Toro 2020 Lawn Mower User Manual

Part No. 96890SL Rev. C
Service Manual
GroundsmasterR 3000/3000–D
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing,
and repair of major systems and components on the
Groundsmaster 3000 and 3000–D.
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR’S MANUALS FOR OPERATING,
MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to
insert the Operator’s Manuals and Parts Catalogs for
your machine. 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.
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 5 – Hydraulic System and Transaxle
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 3
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . 5 – 6
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . 5 – 8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 9
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 11
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 19
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 – 20
SAUER–SUNDSTRAND IHT SERVICE MANUAL
Chapter 2 – Product Records and Maintenance
2–1
2–2
2–3
2–4
2–5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 – 4
FORD VSG–411/413 ENGINE SERVICE MANUAL
Chapter 7 – Rear Axle (2WD)
Chapter 4 – Peugeot Diesel Engine
4–2
4–3
4–8
4–9
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 2
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 7 – 3
Chapter 8 – Rear Axle (4WD)
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 2
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 8 – 3
4WD Rear Axle
2WD Rear Axle
Electrical
System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . .
PEUGEOT TUD5 ENGINE SERVICE MANUAL
Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3
Troubleshooting (GM3000) . . . . . . . . . . . . . . . . . . 6 – 6
Troubleshooting (GM3000–D) . . . . . . . . . . . . . . . . 6 – 6
Electrical System Quick Checks . . . . . . . . . . . . . . 6 – 8
Component Identification and Testing . . . . . . . . . . 6 – 9
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 6 – 35
Peugeot Diesel
Engine
Chapter 3 – Ford Gasoline Engine
Ford Gasoline
Engine
Chapter 6 – Electrical System
2–9
Hydraulic System
and Transaxle
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions . . . . . . . . . . . . . . . .
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Quick Reference Aid . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Operation
and Service History Reports . . . . . . . . . . . . . . . .
Product Records
and Maintenance
Chapter 1 – Safety
Safety
Table Of Contents
Groundsmaster 3000/3000–D
Groundsmaster 3000/3000–D
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 9 – 7
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 – 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 – 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 11 – 8
Chapter 10 – Contour 82I Cutting Unit
Chapter 12 – Electrical Diagrams
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 – 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 – 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . 10 – 7
Groundsmaster 3000 . . . . . . . . . . . . . . . . . . . . . . 12 – 3
Groundsmaster 3000–D . . . . . . . . . . . . . . . . . . 12 – 10
Contour 82
Cutting Unit
Chapter 11 – 72I Cutting Units
Electrical
Diagrams
72 inch
Cutting Units
Chapter 9 – 84I Cutting Units
84 inch
Cutting Units
Table of Contents (continued)
Groundsmaster 3000/3000–D
Groundsmaster 3000/3000–D
Safety
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance and Service . . . . . . . . . . . . . . . . . . . . . 3
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 4
Safety Instructions
The GROUNDSMASTERR 3000 and 3000-D was
tested and certified by TORO for compliance with the
B71.4—1990 specifications of the American National
Standards Institute. Although hazard control and acci­
dent 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, trans­
port, maintenance, and storage of the machine. Improp­
er use or maintenance of the machine can result in injury
or death. To reduce the potential for injury or death, com­
ply with the following safety instructions.
CAUTION
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 fa­
miliar with all controls and know how to stop quickly. A
free replacement manual is available by sending com­
plete 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.
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 op­
eration and who have read this manual should operate
this machine.
Groundsmaster 3000/3000–D
Page 1 – 1
Safety
Safety
Chapter 1
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 flam­
mable, 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 require­
ments.
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 re­
sulting 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.
Safety
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!! When a person or pet
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 re­
sume 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.
Page 1 – 2
Groundsmaster 3000/3000–D
25. Lower the cutting unit or other attached implement
to the ground and remove key from switch whenever
machine is left unattended.
26. Before getting off the seat:
A. Move traction pedal to neutral position and re­
move foot from pedal.
B. Set the parking brake and disengage the PTO.
C. Shut the engine off and remove key from igni­
tion switch. Wait for all movement to stop before
getting off the seat.
Maintenance
27. 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.
Hydraulic fluid escaping under pressure can have suffi­
cient force to penetrate skin and do serious damage. If
fluid is ejected into the skin, it must be surgically re­
moved within a few hours by a doctor familiar with this
form of injury or gangrene may result.
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 connec­
tions with water.
35. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be re­
lieved by stopping engine and lowering implement to the
ground.
30. If the cutting unit discharge area ever plugs, disen­
gage PTO and shut engine off before removing the ob­
struction.
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.
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.
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.
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.
Groundsmaster 3000/3000–D
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.
Page 1 – 3
Safety
Safety
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.
Safety and Instruction Decals (Groundsmaster 3000)
The following safety and instruction decals are mounted on the traction unit. If any decal becomes damaged or illeg­
ible, install a new decal. Part numbers are listed below or in your parts catalog.
On Side of Tool Box
(Part No. 67–1710)
Next to Right Side of Seat
(Part No. 93–5935)
In Compartment Behind Control panel
(Part No. 93–5933)
ON FAN SHROUD
(Part No. 77–3100)
On Hood
(Part No. 93–6328)
On Right Side Of Center
Shroud
(Part No. 93–5617)
On Fuse Compartment Cover
(Part No. 93–5931)
On Steering Tower
(Part No. 95–0814)
On Tool Box Cover
(Part No. 93–5621)
On Frame Above Front Axle
(Part No. 85–4730)
On Frame Next to Traction Pedal
(Part No. 92–5772)
On Control Panel
(Part No. 93–5426)
Safety
Page 1 – 4
Rev. A
Groundsmaster 3000/3000–D
Safety and Instruction Decals (Groundsmaster 3000–D)
Safety
The following safety and instruction decals are mounted on the traction unit. If any decal becomes damaged or illeg­
ible, install a new decal. Part numbers are listed below or in your parts catalog.
On Side of Tool Box
(Part No. 67–1710)
Next to Right Side of Seat
(Part No. 93–5934)
In Compartment Behind Control panel
(Part No. 93–5932)
ON FAN SHROUD
(Part No. 77–3100)
On Radiator Near Inlet
(Part No. 93–7275)
On Fuse Compartment Cover
(Part No. 93–5930)
On Steering Tower
(Part No. 95–0814)
On Frame Above Front Axle
(Part No. 85–4730)
On Tool Box Cover
(Part No. 93–5621– Model 30301)
(Part No. 93–5622– Model 30302)
On Frame Next to Traction Pedal
(Part No. 92–5772)
On Control Panel
(Part No. 93–5425)
Groundsmaster 3000/3000–D
Page 1 – 5 Rev. A
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 Front of Cutting Unit
(Part No. 68–8340)
On Right & Left Covers
(Part No. 93–0299)
On Front of Deck
(Part No. 88–1270)
On Deck Channels, Under Covers
(Part No. 85–6410)
On Front of Cutting Unit
On Right Rear Top of Deck Under Cover
(Part No. 93–4688)
On Each Corner Of
Cutting Unit
(Part No. 93–7815)
(Part No. 93–7818)
Replaces Decal Part No.
68–8340 for CE
On Right Rear Top of Deck
Under Cover
(Part No. 94–3392)
On left Rear Top of Deck
Under Cover
(Part No. 93–4691)
Replaces Decal Part No.
43–8480 for CE
Safety
Page 1 – 6
Rev. A
Groundsmaster 3000/3000–D
Safety
On Rear of Deck
(Part No. 66–6380)
On Front of Deck
(Part No. 66–1340)
On Rear Of Deck
(Part No. 93–7828)
Replaces Decal Part No.
66–6380 for CE
On Front Of Deck
(Part No. 93–7824)
On Each Castor Arm
(Part No. 93–4894)
Replaces Decal Part No.
66–1340 for CE
On Each Castor Arm
(Part No. 93–4690)
Groundsmaster 3000/3000–D
On Deck Channels, Under Covers
(Part No. 93–7814)
Replaces Decal Part No. 85–6410 for CE
Page 1 – 7 Rev. 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 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 Chamber 1 & 4 Castor Supports
(Part No. 95–6001)
On Top of Rear Castor
(Chambers 2 & 4)
(Part No. 95–6002)
On Top of Rear Castor
(Chamber 1) (Part No. 95–6003)
On Left Lift Arm
(Part No. 95–6008)
Safety
On Right Lift Arm
(Part No. 95–6005)
Page 1 – 8
On Side of Rear Support
(Chamber 3)
(Part No. 95–6004)
Groundsmaster 3000/3000–D
Safety and Instruction Decals (Guardian 72I Recycler Cutting Unit)
Safety
The following safety and instruction decals are mounted on the cutting unit. If any decal becomes damaged or illegible,
install a new decal. Part numbers are listed below or in your parts catalog.
On Each Corner Of
Cutting Unit
(Part No. 43–8480)
On Front of Cutting Unit
(Part No. 68–8340)
On Left Caster Arm
(Part No. 93–0299)
On Gearbox Base
(Part No. 93–6697)
On Front of Cutting
Unit (Part No. 93–7818)
On Deck Channels, Under Covers
(Part No. 85–6410)
On Front of Deck
(Part No. 88–1270)
Replaces Decal Part No.
68–8340 for CE
On Right Rear Top of Deck Under Cover
(Part No. 85–6120)
On Each Corner Of
Cutting Unit
(Part No. 93–7815)
On Right Rear Top of Deck
(Part No. 94–3392)
On left Rear Top of Deck
(Part No. 93–4691)
Replaces Decal Part No.
43–8480 for CE
On Deck Channels, Under Covers
(Part No. 93–7814)
On Front Deck Hanger
(Part No. 93–4690)
Groundsmaster 3000/3000–D
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 Each Corner Of
Deck
(Part No. 93–7815)
Replaces Decal Part No.
43–8480 for CE
Safety
On Front Deck Hanger
(Part No. 93–4690)
On Deck Channels, Under Covers
(Part No. 93–7814)
On Left Caster Arm
(Part No. 93–0299)
Replaces Decal Part No. 85–6410 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 Front Of Deck
(Part No. 93–7824)
On Deck Channels, Under Covers
(Part No. 85–6410)
Replaces Decal Part No.
66–1340 for CE
On Right Rear Top of Deck
(Part No. 94–3392)
Groundsmaster 3000/3000–D
On left Rear Top of Deck
(Part No. 93–4691)
Page 1 – 11
On Front of Deck
(Part No. 88–1270)
Safety
Safety
Page 1 – 12
Groundsmaster 3000/3000–D
Chapter 2
Product Records and Maintenance
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . .
Decimal and Millimeter Equivalents . . . . . . . . . . . .
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . .
Capscrew Markings and Torque Values – U.S. . .
Capscrew Markings and Torque Values – Metric .
QUICK REFERENCE MAINTENANCE AID . . . . . . .
1
2
2
2
3
3
3
4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cutting Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION AND SERVICE HISTORY REPORTS
5
5
6
9
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.
Groundsmaster 3000/3000–D
Insert Operator’s Manuals and Parts Catalogs for your
Groundsmaster 3000 or 3000–D at the end of this sec­
tion.
Page 2 – 1
Product Records and Maintenance
Product Records
and Maintenance
Table of Contents
Equivalents and Conversions
Product Records and Maintenance
Page 2 – 2
Groundsmaster 3000/3000–D
Product Records
and Maintenance
Torque Specifications
Groundsmaster 3000/3000–D
Page 2 – 3
Product Records and Maintenance
Product Records and Maintenance
Page 2 – 4
Rev. A
800
800
800
400
800
Groundsmaster 3000/3000–D
Lubrication
Traction Unit
CAUTION
Product Records
and Maintenance
Before servicing or making adjustments to the
machine, stop engine and remove key from the
switch.
The machine has grease fittings that must be lubricated
regularly with No. 2 General Purpose Lithium Base
Grease. If machine is operated under normal conditions, lubricate all bearings and bushings after every 50
hours of operation or immediately after every washing.
Figure 3
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).
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 4
Figure 1
Figure 5
Figure 6
Figure 2
Groundsmaster 3000/3000–D
Page 2 – 5
Product Records and Maintenance
Cutting Units
If machine is operated under normal conditions, lubri­
cate castor bearings and bushings with No. 2 general
purpose lithium base grease or molybdenum base
grease, after every 8 hours of operation or daily, which­
ever comes first. Lubricate fittings immediately after ev­
ery washing, regardless of the interval listed.
CAUTION
Before servicing or making adjustments to the
machine, stop engine and remove key from the
switch.
Guardian 84I Recyler Cutting Unit
Figure 7
Product Records and Maintenance
Page 2 – 6
Groundsmaster 3000/3000–D
Product Records
and Maintenance
Rear Discharge 84I Cutting Unit
Figure 8
Contour 82I Cutting Unit
Figure 9
Groundsmaster 3000/3000–D
Page 2 – 7
Product Records and Maintenance
Guardian 72I Recycler Cutting Unit
Figure 10
Rear Discharge 72I Cutting Unit
Figure 11
Product Records and Maintenance
Page 2 – 8
Groundsmaster 3000/3000–D
Product Records
and Maintenance
EQUIPMENT OPERATION AND SERVICE HISTORY REPORT
for
GROUNDSMASTERR 3000
TORO Model and Serial Number: ______________–______________
Engine Numbers:
_____________________________
Transmission Numbers:
_____________________________
Drive Axle(s) Numbers:
_____________________________
Date Purchased:
_____________________________ Warranty Expires____________
Purchased From:
_____________________________
_____________________________
_____________________________
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
Maintenance Interval & Service
Every
100hrs
Every
50hrs
Every
200hrs
Every
400hrs
Every
800hrs
A Level
Service
} Change Engine Oil and Filter
Inspect Cooling System Hoses
B Level
Service
{ Check Fan, Governor and Alternator Belt Tension
{ Torque Wheel Lug Nuts
Check Governor Oil Level
Service Spark Arrester Muffler
C Level
Service
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
D Level
Service
= Change Hydraulic Oil
= Change Hydraulic Oil Filter
Drain and Clean Fuel Tank
Pack Rear Axle Bearings
Check Rear Wheel Toe–In
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
Annual Recommendations:
Items listed are recommended every 1500
hours or 2 years, whichever occurs first.
(See Operator’s Manual for specifications and procedures.)
Product Records and Maintenance
Page 2 – 10
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
MON
n
Safety Interlock Operation
n
Brake Operation
n
Engine Oil & Fuel Level
n
Cooling System Fluid Level
n
Radiator & Screen for Debris
n
Unusual Engine Noises
n
Unusual Operating Noises
n
Hydraulic System Oil Level
n
Hydraulic Hoses for Damage
n
Fluid Leaks
n
Tire Pressure
n
Instrument Operation
TUES
WED
THURS
FRI
SAT
SUN
Lubricate All Grease Fittings1
Touch–up Damaged Paint
1=
Immediately after every washing, regardless of the interval listed.
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 – 11
Product Records and Maintenance
Product Records
and Maintenance
Daily Maintenance Check For Week Of _________________
Maintenance
Check Item b
Product Records and Maintenance
Page 2 – 12
Groundsmaster 3000/3000–D
R
A B C D E Other
Service to perform (circle):
__________________–__________________
TORO I.D. #:
Check Governor Oil Level
Service Spark Arrestor Muffler
Inspect Cooling System Hoses
Check Tension of all drive belts
A – Service Required
Inspect Air Filter
Check Battery Level/Cable Connections
Check Cutting Unit Gearbox Oil Level
_______________________________
_______________________________
________________________________
________________________________
_______________________________
_______________________________
_______________________________
Change Cutting Unit Gearbox Oil
A, B and C – Service Required
________________________________
(See Operator’s and Service Manual for specifications and procedures.)
A, B, C, and D – Service Required
Change Hydraulic Filter
Torque Head Bolts and Adjust Valves
Check Engine RPM (idle & Full Throttle)
Change Hydraulic Oil
Check Rear Wheel Toe–In
Inspect Fuel Lines and Connections
Change Spark Plugs
Pack Rear Axle Bearings
Drain and Clean Fuel Tank
Change Fuel Filter
Service Air Filter
E – Service (every 800 hours)
_______________________________
________________________________
D – Service (every 400 hours)
________________________________
_______________________________
Check Cutting Unit Drive Belt Adjustment
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
Cooling System Flush/Replace Fluid
Replace Safety Switches
Replace Moving Hoses
Other – Annual Service & Specials
__________________________
_______________________________
Clean Under Cutting Unit Belt Covers
A and B – Service Required
Torque Wheel Lug Nuts
C – Service (every 200 hours)
Change Engine Oil and Filter
B – Service (every 100 hours)
Date: ________________
Lubricate All Grease Fittings
A– Service (every 50 hours)
Technician:
Hours:
Unit Designation:
Remarks:
3000 Supervisor Maintenance Work Order
(Duplicate this page for routine use.)
Groundsmaster
Product Records
and Maintenance
EQUIPMENT OPERATION AND SERVICE HISTORY REPORT
for
GROUNDSMASTERR 3000–D
TORO Model and Serial Number: ______________–______________
Engine Numbers:
_____________________________
Transmission Numbers:
_____________________________
Drive Axle(s) Numbers:
_____________________________
Date Purchased:
_____________________________ Warranty Expires____________
Purchased From:
_____________________________
_____________________________
_____________________________
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
Every
50hrs
Every
100hrs
Every
200hrs
Every
400hrs
Every
800 hrs
A Level
Service
} Change Engine Oil and Filter
Inspect Cooling System Hoses
B Level
Service
{ Check Fan and Alternator Belt Tension
C Level
Service
{ 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
D Level
Service
= 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
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
Annual Recommendations:
Items listed are recommended every 1500
hours or 2 years, whichever occurs first.
(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 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
MON
n
Safety Interlock Operation
n
Brake Operation
n
Engine Oil & Fuel Level
n
Cooling System Fluid Level
TUES
WED
THURS
FRI
SAT
SUN
Drain Water/Fuel Separator
n
Radiator & Screen for Debris
n
Unusual Engine Noises1
n
Unusual Operating Noises
n
Hydraulic System Oil Level
n
Hydraulic Hoses for Damage
n
Fluid Leaks
n
Tire Pressure
n
Instrument Operation
Lubricate All Grease Fittings2
Touch–up Damaged Paint
1=
2=
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.
Notation for areas of concern:
Item
Date
Inspection performed by_____________________________
Information
1
2
3
4
5
6
7
8
Groundsmaster 3000/3000–D
Page 2 – 15
Product Records and Maintenance
Product Records
and Maintenance
Daily Maintenance Check For Week Of _________________
Maintenance
Check Item b
Product Records and Maintenance
Page 2 – 16 Rev. A
Groundsmaster 3000/3000–D
R
A B C D E Other
Service to perform (circle):
__________________–__________________
TORO I.D. #:
_______________________________
_______________________________
________________________________
________________________________
Pack 2WD Rear Axle Bearings
Check Rear Wheel Toe–In
Hyd. Oil (see note on Maint. Sched.)
Hyd. Filter (see note on Maint. Sched.)
A, B, C, and D – Service Required
_______________________________
_______________________________
Inspect Fuel Lines and Connections
Check Engine RPM (Idle & Full Throttle)
Check Rear Axle OIl Level (4WD)
Change Cutting Unit Gearbox Oil
Change Rear Axle OIl (4WD)
A, B, and C – Service Required
________________________________
(See Operator’s and Service Manual for specifications and procedures.)
Drain and Clean Fuel Tank
Inspect Timing Belt
Change Fuel Filter
Service Air Filter
D – Service (every 400 hours)
_______________________________
________________________________
E – Service (every 600 hours)
_______________________________
Check Cutting Unit Drive Belt Adjustment
A–Level Service Required
Check Cutting Unit Gearbox Oil Level
_______________________________
________________________________
Check Fan and Alternator Belt Tension
Check Battery Level/Cable Connections
Clean Under Cutting Unit Belt Covers
A and B – Service Required
Inspect Cooling System Hoses
Inspect Air Filter
_______________________________
_______________________________
_______________________________
_______________________________
Timing Belt (see note on Maint. Sched.)
