Toro 3000 manual

Part No. 96890SL Rev . C Service Manual Groundsmaster R 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 OPERA TOR’S MANUALS FOR OPE[...]

Groundsmaster 3000/3000–D[...]

T able Of Contents Chapter 1 – Safety Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 4 Chapter 2 – Product Records and Maintenance Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1 Equivalents and Conversions . . . . [...]

Groundsmaster 3000/3000–D[...]

T able of Contents (continued) Chapter 9 – 84 I Cutting Units Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 2 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 3 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 9 – 7 Chapter 10 – Contour 82 I Cutting Unit Spec[...]

Groundsmaster 3000/3000–D[...]

Chapter 1 Safety Safety T able of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Instructions The GROUNDSMASTER R 3000 and 3000-D was tested and certified by TORO f[...]

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 [...]

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 getting off the seat: A. Move traction pedal to neutra[...]

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 T ool Box Next to Right Side of Seat In Compartment Behind Control [...]

Safety and Instruction Decals (Groundsmaster 3000–D) 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. (Part No. 67–1710) In Compartment Behind Control panel On Side of T ool Box Next to Right Sid[...]

Safety and Instruction Decals (84 I 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 On Front of Cutting Unit Cutting Unit On Right & Left Covers (Part No. 68–8340[...]

On Front of Deck (Part No. 66–1340) On Front Of Deck (Part No. 93–7824) Replaces Decal Part No. 66–1340 for CE On Rear of Deck (Part No. 66–6380) On Rear Of Deck (Part No. 93–7828) Replaces Decal Part No. 66–6380 for CE On Each Castor Arm (Part No. 93–4894) Safety On Deck Channels, Under Covers On Each Castor Arm (Part No. 93–7814) [...]

Safety and Instruction Decals (Contour 82 I 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 & On T op of Chamber 3 Left Chambers On Right & Left Chambers (Part N[...]

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 Each Corner Of On Left Caster Arm (Part No. 68–8[...]

Safety and Instruction Decals (Rear Discharge 72 I 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 D[...]

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. 66–6380) On Front of Deck (Part No. 66–1340) On Deck Channels, Under Covers On Front Of Deck (Part No. 85–6410) (Part No. 93–7824) Replaces Decal Part No. 66–1340 for CE On Right Rear T op of Deck O[...]

Safety Page 1 – 12 Groundsmaster 3000/3000–D[...]

Chapter 2 Product Records and Maintenance T able of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1 EQUIV ALENTS AND CONVERSIONS . . . . . . . . . . . 2 Decimal and Millimeter Equivalents . . . . . . . . . . . . 2 U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2 TORQUE SPECIFICA TIONS . . . . . . . . .[...]

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

Groundsmaster 3000/3000–D Page 2 – 3 Product Records and Maintenance Product Records and Maintenance T orque Specifications[...]

800 800 800 800 400 Product Records and Maintenance Page 2 – 4 Rev . A Groundsmaster 3000/3000–D[...]

Groundsmaster 3000/3000–D Page 2 – 5 Product Records and Maintenance Lubrication T raction Unit CAUTION 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 [...]

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. Guardian 84 I R[...]

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[...]

Groundsmaster 3000/3000–D Page 2 – 8 Product Records and Maintenance Guardian 72 I Recycler Cutting Unit Figure 10 Rear Discharge 72 I Cutting Unit Figure 1 1[...]

_____________________________ _____________________________ EQUIPMENT OPERA TION AND SERVICE HISTOR Y REPORT for GROUNDSMASTER R 3000 TORO Model and Serial Number: ______________–______________ Engine Numbers: _____________________________ T ransmission Numbers: _____________________________ Drive Axle(s) Numbers: _____________________________ Da[...]

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 Engine Oil and Filter Inspect Cooling System Hoses { { [...]

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 _________________ MON TUES WED THURS FRI SA T SUN [...]

________________________________ _______________________________ _______________________________ ________________________________ __________________________ ________________________________ _______________________________ _______________________________ _______________________________ _______________________________ ________________________________[...]

_____________________________ _____________________________ EQUIPMENT OPERA TION AND SERVICE HISTOR Y REPORT for GROUNDSMASTER R 3000–D TORO Model and Serial Number: ______________–______________ Engine Numbers: _____________________________ T ransmission Numbers: _____________________________ Drive Axle(s) Numbers: ____________________________[...]

Groundsmaster R 3000–D 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 Engine Oil and Filter Inspect Cooling System Hoses [...]

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 _________________ MON TUES WED THURS FRI SA T [...]

________________________________ _______________________________ _______________________________ ________________________________ ________________________________ ________________________________ _______________________________ _______________________________ _______________________________ _______________________________ __________________________[...]

Chapter 3 Ford VSG–41 1 Engine T able of Contents GENERAL INFORMA TION . . . . . . . . . . . . . . . . . . . . . 2 Cooling System Service 8 . . . . . . . . . . . . . . . . . . . . . . SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General Air Cleaner Service 9 . . . . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . [...]

