Toro 3000 - Manual - manualsarea.com

Page 3 - Table Of Contents

Table Of Contents Chapter 1 – Safety Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 4 Chapter 2 – Product Records and Maintenance Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 –...

Page 5 - Contour 82 Cutting Unit

Table of Contents (continued) Chapter 9 – 84 I Cutting Units Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 2Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 3Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 9 – 7 Chapte...

Page 7 - Chapter 1; Safety; Table of Contents; CAUTION; Safety

Chapter 1 Safety Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Instructions The GROUNDSMASTER R 3...

Page 8 - While Operating

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...

Page 9 - Maintenance

24. Do not touch engine, muffler, or radiator while en gine is running or soon after it has stopped. These areas could be hot enough to cause a burn. 25. Lower the cutting unit or other attached implement to the ground and remove key from switch whenever machine is left unattended. 26. Before getti...

Page 10 - Safety and Instruction Decals

Safety and Instruction Decals (Groundsmaster 3000) ible, install a new decal. Part numbers are listed below or in your parts catalog. (Part No. 67–1710) The following safety and instruction decals are mounted on the traction unit. If any decal becomes damaged or illeg On Side of Tool Box Next to Ri...

Page 15 - Recycler Cutting Unit)

Safety and Instruction Decals (Guardian 72 I Recycler 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. Safety On Front of Cutting Unit On ...

Page 19 - Chapter 2; Product Records and Maintenance; OPERATION AND SERVICE HISTORY REPORTS 9; Product Records

Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1 EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2 Decimal and Millimeter Equivalents . . . . . . . . . . . . 2 U.S. to Metric Conversions . . . . . . . . . . . . . . . . ...

Page 20 - Equivalents and Conversions

Equivalents and Conversions Product Records and Maintenance Page 2 – 2 Groundsmaster 3000/3000–D

Page 21 - Torque Specifications

Groundsmaster 3000/3000–D Page 2 – 3 Product Records and Maintenance Product Records and Maintenance Torque Specifications

Page 23 - Lubrication; Traction Unit; Wheel Drive Models only–

Groundsmaster 3000/3000–D Page 2 – 5 Product Records and Maintenance Lubrication Traction Unit CAUTION Before servicing or making adjustments to themachine, stop engine and remove key from theswitch. The machine has grease fittings that must be lubricatedregularly with No. 2 General Purpose Lithium ...

Page 24 - Cutting Units; Recyler Cutting Unit; Figure 7

Cutting Units 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, rega...

Page 25 - Figure 8; Cutting Unit; Figure 9

Rear Discharge 84 I Cutting Unit Figure 8 Contour 82 I Cutting Unit Figure 9 Product Records and Maintenance Groundsmaster 3000/3000–D Page 2 – 7 Product Records and Maintenance

Page 27 - Transmission Numbers:

_____________________________ _____________________________ EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for GROUNDSMASTER R 3000 TORO Model and Serial Number: ______________–______________ Engine Numbers: _____________________________ Transmission Numbers: _____________________________ Drive Axle...

Page 28 - Groundsmaster; Minimum Recommended Maintenance Intervals; Annual Recommendations:

Groundsmaster R 3000 Maintenance Schedule Minimum Recommended Maintenance Intervals 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 } Change Engin...

Page 29 - Daily Maintenance Check For Week Of; Notation for areas of concern:

Groundsmaster R 3000 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 Maintenance Check Item b Daily Maintenance Check For Week Of _____...

Page 30 - 000 Supervisor Maintenance W; – Service Required; Other –; A, B and C – Service Required

________________________________ _______________________________ _______________________________ ________________________________ __________________________ ________________________________ _______________________________ _______________________________ _______________________________ ______________...

Page 33 - Item

Groundsmaster R 3000–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 Maintenance Check Item b Daily Maintenance Check For Week Of ___...

Page 34 - A–Level Service Required; 000–D Supervisor Maintenance W; and B – Service Required

________________________________ _______________________________ _______________________________ ________________________________ ________________________________ ________________________________ _______________________________ _______________________________ _______________________________ ________...

Page 35 - Cooling System Service; Ford Gasoline

Chapter 3 Ford VSG–411 Engine Table of Contents GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Cooling System Service 8 . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General Air Cleaner Service 9 . . . . . . . . ...

Page 37 - Adjustments; Belt Adjustments; Alternator Belt; Figure 1; Cooling & Governor Fan Belts; Tighten mounting nuts to secure adjustment.

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. To adjust belt t...

Page 38 - Governor Adjustment; guard against possible personal; WARNING; Rotate throttle arm closed until it contacts stop.; MPORTANT: Do not over speed the engine because; Carburetor too rich or too lean.; MPORTANT: Never rotate anti–surge screw in too; Figure 2; Figure 3

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...

Page 39 - Service and Repairs; Check Engine Oil; Figure 4; Single Viscosity Oils; Outside Temperature; Multi–Viscosity Oils; Figure 5

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. ...

Page 40 - Change Engine Oil and Filter

Change Engine Oil and Filter Change oil and filter initially after the first 50 hours of operation, 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 ...

Page 41 - Check Coolant; If engine has been running, pressurized

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. The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol an...

Page 42 - – Remove debris from rear; Maintaining Cooling System; – Capacity of the

Cooling System Service 1. Removing Debris – Remove debris from rear screen, oil cooler and radiator daily, clean more frequently 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 thoroughly. B. Release hood l...