Cooling System Flush/Replace Fluid
Replace Safety Switches
Replace Moving Hoses
Other – Annual Service & Specials
________________________________
Torque Wheel Lug Nuts
C – Service (every 200 hours)
Change Engine Oil and Filter
B – Service (every 100 hours)
Date: ________________
Lubricate All Grease Fittings
A– Service (every 50 hours)
Technician:
Hours:
Unit Designation:
Remarks:
3000–D Supervisor Maintenance Work Order
(Duplicate this page for routine use.)
Groundsmaster
Chapter 3
Ford VSG–411 Engine
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Adjustment . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change Engine Oil and Filter . . . . . . . . . . . . . . . . . .
Check Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Groundsmaster 3000
2
2
3
3
4
4
5
6
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
Page 3 – 1
Ford VSG–411 Engine
Ford Gasoline
Engine
Table of Contents
General Information
The engine used in the Groundsmaster 3000 is manufa­
cutured by Ford Motor Company. Order service and re­
pair parts for Ford engines from you local Ford Power
Products Dealer. See the Ford VSG–411/413 Engine
Service Manual for engine identification information.
Specifications
Item
Specification
Make / Designation
Ford Model VSG–411
Firing Order
1–2–4–3
Ignition Timing
Distributorless Ignition System (DIS) Timing controlled by
Universal Electronic Spark Control (UESC)
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
–10 to +60_F
+10_ to +90_F
Above +32_F
Above +50_F
(single viscosity oil)
SAE 10
SAE 20
SAE 30
SAE 40
Ambient temperature
Below +60_F
–10 to +90_F
Above –10_F
Above +10_F
(multi–viscosity oil)
SAE 5W–30
SAE 10W–30
SAE 10W–40 or 10W50
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
2. Rotate alternator away from engine.
3. Hold alternator in position after proper belt tension
setting is achieved and tighten alternator and brace
bolts to secure adjustment.
Figure 1
1. Cooling Fan Belt
2. Governor Fan Belt
Cooling & Governor Fan Belts
The cooling and governor fan belts belt should be ten­
sioned so when they are pressed firmly with thumb, mid­
way 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.
Groundsmaster 3000
Page 3 – 3
Ford VSG–411 Engine
Ford Gasoline
Engine
1. To adjust belt tension, loosen bolt securing brace to
engine, bolt securing alternator to brace and alternator
mounting bolt.
2
Governor Adjustment
1. With engine shut off, move throttle control to FAST
position and open hood. Check between the throttle arm
and the stop on the carburetor base to make sure there
is 1/32” (0.8 mm). If gap is not correct, adjust throttle rod
by turning ball joint ends until gap is 1/32” (0.8 mm). If
gap is correct, proceed to step 2.
9. Bump the throttle lever with your hand so engine
speeds up momentarily. 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 gov­
ernor 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 in­
creased, anti–surge has been turned into the governor
too far and it must be backed out. Then repeat the entire
adjustment procedure.
WARNING
Engine must be running so final adjustment of the governor can be performed.
To guard against possible personal
injury, engage parking brake and keep
hands, feet, face and other parts of the
body away from fan or other moving
parts.
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 le­
ver assembly.
4
1
2. Start engine and move throttle to SLOW position.
Allow engine to warm up to normal operating tempera­
ture.
2
3
3. Rotate throttle arm closed until it contacts stop.
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.
5
Figure 2
1. 1/32” (0.8 mm)
2. Throttle rod
3. Carburetor idle speed screw
2
4. Stop
5. Throttle arm
1
IMPORTANT: Do not over speed the engine because
the transmission could be damaged.
7. Move throttle rapidly from SLOW to FAST. The en­
gine should not surge. if engine surges, proceed to step
8.
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 clock­
wise 1/8 turn at a time until surging stops. Should gover­
nor continue to surge, check the following:
6
4
3
5
A. Carburetor too rich or too lean.
Figure 3
B. Binding in throttle linkage.
1. High idle stop screw
2. Speed control lever
3. Jam nut
C. Governor worn internally.
4. Anti–surge screw
5. Low idle stop screw
IMPORTANT: Never rotate anti–surge screw in too
far so that speed of engine increases.
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. Re­
move dipstick and check level of oil. If level of oil is low,
add enough oil to raise level to notch in dipstick. DO
NOT OVERFILL.
1
5. The engine uses any high–quality detergent oil having the American Petroleum Institute—API—“service
classification” SG. Oil viscosity–weight– must be se­
lected according to ambient temperature. Temperature/
viscosity recommendations are:
Ford Gasoline
Engine
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.
Figure 4
1. Hood Latch
1
Single Viscosity Oils
Outside Temperature
–10_F to +60_F
+10_F to +90_F
Above +32_F
Above +50_F
SAE 10W
SAE 20W–20
SAE 30
SAE 40
Multi–Viscosity Oils
Figure 5
Outside Temperature
Below +60_F
–10_F to +90_F
Above –10_F
Above +10_F
1. Dipstick
SAE 5W–30
SAE 10W–30
SAE 10W–40 or 10W50
SAE 20W–40 or 20W50
1
IMPORTANT: 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 extremely dusty or dirty conditions.
6. Install oil fill cap.
7. Close hood and secure latch.
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 op­
eration, thereafter change oil and filter every 100 hours.
1. Remove drain plug (Fig. 7) and let oil flow into drain
pan. When oil stops, install drain plug.
2. Remove oil filter (Fig. 8). Apply a light coat of clean
oil to the new filter seal before screwing it on. DO NOT
OVER–TIGHTEN.
3. Add oil to crankcase. Capacity is 3.5 U.S. quarts
(3.3 liters) with filter. Refer to Check Engine Oil.
1
Figure 7
1. Drain Plug
1
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.
1
The cooling system is filled with a 50/50 solution of water
and permanent ethylene glycol anti–freeze. Check level
of coolant at beginning of each day before starting the
engine.
2. Check coolant level. Coolant should be up to COLD
line on reserve tank, when engine is cold.
HOT
COLD
Figure 9
1. Reserve Tank
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.
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
Ford Gasoline
Engine
1. Park machine on a level surface. Rotate hood latch
fully counterclockwise and open hood.
Cooling System Service
1. Removing Debris – Remove debris from rear
screen, oil cooler and radiator daily, clean more fre­
quently in dirty conditions.
IMPORTANT: Never spray water onto a hot engine as
damage to engine may occur.
A. Turn engine off and clean hood screen thor­
oughly.
B. Release hood latch and raise hood. Clean engine
area thoroughly of all debris.
C. Clean both sides of oil cooler and radiator area
thoroughly with compressed air. Do not use water.
D. Close hood and secure latch.
Note: Do not use water to clean engine or electrical
components, as damage may occur.
1
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).
Ford VSG–411 Engine
Page 3 – 8
Figure 10
1. Rear Screen
2
1
Figure 11
1. Oil Cooler
2. Radiator
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.
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.
4. Be sure cover is sealing around air cleaner body.
Ford Gasoline
Engine
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 fil­
ter against air cleaner body.
1
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 in­
formation.
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.
2
Figure 12
1. Air cleaner latches
2. Dust cup
1
Figure 13
1. Air cleaner filter
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 out­
er 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
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, dam­
age, 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)
1
Replace the fuel filter after every 400 hours of operation
or yearly, whichever comes first.
3
2
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.
Figure 14
1. Fuel filter
2. Rear elbow
3. Front elbow
Ford VSG–411 Engine
Page 3 – 10
Groundsmaster 3000
Replacing Spark Plugs
Change spark plugs after every 400 operating hours to
assure proper engine performance and reduce exhaust
emission level.
3. Check condition of side electrode, center electrode,
and center electrode insulator to assure there is no dam­
age.
Correct spark plug to use is a Motorcraft–AGSF22C or
AGRF22 or equivalent.
IMPORTANT: A cracked, fouled, dirty or otherwise
malfunctioning spark plug must be replaced. 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.
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.
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.
Ford Gasoline
Engine
Recommended air gap is .040” (1.016 mm).
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. 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.
1
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
Chapter 4
Peugeot TUD5 Engine
Table of Contents
Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . .
Priming Fuel System . . . . . . . . . . . . . . . . . . . . . . . .
Frame, Fuel Tank and Battery . . . . . . . . . . . . . . . .
Muffler and Rear Bumper . . . . . . . . . . . . . . . . . . . .
Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Bracket and Degasser . . . . . . . . . . . . . . . . . .
Center Shroud and Air Cleaner . . . . . . . . . . . . . . .
Radiator and Cooler . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Peugeot TUD5 Overhaul, Checking, Tuning . . . .
14
15
16
17
18
19
20
21
22
23
Peugeot Diesel
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
Groundsmaster 3000–D
Page 4 – 1
Peugeot TUD5 Engine
Specifications
Item
Specification
Make / Designation
Peugeot TUD5
4 cycle, in–line, overhead cam,
liquid cooled diesel engine
Governor Adjustment
High idle 2650 + 50 RPM
Low Idle 1500 + 100 R{M
Oil
SAE 15W–40 CE
Oil capacity
4.75 U.S. qt. with filter (4.5 liters)
Coolant
50/50 mixture
water and Peugeot recommended antifreeze
(Toro Part No. 93–7213)
Coolant capacity
11.5 U.S. qt. (10.9 liters)
Figure 1
Peugeot TUD5 Engine
Figure 2
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
Figure 3
Valve Spring Compression Tool (TOR4024T)
Peugeot Diesel
Engine
Use for removing valve springs.
Figure 4
Air Filter Element Cleaner (TOR277220)
A solution of filter cleaner and water may be used to
wash the air filter element of the Donaldson 3–stage air
cleaners.
DANGER: This compound contains sodium metasilicate which may cause burns and is harmful if
swallowed. Keep this chemical out of the reach of
children.
Figure 5
Groundsmaster 3000–D
Page 4 – 3
Peugeot TUD5 Engine
Injection Nozzle Tester (TOR463610)
When used along with the adapter, TOR437580, injec­
tion nozzles may be examined by performing the follow­
ing tests:
– Injection pressure test.
– Chattering test.
– Nozzle leakage test.
– Spray test.
Figure 6
Digital Belt Tension Tool (TOR4075)
Tool is used to accurately adjust the cam drive belt ten­
sion. NOTE: This tool is not included in TOR4080 kit.
Order separately.
Figure 7
Peugeot TUD5 Diesel Engine Service Tool Kit (TOR4080)
Kit includes: TOR4081, TOR4082, TOR4083,
TOR4084, TOR4085, TOR4086, TOR4087, TOR4088.
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.
Figure 9
Injector Socket (TOR4082)
Peugeot Diesel
Engine
A special deep socket to remove and install injectors.
Figure 10
Torque Angle Gauge (TOR4083)
Provides a method to tighten the fastener a specified
number of degrees after torque loads are applied. Cali­
brated in degrees in large easy to read increments. 1/2
inch square drive.
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.
Figure 12
Timing Pin Set (TOR4085)
Tool set is used to set injection pump engine timing.
Figure 13
Rear Main Seal Installer (TOR4086)
Tool is used to install the crankshaft rear main seal.
Figure 14
Peugeot TUD5 Engine
Page 4 – 6
Groundsmaster 3000–D
Front Seal Installer (TOR4087)
Tool is used to install the crankshaft front seal.
Figure 15
Camshaft Seal Installer (TOR4088)
Peugeot Diesel
Engine
Tool is used to install the camshaft seal.
Figure 16
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.
1
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.
2
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.
Figure 17
1. Fan Belt
2. Alternator belt
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.
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. Re­
move dipstick and check level of oil. If level of oil is low,
add enough oil to raise level to notch in dipstick. DO
NOT OVERFILL.
3. If oil level is low, clean area around oil fill cap, re­
move cap and add SAE 15W–40 CE oil until level reach­
es FULL mark on dipstick. DO NOT OVERFILL.
4. Install oil fill cap.
Peugeot Diesel
Engine
1
Figure 18
5. Close hood and secure latch.
1. Hood Latch
2
1
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 op­
eration, thereafter change oil and filter every 100 hours.
1. Remove drain plug (Fig. 20) and let oil flow into drain
pan. When oil stops, install drain plug and new plug seal,
Part No. 74–7850.
2. Remove oil filter (Fig. 21). Apply a light coat of clean
oil to the new filter seal before screwing it on. DO NOT
OVER–TIGHTEN.
3. Add 15W–40 CE oil to crankcase. Capacity is 4.75
quarts with filter.
1
Figure 20
1. Drain Plug
1
Figure 21
1. Oil Filter
Peugeot TUD5 Engine
Page 4 – 10
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 lev­
el. Coolant level should be up to or above tabs In degasser tank, when engine is cold.
1
CAUTION
If engine has been running, pressurized
hot coolant can escape and cause burns
if degasser cap is removed. Allow engine
to cool at least 15 minutes or until the
degasser cap is cool enough to touch
without burning hand.
Figure 22
Peugeot Diesel
Engine
1. Degasser Tank
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 WATER ONLY OR ALCOHOL/METHANOL BASE COOLANTS.
4. Install degasser tank cap.
5. Close hood and secure latch.
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 fre­
quently in dirty conditions.
IMPORTANT: Never spray water onto a hot engine as
damage to engine may occur.
A. Turn engine off and clean hood screen thor­
oughly.
B. Release hood latch and raise hood. Clean engine
area thoroughly of all debris.
C. Clean both sides of oil cooler and radiator area
thoroughly with compressed air. Do not use water.
D. Close hood and secure latch.
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 recom­
mended 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).
1
Figure 23
1. Rear Screen
2
1
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.
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.
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.
1
Peugeot Diesel
Engine
2. Gently slide filter (Fig. 26) out of air cleaner body to
reduce the amount of dust dislodged. Avoid knocking fil­
ter 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 in­
formation.
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 sealing end of filter. Do not install a damaged filter.
2
Figure 25
1. Air cleaner latches
2. Dust cup
1
Figure 26
1. Air cleaner filter
6. Insert new filter properly into air cleaner body. Make
sure filter is sealed properly by applying pressure to out­
er 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–D
Page 4 – 13
Peugeot TUD5 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.
1
3
DANGER
Because diesel fuel is highly flammable,
use caution when storing or handling it.
Do not smoke while filling the fuel tank. Do
not fill fuel tank while engine is running,
hot, or when machine is in an enclosed
area. 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.
2
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, dam­
age, 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 con­
tainer.
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 dis­
assembling 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.
2
1. Unlatch and raise hood.
2. Insert a 3/16 inch (5 mm) hose over bleed screw
and run other end into a container to catch fuel.
3. Loosen fuel filter / water separator bleed screw (Fig.
28) a few turns. Pump priming plunger until a steady
stream of fuel comes out of hole in bleed screw. When
fuel stops foaming, tighten the bleed screw during the
downstroke of the priming plunger. Wipe up any spilled
fuel.
Figure 28
1. Primer Plunger
2. Bleed Screw
Peugeot Diesel
Engine
4. Pump priming plunger until resistance is felt. Try to
start engine. If engine does not start repeat step 3.
1
Groundsmaster 3000–D
Page 4 – 15
Peugeot TUD5 Engine
Frame, Fuel Tank and Battery
6
5
9
4
10
11
12
13
14
15
3
16
2
8
7
42
19
18
20
17
1
43
19
22
41
39
36
38
21
23
24 25
26
37
28
27
35
26
44
34
40
33
32
31
30
30
29
Figure 29
1. Bushing
2. Fuel hose
3. Hose clamp
4. Fitting
5. Lock washer
6. Fuel hose
7. Gasket
8. Fuel sender
9. Screw
10. Fuel cap
Peugeot TUD5 Engine
11. Stand pipe
12. Fuel hose
13. Screw
14. Washer
15. Spacer
16. Fuel tank
17. Lock nut
18. Frame
19. Clinch nut
20. Bumper
Page 4 – 16
21. Battery cable (+)
22. Ground cable
23. Battery rod
24. Battery cable (–)
25. Washer
26. Lock nut
27. Threaded rod
28. Battery cover
29. Cover retainer
30. Flat washer
31. Retaining ring
Groundsmaster 3000–D
Muffler and Bumper
3
2
4
5
6
7
9
8
10
1
11
12
11
15
13
14
Figure 30
1. Lock nut
2. Nut
3. Bumper
4. Screw
5. Bumper cap
Groundsmaster 3000–D
6. Nut
7. Clinch nut
8. Rubber hanger
9. Spacer
10. Muffler guard
Page 4 – 17
11. Screw
12. Flat washer
13. Muffler
14. Muffler clamp
15. Carriage screw
Peugeot TUD5 Engine
Peugeot Diesel
Engine
1
Hood
7
5
4
6
8
3
2
1
9
20
19
11
18
17
12
14
13
15
16
Figure 31
1. Decal
2. Latch handle
3. Decal
4. Side seal
5. Top seal
6. Rear screen
7. Tinnermann nut
Peugeot TUD5 Engine
8. Toro logo plate
9. Pop rivet
10. Flat washer
11. Hair pin cotter
12. Decal
13. Hood
14. Screw
Page 4 – 18
15. Foam strip
16. Clinch nut
17. Hood pivot
18. Clevis pin
19. Latch arm
20. Caution decal (Europe)
Groundsmaster 3000–D
Center Shroud and Air Cleaner
2
3
1
4
5
24
6
26 20
7
8
9
29
10
11
28
15
27
23
30
19
14
13
12
21
18
17
16
Figure 32
1. Center shroud
2. ROPS
3. Foam strip
4. Hose clamp
5. Fuel hose
6. Fuel hose
7. Air cleaner hose
8. Hose clamp
9. Air cleaner
10. Hose clamp
Groundsmaster 3000–D
11. Intake spacer
12. Air cleaner hose
13. Screw (Model 30302 only)
14. Washer (Model 30302 only)
15. Bar (Europe)
16. Nut
17. Decal – 4wd (Model 30302 only)
18. Screw
19. Flat washer
20. Screw
Page 4 – 19
21. Tube cover (Model 30301 only)
22. Screw
23. Nut
24. Hose
25. Hose
26. Lock washer
27. Nut
28. Lock washer
29. ROPS decal
30. Safety decal (Model 30301 only)
Peugeot TUD5 Engine
Peugeot Diesel
Engine
25
Fan Bracket and Degasser
1
2
3
2
23
22
5
7
8
9
10
11
6
19
18
21
20
17
12
13
16
14
15
Figure 33
1. Hose
2. Hose clamp
3. Hose clamp
5. Screw
6. Lock nut
7. Screw
8. Lock nut
Peugeot TUD5 Engine
9. Idler spacer
10. Idler pulley
11. Nut
12. Lever
13. Fan bracket
14. Screw
15. Carriage screw
Page 4 – 20
16. Degasser bracket
17. Screw
18. Degasser hose
19. Hose
20. Nut
21. Radiator cap
22. Decal
Groundsmaster 3000–D
Radiator and Cooler
12
10
43
42
41
11
9
Pipe thread
sealant
38
4
2
14
13 40
13
8
3
15
7
5
1
20
Pipe thread
sealant
18
19
5
36
35
37
4
39
34
Peugeot Diesel
Engine
13
44
Fan clearance
minimum .18 inch (5 mm)
33
26
25
24
23
22
32
2
27
28
31
30
29
Figure 34
1. Upper radiator hose
2. Hose clamp
3. Hose
4. Hose clamp
5. Decal (Europe)
7. Spacer
8. Rubber grommet
9. Lock nut
10. Upper radiator support
11. Decal – starting fluid (Europe)
12. RH radiator support
13. Screw
14. Heat exchanger
15. Adapter fitting
Groundsmaster 3000–D
18. Lower radiator support
19. Lock nut
20. LH radiator support
22. Screw
23. Radiator
24. Radiator shroud
25. Flat washer
26. Screw
27. Restriction fitting
28. Clamp
29. Hose
30. O–ring
31. Radiator hose
32. Radiator hose fitting
Page 4 – 21
Rev. A
33. Lower radiator hose
34. Draiin cock fitting
35. Female hose barb
36. Hose
37. Foam plug
38. Foam strip
39. Rubber grommet
40. Cooler mount bracket
41. Clinch nut
42. R–clamp
43. Screw
44. Shield
Peugeot TUD5 Engine
Engine
18
17
16
14
36
15
19
50
24
8
9
10
49
11
13
7
12
6
34
44
5
20
4
21
22
32
47
3
28
24
43
29
23
25
28
26
2
1
29
30
27
24
2
4
42
34
45
33
48
42
34
37
41 40
31
41
34
47
38
39
46
3
35
33
7
Figure 35
1. Front engine plate
2. Screw
3. Snubbing washer
4. Engine mount
5. Lower radiator hose
6. R.H. engine mount
7. Lock nut
8. Fuel hose
9. Hose clamp
10. Fuel hose
11. Engine
12. Bearing
13. Retaining ring
14. Screw
15. Fan hub
16. Fan hub
17. V–belt
18. Screw
19. Fan
20. Screw
21. Fan pulley
22. Fan bracket
23. Screw
24. Lock washer
25. Crank pulley
26. Crank spacer
27. L.H. engine mount
28. Screw
29. Flat washer
30. Hose
31. R–clamp
32. Nut
33. Lock nut
34. Screw
35. Exhaust pipe
36. Screw
37. Nut
38. Nut
39. Screw
40. Screw
41. Lock washer
42. Screw
43. R–clamp
44. Throttle cable mount
45. Screw
46. Lock washer – external tooth
47. Flat washe
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 informa­
tion. See the Toro Parts Catalog for parts indentification.
