Toro 3000, 3000D User Manual

GroundsmasterR 3000/3000–D

Preface

The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Groundsmaster 3000 and 3000–D.

REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine. Replacement Operator’s Manuals are available by sending complete Model and Serial Number to:

The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420

The Toro Company reserves the right to change product specifications or this publication without notice.

Part No. 96890SL Rev. C

Service Manual

This safety symbol means DANGER, WARNING, or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions may result in personal injury.

NOTE: A NOTE will give general information about the correct operation, maintenance, service, testing or repair of the machine.

IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the machine.

E The Toro Company – 1997, 1998, 2003, 2004

Groundsmaster 3000/3000–D

Chapter 1 – Safety

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1

Safety and Instruction Decals

Chapter 2 – Product Records and Maintenance

Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1

Equivalents and Conversions Torque Specifications Maintenance Quick Reference Aid Lubrication Equipment Operation

and Service History Reports . . . . . . . . . . . . . . . . 2 – 9

Chapter 3 – Ford Gasoline Engine

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2

General Information Adjustments Service and Repairs FORD VSG–411/413 ENGINE SERVICE MANUAL

Chapter 4 – Peugeot Diesel Engine

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 2

Special Tools Adjustments Service and Repairs PEUGEOT TUD5 ENGINE SERVICE MANUAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 8

. . . . . . . . . . . . . . . . . . . . . . . 2 – 3

. . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2

. . . . . . . . . . . . . . . . . . . . . . . . 3 – 4

. . . . . . . . . . . . . . . . . . . . . . . . 4 – 9

. . . . . . . . . . . . . . . . 1 – 4

. . . . . . . . . . . . . . . . 2 – 2

. . . . . . . . . . . . 2 – 4

Chapter 5 – Hydraulic System and Transaxle

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 2

General Information Hydraulic Schematics Hydraulic Components Special Tools Testing Adjustments Service and Repairs SAUER–SUNDSTRAND IHT SERVICE MANUAL

Chapter 6 – Electrical System

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2

Special Tools Troubleshooting (GM3000) Troubleshooting (GM3000–D) Electrical System Quick Checks Component Identification and Testing Service and Repairs

Chapter 7 – Rear Axle (2WD)

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 2

Service and Repairs

Chapter 8 – Rear Axle (4WD)

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 2

Service and Repairs

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 19

. . . . . . . . . . . . . . . . . . . . . . . . . 5 – 3

. . . . . . . . . . . . . . . . . . . . . . . 5 – 6

. . . . . . . . . . . . . . . . . . . . . . 5 – 8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 9

. . . . . . . . . . . . . . . . . . . . . . . 5 – 20

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3

. . . . . . . . . . . . . . . . . . 6 – 6

. . . . . . . . . . . . . . . . 6 – 6

. . . . . . . . . . . . . . 6 – 8

. . . . . . . . . . 6 – 9

. . . . . . . . . . . . . . . . . . . . . . . 6 – 35

. . . . . . . . . . . . . . . . . . . . . . . . 7 – 3

. . . . . . . . . . . . . . . . . . . . . . . . 8 – 3

SafetyProduct Records

and Maintenance

Engine

Ford Gasoline

Engine

Peugeot Diesel

and Transaxle

Hydraulic SystemElectrical

System

2WD Rear Axle

4WD Rear Axle

Groundsmaster 3000/3000–D

Table of Contents (continued)

Chapter 9 – 84I Cutting Units

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 2

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 3

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 9 – 7

Chapter 10 – Contour 82I Cutting Unit

Specifications

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 – 3

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . 10 – 7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 – 2

Chapter 11 – 72I Cutting Units

Specifications

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 – 3

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 11 – 8

Chapter 12 – Electrical Diagrams

Groundsmaster 3000

Groundsmaster 3000–D . . . . . . . . . . . . . . . . . . 12 – 10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 – 2

. . . . . . . . . . . . . . . . . . . . . . 12 – 3

84 inchContour 82

Cutting Units

Cutting Unit

72 inch

Cutting Units

Electrical

Diagrams

Groundsmaster 3000/3000–D

Table of Contents

Chapter 1

Safety

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1

Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Instructions

The GROUNDSMASTERR 3000 and 3000-D was tested and certified by TORO for compliance with the B71.4—1990 specifications of the American National Standards Institute. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine. Improper use or maintenance of the machine can result in injury or death. To reduce the potential for injury or death, comply with the following safety instructions.

Before Operating

1. Read and understand the contents of this manual

before starting and operating the machine. Become familiar with all controls and know how to stop quickly. A free replacement manual is available by sending complete Model and Serial Numbers to:

The Toro Company 8111 Lyndale Avenue South Minneapolis, Minnesota 55420–1196.

Use the Model and Serial Number when referring to your machine. If you have questions about this Service Manual, please contact:

The Toro Company Commercial Service Department 8111 Lyndale Avenue South Minneapolis, Minnesota 55420.

Maintenance and Service . . . . . . . . . . . . . . . . . . . . . 3

SAFETY AND INSTRUCTION DECALS

. . . . . . . . . . 4

CAUTION

TO REDUCE THE POTENTIAL FOR INJURY OR DEA TH, COMPL Y WITH THE FOLLOWING SAFETY INSTRUCTIONS.

3. Never operate machine when under the influence of

drugs or alcohol.

4. Remove all debris or other objects that might be

picked up and thrown by cutter blades or fast moving components from other attached implements. Keep all bystanders away from the operating area.

5. Keep all shields and safety devices in place. If a

shield, safety device, or decal is defective or damaged, repair or replace it before operation is commenced. Also, tighten any loose nuts, bolts, and screws to insure machine is in safe operating condition.

6. Do not wear loose–fitting clothing because it could

get caught in moving parts. Always wear long pants and substantial shoes. Wearing safety glasses, safety shoes, and a helmet is advisable and required by some local ordinances and insurance regulations.

2. Never allow children to operate the machine. Do not

allow adults to operate the machine without proper instruction. Only trained operators, skilled in slope operation and who have read this manual should operate this machine.

Groundsmaster 3000/3000–D

Page 1 – 1

Safety

7. Check interlock switches daily for proper operation.

Do not rely entirely on safety switches -shut off engine before getting off seat. If a switch fails, replace it before operating the machine. The interlock system is for your protection, so do not bypass it. Replace all interlock switches every two years. Interlock switches should be adjusted so:

A. Engine cannot be started unless traction pedal is released (neutral position).

B. Engine stops if operator gets off seat when traction pedal is depressed.

C. PTO disengages if operator gets off seat when PTO lever is ENGAGED (on position).

8. Fill fuel tank with diesel fuel before starting the en-

gine. Avoid spilling any fuel. Since diesel fuel is flammable, handle it carefully.

A. Use an approved fuel container. B. Do not fill fuel tank when engine is hot or

running. C. Do not smoke while handling fuel. D. Fill fuel tank outdoors and up to about one

inch (25 mm) from the top of the tank, not the filler neck.

E. Wipe up any spilled fuel.

9. Sit on the seat when starting the engine and operat-

ing the machine.

10. Always use seat belt and ROPS together. Make

sure seat is latched.

11. Before starting the engine:

A. Engage parking brake. B. Make sure traction pedal is in neutral. C. After engine is started, release parking brake

and keep foot off traction pedal. Machine must not move. If movement is evident, the neutral return mechanism is adjusted incorrectly. Shut engine off and adjust until machine does not move when traction pedal is released.

12. Do not run the engine in a confined area without ad-

equate ventilation. Exhaust fumes are hazardous and could possibly be deadly.

13. Maximum seating capacity is one person. There-

fore, never carry passengers.

14. This traction unit is intended to be used with an im-

plement. Refer to implement operator’s manual for sound and vibration information and rear weight requirements.

15. Check carefully for overhead clearances before

driving under any objects.

While Operating

16. Using the machine demands the operator’s com-

plete attention. To prevent loss of control:

A. Operate only in daylight or when there is good artificial light.

B. Drive slowly. C. Avoid sudden stops and starts. D. Look behind machine before backing up. E. Watch for holes or other hidden hazards. F. Do not drive close to a sand trap, ditch, creek,

or hazard. G. Reduce speed when making sharp turns and

when turning on a hillside. H. The cutting deck must be lowered when going

down slopes for steering control.

17. Operator must be skilled and trained in how to drive

on hillsides. Failure to use caution on slopes or hills may cause loss of control and vehicle to tip or roll possibly resulting in personal injury or death.

18. Traverse slopes carefully. Do not start or stop sud-

denly when traversing slopes or when traveling uphill or downhill.

19. If engine stalls or machine loses headway and can-

not make it to the top of a slope, do not turn machine around. Always back slowly straight down the slope.

20. This product is designed to drive objects into the

ground where they lose energy quickly in grassy areas. However, don’t take an injury risk!! appears unexpectedly in or near the mowing area, STOP MOWING. Careless operation, combined with terrain angles, ricochets, or improperly positioned guards, can lead to thrown object injuries. Do not resume mowing until area is cleared.

21. Never raise the cutting unit or other attached imple-

ment while the blades or other parts are rotating.

22. If cutting blades or other implement components

strike a solid object or the machine vibrates abnormally, disengage PTO, move throttle to SLOW, set parking brake, and shut engine off. Remove key from switch to prevent possibility of accidental starting. Check cutting unit or other implement and traction unit for damage and defective parts. Repair any damage before restarting the engine and operating the implement or cutting unit. Assure cutting unit blades are in good condition and blade bolts are torqued to proper specifications (See Cutting Deck Operator’s Manual).

23. To stop machine, remove foot from traction pedal

and use brakes. Gradually reversing the traction pedal can provide additional braking.

When a person or pet

Safety

Page 1 – 2

Groundsmaster 3000/3000–D

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.

Maintenance

26. Before getting off the seat:

A. Move traction pedal to neutral position and remove foot from pedal.

B. Set the parking brake and disengage the PTO. C. Shut the engine off and remove key from igni-

tion switch. Wait for all movement to stop before getting off the seat.

Safety

27. Remove key from ignition switch to prevent acci-

dental starting of the engine when servicing, adjusting, or storing the machine.

28. If major repairs are ever needed or assistance is de-

sired, contact an Authorized TORO Distributor.

29. To reduce potential fire hazard, keep the engine free

of excessive grease, grass, leaves, and accumulations of dirt. Never wash a warm engine or electrical connections with water.

30. If the cutting unit discharge area ever plugs, disen-

gage PTO and shut engine off before removing the obstruction.

31. Make sure machine is in safe operating condition by

keeping nuts, bolts, and screws tight. Check attachment mounting hardware and all cutting unit blade mounting bolts frequently to assure they are torqued to proper specifications.

32. Periodically inspect the roll bar and roll bar mount-

ing. Repair, as necessary. Do not weld, cut, drill, or modify roll bar in any manner.

33. Make sure all hydraulic line connectors are tight,

and all hydraulic hoses and lines are in good condition before applying pressure to the system.

34. Keep body and hands away from pin hole leaks or

nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks.

Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and do serious damage. If fluid is ejected into the skin, it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.

35. Before disconnecting or performing any work on the

hydraulic system, all pressure in system must be relieved by stopping engine and lowering implement to the ground.

36. If the engine must be running to perform mainte-

nance or an adjustment, keep clear of PTO shaft, cutting unit blades, and other moving parts.

37. Do not overspeed the engine by changing the gov-

ernor settings. To ensure safety and accuracy, have an Authorized TORO Distributor check maximum engine speed with a tachometer.

38. Engine must be shut off before checking oil or ad-

ding oil to the crankcase.

39. At the time of manufacture, the machine conformed

to safety standards in effect for riding mowers. To ensure optimum performance and continued safety certification of the machine, use genuine TORO replacement parts and accessories. Replacement parts and accessories made by other manufacturers may result in non–conformance with the safety standards, and the warranty may be voided.