Page 43 - Never operate machine without complete air; Service Air Cleaner; Washing Method; Compressed Air Method

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 f...

Page 44 - Disconnect elbow fitting from rear of fuel 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...

Page 46 - Servicing Spark Arrestor Muffler; Remove pipe plug from clean–out port at lower side; Start engine. Plug the normal muffler exit with block; Stop engine and replace pipe plug.

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 wi...

Page 47 - Chapter 4; Peugeot TUD5 Engine

Chapter 4 Peugeot TUD5 Engine Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . 14 SPECIAL TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Priming Fuel System . . . . . . . ...

Page 48 - Specifications

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 Peug...

Page 49 - Special Tools; Valve Spring Compression Tool (TOR4024T); Use for removing valve springs.

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) Use for removing valve springs. Figure 4 ...

Page 50 - Figure 6; NOTE: This tool is not included in TOR4080 kit.; Peugeot TUD5 Diesel Engine Service Tool Kit (TOR4080); See the following pages for

Injection Nozzle Tester (TOR463610) When used along with the adapter, TOR437580, injection nozzles may be examined by performing the following tests: – Injection pressure test. – Chattering test. – Nozzle leakage test. – Spray test. Figure 6 Digital Belt Tension Tool (TOR4075) Tool is used to accu...

Page 54 - Engine Belts; on the belt midway between the pulleys, when pressed

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 ...

Page 55 - Peugeot Diesel

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....

Page 56 - Add 15W–40 CE oil to crankcase. Capacity is 4.75

Change Engine Oil and Filter Change oil and filter initially after the first 50 hours of operation, 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...

Page 57 - Check Cooling System; Coolant level should be up to or above tabs In de-; hot coolant can escape and cause burns

Check Cooling System 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 de- gasser tank, when engine is cold. If engine ...

Page 59 - General Air Cleaner Maintenance; Servicing the Air Cleaner

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 (mo...

Page 60 - Fuel System Service; Drain and clean fuel tank every 800 hours of operation or; DANGER; Place a clean container under fuel filter.

Fuel System Service Drain and clean fuel tank every 800 hours of operation or if fuel system becomes contaminated or if machine is to be stored for an extended period. Use clean fuel to flush out the tank. DANGER Because diesel fuel is highly flammable, Do not smoke while filling the fuel tank. Do n...

Page 61 - Priming Fuel System; Unlatch and raise hood.

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. 1. Unlatch and raise hood. 2. Insert a 3/16 inch (5 mm) hose over bleed screw and run other end into a conta...

Page 62 - Frame, Fuel Tank and Battery

Groundsmaster 3000–D Page 4 – 16 Peugeot TUD5 Engine Frame, Fuel Tank and Battery 33 34 36 37 38 39 1 2 3 4 5 6 7 8 9 10 16 17 18 21 22 23 24 25 26 27 29 30 31 32 11 12 13 14 15 44 28 19 35 20 40 19 41 30 42 43 26 Figure 29 1. Bushing 11. Stand pipe 21. Battery cable (+) 2. Fuel hose 12. Fuel hose 2...

Page 63 - Muffler and Bumper

Groundsmaster 3000–D Page 4 – 17 Peugeot TUD5 Engine Muffler and Bumper 1 2 3 4 5 7 8 9 6 10 15 11 12 11 13 14 1 Figure 30 1. Lock nut 6. Nut 11. Screw 2. Nut 7. Clinch nut 12. Flat washer 3. Bumper 8. Rubber hanger 13. Muffler 4. Screw 9. Spacer 14. Muffler clamp 5. Bumper cap 10. Muffler guard 15....

Page 64 - Hood

Hood 2 4 3 6 7 8 9 12 13 14 15 16 17 19 18 1 5 11 20 Figure 31 1. Decal 8. Toro logo plate 15. Foam strip 2. Latch handle 9. Pop rivet 16. Clinch nut 3. Decal 10. Flat washer 17. Hood pivot 4. Side seal 11. Hair pin cotter 18. Clevis pin 5. Top seal 12. Decal 19. Latch arm 6. Rear screen 13. Hood 20...

Page 65 - Center Shroud and Air Cleaner

Groundsmaster 3000–D Page 4 – 19 Peugeot TUD5 Engine Center Shroud and Air Cleaner 1 2 3 4 5 6 7 8 9 10 18 11 12 13 16 17 20 19 14 15 21 25 23 24 28 27 26 29 30 Figure 32 1. Center shroud 11. Intake spacer 21. Tube cover (Model 30301 only) 2. ROPS 12. Air cleaner hose 22. Screw 3. Foam strip 13. Scr...

Page 66 - Fan Bracket and Degasser

Fan Bracket and Degasser 1 2 3 5 6 7 8 9 10 16 17 18 19 11 12 13 14 15 20 22 21 2 23 Figure 33 1. Hose 9. Idler spacer 16. Degasser bracket 2. Hose clamp 10. Idler pulley 17. Screw 3. Hose clamp 11. Nut 18. Degasser hose 5. Screw 12. Lever 19. Hose 6. Lock nut 13. Fan bracket 20. Nut 7. Screw 14. Sc...

Page 67 - Radiator and Cooler

Peugeot Diesel Engine Rev. A Groundsmaster 3000–D Page 4 – 21 Peugeot TUD5 Engine Radiator and Cooler 30 31 32 33 1 2 3 4 5 7 8 9 10 18 19 20 5 22 23 24 25 26 27 28 29 11 12 13 4 2 34 35 36 37 38 39 13 40 41 43 42 14 15 13 44 Fan clearanceminimum .18 inch (5 mm) Pipe threadsealant Pipe threadsealant...