Refer to the Special Tools list starting on Page 4 – 3 of
the Toro Groundsmaster 3000/3000–D Service Manual.
The tool numbers referred to in the Peugeot manual are
Peugeot numbers, which Toro does not use.
Peugeot Diesel
Engine
Use the TORO lubrication, maintenance and fluid rec­
ommendations if they are different from the information
in the Peugeot manual.
Groundsmaster 3000–D
Page 4 – 23
Peugeot TUD5 Engine
Peugeot TUD5 Engine
Page 4 – 24
Groundsmaster 3000–D
Chapter 5
Hydraulic System and Transaxle
Table of Contents
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . .
Check Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . .
Check Wheel Nut Torque . . . . . . . . . . . . . . . . . . . .
Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . .
Change Hydraulic Oil and Filter . . . . . . . . . . . . . .
Traction Control Linkage . . . . . . . . . . . . . . . . . . . . .
Brake Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driveshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Control . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Hydraulic System Components . . . . .
Manifold Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cartridge Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Hydraulic Pump . . . . . . . . . . . . . . . . . . . .
Transaxle Service . . . . . . . . . . . . . . . . . . . . . . . . . .
SAUER–SUNDSTRAND IHT SERVICE MANUAL
21
21
21
22
23
24
25
26
27
28
30
31
32
33
34
35
36
Hydraulic System
and Transaxle
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
Groundsmaster 3000/3000–D
Page 5 – 1
Hydraulic System
Specifications
Item
Specification
Transaxle
Sauer–Sundstrand IHT–M15
Charge Pressure: 80 – 130 PSI (5.5 – 9 Bar)
Implement Relief Pressure: 1,000 – 1,100 PSI (69 – 76 Bar)
Traction Forward Pressure: 6,200 PSI (428 Bar) maximum
Traction reverse pressure: 5,000 PSI (345 Bar) maximum
Manifold Block
Toro logic cartridge, elec./hyd., solenoid actuated
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):
1,000 – 1,100 PSI (69 – 76 Bar)
Steering Control
Eaton Series 2 steering control unit with power beyond
Hydraulic Fluid
Mobil 424
(see Check Hydraulic Fluid in Service and Repairs
section of this chapter for alternatives)
Hydraulic Fluid Capacity
Hydraulic System
Approximately 12 U.S. qts. (11.4 liters)
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 stan­
dard procedure.
IMPORTANT: Do no push or tow the traction unit
faster than 10 mph (16 km/hr). If traction unit must
be moved a considerable distance, transport it on a
truck or trailer.
1
1. Locate towing lever on right side of axle assembly.
2. Remove cotter pin and clevis pin securing lever to
plate on side of axle.
3. 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.
Figure 1
1. Towing Lever
Hydraulic System
and Transaxle
4. After completion of towing operation, pivot lever
back to original position and re–secure.
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 condi­
tions or mishandling during operation or maintenance.
These conditions can cause damage or premature dete­
rioration. Some hoses are more susceptible to these
conditions than others. Inspect the hoses frequently for
signs of deterioration or damage.
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.
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.
Hydraulic Fitting Installation
O–Ring Face Seal
Nut
1. Make sure both threads and sealing surfaces are free
of burrs, nicks, scratches, or any foreign material.
Body
Sleeve
2. Make sure the O–ring is installed and properly seated
in the groove. It is recommended that the O–ring be re­
placed any time the connection is opened.
Seal
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.
Figure 2
5. Mark the nut and fitting body. Hold the body with a
wrench. Use another wrench to tighten the nut to the cor­
rect 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.)
Final
Position
F.F.F.T.
.75 + .25
.75 + .25
.75 + .25
1.00 + .25
.75 + .25
.75 + .25
Mark Nut
and Body
Extend Line
Finger Tight
Initial
Position
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.
O–Ring
3. Lubricate the O–ring with a light coating of oil.
4. Install the fitting into the port and tighten it down full
length until finger tight.
5. Tighten the fitting to the correct flats from finger tight
(F.F.F.T.).
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
Figure 4
F.F.F.T.
1.00 + .25
1.50 + .25
1.50 + .25
1.50 + .25
1.50 + .25
1.50 + .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.
backup Washer
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).
O–Ring
Figure 5
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
Step 3
Step 2
Step 4
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
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.)
Groundsmaster 3000/3000–D
F.F.F.T.
1.00 + .25
1.50 + 25
1.50 + .25
1.50 + .25
1.50 + .25
1.50 + .25
Page 5 – 5
Figure 6
Hydraulic System
Hydraulic System
and Transaxle
Lock Nut
15CC
VARIABLE
PUMP
Hydraulic System
PF
CHARGE
PRESSURE
PRIORITY VALVE
RESERVOIR
INLET
FILTER
PV
CHARGE/
IMPLEMENT
PUMP
IHT–M15 TRANSAXLE
Page 5 – 6
6.1 IN DISPLACEMENT
3
STEERING CONTROL UNIT
IMPLEMENT CIRCUIT
PRESSURE RELIEF VALVE
”EASY–RIDE”
VALVES
MV
25CC
VARIABLE
MOTOR
R
T
T1
STEERING CYLINDER
1.625 BORE
7.00 STROKE
.625 ROD
L
P PB
P3
P2
T3
S
T2
C3
S2
OFF
OFF
ON
S1
ON
OFF
OFF
SOLENOIDS
OIL
COOLER
OUT
S1
N1
G1
LC1
75–220 PSI
ADJ ORIFICE
STD .187
LIFT CYLINDERS
2.5” BORE
3.5” STROKE
LIFT/
1” ROD
COUNTERBALANCE
MANIFOLD
CYL1
LIFT
HOLD
LOWER/FLOAT
LIFT/LOWER
CONTROL
P
CYL2
S2
Hydraulic Schematic
T–2350–4
Groundsmaster 3000/3000–D
15CC
VARIABLE
PUMP
PV
Groundsmaster 3000/3000–D
Page 5 – 7
Rev. A
A
VARIABLE MOTOR OPTION
DETAIL
MV
25CC
VARIABLE
MOTOR
SCREW CLOCKWISE TO
MAX SETTING WITH
HYD. KIT INSTALLED.
25CC
FIXED
MOTOR
P2
T3
S
DETAIL
P3
R
T
1000 PSI
5 PSI
Hydraulic System
Hydraulic System
and Transaxle
STEERING CYLINDER
1.625 BORE
7.00 STROKE
.625 ROD
L
A
OIL
COOLER
T2
C3
33CC
CCW
INPUT
QUICK
COUPLER
3625
PSI
QUICK
COUPLER
AUX FILTER
OUT
18CC
M1
1750
PSI
S1
N1
G1
CYL1
1750
PSI
18CC
M2
P
S2
CYL2
1750
PSI
18CC
M3
DECK MOTORS
BRAKING VALVE
600 PSI
LC1
75–220PSI
ADJ ORIFICE
STD .187
LIFT CYLINDERS
2.5” BORE
3.5” STROKE
1” ROD
SOLENOIDS
S1
S2
ON
OFF
OFF
OFF
OFF
ON
LIFT/
COUNTERBALANCE
MANIFOLD
LIFT/LOWER
CONTROL
LIFT
HOLD
LOWER/FLOAT
SUNDSTRAND IHT
IDLE 1650 RPM
LOADED 1560 RPM
T1
FIXED MOTOR OPTION
STEERING CONTROL UNIT
6.1 IN3 DISPLACEMENT
P PB
MF
”EASY–RIDE”
VALVES
IMPLEMENT CIRCUIT
PRESSURE RELIEF VALVE
”EASY–RIDE”
VALVES
CHARGE
PRESSURE
PRIORITY VALVE
RESERVOIR
INLET
FILTER
PF
CHARGE/
IMPLEMENT
PUMP
IHT–M15 TRANSAXLE
1750
PSI
18CC
M4
IHT
RESERVOIR
QUICK
COUPLER
Hydraulic Schematic (with Model 30726 Hyd. Kit and Contour 82 Cutting Unit)
Hydraulic Components
Steering cylinder
Oil cooler
Manifold block
Lift cylinder
Lift cylinder
Steering
control unit
Hydraulic System
Page 5 – 8
Groundsmaster 3000/3000–D
Special Tools
NOTE: Order special tools from the TORO SPECIAL
TOOLS AND APPLICATIONS GUIDE (COMMERCIAL
PRODUCTS). Some tools may also be available from a
local supplier.
Hydraulic Pressure Test Kit – TOR47009
Use to take various pressure readings for diagnostic
tests. Quick disconnect fittings provided attach directly
to mating fittings on machine test ports without tools. A
high pressure hose is provided for remote readings.
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.
Figure 7
Hydraulic Test Fitting Kit – TOR4079
Hydraulic System
and Transaxle
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.
Figure 8
Measuring Container – TOR4077
Use this container for doing hydraulic motor efficiency
testing (motors with case drain lines only). Measure effi­
ciency 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 9
Groundsmaster 3000/3000–D
Page 5 – 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 cir­
cuit to the inlet side of the hydraulic tester.
2. LOAD VALVE: If required, upon turning the valve to
restrict flow, a simulated working load is created in the
circuit.
4. HIGH PRESSURE GAUGE: High range gauge to ac­
commodate 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 hy­
draulic tester to be connected to the hydraulic system
circuit.
3. LOW PRESSURE GAUGE: Low range gauge to pro­
vide 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.
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.)
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.
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 link­
age, 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.
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.
Groundsmaster 3000/3000–D
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 us­
ing 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.
10. All hydraulic tests should be made with the hydraulic
oil at normal operating temperature.
Page 5 – 11
Hydraulic System
Hydraulic System
and Transaxle
CAUTION
IMPORTANT: Test ports on the transaxle are painted
closed. Opening the ports will loosen the paint.
Make sure dirt or paint particles do not fall into the
open port.
Charge Pressure Test
NOTE: See Sauer–Sundstrand IHT Service Manual for
more information.
Use a 500 or 1,000 PSI (35 or 70 Bar) test gauge.
Specification: 80 to 130 PSI (5.5 to 9 Bar)
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes.
1
2. 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.
Figure 11
1. Charge pressure port
4. Start the engine and move the throttle control all the
way forward. Take pressure reading with machine sta­
tionary. 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.
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 speci­
fication 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 opera­
tion of the charge priority valve. Rotate the steering
wheel to create back–pressure while observing the
gauge. The gauge should not have a significant pres­
sure 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
NOTE: When you move the traction pedal to create
pressure, move it a short distance first and wait for a
change in sound before moving the pedal further. The
change in sound indicates that the easy ride valve has
closed.
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes.
1
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 en­
gine at full speed. Slowly push the traction pedal forward
and listen for engagement of the easy ride valve. Contin­
ue to push the traction pedal and read the gauge.
Figure 12
1. Forward traction pressure port
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
NOTE: When you move the traction pedal to create
pressure, move it a short distance first and wait for a
change in sound before moving the pedal further. The
change in sound indicates that the easy ride valve has
closed.
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes.
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 en­
gine at full speed. Slowly push the traction pedal in re­
verse and listen for engagement of the easy ride valve.
Continue to push the traction pedal and read the gauge.
Groundsmaster 3000/3000–D
Page 5 – 13
1
Figure 13
1. Reverse traction pressure port
Hydraulic System
Hydraulic System
and Transaxle
Reverse Traction Test
Implement Relief Pressure Test
NOTE: See Sauer–Sundstrand IHT Service Manual for
more information.
Use a 5,000 PSI (350 Bar) test gauge.
1
Specification:1,000 to 1,100 PSI (69 to 76 Bar)
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes.
2. Lower cutting unit, engage parking brake and stop the
engine.
3. Install a 5,000 PSI (350 Bar) pressure gauge with
quick connect adapter on the test port.
4. Start the engine and move the throttle control all the
way forward. Pull back on the lift lever until the imple­
ment is fully raised. Continue holding the lift lever back
to cause the relief valve to open, then read the gauge.
Figure 14
1. Test Port
1
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 addi­
tional valve is present, adjust relief pressure at the new
location only.
Figure 15
1. Implement relief valve (standard)
1
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)
2
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes.
1
2. Lower cutting unit, engage parking brake and stop the
engine.
Figure 17
1. Test Port
2. Counterbalance valve
3. Install a 500 or 1,000 PSI (35 or 70 Bar) pressure
gauge with quick connect adapter on the test port.
Hydraulic System
and Transaxle
4. Start the engine and move the throttle control all the
way forward. Read the gauge. Do not raise the imple­
ment when testing counterbalance pressure. Move the
lift lever forward to make sure the lift system is in the
“float” position.
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 steer­
ing valve has adequate flow and pressure.
2. Lower cutting unit, engage parking brake and stop the
engine.
3. Disconnect the tee from the cylinder. Install a cap on
the cylinder and a plug on the open tee port.
Cylinder Test
This test checks the steering cylinder for internal
bypass, and assumes that the steering valve is working
correctly. 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.
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 dam­
aged internal seal. Repair or replace the cylinder. If the
pressure does not increase by rotating in either direc­
tion, repair or replace the steering valve.
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)
1
Figure 18
4. Start the engine and move the throttle control all the
way forward. Rotate the steering wheel counterclock­
wise until the cylinder reaches the end of its travel. Con­
tinue 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.
1. Right side steering cylinder fitting
Steering Valve Test
This test determines if the steering valve is working cor­
rectly. If this test is good and the first test is not, the prob­
lem 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.
8
2
4
1
Use a tester with pressure and flow capabilities.
3
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.
Flow
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.
6
7
5
Figure 20
1.
2.
3.
4.
5.
6.
7.
8.
45 degree fitting
Quick coupler nipple
Pump
Splined coupler
Flush faced coupler
Pump supply hose
Hose bracket
Square O–ring
Hydraulic System
and Transaxle
IMPORTANT: 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.
Groundsmaster 3000/3000–D
Page 5 – 17
Flow
1
2
Figure 21
1. Oil filter assembly
2. Flush faced fitting
Hydraulic System
This page is blank.
Hydraulic System
Page 5 – 18
Groundsmaster 3000/3000–D
Hydraulic System
and Transaxle
This page is blank.
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 trac­
tion 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)
1
Figure 22
1. Traction Pedal Stop
2
1
3
Figure 23
1. Traction Rod
2. Traction Rod Hub
3. Lever
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 ad­
just linkage until there is a slight drag on rotor.
2
1
4. Back off clevis one full turn and reinstall to bellcrank.
5. Tighten jam nut.
3
6. Repeat procedure on opposite wheel.
Figure 24
1. Bellcrank
2. Frame stop
3. Linkage Clevis
Hydraulic System
Page 5 – 20
Groundsmaster 3000/3000–D
Service and Repairs
Wheel and Tires
Check Tire Pressure
Check Wheel Nut Torque
The tires are over–inflated for shipping. Therefore, re­
lease some of the air to reduce the pressure. Correct air
pressure in the front and rear tires is 15 psi (1 Bar).
IMPORTANT: Maintain even pressure in all tires to as­
sure a good quality–of–cut and proper machine perfor­
mance. DO NOT UNDER INFLATE.
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.
Lubrication
The machine has grease fittings that must be lubricated
regularly with No. 2 General Purpose Lithium Base
Grease. If machine is operated under normal condi­
tions, lubricate all bearings and bushings after every 50
hours of operation or immediately after every washing.
Hydraulic System
and Transaxle
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).
Figure 26
Figure 25
Figure 27
Figure 28
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 hydraulic fluid before engine is first started and daily
thereafter.
1
1. Position machine on a level surface, raise the imple­
ment, and stop the engine.
2. Unscrew dipstick cap from the filler neck and wipe it
with a clean rag. 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.
Figure 29
1. Dipstick cap
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.
IMPORTANT: Do Not Use Biodegradable Hydraulic
Fluid.
IMPORTANT: 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 Dis­
tributor
Hydraulic System
Page 5 – 22
Groundsmaster 3000/3000–D
Change Hydraulic Oil and Filter
The hydraulic system oil and filter must be changed ini­
tially at 200 hours and thereafter every 800 hours of op­
eration or seasonally, whichever comes first. NOTE:
Change oil and filters every 400 hours if equipped with
Model 30726 Hydraulic Kit. The hydraulic system is de­
signed to operate on anti–wear hydraulic fluid. The ma­
chines reservoir is filled at the factory with
approximately 12 U.S. quarts (11.4 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
Figure 31
1. Drain plug
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, imple­
ment may be removed from traction unit.
1
4. Remove drain plug from axle housing and allow oil
to flow into drain pan.
5. Clean area around hydraulic oil filter and remove fil­
ter. NOTE: Also replace filter for Model 30726 Hydraulic
Kit.
6. Lubricate new filter seal and install filter.
Figure 32
Hydraulic System
and Transaxle
1. Hydraulic 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 steer­
ing wheel lock to lock to purge air trapped in the system.
Shut the engine off.
10. Let machine set for two additional minutes, then re­
move 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.