Groundsmaster 3000/3000–D

Page 1 – 3

Safety

Safety and Instruction Decals (Groundsmaster 3000)

The following safety and instruction decals are mounted on the traction unit. If any decal becomes damaged or illegible, install a new decal. Part numbers are listed below or in your parts catalog.

On Side of Tool Box

(Part No. 67–1710)

Next to Right Side of Seat

(Part No. 93–5935)

On Fuse Compartment Cover

(Part No. 93–5931)

In Compartment Behind Control panel

(Part No. 93–5933)

ON FAN SHROUD

(Part No. 77–3100)

On Hood

(Part No. 93–6328)

On Right Side Of Center

Shroud

(Part No. 93–5617)

On Steering Tower

(Part No. 95–0814)

Safety

On Tool Box Cover

(Part No. 93–5621)

On Control Panel

(Part No. 93–5426)

On Frame Above Front Axle

(Part No. 85–4730)

Page 1 – 4 Rev. A

On Frame Next to Traction Pedal

(Part No. 92–5772)

Groundsmaster 3000/3000–D

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 illegible, install a new decal. Part numbers are listed below or in your parts catalog.

On Side of Tool Box

(Part No. 67–1710)

In Compartment Behind Control panel

Next to Right Side of Seat

(Part No. 93–5934)

(Part No. 93–5932)

ON FAN SHROUD

(Part No. 77–3100)

Safety

On Fuse Compartment Cover

(Part No. 93–5930)

On Tool Box Cover (Part No. 93–5621– Model 30301) (Part No. 93–5622– Model 30302)

On Radiator Near Inlet

(Part No. 93–7275)

On Steering Tower

(Part No. 95–0814)

On Frame Above Front Axle

(Part No. 85–4730)

Groundsmaster 3000/3000–D

On Control Panel

(Part No. 93–5425)

Page 1 – 5

Rev. A

On Frame Next to Traction Pedal

(Part No. 92–5772)

Safety

Safety and Instruction Decals (84I Cutting Units)

The following safety and instruction decals are mounted on the cutting unit. If any decal becomes damaged or illegible, install a new decal. Part numbers are listed below or in your parts catalog.

On Each Corner Of

Cutting Unit

(Part No. 43–8480)

On Gearbox Base

(Part No. 93–6697)

On Right & Left Covers

(Part No. 93–0299)

On Front of Deck

(Part No. 88–1270)

On Front of Cutting Unit

(Part No. 68–8340)

On Deck Channels, Under Covers

(Part No. 85–6410)

Safety

On Right Rear Top of Deck Under Cover

(Part No. 93–4688)

On Each Corner Of

Cutting Unit

(Part No. 93–7815)

Replaces Decal Part No.

43–8480 for CE

On Right Rear Top of Deck On left Rear Top of Deck

Page 1 – 6 Rev. A

On Front of Cutting Unit

(Part No. 93–7818)

Replaces Decal Part No.

68–8340 for CE

Under Cover Under Cover

(Part No. 94–3392) (Part No. 93–4691)

Groundsmaster 3000/3000–D

On Front of Deck

(Part No. 66–1340)

Safety

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 Front Of Deck

(Part No. 93–7824)

Replaces Decal Part No.

66–1340 for CE

On Each Castor Arm

(Part No. 93–4690)

On Each Castor Arm

(Part No. 93–4894)

On Deck Channels, Under Covers

(Part No. 93–7814)

Replaces Decal Part No. 85–6410 for CE

Groundsmaster 3000/3000–D

Page 1 – 7

Rev. A

Safety

Safety and Instruction Decals (Contour 82I Cutting Unit)

The following safety and instruction decals are mounted on the cutting unit. If any decal becomes damaged or illegible, install a new decal. Part numbers are listed below or in your parts catalog.

On Sides of Right &

Left Chambers

(Part No. 43–8480)

On Top of Chamber 2

(Part No. 88–1270)

On Chamber 1 & 4 Castor Supports

(Part No. 95–6001)

On Right & Left Chambers

(Part No. 93–0299)

On Top of Chamber 3

(Part No. 93–7818)

Replaces Decal Part No.

68–8340 for CE

On Top of Chamber 3

(Part No. 68–8340)

On Sides of Right &

Left Chambers

(Part No. 93–7815)

Replaces Decal Part No.

43–8480 for CE

On Top of Rear Castor

(Chamber 1)

(Part No. 95–6003)

On Left Lift Arm On Right Lift Arm

(Part No. 95–6008) (Part No. 95–6005)

Safety

Page 1 – 8

On Top of Rear Castor

(Chambers 2 & 4)

(Part No. 95–6002)

On Side of Rear Support

(Chamber 3)

(Part No. 95–6004)

Groundsmaster 3000/3000–D

Safety and Instruction Decals (Guardian 72I 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 Each Corner Of

Cutting Unit

(Part No. 43–8480)

On Gearbox Base

(Part No. 93–6697)

On Front of Cutting

Unit

(Part No. 93–7818)

Replaces Decal Part No.

68–8340 for CE

On Left Caster Arm

(Part No. 93–0299)

On Front of Deck

(Part No. 88–1270)

On Front of Cutting Unit

(Part No. 68–8340)

On Deck Channels, Under Covers

(Part No. 85–6410)

On Right Rear Top of Deck Under Cover

(Part No. 85–6120)

On Each Corner Of

Cutting Unit

(Part No. 93–7815)

Replaces Decal Part No.

43–8480 for CE

On Front Deck Hanger

(Part No. 93–4690)

Groundsmaster 3000/3000–D

On Right Rear Top of Deck On left Rear Top of Deck

(Part No. 94–3392)

(Part No. 93–4691)

On Deck Channels, Under Covers

(Part No. 93–7814)

Replaces Decal Part No. 85–6410 for CE

Page 1 – 9

Safety

Safety and Instruction Decals (Rear Discharge 72I Cutting Unit)

The following safety and instruction decals are mounted on the cutting unit. If any decal becomes damaged or illegible, install a new decal. Part numbers are listed below or in your parts catalog.

On Gearbox Base

(Part No. 93–6697)

On Front of Deck

(Part No. 68–8340)

On Front of Deck

(Part No. 93–7818)

Replaces Decal Part No.

68–8340 for CE

On Each Corner Of

Deck

(Part No. 43–8480)

On Left Caster Arm

(Part No. 93–0299)

On Front Deck Hanger

(Part No. 93–4690)

On Deck Channels, Under Covers

(Part No. 93–7814)

Replaces Decal Part No. 85–6410 for CE

Safety

On Each Corner Of

Deck

(Part No. 93–7815)

Replaces Decal Part No.

43–8480 for CE

On Right Rear Top of Deck Under Cover

(Part No. 85–6120)

Page 1 – 10

Groundsmaster 3000/3000–D

On Front of Deck

(Part No. 66–6380)

On Rear Of Deck

(Part No. 93–7828)

Replaces Decal Part No.

66–6380 for CE

On Rear Of Deck

(Part No. 93–4977)

On Front of Deck

(Part No. 66–1340)

On Deck Channels, Under Covers

(Part No. 85–6410)

On Right Rear Top of Deck On left Rear Top of Deck

(Part No. 94–3392) (Part No. 93–4691)

On Front Of Deck

(Part No. 93–7824)

Replaces Decal Part No.

66–1340 for CE

On Front of Deck

(Part No. 88–1270)

Groundsmaster 3000/3000–D

Page 1 – 11

Safety

Page 1 – 12

Groundsmaster 3000/3000–D

Product Records and Maintenance

Table of Contents

Chapter 2

PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1

EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2

Decimal and Millimeter Equivalents . . . . . . . . . . . . 2

U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 3

Capscrew Markings and Torque Values – U.S. . . 3 Capscrew Markings and Torque Values – Metric . 3

QUICK REFERENCE MAINTENANCE AID . . . . . . . 4

Product Records

Record information about your Groundsmaster 3000 or 3000–D on the OPERATION AND SERVICE HISTORY REPORT form. Use this information when referring to your machine.

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Cutting Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

OPERATION AND SERVICE HISTORY REPORTS 9

Insert Operator’s Manuals and Parts Catalogs for your Groundsmaster 3000 or 3000–D at the end of this section.

Product Records

and Maintenance

Groundsmaster 3000/3000–D

Page 2 – 1

Product Records and Maintenance

Equivalents and Conversions

Product Records and Maintenance

Page 2 – 2

Groundsmaster 3000/3000–D

Torque Specifications

Product Records

and Maintenance

Groundsmaster 3000/3000–D

Page 2 – 3

Product Records and Maintenance

800

Product Records and Maintenance

Page 2 – 4 Rev. A

800 800

400

Groundsmaster 3000/3000–D

Lubrication

Traction 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 normal conditions, lubricate all bearings and bushings after every 50 hours of operation or immediately after every washing.

The grease fitting locations and quantities are:

2 Wheel Drive Models only–Steering cylinder ball joint,

Rear axle tie rod (2), Rear axle pivot (1) Rear Spindle Shafts (2) (Fig. 1).

Figure 3

Product Records

and Maintenance

4 Wheel Drive Models only–Steering cylinder ball

joints, Rear axle tie rod (2), Rear axle pivot (1), Double Cardan joints (2 ea. side) (Fig. 2) and Rear DrIve Shaft (3) (Fig.3)

All Models–Intermediate Drive Shaft (3) (Fig. 4); Pedal

Pivots (5), Traction pedal (In square tube under floor plate) (1) (Fig. 5) and Lift arm pivot (2) (Fig. 6).

Figure 1

Figure 4

Figure 5

Figure 2

Groundsmaster 3000/3000–D

Page 2 – 5

Figure 6

Product Records and Maintenance

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, regardless of the interval listed.

Guardian 84I Recyler Cutting Unit

CAUTION

Before servicing or making adjustments to the machine, stop engine and remove key from the switch.

Product Records and Maintenance

Figure 7

Page 2 – 6

Groundsmaster 3000/3000–D

Rear Discharge 84I Cutting Unit

Product Records

and Maintenance

Contour 82I Cutting Unit

Figure 8

Groundsmaster 3000/3000–D

Figure 9

Page 2 – 7

Product Records and Maintenance

Guardian 72I Recycler Cutting Unit

Figure 10

Rear Discharge 72I Cutting Unit

Product Records and Maintenance

Figure 11

Page 2 – 8

Groundsmaster 3000/3000–D

EQUIPMENT OPERATION AND SERVICE HISTORY REPORT

for

GROUNDSMASTERR 3000

TORO Model and Serial Number: ______________–______________

Engine Numbers: _____________________________

Transmission Numbers: _____________________________

Drive Axle(s) Numbers: _____________________________

Date Purchased: _____________________________ Warranty Expires____________

Product Records

and Maintenance

Purchased From: _____________________________

_____________________________

Contacts: Parts _____________________________ Phone____________________

Service _____________________________ Phone____________________

Sales _____________________________ Phone____________________

Groundsmaster 3000/3000–D

Page 2 – 9

Product Records and Maintenance

GroundsmasterR3000 Maintenance Schedule

Minimum Recommended Maintenance Intervals

Maintenance Procedure

Lubricate All Grease Fittings

Inspect Air Filter

Check Battery Level/Cable Connections

Check Cutting Unit Gearbox Oil Level

Clean Under Cutting Unit Belt Covers

Check Cutting Unit Drive Belt Adjustment

} Change Engine Oil and Filter

Inspect Cooling System Hoses

{

Check Fan, Governor and Alternator Belt Tension

{

Torque Wheel Lug Nuts

Check Governor Oil Level

Service Spark Arrester Muffler

Service Air Filter

Change Fuel Filter

Inspect Fuel Lines and Connections

Change Spark Plugs

} Check Engine RPM (idle and full throttle)

Torque Head and Adjust Valves

Change Cutting Unit Gearbox Oil

Every 50hrs

A Level Service

Maintenance Interval & Service

Every

800hrs

Every

100hrs

B Level Service

Every

200hrs

C Level Service

Every

400hrs

D Level Service

= Change Hydraulic Oil = Change Hydraulic Oil Filter

Drain and Clean Fuel Tank

Pack Rear Axle Bearings

Check Rear Wheel Toe–In

{ Initial break in at 10 hours } Initial break in at 50 hours = Initial break in at 200 hours

Replace Moving Hoses

Replace Safety Switches

Cooling System Flush/Replace Fluid

(See Operator’s Manual for specifications and procedures.)