Page 68 - Engine; NOTE: See the Toro Parts Catalog for more information.

Groundsmaster 3000–D Page 4 – 22 Peugeot TUD5 Engine Engine 1 2 3 4 5 6 7 8 9 11 17 18 19 20 21 22 23 24 25 26 27 28 29 30 12 49 14 15 16 2 3 4 7 48 41 34 31 33 34 35 34 33 24 38 39 40 42 43 10 41 37 44 45 42 46 34 36 24 47 47 13 50 32 29 28 Figure 35 1. Front engine plate 17. V–belt 33. Lock nut 2....

Page 69 - Peugeot TUD5 Overhaul, Checking Tuning; Refer to the; list starting on Page 4 – 3 of

Peugeot TUD5 Overhaul, Checking Tuning See the Peugeot Citroen Moteurs TUD5 Overhaul, Checking, Tuning manual for detailed service information. 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 ...

Page 71 - Chapter 5; Hydraulic System and Transaxle; Hydraulic System

Chapter 5 Hydraulic System and Transaxle Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 21 GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Check Tire Pressure . . . . . . . . . ....

Page 73 - General Information; Pushing or Towing Traction Unit; Locate towing lever on right side of axle assembly.

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 standard 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 dis...

Page 74 - O–Ring Face Seal; Lubricate the O–ring with a light coating of oil.; Finger Tight

Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as, pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions or mishandling during operation or maintenance. These conditions can cause damage or premature deterioration. Som...

Page 76 - Hydraulic Schematic

LIFT/LOWER CONTROL LIFT SOLENOIDS S1 S2 ON OFF Groundsmaster 3000/3000–D Page 5 – 6 Hydraulic System L PB P R T 6.1 IN DISPLACEMENT 3 STEERING CYLINDER S2 CYL1 CYL2 2.5” BORE 3.5” STROKE 1” ROD N1 S1 LC1 75–220 PSI P S OIL COOLER OUT LIFT/ COUNTERBALANCE MANIFOLD 1.625 BORE 7.00 STROKE .625 ROD T–23...

Page 77 - and T

Hydraulic System Groundsmaster 3000/3000–D Page 5 – 7 Hydraulic System Hydraulic Schematic L R T 6.1 IN DISPLACEMENT STEERING CYLINDER S2 CYL1 CYL2 2.5” BORE 3.5” STROKE 1” ROD N1 S1 G1 1000 PSI S OUT 1.625 BORE 7.00 STROKE .625 ROD LC1 75–220PSI P T2 T1 5 PSI T3 P2 P3 C3 SUNDSTRAND IHT IDLE 1650 RP...

Page 78 - Hydraulic Components

Groundsmaster 3000/3000–D Page 5 – 8 Hydraulic System Hydraulic Components Lift cylinder Steering cylinder Oil cooler Steeringcontrol unit Manifold block Lift cylinder

Page 79 - NOTE: Order special tools from the; Hydraulic Pressure Test Kit – TOR47009; Hydraulic Test Fitting Kit – TOR4079; Measuring Container – TOR4077

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 provi...

Page 80 - Hydraulic Tester – With Pressure and Flow Capabilities – TOR214678

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 circuit to the inlet side of the hydraulic tester. 2. LOAD VALVE: If re...

Page 81 - Testing; Check the oil level in the reservoir.

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.) CAUTION dures could result in damage to ga...

Page 82 - Charge Pressure Test; Charge Pressure Priority Valve Test

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 ga...

Page 83 - Forward Traction Test; Reverse Traction Test

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 1. Make sure hydraulic oil is at normal operating temper-ature by operating the machine for approximately 10 minutes. 2. Lower cuttin...

Page 84 - Implement Relief Pressure Test; quick connect adapter on the test port.

Implement Relief Pressure Test NOTE: See Sauer–Sundstrand IHT Service Manual for more information. Use a 5,000 PSI (350 Bar) test gauge. Specification: 1,000 to 1,100 PSI (69 to 76 Bar) 1. Make sure hydraulic oil is at normal operating temper-ature by operating the machine for approximately 10 minut...

Page 85 - Counterbalance Pressure Test and Adjustment; gauge with quick connect adapter on the test port.

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) 1. Mak...

Page 86 - Steering Circuit Test; Cylinder Test

Steering Circuit Test The steering and implement lift circuits are connected in series. If the implement lift operates correctly, the steering valve has adequate flow and pressure. Cylinder Test This test checks the steering cylinder for internal bypass, and assumes that the steering valve is worki...

Page 87 - Auxiliary Hydraulic Pump Efficiency Test; Use a tester with pressure and flow capabilities.

Groundsmaster 3000/3000–D Page 5 – 17 Hydraulic System Auxiliary Hydraulic Pump Efficiency Test (Model 30726 Hydraulic Kit) A worn or damaged pump will by–pass oil and make thepump less efficient. Eventually, enough by–passing willoccur to cause the cutting units to to stall in heavy cuttingconditio...

Page 90 - Traction Pedal Linkage Adjustment; Service Brake Adjustment; Back off clevis one full turn and reinstall to bellcrank.

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). L...

