Recycler) . . . Deck Pitch Adjustment . . . . . . .
Specifications Type: 72 inch (1.8 m) width of cut, 3 blades. Height Of Cut: 1 to 5 inches (25 to 127 mm) adjustable in 1/2 inch (13 mm) increments. Front adjustment is with snapper pin and grooves in castor shaft. Rear adjust ment is with hanger brackets and pin. Construction: Housing is made of 12 gauge steel and reinforced with 2–1/2 inch x 10 gauge angle. Cutter Drive: Gear box mounted on cutting unit is driven by PTO shaft. Power is transmitted to the blades by one hex B section belt.
Adjustments Transport Latch Adjustment 1. Start tractor and raise deck to highest possible posi tion and turn off engine. 2 2. Loosen (2) flange head capscrews securing latch plate to side of gearbox. 3. Rotate latch rod downward from front of traction unit. 1 4. Insert latch rod into rear hole (transport position) in latch plate. 6. Loosen latch plate flange head capscrews and ad just latch plate position if required. 7. Tighten flange head capscrews securing latch plate to gearbox.
Height of Cut Adjustment The height–of–cut is adjustable from 1 to 5 inches (25 to 127 mm) in 1/2 inch (13 mm) increments. 1. Start engine and raise cutting. Stop engine after cut ting unit is raised. 1 2. Remove front snapper pins from castor arms and slide castor wheel assembly up or down. 3. Insert snapper pin into castor arm and through groove in castor shaft to get desired height–of–cut. 4. Remove hair pin cotter and clevis pin securing height–of–cut chain to rear of deck. 5.
Skid Adjustment 1. Adjust skids by loosening flange nuts, positioning as desired and re–tightening flange nuts. 1 72 inch Cutting Units 2 Figure 8 (Rear Discharge) 1. Skid 2. Flange nut 1 2 Figure 9 (Guardian Recycler) 1. Skid 2.
Gage Wheel Adjustment (Rear Discharge Cutting Unit) Note: If cutting unit is to be used in the 1 inch (25 mm) height–of–cut setting, cutting unit gage wheels must be positioned in highest position. 1. Adjust gage wheels by loosening locking hub, posi tioning gage wheel support at desired height and re– tightening locking hub. Make sure gage wheel support pins are positioned in holes in deck. 2 3 1 Figure 10 1. Gage wheel 2. Gage wheel support 3.
Deck Pitch Adjustment Deck pitch is the difference in height–of–cut from the front of the blade plane to the back of the blade plane. TORO recommends a blade pitch of .25 inches (6 mm). That is the back of the blade plane is .25 inches (6 mm) higher than the front. 2 1. Position machine on a level surface on shop floor. 2. Set deck to the desired height–of–cut. 1 3. Rotate (1) blade so it points straight forward. 4. Using a short ruler, measure from floor to front tip of blade.
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 operating 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.
Grease Bearings, Bushings and Gear Box The cutting unit must be lubricated regularly. If machine is operated under normal conditions, lubricate castor bearings and bushings with No. 2 general purpose lithium base grease or molybdenum base grease, after every 8 hours of operation or daily, whichever comes first. Lubricate fittings immediately after every washing, regardless of the interval listed. 1.
Disconnect Cutting Unit From Traction Unit Note: Implements are heavy and may require two people to handle. 1. Start tractor and raise deck to highest possible position and turn off engine. 2. Rotate ignition key to run position and move lift lever forward to lower cutting unit. 1 3. Remove hair pin cotters and clevis pins securing height–of–cut chains to rear height–of–cut brackets. 4. Raise seat and open needle valve. This allows lift arms to float freely. 5.
Connect Cutting Unit to Traction Unit 2. Raise seat and open needle valve. This allows lift arms to float freely. 3. Adjust lift arms heights making sure that the ma chined surface on top of each traction unit lift arm is par allel to ground (Fig. 17). (Raise or lower lift arm casting by pushing up or down from behind the front tires or us ing wrench in front of tractor) 4. Check for dirt and debris on mating parts and clean as required. 5. Turn castor wheels so they point straight forward. 6.
Drive Belt Replacement The blade drive belt, tensioned by the spring loaded idler, is very durable. However, after many hours of use, the belt will show signs of wear. Signs of a worn belt are: squealing when belt is rotating, blades slipping when cutting grass, frayed edges, burn marks and cracks. Re place the belt if any of these conditions are evident. 2 1 1. Lower cutting unit to the shop floor. Remove belt covers from top of cutting unit and set covers aside. 2.