Product Records and Maintenance

Page 2 – 10

E Level Service

Annual Recommendations:

Items listed are recommended every 1500

hours or 2 years, whichever occurs first.

Groundsmaster 3000/3000–D

GroundsmasterR3000 Daily Maintenance Check List

Unit Designation: ____________

TORO ID #: ________–________

Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator’s Manual for fluid specifications

Maintenance Check Item b

n Safety Interlock Operation n Brake Operation n Engine Oil & Fuel Level n Cooling System Fluid Level n Radiator & Screen for Debris n Unusual Engine Noises n Unusual Operating Noises n Hydraulic System Oil Level n Hydraulic Hoses for Damage n Fluid Leaks n Tire Pressure n Instrument Operation

Lubricate All Grease Fittings

Touch–up Damaged Paint

= Immediately after every washing, regardless of the interval listed.

Daily Maintenance Check For Week Of _________________

MON TUES WED THURS FRI SAT SUN

Product Records

and Maintenance

Notation for areas of concern: Inspection performed by__________________

Item Date Information

Groundsmaster 3000/3000–D

Page 2 – 11

Product Records and Maintenance

Date: ________________

Check Governor Oil Level

Torque Wheel Lug Nuts

Service Spark Arrestor Muffler

__________________________

A and B – Service Required

________________________________

_______________________________

Replace Moving Hoses

Replace Safety Switches

Cooling System Flush/Replace Fluid

_______________________________

Other – Annual Service & Specials

_______________________________

Remarks:

3000 Supervisor Maintenance Work Order

A B C D E Other

__________________–__________________

TORO I.D. #:

Service to perform (circle):

Groundsmaster

Unit Designation:

(Duplicate this page for routine use.)

Hours:

Technician:

_______________________________

Change Engine Oil and Filter

Inspect Cooling System Hoses

Check Tension of all drive belts

Lubricate All Grease Fittings

A– Service (every 50 hours) B – Service (every 100 hours) C – Service (every 200 hours)

Check Battery Level/Cable Connections

Inspect Air Filter

_______________________________

A – Service Required

Check Cutting Unit Gearbox Oil Level

_______________________________

Clean Under Cutting Unit Belt Covers

Check Cutting Unit Drive Belt Adjustment

_______________________________

________________________________

_______________________________

________________________________

E – Service (every 800 hours)

Drain and Clean Fuel Tank

Pack Rear Axle Bearings

Change Fuel Filter

Service Air Filter

D – Service (every 400 hours)

Change Hydraulic Oil

Check Rear Wheel Toe–In

Inspect Fuel Lines and Connections

Change Hydraulic Filter

Change Spark Plugs

Check Engine RPM (idle & Full Throttle)

_______________________________

A, B, C, and D – Service Required

Torque Head Bolts and Adjust Valves

Change Cutting Unit Gearbox Oil

_______________________________

________________________________

A, B and C – Service Required

(See Operator’s and Service Manual for specifications and procedures.)

Product Records and Maintenance

Page 2 – 12

Groundsmaster 3000/3000–D

EQUIPMENT OPERATION AND SERVICE HISTORY REPORT

for

GROUNDSMASTERR 3000–D

TORO Model and Serial Number: ______________–______________

Engine Numbers: _____________________________

Transmission Numbers: _____________________________

Drive Axle(s) Numbers: _____________________________

Date Purchased: _____________________________ Warranty Expires____________

Product Records

and Maintenance

Purchased From: _____________________________

_____________________________

Contacts: Parts _____________________________ Phone____________________

Service _____________________________ Phone____________________

Sales _____________________________ Phone____________________

Groundsmaster 3000/3000–D

Page 2 – 13

Product Records and Maintenance

GroundsmasterR3000–D Maintenance Schedule

Minimum Recommended Maintenance Intervals

Maintenance Procedure Maintenance Interval & Service

Lubricate All Grease Fittings

Inspect Air Filter

Check Battery Level/Cable Connections

Check Cutting Unit Gearbox Oil Level

Clean Under Cutting Unit Belt Covers

Check Cutting Unit Drive Belt Adjustment

} Change Engine Oil and Filter

Inspect Cooling System Hoses

{

Check Fan and Alternator Belt Tension

{

Torque Wheel Lug Nuts

Service Air Filter

Change Fuel Filter

Inspect Fuel Lines and Connections

} Check Engine RPM (idle and full throttle)

Check Rear Axle Oil Level (4wd)

Change Cutting Unit Gearbox Oil

= Change Rear Axle Oil (4wd) = Change Hydraulic Oil (see note below)

= Change Hydraulic Oil Filter (see note below)

Inspect Engine Timing Belt (see note below)

Drain and Clean Fuel Tank

Pack 2WD Rear Axle Bearings

Check Rear Wheel Toe–In

Every 50hrs

A Level Service

Every

100hrs

B Level Service

Every

200hrs

C Level Service

Every

400hrs

D Level

Service

Every

800 hrs

E Level Service

{ Initial break in at 10 hours } Initial break in at 50 hours = Initial break in at 200 hours

Replace Moving Hoses

Replace Safety Switches

Cooling System Flush/Replace Fluid

(See Operator’s Manual for specifications and procedures.)

NOTE: Replace Timing Belt after every 1500 hours of operation or if worn, cracked, oil soaked or

any time the Belt is removed or loosened.

NOTE: Replace Hydraulic Oil and Filter every 400 hours of operation if machine is equipped with Model 30726 Auxiliary Hydraulic Kit.

Product Records and Maintenance

Page 2 – 14

Annual Recommendations:

Items listed are recommended every 1500

hours or 2 years, whichever occurs first.

Rev. B

Groundsmaster 3000/3000–D

GroundsmasterR3000–D Daily Maintenance Check List

Unit Designation: ____________

TORO ID #: ________–________

Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator’s Manual for fluid specifications

Maintenance Check Item b

n Safety Interlock Operation n Brake Operation n Engine Oil & Fuel Level n Cooling System Fluid Level

Drain Water/Fuel Separator

n Radiator & Screen for Debris n Unusual Engine Noises n Unusual Operating Noises n Hydraulic System Oil Level n Hydraulic Hoses for Damage n Fluid Leaks n Tire Pressure n Instrument Operation

Lubricate All Grease Fittings

Touch–up Damaged Paint

= Check glow plug and injector nozzles, if hard starting, excess smoke or rough running is noted.

= Immediately after every washing, regardless of the interval listed.

Daily Maintenance Check For Week Of _________________

MON TUES WED THURS FRI SAT SUN

Product Records

and Maintenance

Notation for areas of concern: Inspection performed by_____________________________

Item Date Information

1 2 3 4 5 6 7 8

Groundsmaster 3000/3000–D

Page 2 – 15

Product Records and Maintenance

Date: ________________

________________________________

Torque Wheel Lug Nuts

A and B – Service Required

________________________________

Other – Annual Service & Specials

Replace Moving Hoses

Replace Safety Switches

Timing Belt (see note on Maint. Sched.)

Cooling System Flush/Replace Fluid

_______________________________

Remarks:

3000–D Supervisor Maintenance Work Order

A B C D E Other

__________________–__________________

TORO I.D. #:

Service to perform (circle):

Groundsmaster

Unit Designation:

(Duplicate this page for routine use.)

Hours:

Technician:

_______________________________

Change Engine Oil and Filter

Inspect Cooling System Hoses

Lubricate All Grease Fittings

A– Service (every 50 hours) B – Service (every 100 hours) C – Service (every 200 hours)

Inspect Air Filter

A–Level Service Required

_______________________________

Check Fan and Alternator Belt Tension

Check Battery Level/Cable Connections

Check Cutting Unit Gearbox Oil Level

_______________________________

Clean Under Cutting Unit Belt Covers

Check Cutting Unit Drive Belt Adjustment

_______________________________

________________________________

Inspect Timing Belt

Drain and Clean Fuel Tank

Pack 2WD Rear Axle Bearings

Check Rear Wheel Toe–In

Hyd. Oil (see note on Maint. Sched.)

_______________________________

________________________________

E – Service (every 600 hours)

Change Fuel Filter

Service Air Filter

D – Service (every 400 hours)

Inspect Fuel Lines and Connections

Check Engine RPM (Idle & Full Throttle)

Hyd. Filter (see note on Maint. Sched.)

A, B, C, and D – Service Required

Change Rear Axle OIl (4WD)

Change Cutting Unit Gearbox Oil

Check Rear Axle OIl Level (4WD)

_______________________________

________________________________

A, B, and C – Service Required

(See Operator’s and Service Manual for specifications and procedures.)

Product Records and Maintenance

Page 2 – 16

Rev. A

Groundsmaster 3000/3000–D

Table of Contents

Chapter 3

Ford VSG–411 Engine

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Belt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Governor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4

Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Change Engine Oil and Filter . . . . . . . . . . . . . . . . . . 6

Check Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Cooling System Service 8. . . . . . . . . . . . . . . . . . . . . .

General Air Cleaner Service 9. . . . . . . . . . . . . . . . . .

Servicing Air Cleaner 9. . . . . . . . . . . . . . . . . . . . . . . .

Fuel System Service 10. . . . . . . . . . . . . . . . . . . . . . . .

Replacing Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . 11

Check Governor Oil Level . . . . . . . . . . . . . . . . . . . . 11

Servicing Spark Arrestor Muffler 12. . . . . . . . . . . . . .

FORD VSG–411/413 ENGINE SERVICE MANUAL

Engine

Ford Gasoline

Groundsmaster 3000

Page 3 – 1

Ford VSG–411 Engine

General Information

The engine used in the Groundsmaster 3000 is manufacutured by Ford Motor Company. Order service and repair parts for Ford engines from you local Ford Power Products Dealer. See the Ford VSG–411/413 Engine Service Manual for engine identification information.

Specifications

Item Specification

Make / Designation Ford Model VSG–411

Firing Order 1–2–4–3

Ignition Timing Distributorless Ignition System (DIS) Timing controlled by

Spark Plug Motorcraft AGSF22C or AGRF22 or equivalent

Spark Plug Gap 0.040 in. (1.0 mm)

Crankcase Oil Capacity 3.5 U.S. qt. (3.25 liter) including filter

Oil Service Classification API SG Oil Viscosity Ambient temperature (single viscosity oil)

–10 to +60_F SAE 10 +10_ to +90_F SAE 20 Above +32_F SAE 30 Above +50_F SAE 40

Universal Electronic Spark Control (UESC)

Ambient temperature (multi–viscosity oil)

Below +60_F SAE 5W–30 –10 to +90_F SAE 10W–30 Above –10_F SAE 10W–40 or 10W50 Above +10_F SAE 20W40 or 20W50

Fuel Unleaded gasoline 87 octane or higher

Coolant 50 / 50 ethylene glocol anti–freeze and water

Cooling System Capacity 9 U.S. qt. (8.5 liter)

Carburetor Idle Speed Setting (throttle arm against stop) 1350 + 50 RPM

Governor Idle Speed Setting 1500 + 50 RPM

Governor High Speed Setting 3150 + 100 RPM

Ford VSG–411 Engine

Page 3 – 2 Rev. A

Groundsmaster 3000

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 tension, loosen bolt securing brace to engine, bolt securing alternator to brace and alternator mounting bolt.

2. Rotate alternator away from engine.

3. Hold alternator in position after proper belt tension setting is achieved and tighten alternator and brace bolts to secure adjustment.

Cooling & Governor Fan Belts

The cooling and governor fan belts belt should be tensioned so when they are pressed firmly with thumb, midway between pulleys, they deflect .38 inch (9.7 mm).