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–41 1/413 Engine Service Manual for engine identification information. Specifications Item Specification Make / Designation Ford Mode[...]

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. T o adjust belt tension, loosen bolt securing brace to engine, bol[...]

Governor Adjustment 1. With engine shut off, move throttle control to F AST 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. Engi[...]

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 le[...]

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 screwi[...]

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 anti–freeze. Check level of coolant at beginning [...]

Cooling System Service 1. Removing Debris – Remove debris from rear screen, oil cooler and radiator daily , clean more fre- quently in dirty conditions. IMPORT ANT : Never spray water onto a hot engine as damage to engine may occur . A. T urn engine off and clean hood screen thor- oughly . B. Release hood latch and raise hood. Clean engine area t[...]

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). [...]

Fuel System Service Fuel T ank 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 [...]

Replacing Spark Plugs Change spark plugs after every 400 operating hours to assure proper engine performance and reduce exhaust emission level. Correct spark plug to use is a Motorcraft–AGSF22C or AGRF22 or equivalent. Recommended air gap is .040” (1.016 mm). Note: The spark plug usually lasts a long time; however , the plug should be removed a[...]

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 flo[...]

Chapter 4 Peugeot TUD5 Engine T able of Contents SPECIFICA TIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . 14 SPECIAL T OOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Priming Fuel System . . . . . . . . . . . . . . . . . . . . . . . . 15 ADJUSTMENT[...]

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 (T oro Part No. 93?[...]

Special T ools Compression T est 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 V alve Spring Compression T ool (TOR4024T) Use for removing valve springs. Figure 4 Air Filter Element Cleaner (TOR277220)[...]

Injection Nozzle T ester (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 T ension T ool (TOR4075) T ool is used to accurately adjust the cam drive belt te[...]

V alve Guide Seal Remover (TOR4081) Use to remove old valve guide seals. Figure 9 Injector Socket (TOR4082) A special deep socket to remove and install injectors. Figure 10 T orque 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 re[...]

Camshaft Pinion Setting T ool (T OR4084) T ool is used to hold the camshaft gear and / or injector pump gear while tightening the fasteners. Figure 12 Timing Pin Set (T OR4085) T ool set is used to set injection pump engine timing. Figure 13 Rear Main Seal Installer (TOR4086) T ool is used to install the crankshaft rear main seal. Figure 14 Peugeot[...]

Front Seal Installer (TOR4087) T ool is used to install the crankshaft front seal. Figure 15 Camshaft Seal Installer (TOR4088) T ool is used to install the camshaft seal. Figure 16 Groundsmaster 3000–D Page 4 – 7 Peugeot TUD5 Engine Peugeot Diesel Engine[...]

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 pull[...]

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. In[...]

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 [...]

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 has been running, pressurized if degasser cap is r[...]

Cooling System Service 1. Removing Debris – Remove debris from rear screen, oil cooler and radiator daily , clean more fre- quently in dirty conditions. IMPORT ANT : Never spray water onto a hot engine as damage to engine may occur . A. T urn engine off and clean hood screen thor- oughly . B. Release hood latch and raise hood. Clean engine area t[...]

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 condition[...]

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 not fill fuel tank while engine is running, hot, or[...]

Priming Fuel System IMPORT ANT : 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 container to catch fuel. 3. Loosen fuel filter / wate[...]

Groundsmaster 3000–D Page 4 – 16 Peugeot TUD5 Engine Frame, Fuel T ank 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 1 1. Stand pipe 21. Battery cable (+) 2. Fuel hose 12. Fuel hose 22. Ground cable 3. Hose clamp 13. Screw 23. [...]

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 1 1. 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. Carriage screw Peugeot Diesel Engine[...]

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. T oro 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 1 1. Hair pin cotter 18. Clevis pin 5. T op seal 12. Decal 19. Latch arm 6. Rear screen 13. Hood 20. Caution decal (Europe) 7. Tinnermann nut 14. [...]

Groundsmaster 3000–D Page 4 – 19 Peugeot TUD5 Engine Center Shroud and Air Cleaner 1 2 34 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 1 1. Intake spacer 21. T ube cover (Model 30301 only) 2. ROPS 12. Air cleaner hose 22. Screw 3. Foam strip 13. Screw (Model 30302 only) 23. Nut 4. Hose clamp 1[...]

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 1 1. Nut 18. Degasser hose 5. Screw 12. Lever 19. Hose 6. Lock nut 13. Fan bracket 20. Nut 7. Screw 14. Screw 21. Radiator cap 8. Lock nut 15. Carriage scr[...]

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 clearance minimum .18 inch (5 mm) Pipe thread sealant Pipe thread sealant Figure 34 1. Upper radiator hose 18. Lowe[...]