Front Castor Fork Bushing Service 5 6 1. Start tractor and raise deck to highest possible posi tion and turn off engine. 2. Remove front snapper pins from castor arms and slide castor wheel assembly out of castor arm tube. 3. Remove locknut from capscrew holding castor wheel assembly between castor fork. Grasp castor wheel and slide capscrew out of fork. 1 6 3 4 4. Remove retaining ring, washer and wavey washer securing castor shaft to castor fork. Remove shaft from fork. 2 5.
Castor Wheel and Bearing Service The castor wheel rotates on a high–quality roller bear ing. Even after many hours of use, provided that the bearing was kept well–lubricated, bearing wear will be minimal. However, failure to keep bearing lubricated will cause rapid wear. A wobbly castor wheel usually indi cates a worn bearing. 60 – 80 ft–lb (8 – 11 Kgm) 1. Remove locknut from capscrew holding castor wheel assembly between castor fork. Grasp castor wheel and slide capscrew out of fork. 2.
Cutter Blade Removal The blade must be replaced if a solid object is hit, the blade is out–of–balance or if the blade is bent. Always use genuine TORO replacement blades to be sure of safety and optimum performance. Never use replace ment blades made by other manufacturers because they could be dangerous. 1. Raise cutting unit to highest position, shut the en gine off and engage the parking brake. 2 2. Remove hair pin cotters and clevis pins securing height–of–cut chains to rear of deck.
Inspecting and Sharpening Blade 1. Raise cutting unit to highest position, shut the en gine off and engage the parking brake. 2. Remove hair pin cotters and clevis pins securing height–of–cut chains to rear of deck. 3. Rotate front of deck upward and insert latch rod into front hole (service position) in latch plate. 4. Examine cutting ends of the blade carefully, espe cially where the flat and curved parts of the blade meet (Fig. 25–A).
Blade Spindle Service Removing Spindle Housing Assembly 1 2 1. Lower the cutting unit, shut the engine off and engage the parking brake. 85 – 110 ft–lb (12 – 15 Kgm) 2. Remove deck covers from top of cutting unit. Release belt tension. Remove belt from spindle to be serviced. Install seal with lip facing IN 3 4 5 3. Start the engine and raise the cutting unit. Turn the engine OFF and remove the key from the key switch. Block up the cutting unit so it cannot fall accidentally. 6 7 15 8 4.
IMPORTANT: If a new spindle housing is being used, new bearings and matched snap ring set must be installed; see step 1 below. Never use old bearings, spacer, and snap ring with a new spindle housing. If installing bearings into a used spindle housing that still has a snap ring installed, use only new bearings with cups and spacer – not the large snap ring because it is not required; see step 2 below. 11. Slide pulley end of spindle assembly through hole in cutting unit.
Correcting Cutting Unit Mismatch 1. Using a 3 foot (1 m) long carpenters level, find a lev el surface on the shop floor. 2. Raise height–of–cut to the highest position: refer to Adjusting Height–Of–Cut. 3. Lower cutting unit onto flat surface. Remove covers from top of cutting unit. 4. Unhook spring from idler arm bracket to release belt tension. 5. Rotate blades until the ends face forward and back ward. Measure from floor to front tip of cutting edge and remember this dimension.
Gearbox 27 29 3 4 5 28 6 1 2 1 25 7 8 26 21 22 24 9 23 10 11 20 12 19 17 18 13 14 7 15 16 170 – 190 in–lb (196 – 219 Kgcm) 16:1 Figure 32 1. Screw 2. Latch plate 3. Flat washer 4. Gear box 5. Screw 6. Shield 7. Nut 8. Flat washer 9. Rubber mount 10. Screw 72 inch Cutting Units 11. Rivet 12. Rubber bumper 13. Belt 14. Flat washer 15. Gear box pulley 16. Taper lock bushing 16:1. Screw 17. Torque decal 18. Blade bolt decal (Europe) 19. Gearbox mount Page 11 – 20 20. Screw 21.
4 15 14 13 2 16 12 1 17 9 4 11 5 3 5 2 72 inch Cutting Units 18 20 21 7 19 8 10 6 22 23 2 Figure 33 1. Housing 2. Capscrew 3. Cap 4. Bearing cone 5. Bearing cup 6. R.H. gear 7. Bearing cup 8. Bearing cone 9. Spacer 10. Lower shaft 11. Upper seal 12. Cap 13. Gasket (.015) 14. Gasket (.005) 15. Gasket (.003) 16. Upper shaft 17. L.H. gear 18. Plug 19. Lower seal 20. Bearing cone 21. Bearing cup 22. Cap 23. Washer Shaft End Play Adjustment The lower shaft (Fig.