1
1
Figure 33
1. Hydraulic filter (Model 30726 Hydraulic Kit)
Figure 30
1. Dipstick cap
Groundsmaster 3000/3000–D
Page 5 – 23
Hydraulic System
Traction Control Linkage
1
2
26
3
4
5
7
6
8
9
10
11
12
22
13
21
25
14
24
20
23
15
16
19
18
17
Figure 34
1. Carriage bolt
2. Traction lever
3. Rod end bearing
4. Jam nut
5. Control tube
6. Flat washer
7. Hair pin cotter
8. Hub
9. Rubber bushing
Hydraulic System
10. Hub post
11. Lever
12. Lock nut
13. Lock nut
14. Screw
15. Pedal abrasive
16. Pedal abrasive
17. Traction pedal
18. Nut
Page 5 – 24
19. Screw
20. Screw
21. Flange bushing
22. Pedal bracket
23. Grease fitting
24. Nut
25. Roll pin
26. Flat washer
Groundsmaster 3000/3000–D
Brake Linkage
9
8
12
11
13
2
14
1
17
8
15
34
10
7
3
16
6
4
5
33
21
20
22
29
23
32
13
19
7
18
24
31
34
1
30
27
Hydraulic System
and Transaxle
28
25
26
Figure 35
1. Control rod
2. Cotter pin
3. Carriage screw
4. Clevis pin
5. Jam nut
6. Clevis
7. Hair pin cotter
8. Bellcrank
9. Extension spring
10. Screw
11. R.H. pedal
12. Foot pad
Groundsmaster 3000/3000–D
13. Lock nut
14. Foot pad
15. L.H. pedal
16. Screw
17. Nylon bushing
18. Retaining ring
19. Thrust washer
20. Screw
21. Nut
22. Lock arm
23. L.H. brake arm
24. Pillow block bearing
Page 5 – 25
25. L.H. brake lever
26. Roll pin
27. Grease fitting
28. Retaining ring
29. Clevis
30. Brake latch
31. R.H. brake arm
32. Flat washer
33. R.H. brake lever
34. Cotter pin
Hydraulic System
Driveshafts
9
8
7
6
5
4
3
2
10
1
11
21
20
19
16
12
15
13
18
17
Never–seez
14
13
Figure 36
1. Screw
2. Cross and bearing kit
3. Slip yoke
4. Grease fitting
5. Yoke and shaft
6. Screw
7. Lock washer
Hydraulic System
8. Flange yoke
9. Engine adapter plate
10. Lock nut (Model 30302)
11. Screw (Model 30302)
12. Clamp yoke (Model 30302)
13. Grease fitting (Model 30302)
14. Yoke and sleeve (Model 30302)
Page 5 – 26
15. Yoke and shaft (Model 30302)
16. Cross & bearing kit (Model 30302)
17. Lock nut
18. Yoke and clamp
19. Grease fitting
20. Screw
21. Lock washer
Groundsmaster 3000/3000–D
Lift Arms
11
9
6
8
66 ft–lb
(9 Kgm)
12
7
20
5
13
4
3
250 ft–lb
(35 Kgm)
2
Hydraulic System
and Transaxle
19
1
Figure 37
1. Lift arm (L.H. shown)
2. Flange bushing
3. Nut
4. Grease fitting
5. Hydraulic cylinder
6. Bushing
Groundsmaster 3000/3000–D
7. Cylinder spacer
8. Screw
9. Pin
11. Lock nut
12. Screw
13. Screw
Page 5 – 27
14. Screw
19. Pivot spacer
20. Bushing
Hydraulic System
Steering Control
30
31
13
8
7
9
10
14
35 – 45 ft–lb
(5 – 6 Kgm)
15
3
11
2
4
5
6
16
17
12
18
20
1
19
21
28
27
22
29
23
3
24
25
6
26
Figure 38
1. Tower housing
2. Tower decal
3. Screw
4. Screw
5. Spacer
6. Clinch nut
7. Tower decal
8. Steering column
9. Flange bushing
10. Washer
Hydraulic System
11. Knob
12. Tower cover
13. Steering wheel
14. Nut
15. Flat washer
16. Foam collar
17. Steering seal
18. Retaining ring
19. Steering shaft
20. Vinyl cap
Page 5 – 28
21. Parking brake rod
22. Extension spring
23. Hair pin cotter
24. Brake pawl
25. Hair pin cotter
26. Steering control unit
27. Clevis pin
28. Tilt rod
29. Nut
30. Cover
Groundsmaster 3000/3000–D
#4 Tube
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#3 Tube
#2 Tube
#5 Tube
#1 Tube
#3
#5
#1
#2
Hydraulic System
and Transaxle
#4
Figure 39
Groundsmaster 3000/3000–D
Page 5 – 29
Hydraulic System
Removing Hydraulic System Components
1. Thoroughly clean the machine before disconnecting,
removing or disassembling any hydraulic components.
Always keep in mind the need for cleanliness when
working on hydraulic equipment.
2. Put caps or plugs on any hydraulic lines or fittings left
open or exposed.
3. Put labels on disconnected hydraulic lines and hoses
for proper installation after repairs are completed.
2. After repairs, check control linkage for proper adjust­
ment, binding or broken parts.
3. After disconnecting or replacing any hydraulic com­
ponents, operate machine functions slowly until air is
out of system.
4. Check for hydraulic oil leaks. Shut off engine and cor­
rect leaks if necessary. Check oil level in hydraulic reser­
voir and add correct oil if necessary.
After Repair or Replacement of Components
1. Check oil level in hydraulic reservoir and add correct
oil if necessary. Drain and refill hydraulic system reser­
voir and change oil filter if component failure was severe
or system is contaminated.
Hydraulic System
Page 5 – 30
Groundsmaster 3000/3000–D
Manifold Block
7
8
11
12
10
6
13
3
9
11
2
28
5
4
2
3
24
2
23
22
16
3
12
17
1
Torque to
35 ft–lb 15
(5 Kgm)
Torque to
15 in–lb
(17 Kg–cm)
Apply
Loctite 242
to threads
14
14
15
18
26
19
27
26
Hydraulic System
and Transaxle
25
15
20
14
21
Figure 40
1. Body
2. O–ring
3. O–ring
4. Needle valve
5. Wheel
6. Set screw
7. Knob
8. Logic valve
9. Orifice plug (.187 dia.)
10. Cartridge – N.C. poppet
11. O–ring
12. Solenoid coil
13. Nut
14. Plug
15. O–ring
16. Nut
17. Cartridge – N.O. poppet
18. Plug
19. O–ring
20. O–ring
21. Plug
22. O–ring
23. O–ring
24. O–ring
25. Plug
26. O–ring
27. Plug
28. Cavity plug
NOTE: Assembly kits are available for servicing this
component. See the Parts Catalog for more information.
Groundsmaster 3000/3000–D
Page 5 – 31
Hydraulic System
Cartridge Valves
1. Clean valve block to prevent contamination when
valve cartridge is removed.
Cartridge Installation
1. Lubricate all o–rings with clean hydraulic oil.
2. Remove cartridge valve:
2. Carefully thread cartridge into the port by hand. Valve
cartridge should go in easily without binding.
A. Remove nut from solenoid.
B. Remove solenoid coil and o–ring at each end of
solenoid coil.
C. Use a deep socket to remove cartridge valve.
NOTE: Use care when handling valve cartridges,
because slight bending or distortion of stem tube
can cause binding and malfunction.
3. Visually inspect port in block for damage to sealing
areas, damaged threads or contamination.
4. Visually inspect cartridge for damaged seals and con­
tamination.
A. O–rings and backup rings must be arranged
properly on the valve for proper operation and seal­
ing. Replace any damaged seals.
3. Use a torque wrench and deep socket to tighten car­
tridge valves to a torque of 35 ft–lb (5 Kgm). Excessive
torque may cause the spool to bind and malfunction.
NOTE: Use care when handling solenoid valve car­
tridges because slight bending or distortion of stem tube
can cause binding and malfunction.
4. Install solenoid coil. Make sure there is an o–ring at
each end of the coil. Apply “Loctite 242” or equivalent to
threads of stem tube before installing nut. Tighten nut to
a torque of 15 in–lb (17 Kg–cm).
5. If problem still exists, remove valve and clean again
or replace valve.
B. Contamination may cause valves to stick or hang
up. Contamination can become lodged in small
valve orifices or seal areas on poppet type valves
causing malfunction.
C. If cartridge valve seals appear pitted or dam­
aged, the hydraulic system may be overheating or
there may be water in the system.
5. Clean and check for proper valve operation:
A. Use clean mineral spirits to clean cartridge valve.
Submerge the valve in clean mineral spirits and use
a brass or plastic probe to push the internal spool in
and out 20 to 30 times to flush out contamination.
Mineral spirits does not affect the o–ring material.
Particles as fine as talcum powder can affect the op­
eration of high pressure hydraulic valves.
Figure 41
Hydraulic System
Page 5 – 32 Rev. A
Groundsmaster 3000/3000–D
Lift Cylinder
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Hydraulic System
and Transaxle
15
Figure 42
1. Tube
2. Lock nut
3. Piston seal
4. Piston
5. Wear ring
6. O–ring
7. Rod
8. Bushing
9. O–ring
10. Backup washer
11. Head
12. Wiper
13. Retaining ring
14. Spacer
15. Retaining ring
NOTE: Assembly kits are available for servicing this
component. See the Parts Catalog for more information.
Groundsmaster 3000/3000–D
Page 5 – 33
Hydraulic System
Steering Cylinder
1
2
3
4
5
6
7
8
9
10
11
12
19
13
14
15
16
18
17
Figure 43
1. Rod wiper
2. Threaded cap
3. Head
4. U–cup
5. Backup ring
6. Rod
7. O–ring
8. O–ring
9. Piston ring
10. O–ring
11. Piston
12. Wear ring
13. Lock nut
14. Barrel
15. Roll pin
16. Slotted nut
17. Tie rod end
18. Jam nut
19. Set screw
NOTE: Assembly kits are available for servicing this
component. See the Parts Catalog for more information.
Hydraulic System
Page 5 – 34
Groundsmaster 3000/3000–D
Auxiliary Hydraulic Pump (Model 30726 Hydraulic Kit)
16 15:1 15
15:2
2
3
4
5
1
7
8:2
6
8
8:1
14
17
8:2
8
18
8:1
19
13
12:2
12
12:1
11:1
11
10
Hydraulic System
and Transaxle
9
9:1
Figure 44
1. Hydraulic pump
2. Adapter
3. O–ring
4. Splined coupler
5. Internal snap ring
6. Screw
7. Lock nut
Groundsmaster 3000/3000–D
8. Hydraulic fitting
9. Hydraulic fitting
10. Flush face fitting
11. Elbow fitting
12. Adapter
13. Hydraulic coupler
14. Hose
Page 5 – 35
Rev. A
15. Hydraulic fitting
16. Nipple
17. Screw
18. Hose bracket
19. Grommet
Hydraulic System
Transaxle Service
Some of the components shown in the Sauer–Sundstrand IHT Service Manual may not be used on the Toro
application. See your Toro Parts Catalog for more information.
Toro recommended fluids and maintenance intervals
may be different than those listed in the Sauer–Sundstrand IHT Service Manual. When doing maintenance or
service on the transaxle, use the Toro recommended
fluids and maintenance intervals.
6
1
2
3
4
5
7
28
29
10
8
11
9
12
13
27
14
30
Brake rotor must be
free of paint, grease,
oil or other contamination
16
15
26
45 – 50 ft–lb
(6 – 7 Kgm)
24
17
23
34 21
22
70 – 80 ft–lb
(10 – 11 Kgm)
33
31
18
32
19
Figure 45
1. Hair pin cotter
2. Screw
3. Lever
4. Lock nut
5. Clevis pin
6. Screw
7. Nut
8. Screw
9. Belleville washer
10. Mounting bracket
11. Housing
12. Lever
13. Washer
14. Screw
15. Pad
16. Tire
17. Valve stem
18. Lug nut
19. Rim
21. Brake rotor
22. Screw
23. Flat washer
24. Axle plate
26. Axle
27. Lock nut
28. Transaxle bracket
29. Screw
30. Brake shield
31. Switch bracket
32. Switch
33. Lock washer
34. Jam nut
NOTE: Assembly kits are available for servicing this
component. See the Parts Catalog for more information.
Hydraulic System
Page 5 – 36
Groundsmaster 3000/3000–D
Chapter 6
Electrical System
Table of Contents
50 Ampere Thermal Breaker (GM 3000–D) . . . . 16
Fuel Stop Solenoid (GM 3000–D) . . . . . . . . . . . . 17
Injection Advance Solenoid (GM 3000–D) . . . . . 18
Alternator (GM 3000–D) . . . . . . . . . . . . . . . . . . . . 19
Temperature Sender (GM 3000–D) . . . . . . . . . . . 20
Temperature Gauge (GM 3000–D) . . . . . . . . . . . 21
Oil Pressure Switch (GM 3000–D) . . . . . . . . . . . . 21
Temperature Sending Unit (GM 3000–D) . . . . . . 22
Transport Solenoid (GM 3000–D) . . . . . . . . . . . . 23
Glow Plugs (GM 3000–D) . . . . . . . . . . . . . . . . . . . 23
H2O in Fuel Sensor (GM 3000–D) . . . . . . . . . . . . 24
Coolant Level Sensor (GM 3000–D) . . . . . . . . . . 25
Indicator Lights and Circuits (GM 3000–D) . . . . 26
Ford Engine (VSG–411) Electrical Component Loca­
tions (GM 3000) . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Temperature Gauge (GM 3000) . . . . . . . . . . . . . . 30
Thermistor (GM 3000) . . . . . . . . . . . . . . . . . . . . . . 30
Oil Pressure Switch (GM 3000) . . . . . . . . . . . . . . 31
High Temperature Switch (GM 3000) . . . . . . . . . 32
Anti–dieseling Valve Solenoid (GM 3000) . . . . . 33
Indicator Lights and Circuits (GM 3000) . . . . . . . 34
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 35
Verify Interlock System Operation . . . . . . . . . . . . 35
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . 36
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Electrical
System
ELECTRICAL SCHEMATICS, WIRING DIAGRAMS,
AND HARNESS DRAWINGS . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING (Groundsmaster 3000) . . . . 4
Starting Problems (GM 3000) . . . . . . . . . . . . . . . . . 4
General Run & Transport Problems (GM 3000) . 5
Cutting Unit Operating Problems (GM 3000) . . . . 5
TROUBLESHOOTING (Groundsmaster 3000–D) . . 6
Starting Problems (GM 3000–D) . . . . . . . . . . . . . . 6
General Run & Transport Problems (GM 3000–D) 7
Cutting Unit Operating Problems (GM 3000–D) . 7
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . . 8
Battery Test (Open Circuit Test) . . . . . . . . . . . . . . . 8
Glow Plug System Test (GM 3000–D) . . . . . . . . . . 8
COMPONENT IDENTIFICATION AND TESTING . . 9
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Diode Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . 10
Neutral Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic Valve Solenoids . . . . . . . . . . . . . . . . . . . 12
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cruise Control Coil . . . . . . . . . . . . . . . . . . . . . . . . . 13
PTO (Clutch) Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fuel Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Relays and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Groundsmaster 3000/3000–D
Page 6 – 1
Electrical System
Electrical Schematics, Wiring Diagrams,
and Harness Drawings
All electrical schematics, diagrams, and drawings for
both the Groundsmaster 3000 and Groundsmaster
3000–D are located in Chapter 14 – Electrical Dia­
grams.
Electrical System
Page 6 – 2
Groundsmaster 3000/3000–D
Special Tools
Order special tools from the TORO SPECIAL TOOLS
AND APPLICATIONS GUIDE (COMMERCIAL PROD-
UCTS).
Some tools may also be available from a local supplier.
Multimeter
The meter can test electrical components and circuits
for current, resistance, or voltage.
NOTE: Toro recommends the use of a DIGITAL Volt–
Ohm–Amp multimeter when testing electrical circuits.
The high impedance (internal resistance) of a digital me­
ter in the voltage mode will make sure that excess cur­
rent is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.
Figure 1
Skin–Over Grease
Electrical
System
Special non–conductive grease which forms a light pro­
tective skin which helps waterproof electrical switches
and contacts.
Figure 2
Groundsmaster 3000/3000–D
Page 6 – 3
Electrical System
Troubleshooting (Groundsmaster 3000)
For effective troubleshooting and repairs, you must
have a good understanding of the electrical circuits and
components used on this machine (see Wiring Sche­
matics section of this chapter).
CAUTION
Remove all jewelry, especially rings and
watches, before doing any electrical troubleshooting or testing. Disconnect the battery
cables unless the test requires battery voltage.
If the machine has any interlock switches by–passed,
they must be reconnected for proper troubleshooting
and safety.
Starting Problems
Problem
Possible Causes
Starter solenoid clicks, but starter will not crank
(if solenoid clicks, the problem is not with the Ignition
module or its inputs).
Battery charge is low.
Battery cables are loose or corroded.
Battery ground to engine is loose or corroded.
Wiring at starter is faulty.
Starter solenoid is faulty.
Starter mounting bolts are loose or not supplying a
sufficient ground for solenoid.
Starter is faulty causing incomplete circuit for solenoid.
Nothing happens when a start attempt is made.
Wiring to start circuits (see Wiring Schematics) is
loose, corroded, or damaged.
Battery is dead.
20 ampere fuse to start relay or 10 ampere fuse to
ignition switch is blown.
Neutral switch is faulty or traction pedal is depressed.
Ignition switch is faulty.
Start relay is faulty.
Starter is faulty.
Engine cranks, but does not fire.
Wiring to start circuits (see Wiring Schematics) is
loose, corroded, or damaged.
Ignition switch is faulty.
A high temperature condition exists, high temperature
switch is shorted, or the high temperature relay is
faulty.
Fuel solenoid is faulty.
Ignition module or components imputing into it are
faulty (see Chapter 3 – Ford Gasoline Engine).
Engine or fuel system is malfunctioning (see Chapter 3
– Ford Gasoline Engine).
Electrical System
Page 6 – 4
Groundsmaster 3000/3000–D
General Run and Transport Problems (Groundsmaster 3000)
Problem
Possible Causes
Engine kills when the traction pedal is positioned to
either forward or reverse.
Operator is sitting too far forward on the seat (seat
switch not depressed).
Wiring to seat and shutdown delay circuits (see Wiring
Schematics) is loose, corroded, or damaged.
2 ampere fuse, seat switch, or seat relay is faulty.
Diode (D1) or shutdown delay relay is faulty.
20 ampere fuse to seat relay is blown.
Battery does not charge.
Wiring to the charging circuit (see Wiring Schematics)
components is loose, corroded, or damaged.
Voltage regulator/alternator is faulty.
50 ampere fuse is open.
Battery is dead.
Cutting Unit Operating Problems (Groundsmaster 3000)
Problem
Possible Causes
Cutting unit does not engage.
Wiring to PTO circuit (see Wiring Schematics)
components is loose, corroded, or damaged.
PTO switch, relay, or coil is faulty.
Cutting unit does not lift.
Wiring to lift/xbal switch circuit (see Wiring Schematics)
components is loose, corroded, or damaged.
Lift/xbal switch or solenoid is faulty.
Cutting unit does not lower.
Wiring to float/hold switch circuit (see Wiring
Schematics) components is loose, corroded, or
damaged.
Float/hold switch or solenoid is faulty.
Hydraulic solenoid valve is malfunctioning.
Groundsmaster 3000/3000–D
Page 6 – 5 Rev. A
Electrical System
Electrical
System
The hydraulic system is malfunctioning.
Troubleshooting (Groundsmaster 3000–D)
For effective troubleshooting and repairs, you must
have a good understanding of the electrical circuits and
components used on this machine (see Wiring Sche­
matics section of this chapter).
CAUTION
Remove all jewelry, especially rings and
watches, before doing any electrical troubleshooting or testing. Disconnect the battery
cables unless the test requires battery voltage.
If the machine has any interlock switches by–passed,
they must be reconnected for proper troubleshooting
and safety.
Starting Problems
Problem
Possible Causes
Starter solenoid clicks, but starter will not crank
(if solenoid clicks, the problem is not with the Ignition
module or its inputs).
Battery charge is low.
Battery cables are loose or corroded.
Battery ground to frame is loose or corroded.
Wiring at starter is faulty.
Starter solenoid is faulty.
Starter mounting bolts are loose or not supplying a
sufficient ground for solenoid.
Starter is faulty causing incomplete circuit for solenoid.
Nothing happens when a start attempt is made.
Wiring to start circuits (see Wiring Schematics) is
loose, corroded, or damaged.
Battery is dead.
20 ampere fuse to start relay or 10 ampere fuse to
ignition switch is blown.
Neutral switch is faulty or traction pedal is depressed.
Ignition switch is faulty.
Start relay is faulty.
Starter is faulty.
Engine cranks, but does not fire.
Wiring to start circuits (see Wiring Schematics) is
loose, corroded, or damaged.