1. To adjust belt tension, loosen upper and lower nuts securing idler arm to front engine mount.

2. Pull out on idler arm until desired belt tension is achieved.

3. Tighten mounting nuts to secure adjustment.

Figure 1

1. Cooling Fan Belt

2. Governor Fan Belt

Engine

Ford Gasoline

Groundsmaster 3000

Page 3 – 3

Ford VSG–411 Engine

Governor Adjustment

1. With engine shut off, move throttle control to FAST position and open hood. Check between the throttle arm and the stop on the carburetor base to make sure there is 1/32” (0.8 mm). If gap is not correct, adjust throttle rod by turning ball joint ends until gap is 1/32” (0.8 mm). If gap is correct, proceed to step 2.

WARNING

Engine must be running so final adjustment of the governor can be performed.

guard against possible personal

To injury, engage parking brake and keep hands, feet, face and other parts of the body away from fan or other moving parts.

2. Start engine and move throttle to SLOW position. Allow engine to warm up to normal operating temperature.

3. Rotate throttle arm closed until it contacts stop.

9. Bump the throttle lever with your hand so engine speeds up momentarily. If governor is working properly, engine speed should return to normal within one or two surges of the governor. More than two surges of the governor usually indicates than the anti–surge screw must be turned in slightly more than it is. When adjustment is correct, lock jam nut against governor body.

10. Check low and high idle speed to be sure there is no change from the initial setting. If high idle speed has increased, anti–surge has been turned into the governor too far and it must be backed out. Then repeat the entire adjustment procedure.

Note: If the throttle control on the instrument panel will not stay in the FAST position during operation, remove the panel cover and tighten the nut at base of throttle lever assembly.

4. Check idle speed and adjust carburetor idle speed screw if necessary to attain 1350 +

50 rpm.

5. Release throttle arm, loosen jam nut on governor low idle speed screw and adjust it to attain 1500 + 100 rpm.

6. Slowly move throttle to FAST position until engine speed reaches 3150 +

100 rpm. Shut off engine. Adjust

high idle stop screw until it contacts speed control lever.

IMPORT ANT : Do not over speed the engine because

the transmission could be damaged.

7. Move throttle rapidly from SLOW to FAST. The engine should not surge. if engine surges, proceed to step

8. Check V–belts from engine to governor pulley and assure they are tight. If belts are loose, the engine will surge. If belts are tensioned properly, loosen jam nut that retains the anti–surge screw. Rotate screw clockwise 1/8 turn at a time until surging stops. Should governor continue to surge, check the following:

A. Carburetor too rich or too lean. B. Binding in throttle linkage. C. Governor worn internally.

IMPORTANT: Never rotate anti–surge screw in too far so that speed of engine increases.

Figure 2

1. 1/32” (0.8 mm)

2. Throttle rod

3. Carburetor idle speed screw

Figure 3

1. High idle stop screw

2. Speed control lever

3. Jam nut

4. Stop

5. Throttle arm

4. Anti–surge screw

5. Low idle stop screw

Ford VSG–411 Engine

Page 3 – 4

Groundsmaster 3000

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. Remove dipstick and check level of oil. If level of oil is low, add enough oil to raise level to notch in dipstick. DO NOT OVERFILL.

3. Install dipstick into tube.

4. If oil level is low, clean area around oil fill cap, re-

move cap and add oil until level reaches FULL mark on dipstick. DO NOT OVERFILL.

5. The engine uses any high–quality detergent oil hav-

ing the American Petroleum Institute—API—“service classification” SG. Oil viscosity–weight– must be selected according to ambient temperature. Temperature/ viscosity recommendations are:

Figure 4

1. Hood Latch

Engine

Ford Gasoline

Single Viscosity Oils

Outside Temperature

–10_F to +60_F SAE 10W +10_F to +90_F SAE 20W–20 Above +32_F SAE 30 Above +50_F SAE 40

Multi–Viscosity Oils

Outside Temperature

Below +60_F SAE 5W–30 –10_F to +90_F SAE 10W–30 Above –10_F SAE 10W–40 or 10W50 Above +10_F SAE 20W–40 or 20W50

IMPORT ANT : Check level of oil after every 5 hours of operation or daily. Change oil after initial 50 hours and every 100 hours thereafter. Change oil and filter more frequently when engine is operated in ex tremely dusty or dirty conditions.

6. Install oil fill cap.

7. Close hood and secure latch.

Figure 5

1. Dipstick

Figure 6

1. Oil Fill Cap

Groundsmaster 3000

Page 3 – 5

Ford VSG–411 Engine

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 of clean

oil to the new filter seal before screwing it on. DO NOT OVER–TIGHTEN.

3. Add oil to crankcase. Capacity is 3.5 U.S. quarts

(3.3 liters) with filter. Refer to Check Engine Oil.

Figure 7

1. Drain Plug

Figure 8

1. Oil Filter

Ford VSG–411 Engine

Page 3 – 6

Groundsmaster 3000

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 of each day before starting the engine.

1. Park machine on a level surface. Rotate hood latch

fully counterclockwise and open hood.

2. Check coolant level. Coolant should be up to COLD

line on reserve tank, when engine is cold.

CAUTION

If engine has been running, pressurized hot coolant can escape and cause burns if radiator cap is removed. Allow engine to cool at least 15 minutes or until the radiator cap is cool enough to touch without burning hand.

HOT

COLD

Figure 9

1. Reserve Tank

Engine

Ford Gasoline

3. If coolant is low, remove reserve tank cap and add a

50/50 mixture of water and permanent ethylene glycol

anti–freeze. DO NOT OVERFILL.

4. Install reserve tank cap.

5. Close hood and secure latch.

Groundsmaster 3000

Page 3 – 7

Ford VSG–411 Engine

Cooling System Service

1. Removing Debris – Remove debris from rear

screen, oil cooler and radiator daily, clean more frequently in dirty conditions.

IMPORT ANT : 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 latch and raise hood. Clean engine area thoroughly of all debris.

C. Clean both sides of oil cooler and radiator area

thoroughly with compressed air. Do not use water .

D. Close hood and secure latch.

Note: Do not use water to clean engine or electrical

components, as damage may occur.

2. Maintaining Cooling System – Capacity of the

system is 9 quarts (8.5 liters). Always protect cooling system with a 50/50 solution of water and permanent ethylene glycol anti–freeze. DO NOT USE WATER ONLY IN COOLING SYSTEM.

A. After every 100 operating hours, inspect and tighten hose connections. Replace any deteriorated hoses.

B. After every 2 years, drain and flush the cooling system. Add anti–freeze (refer to Check Cooling System).

Figure 10

1. Rear Screen

Figure 11

1. Oil Cooler

2. Radiator

Ford VSG–411 Engine

Page 3 – 8

Groundsmaster 3000

General Air Cleaner Service

1. Inspect air cleaner after every 50 hours of operation.

More frequent in dusty or dirty conditions.

2. Check air cleaner body for damage which could

possibly cause an air leak. Replace a damaged air cleaner body.

3. Service the air cleaner filter every 400 hours (more

frequently in extreme dusty or dirty conditions). Do not over service air filter.

4. Be sure cover is sealing around air cleaner body.

Service Air Cleaner

1. Release latches securing air cleaner cover to air

cleaner body. Separate cover from body. Clean inside of air cleaner cover.

2. Gently slide filter (Fig. 13) out of air cleaner body to

reduce the amount of dust dislodged. Avoid knocking filter against air cleaner body.

CAUTION

Never operate machine without complete air cleaner assembly in place and latched properly or a damaged air cleaner Debris entering engine can cause engine failure.

Engine

Ford Gasoline

3. Inspect filter and discard if damaged. Do not wash

or reuse a damaged filter.

Washing Method

A. Prepare a solution of filter cleaner and water and soak filter element about 15 minutes. Refer to directions on filter cleaner carton for complete information.

B. After soaking filter for 15 minutes, rinse it with clear water. Maximum water pressure must not exceed 40 psi to prevent damage to the filter element. Rinse filter from clean side to dirty side.

C. Dry filter element using warm, flowing air (160_F ) max), or allow element to air–dry. Do not use a light bulb to dry the filter element because damage could result.

Compressed Air Method

A. Blow compressed air from inside to the outside of dry filter element. Do not exceed 100 psi to prevent damage to the element.

B. Keep air hose nozzle at least 2” from filter and move nozzle up and down while rotating the filter element. Inspect for holes and tears by looking through the filter toward a bright light.

5. Inspect new filter for shipping damage. Check seal-

ing end of filter. Do not install a damaged filter.

6. Insert new filter properly into air cleaner body. Make

sure filter is sealed properly by applying pressure to outer rim of filter when installing. Do not press on flexible center of filter.

7. Reinstall cover and secure latches. Make sure cov-

er is positioned with TOP side up.

Groundsmaster 3000

Page 3 – 9

Figure 12

1. Air cleaner latches

2. Dust cup

Figure 13

1. Air cleaner filter

Ford VSG–411 Engine

Fuel System Service

Fuel Tank

Drain and clean fuel tank every 800 hours of operation or yearly, whichever comes first. Also, drain and clean tank if fuel system becomes contaminated or if machine is to be stored for an extended period. Use clean fuel to flush out the tank.

Fuel Lines and Connections

Check lines and connections every 400 hours or yearly, whichever comes first. Inspect for deterioration, damage, or loose connections.

DANGER

Because gasoline is flammable, caution must be used when storing or handling it. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area. Vapors may build up and be ignited by a spark or flame source many feet away . DO NOT SMOKE while filling the fuel tank to prevent the possibility of an explosion. Always fill fuel tank outside and wipe up any spilled gasoline before starting engine. Use a funnel or spout to prevent spilling gasoline and fill tank to about 1 inch (25 mm) below the filler neck. Store gasoline in a clean, safety–approved container and keep the cap in place on the container. Keep gasoline in a cool, well–ventilated place, never in an enclosed area such as a hot storage shed. To assure volatility, do not buy more than a 6 month supply. Gasoline is a fuel for internal combustion engines; therefore, do not use it for any other purpose. Since many children like the smell of gas, keep it out of their reach because the fumes are explosive and dangerous to inhale.

Replacing Fuel Filter (Fig. 14)

Replace the fuel filter after every 400 hours of operation or yearly, whichever comes first.

1. Disconnect elbow fitting from rear of fuel filter.

2. Disconnect front of filter from elbow fitting.

3. Install new filter and connect fittings. Start engine

and check for leaks.

Ford VSG–411 Engine

Page 3 – 10

Figure 14

1. Fuel filter

2. Rear elbow

3. Front elbow

Groundsmaster 3000

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 and checked whenever the engine malfunctions.

1. Clean area around spark plugs so foreign matter

cannot fall into cylinder when spark plug is removed.

2. Pull spark plug wires off spark plugs and remove

plugs from cylinder head.

Check Governor Oil Level

The governor is shipped with oil in it, but the level of oil must be checked after every 250 hours of operation.

1. Position machine on level surface and shut engine

off.

2. Disengage hood latch and open the hood.

3. Check condition of side electrode, center electrode,

and center electrode insulator to assure there is no damage.

IMPORTANT: A cracked, fouled, dirty or otherwise

malfunctioning spark plug must be replaced. Do not sand blast, scrape, or clean electrodes by using a wire brush because grit may eventually release from the plug and fall into the cylinder. The result is usually a damaged engine.

4. Set air gap between center and side of electrodes at

.040” (1.016 mm). Install correctly gapped spark plug and tighten plug to 11–15 ft–lb. If torque wrench is not used, tighten plug firmly.

5. Install spark plug wires.

Engine

Ford Gasoline

3. Clean area around check plug on governor.

4. Remove check plug. Oil level must be up to bottom

of filler hole. If oil level is low, remove oil fill plug and add same oil that is being used in engine. When oil is at point of overflowing out of check plug hole, install the check plug and fill plug.

Figure 15

1. Oil check plug

Groundsmaster 3000

Page 3 – 11

Ford VSG–411 Engine

Servicing Spark Arrestor Muffler

Every 200 hours operation, clear the muffler of carbon buildup.