Drive Shaft 2 4 8 5 7 3 6 Figure 34 2. Yoke 3. U–joint kit 4. Slip yoke shaft 72 inch Cutting Units 5. Slip yoke tube 6. Yoke Page 11 – 22 7. Grease fitting 8.
Chapter 12 Electrical Diagrams Table of Contents 3 3 4 5 6 7 8 9 Groundsmaster 3000–D Electrical Schematics, Wiring Diagrams, and Harness Drawings . . . . . . 10 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . 10 Start Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Run Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Wiring Diagram (Rear Section) . . . . . . . . . . . . 13 Wiring Diagram (Front Section) . . . . . . . . . . . .
Electrical Diagrams Page 12 – 2 Groundsmaster 3000/3000–D
FLOAT/HOLD SOLENOID (SV2) LIGHT ALTERNATOR PINK RED BLUE WHITE BLUE VIOLET LIFT LEVER POSITION Y FLOAT/HOLD DIODE (D2) SWITCH VIOLET SV1 SV2 LIFT ON OFF HOLD OFF OFF LOWER/FLOAT OFF ON DIODE (D8) 1 VIOLET + 1 VIOLET WHITE 4 ANTI–DIESELING VALVE SOLENOID HI TEMP SWITCH GRAY 6 7 HI TEMP 8 PINK WHITE ENGINE COOLANT TEMPERATURE SENSOR (ECT) 5 R LIGHT LIFT/XBAL SOLENOID (SV1) PINK GRAY HI TEMP OIL PRESSURE SWITCH OVERRIDE GREEN OPTIONAL CRUISE CONTROL R SWITCH PI
FLOAT/HOLD SOLENOID (SV2) LIGHT ALTERNATOR PINK RED BLUE WHITE BLUE VIOLET LIFT LEVER POSITION Y FLOAT/HOLD DIODE (D2) SWITCH VIOLET + 1 PINK WHITE ENGINE COOLANT TEMPERATURE SENSOR (ECT) SWITCH GRAY HI TEMP 8 R LOWER/FLOAT OFF ON DIODE (D5) LIFT/XBAL PINK GRAY HI TEMP OIL PRESSURE SWITCH OVERRIDE RELAY SWITCH GREEN OPTIONAL CRUISE CONTROL R CRUISE RELAY TAN 9 PINK PINK PINK TAN TAN CRUISE SEAT RELAY VIOLET DIODE (D6) SWITCH 3 TAN 5 G BLUE PINK DISTRIBUTORLE
FLOAT/HOLD SOLENOID (SV2) LIGHT ALTERNATOR PINK RED BLUE WHITE BLUE VIOLET LIFT LEVER POSITION Y FLOAT/HOLD DIODE (D2) SWITCH VIOLET + 1 WHITE VIOLET 4 PINK WHITE ENGINE COOLANT TEMPERATURE SENSOR (ECT) HI TEMP SWITCH 7 HI TEMP 8 R SWITCH LOWER/FLOAT OFF ON DIODE (D5) LIFT/XBAL PINK GRAY HI TEMP OIL PRESSURE SWITCH OVERRIDE GREEN OPTIONAL CRUISE CONTROL R SWITCH PINK PINK PINK TAN TAN CRUISE SEAT RELAY VIOLET DIODE (D6) SWITCH 3 TAN 5 G BLUE PINK GREEN IGN
P3 P4 FLOAT/HOLD LIFT/XBAL COIL COIL STARTER J12 J8 B P7 PTO COIL P6 SEAT SWITCH B 1 2 A P8 SERVICE BRAKE B A WIRE IDENTIFICATION B W26 W32 W30 W31 W6 W11 W32 W29 ALTERNATOR P9 LABEL W1 W2 W3 W4 W5 W6 W7 W8 W9 W10 W11 W16 W17 W18 W19 W20 W21 W22 W24 W25 W26 W27 W28 W29 W30 W31 W32 W33 W28 W27 W26 W25 W24 W10 W22 W21 S1 W18 W33 A W20 J13 A W19 2 B W18 1 W17 A W16 P10 FORD ECM B W9 W33 P12 CHARGE CIRCUIT PROTECTION A P5 NEUTRAL SWITCH W9 W30 W8 J9 COLOR BL