Ignition switch is faulty.
A high temperature condition exists, high temperature
switch is shorted, or the high temperature relay is
faulty.
Fuel stop solenoid is faulty.
Preheating unit or components inputing into it are
faulty.
Engine or fuel system is malfunctioning (see Chapter 4
– Peugeot Diesel Engine).
Electrical System
Page 6 – 6
Groundsmaster 3000/3000–D
General Run and Transport Problems (GM 3000–D)
Problem
Possible Causes
Engine kills when the traction pedal is positioned to
either forward or reverse.
Operator is sitting too far forward on the seat (seat
switch not depressed).
Wiring to seat and shutdown delay circuits (see Wiring
Schematics) is loose, corroded, or damaged.
7.5 ampere fuse, seat switch, or seat relay is faulty.
Diode (D1) or shutdown delay relay is faulty.
20 ampere fuse to seat relay is open.
Battery does not charge.
Wiring to the charging circuit (see Wiring Schematics)
components is loose, corroded, or damaged.
Voltage regulator/alternator is faulty.
80 ampere fuse is open.
Battery is dead.
Cutting Unit Operating Problems (GM 3000–D)
Problem
Possible Causes
Cutting unit do not engage.
Wiring to PTO circuit (see Wiring Schematics)
components is loose, corroded, or damaged.
PTO switch, relay, or coil is faulty.
Cutting unit does not lift.
Wiring to lift/xbal circuit (see Wiring Schematics)
components is loose, corroded, or damaged.
Lift/xbal switch or solenoid is faulty.
Cutting unit does not lower.
Wiring to float/hold circuit (see Wiring Schematics)
components is loose, corroded, or damaged.
Float/hold switch or solenoid is faulty.
Hydraulic solenoid valve is malfunctioning.
Groundsmaster 3000/3000–D
Page 6 – 7 Rev. A
Electrical System
Electrical
System
The hydraulic system is malfunctioning.
Electrical System Quick Checks
Battery Test (Open Circuit Test)
Note: This test provides a relative condition of the bat­
tery. Load testing of the battery will provide additional
and more accurate information.
1. The battery temperature should be from 60_ to 100_
F. The ignition key should be off and all accessories
turned off.
2. Set multimeter to the DC volts setting.
Voltage Measured
Battery Charge Level
12.68 V (or higher)
Fully charged (100%)
12.45 V
75% charged
12.24 V
50% charged
12.06 V
25% charged
11.89 V
0% charged
4. Record voltage.
3. Connect positive (+) meter lead to the positive bat­
tery post and negative (–) meter lead to the the negative
battery post.
Glow Plug System Test (GM 3000–D)
This fast, simple test can help you determine a glow plug
system’s integrity and operation. Run this test anytime
hard starting (cold) is encountered on the diesel engine.
GLOW PLUGS
GLOW PLUGS
Tool(s) required: Digital multimeter and/or AC/DC
current transducer (Hall Effect).
1. Properly connect current transducer to the digital
multimeter. Set multimeter on the proper volts scale (re­
fer to manufacturer’s instructions).
2. Make sure engine is off. Place current transducer
around the orange wire connected to glow plugs (Fig. 3).
ORANGE WIRE
Figure 3
3. Read meter prior to activating glow plug system. Ad­
just the transducer to read zero (if applicable).
4. Turn ignition switch to RUN and record current. Re­
peat test.
Note: The glow control unit will cause the glow plugs
to time off after a determined amount of time. This condi­
tion should not be misinterpreted as a malfunctioning
system.
5. The meter should read from 31 to 61 Amps.
Electrical System
Page 6 – 8
Groundsmaster 3000/3000–D
Component Identification and Testing
For accurate resistance and/or continuity checks, elec­
trically disconnect the component being tested from the
circuit (e.g. unplug the ignition switch connector before
doing a continuity check).
CAUTION
When testing electrical components for continuity with a multimeter (ohms setting), make sure
that power to the circuit has been disconnected.
Ignition Switch
A
B
S
TORO
The ignition (key) switch has three positions (OFF,
START and RUN). The terminals are marked as shown.
The circuitry of the ignition switch is shown in the chart.
With the use of a continuity tester, the switch functions
may be tested to determine whether all circuits are being
completed while the key is moved to each position.
Y
I
X
Figure 4
1. OFF
CONTINUITY
AMONG
TERMINALS
NONE
OTHER
CIRCUITS
MADE
NONE
2. RUN
B+I+A
3. START
B+I+S
X+Y
NONE
Figure 5
Groundsmaster 3000/3000–D
Page 6 – 9
Electrical System
Electrical
System
POSITION
Diode Circuit Boards
Each circuit board contains four diodes. The diodes are
used for circuit protection from inductive voltage spikes,
battery charging indication, and for safety circuit logic.
Diodes D4 and D8 are not used.
D2
On the GM 3000 wiring diagram, the diode circuit cards
a designated P3 and P5. On the GM 3000–D wiring diagrams, the diode circuit cards are designated P7 and
P5.
D3
Diode D1
D8
D7
D1
D5
A
B
C
Directs current flow from the deck capacitor to the deck
relay when the seat relay is de–energized to provide a
1 second delay.
Diode D2
D6
D4
D
DIODE
DIAGRAM
E
F
G
H
Figure 6
P3 or P7
P5
Provides current flow logic for the charging circuit light.
Diode D3
Prevents a negative spike from damaging the PTO
switch by allowing a ground path for the PTO relay and
PTO coil when they de–energize.
DIODE
CIRCUIT BOARDS
Diode D4
Figure 7
This component is not used.
Diode D5
Red Lead (+)
on Terminal
Black Lead (–)
on Terminal
Continuity
H
A
YES
A
H
NO
G
B
YES
B
G
NO
F
C
YES
Prevents a negative spike from damaging the Lift/Xbal
switch by allowing a ground path for the Lift/Xbal sole­
noid (SV1) when it de–energizes.
Diode D6
Prevents a negative spike from damaging the Cruise
switch by allowing a ground path for the Cruise relay and
Cruise coil when they de–energize.
C
F
NO
Diode D7
E
D
YES
Prevents a negative spike from damaging the Transport
switch by allowing a ground path for the Transport relay
and Transport coil when they de–energize.
D
E
NO
Diode D8
DIODE CIRCUIT BOARD
Prevents a negative spike from damaging the Float/
Hold switch by allowing a ground path for the Float/Hold
solenoid (SV2) when it de–energizes.
Testing
The diodes can be individually tested using a digital
multimeter (ohms setting) and the table to the right.
Figure 8
Electrical System
Page 6 – 10
Groundsmaster 3000/3000–D
Neutral Switch
This switch is closed when the traction pedal is in the
neutral position. The switch and its electrical connector
are located under the seat on the side of the transaxle.
SWITCH
1. Make sure the engine is off.
2. Disconnect electrical connector from the switch.
3. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the connector termi­
nals.
4. With the traction pedal in the neutral position, there
should be continuity between the terminals.
Figure 9
5. With the traction pedal in the the forward or backward position, there should be no continuity between
the terminals.
Seat Switch
This switch is closed when the operator is on the seat.
The switch and its electrical connector are located on
the bottom of the seat.
2
1. Make sure the engine is off. Remove seat from the
support assembly by removing four lock nuts from the
seat bolts.
2. Disconnect electrical connector from the switch.
1
3. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the connector termi­
nals.
4. With no operator in the seat, there should be no con­
tinuity between the terminals.
2. Seat switch
6. Connect switch electrical connector. Reinstall seat.
Groundsmaster 3000/3000–D
Page 6 – 11 Rev. A
Electrical System
Electrical
System
5. Press directly onto the seat switch through the seat
cushion. There should be continuity as the seat cushion
approaches the bottom of its travel.
Figure 10
1. Electrical connector
Hydraulic Valve Solenoids
The hydraulic valve solenoids are located below the
seat and on the hydraulic manifold block.
1
Note: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The me­
ter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal re­
sistance of the meter and test leads. Subtract this value
from from the measured value of the component you are
testing.
2
1. Make sure engine is off. Disconnect solenoid valve
electrical connector.
2. Apply 12VDC source directly to the solenoid. Listen
for solenoid to switch on. Remove voltage source.
Figure 11
1. Electrical connector
2. Solenoid
3. Measure resistance between the two connector ter­
minals. The resistance should be approximately 7.2
ohms.
Hour Meter
1. Remove electrical connections from meter.
2. Connect the positive (+) terminal of a 12 VDC
source to the positive terminal of the hour meter.
3. Connect the negative (–) terminal of the voltage
source to the other terminal of the hour meter.
4. The hour meter should move a 1/10 of an hour in six
minutes.
Figure 12
5. Disconnect the voltage source from the hour meter.
6. Reconnect electrical connections to meter. Make
sure to observe polarity.
Electrical System
Page 6 – 12
Rev. A
Groundsmaster 3000/3000–D
Cruise Control Coil (Optional)
The cruise control coil is located below the seat.
Note: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The me­
ter will display a small resistance value (usually 0.5
ohms or less). Subtract internal resistance of the meter
and test leads from the measured value of the compo­
nent you are testing.
1. Make sure engine is off. Disconnect blue and violet
wires to the coil.
CRUISE CONTROL
COIL
2. Apply 12 VDC source directly to the coil wires. Lis­
ten for coil to pull in clutch plate.
Figure 13
3. Measure resistance between the two coil wires. The
resistance should be from 3.6 to 4.0 ohms.
PTO (Clutch) Coil
The PTO (clutch) coil is located inside the IHT transmis­
sion. The electrical connector to the coil is below the
seat.
CONNECTOR TO PTO COIL
Note: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The me­
ter will display a small resistance value (usually 0.5
ohms or less). Subtract internal resistance of the meter
and test leads from the measured value of the compo­
nent you are testing.
1. Make sure engine is off. Disconnect connector to
the coil.
2. Apply 12 VDC source directly to the coil wires. Listen for PTO clutch to engage.
Figure 14
Groundsmaster 3000/3000–D
Page 6 – 13
Electrical
System
3. Measure resistance between the two coil wires. The
resistance should be about 3.1 ohms.
Rev. A
Electrical System
Fuel Sender
The sender is located on top of the fuel tank inside the
center shroud area.
GROUND WIRE
1. Remove blue wire and black ground wire from the
sender.
2. Remove remaining screws and lock washers from
the sender and fuel tank.
3. Remove sender and gasket from the fuel tank.
Clean any fuel from the sender.
BLUE WIRE
Note: Before taking small resistance readings with a
digital multimeter, short test leads together. The meter
will display a small resistance value. This internal resis­
tance of the meter and test leads should be subtract
from the measured value of the component.
4. Check resistance of the sender with a multimeter.
Resistance with the float in the full position should be
27.5 to 39.5 ohms. Resistance with the float in the empty
position should be 240 to 260 ohms.
Figure 15
FULL POSITION
EMPTY POSITION
Figure 16
Fuel Gauge
The fuel gauge can be tested using a new gauge as a
substitute or by the use of a DC voltage source and a
variable resistance box.
EMPTY
Note: Before taking small resistance readings with a
digital multimeter, short test leads together. The meter
will display a small resistance value. This internal resis­
tance of the meter and test leads should be subtract
from the measured value of the component.
HALF
FULL
G
1. Connect the fuel gauge to the variable resistance
and DC voltage source (Fig. 17).
S
I
2. Adjust resistance until the gauge needle points to
following test points on the gauge (Fig. 17):
A. The left edge of the red area (empty); the resis­
tance setting should be from 235 to 245 ohms.
VARIABLE
RESISTANCE
B. The middle of the green area (half); the resis­
tance setting should be from 98 to 108 ohms.
14 VDC
–
+
Figure 17
C. The right edge of the green area (full); the resis­
tance setting should be from 30.5 to 40.0 ohms.
3. Disconnect the voltage source, gauge, and variable
resistance.
Electrical System
Page 6 – 14 Rev. A
Groundsmaster 3000/3000–D
Relays and Fuses
Relay Testing
87A
86
87
1. Verify coil resistance between terminals 86 and 85
with a multimeter (ohms setting). Resistance should be
from 75 to 95 ohms. There should be continuity between
terminals 87A and 30.
2. Connect multimeter (ohms setting) leads to relay
terminals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as 12 VDC is ap­
plied and removed from terminal 85.
85
‘
The relays and fuses and are located in the compart­
ment that is rear of the control panel (Fig. 18). There is
an 80 ampere fuse (50 ampere on the GM 3000) located
by the alternator (Fig. 22).
30
30 85
86 87 87A
Figure 19
3. Disconnect voltage from terminal 85 and multimeter
lead from terminal 87.
4. Connect multimeter (ohms setting) lead to relay ter­
minal 30 and 87A. Apply +12 VDC to terminal 85. The
relay should break and make continuity between termi­
nals 30 and 87A as 12 VDC is applied and removed from
terminal 85.
Relay and Fuse Location
(Groundsmaster 3000)
Figure 20
Relay and Fuse Location
(Groundsmaster 3000–D)
Figure 21
GM 3000–D SHOWN
Figure 18
Fuse Testing
Note: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The me­
ter will display a small resistance value (usually 0.5
ohms or less). Subtract internal resistance of the meter
and test leads from the measured value of the compo­
nent you are testing.
1. Use a digital multimeter and check continuity of
fuse.
Figure 22
2. Resistance of fuse should be less than 1 ohm.
Groundsmaster 3000/3000–D
Page 6 – 15
Electrical System
Electrical
System
5. Disconnect voltage and multimeter leads from relay
terminals.
50 Ampere Thermal Breaker (GM 3000–D)
This device operates as a thermal overload. After the
device trips, time should be allowed for it to cool and re­
set. It is located near the starter.
1. Verify continuity between the two terminals. Conti­
nuity should be less than 1 ohm.
THERMAL
BREAKER
Figure 23
Figure 24
Electrical System
Page 6 – 16
Rev. A
Groundsmaster 3000/3000–D
Fuel Stop Solenoid (GM 3000–D)
The fuel stop solenoid is located on the front end of the
injection pump, which is on the right side of the engine.
Its has a black wire connected to it that leads to a con­
nector with a white and orange wire. The solenoid is
powered from the white wire (Fig. 25).
In Place Testing
Note: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The me­
ter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal re­
sistance of the meter and test leads. Subtract this value
from from the measured value of the component you are
testing.
CONNECTOPR
SOLENOID
Figure 25
1. Disconnect black wire from the solenoid.
SOLENOID
2. Using a digital multimeter, ground one lead to the
base of the solenoid and connect the other to the sole­
noid terminal.
3. The resistance should be approximately 8.0 ohms.
Live testing
1. Remove black wire from the solenoid.
PLUNGER
Note: The solenoid may be removed from the engine
or tested in place.
2. Connect a positive (+) test lead from a 12 VDC
source to the solenoid terminal.
4. Disconnect the test leads from the solenoid.
5. Connector black wire to the solenoid if tested in
place.
Electrical
System
3. Touch a negative (–) test lead from the 12 VDC
source to the solenoid body. The plunger should retract
making an audible ”click”.
Figure 26
Groundsmaster 3000/3000–D
Page 6 – 17
Rev. A
Electrical System
Injection Advance Solenoid (GM 3000–D)
The injection advance solenoid is located on top of the
injector pump, which is on the right side of the engine.
Its has two black wires connected to it. One wire leads
to a connector with orange and white wires. The other
wire is grounded to the injector pump. The solenoid is
powered from the orange (top) wire (Fig. 52).
In Place Testing
CONNECTOR
Note: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The me­
ter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal re­
sistance of the meter and test leads. Subtract this value
from from the measured value of the component you are
testing.
SOLENOID
1. Remove wire clip from the connector and discon­
nect connector.
GROUND WIRE
2. Using a digital multimeter, attach one lead to the lug
of the ground wire. Connect other lead to the pin in the
connector that is attached to the injector pump. The
orange wire on the harness connector powers the sole­
noid.
3. The resistance should be about 14.6 ohms.
Live testing
1. Remove wire clip from the connector and discon­
nect connector.
Figure 27
2. Connect a positive (+) test lead from a 12 VDC
source to the pin in the connector that is attached to the
injector pump. The orange wire on the harness connec­
tor powers the solenoid.
3. Touch a negative (–) test lead from the 12 VDC
source to the solenoid body. The plunger should retract
making an audible ”click”.
4. Disconnect the test leads from the solenoid and
connector. Reconnect connector and wire clip.
Electrical System
Page 6 – 18
Rev. A
Groundsmaster 3000/3000–D
Alternator (GM 3000–D)
The alternator is belt driven with a internal regulator. It
is located on the bottom right end of the engine. If either
the alternator or the regulator is damaged, the entire unit
must be replaced (Fig. 28).
Note: Prior to testing the charging system, make sure
the poly V–belt to the alternator is in good operation
condition and adjusted properly (see Belt Adjustment in
Chapter 4 – Peugeot Diesel Engine).
Test Equipment
Use a shunt capable of handling at least 70 ampere.
Also, a digital multimeter with a high impedance millivolt
scale (with at least 300mv range) can be used in con­
junction with the shunt (Fig. 29).
Figure 28
Testing for DC Current Output (Fig. 30)
Note: Follow the manufacturer’s instructions when
using a DC shunt.
1. Make sure engine is off.
IMPORTANT: To perform this test properly, the battery must “not” be fully charged. See Battery Test in
the Electrical Quick Checks section.
SHUNT
HIGH IMPEDENCE
MULTIMETER
3. Attach RED meter test lead to the POSITIVE post of
the shunt.
4. Attach BLACK meter test lead to the NEGATIVE
post of the shunt.
5. Place multimeter to the millivolts scale.
Figure 29
NEGATIVE
BATTERY
CABLE
BLACK
LEAD
Electrical
System
2. Install the DC shunt on the negative terminal of the
battery. Make sure all connections are clean and tight for
reliable amperage readings.
RED
LEAD
6. Start the engine and run at 2000 rpm. Determine
current output. Current output should be from 1 to 45
ampere depending upon battery voltage and/or current
draw on the system.
7. Place multimeter to the volts scale, and verify that
battery voltage is 13.5 VDC while the alternatoer is
charging.
Figure 30
Groundsmaster 3000/3000–D
Page 6 – 19
Rev. A
Electrical System
Temperature Sender (GM 3000–D)
The temperature sender is located on the top right side
of the water outlet box. It has a green connector with
blue and black wires. The sender supplies a signal to the
glow control unit (Fig. 31).
TEMP SENDER
CAUTION
Make sure engine is cool and coolant system is
depressurized before removing the thermistor.
1. Lower the coolant level in the engine and remove
the thermistor from the water pump.
Figure 31
2. Put the sender in a container of oil with a thermome­
ter and slowly heat the oil (Fig. 33).
TO GLOW CONTROL UNIT
PIN 2 (BLUE WIRE)
CAUTION
Handle the hot oil with extreme care to prevent
personal injury or fire.
3. Check resistance of the sender with a multimeter.
Check resistance between pin 1 and the sender casing
(Fig. 33).
TO GROUND
(BLACK WIRE)
A. The resistance should be from 1088.8 to 1225.4
OHMS at 104_F (40_C).
Figure 32
B. As the temperature increases,the resistance
should be from 166.2 to 185.2 OHMS at 212_F
(100_C).
Figure 33
Electrical System
Page 6 – 20
Rev. A
Groundsmaster 3000/3000–D
Temperature Gauge (GM 3000–D)
The temperature gauge can be tested using a new
gauge as a substitute or by the use of a DC voltage
source and a variable resistance box.
150_F
220_F
1. Connect the temperature gauge to the variable re­
sistance and DC voltage source (Fig. 34).
2. Adjust resistance until the gauge needle points to
following test points on the gauge (Fig. 34):
A. At 220_F the resistance setting should be from
125.2 to 138.4 ohms.
I
VARIABLE
RESISTANCE
+
B. At 150_F the resistance setting should be from
475 to 525 ohms.