Page 91 - Wheel and Tires; Check Tire Pressure; Maintain even pressure in all tires to as

Service and Repairs Wheel and Tires Check Tire Pressure Check Wheel Nut Torque The tires are over–inflated for shipping. Therefore, release 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 a...

Page 92 - Check Hydraulic Fluid; The following fluids are recommended for use:

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 hy- draulic fluid before engine is first started and daily the...

Page 93 - Change Hydraulic Oil and Filter; Check level of hydraulic; Lubricate new filter seal and install filter.

Change Hydraulic Oil and Filter The hydraulic system oil and filter must be changed initially at 200 hours and thereafter every 800 hours of operation or seasonally, whichever comes first. NOTE: Change oil and filters every 400 hours if equipped with Model 30726 Hydraulic Kit. The hydraulic system...

Page 94 - Traction Control Linkage

Traction Control Linkage 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 21 22 23 24 25 11 13 14 15 26 12 19. Screw 20. Screw 21. Flange bushing 22. Pedal bracket 23. Grease fitting24. Nut25. Roll pin26. Flat washer 1. Carriage bolt2. Traction lever 3. Rod end bearing4. Jam nut5. Control tube6. Flat washer7. Ha...

Page 95 - Brake Linkage

Groundsmaster 3000/3000–D Page 5 – 25 Hydraulic System Brake Linkage 1 3 4 5 6 7 8 9 11 16 17 8 18 19 1 20 21 23 24 27 28 29 30 31 10 12 13 14 15 2 13 33 32 7 25 26 22 34 34 Figure 35 1. Control rod 13. Lock nut 25. L.H. brake lever 2. Cotter pin 14. Foot pad 26. Roll pin 3. Carriage screw 15. L.H. ...

Page 96 - Driveshafts

Groundsmaster 3000/3000–D Page 5 – 26 Hydraulic System Driveshafts 2 3 4 5 6 7 8 9 10 16 17 18 11 12 13 14 13 1 19 15 20 21 Never–seez Figure 36 1. Screw 8. Flange yoke 15. Yoke and shaft (Model 30302) 2. Cross and bearing kit 9. Engine adapter plate 16. Cross & bearing kit (Model 30302) 3. Slip...

Page 97 - Lift Arms

Lift Arms 1 2 3 4 5 20 7 8 9 19 11 12 13 6 66 ft–lb (9 Kgm) 250 ft–lb (35 Kgm) Figure 37 1. Lift arm (L.H. shown) 7. Cylinder spacer 14. Screw 2. Flange bushing 8. Screw 19. Pivot spacer 3. Nut 9. Pin 20. Bushing 4. Grease fitting 11. Lock nut 5. Hydraulic cylinder 12. Screw 6. Bushing 13. Screw Hyd...

Page 98 - Steering Control

Groundsmaster 3000/3000–D Page 5 – 28 Hydraulic System Steering Control 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 21 22 23 24 25 26 27 28 11 12 13 14 15 3 29 6 30 31 35 – 45 ft–lb(5 – 6 Kgm) Figure 38 1. Tower housing 11. Knob 21. Parking brake rod 2. Tower decal 12. Tower cover 22. Extension spring 3. Sc...

Page 100 - Removing Hydraulic System Components; After Repair or Replacement of Components

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 expose...

Page 101 - Manifold Block

Manifold Block 27 1 2 3 4 5 6 7 8 9 10 19 20 21 15 11 12 13 14 2 3 11 15 14 15 16 12 18 14 17 22 23 24 25 26 26 2 3 28 15 in–lb (17 Kg–cm) Apply Loctite 242 to threads 35 ft–lb (5 Kgm) Torque to Torque to Figure 40 1. Body 11. O–ring 21. Plug 2. O–ring 12. Solenoid coil 22. O–ring 3. O–ring 13. Nut ...

Page 102 - Cartridge Valves; Clean and check for proper valve operation:; Cartridge Installation; Lubricate all o–rings with clean hydraulic oil.

Cartridge Valves 1. Clean valve block to prevent contamination when valve cartridge is removed. 2. Remove cartridge valve: 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. NOTE: Use care when handling valve ...

Page 103 - Lift Cylinder

Lift Cylinder 1 2 3 4 5 9 6 7 8 10 11 13 12 14 15 Figure 42 1. Tube 6. O–ring 11. Head 2. Lock nut 7. Rod 12. Wiper 3. Piston seal 8. Bushing 13. Retaining ring 4. Piston 9. O–ring 14. Spacer 5. Wear ring 10. Backup washer 15. Retaining ring NOTE: Assembly kits are available for servicing this compo...

Page 104 - Steering Cylinder

Steering Cylinder 1 2 3 4 5 6 7 8 9 10 16 17 18 19 11 12 13 14 15 Figure 43 1. Rod wiper 8. O–ring 15. Roll pin 2. Threaded cap 9. Piston ring 16. Slotted nut 3. Head 10. O–ring 17. Tie rod end 4. U–cup 11. Piston 18. Jam nut 5. Backup ring 12. Wear ring 19. Set screw 6. Rod 13. Lock nut 7. O–ring 1...

Page 105 - Auxiliary Hydraulic Pump

Hydraulic System and T ransaxle Rev. A Groundsmaster 3000/3000–D Page 5 – 35 Hydraulic System Auxiliary Hydraulic Pump (Model 30726 Hydraulic Kit) 1 2 3 4 5 6 7 8 9 10 16 17 18 19 11 12 13 14 15 8 15:2 15:1 8:1 8:2 12:2 12:1 11:1 9:1 8:1 8:2 Figure 44 1. Hydraulic pump 8. Hydraulic fitting 15. Hydra...