Groundsmaster 3000–D Page 4 – 22 Peugeot TUD5 Engine Engine 1 2 3 4 5 6 7 89 1 1 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. Screw 18. Screw 34. Screw 3. Snubbing washe[...]

Peugeot TUD5 Overhaul, Checking T uning See the Peugeot Citroen Moteurs TUD5 Overhaul, Checking, T uning manual for detailed service informa- tion. See the T oro Parts Catalog for parts indentification. Refer to the Special T ools list starting on Page 4 – 3 of the T oro Groundsmaster 3000/3000–D Service Manual. The tool numbers referred to in [...]

Peugeot TUD5 Engine Page 4 – 24 Groundsmaster 3000–D[...]

Chapter 5 Hydraulic System and T ransaxle T able of Contents SPECIFICA TIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . SER VICE AND REP AIRS . . . . . . . . . . . . . . . . . . . . . 21 GENERAL INFORMA TION 3 . . . . . . . . . . . . . . . . . . . . . Check T ire Pressure . . . . . . . . . . . . . . . . . . . . . . . . 21 Pushing or [...]

Specifications Item Specification T ransaxle Sauer–Sundstrand IHT–M15 Charge Pressure: 80 – 130 PSI (5.5 – 9 Bar) Implement Relief Pressure: 1,000 – 1,100 PSI (69 – 76 Bar) T raction Forward Pressure: 6,200 PSI (428 Bar) maximum T raction reverse pressure: 5,000 PSI (345 Bar) maximum Manifold Block T oro logic cartridge, elec./hyd., sol[...]

General Information Pushing or T owing T raction Unit In an emergency , the traction unit can be pushed or towed. However , T oro does not recommend this as stan- dard procedure. IMPORT ANT : 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 [...]

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 condition[...]

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 fit- ting shows signs of leakage. 3. Lubricate the O–ring with a light coating of oil. 4. Install the fitting into the port and ti[...]

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–2350–4 HOLD OFF OFF OFF ON ADJ ORIFI[...]

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 RPM LOADED 1560 RPM QUICK COUPLER CCW IN[...]

Groundsmaster 3000/3000–D Page 5 – 8 Hydraulic System Hydraulic Components Lift cylinder Steering cylinder Oil cooler Steering control unit Manifold block Lift cylinder[...]

Special T ools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICA TIONS GUIDE (COMMERCIAL PRODUCTS) . Some tools may also be available from a local supplier . Hydraulic Pressure T est Kit – T OR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on [...]

Hydraulic T ester – With Pressure and Flow Capabilities – T OR214678 Figure 10 Y ou 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 V AL VE: If required, upon turning the valve to res[...]

T esting 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 T ools section in this Chapter .) CAUTION dures could result in damage to gauge and possible personal injury from leaking h[...]

IMPORT ANT : T est 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 T est 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 [...]

Forward T raction T est 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 cutting unit, engage parking brake and stop the eng[...]

Implement Relief Pressure T est 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 minutes. 2. Lower cutting unit, engage parking brak[...]

Counterbalance Pressure T est 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. Make sure hydraulic oil is at normal operati[...]

Steering Circuit T est 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. Cylinder T est This test checks the steering cylinder for internal bypass, and assumes that the steering valve is working correctly . The Steering V alve T est will [...]

Groundsmaster 3000/3000–D Page 5 – 17 Hydraulic System Auxiliary Hydraulic Pump Efficiency T est (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, [...]

This page is blank. Hydraulic System Page 5 – 18 Groundsmaster 3000/3000–D[...]

This page is blank. Hydraulic System and T ransaxle Groundsmaster 3000/3000–D Page 5 – 19 Hydraulic System[...]

Adjustments T raction Pedal Linkage Adjustment T raction 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. [...]

Service and Repairs Wheel and Tires Check Tire Pressure Check Wheel Nut T orque 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). IMPORT ANT : Maintain even pressure in all tires to as- sure a good quality–of–cut and proper[...]

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 (1 1.4 liters) of Mobil 424 hydraulic fluid. Check level of hy - draulic fluid before engine is first started and daily thereafter . 1. Position machine on a level surfa[...]

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 hydrau[...]

T raction 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 fitting 24. Nut 25. Roll pin 26. Flat washer 1. Carriage bolt 2. T raction lever 3. Rod end bearing 4. Jam nut 5. Control tube 6. Flat washer 7. Hair pin cotter 8. Hub 9. Rubber bushing F[...]

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. pedal 27. Grease fitting 4. Clevis pin 16. Scr[...]

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. Y oke and shaft (Model 30302) 2. Cross and bearing kit 9. Engine adapter plate 16. Cross & bearing kit (Model 30302) 3. Slip yoke 10. Lock nut (Model 30302) 17. Lock n[...]