1. Remove pipe plug from clean–out port at lower side

of muffler.

CAUTION

Be careful while working around muffler as it may be hot and could cause injury.

2. Start engine. Plug the normal muffler exit with block

of wood or metal plate so exhaust flow will be forced out of the clean–out port. Continue to block exit until carbon deposits cease coming out port.

CAUTION

Do not stand in line with the clean–out port. Always wear safety glasses.

3. Stop engine and replace pipe plug.

Ford VSG–411 Engine

Page 3 – 12

Groundsmaster 3000

Table of Contents

Chapter 4

Peugeot TUD5 Engine

SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Belt Adjustments 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE AND REPAIRS 9. . . . . . . . . . . . . . . . . . . . . .

Check Engine Oil 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change Engine Oil and Filter 10. . . . . . . . . . . . . . . . .

Check Cooling System . . . . . . . . . . . . . . . . . . . . . . . 11

Cooling System Service 12. . . . . . . . . . . . . . . . . . . . .

General Air Cleaner Service 13. . . . . . . . . . . . . . . . .

Servicing Air Cleaner 13. . . . . . . . . . . . . . . . . . . . . . .

Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . 14

Priming Fuel System . . . . . . . . . . . . . . . . . . . . . . . . 15

Frame, Fuel Tank and Battery . . . . . . . . . . . . . . . . 16

Muffler and Rear Bumper . . . . . . . . . . . . . . . . . . . . 17

Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fan Bracket and Degasser . . . . . . . . . . . . . . . . . . 19

Center Shroud and Air Cleaner . . . . . . . . . . . . . . . 20

Radiator and Cooler . . . . . . . . . . . . . . . . . . . . . . . . 21

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Peugeot TUD5 Overhaul, Checking, Tuning . . . . 23

Engine

Peugeot Diesel

Groundsmaster 3000–D

Page 4 – 1

Peugeot TUD5 Engine

Specifications

Item Specification

Make / Designation Peugeot TUD5

Governor Adjustment High idle 2650 + 50 RPM

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

Coolant capacity 11.5 U.S. qt. (10.9 liters)

4 cycle, in–line, overhead cam,

liquid cooled diesel engine

Low Idle 1500 +

(Toro Part No. 93–7213)

100 R{M

Figure 1 Figure 2

Peugeot TUD5 Engine

Page 4 – 2

Groundsmaster 3000–D

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

Valve Spring Compression Tool (TOR4024T)

Use for removing valve springs.

Figure 3

Air Filter Element Cleaner (TOR277220)

A solution of filter cleaner and water may be used to wash the air filter element of the Donaldson 3–stage air cleaners.

DANGER: This compound contains sodium metasilicate which may cause burns and is harmful if swallowed. Keep this chemical out of the reach of children.

Engine

Peugeot Diesel

Figure 4

Figure 5

Groundsmaster 3000–D

Page 4 – 3

Peugeot TUD5 Engine

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.

Digital Belt Tension Tool (TOR4075)

Tool is used to accurately adjust the cam drive belt ten-

sion. NOTE: This tool is not included in T OR4080 kit.

Order separately.

Figure 6

Peugeot TUD5 Diesel Engine Service Tool Kit (TOR4080)

Kit includes: TOR4081, TOR4082, TOR4083, TOR4084, TOR4085, TOR4086, TOR4087, TOR4088.

Figure 7

See the following pages for individual tool descriptions.

Figure 8

Peugeot TUD5 Engine

Page 4 – 4

Groundsmaster 3000–D

Valve Guide Seal Remover (TOR4081)

Use to remove old valve guide seals.

Injector Socket (TOR4082)

A special deep socket to remove and install injectors.

Figure 9

Torque Angle Gauge (TOR4083)

Provides a method to tighten the fastener a specified number of degrees after torque loads are applied. Calibrated in degrees in large easy to read increments. 1/2 inch square drive.

Engine

Peugeot Diesel

Figure 10

Figure 11

Groundsmaster 3000–D

Page 4 – 5

Peugeot TUD5 Engine

Camshaft Pinion Setting Tool (TOR4084)

Tool is used to hold the camshaft gear and / or injector pump gear while tightening the fasteners.

Timing Pin Set (TOR4085)

Tool set is used to set injection pump engine timing.

Figure 12

Rear Main Seal Installer (TOR4086)

Tool is used to install the crankshaft rear main seal.

Figure 13

Figure 14

Peugeot TUD5 Engine

Page 4 – 6

Groundsmaster 3000–D

Front Seal Installer (TOR4087)

Tool is used to install the crankshaft front seal.

Camshaft Seal Installer (TOR4088)

Tool is used to install the camshaft seal.

Figure 15

Figure 16

Engine

Peugeot Diesel

Groundsmaster 3000–D

Page 4 – 7

Peugeot TUD5 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 pulleys, when pressed firmly with thumb.

2. If deflection exceeds 1/8 in. (3.2 mm), loosen alter-

nator mounting bolts. Adjust belt tension and tighten mounting bolts. Check deflection of belt again to assure tension is correct.

Fan Belt

1. Proper tension will allow 3/8 in. (9.5 mm) deflection

on the belt midway between the pulleys, when pressed firmly with thumb.

2. If deflection exceeds 3/8 in. (9.5 mm), loosen pulley

mounting bolt. Adjust belt tension and tighten mounting bolt. Check deflection of belt again to assure tension is correct.

Figure 17

1. Fan Belt

2. Alternator belt

Peugeot TUD5 Engine

Page 4 – 8

Groundsmaster 3000–D

Service and Repairs

CAUTION

Before servicing or making adjustments to the machine, stop engine and remove key from the switch.

Check Engine Oil

Crankcase capacity is 4.75 U.S. qt. (4.5 liters) with filter.

1. Park machine on a level surface. Rotate hood latch

fully counterclockwise and open hood.

2. Remove dipstick and wipe it with a clean rag. Insert

dipstick into tube and make sure it is fully seated. Remove dipstick and check level of oil. If level of oil is low, add enough oil to raise level to notch in dipstick. DO NOT OVERFILL.

3. If oil level is low, clean area around oil fill cap, re-

move cap and add SAE 15W–40 CE oil until level reaches FULL mark on dipstick. DO NOT OVERFILL.

4. Install oil fill cap.

5. Close hood and secure latch.

Figure 18

1. Hood Latch

Engine

Peugeot Diesel

Figure 19

1. Dipstick

2. Oil Fill Cap

Groundsmaster 3000–D

Page 4 – 9

Peugeot TUD5 Engine

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 filter (Fig. 21). Apply a light coat of clean

oil to the new filter seal before screwing it on. DO NOT OVER–TIGHTEN.

3. Add 15W–40 CE oil to crankcase. Capacity is 4.75

quarts with filter.

Figure 20

1. Drain Plug

Peugeot TUD5 Engine

Page 4 – 10

Figure 21

1. Oil Filter

Groundsmaster 3000–D

Check Cooling System

Capacity of system is 11.5 qts. (10.9 l).

Check cooling system if low water level light illuminates.

1. Park machine on a level surface. Release hood

latch and open hood.

2. Remove degasser tank cap and check coolant level. Coolant level should be up to or above tabs In de-

gasser tank, when engine is cold.

CAUTION

If engine has been running, pressurized hot coolant can escape and cause burns if degasser cap is removed. Allow engine to cool at least 15 minutes or until the degasser cap is cool enough to touch without burning hand.

3. If coolant is low, remove degasser tank cap and add

a 50/50 mixture of water and Peugeot recommended

anti–freeze (Toro Part No. 93–7213). DO NOT USE WA-

TER ONL Y OR ALCOHOL/METHANOL BASE COOLANTS.

4. Install degasser tank cap.

5. Close hood and secure latch.

Figure 22

1. Degasser Tank

Engine

Peugeot Diesel

Groundsmaster 3000–D

Page 4 – 11

Peugeot TUD5 Engine

Cooling System Service

1. Removing Debris – Remove debris from rear

screen, oil cooler and radiator daily, clean more frequently in dirty conditions.

IMPORT ANT : 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 latch and raise hood. Clean engine area thoroughly of all debris.

C. Clean both sides of oil cooler and radiator area

thoroughly with compressed air. Do not use water .

D. Close hood and secure latch.

Note: Do not use water to clean engine or electrical

components, as damage may occur.

2. Maintaining Cooling System – Capacity of the

system is 11.5 quarts. Always protect cooling system with a 50/50 solution of water and Peugeot recommended anti–freeze (Part No. 93–7213). DO NOT USE WATER ONLY IN COOLING SYSTEM.

A. After every 100 operating hours, inspect and tighten hose connections. Replace any deteriorated hoses.

B. After every 2 years, drain and flush the cooling system. Add anti–freeze (refer to Check Cooling System).

Figure 23

1. Rear Screen

Figure 24

1. Oil Cooler

2. Radiator

Peugeot TUD5 Engine

Page 4 – 12

Groundsmaster 3000–D

General Air Cleaner Maintenance

1. Inspect air cleaner after every 50 hours of operation.

More frequent in dusty or dirty conditions.

2. Check air cleaner body for damage which could

possibly cause an air leak. Replace a damaged air cleaner body.

3. Service the air cleaner filter every 400 hours (more

frequently in extreme dusty or dirty conditions). Do not over service air filter.

4. Be sure cover is sealing around air cleaner body.

Servicing the Air Cleaner

1. Release latches securing air cleaner cover to air

cleaner body. Separate cover from body. Clean inside of air cleaner cover.

2. Gently slide filter (Fig. 26) out of air cleaner body to

reduce the amount of dust dislodged. Avoid knocking filter against air cleaner body.

3. Inspect filter and discard if damaged. Do not wash

or reuse a damaged filter.

Washing Method

A. Prepare a solution of filter cleaner and water and soak filter element about 15 minutes. Refer to directions on filter cleaner carton for complete information.

B. After soaking filter for 15 minutes, rinse it with clear water. Maximum water pressure must not exceed 40 psi to prevent damage to the filter element. Rinse filter from clean side to dirty to side.

C. Dry filter element using warm, flowing air (160_F ) max), or allow element to air–dry. Do not use a light bulb to dry the filter element because damage could result.

Compressed Air Method

A. Blow compressed air from inside to the outside of dry filter element. Do not exceed 100 psi to prevent damage to the element.

B. Keep air hose nozzle at least 2” from filter and move nozzle up and down while rotating the filter element. Inspect for holes and tears by looking through the filter toward a bright light.

5. Inspect new filter for shipping damage. Check seal-

ing end of filter. Do not install a damaged filter.

6. Insert new filter properly into air cleaner body. Make

sure filter is sealed properly by applying pressure to outer rim of filter when installing. Do not press on flexible center of filter.

7. Reinstall cover and secure latches. Make sure cov-

er is positioned with TOP side up.

CAUTION

Never operate machine without complete air cleaner assembly in place and latched properly or a damaged air cleaner Debris entering engine can cause engine failure.

Engine

Peugeot Diesel

Figure 25

1. Air cleaner latches

2. Dust cup

Figure 26

1. Air cleaner filter

Groundsmaster 3000–D

Page 4 – 13

Peugeot TUD5 Engine

Fuel System Service

Fuel Tank

DANGER

Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety– approved container and keep cap in place. Use diesel fuel for the engine only; not for any other purpose.

Figure 27

1. Fuel Filter

2. Drain Screw

3. Primer plunger

Fuel Lines and Connections

Check lines and connections every 400 hours or yearly, whichever comes first. Inspect for deterioration, damage, or loose connections.

Draining Fuel Filter / Water Separator

Drain water or other contaminants from fuel filter / water separator daily.

1. Place a clean container under fuel filter.

2. Loosen drain screw on bottom of fuel filter and press

primer plunger until only fuel is evident draining into container.

Changing Fuel Filter

Replace fuel filter if fuel flow becomes restricted, after every 400 hours of operation or annually, whichever comes first.