Page 106 - Transaxle Service

Groundsmaster 3000/3000–D Page 5 – 36 Hydraulic System Transaxle Service Toro recommended fluids and maintenance intervalsmay be different than those listed in the Sauer–Sunds-trand IHT Service Manual. When doing maintenance orservice on the transaxle, use the Toro recommendedfluids and maintenance ...

Page 107 - Chapter 6; COMPONENT IDENTIFICATION AND TESTING . . 9; Electrical System

Chapter 6 Electrical System Table of Contents ELECTRICAL SCHEMATICS, WIRING DIAGRAMS, AND HARNESS DRAWINGS . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TROUBLESHOOTING (Groundsmaster 3000) . . . . 4 Starting Problems (GM 3000) . . . . ....

Page 109 - Multimeter

Special Tools Order special tools from the TORO SPECIAL TOOLS Some tools may also be available from a local supplier. AND APPLICATIONS GUIDE (COMMERCIAL PROD-UCTS). Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: Toro recommends the use of ...

Page 110 - Troubleshooting

Troubleshooting (Groundsmaster 3000) CAUTION Remove all especially rings and watches, before doing any electrical trouble- cables unless the test requires battery voltage. jewelry, shooting or testing. Disconnect the battery For effective troubleshooting and repairs, you must have a good understandi...

Page 111 - General Run and Transport Problems; Cutting Unit Operating Problems; Problem

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 Schemat...

Page 114 - Electrical System Quick Checks; Voltage Measured; Glow Plug System Test; proper

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...

Page 115 - Component Identification and Testing; OR

Component Identification and Testing For accurate resistance and/or continuity checks, electrically 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 continu-ity with a m...

Page 116 - Diode Circuit Boards

DIODE Diode Circuit Boards Each circuit board contains four diodes. The diodes are D2 used for circuit protection from inductive voltage spikes, battery charging indication, and for safety circuit logic. D4 D6 Diodes D4 and D8 are not used. D8 On the GM 3000 wiring diagram, the diode circuit cards D...

Page 117 - Neutral Switch; no; Seat Switch; Electrical

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. 1. Make sure the engine is off. 2. Disconnect electrical connector from the switch. 3. Check the continuity of the...

Page 118 - Hydraulic Valve Solenoids; Prior to taking small resistance readings with a; Hour Meter; Remove electrical connections from meter.

Hydraulic Valve Solenoids The hydraulic valve solenoids are located below the seat and on the hydraulic manifold block. Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0.5 ohms or less...

Page 119 - ten for PTO clutch to engage.

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 meter will display a small resistance value (usually 0.5 ohms or less). Subtract internal resistance of the...

Page 120 - Fuel Sender; Fuel Gauge; Before taking small resistance readings with a

Fuel Sender The sender is located on top of the fuel tank inside the center shroud area. 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 sende...

Page 121 - Relays and Fuses; Relay Testing; Fuse Testing; less than 1 ohm; Relay and Fuse Location

Relays and Fuses The relays and fuses and are located in the compartment that is rear of the control panel (Fig. 18). There is an 80 ampere fuse (50 ampere on the GM 3000) located by the alternator (Fig. 22). Relay Testing 1. Verify coil resistance between terminals 86 and 85 with a multimeter (ohm...

Page 122 - 0 Ampere Thermal Breaker

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 reset. It is located near the starter. 1. Verify continuity between the two terminals. Continuity should be less than 1 ohm . THERMAL BREAKER Figure 2...

Page 123 - Fuel Stop Solenoid; In Place Testing; Live testing

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 connector with a white and orange wire. The solenoid is powered from the white wire (Fig. 25). In P...

Page 124 - Injection Advance Solenoid

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....

Page 125 - Alternator; Test Equipment

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...

Page 126 - Check resistance of the sender with a multimeter.

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). CAUTION 1. Lower the coolant level in the engine and remove the thermis...

Page 127 - Temperature Gauge; F the resistance setting should be from; Oil Pressure Switch; Testing with the Engine Off; A. If the lamp comes on the switch is bad.; Testing with the Engine On; Disconnect the gray wire from the switch.

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. 1. Connect the temperature gauge to the variable resistance and DC voltage source (Fig. 34). 2. Adjust resistance until the gauge n...

Page 128 - Make sure engine is cool and coolant system is; Check continuity of the switch component with a

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 rel...

Page 129 - Transport Solenoid; Glow Plugs

Transport Solenoid (GM 3000–D) The transport solenoid is located below the seat and on the front right side of the hydraulic housing. Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0....

Page 130 - O in Fuel Sensor; ohm or; D. Correct any problem circuitry if necessary.; Replace sensor with new one if necessary.

H 2 O 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 engine. It energizes a red warning light when too much water has collected in the fuel filter bowl (Fig. 42). 1. Make sure engine is OFF. Remove start ...

Page 131 - Reinstall start relay to the control center.

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 warning light when coolant level in the degassing box and radiator is to low (Fig. 44). 1. Make sure engine is OFF. Remove start relay from the control cent...

Page 132 - Indicator Lights and Circuits

Groundsmaster 3000/3000–D Page 6 – 26 Electrical System 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 totheir wiring terminals (Fig 46). Low Oil Pressure Light The oil pressure light should come on ...