G
S
14 VDC
–
3. Disconnect the voltage source, gauge, and variable
resistance.
Figure 34
Oil Pressure Switch (GM 3000–D)
The switch is located on the left side of the engine block
above the oil filter. It is a normally closed switch and
opens with increasing oil pressure. The operating range
for the switch is 6.1 to 8.4 PSI (0.42 to 0.58 Bar).
Testing with the Engine Off
1. Turn the ignition switch to ON. The oil pressure lamp
should be on.
A. If the lamp comes on the switch is bad.
Figure 35
B. If the lamp does not come on in step 2, check the
indicating circuit (see Electrical Schematic
(GM3000–D)).
3. Turn the ignition switch to ON. The oil pressure lamp
should be out.
Testing with the Engine On
4. If the light is still on, check for short circuiting in the
indication circuit (see Indicating and Safety Circuits).
1. If the lamp is on with the engine running, shut off the
engine immediately.
5. Return ignition switch to OFF.
2. Disconnect the gray wire from the switch.
6. Test engine oil pressure (see Peugeot Citroen Mo­
teurs TUD5 Overhaul Checking Tuning manual).
Groundsmaster 3000/3000–D
Page 6 – 21
Electrical System
Electrical
System
2. If the lamp does not come on in step 1 above no, dis­
connect the gray wire from the switch and ground it to
the engine block.
Temperature Sending Unit (GM 3000–D)
The temperature sending unit is located on the top right
side of the water outlet box, which is located on the front
end of the engine block. It has a blue connector with gray
and violet wires. The violet wire supplies a signal to the
high coolant temperature relay from the switch compo­
nent of the sending unit. The gray wire supplies a signal
to the temperature gauge from the thermistor compo­
nent of the sending unit (Fig. 36).
SENDING UNIT
CAUTION
Make sure engine is cool and coolant system is
depressurized before removing the temperature
sending unit.
1. Lower the coolant level in the engine and remove
the temperature sending unit from the engine.
Figure 36
TO TEMP GAUGE
(VIOLET WIRE)
2. Put the switch in a container of oil with a thermometer and slowly heat the oil (Fig. 38).
CAUTION
Handle the hot oil with extreme care to prevent
personal injury or fire.
TO HIGH TEMP RELAY
(GRAY WIRE)
3. Check continuity of the switch component with a
multimeter (ohms setting). Check continuity between
post 2 and the sender casing. The switch is normally
open and should close between 226 to 234_F (108 to
112_C) (Fig. 37).
Figure 37
4. Allow the oil to cool. The switch should open below
226_F (108_C).
5. After oil has cooled below 158_F (70_C), slowly
heat oil and switch again (Fig. 38).
6. Check resistance of the thermistor component with
a multimeter. Check resistance between post 1 and the
sender casing (Fig. 37).
Figure 38
A. The resistance should be about 390 ohms at
158_F (70_C).
B. As the temperature increases,the resistance
should be about 143 ohms at 212_F (100_C).
Electrical System
Page 6 – 22
Rev. A
Groundsmaster 3000/3000–D
Transport Solenoid (GM 3000–D)
The transport solenoid is located below the seat and on
the front right side of the hydraulic housing.
TO CONNECTOR
Note: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The me­
ter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal re­
sistance of the meter and test leads. Subtract this value
from from the measured value of the component you are
testing.
SOLENOID
1. Make sure engine is off. Disconnect solenoid elec­
trical connector.
2. Apply 12 VDC source directly to the solenoid. Listen
for solenoid to switch on.
Figure 39
3. Measure resistance between the two connector ter­
minals. The resistance should be about 9.0 ohms.
Glow Plugs (GM 3000–D)
The glow plugs are located on the top of the cylinder
block and on the right side of the engine. They are con­
nected in parallel with black wires to an orange lead wire
(Fig. 40).
GLOW PLUGS
GLOW PLUGS
Note: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The me­
ter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal re­
sistance of the meter and test leads. Subtract this value
from from the measured value of the component you are
testing.
1. Disconnect black wire from the glow plug.
Figure 40
Electrical
System
2. Using a digital multimeter, connect one lead to the
post of the terminal and connect the other to the cylinder
block near the plug.
3. The resistance should be about 0.6 to 1.5 ohms.
Figure 41
Groundsmaster 3000/3000–D
Page 6 – 23
Rev. A
Electrical System
H2O in Fuel Sensor (GM 3000–D)
The sensor is located on the fuel filter assembly, which
is inside the center shroud area to the left side of the en­
gine. It energizes a red warning light when too much wa­
ter has collected in the fuel filter bowl (Fig. 42).
FILTER ASSEMBLY
1. Make sure engine is OFF. Remove start relay from
the control center.
SENSOR
2. Disconnect connector from the sensor. Verify cir­
cuitry to the sensor at the connector using a multimeter
and the following steps:
A. Place ignition switch in RUN. Battery voltage
from the pin for the blue wire to chassis ground
should be indicated and the red warning light should
come on. Turn switch OFF.
Figure 42
B. Hold ignition switch in START. Battery voltage
from the pin for the white wire to chassis ground
should be indicated. Turn switch OFF.
FILTER
ASSEMBLY
C. Check continuity from the pin for the black wire to
chassis ground. Continuity should be 1 ohm or
less.
O–RING
D. Correct any problem circuitry if necessary.
FILTER
ELEMENT
3. Drain fuel filter assembly into a suitable container.
GASKET
4. Unscrew fuel filter bowl from the assembly. Remove
filter element, gaskets, and O–ring from the assembly.
Store seals in a clean place (Fig. 43).
5. Reconnect connector to the sensor. Fill fuel filter
bowl with tap water.
GASKET
FUEL FILTER
BOWL
SENSOR
6. Test sensor using the following steps:
A. Place ignition switch in RUN. The red warning
light should come on. Turn switch OFF.
DRAIN
PLUG
Figure 43
B. Hold ignition switch in START. The red warning
light should come on. Turn switch OFF.
7. Drain water from the fuel filter bowl. Test sensor us­
ing the following steps:
8. Disconnect connector from sensor. Reassemble
fuel filter assembly. Reconnect connector to sensor.
9. Replace sensor with new one if necessary.
A. Place ignition switch in RUN. The red warning
light should stay off. Turn switch OFF.
10. Reinstall start relay to the control center.
B. Hold ignition switch in START. The red warning
light should stay off. Turn switch OFF.
Electrical System
Page 6 – 24
Groundsmaster 3000/3000–D
Coolant Level Sensor (GM 3000–D)
The sensor is located on the degassing box, which is on
the upper left end of the engine. It energizes a red warn­
ing light when coolant level in the degassing box and ra­
diator is to low (Fig. 44).
PRESSURE
PLUG
CONNECTOR
1. Make sure engine is OFF. Remove start relay from
the control center.
DEGASSING
BOX
SENSOR
DANGER
Make sure engine and cooling system have
cooled down prior to checking coolant system
levels. Possible steam burns may occur when removing the pressure plug.
Figure 44
2. Make sure cooling system is full (see Check Cooling
System in Chapter 4 – Peugeot Diesel Engine).
3. Disconnect connector from the sensor. Verify cir­
cuitry to the sensor at the connector using a jumper and
multimeter.
B. Hold ignition switch in START. Battery voltage
from the pin for the white wire to chassis ground
should be indicated. Turn switch OFF.
Figure 45
C. Check continuity (1 ohm or less) from the pin for
the black wire to chassis ground..
5. Disconnect connector from the sensor. Unscrew
sensor from box and dry electrodes. Reconnect connec­
tor to sensor. Test sensor using the following steps (Fig.
45):
D. Replace light bulb or correct any problem circuit­
ry if necessary.
A. Place ignition switch in RUN. The red warning
light should come on. Turn switch OFF.
4. Reconnect connector to the sensor. Test sensor us­
ing the following steps:
A. Place ignition switch in RUN. The red warning
light should be off. Turn switch OFF.
B. Hold ignition switch in START. The red warning
light should be off. Turn switch OFF.
B. Hold ignition switch in START. The red warning
light should come on. Turn switch OFF.
6. Reinstall start relay to the control center.
7. Replace sensor with new one if necessary.
8. Disconnect connector from sensor. Install sensor to
box. Reconnect connector to sensor.
Groundsmaster 3000/3000–D
Page 6 – 25
Electrical System
Electrical
System
ELECTRODES
A. Place ignition switch in RUN. Jumper from the
pin for the tan wire to chassis ground, the red warn­
ing light should come on. Turn switch OFF.
Indicator Lights and Circuits (GM 3000–D)
Note: Individual light bulbs can be tested by removing
them from the lighting cluster and applying 12 VDC to
their wiring terminals (Fig 46).
LOW OIL
PRESSURE
(RED)
LOW
WATER
LEVEL
(RED)
Low Oil Pressure Light
The oil pressure light should come on when the ignition
switch is in the ON position with the engine not running.
Also, it should light with the engine running when the oil
pressure drops below 7 PSI (0.48 Bar).
BATT
(AMBER)
1. Disconnect gray wire from the oil pressure switch.
2. Ground gray wire to the engine block.
FRONT OF GAUGE
HIGH
COOLANT
TEMPERATURE
(RED)
WATER
IN
FUEL
(RED)
3. Turn the ignition switch to ON; the light should come
on.
4. Turn the ignition switch to OFF and connect gray
wire to the oil pressure switch.
High Coolant Temperature Light
The temperature light should come on only if the high
temperature shutdown switch and relay have stopped
the engine when the coolant temperature is from 226 to
234_F (108 to 112_C). The ignition switch must be in either the ON or START position for the light to come on.
1. Disconnect gray wire from the high temperature
shutdown switch.
2. Ground the gray wire to the engine block.
3. Turn the ignition switch to ON; the light should come
on and the high temperature shutdown relay should
click.
4. Turn the ignition switch to OFF and connect gray
wire to the high temperature shutdown switch.
GLOW
PLUG
INDICATOR
(RED)
Figure 46
Battery Light
The battery light should come on when the ignition
switch is in ON with the engine not running or with an improperly operating charging circuit while the engine is
running.
1. Turn ignition switch to ON; the light should come on.
2. Turn ignition switch to OFF.
Water in Fuel Light
Low Water Level Light
This light comes on to warn that the coolant level in the
radiator is low enough to cause over heating of the engine.
1. Disconnect electrical connector from the wire from
the coolant level sensor.
This light comes on to warn that there is sufficient water
in the fuel system to cause engine problems..
1. Disconnect electrical connector from the wire from
the water in fuel sensor.
2. Ground blue wire of the connector to the vehicle
frame.
2. Ground tan wire of the connector to the vehicle
frame.
3. Turn ignition switch to ON; the light should come on.
3. Turn ignition switch to ON; the light should come on.
4. Turn ignition switch to OFF and connect electrical
connector to the water in fuel sensor.
4. Turn ignition switch to OFF and connect electrical
connector to the coolant level sensor.
Electrical System
Page 6 – 26
Groundsmaster 3000/3000–D
Glow Plug Indicator Light
BACK OF GAUGE
This light comes on when the glow control relay supplies
power to the glow plugs.
1. Disconnect wire clip and pin connector (pins 1 to 7)
from the pre/post heat relay.
A
F
B
E
2. Jumper from post # 8 (brass) on the glow control
relay to female receptor # 5 (green wire) on the pin con­
nector.
3. The light should come on. Remove jumper from
relay post and pin connector.
4. Connect pin connector and wire clip to the glow con­
trol relay.
A
B
C
D
E
F
Figure 47
SCHEMATIC
B
E
COOLANT
TEMP
C
B
BATTERY
F
LOW
COOLANT
A
OIL
PRESSURE
A
D
GLOW
D
E
F
C
WATER
IN
FUEL
Electrical
System
Figure 48
Groundsmaster 3000/3000–D
Page 6 – 27
Electrical System
Ford Engine (VSG–411) Electrical Component Locations (GM3000)
Note: See the Ford VSG–411/413 Engine Service
Manual for component testing information.
The starter is located on the front end and lower right
side of the engine block (Fig. 49).
Figure 49
The alternator is located on the lower right side of the
engine block and just forward of the radiator (Fig. 50).
Figure 50
The distributorless ignition coil is located the left side
of the engine block just forward of the oil dip stick and
below the intake manifold (Fig. 51).
Figure 51
Electrical System
Page 6 – 28
Groundsmaster 3000/3000–D
The engine coolant temperature (ECT) sensor is lo­
cated on the bottom of the intake manifold, which is lo­
cated on the left side of the engine. It has a connector
with green/white and gray/white wires (Fig. 52).
Figure 52
The universal electronic spark control is located in­
side the black center shroud in the upper left corner (Fig.
53).
Figure 53
Electrical
System
The variable reluctance sensor (VRS) is located on
the front right end of the engine block behind the fly
wheel and front engine plate. It has a connector with
green and white wires (Fig. 54).
Figure 54
Groundsmaster 3000/3000–D
Page 6 – 29
Electrical System
Temperature Gauge (GM 3000)
The temperature gauge can be tested using a new
gauge as a substitute or by the use of a DC voltage
source and a variable resistance box.
150_F
1. Connect the temperature gauge to the variable re­
sistance and DC voltage source (Fig. 34).
180_F
ÄÄ
ÄÄ
2. Adjust resistance until the gauge needle points to
following test points on the gauge (Fig. NO TAG):
G
A. At 150_F the resistance setting should be from
113 to 123 ohms.
S
240_F
I
B. At 180_F the resistance setting should be from
68 to 73 ohms.
C. At 240_F the resistance setting should be from
24 to 37 ohms.
3. Disconnect the voltage source, gauge, and variable
resistance.
VARIABLE
RESISTANCE
12 VDC
BACK
–
+
Figure 55
Thermistor (GM 3000)
The thermistor is located on the bottom right side of the
water pump, which is located on the rear end of the en­
gine block. It has a connector which a tan wire (Fig. 56).
1. Lower the coolant level in the engine and remove
the thermistor from the water pump.
2. Put the thermistor in a container of oil with a ther­
mometer and slowly heat the oil (Fig. 57).
CAUTION
Handle the hot oil with extreme care to prevent
personal injury or fire.
Figure 56
3. Check the resistance of the thermistor with a multi­
meter (ohms setting) as the temperature increases. The
following resistance readings should be indicated:
108 to 78 OHMS at 140_F (60_C)
59 to 51 OHMS at 212_F (99_C)
Figure 57
Electrical System
Page 6 – 30
Groundsmaster 3000/3000–D
Oil Pressure Switch (GM 3000)
The switch is located on the left side of the engine block
above the oil filter. It is a normally closed switch when the
engine is not running and opens with increasing oil pres­
sure.
Testing with the Engine Off
1. Turn the ignition switch to ON. The oil pressure lamp
should be on.
2. If the lamp does not come on in step 1 above no, dis­
connect the gray wire from the switch and ground it to
the engine block.
A. If the lamp comes on the switch is bad.
Figure 58
B. If the lamp does not come on in step 2, check the
indicating circuit (see Electrical Schematic
(GM3000)).
5. Remove switch and install test gauge in the oil pres­
sure switch port.
6. Return ignition switch to OFF and connect the gray
wire to the switch.
Testing with the Engine On
1. If the lamp is on with the engine running, shut off the
engine immediately.
2. Disconnect the gray wire from the switch.
3. Turn the ignition switch to ON. The oil pressure lamp
should be out.
7. Start the engine and check for a minimum of 21.7
psi (1.5 Bar) at 2000 RPM (with engine hot). If the engine
oil pressure is low, shut off the engine immediately.
8. Shut off the engine and remove the test gauge.
9. If engine oil pressure is good, replace the switch.
Electrical
System
4. If the light is still on, check for short circuiting in the
indication circuit (see Indicating and Safety Circuits).
Groundsmaster 3000/3000–D
Page 6 – 31
Electrical System
High Temperature Switch
The high temperature switch is located on the top right
side of the water pump, which is located on the rear end
of the engine block. It has a connector which a gray wire
(Fig. 59).
CAUTION
Make sure engine is cool before removing the
temperature switch.
1. Lower the coolant level in the engine and remove
the high temperature switch.
Figure 59
2. Put the switch in a container of oil with a thermome­
ter and slowly heat the oil (Fig. 60).
CAUTION
Handle the hot oil with extreme care to prevent
personal injury or fire.
Figure 60
3. Check the continuity of the switch with a multimeter
(ohms setting). The switch is normally open and should
close between 245 to 255_F (118 to 124_C).
Electrical System
4. Allow the oil to cool. The switch should open below
245_F (118_C).
Page 6 – 32
Groundsmaster 3000/3000–D
Anti–Dieseling Valve Solenoid (GM 3000)
The anti–dieseling valve solenoid is located on the right
side of the carburetor, which is on the top rear end of the
engine. Its has two white wires (Fig. 61 and 62).
SOLENOID
In Place Testing
Note: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The me­
ter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal re­
sistance of the meter and test leads. Subtract this value
from from the measured value of the component you are
testing.
Figure 61
1. Disconnect connector from the solenoid.
2. Using a digital multimeter, ground one lead to the
engine block and connect the other to the solenoid ter­
minal.
SOLENOID
3. The resistance should be about 25.0 ohms.
4. Connect the wire back to the solenoid.
Live testing
1. Remove the connector from the solenoid.
Figure 62
Note: The solenoid may be removed from the engine
or tested in place.
4. Disconnect the test leads from the solenoid.
2. Connect a positive (+) test lead from a 12 VDC
source to the solenoid terminal.
5. Reinstall the connector to the solenoid if tested in
place.
Electrical
System
3. Touch a negative (–) test lead from the 12 VDC
source to the solenoid body. The plunger should retract
making an audible ”click”.
Groundsmaster 3000/3000–D
Page 6 – 33
Electrical System
Indicator Lights and Circuits (GM 3000)
Note: Individual light bulbs can be tested by removing
them from the lighting cluster and applying 12 VDC to
their wiring terminals (Fig 63).
LOW OIL
PRESSURE
(RED)
LOW
WATER
LEVEL
(RED)
Low Oil Pressure Light
The oil pressure light should come on when the ignition
switch is in the ON position with the engine not running.
Also, it should light with the engine running when the oil
pressure drops below 7 PSI (0.48 Bar).
1. Disconnect gray wire from the oil pressure switch.
HIGH
COOLANT
TEMPERATURE
(RED)
BATT
(AMBER)
FRONT OF GAUGE
2. Ground gray wire to the engine block.
Figure 63
3. Turn the ignition switch to ON; the light should come
on.
BACK OF GAUGE
4. Turn the ignition switch to OFF and connect gray
wire to the oil pressure switch.
High Coolant Temperature Light
The temperature light should come on only if the high
temperature shutdown switch and relay have stopped
the engine when the coolant temperature is from 245 to
255_F (118 to 124_C). The ignition switch must be in ei­
ther the ON or START position for the light to come on.
A
F
B
E
1. Disconnect gray wire from the high temperature
shutdown switch.
2. Ground the gray wire to the engine block.
3. Turn the ignition switch to ON; the light should come
on and the high temperature shutdown relay should
click.
A
B
C
D
E
F
Figure 64
4. Turn the ignition switch to OFF and connect gray
wire to the high temperature shutdown switch.
SCHEMATIC
Battery Light
B
The battery light should come on when the ignition
switch is in ON with the engine not running or with an im­
properly operating charging circuit while the engine is
running.
E
COOLANT
TEMP
C
BATTERY
1. Turn ignition switch to ON; the light should come on.
2. Turn ignition switch to OFF.
F
LOW
COOLANT
A
OIL
PRESSURE
D
Low Water Level Light
This light is not used on models with the Ford VSG–411
gasoline engine.
Figure 65
Electrical System
Page 6 – 34
Groundsmaster 3000/3000–D
Service and Repairs
NOTE: See the Peugeot TUD5 Repair Manual or Ford
VSG–411/413 Engine Service Manual for more compo­
nent repair information.