1. Loosen bolt and unscrew bottom filter cap from filter

assembly. Remove cap, gaskets, o-ring and filter from assembly. Note position of gaskets and o-ring when disassembling from filter.

2. Install new filter, gaskets, o-ring with filter assembly

cap.

3. Prime fuel system, refer to Priming Fuel System.

Peugeot TUD5 Engine

Page 4 – 14

Groundsmaster 3000–D

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 container to catch fuel.

3. Loosen fuel filter / water separator bleed screw (Fig.

28) a few turns. Pump priming plunger until a steady stream of fuel comes out of hole in bleed screw. When fuel stops foaming, tighten the bleed screw during the downstroke of the priming plunger. Wipe up any spilled fuel.

4. Pump priming plunger until resistance is felt. Try to

start engine. If engine does not start repeat step 3.

Figure 28

1. Primer Plunger 2. Bleed Screw

Engine

Peugeot Diesel

Groundsmaster 3000–D

Page 4 – 15

Peugeot TUD5 Engine

Frame, Fuel Tank and Battery

2930

1. Bushing 11. Stand pipe 21. Battery cable (+)

2. Fuel hose 12. Fuel hose 22. Ground cable

3. Hose clamp 13. Screw 23. Battery rod

4. Fitting 14. Washer 24. Battery cable (–)

5. Lock washer 15. Spacer 25. Washer

6. Fuel hose 16. Fuel tank 26. Lock nut

7. Gasket 17. Lock nut 27. Threaded rod

8. Fuel sender 18. Frame 28. Battery cover

9. Screw 19. Clinch nut 29. Cover retainer

10. Fuel cap 20. Bumper 30. Flat washer

Peugeot TUD5 Engine

Figure 29

Page 4 – 16

31. Retaining ring

Groundsmaster 3000–D

Muffler and Bumper

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. Carriage screw

Engine

Peugeot Diesel

Groundsmaster 3000–D

Page 4 – 17

Peugeot TUD5 Engine

Hood

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. Caution decal (Europe)

7. Tinnermann nut 14. Screw

Peugeot TUD5 Engine

Page 4 – 18

Groundsmaster 3000–D

Center Shroud and Air Cleaner

34 5

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. Screw (Model 30302 only) 23. Nut

4. Hose clamp 14. Washer (Model 30302 only) 24. Hose

5. Fuel hose 15. Bar (Europe) 25. Hose

6. Fuel hose 16. Nut 26. Lock washer

7. Air cleaner hose 17. Decal – 4wd (Model 30302 only) 27. Nut

8. Hose clamp 18. Screw 28. Lock washer

9. Air cleaner 19. Flat washer 29. ROPS decal

10. Hose clamp 20. Screw 30. Safety decal (Model 30301 only)

Engine

Peugeot Diesel

Groundsmaster 3000–D

Page 4 – 19

Peugeot TUD5 Engine

Fan Bracket and Degasser

1 2 3

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. Screw 21. Radiator cap

8. Lock nut 15. Carriage screw 22. Decal

Peugeot TUD5 Engine

Page 4 – 20

Groundsmaster 3000–D

Radiator and Cooler

Pipe thread sealant

Engine

Fan clearance minimum .18 inch (5 mm)

2223242526

Peugeot Diesel

1. Upper radiator hose 18. Lower radiator support 33. Lower radiator hose

2. Hose clamp 19. Lock nut 34. Draiin cock fitting

3. Hose 20. LH radiator support 35. Female hose barb

4. Hose clamp 22. Screw 36. Hose

5. Decal (Europe) 23. Radiator 37. Foam plug

7. Spacer 24. Radiator shroud 38. Foam strip

8. Rubber grommet 25. Flat washer 39. Rubber grommet

9. Lock nut 26. Screw 40. Cooler mount bracket

10. Upper radiator support 27. Restriction fitting 41. Clinch nut

11. Decal – starting fluid (Europe) 28. Clamp 42. R–clamp

12. RH radiator support 29. Hose 43. Screw

13. Screw 30. O–ring 44. Shield

14. Heat exchanger 31. Radiator hose

15. Adapter fitting 32. Radiator hose fitting

Groundsmaster 3000–D

Figure 34

Page 4 – 21

Rev. A

Peugeot TUD5 Engine

Engine

89 11

Figure 35

1. Front engine plate 17. V–belt 33. Lock nut

2. Screw 18. Screw 34. Screw

3. Snubbing washer 19. Fan 35. Exhaust pipe

4. Engine mount 20. Screw 36. Screw

5. Lower radiator hose 21. Fan pulley 37. Nut

6. R.H. engine mount 22. Fan bracket 38. Nut

7. Lock nut 23. Screw 39. Screw

8. Fuel hose 24. Lock washer 40. Screw

9. Hose clamp 25. Crank pulley 41. Lock washer

10. Fuel hose 26. Crank spacer 42. Screw

11. Engine 27. L.H. engine mount 43. R–clamp

12. Bearing 28. Screw 44. Throttle cable mount

13. Retaining ring 29. Flat washer 45. Screw

14. Screw 30. Hose 46. Lock washer – external tooth

15. Fan hub 31. R–clamp 47. Flat washe

16. Fan hub 32. Nut 48. Lock washer

NOTE: See the Toro Parts Catalog for more information.

Peugeot TUD5 Engine

Page 4 – 22

Groundsmaster 3000–D

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 T ools list starting on Page 4 – 3 of

the Toro Groundsmaster 3000/3000–D Service Manual. The tool numbers referred to in the Peugeot manual are Peugeot numbers, which Toro does not use.

Use the TORO lubrication, maintenance and fluid recommendations if they are different from the information in the Peugeot manual.

Engine

Peugeot Diesel

Groundsmaster 3000–D

Page 4 – 23

Peugeot TUD5 Engine

Page 4 – 24

Groundsmaster 3000–D

Hydraulic System and Transaxle

Table of Contents

Chapter 5

SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION 3. . . . . . . . . . . . . . . . . . . . .

Pushing or Towing Traction Unit 3. . . . . . . . . . . . . . .

Hydraulic Hoses 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Fitting Installation 3. . . . . . . . . . . . . . . . . . .

HYDRAULIC SCHEMATICS 6. . . . . . . . . . . . . . . . . . . .

HYDRAULIC COMPONENTS 8. . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Charge Pressure Test 12. . . . . . . . . . . . . . . . . . . . . . .

Forward Traction Test 13. . . . . . . . . . . . . . . . . . . . . . .

Reverse Traction Test 13. . . . . . . . . . . . . . . . . . . . . . .

Implement Relief Pressure Test 14. . . . . . . . . . . . . .

Counterbalance Pressure Test 15. . . . . . . . . . . . . . .

Steering Circuit Test 16. . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Hydraulic Pump Efficiency Test 17. . . . . . .

ADJUSTMENTS 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traction Pedal Linkage 20. . . . . . . . . . . . . . . . . . . . . .

Service Brakes 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 21

Check Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . 21

Check Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . 21

Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 22

Change Hydraulic Oil and Filter . . . . . . . . . . . . . . 23

Traction Control Linkage . . . . . . . . . . . . . . . . . . . . . 24

Brake Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Driveshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Steering Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Removing Hydraulic System Components . . . . . 30

Manifold Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Cartridge Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Auxiliary Hydraulic Pump . . . . . . . . . . . . . . . . . . . . 35

Transaxle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 36

SAUER–SUNDSTRAND IHT SERVICE MANUAL

and Transaxle

Hydraulic System

Groundsmaster 3000/3000–D

Page 5 – 1

Hydraulic System

Specifications

Item Specification

Transaxle Sauer–Sundstrand IHT–M15

Implement Relief Pressure: 1,000 – 1,100 PSI (69 – 76 Bar)

Traction Forward Pressure: 6,200 PSI (428 Bar) maximum

Traction reverse pressure: 5,000 PSI (345 Bar) maximum

Manifold Block Toro logic cartridge, elec./hyd., solenoid actuated

Charge Pressure: 80 – 130 PSI (5.5 – 9 Bar)

Recommended 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)

Implement Relief Pressure (Model 30724 Hyd. Kit):

Steering Control Eaton Series 2 steering control unit with power beyond

Hydraulic Fluid Mobil 424

(see Check Hydraulic Fluid in Service and Repairs

Hydraulic Fluid Capacity Approximately 12 U.S. qts. (11.4 liters)

1,000 – 1,100 PSI (69 – 76 Bar)

section of this chapter for alternatives)

Hydraulic System

Page 5 – 2 Rev. A

Groundsmaster 3000/3000–D

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 distance, transport it on a truck or trailer.

1. Locate towing lever on right side of axle assembly.

2. Remove cotter pin and clevis pin securing lever to plate on side of axle.

3. Pivot lever rearward until hole is aligned with rear hole in plate. Secure lever to rear hole with cotter pin and clevis pin previously removed.

4. After completion of towing operation, pivot lever back to original position and re–secure.

Figure 1

1. Towing Lever

and Transaxle

Hydraulic System

Groundsmaster 3000/3000–D

Page 5 – 3

Hydraulic System

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. Some hoses are more susceptible to these conditions than others. Inspect the hoses frequently for signs of deterioration or damage.

When replacing a hydraulic hose, be sure that the hose is straight (not twisted) before tightening the fittings. This can be done by observing the imprint on the hose. Use two wrenches; one to hold the hose straight and one to tighten the hose swivel nut onto the fitting.

Hydraulic Fitting Installation

O–Ring Face Seal

1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material.

WARNING

Before disconnecting or performing any work on hydraulic system, all pressure in system must be relieved by stopping the engine and lowering or supporting the box and/or other attachment.

Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and do serious damage. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result.

Nut

Sleeve

Body

2. Make sure the O–ring is installed and properly seated in the groove. It is recommended that the O–ring be replaced any time the connection is opened.

3. Lubricate the O–ring with a light coating of oil.

4. Put the tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight.

5. Mark the nut and fitting body. Hold the body with a wrench. Use another wrench to tighten the nut to the correct flats from finger tight (F.F.F.T.). The markings on the nut and fitting body will verify that the connection has been tightened.

Size

4 (1/4 in. nominal hose or tubing) 6 (3/8 in.) 8 (1/2 in.) 10 (5/8 in.) 12 (3/4 in.) 16 (1 in.)

F.F.F.T.

.75 + .25 .75 + .75 +

1.00 + .75 + .75 +

.25 .25 .25 .25 .25

Seal

Figure 2

Final Position

Mark Nut and Body

Extend Line

Initial Position

Finger Tight After Proper Tightening

Figure 3

Hydraulic System

Page 5 – 4

Groundsmaster 3000/3000–D

SAE Straight Thread O–Ring Port – Non–adjustable

1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material.

2. Always replace the O–ring seal when this type of fitting shows signs of leakage.

3. Lubricate the O–ring with a light coating of oil.

4. Install the fitting into the port and tighten it down full length until finger tight.

5. Tighten the fitting to the correct flats from finger tight (F.F.F.T.).

Size F.F.F.T.

O–Ring

Figure 4

4 (1/4 in. nominal hose or tubing) 1.00 + 6 (3/8 in.) 1.50 + 8 (1/2 in.) 1.50 + 10 (5/8 in.) 1.50 + 12 (3/4 in.) 1.50 + 16 (1 in.) 1.50 +

.25 .25 .25 .25 .25 .25

SAE Straight Thread O–Ring Port – Adjustable

1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material.

2. Always replace the O–ring seal when this type of fitting shows signs of leakage.

3. Lubricate the O–ring with a light coating of oil.

4. Turn back the jam nut as far as possible. Make sure the back up washer is not loose and is pushed up as far as possible (Step 1).

5. Install the fitting into the port and tighten finger tight until the washer contacts the face of the port (Step 2).

6. To put the fitting in the desired position, unscrew it by the required amount, but no more than one full turn (Step 3).

Step 1

Figure 5

Step 3

Lock Nut

backup Washer

O–Ring

and Transaxle

Hydraulic System

7. Hold the fitting in the desired position with a wrench and turn the jam nut with another wrench to the correct flats from finger tight (F.F.F.T.) (Step 4)

Size F.F.F.T.