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 1 1. Lock nut 5. Hydraulic cylinder 12. Screw 6. Bushing 13. Screw Hydraulic System and T ransaxle Groundsmaster 30[...]

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. T ower housing 1 1. Knob 21. Parking brake rod 2. T ower decal 12. T ower cover 22. Extension spring 3. Screw 13. Steering wheel 23. Hair pin[...]

#1 #2 #3 #4 #5 #3 T ube #2 T ube #1 T ube #4 T ube #5 T ube Figure 39 Hydraulic System and T ransaxle 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 a[...]

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) T orque to T orque to Figure 40 1. Body 1 1. O–ring 21. Plug 2. O–ring 12. Solenoid coil 22. O–ring 3. O–ring 13. Nut 23. O–ring 4. Needle valve 14. [...]

Cartridge V alves 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 cartridges, because slight bending or distortio[...]

Lift Cylinder 1 2 3 4 5 9 6 7 8 10 11 13 12 14 15 Figure 42 1. T ube 6. O–ring 1 1. 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 component. See the Parts Catalog for more informa[...]

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. T ie rod end 4. U–cup 1 1. Piston 18. Jam nut 5. Backup ring 12. Wear ring 19. Set screw 6. Rod 13. Lock nut 7. O–ring 14. Barrel NOTE: Assembly kits are availa[...]

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 1 1:1 9:1 8:1 8:2 Figure 44 1. Hydraulic pump 8. Hydraulic fitting 15. Hydraulic fitting 2. Adapter 9. Hydraulic fitting[...]

Groundsmaster 3000/3000–D Page 5 – 36 Hydraulic System T ransaxle Service T oro recommended fluids and maintenance intervals may be different than those listed in the Sauer–Sunds- trand IHT Service Manual. When doing maintenance or service on the transaxle, use the T oro recommended fluids and maintenance intervals. Some of the components sho[...]

Chapter 6 Electrical System T able of Contents ELECTRICAL SCHEMA TICS, WIRING DIAGRAMS, AND HARNESS DRA WINGS . . . . . . . . . . . . . . . . . 2 SPECIAL T OOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING (Groundsmaster 3000) . . . . 4 Starting Problems (GM 3000) . . . . . . . . . . . . . . . . . 4 General Run & [...]

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. Electrical System Page 6 – 2 Groundsmaster 3000/3000–D[...]

Special T ools Order special tools from the TORO SPECIAL TOOLS Some tools may also be available from a local supplier . AND APPLICA TIONS GUIDE (COMMERCIAL PROD- UCTS) . Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: T oro recommends the use of a DIGIT AL V olt– Ohm–Amp multimeter whe[...]

T roubleshooting (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 understanding of the electrical circuits and components use[...]

General Run and T ransport 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 fus[...]

T roubleshooting (Groundsmaster 3000–D) 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 understanding of the electrical circuits and components[...]

General Run and T ransport 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, se[...]

Electrical System Quick Checks Battery T est (Open Circuit T est) 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 multim[...]

Component Identification and T esting 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 continu- ity with a multimeter (ohms setting), make sure that power [...]

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 D3 a designated P3 and P5. On the GM 3000–D wirin[...]

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 switch by connecting a multimeter (ohms setting) [...]

Hydraulic V alve 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 me- ter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal re- [...]

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 o[...]

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 sender . Note: Before taking small resistance readings[...]

Relays and Fuses The relays and fuses and are located in the compart- ment 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 T esting 1. V erify coil resistance between terminals 86 and 85 with a multimeter (ohms setting). Resistance should be from 75 to 95 [...]

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. V erify continuity between the two terminals. Conti- nuity should be less than 1 ohm . THERMAL BREAKER Figure 23 Figure 24 Electrical System Page 6 – 16 [...]

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 T esting Note: Prior to taking small resis[...]

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) w[...]

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 condi[...]

T emperature 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 thermistor from the water pump. Make sure engine is co[...]

T emperature 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 re- sistance and DC voltage source (Fig. 34). 2. Adjust resistance until the gauge needle points to following test points on the g[...]

T emperature 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 u[...]

T ransport 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 me- ter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to t[...]

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 en- gine. It energizes a red warning light when too much wa- ter has collected in the fuel filter bowl (Fig. 42). 1. Make sure engine is OFF . Remove start relay from the control center . 2. Disconnec[...]

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). 1. Make sure engine is OFF . Remove start relay from the control center . DANGER Make sure engine and cooling syst[...]

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 to their wiring terminals (Fig 46). Low Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON posit[...]

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) on the pin con- nector . 3. The light should co[...]

Ford Engine (VSG–41 1) Electrical Component Locations (GM3000) Note: See the Ford VSG–41 1/413 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 th[...]

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 [...]

T emperature 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 re- sistance and DC voltage source (Fig. 34). 2. Adjust resistance until the gauge needle points to following test points on the gauge[...]