Verify Interlock System Operation
The machine has interlock switches in the electrical sys­
tem. These switches are designed to stop the engine
when operator gets off the seat when traction pedal is
depressed. However, operator may get off the seat while
engine is running. Although engine will continue to run if
PTO switch is disengaged and traction pedal is re­
leased, it is strongly recommended that the engine be
stopped before dismounting from the seat.
To check operation of interlock switches:
1. Drive the machine slowly to a large, relatively open
area. Lower cutting unit, stop the engine and apply park­
ing brake.
2. Sit on seat. Depress the traction pedal. Try to start
the engine. The engine should not crank. If the engine
cranks, there is a malfunction in the interlock system that
should be corrected before beginning operation.
CAUTION
WARNING
Do not operate machine without implement
unless the PTO driveshaft is also removed.
3. Sit on seat and start the engine. Raise off the seat and
move the PTO lever to ON. The PTO should not engage.
If the PTO engages, there is a malfunction in the inter­
lock system that should be corrected before beginning
operation.
Electrical
System
Do not disconnect the interlock switches.
Check operation of switches daily to assure interlock system is operating correctly. If a
switch is malfunctioning, replace it before operating the machine. To ensure maximum safety, replace all switches after every two years or
1000 hours, whichever comes first.
Groundsmaster 3000/3000–D
Page 6 – 35
Electrical System
Battery Maintenance
Check battery condition weekly or after every 50 hours
of operation. Keep terminals and entire battery case
clean because a dirty battery will discharge slowly. To
clean the battery, wash the entire case with solution of
baking soda and water. Rinse with clear water. Coat the
battery posts and cable connectors with Grafo 112X
(skin–over) grease (Toro Part No. 505-47) or petroleum
jelly to prevent corrosion.
IMPORTANT: Before welding on the machine, disconnect both cables from the battery and the terminal connector from the alternator to prevent
damage to the electrical system.
1
1. Loosen knobs securing battery cover to machine.
Figure 66
1. Battery Cover
CAUTION
1
Wear safety goggles and rubber gloves
when working with electrolyte. Charge
the battery in a well ventilated so gases
produced while charging can dissipate.
Since the gases are explosive, keep open
flame and electrical spark away from the
battery; do not smoke. Nausea may
result if the gases are inhaled. Unplug
charger from electrical outlet before connecting to, or disconnecting charger
leads from battery posts.
Figure 67
1. Battery
Electrical System
Page 6 – 36
Groundsmaster 3000/3000–D
Battery Service
The battery is the heart of the electrical system. With
regular and proper service, battery life can be extend.
Additionally, battery and electrical component failure
can be prevented.
6
7
3
4
WARNING
When working with batteries, use extreme caution to avoid slashing or spilling electrolyte.
Electrolyte can destroy clothing and burn skin
or eyes. Always wear safety goggles and a face
shield when working with batteries.
2
2
Electrolyte Specific Gravity
Fully charged: 1.265 corrected to 80_F (26.7_C)
Discharged: less than 1.240
Battery Specifications
Groundsmaster 3000
BCI Group 24 Battery
370 Amp Cranking Performance at 0_ F (–17.8_ C)
45 Minute Reserve Capacity at 80_F (26.7_C)
Groundsmaster 3000–D (U.S.)
BCI Group 24 Battery
650 Amp Cranking Performance at 0_ F (–17.8_ C)
130 Minute Reserve Capacity at 80_F (26.7_C)
5
1
Figure 68
1.
2.
3.
4.
Lock nut
Threaded rod
Lock nut & washer
Battery rod
5. Battery bracket
6. Ground cable
7. Positive cable
FILLER CAPS
CAP TUBES
CORRECT
WATER
LEVEL
COVER SEAL
Groundsmaster 3000–D (International)
BCI Group 24 Battery
630 Amp Cranking Performance at 0_ F (–17.8_ C)
105 Minute Reserve Capacity at 80_F (26.7_C)
Removal (Fig. 68 and 69)
IMPORTANT: Be careful not to damage terminal
posts or cable connectors when removing the battery cables.
B. Check battery terminal posts for corrosion. Use
a terminal brush or steel wool to clean corrosion
from the battery terminal posts.
1. Remove lock nuts, washer, threaded rod, and bat-
tery bracket from the battery rod and frame.
IMPORTANT: Before cleaning the battery, tape or
block the vent holes to the filler caps and make sure
the caps are on tightly.
2. Disconnect the ground cable (–) first to prevent
short circuiting the battery, other components, or the operators hands. Disconnect the positive (+) cable.
3. Make sure that the filler caps are on tightly.
4. Remove battery from the battery compartment to a
service area. This will minimize possible battery damage and allow better access for inspection and service.
Inspection, Maintenance, and Testing
1. Perform following inspections and maintenance:
A. Check for cracks caused by overly tight or loose
hold–down clamp. Replace battery if cracked and
leaking.
Groundsmaster 3000/3000–D
Page 6 – 37
C. Check for signs of wetness or leakage on the top
of the battery which might indicate a loose or mis­
sing filler cap, overcharging, loose terminal post, or
overfilling. Also, check the battery case for dirt and
oil. Clean the battery with a solution of baking soda
and water, then rinse it with clean water.
D. Check that the cover seal is not broken away.
Replace the battery if the seal is broken or leaking.
E. Check the electrolyte level in each cell. If the lev­
el is below the tops of the plates in any cell, fill all
cells with distilled water to the bottom of the cap
tubes. Charge at 15 to 25 amps for 15 minutes to al­
low sufficient mixing of the electrolyte.
Electrical System
Electrical
System
Figure 69
E. Connect a battery load tester to the battery ter­
minals following the manufacturer’s instructions. Connect a digital multimeter to the battery
terminals.
2. Conduct a hydrometer test of the battery electrolyte.
IMPORTANT: Make sure the area around the cells is
clean before opening the battery caps.
A. Measure the specific gravity of each cell with a
hydrometer. Draw electrolyte in and out of the
hydrometer barrel prior to taking a reading to warm–
up the hydrometer. At the same time take the tem­
perature of the cell.
B. Temperature correct each cell reading. For each
10_F (5.5_C) above 80_F (26.7_C) add 0.004 to the
specific gravity reading. For each 10_F (5.5_C) be­
low 80_F (26.7_C) subtract 0.004 from the specific
gravity reading.
Example:
Cell Temperature 100_F
Cell Gravity
ADD (20_ above 80_F)
Correction to 80_F
F. Apply a test load of one half the Cranking Perfor­
mance (see Battery Specifications) rating of the bat­
tery for 15 seconds.
G. Take a voltage reading at 15 seconds, then re­
move the load.
H. Using the table below, determine the minimum
voltage for the cell temperature reading.
Minimum
Voltage
1.245
0.008
1.253
C. If the difference between the highest and lowest
cell specific gravity is 0.050 or greater or the lowest
cell specific gravity is less than 1.225, charge the
battery. Charge at the recommended rate and time
given in Charging or until all cells specific gravity is
1.225 or greater with the difference in specific grav­
ity between the highest and lowest cell less than
0.050. If these charging conditions can not be met,
replace the battery.
9.6
70_F (and up)
21.1_C (and up)
9.5
60_F
15.6_C
9.4
50_F
10.0_C
9.3
40_F
4.4_C
9.1
30_F
–1.1_C
8.9
20_F
–6.7_C
8.7
10_F
–12.2_C
8.5
0_F
–17.8_C
I. If the test voltage is below the minimum, replace
the battery. If the test voltage is at or above the mini­
mum, return the battery to service.
3. Perform a high–discharge test with an adjustable
load tester.
This is one of the most reliable means of testing a battery
as it simulates the cold–cranking test. A commercial bat­
tery load tester is required to perform this test.
Battery Electrolyte
Temperature
Installation
IMPORTANT: To prevent possible electrical problems, install only a fully charged battery.
1. Make sure the ignition switch and all accessories
are off.
CAUTION
Follow the manufacturer’s instructions when using a battery tester.
A. Check the voltage across the battery terminals
prior to testing the battery. If the voltage is less than
12.0 VDC, recharge the battery.
B. If the battery has been charged, apply a 150 amp
load for 15 seconds to remove the surface charge.
Use a battery load tester following the manufacturer’s instructions.
C. Make sure the battery terminals are free of corro­
sion.
2. Make sure the battery compartment is clean and re­
painted if necessary.
3. Make sure all battery cables and connection are in
good condition and that the battery bracket has been re­
paired or replaced.
4. Place battery in its compartment. Make sure battery
is level and flat. Push the positive cable connector onto
positive battery post. Do not hammer; this will damage
the battery. Tighten bolts with two wrenches.
5. Install battery bracket and threaded rod to the bat­
tery rod and frame. Install lock nut and washer to battery
rod. Install lock nut to threaded rod (Fig. 68).
D. Measure the temperature of the center cell.
Electrical System
Page 6 – 38
Groundsmaster 3000/3000–D
6. Apply a light coat of grease on all battery posts and
cable connectors to reduce corrosion after connections
are made.
7. Connect a digital multimeter (set to amps) between
the negative battery post and the negative (ground)
cable connector. The reading should be less than 0.1
amp. If the reading is 0.1 amp or more, the unit’s electri­
cal system should be tested and repaired.
8. Connect the negative (ground) cable connector to
the negative battery post.
Charging
To minimize possible damage to the battery and allow
the battery to be fully charged, the slow charging meth­
od is presented here. This charging method can be ac­
complished with a constant current battery charger
which is available in most shops.
Battery
Reserve
Capacity
(Minutes)
Battery Charge Level
(Percent of Fully Charged)
75%
50%
25%
0%
80 or less
3.8 hrs
@
3 amps
7.5 hrs
@
3 amps
11.3 hrs
@
3 amps
15 hrs
@
3 amps
81 to 125
5.3 hrs
@
4 amps
10.5 hrs
@
4 amps
15.8 hrs
@
4 amps
21 hrs
@
4 amps
126 to
170
5.5 hrs
@
5 amps
11 hrs
@
5 amps
16.5 hrs
@
5 amps
22 hrs
@
5 amps
171 to
250
5.8 hrs
@
6 amps
11.5 hrs
@
6 amps
17.3 hrs
@
6 amps
23 hrs
@
6 amps
above
250
6 hrs
12 hrs
18 hrs
24 hrs
@
@
@
@
10 amps 10 amps 10 amps 10 amps
CAUTION
CAUTION
Note: Using specific gravity of the battery cells is the
most accurate method of determining battery condition.
1. Determine the battery charge level from either its
open specific gravity or circuit voltage.
Battery Charge
Level
Specific
Gravity
Open Circuit
Voltage
100%
1.265
12.68
75%
1.225
12.45
50%
1.190
12.24
25%
1.155
12.06
0%
1.120
11.89
Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to
60_F (15.5_ C) before connecting to a charger.
Charge the battery in a well–ventilated place to
dissipate gases produced from charging. These
gases are explosive; keep open flame and electrical spark away from the battery. Do not smoke.
Nausea may result if the gases are inhaled. Unplug the charger from the electrical outlet before
connecting or disconnecting the charger leads
from the battery posts.
3. Following the manufacturer’s instructions, con­
nect the charger cables to the battery. Make sure a good
connection is made.
4. Charge the battery following the manufacturer’s
instructions.
2. Determine the charging time and rate using the
manufacturer’s battery charger instructions or the
following table.
5. Occasionally check the temperature of the battery
electrolyte. If the temperature exceeds 125_F (51.6_C)
or the electrolyte is violently gassing or spewing, the
charging rate must be lowered or temporarily stopped.
6. Three hours prior to the end of the charging, mea­
sure the specific gravity of a battery cell once per hour.
The battery is fully charged when the cells are gassing
freely at a low charging rate and there is less than a
0.003 change in specific gravity for three consecutive
readings.
Groundsmaster 3000/3000–D
Page 6 – 39
Electrical System
Electrical
System
Follow the manufacturer’s instructions when using a battery charger.
Electrical System
Page 6 – 40
Groundsmaster 3000/3000–D
Chapter 7
2WD Rear Axle
Table of Contents
2
2
3
3
Wheel Lug Nut Torque . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Bearing Service . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
4
5
2WD Rear Axle
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wheel Toe–in . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Check Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . .
Groundsmaster 3000/3000–D
Page 7 – 1
Rev. A
2WD Rear Axle
Adjustments
Rear Wheel Toe–In
After every 800 operating hours or annually, check rear
wheel toe–in.
1. Measure center–to–center distance (at axle height)
at front and rear of steering tires. Front measurement
must be 1/8 in. (3 mm) less than rear measurement.
2. To adjust toe–in:
A. Remove cotter pins and nuts securing ball joints
to steering arms. Separate ball joint from arm.
B. Loosen clamps at both ends of tie rod.
2
1
2
Figure 1
C. Rotate ball joints to move front of tire inward or
outward.
1. Tie Rod
2. Tie Rod Clamps
D. Tighten tie rod clamps when adjustment is cor­
rect.
2WD Rear Axle
Page 7 – 2
Groundsmaster 3000/3000–D
Service and Repairs
Wheel and Tire Service
Check Tire Pressure
The tires are over–inflated for shipping. Therefore, re­
lease some of the air to reduce the pressure. Correct air
pressure in the front and rear tires is 15 psi (1 Bar).
IMPORTANT: Maintain even pressure in all tires to as­
sure a good quality–of–cut and proper machine perfor­
mance. DO NOT UNDER INFLATE.
Check Wheel Nut Torque
WARNING
1
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 2
1. Rear wheel and tire
Lubrication
The machine has grease fittings that must be lubricated
regularly with No. 2 General Purpose Lithium Base
Grease. If machine is operated under normal condi­
tions, lubricate all bearings and bushings after every 50
hours of operation or immediately after every washing.
Steering cylinder ball joint, Rear axle tie rod (2), Rear
axle pivot (1) Rear Spindle Shafts (2).
2WD Rear Axle
Figure 3
Groundsmaster 3000/3000–D
Page 7 – 3
Rev. A
2WD Rear Axle
Wheel Bearing Service
Disassemble, clean, repack and adjust the rear wheel
bearings after each 800 hours of operation. Use No. 2
general purpose lithium base grease containing E.P. ad­
ditive. If operating conditions are extremely dusty and
dirty, it may be necessary to perform this maintenance
more often.
10. Adjust preload on the wheel bearings.
A. Tighten the jam nut to 75 – 80 in–lb (86 – 270 Kg–
cm) while turning the hub to seat the bearings and
remove all end play.
B. Loosen the jam nut until it is away from the tab
washer and the hub has end play. Tighten the jam
nut to 15 – 20 in–lb (17 – 23 Kg–cm) while rotating
the hub.
1. Slightly loosen the wheel lug nuts. Jack up the rear of
the machine until the tire is off the floor. Support the ma­
chine with jack stands or blocks to prevent it from falling.
Remove the wheel.
2. Remove the hubcap from the end of the wheel
spindle.
C. Put the retainer over the jam nut. If the cotter pin
hole is not aligned with a retainer slot, remove the
retainer and re–orient it until alignment occurs.
3. Remove the cotter pin, retainer, jam nut, and washer.
Slide the hub off of the spindle shaft.
D. Insert the cotter pin. Bend both legs of the cotter
pin and tap out of the way. Install the cap.
4. Pull the seal out of the hub.
5. Remove the bearing cones from both sides of the hub
assembly. Clean the bearings in solvent. Make sure the
bearings are in good operating condition. Clean the in­
side of the wheel hub. Check the bearing cups for wear,
pitting or other noticeable damage. Replace worn or
damaged parts.
8
7
9
10
11
6
12
6. If bearing cups were removed from the hub assembly,
press new ones into the hub until they seat against the
shoulder.
1
2
7. Pack bearing cones with grease. Install one bearing
cone into the cup on inboard side of the hub assembly.
Lubricate the inside of the new lip seal and press it into
the hub assembly.
IMPORTANT: The lip seal must be pressed in so it is
flush with the end of the hub.
8. Pack inside of hub assembly with some grease (not
full). Install remaining bearing cone into the bearing cup.
9. Slide the hub onto the spindle shaft and secure it in
place with the tab washer, jam nut, and retainer. DO
NOT tighten the nut or install the cotter pin.
2WD Rear Axle
3
5
Page 7 – 4
4
Figure 4
1. Cotter pin
2. Spindle
3. Cap
4. Washer
5. Seal
6. Inner bearing cone
7. Inner bearing cup
8. Wheel hub
9. Outer bearing cup
10. Outer bearing cone
11. Washer
12. Retainer
13. Jam nut
Groundsmaster 3000/3000–D
Rear Axle
9
49
7
1
2
3
4
5
6
8
34.5 in. (876 mm)
installed
50
11
12
13
150 ft–lb
(21 Kgm)
14
15
45
20
51
44
43
46
150 ft–lb
(21 Kgm)
48
16
47
42
18
41
4
19
17
20
5
40
15 inch (38 mm)
compressed length
8
21
22
23 24 25 26
39
27
28
29
30
38
37
36
35
34
33
70 – 80 ft–lb
(10 – 11 Kgm)
31
32
1. Nut
2. R.H. spindle
3. Seal
4. Rod end
5. Grease fitting
6. Lock nut
7. Screw
8. Cotter pin
9. Screw
10. Axle pivot pin
11. Grease fitting
12. Spring pin
13. Axle pivot
14. Castor bushing
15. Tie rod assy
16. Bushing
17. Grease fitting
Groundsmaster 3000/3000–D
18. Screw
19. Flat washer
20. Castle nut
21. Hub seal
22. Bearing cone
23. Bearing cup
24. Tab washer
25. Jam nut
26. Retainer
27. Cotter pin
28. Tire
29. Dust cap
30. Rim
31. Valve
32. Lug nut
33. Hub
34. Stud
Page 7 – 5
35. L.H. spindle
36. Spring pin
37. Thrust washer
38. Spindle pivot pin
39. Steering cylinder
40. Lock nut
41. Rod end
42. Screw
43. Screw
44. Flat washer
45. Lock nut
46. Rear axle
47. Screw
48. Clamp and tube
49. Weight plate
50. Screw
51. Nut
2WD Rear Axle
2WD Rear Axle
Figure 5
2WD Rear Axle
Page 7 – 6
Groundsmaster 3000/3000–D
Chapter 8
4WD Rear Axle
Table of Contents
2
2
3
3
3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Rear Axle Lubricant . . . . . . . . . . . . . . . . . . .
Replace Rear Axle Lubricant . . . . . . . . . . . . . . . . . .
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
4
4
5
4WD Rear Axle
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wheel Toe–in . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Check Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . .
Check Wheel Lug Nut Torque . . . . . . . . . . . . . . . . .
Groundsmaster 3000/3000–D
Page 8 – 1
Rev. A
4WD Rear Axle
Adjustments
Rear Wheel Toe–In
After every 800 operating hours or annually, check rear
wheel toe–in.
1. Measure center–to–center distance (at axle height)
at front and rear of steering tires. Front measurement
must be 1/8 in. (3 mm) less than rear measurement.
2. To adjust toe–in:
A. Remove cotter pins and nuts securing ball joints
to steering arms. Separate ball joint from arm.
B. Loosen clamps at both ends of tie rod.
2
1
2
Figure 1
C. Rotate ball joints to move front of tire inward or
outward.
1. Tie Rod
2. Tie Rod Clamps
D. Tighten tie rod clamps when adjustment is cor­
rect.
4WD Rear Axle
Page 8 – 2
Groundsmaster 3000/3000–D
Service and Repairs
Wheel and Tire Service
Check Tire Pressure
The tires are over–inflated for shipping. Therefore, re­
lease some of the air to reduce the pressure. Correct air
pressure in the front and rear tires is 15 psi (1 Bar).
IMPORTANT: Maintain even pressure in all tires to as­
sure a good quality–of–cut and proper machine perfor­
mance. DO NOT UNDER INFLATE.