Page 133 - Glow Plug Indicator Light; BACK OF GAUGE

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. 2. Jumper from post # 8 (brass) on the glow control relay to female receptor # 5 (green wire...

Page 134 - Ford Engine (VSG–411) Electrical Component Locations; Manual

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 sid...

Page 136 - Thermistor

ÄÄ 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. 1. Connect the temperature gauge to the variable resistance and DC voltage source (Fig. 34). 2. Adjust resistance until the gauge ...

Page 138 - Lower the coolant level in the engine and remove; Allow the oil to cool. The switch should open below

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 ...

Page 139 - Anti–Dieseling Valve Solenoid

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). In Place Testing Note: Prior to taking small resistance readings with a digital multimeter, ...

Page 140 - Low Oil Pressure Light; High Coolant Temperature Light

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 Light The oil pressure light should come on when the ignition switch is in the ON position with the e...

Page 141 - Verify Interlock System Operation; Do not disconnect the interlock switches.; To check operation of interlock switches:; Do not operate machine without implement; unless the PTO driveshaft is also removed.; Sit on seat and start the engine. Raise off the seat and

Service and Repairs NOTE: See the Peugeot TUD5 Repair Manual or Ford VSG–411/413 Engine Service Manual for more component repair information. Verify Interlock System Operation The machine has interlock switches in the electrical system. These switches are designed to stop the engine when operator ...

Page 142 - Battery Maintenance; Loosen knobs securing battery cover to machine.; leads from battery posts.

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 bat...

Page 143 - Battery Service

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. When working with batteries, use extreme cau- Electrolyte can destroy clothing and burn skin or eye...

Page 147 - Chapter 7; WD Rear Axle

Chapter 7 2WD Rear Axle Table of Contents ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Wheel Lug Nut Torque . . . . . . . . . . . . . . . . . . . . . . . 3 Rear Wheel Toe–in . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Lubrication . . . . . . . . . . . . . . . ....

Page 148 - 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 pi...

Page 149 - Wheel and Tire Service; Kgm) after 1-4 hours of operation and again

Service and Repairs Wheel and Tire Service The tires are over–inflated for shipping. Therefore, release some of the air to reduce the pressure. Correct air pressure in the front and rear tires is 15 psi (1 Bar). Maintain even pressure in all tires to as sure a good quality–of–cut and proper machin...

Page 150 - Wheel Bearing Service; Adjust preload on the wheel bearings.

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. additive. If operating conditions are extremely dusty and dirty, it may be necessary to perform this maintenance more ...

Page 151 - Rear Axle; WD Rear

Groundsmaster 3000/3000–D Page 7 – 5 2WD Rear Axle Rear Axle 15 inch (38 mm)compressed length 30 31 32 33 34 35 36 37 38 39 41 42 43 44 45 20 47 1 2 3 4 5 6 7 8 16 17 18 19 20 8 21 22 23 24 25 26 27 28 29 11 12 13 14 15 5 40 4 46 48 50 49 9 51 150 ft–lb(21 Kgm) 150 ft–lb(21 Kgm) 70 – 80 ft–lb(10 – 1...

Page 153 - Chapter 8; WD Rear Axle

Chapter 8 4WD Rear Axle Table of Contents ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rear Wheel Toe–in . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Check Rear Axle Lubricant . . . ...

Page 156 - Check Rear Axle Lubricant

Groundsmaster 3000/3000–D Page 8 – 4 4WD Rear Axle Check Rear Axle Lubricant The rear axle reservoir uses Mobil 424 hydraulic fluid.Although the axle is shipped with lubricant from the fac-tory, check the level before operating the machine. 1. Position the machine on a level surface. 2. Remove check...

Page 157 - WD Axle; WD Rear

Groundsmaster 3000/3000–D Page 8 – 5 4WD Rear Axle 4WD Axle 1 2 3 4 5 6 7 8 9 10 16 17 18 1 11 12 13 14 15 1 2 3 4 29 19 20 22 23 24 25 26 27 28 16 1 16 21 70 – 80 ft–lb(10 – 11 Kgm) 150 ft–lb(21 Kgm) 90 – 110 ft–lb(12 – 15 Kgm) 15 inch (38 mm)compressed length 34.5 in. (876 mm)installed Figure 6 1....

Page 162 - : Deck is centered on tractor with 15

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...

Page 163 - Transport Latch Adjustment

Adjustments 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. 3. Rotate latch rod downward from front of traction unit. 4. Insert latch rod into rear hole (transp...

Page 164 - Height of Cut Adjustment; 4 inch Cutting Units

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. 2. Remove front snapper pins from castor arms and slide castor wheel assembly up or down. 3. In...

Page 165 - Skid Adjustment; Adjust skids by removing flange nuts, positioning as; Anti–Scalp Roller Adjustment; Adjust anti–scalp rollers by removing lock nut and

Skid Adjustment 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 Rol...

Page 166 - Deck Pitch Adjustment

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. 1. Position machine on a level sur...

Page 167 - To prevent accidental starting of the engine,; Check Gear Box Lubricant

Service and Repairs while performing maintenance, shut engine off and remove key from ignition switch. CAUTION To prevent accidental starting of the engine, 84 inch Cutting Units Check Gear Box Lubricant The gear box is designed to operate with SAE 80–90 wt. gear lube. Although the gear box is shipp...

Page 168 - Lubricate Bearings, Bushings and Gear Box; The cutting unit has bearings and bushings that

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 lithium base grease or molybdenum base grease, after every 8 hours of operation or daily, which...