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. T esting with the Engine Off 1. T urn the ignition switch to ON. The oil pressure lamp should be on. 2. If the lamp does not come on i[...]

High T emperature 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 Figure 59 the high[...]

Anti–Dieseling V alve 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 T esting Note: Prior to taking small resistance readings with a digital multimeter , short the test leads together . The me- te[...]

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 engine not running. Also, it should light with the [...]

Service and Repairs NOTE: See the Peugeot TUD5 Repair Manual or Ford VSG–41 1/413 Engine Service Manual for more compo- nent repair information. V erify 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 dep[...]

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 . T o 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 1 [...]

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 eyes. Always wear safety goggles and a face shield w[...]

2. Conduct a hydrometer test of the battery electrolyte. IMPORT ANT : 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 . At the same time take the t[...]

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 sy[...]

Electrical System Page 6 – 40 Groundsmaster 3000/3000–D[...]

Chapter 7 2WD Rear Axle T able of Contents ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Wheel Lug Nut T orque . . . . . . . . . . . . . . . . . . . . . . . 3 Rear Wheel T oe–in . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SER VICE[...]

Adjustments Rear Wheel T oe–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. T o adjust toe–in: A. Remove cotter pins and nuts securing ball joints to s[...]

Service and Repairs Wheel and Tire Service 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). Maintain even pressure in all tires to as- sure a good quality–of–cut and proper machine perfor- Kgm) after 1-4 hours of operation[...]

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. 1. Slightly loosen the wheel lug nuts. J[...]

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 56 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 1 Kgm) 34.5 in. (876 mm) install[...]

2WD Rear Axle Page 7 – 6 Groundsmaster 3000/3000–D[...]

Chapter 8 4WD Rear Axle T able of Contents ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rear Wheel T oe–in . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Check Rear Axle Lubricant . . . . . . . . . . . . . . . . . . . 4 SER VICE AND[...]

Adjustments Rear Wheel T oe–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. T o adjust toe–in: A. Remove cotter pins and nuts securing ball joints to s[...]

Service and Repairs Wheel and Tire Service 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). Maintain even pressure in all tires to as- sure a good quality–of–cut and proper machine perfor- Kgm) after 1-4 hours of operation[...]

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 plug from axle and make sure lubri- cant i[...]

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 – 1 1 Kgm) 150 ft–lb (21 Kgm) 90 – 1 10 ft–lb (12 – 15 Kgm) 15 inch (38 mm) compressed length 34.5 in. (876 mm) installed Figure 6 1. Nut 1 1. Grease fitting [...]

Groundsmaster 3000/3000–D Page 8 – 6 4WD Rear Axle 1 2 3 45 6 7 19 24 21 8 22 10 9 8 8 9 10 11 12 13 14 15 20 17 18 23 23 27 16 24 25 26 Figure 7 1. Inboard yoke shaft 10. Kingpin trunnion 19. Screw 2. Cross and bearing kit 1 1. Belleville washer 20. Retaining ring 3. Double pivot yoke 12. L.H. spindle flange 21. Lip seal 4. Outboard yoke shaft[...]

Groundsmaster 3000/3000–D Page 8 – 7 4WD Rear Axle 1 2 3 4 5 6 7 8 9 10 15 11 12 13 14 11 14 15 16 16 17 17 22 19 20 21 18 Figure 8 1. Clutch housing 9. Retaining ring 17. Differential 2. O–ring 10. Ball bearing 18. Screw 3. Lip seal 1 1. Bushing 19. Side cover 4. Internal retaining ring 12. Breather vent 20. O–ring 5. Thrust washer 13. Axl[...]

4WD Rear Axle Page 8 – 8 Groundsmaster 3000/3000–D[...]

Chapter 9 8 4 " Cutting Units T able of Contents SPECIFIC A TIONS 2 Connecting Cutting Unit to T raction Unit 0 1 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS 3 Install Lift Arm Ball Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T ransport L[...]

Specifications T ype : 84 inch (2.1 m) width of cut, 5 blades, 3 blade cen- ter section, and 2 one blade wings. T oro 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). T rimming Ability : Deck is centered on tractor with 15 inches (38 mm) of over hang on each side. Uncut circ[...]

Adjustments T ransport 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 (transport position) in latch plate. 5. Tighten flange h[...]

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. Insert snapper pin into castor arm and through g[...]

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 Roller Adjustment Anti–scalp rollers [...]

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 surface on shop floor . 2. Set deck to the desire[...]

Service and Repairs while performing maintenance, shut engine off and remove key from ignition switch. CAUTION T o 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 shipped with lubri- cant from the factory , check th[...]

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 immediate[...]

Groundsmaster 3000/3000–D Page 9 – 9 84 inch Cutting Units Disconnect Cutting Unit From T raction 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 height–of–cut chains to rear height–of[...]