4 (1/4 in. nominal hose or tubing) 1.00 + .25 6 (3/8 in.) 1.50 + 8 (1/2 in.) 1.50 + 10 (5/8 in.) 1.50 + 12 (3/4 in.) 1.50 + 16 (1 in.) 1.50 + .25

Groundsmaster 3000/3000–D

25 .25 .25 .25

Page 5 – 5

Step 2

Step 4

Figure 6

Hydraulic System

Hydraulic Schematic

SOLENOIDS

LIFT/LOWER

ON OFF

LIFT

CONTROL

OFF

LOWER/FLOAT

HOLD

1” ROD

2.5” BORE

3.5” STROKE

LIFT CYLINDERS

LIFT/

COUNTERBALANCE

CYL1 CYL2

ADJ ORIFICE

MANIFOLD

STD .187

LC1

75–220 PSI

OUT

T1 T2

OIL

COOLER

PBP

1.625 BORE

7.00 STROKE

STEERING CYLINDER

.625 ROD

25CC

VARIABLE

MOTOR

IHT–M15 TRANSAXLE

CHARGE/

IMPLEMENT

PUMP

15CC

PUMP

VARIABLE

VALVES

”EASY–RIDE”

PRIORITY VALVE

CHARGE

PRESSURE

INLET

FILTER

IMPLEMENT CIRCUIT

PRESSURE RELIEF VALVE

RESERVOIR

6.1 IN DISPLACEMENT

STEERING CONTROL UNIT

T–2350–4

Hydraulic System

Page 5 – 6

Groundsmaster 3000/3000–D

Hydraulic Schematic

CYL1 CYL2

1” ROD

LIFT CYLINDERS

2.5” BORE

3.5” STROKE

(with Model 30726 Hyd. Kit and Contour 82 Cutting Unit)

IHT

COUPLER

STD .187

ADJ ORIFICE

LC1

75–220PSI

600 PSI

BRAKING VALVE

QUICK

DECK MOTORS

18CC 18CC 18CC 18CC

M3 M4

RESERVOI

1750

PSI

SOLENOIDS

S1 S2

ON OFF

OFF OFF

OFF ON

CONTROL

LIFT/LOWER

LOWER/FLOAT

LIFT

HOLD

DETAIL

FIXED MOTOR OPTION

25CC

FIXED

MOTOR

LIFT/

COUNTERBALANCE

VALVES

”EASY–RIDE”

MANIFOLD

QUICK

3625

PSI

COOLER

COUPLER

33CC

CCW

INPUT

SUNDSTRAND IHT

IDLE 1650 RPM

L R

1.625 BORE

STEERING CYLINDER

LOADED 1560 RPM

7.00 STROKE

.625 ROD

and Transaxle

Hydraulic System

QUICK

COUPLER

AUX FILTER

OUT

T2T1

5 PSI

1000 PSI

PBP

STEERING CONTROL UNIT

6.1 IN DISPLACEMENT

OIL

CHARGE/

IMPLEMENT

VARIABLE

15CC

PUMP

IHT–M15 TRANSAXLE

Groundsmaster 3000/3000–D

PRIORITY VALVE

CHARGE

PRESSURE

FILTER

INLET

SCREW CLOCKWISE TO

HYD. KIT INSTALLED.

PRESSURE RELIEF VALVE

IMPLEMENT CIRCUIT

MAX SETTING WITH

RESERVOIR

Page 5 – 7

Rev. A

VARIABLE

25CC

MOTOR

VALVES

”EASY–RIDE”

DETAIL

VARIABLE MOTOR OPTION

Hydraulic System

Hydraulic Components

Manifold block

Lift cylinder

Steering cylinder

Oil cooler

Steering control unit

Hydraulic System

Page 5 – 8

Groundsmaster 3000/3000–D

Special Tools

NOTE: Order special tools from the

TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS)

local supplier.

. Some tools may also be available from a

TORO SPECIAL

Hydraulic Pressure Test Kit – TOR47009

Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges. Use gauges as recommended in Testing section of this chapter.

Hydraulic Test Fitting Kit – TOR4079

Figure 7

This kit includes a variety of O–ring Face seal fittings to enable you to connect test gauges into the system.

The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings.

Measuring Container – TOR4077

Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only). Measure efficiency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system.

Figure 8

and Transaxle

Hydraulic System

Groundsmaster 3000/3000–D

Page 5 – 9

Figure 9

Hydraulic System

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 required, upon turning the valve to restrict flow, a simulated working load is created in the circuit.

3. LOW PRESSURE GAUGE: Low range gauge to provide accurate reading at low pressure, 0 – 1000 PSI.

This gauge has a protector valve which cuts out when pressure is about to exceed the normal range for the gauge. The cutout pressure is adjustable.

4. HIGH PRESSURE GAUGE: High range gauge to accommodate pressure beyond the capacity of the low pressure gauge, 0 – 5,000 PSI.

5. FLOW METER: This meter measures actual oil flow in the operation circuit, with a gauge rated at 15 GPM.

6. OUTLET HOSE: Hose from the outlet side of the hydraulic tester to be connected to the hydraulic system circuit.

Hydraulic System

Page 5 – 10

Groundsmaster 3000/3000–D

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

Failure to use gauges with recommended pressure (psi) rating as listed in test procedures could result in damage to gauge and possible personal injury from leaking hot oil.

Before Performing Hydraulic Tests

All obvious areas such as oil supply, filter, binding linkage, loose fasteners, or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem being experienced.

WARNING

Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved by stopping the engine and lowering or supporting the cutting units or other implements.

1. Thoroughly clean the machine before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment.

2. Put caps or plugs on any hydraulic lines left open or exposed during testing or removal of components.

3. The engine must be in good operating condition. Use a tachometer when making a hydraulic test. Engine speed can affect the accuracy of the tester readings.

4. To prevent damage to tester or components, the inlet and the outlet hoses must be properly connected, and not reversed (tester with pressure and flow capabilities).

5. To minimize the possibility of damaging components, completely open load valve in hydraulic tester (when using tester with pressure and flow capabilities).

6. Install fittings finger tight, far enough to insure that they are not cross–threaded, before tightening with a wrench.

7. Position the tester hoses so that rotating machine parts will not make contact with them and result in hose or tester damage.

8. Check the oil level in the reservoir.

9. Check the control linkage for improper adjustment, binding or broken parts.

Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and do serious damage. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result.

10. All hydraulic tests should be made with the hydraulic oil at normal operating temperature.

and Transaxle

Hydraulic System

Groundsmaster 3000/3000–D

Page 5 – 11

Hydraulic System

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 Test

NOTE: See Sauer–Sundstrand IHT Service Manual for more information.

Use a 500 or 1,000 PSI (35 or 70 Bar) test gauge.

Specification: 80 to 130 PSI (5.5 to 9 Bar)

1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes.

2. Lower cutting unit, engage parking brake and stop the engine.

3. Remove the plug from the charge pressure port and install a 500 or 1,000 PSI (35 or 70 Bar) pressure gauge with extension hose.

4. Start the engine and move the throttle control all the way forward. Take pressure reading with machine stationary. Also take a pressure reading while operating the machine in forward and reverse. To test in forward and reverse, engage the brakes and push the traction pedal forward, then reverse.

Figure 11

1. Charge pressure port

NOTE: When you move the traction pedal to create pressure, move it a short distance first and wait for a change in sound before moving the pedal further. The change in sound indicates that the easy ride valves have closed.

If pressure is good under no load, but drops below specification when under traction load, the piston pump and motor should be suspected of wear and inefficiency. When the pump and/or motor is worn or damaged the charge pump is not able to supply enough oil to keep up with internal leakage in the closed loop circuit.

Charge Pressure Priority Valve Test

While checking charge pressure, check the the operation of the charge priority valve. Rotate the steering wheel to create back–pressure while observing the gauge. The gauge should not have a significant pressure increase during steering operation.

Hydraulic System

Page 5 – 12

Groundsmaster 3000/3000–D

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 temperature by operating the machine for approximately 10 minutes.

2. Lower cutting unit, engage parking brake and stop the engine.

3. Remove the plug from the forward traction pressure port and install a 10,000 PSI (700 Bar) pressure gauge with extension hose.

4. On 4WD machines, raise the implement and engage the transport switch so the IHT operates with less torque to the wheels. Engage the parking brake, and run the engine at full speed. Slowly push the traction pedal forward and listen for engagement of the easy ride valve. Continue to push the traction pedal and read the gauge.

Figure 12

1. Forward traction pressure port

Reverse Traction Test

NOTE: See Sauer–Sundstrand IHT Service Manual for more information.

Use a 10,000 PSI (700 Bar) gauge.

Specification: 5,000 PSI (345 Bar) maximum

1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes.

2. Lower cutting unit, engage parking brake and stop the engine.

3. Remove the plug from the reverse traction pressure port and install a 10,000 PSI (700 Bar) pressure gauge with extension hose.

4. On 4WD machines, raise the implement and engage the transport switch so the IHT operates with less torque to the wheels. Engage the parking brake, and run the engine at full speed. Slowly push the traction pedal in reverse and listen for engagement of the easy ride valve. Continue to push the traction pedal and read the gauge.

Figure 13

1. Reverse traction pressure port

and Transaxle

Hydraulic System

Groundsmaster 3000/3000–D

Page 5 – 13

Hydraulic System

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 temperature by operating the machine for approximately 10 minutes.

2. Lower cutting unit, engage parking brake and stop the engine.

3. Install a 5,000 PSI (350 Bar) pressure gauge with quick connect adapter on the test port.

4. Start the engine and move the throttle control all the way forward. Pull back on the lift lever until the implement is fully raised. Continue holding the lift lever back to cause the relief valve to open, then read the gauge.

NOTE: Normal location for adjusting implement relief pressure is on the top of the IHT. If the machine is equipped with Model 30726 Hydraulic Kit, the original valve is permanently closed, and a new implement relief valve is installed in the hydraulic manifold. If the additional valve is present, adjust relief pressure at the new location only.

Figure 14

1. Test Port

Figure 15

1. Implement relief valve (standard)

Figure 16

1. Implement relief valve (Port R1) (Model 30726 Hydraulic Kit)

Hydraulic System

Page 5 – 14

Groundsmaster 3000/3000–D

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. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes.

2. Lower cutting unit, engage parking brake and stop the engine.

3. Install a 500 or 1,000 PSI (35 or 70 Bar) pressure gauge with quick connect adapter on the test port.

4. Start the engine and move the throttle control all the way forward. Read the gauge. Do not raise the implement when testing counterbalance pressure. Move the lift lever forward to make sure the lift system is in the “float” position.

Figure 17

1. Test Port

2. Counterbalance valve

and Transaxle

Hydraulic System

Groundsmaster 3000/3000–D

Page 5 – 15

Rev. A

Hydraulic System

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 working correctly. The Steering Valve Test will determine if the steering valve is faulty.

1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes.

2. Lower cutting unit, engage parking brake and stop the engine.

3. Install a tee fitting and a 5,000 PSI (350 Bar) test gauge onto the right side steering cylinder fitting. Use parts from TOR4079 test fitting kit or the following Toro parts:

Cap (340–117) Plug (340–116) Tee (340–115) Quick connect fitting (86–5480)

4. Start the engine and move the throttle control all the way forward. Rotate the steering wheel counterclockwise until the cylinder reaches the end of its travel. Continue rotating the steering wheel (without excessive force) while watching the pressure gauge. Pressure should be 1,100 PSI (76 Bar). If cylinder does not move, pressure is very low, or the steering wheel rotates easily, the internal seal may be bypassing in the cylinder.

2. Lower cutting unit, engage parking brake and stop the engine.

3. Disconnect the tee from the cylinder. Install a cap on the cylinder and a plug on the open tee port.

4. Start the engine and move the throttle control all the way forward. Gently rotate the steering wheel while observing the pressure gauge. If the pressure now increases to 1,100 PSI (76 Bar), the cylinder has a damaged internal seal. Repair or replace the cylinder. If the pressure does not increase by rotating in either direction, repair or replace the steering valve.