Page 169 - Disconnect Cutting Unit From Traction Unit

Groundsmaster 3000/3000–D Page 9 – 9 84 inch Cutting Units 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 posi- tion and turn off engine. 2. Remove hair pin cotter and clevis pin securing...

Page 170 - Connect Cutting Unit to Traction Unit

Groundsmaster 3000/3000–D Page 9 – 10 84 inch Cutting Units 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 ma...

Page 171 - Install Lift Arm Ball Joints; Drive Belt Replacement

Install Lift Arm Ball Joints 1. Adjust ball joint in each lift arm assembly until a di- 140 ft–lb (19 Kgm) mension of 2.75 inches (70 mm) from end of lift arm tocenter of ball joint is attained. 1 2 2.75 in. (70 mm) then continue tightening until slot in nut aligns with cotter pin hole 84 inch Cutti...

Page 172 - Front Castor Fork Bushing Service

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, bus...

Page 173 - Castor Wheel and Bearing Service

Castor Wheel and Bearing Service The castor wheel rotates on a high–quality roller bearing. 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 usuall...

Page 174 - Cutter Blade Removal and Installation; certification of the product.; use a new blade to assure continued safety

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 replacement blades made by other manufacturers because t...

Page 175 - Inspecting and Sharpening Blade; between the sail and flat part of the blade

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 straps to rear of deck. 3. Rotate front of deck upward and insert latch rod into front hole (service positi...

Page 176 - Blade Spindle Service; Removing Spindle Housing Assembly

Blade Spindle Service Removing Spindle Housing Assembly 1. Lower the cutting unit, shut the engine off and engage the parking brake. 2. Remove deck covers from top of cutting unit. Releasebelt tension. Remove belt from spindle to be serviced. 3. Start the engine and raise the cutting unit. Turn the ...

Page 178 - Correcting Cutting Unit Mismatch

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. Position machine on a level surface on the shop floor. 2. Re...

Page 179 - Gearbox

Groundsmaster 3000/3000–D Page 9 – 19 84 inch Cutting Units Gearbox 16 19:1 19 20 21 22 8 9 7 4 3 6 5 1 2 11 13 12 14 10 9:3 9:2 12 15 8 17 170 – 190 in–lb(196 – 219 Kgcm) Figure 31 1. Gearbox 9. Gearbox mount 15. Latch plate 2. Shroud 9:2. Lube decal 16. Screw 3. Lock nut 9:3. Threaded insert 17. W...

Page 181 - Drive Shaft

Drive Shaft 84 inch Cutting Units 6 3 5 4 2 7 8 Figure 33 2. Yoke 5. Slip yoke tube 7. Grease fitting 3. U–joint kit 6. Yoke 8. Grease fitting 4. Slip yoke shaft Groundsmaster 3000/3000–D Page 9 – 21 84 inch Cutting Units

Page 184 - Sound Levels

Specifications Deck Configuration: Out front deck with a right hand trim offset. Four individual chambers jointed for articula-tion. 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 stre...

Page 185 - Start the engine and raise the cutting unit so height–; Front Castor Wheels; Push castor spindle through front castor arm install

Adjustments Height of Cut Adjustment The height–of–cut is adjustable from 1 to 4 inches (25 to 102 mm) in 1/4 inch (6 mm) increments. 1. Start the engine and raise the cutting unit so height– of–cut can be changed. Stop engine after cutting unit is raised. Front Castor Wheels 1. Remove H.O.C. cap fr...

Page 186 - Rear Castor Wheels; Remove hairpin cotter and cotter pin securing rear

Rear Castor Wheels 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. 1 Figure 4 1. Rear Castor Pivot Figure 5 Contour 82...

Page 187 - Rear Deck Chain

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 Adjust- ing Deck Pitch. 1 Figure 6 1. Height–of–Cu...

Page 189 - and remove key from ignition switch.; Grease Bearings and Bushings; The cutting unit has (19) bearings and bushings that

Service and Repairs and remove key from ignition switch. CAUTION To prevent accidental starting of the engine, while performing maintenance, shut engine off Grease Bearings and Bushings The cutting unit must be lubricated regularly. If machine is operated under normal conditions, lubricate castor be...

Page 190 - Disconnect Cutting Unit from Traction Unit

1 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...

Page 194 - Cutting Blade Removal and Installation; Lock transport levers, raise cutting unit to highest

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 replace-ment blades made by other manufacturers because ...

Page 195 - Inspect cutting edges of all blades. Sharpen the cut-

Inspecting and Sharpening Blade 1. Lock transport levers, raise cutting unit to highest position, shut the engine off and engage the parking brake. 2. Examine cutting ends of the blade carefully, espe- cially where the flat and curved parts of the blade meet (Fig. 21–A). Since sand and abrasive mate...

Page 197 - Chamber Pivot Service

Chamber Pivot Service If cutting unit chamber pivot assemblies should ever have to be separated for service or repair, use the follow-ing procedure. 1. Pivot assembly dis–assembly. A. Remove capscrews and nut from pivot cast- ing. B. Loosen capscrew locking eccentric cam in place. C. Using a 1/2 inc...

Page 200 - Lift Arm Ball Joint Installation

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 ...