Groundsmaster 3000/3000–D Page 9 – 10 84 inch Cutting Units Connect Cutting Unit to T raction 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- chined surface on top of each traction uni[...]

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 to center 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 Cutting Units Figure 18 1. Ball Joint 2. Lift Arm Dr[...]

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 . T o 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. Start tr[...]

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. 1. Remove loc[...]

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[...]

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 position) in latch plate. 4. Examine cutting ends of[...]

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. Release belt tension. Remove belt from spindle to be serviced. 3. Start the engine and raise the cutting unit. T urn the engine OFF and remove the key from the key switc[...]

Installing Spindle, Bearings and Seals Into Spindle Housing IMPORT ANT : 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 install[...]

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 tr[...]

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 oodruff key 4. Drive shaft 10. Rubber [...]

2 12 10 3 5 4 17 1 13 16 11 22 2 19 6 8 4 18 2 20 21 7 5 14 15 9 23 Figure 32 1. Housing 9. Spacer 17. L.H. gear 2. Capscrew 10. Lower shaft 18. Plug 3. Cap 1 1. Upper seal 19. Lower seal 4. Bearing cone 12. Cap 20. Bearing cone 5. Bearing cup 13. Gasket (.015) 21. Bearing cup 6. R.H. gear 14. Gasket (.005) 22. Cap 7. Bearing cup 15. Gasket (.003) [...]

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

84 inch Cutting Units Page 9 – 22 Groundsmaster 3000/3000–D[...]

Chapter 10 Contour 82  Cutting Unit T able of Contents SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Height of Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Deck Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

Specifications Deck Configuration: Out front deck with a right hand trim of fse t. 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 (1 14 mm) deep, welded construction and reinforced with 10 GA high strength formed plates. Height–of–Cut (HOC): [...]

Adjustments Height of Cut Adjustment The height–of–cut is adjustable fr om 1 t o 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 from spindle shaft and slide spindle out o[...]

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– cu t 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 Cutting Unit Page 10 – 4 Groundsmaster 30[...]

Rear Deck Chain 1. Remove hair pin cotter and clevis pin securing height–of–cut chain to chamber bracket. 2. Mount heigh t–of –cut chai n to d e sired height–of–cut hole with clevis pin and hair pin cotter . 3. V erify deck pitch on No. 3 chamber . Refer to Adjust- ing Deck Pitch. 1 Figure 6 1. Height–of–Cut chain Figure 7 Contour 8[...]

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. Fo r the Contour 82, TORO r ecommends a blade pitch of 7/16 inch (1 1 mm). That is the back of the blade plane is 7/16 inch (1 1 mm) higher than the front. 1. Position machine on a level surface on shop floor . 2[...]

Service and Repairs and remove key from ignition switch. CAUTION T o 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 bearings and bushings with No. 2 general purpose l[...]

1 1 Disconnect Cutting Unit from T raction 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. 3. Rotate ignition key to [...]

Connect Cutting Unit to T raction Unit 1. Center t raction 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- chined su rf ace on top of each traction unit lift arm is par- allel to ground (Fig. 12). (Raise or lower[...]

Front Castor Fork Bushing Service Th e castor forks have bushings pressed into the top and bottom of the chamber and after many hours of opera- tion, the bushings will wear . T o check the bushings, mov e 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. Lock[...]

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. 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.[...]

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 they could be dangerous. 1. Lock transport le[...]

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 material can wear away the metal that connects the [...]

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. Raise the height–of –cut to the highest position and lower deck to the floor . 2. Position machine on a l[...]

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 inch (13 mm) diameter drive pin, drive pi lot pi[...]

3. Pivot assembly re–assemble. A. Press ball joints into pivot casting. Bottom ball joint first. B. Insert and orientate grease fittings to face up- ward. 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[...]

4. Adjustment of Chamber Pivots. A. Se t deck to its maximum height of cut: 4 inches (102 mm). B. Place t he deck on a level surface with the lock and lift cables in the unlocked position. C. T ighten capscrew against the eccentric cam, then, back off 1/2 turn. D. Use two 1–1/4 inch wrenches on the eccentric cam to rotate simultaneously . V erify[...]

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). Th e 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 distance[...]

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 11 12 85 – 1 10 ft–lb (12 – 15 Kgm) 7 Figure 30 1. Motor 5. Screw 9. Blade 2. O–ring 6. W asher 10. Anti scalp cup 3. Spindle Assy 7. Locknut 1 1. Hardended washer 4. Support plate 8. Screw 12. Blade screw Contour 82 Cutti[...]

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. R em o v e two cap screws that secure hydraulic motor to the cutting unit. Remove hydraulic motor and O–ring from deck (Fig. 30). 3. Start the engine and raise the cutting unit. [...]

Assembly IMPORT ANT : If ne w 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 th[...]