P5 DIODE PACK 1 3 1 W10 3 W33 2 2 4 5 J15 J16 W46 W55 W28 W11 W60 W15 W60 W29 W59 W42 W61 2 3 W34 W32 W18 W31 W30 W29 5 W35 6 W63 7 W54 8 W64 P10 CRUISE SWITCH E3 W27 E4 W26 E5 W25 W24 8 4 W22 7 3 W21 6 2 W6 5 1 W16 B START RELAY F1 W19 F2 F5 W18 W14 W17 F4 W16 G1 W15 W13 W14 W8 G2 PTO RELAY G5 G4 STARTER ”B” TERMINAL 2 W66 3 W46 4 W67 5 LABEL W1 W2 W3 W4 W5 W6 W7 W8 W9 W10 W11 W12 W13 W14 W15 W16 W17 W18 W19 W20 W21 W22 W23 W24 W25 W2
J6 P3 FLOAT/HOLD SOLENOID OIL PRESSURE BA BA P5 NEUTRAL SWITCH AB P7 PTO COIL P6 SEAT SWITCH CARB SOLENOID 1 2 J5 ”S1” W18 W20 W26 W30 W31 GROUND J11 BA LIFT/XBAL SOLENOID P4 ALTERNATOR J7 J13 P9 BA TEMP SWITCH J4 SERVICE BRAKE SWITCH P8 J10 J9 CRUISE COIL J3 TEMP SENDER CHARGE CIRCUIT PROTECTION A B P12 1 P10 2 FORD ECM FUEL SENDER STARTER J1 J2 A B C D H G F E A B C D E + + + + + + + + + + J12 P13 HARNESS INTERFACE + + + + + + + + J8 B A K J H G F Groundsmaster 3
5 6 3 1 2 4 7 8 5 5 F 1 4 1 3 4 3 2 E 2 4 3 1 5 1 G 5 INPUT POWER J1 CONVENIENCE CENTER P4 4 3 2 D 2 H 5 5 2 Y S 2 1 HOUR METER 3 2 6 1 K B 5 4 J 2 J3 J12 + + X 5 P6 P9 2 3 5 4 1 3 J2 J5 + 3 FLOAT/HOLD SWITCH 1 4 4 J4 C 5 SEAT CAPACITOR 1 + + B + 3 1 4 1 3 A 4 DECK CAPACITOR PTO SWITCH 2 IGNITION SWITCH WARNING LIGHT CLUSTER 6 P11 12 J13 J14 3 4 5 6 3 2 3 A 1 2 ACCESSORY P8 IMPLEMENT BA J18 P13 P12 LIGHT KIT LIFT/XB
LIGHT DIODE (D2) RED BLUE WHITE PINK VIOLET FLOAT/HOLD SOLENOID (SV2) Y ALTERNATOR LIFT LEVER POSITION FLOAT/HOLD SWITCH SV1 SV2 LIFT ON OFF HOLD OFF OFF LOWER/FLOAT OFF ON VIOLET BLUE DIODE (D8) FUEL STOP SOLENOID VIOLET 1 BLUE RED 2 PREHEATING UNIT VIOLET BLUE WHITE TEMP SENDER BLUE WHITE 3 IMPLEMENT FLOAT RELAY PINK PINK PINK HIGH TEMP SWITCH TAN 4 DIODE (D5) LIFT/XBAL SWITCH LIFT/XBAL SOLENOID (SV1) LIGHT GREEN R 80A OIL PRESSURE SWITCH OPTIONAL CRUISE CON
LIGHT DIODE (D2) RED WHITE PINK BLUE VIOLET FLOAT/HOLD SOLENOID (SV2) Y ALTERNATOR LIFT LEVER POSITION FLOAT/HOLD SWITCH SV1 SV2 LIFT ON OFF HOLD OFF OFF LOWER/FLOAT OFF ON VIOLET BLUE DIODE (D8) FUEL STOP SOLENOID VIOLET 1 BLUE RED 2 PREHEATING UNIT VIOLET BLUE WHITE TEMP SENDER BLUE WHITE 3 IMPLEMENT FLOAT RELAY PINK PINK PINK HIGH TEMP SWITCH TAN 4 DIODE (D5) LIFT/XBAL SWITCH LIFT/XBAL SOLENOID (SV1) LIGHT GREEN R 80A OIL PRESSURE SWITCH OPTIONAL CRUISE CON