Page 201 - Hydraulic Motor and Blade

Rev. C Groundsmaster 3000/3000–D Page 10 – 19 Contour 82 Cutting Unit Hydraulic Motor and Blade 1 2 3 4 5 6 8 9 10 1112 85 – 110 ft–lb (12 – 15 Kgm) 7 Figure 30 1. Motor 5. Screw 9. Blade 2. O–ring 6. Washer 10. Anti scalp cup 3. Spindle Assy 7. Locknut 11. Hardended washer 4. Support plate 8. Screw...

Page 202 - Disassembly

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. 2. Remove two cap screws that secure hydraulic motor to the cutting unit. Remove hydraulic motor and O–ring from deck (Fig. 30). 3. S...

Page 203 - Assembly; The bottom seal must have the lip facing; When greasing spindles, grease

Assembly 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 ...

Page 204 - Hydraulic Assembly

Hydraulic Assembly 6 8 1 2:1 2 2:2 1:1 3 4 4:1 5 12:1 12 11 6:2 10 9:1 9 9:2 6:1 7 2 11 Hydraulic Flow Direction Inlet Outlet Case drain 11:1 11:2 11:1 Figure 34 1. Hose 6. Hydraulic fitting 11. Tee 1:1 O–ring 6:1. O–ring 11:1. O–ring 2. Hydraulic fitting 6:2. O–ring 11:2. O–ring 2:1. O–ring 7. Hose...

Page 205 - 2 inch Cutting Units

Chapter 11 72 I Cutting Units Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport Latch Adjustment . . . . . . . . . . . . . . . . . . . Height of Cut Adjustment . . . . . . . . . ....

Page 209 - Adjust skids by loosening flange nuts, positioning as

Skid Adjustment 1. Adjust skids by loosening flange nuts, positioning as desired and re–tightening flange nuts. 1 2 Figure 8 (Rear Discharge) 1. Skid 2. Flange nut 1 2 Figure 9 (Guardian Recycler) 1. Skid 2. Flange nut 72 inch Cutting Units Groundsmaster 3000/3000–D Page 11 – 5 72 inch Cutting Units

Page 210 - To adjust front and rear rollers:

3 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 a...

Page 212 - Change lubricant in gear box initially; Replace Gear Box Lubricant

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

Page 213 - Grease Bearings, Bushings and Gear Box

Groundsmaster 3000/3000–D Page 11 – 9 72 inch Cutting Units Grease Bearings, Bushings and Gear Box The cutting unit must be lubricated regularly. If machineis operated under normal conditions, lubricate castorbearings and bushings with No. 2 general purpose lithi-um base grease or molybdenum base gr...

Page 219 - Cutter Blade Removal

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 replacement blades made by other manufacturers because they could be dang...

Page 227 - Groundsmaster 3000 Electrical Schematics,; Electrical Diagrams

Chapter 12 Electrical Diagrams Table of Contents Groundsmaster 3000 Electrical Schematics, Groundsmaster 3000–D Electrical Schematics, Wiring Diagrams, and Harness Drawings . . . . . . . 3 Wiring Diagrams, and Harness Drawings . . . . . . 10 Electrical Schematic . . . . . . . . . . . . . . . . . . ....

Page 229 - Electrical Schematic

LIFT HOLD SV1 SV2 WHITE HI TEMP SWITCH Y X I A S B + – B S 1 2 3 ANTI–DIESELING SOLENOID 4 5 6 7 8 9 10A BRAKE SWITCH 20A CRUISE COIL CRUISE DIODE (D3) DIODE (D8) SOLENOID (SV2) SWITCH NEUTRAL SWITCH 10 11 12 DISTRIBUTORLESS IGNITION + 1 R HI TEMP OVERRIDE SWITCH Y LIFT/XBAL SOLENOID (SV1) DIODE (D6...

Page 230 - Start Circuits

LIFT HOLD SV1 SV2 WHITE HI TEMP SWITCH Y X I A S B + – B S 1 2 3 ANTI–DIESELING SOLENOID 4 5 6 7 8 9 10A BRAKE SWITCH 20A CRUISE COIL CRUISE DIODE (D3) DIODE (D8) SOLENOID (SV2) SWITCH NEUTRAL SWITCH 10 11 12 DISTRIBUTORLESS IGNITION + 1 R HI TEMP OVERRIDE SWITCH Y LIFT/XBAL SOLENOID (SV1) DIODE (D6...

Page 231 - Run Circuits

LIFT HOLD SV1 SV2 WHITE HI TEMP SWITCH Y X I A S B + – B S 1 2 3 ANTI–DIESELING SOLENOID 4 5 6 7 8 9 10A BRAKE SWITCH 20A CRUISE COIL CRUISE DIODE (D3) DIODE (D8) SOLENOID (SV2) SWITCH NEUTRAL SWITCH 10 11 12 DISTRIBUTORLESS IGNITION + 1 R HI TEMP OVERRIDE SWITCH Y LIFT/XBAL SOLENOID (SV1) DIODE (D6...

Page 237 - Crank Circuits

GREEN RED BROWN WHITE WHITE PINK PINK PINK PINK PINK VIOLET ORANGE ORANGE RED BROWN GREEN BLUE WHITE YELLOW YELLOW GREEN R RED RED RED RED BLUE BLUE WHITE RED PINK WHITE BLUE WHITE GREEN ORANGE BLUE VIOLET BROWN GREEN BLUE ORANGE ORANGE ORANGE BLUE VIOLET ORANGE DIODE (D2) Y LIGHT WHITE VIOLET BROWN...

Toro 3000 - Manual

Table of Contents:

Summary

Other Toro Models