Figure 18

1. Right side steering cylinder fitting

Steering Valve Test

This test determines if the steering valve is working correctly. If this test is good and the first test is not, the problem is in the steering valve.

1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes.

Hydraulic System

Page 5 – 16 Rev. A

Figure 19

Groundsmaster 3000/3000–D

Auxiliary Hydraulic Pump Efficiency Test (Model 30726 Hydraulic Kit)

A worn or damaged pump will by–pass oil and make the pump less efficient. Eventually, enough by–passing will occur to cause the cutting units to to stall in heavy cutting conditions. Continued operation with a worn, inefficient pump can generate a lot of heat and cause damage to seals and other components in the hydraulic system.

Use a tester with pressure and flow capabilities.

Specification:

Minimum 12 GPM (45 liter/min.) at 2,500 PSI (173 Bar)

1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes.

2. Lower cutting unit, engage parking brake and stop the engine.

3. Disconnect the large pressure hose from the coupler at the pump. Disconnect the large return hose from the coupler at the return filter. Install the tester between the pump outlet and filter inlet.

IMPORT ANT : Make sure the oil flow indicator on the flow meter shows that the oil will flow from the pump, through the tester and into the return filter. Make sure the flow control valve is open before starting the engine.

4. Start the engine and move the throttle control all the way forward. Engage the PTO.

5. Slowly close the flow control valve until the gauge reads 2,500 PSI (173 Bar). Read the flow meter. Disengage the PTO, stop the engine and open the flow control valve on the tester. If flow is less than 12 GPM (45 liter/ min.) the pump is inefficient and should be repaired or replaced.

NOTE: The pump has an integral relief valve that is set at 3,625 PSI (250 Bar). This relief valve protects the pump from shock stress. If you cannot reach 2,500 PSI (173 Bar) when closing the flow control valve on the tester, this relief valve may be stuck open. This could be caused by debris or contamination in the hydraulic system.

Flow

1. 45 degree fitting

2. Quick coupler nipple

3. Pump

4. Splined coupler

Flow

1. Oil filter assembly

2. Flush faced fitting

Figure 20

5. Flush faced coupler

6. Pump supply hose

7. Hose bracket

8. Square O–ring

Figure 21

and Transaxle

Hydraulic System

Groundsmaster 3000/3000–D

Page 5 – 17

Hydraulic System

This page is blank.

Hydraulic System

Page 5 – 18

Groundsmaster 3000/3000–D

This page is blank.

and Transaxle

Hydraulic System

Groundsmaster 3000/3000–D

Page 5 – 19

Hydraulic System

Adjustments

Traction Pedal Linkage Adjustment

Traction pedal to reach full stroke prior to contact with stop.

1. Park machine on a level surface, shut engine off and lower cutting unit to the floor.

2. Check pedal stop adjustment. Distance from top of stand to top of stop must be 1.25 in. (32 mm). Loosen jam nuts and adjust stop if required.

3. Loosen jam nut securing hub to rod.

4. Remove hair pin cotter and washer securing traction rod hub to lever rod on side of axle assembly.

5. Adjust hub so traction pedal reaches full forward stroke just before pedal contacts stop.

6. Re–assemble linkage to lever after adjustment.

1.25 in. (32 mm)

Figure 22

1. Traction Pedal Stop

Service Brake Adjustment

If excessive pedal travel is required to engage brake or as brake pads wear, an adjustment to the brake linkage may be required.

1. Jack up front of machine and support with jack stands.

2. Remove left front tire.

3. With brake linkage bellcrank against frame stop, loosen jam nut disconnect clevis from bellcrank and adjust linkage until there is a slight drag on rotor.

4. Back off clevis one full turn and reinstall to bellcrank.

5. Tighten jam nut.

6. Repeat procedure on opposite wheel.

Figure 23

1. Traction Rod

2. Traction Rod Hub

3. Lever

Hydraulic System

Page 5 – 20

Figure 24

1. Bellcrank

2. Frame stop

3. Linkage Clevis

Groundsmaster 3000/3000–D

Service and Repairs

Wheel and Tires

Check Tire Pressure

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 as-

sure a good quality–of–cut and proper machine performance. DO NOT UNDER INFLATE.

Lubrication

Intermediate Drive Shaft (3) (Fig. 25), 4WD Rear DrIve Shaft (3) (Fig.26), Pedal Pivots (5), Traction pedal (In square tube under floor plate) (1) (Fig. 27) and Lift arm pivot (2) (Fig. 28).

Check Wheel Nut Torque

WARNING

Torque wheel nuts to 70–80 ft–lb (10–11 Kgm) after 1-4 hours of operation and again after 10 hours of operation and every 200 hours thereafter. Failure to maintain proper torque could result in failure or loss of wheel and may result in personal injury.

Figure 25

Figure 26

Figure 27

Figure 28

and Transaxle

Hydraulic System

Groundsmaster 3000/3000–D

Page 5 – 21

Rev. A

Hydraulic System

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 thereafter.

1. Position machine on a level surface, raise the implement, and stop the engine.

2. Unscrew dipstick cap from the filler neck and wipe it

with a clean rag. Screw dipstick cap finger tight onto filler neck. Unscrew the dipstick and check level of oil. If level is not up to FULL mark on dipstick, add enough oil to raise level to mark. DO NOT OVERFILL.

3. Screw dipstick filler cap finger–tight onto filler neck.

4. Lower the implement.

The following fluids are recommended for use:

ISO type 46/68 anti–wear hydraulic fluid

Mobil Mobil Fluid 424 Amoco Amoco 1000 International Harvester Hy–Tran Texaco TDH Shell Donax TD Union OIl Hydraulic/Tractor Fluid Chevron Tractor Hydraulic Fluid BP Oil BP HYD TF Boron OIl Eldoran UTH Exxon Torque Fluid Conoco Power–Tran 3 Kendall Hyken 052 Phillips HG Fluid

Note: The fluids within this group are interchangeable.

Figure 29

1. Dipstick cap

IMPORTANT: Do Not Use Biodegradable Hydraulic Fluid.

IMPORT ANT : Use only types of hydraulic fluids specified. Other fluids could cause system damage.

Note: A red dye additive for detecting leaks in the hy-

draulic system is available in 2/3 oz. bottles. One bottle is sufficient for 4–6 gal. (15 – 23 liters) of hydraulic fluid. Order Part No. 44–2500 from your Authorized Toro Distributor

Hydraulic System

Page 5 – 22

Groundsmaster 3000/3000–D

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 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 (See Check Hydraulic Oil in this section

for recommended fluids). Check level of hydraulic

fluid before engine is first started and daily thereafter.

1. Start engine, park machine on a level surface, lower implement to the shop floor, set the parking brake, and shut engine off.

2. Clean area around dipstick cap and remove cap from axle filler tube.

3. To ease access to axle housing drain plug, implement may be removed from traction unit.

4. Remove drain plug from axle housing and allow oil to flow into drain pan.

5. Clean area around hydraulic oil filter and remove filter. NOTE: Also replace filter for Model 30726 Hydraulic Kit.

6. Lubricate new filter seal and install filter.

7. Install drain plug in axle housing.

8. Through axle filler tube, fill axle to proper level with Mobil 424 hydraulic fluid. Install dipstick cap.

9. Start and run the engine at idle speed for about two minutes, raise and lower implement and turn the steering wheel lock to lock to purge air trapped in the system. Shut the engine off.

10. Let machine set for two additional minutes, then remove dipstick and check oil level in axle. If level is low, add oil until level matches groove in dipstick. If level is too high, remove drain plug and drain oil until oil level matches Full mark on dipstick.

Figure 31

1. Drain plug

Figure 32

1. Hydraulic Filter

and Transaxle

Hydraulic System

Figure 30

1. Dipstick cap

Groundsmaster 3000/3000–D

Page 5 – 23

Figure 33

1. Hydraulic filter (Model 30726 Hydraulic Kit)

Hydraulic System

Traction Control Linkage

1 2 3 4 5 6

1. Carriage bolt

2. Traction lever

3. Rod end bearing

4. Jam nut

5. Control tube

6. Flat washer

7. Hair pin cotter

8. Hub

9. Rubber bushing

Figure 34

10. Hub post

11. Lever

12. Lock nut

13. Lock nut

14. Screw

15. Pedal abrasive

16. Pedal abrasive

17. Traction pedal

18. Nut

19. Screw

20. Screw

21. Flange bushing

22. Pedal bracket

23. Grease fitting

24. Nut

25. Roll pin

26. Flat washer

Hydraulic System

Page 5 – 24

Groundsmaster 3000/3000–D

Brake Linkage

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. Screw 28. Retaining ring

5. Jam nut 17. Nylon bushing 29. Clevis

6. Clevis 18. Retaining ring 30. Brake latch

7. Hair pin cotter 19. Thrust washer 31. R.H. brake arm

8. Bellcrank 20. Screw 32. Flat washer

9. Extension spring 21. Nut 33. R.H. brake lever

10. Screw 22. Lock arm 34. Cotter pin

11. R.H. pedal 23. L.H. brake arm

12. Foot pad 24. Pillow block bearing

and Transaxle

Hydraulic System

Groundsmaster 3000/3000–D

Page 5 – 25

Hydraulic System

Driveshafts

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 yoke 10. Lock nut (Model 30302) 17. Lock nut

4. Grease fitting 11. Screw (Model 30302) 18. Yoke and clamp

5. Yoke and shaft 12. Clamp yoke (Model 30302) 19. Grease fitting

6. Screw 13. Grease fitting (Model 30302) 20. Screw

7. Lock washer 14. Yoke and sleeve (Model 30302) 21. Lock washer

Hydraulic System

Page 5 – 26

Groundsmaster 3000/3000–D

Lift Arms

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

Figure 37

66 ft–lb (9 Kgm)

250 ft–lb (35 Kgm)

and Transaxle

Hydraulic System

Groundsmaster 3000/3000–D

Page 5 – 27

Hydraulic System

Steering Control

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. Screw 13. Steering wheel 23. Hair pin cotter

4. Screw 14. Nut 24. Brake pawl

5. Spacer 15. Flat washer 25. Hair pin cotter

6. Clinch nut 16. Foam collar 26. Steering control unit

7. Tower decal 17. Steering seal 27. Clevis pin

8. Steering column 18. Retaining ring 28. Tilt rod

9. Flange bushing 19. Steering shaft 29. Nut

10. Washer 20. Vinyl cap 30. Cover

Hydraulic System

Page 5 – 28

Groundsmaster 3000/3000–D

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#2 Tube

#4 Tube

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Hydraulic System

Groundsmaster 3000/3000–D

Page 5 – 29

Hydraulic System

Removing Hydraulic System Components

1. Thoroughly clean the machine before disconnecting, removing or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment.

2. Put caps or plugs on any hydraulic lines or fittings left open or exposed.

3. Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed.

After Repair or Replacement of Components

1. Check oil level in hydraulic reservoir and add correct oil if necessary. Drain and refill hydraulic system reservoir and change oil filter if component failure was severe or system is contaminated.

2. After repairs, check control linkage for proper adjustment, binding or broken parts.

3. After disconnecting or replacing any hydraulic components, operate machine functions slowly until air is out of system.

4. Check for hydraulic oil leaks. Shut off engine and correct leaks if necessary. Check oil level in hydraulic reservoir and add correct oil if necessary.

Hydraulic System

Page 5 – 30

Groundsmaster 3000/3000–D

Toro 3000, 3000D User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Table Of Contents

Safety Instructions

Product Records

Equivalents and Conversions

Torque Specifications

Lubrication

General Information

Specifications

Adjustments

Service and Repairs

Specifications

Special Tools

Adjustments

Service and Repairs

Specifications

General Information

Hydraulic Schematic

Hydraulic Components

Special Tools

Testing

Adjustments

Service and Repairs