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 1 1:1 1 1:2 1 1:1 Figure 34 1. Hose 6. Hydraulic fitting 1 1. T e e 1:1 O–ring 6:1. O–ring 1 1:1. O–ring 2. Hydraulic fitting 6:2. O–ring 1 1:2. O–ring 2:1. O–ring 7. Hose 12. Hydraulic fitting 2:2. O?[...]

Chapter 1 1 72 I Cutting Units T able of Contents SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T ransport Latch Adjustment . . . . . . . . . . . . . . . . . . . Height of Cut Adjustment . . . . . . . . . . . . . . . . . . . . . Skid Adjustment . . . .[...]

Specifications T ype : 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 [...]

Adjustments T ransport 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 (transport position) in latch plate. 5. Rotate front of [...]

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. 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 groo[...]

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 1 1 – 5 72 inch Cutting Units[...]

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 and re– tightening locking hub. Make sure gag[...]

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 surface on shop floor . 2. Set deck to the desire[...]

Service and Repairs while performing maintenance, shut engine off and remove key from ignition switch. CAUTION T o 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 lubri- cant from the factory , check the level before operati[...]

Groundsmaster 3000/3000–D Page 1 1 – 9 72 inch Cutting Units 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 lithi- um base grease or molybdenum base grease, after ev- ery 8 hours of operation [...]

Groundsmaster 3000/3000–D Page 1 1 – 10 72 inch Cutting Units Disconnect Cutting Unit From T raction 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. Rotate ignition key to run position and move lift lever forward to lower cutting unit. 3[...]

Connect Cutting Unit to T raction 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- chined surface on top of each traction unit lift arm is par- allel to ground (Fig. 17). (Raise or lower li[...]

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 a[...]

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 . T o 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. Start tr[...]

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. 1. Remove loc[...]

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 posit[...]

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[...]

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. Release belt tension. Remove belt from spindle to be serviced. 3. Start the engine and raise the cutting unit. T urn the engine OFF and remove the key from the key switc[...]

Installing Spindle, Bearings and Seals Into Spindle Housing IMPORT ANT : 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 install[...]

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. Using a 3 foot (1 m) long carpenters level, find a lev- el surface on the shop floor . 2. Raise height–of?[...]

Groundsmaster 3000/3000–D Page 1 1 – 20 72 inch Cutting Units Gearbox 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 1 7 18 16:1 170 – 190 in–lb (196 – 219 Kgcm) Figure 32 1. Screw 1 1. Rivet 20. Screw 2. Latch plate 12. Rubber bumper 21. Safety decal 3. Flat washer 13. Belt 22. CE decal 4. Gear box 14. Flat wa[...]

72 inch Cutting Units 10 3 5 4 17 1 13 16 11 22 2 19 6 8 4 18 2 20 21 7 5 14 15 9 23 Figure 33 1. Housing 9. Spacer 17. L.H. gear 2. Capscrew 10. Lower shaft 18. Plug 3. Cap 1 1. Upper seal 19. Lower seal 4. Bearing cone 12. Cap 20. Bearing cone 5. Bearing cup 13. Gasket (.015) 21. Bearing cup 6. R.H. gear 14. Gasket (.005) 22. Cap 7. Bearing cup 1[...]

Drive Shaft 6 3 5 4 2 7 8 Figure 34 2. Y oke 5. Slip yoke tube 7. Grease fitting 3. U–joint kit 6. Y oke 8. Grease fitting 4. Slip yoke shaft 72 inch Cutting Units Page 1 1 – 22 Groundsmaster 3000/3000–D[...]

Chapter 12 Electrical Diagrams T able 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 . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical Schematic . . . . . . . .[...]

Electrical Diagrams Page 12 – 2 Groundsmaster 3000/3000–D[...]

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) DIODE (D5) DECK G LIFT/XBAL SWITCH HI TEMP L[...]

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) DIODE (D5) DECK G LIFT/XBAL SWITCH HI TEMP L[...]

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) DIODE (D5) DECK G LIFT/XBAL SWITCH HI TEMP L[...]

P3 P4 P5 P6 P7 P8 WIRE IDENTIFICA TION LABEL COLOR AWG TYPE ROUTE ST ARTER FLOA T/HOLD LIFT/XBAL NEUTRAL SEA T PTO SERVICE W1 BLU 18 GPT J1, P2––C COIL COIL SWITCH SWITCH COIL BRAKE W2 BLK 16 GPT J2, J11 W3 T AN 18 GPT J5 J4 W2 A W1 W1 A A A A B B B B B A 1 2 W9 W8 W8 W18 W17 W17 W19 J3 W9 J6 W18 W6 W19 E G K G F J2 J H J1 W4 W5 W5 P9 W3 W3 W4 [...]