LIGHT DIODE (D2) RED BLUE WHITE PINK VIOLET FLOAT/HOLD SOLENOID (SV2) Y ALTERNATOR LIFT LEVER POSITION FLOAT/HOLD SWITCH SV1 SV2 LIFT ON OFF HOLD OFF OFF LOWER/FLOAT OFF ON VIOLET BLUE DIODE (D8) RED FUEL STOP SOLENOID VIOLET 1 BLUE 2 PREHEATING UNIT VIOLET BLUE WHITE TEMP SENDER BLUE WHITE 3 IMPLEMENT FLOAT RELAY PINK PINK PINK HIGH TEMP SWITCH TAN 4 DIODE (D5) LIFT/XBAL SWITCH LIFT/XBAL SOLENOID (SV1) LIGHT GREEN R 80A OIL PRESSURE SWITCH OPTIONAL CRUISE CON
P19 CHARGE CIRCUIT PROTECTION P16 FLOAT/HOLD COIL STARTER P11 SEAT SWITCH P12 PTO COIL A A 1 A B 2 P13 SERVICE BRAKE B A B W32 W31 W30 W29 W28 W27 W26 W24 W14 W22 THERMAL BREAKER W30 W37 S3 W13 W45 J5 B W25 W18 B P18 NEUTRAL SWITCH W24 W17 A P17 LIFT/XBAL COIL W23 W16 J8 W22 W49 J7 W21 3 W20 2 W19 1 W14 B W49 A W48 J6 WIRE IDENTIFICATION P6 COOLANT LEVEL SENSOR W33 A P5 INJECTION ADVANCE 1 2 J14 W34 W10 B P14 DECK POSITION SWITCH W15 W48 W36
WIRE IDENTIFICATION P5 DIODE PACK A 2 3 1 P1 PTO SWITCH 3 1 2 4 5 J15 J16 W69 W62 W28 W11 W68 W15 W68 W85 W67 E5 1 W38 TEMP RELAY Y W34 W66 E4 X W47 HIGH COOLANT B W66 W24 W65 E3 A W64 D1 S W7 D2 J14 W63 D5 J13 W5 W60 W17 W65 W62 TRANSPORT RELAY J12 W61 D4 J11 J10 W59 W60 W57 C1 J9 W59 W56 C2 W51 FUEL GAUGE J8 W58 C5 W50 J7 W57 W54 IMPLEMENT FLOAT RELAY W49 J6 H W56 W52 C4 G W55 B1 F W54 W53 B2 TEMP GAUGE E W52 CRUISE RELAY D P4 I
P18 NEUTRAL SWITCH P16 FLOAT/HOLD SOLENOID P12 PTO COIL BA BA AB THERMAL BREAKER J6 J7 X X X X X X X X X X X X X X P11 SEAT SWITCH J5 1 STARTER 2 J8 ”S3” D W22 J3 GLOW PLUGS BA W24 J13 GROUND W30 W37 1 2 W45 P17 LIFT/XBAL SOLENOID AB P2 TEMPERATURE SWITCH SENDER P14 DECK POSITION SWITCH P15 TRANSPORT SOLENOID P19 CHARGE CIRCUIT PROTECTION P13 SERVICE BRAKE SWITCH AB BA 2 1 P5 INJECTION ADVANCE 2 1 A B P3 THERMISTER 3 2 1 J10 CRUISE COIL J9 P6 LOW COOLANT LEVEL ”S1” B A
5 6 7 8 J18 ACCESSORY 1 2 3 4 5 5 E 4 1 3 F 1 3 4 2 25 5 D 4 1 G 3 1 3 4 2 2 5 5 PTO SWITCH 2 B Y S 1 3 2 25 A 1 + + 3 4 + + + 4 5 B 1 4 J SEAT CAPACITOR J2 J3 IGNITION SWITCH + C 4 1 H 1 3 HOUR METER 2 2 5 6 1 4 K 1 2 3 4 5 6 J13 J12 P12 P11 3 4 DECK CAPACITOR J4 J5 WARNING LIGHT CLUSTER WARNING LIGHT CLUSTER 1 2 3 4 5 6 5 X P1 P4 J14 3 6 P2 FLOAT/HOLD SWITCH 1 2 3 3 A 2 3 1 2 BA P16 IMPLEMENT P15 KIT LIGHT P3 LIFT/X