P7 P8 WIRE IDENTIFICA TION LABEL COLOR A WG TYPE ROUTE P5 DIODE TEMP FUEL METER P6 LIFT/XBAL FLOA T/ P9 HI TEMP P ACK GAUGE GAUGE HOUR IGNITION SWITCH SWITCH HOLD SW PT O SWITCH OVERRIDE W1 BLU 16 GPT P4––J4, P4––H4 W2 GRN 18 W3 BLK 18 W4 BLK 18 W5 ORN 18 W6 BLU 16 W7 YEL 18 W8 BLK 18 W9 BRN 18 W10 BRN 18 W1 1 T AN 18 W12 VIO 18 W13 VIO 18 [...]

J6 OIL PRESSURE B A SOLENOID P3 P5 NEUTRAL SWITCH B A FLOA T/HOLD COIL A B PTO P7 SWITCH 1 2 P6 SEA T B A LIFT/XBAL SOLENOID FUEL SENDER CRUISE COIL CARB SOLENOID ++++ + ++++ + + + J7 P9 J5 P4 J10 J9 P10 FORD ECM 1 2 J13 AB CHARGE CIRCUIT PROTECTION P12 W18 W20 W26 W30 W31 ”S1” GROUND AL TERNA TOR + + + + + + HARNESS INTERF ACE J1 1 BRAKE SWITC[...]

J2 J3 J4 J5 J9 J10 J6 J7 J8 J15 J16 ++ ++++ ++++++++ P5 ++ ++ ++ + + J12 J13 + + + + + + DECK FUEL GAUGE GAUGE HOUR METER SWITCH DIODE DIODE CONVENIENCE CENTER OVER–RIDE 1 6 5 4 3 2 LIGHT CLUSTER X Y A B S IGNITION SWITCH 1 23 1 2 3 4 5 6 7 8 CRUISE SWITCH 5 1 6 2 7 3 8 4 A B C D E K J H G F 1 3 5 4 2 1 3 5 4 2 1 3 5 4 2 1 3 5 4 2 2 1 3 1 5 3 4 2[...]

80A 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 ORANGE WHITE BLUE WHITE BLUE VIOLET BLUE VIOL[...]

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 ORANGE WHITE BLUE WHITE BLUE VIOLET BLUE VIOLET V[...]

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 ORANGE WHITE BLUE WHITE BLUE VIOLET BLUE VIOLET V[...]

P19 P6 CHARGE COOLANT P16 P17 P18 CIRCUIT LEVEL FLOAT/HOLD LIFT/XBAL NEUTRAL PROTECTION SENSOR STARTER COIL COIL SWITCH WIRE IDENTIFICA TION P1 1 P12 P13 LABEL COLOR A WG TYPE ROUTE SEA T PTO SERVICE W1 BLU 18 GPT P1––1, P10––A SWITCH COIL BRAKE W2 BLK 18 GPT P1––2, J1 W3 WHT 18 GPT P1––3, S2 W4 BLK 18 GPT J1, S1 W5 BLU 18 GPT J2, P[...]

WIRE IDENTIFICA TION P5 P3 P2 HI TEMP LABEL COLOR A WG TYPE ROUTE DIODE HOUR P4 LIFT/XBAL FLOA T/HOLD P1 OVERRIDE W1 BLU 16 GPT P6––J4, P6––H4 P6 CONVENIENCE CENTER W2 GRN 18 GPT P6––J5, J5 P ACK TEMP GAUGE FUEL GAUGE METER IGNITION SWITCH SWITCH SWITCH PTO SWITCH SWITCH W3 BLK 18 GPT P6––J2, J4 W4 BLK 18 GPT P6––J2, P6––H2 [...]

P18 B A SWITCH LIFT/XBAL SOLENOID B A SOLENOID FUEL SENDER GLOW PLUGS NEUTRAL SWITCH D GROUND SOLENOID OIL SWITCH SENDER LOW COOLANT LEVEL IN FUEL CRUISE COIL BRAKE SWITCH THERMISTER 2 2 DECK POSITION SWITCH UNIT P7 1 2345 67 1 3 P1 J2 J1 21 P4 1 3 P6 21 21 INJECTION P5 P3 J3 12 P2 P15 P13 P14 1 2 J4 J12 J7 J8 P16 P17 J10 J9 ”S3” W22 W24 W30 W3[...]

5 1 6 2 7 3 8 4 E F 1 5 5 4 J18 ACCESSORY 3 3 A B C D H G 4 2 1 5 4 2 1 3 5 4 2 1 3 5 4 2 2 1 3 1 3 2 5 4 3 2 1 5 4 3 2 1 5 4 3 2 1 1 2 3 4 5 6 J9 J10 J11 J6 J7 J8 J15 J16 J12 J13 HOUR METER 12 3 4 5 6 P11 LIGHT 1 6 5 4 3 2 LIGHT P12 X Y A B S IGNITION 8 3 2 1 P13 TRANSPORT P4 J14 A B WARNING CLUSTER WARNING CLUSTER SWITCH SWITCH + + + + + P1 PTO 1[...]