Check Wheel Nut Torque
WARNING
1
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 2
1. Rear wheel and tire
Lubrication
The machine has grease fittings that must be lubricated
regularly with No. 2 General Purpose Lithium Base
Grease. If machine is operated under normal condi­
tions, lubricate all bearings and bushings after every 50
hours of operation or immediately after every washing.
Steering cylinder ball joints, Rear axle tie rod (2), Rear
axle pivot (1) and Double Cardan joints (2 ea. side).
4WD Rear Axle
Figure 3
Groundsmaster 3000/3000–D
Page 8 – 3
Rev. A
4WD Rear Axle
Check Rear Axle Lubricant
The rear axle reservoir uses Mobil 424 hydraulic fluid.
Although the axle is shipped with lubricant from the factory, check the level before operating the machine.
1
1. Position the machine on a level surface.
2. Remove check plug from axle and make sure lubricant is up to bottom of hole. If level is low, add enough
lubricant to bring the level up to the bottom of the check
hole (Fig. 4).
2
Figure 4
1. Check Plug
2. Drain Plug
Change Rear Axle Lubricant
Initially, change oil in rear axle after 200 hours, thereafter change every 400 hours of operation.
1
1. Position machine on a level surface.
2. Clean area around drain plug on rear axle.
3. Remove check plug to ease draining of oil.
4. Remove drain plug allowing oil to drain into pan.
5. Install drain plug.
2
6. Fill axle with approximately 16 oz. (473 ml) of Mobile 424 or until lubricant is up to bottom of check hole.
7. Install check plug.
4WD Rear Axle
Figure 5
1. Check Plug
2. Drain Plug
Page 8 – 4
Groundsmaster 3000/3000–D
4WD Axle
11
8
9
10
34.5 in. (876 mm)
installed
12
7
150 ft–lb
(21 Kgm)
1
16
6
5
4
3
2
1
19
20
13
14
1
17
90 – 110 ft–lb
(12 – 15 Kgm)
18
15
16
3
2
29
1
16
28
21
4
22
27
15 inch (38 mm)
compressed length
26
23
25
24
70 – 80 ft–lb
(10 – 11 Kgm)
Figure 6
1. Nut
2. Seal
3. Rod end
4. Grease fitting
5. Screw
6. Flat washer
7. Lock nut
8. Screw
9. Axle pivot
10. Axle pivot pin
11. Grease fitting
12. Spring pin
13. Screw
14. Clamp and tube assy
15. Lock nut
16. Cotter pin
17. Castor bushing
18. Tie rod assy
19. Cylinder anchor
20. Tapered screw
21. Tire
22. Rim
23. Valve stem
24. Lug nut
25. Axle
26. Steering cylinder
27. Lock nut
28. Rod end ball joint
29. Screw
4WD Rear Axle
NOTE: Assembly kits are available for servicing this
component. See the Parts Catalog for more information.
Groundsmaster 3000/3000–D
Page 8 – 5
4WD Rear Axle
1
2
3
9
8
4
5
6
7
10
11
12
13
14
15
19
16
18
17
23
10
9
24
8
27
26
8
25
24
22 21
23
20
Figure 7
1. Inboard yoke shaft
2. Cross and bearing kit
3. Double pivot yoke
4. Outboard yoke shaft
5. Washer
6. Retaining ring
7. Tapered bearaing
8. Screw
9. Kingpin cover
10. Kingpin trunnion
11. Belleville washer
12. L.H. spindle flange
13. Wheel hub
14. Washer
15. Nut
16. Dust cap
17. Wheel stud
18. Nut
19. Screw
20. Retaining ring
21. Lip seal
22. Journal bearing
23. Bearing cone
24. Bearing cup
25. Kingpin housing
26. O–ring
27. R.H. spindle flange
4WD Rear Axle
NOTE: Assembly kits are available for servicing this
component. See the Parts Catalog for more information.
4WD Rear Axle
Page 8 – 6
Groundsmaster 3000/3000–D
13
11
14
12
15
16
16
15
11
10
9
8
7
14
17
6
17
5
4
3
2
1
21 20 19
18
22
Figure 8
1. Clutch housing
2. O–ring
3. Lip seal
4. Internal retaining ring
5. Thrust washer
6. Clutch
7. Clutch race
8. Needle bearing
9. Retaining ring
10. Ball bearing
11. Bushing
12. Breather vent
13. Axle housing
14. Plug
15. Bearing cup
16. Bearing cone
17. Differential
18. Screw
19. Side cover
20. O–ring
21. Differential shim kit
22. Screw
4WD Rear Axle
NOTE: Assembly kits are available for servicing this
component. See the Parts Catalog for more information.
Groundsmaster 3000/3000–D
Page 8 – 7
4WD Rear Axle
4WD Rear Axle
Page 8 – 8
Groundsmaster 3000/3000–D
84" Cutting Units
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport Latch Adjustment . . . . . . . . . . . . . . . . . . .
Height of Cut Adjustment . . . . . . . . . . . . . . . . . . . . .
Skid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Anti–Scalp Roller Adjustment . . . . . . . . . . . . . . . . .
Deck Pitch Adjustment . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Check Gear Box Lubricant . . . . . . . . . . . . . . . . . . . .
Replace Gear Box Lubricant . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnecting Cutting Unit from Traction Unit . . .
Groundsmaster 3000/3000–D
2
3
3
4
5
5
6
7
7
7
8
9
Connecting Cutting Unit to Traction Unit . . . . . . . 1
0
Install Lift Arm Ball Joints . . . . . . . . . . . . . . . . . . . . . 1
1
Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . 1
1
Front Castor Fork Service . . . . . . . . . . . . . . . . . . . 1
2
Castor Wheel and Bearing Service . . . . . . . . . . . . 1
3
Cutter Blade Removal and Installation . . . . . . . . . 1
4
Inspecting and Sharpening Blade . . . . . . . . . . . . . 1
5
Blade Spindle Service . . . . . . . . . . . . . . . . . . . . . . . 1
6
Cutting Unit Mismatch . . . . . . . . . . . . . . . . . . . . . . . 1
8
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9
Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1
Page 9 – 1
84 inch Cutting Units
84 inch
Cutting Units
Chapter 9
Specifications
Type: 84 inch (2.1 m) width of cut, 5 blades, 3 blade cen­
ter section, and 2 one blade wings. Toro Recycler
technology on Guardian Recycler.
Mowing Rate: Mows up to 4.7 acres/hr (1.9 hectares/
hr) at 5.5 mph (8.8 km/hr).
Trimming Ability: Deck is centered on tractor with 15
inches (38 mm) of over hang on each side. Uncut circle
is 24.0 inches (610 mm) on both left and right with no
brakes.
Height Of Cut: 1–5 inches (25 to 127 mm) adjustable in
1/2 inch (13 mm) increments. Front adjustment is with
snapper pin and grooves in castor shaft. Rear adjust­
ment is with hanger brackets and pin.
Construction: 12 gauge steel, 4.25 inches (108 mm)
deep, welded construction and reinforced with 10 gauge
steel channels. Bolt–in 12 gauge steel chambers.
Cutter Drive: Isolation mount PTO driven gearbox with
1:1.35 spiral bevel gears. One ”BB” section belt on center section. One ”B” section belt on each wing. Fixed
idler on main deck with spring adjustment. Self–tensioning idler pulleys on each wing. 1.25 inch diameter (32
mm) spindle shafts, turn on two greaseable tapered roll­
er bearings (greaseable from top of deck). A positive
splined connection attaches pulleys to spindle shafts for
high torque capacity.
Blades: Five 19 inch (483 mm) long, .25 inch (6 mm)
thick, heat–treated steel.
Suspension & Castor Wheels: Two front castors, con­
sisting of 10 inch (254 mm) pneumatic wheel and tire as­
sembly with sealed ball bearings. Rear of deck is
suspended from lift arms with adjustable deck rake. Hy­
draulic counter balance and lift system designed inte­
gral with deck for maximum flotation.
Anti–scalp Features: Anti–scalp cup located on each
blade. Three anti–scalp rollers on center deck. Anti–
scalp wheel and adjustable skid on each wing. Wings
flex 0–15 degrees up.
Deck Covers: High impact plastic covers.
Quick Attach System: Tapered joint with over center
adjustable tensioning latch.
Weight: Guardian Recylcer 660 lbs (299 Kg), Rear Dis­
charge 665 lbs (302 Kg).
Specifications and design subject to change without notice.
84 inch Cutting Units
Page 9 – 2
Rev. A
Groundsmaster 3000/3000–D
Adjustments
84 inch
Cutting Units
Transport Latch Adjustment
1. Start tractor and raise deck to highest possible posi­
tion and turn off engine.
2. Loosen (2) flange head capscrews securing latch
plate to side of gearbox.
2
3. Rotate latch rod downward from front of traction
unit.
1
4. Insert latch rod into rear hole (transport position) in
latch plate.
5. Tighten flange head capscrews securing latch plate
to gearbox.
6. Remove hair pin cotters and clevis pins securing
height–of–cut straps to rear of deck.
7. Remove latch rod from rear hole in latch plate.
8. Rotate front of deck upward and insert latch rod into
front hole (service position) in latch plate.
9. Loosen latch plate flange head capscrews and adjust latch plate position if required.
Groundsmaster 3000/3000–D
Page 9 – 3
Figure 1
1. Latch Plate
2. Latch Rod
84 inch Cutting Units
Height of Cut Adjustment
The height–of–cut is adjustable from 1 to 5 inches (25 to
127 mm) in 1/2 inch (13 mm) increments.
1. Start engine and raise cutting unit. Stop engine after
cutting unit is raised.
1
2. Remove front snapper pins from castor arms and
slide castor wheel assembly up or down.
3. Insert snapper pin into castor arm and through
groove in castor shaft to get desired height–of–cut.
4. Remove hair pin cotter and clevis pin securing
height–of–cut chain to rear of deck.
5. Mount height–of–cut chain to desired height–of–cut
hole with clevis pin and hair pin cotter.
Figure 2
1. Snapper Pin
6. When using 1 inch (25 mm) height–of–cut, move
skids, anti–scalp rollers, and wings wheels to the high­
est holes.
Figure 3
1
Figure 4
1. Height–of–Cut chain
Figure 5
84 inch Cutting Units
Page 9 – 4
Groundsmaster 3000/3000–D
Skid Adjustment
84 inch
Cutting Units
Skids should be located in upper holes for 1 (25 mm) and
1–1/2 inch (38 mm) heights–of–cut and lower holes for 2
(51 mm) to 5 inch (127 mm) heights–of–cut.
1. Adjust skids by removing flange nuts, positioning as
desired and re–installing flange nuts.
1
Figure 6
1. Skid
Anti–Scalp Roller Adjustment
Anti–scalp rollers should be located in upper holes for 1
(25 mm) and 1–1/2 inch (38 mm) heights–of–cut and
lower holes for 2 (51 mm) to 5 inch (127 mm) heights–
of–cut. Five rollers are located on the deck, three under
the main deck and one on each wing.
1. Adjust anti–scalp rollers by removing lock nut and
bolt, positioning as desired and reinstalling lock nut and
bolt.
1
Figure 7
1. Anti–scalp roller
Groundsmaster 3000/3000–D
Page 9 – 5
84 inch Cutting Units
Deck Pitch Adjustment
Deck pitch is the difference in height–of–cut from the
front of the blade plane to the back of the blade plane.
TORO recommends a blade pitch of .25 inches (6 mm).
That is the back of the blade plane is .25 inches (6 mm)
higher than the front.
2
1. Position machine on a level surface on shop floor.
2. Set deck to the desired height–of–cut.
1
3. Rotate one blade so it points straight forward.
4. Using a short ruler, measure from floor to front tip of
blade. Then, measure from floor to rear tip of blade.
5. Subtract the front dimension from rear dimension to
calculate your pitch.
6. To adjust pitch, start tractor and raise deck to highest possible position and turn off engine.
Figure 8
1. Height–of–Cut chain
2. U–bolt
7. Loosen jam nuts on top or bottom of height of cut
chain u–bolts.
8. Adjust other set of nuts to raise or lower rear of deck
and get correct deck pitch.
9. Tighten jam nuts.
10. Lower deck.
84 inch Cutting Units
Page 9 – 6
Groundsmaster 3000/3000–D
Service and Repairs
84 inch
Cutting Units
CAUTION
To prevent accidental starting of the engine,
while performing maintenance, shut engine off
and remove key from ignition switch.
Check Gear Box Lubricant
The gear box is designed to operate with SAE 80–90 wt.
gear lube. Although the gear box is shipped with lubri­
cant from the factory, check the level before operating
the cutting unit.
1. Position the machine and cutting unit on a level sur­
face.
2. Remove check plug from side of gear box and make
sure lubricant is up to bottom of hole. If level of lubricant
is low, remove fill plug on top of gear case and add
enough lubricant to bring it up to bottom of hole in side.
1
2
Figure 9
1. Filler Plug
2. Check Plug
Replace Gear Box Lubricant
The gear box lubricant must be changed initially, after
the first 400 hours of operation, and thereafter every
1600 hours of operation.
1. Position the machine and cutting unit on a level sur­
face.
2
1
2. Loosen fixed idler pulley locking nut.
3. Loosen spring tensioning nut as required and re­
move belt.
4. Remove (4) locknuts securing gearbox mount to
deck.
5. Remove belt from pulley.
6. Remove check plug from side of gear box and tip
gear box assembly allowing lubricant to drain from gear
box.
7. Reinstall belt to pulley.
8. Reinstall gear box assembly to deck
9. Remove fill plug on top of gear case and add SAE
80–90 wt. gear lube until level is up to bottom of hole in
side.
10. Reinstall check plug to side of gear box and fill plug
to top of gear case.
11. Re–tension belt. Refer to Replacing Drive Belts.
Groundsmaster 3000/3000–D
Page 9 – 7
3
Figure 10
1. Gear Box Mount
2. Filler Plug
3. Check Plug
84 inch Cutting Units
Lubricate Bearings, Bushings and Gear Box
The cutting unit must be lubricated regularly. If machine
is operated under normal conditions, lubricate castor
bearings and bushings with No. 2 general purpose lithi­
um base grease or molybdenum base grease, after ev­
ery 8 hours of operation or daily, whichever comes first.
Lubricate fittings immediately after every washing, re­
gardless of the interval listed.
1. The cutting unit has bearings and bushings that
must be lubricated, and these lubrication points are:
front castor shaft bushings (2), blade spindle bearings
(5), idler arm pivots (2), drive shaft (3), Wing deck pivots
(2) and right and left push arm ball joints (Fig. 11).
2. Position the machine and cutting unit on a level sur­
face and lower cutting unit. Remove check plug from
side of gear box and make sure lubricant is up to bottom
of hole. If level of lubricant is low, remove fill plug on top
of gear case and add SAE 80–90 wt. gear lube until level
is up to bottom of hole in side.
1
2
Figure 11
1. Filler Plug
2. Check/Drain Plug
84 inch Cutting Units
Page 9 – 8
Groundsmaster 3000/3000–D
Disconnect Cutting Unit From Traction Unit
84 inch
Cutting Units
Note: Implements are heavy and may require two
people to handle.
1. Start tractor and raise deck to highest possible position and turn off engine.
2. Remove hair pin cotter and clevis pin securing
height–of–cut chains to rear height–of–cut brackets.
1
3. Rotate ignition key to run position and move lift lever
forward to lower cutting unit.
4. Raise seat and open needle valve. This allows lift
arms to float freely.
5. Remove hair pin cotter and clevis pin securing latch
cover to lift arm .
Figure 12
6. Loosen release lever by rotating it counterclockwise.
1. Height–of–Cut chain
7. Pivot release lever upward and remove shaft latch
from slot in traction unit lift arm.
8. Pull rearward on lock collar to release drive shaft
coupler from tractor.
9. Stay clear of lift arms and move deck away from
tractor allowing lift arms to fall.
1
10. Secure hair pin cotter and clevis pin to height–of–
cut chains for storage.
11. Close needle valve
Figure 13
1. Needle Valve
5
1
3
2
4
Figure 14
1. Latch Cover
2. Release Lever
3. Shaft latch
Groundsmaster 3000/3000–D
Page 9 – 9
4. Traction Unit Lift Arm
5. Machined Surface
84 inch Cutting Units
Connect Cutting Unit to Traction Unit
1. Center traction unit in front of cutting unit on any flat
hard surface.
2. Raise seat and open needle valve. This allows lift
arms to float freely.
3. Adjust lift arms heights making sure that the machined surface on top of each traction unit lift arm is parallel to ground. (Raise or lower lift arm casting by
pushing up or down from behind the front tires or using
wrench in front of tractor)
1
4. Check for dirt and debris on mating parts and clean
as required.
5. Turn castor wheels so they point straight forward.
Figure 15
6. Secure first lift arm assembly to traction unit as follows:
1. Needle Valve
A. Remove hair pin cotter and clevis pin securing
latch cover to lift arm.
5
1
B. Pivot release lever upward.
3
C. Slide cutting unit lift arm onto traction unit lift
arm, inserting shaft latch into slot in traction unit
lift arm.
Note: If latch does not fall into slot in traction unit
lift arm, raise or lower lift arm casting by pushing
up or down from behind the front tires.
2
4
D. Pivot release lever downward and tighten securely by rotating clockwise.
7. Install other lift arm on tractor by rotating deck towards tractor, aligning lift arm to tractor arm and repeating step 5. If latch does not fall into slot in traction unit lift
arm the arms are not lined up.
A. If lift arms on traction unit are not at the correct
height for deck arms to slide on, push up or down
on lift arm castings from behind the front tires until
deck arm line up and slide on.
Figure 16
1. Latch Cover
2. Release Lever
3. Shaft latch
4. Traction Unit Lift Arm
5. Machined Surface
1
B. If lift arms on deck do not line up side to side.
Rotate castor wheels side ways so deck moves
side to side easier. Move deck side to side until lift
arms line up and slide on.
8. Move deck from side to side to check for tightness
and re–tighten latches, if required.
9. Install latch covers to lift arms and secure with clevis
pins and hair pin cotters.
10. Connect drive shaft to traction unit.
Figure 17
1. Height–of–Cut chain
11. Close needle valve and lower seat.
12. Start tractor and raise deck to highest possible position and turn off engine.
13. Align height–of–cut chains with hole for desired
height–of–cut, install clevis pin and secure with hair pin
cotter.
84 inch Cutting Units
Page 9 – 10
Groundsmaster 3000/3000–D
Install Lift Arm Ball Joints
140 ft–lb (19 Kgm)
then continue tightening
until slot in nut aligns
with cotter pin hole
1
84 inch
Cutting Units
1. Adjust ball joint in each lift arm assembly until a dimension of 2.75 inches (70 mm) from end of lift arm to
center of ball joint is attained.
2.75 in. (70 mm) 2
Figure 18
1. Ball Joint
2. Lift Arm
Drive Belt Replacement
The blade drive consists of three belts, one main drive
belt and two wing belts. The main drive belt is tensioned
by a fixed idler with a spring adjustment. The wing belts
have spring loaded idlers. All belts are very durable but
after many hours of use, the belt will show signs of wear.
Signs of a worn belt are: squealing when belt is rotating,
blades slipping when cutting grass, frayed edges, burn
marks and cracks. Replace any belt if any of these
conditions are evident. Adjust belt tension on main belt
after first 5 hours of operation to assure maximum dura­
bility and thereafter, check tension every 50 hours.
3
4.35 in. (111 mm)
1
1. Lower cutting unit to the shop floor. Remove belt
covers from top of cutting unit and set covers aside.
2. Pull on spring loaded idlers and remove wing belts.
3. Loosen fixed idler pulley locking nut.
4. Loosen spring tensioning nut as required and re­
move belt.
5. Tighten spring tensioning nut until spring length is
4.35 inches (111 mm) inside spring loops.
6. Tighten idler pulley locking nut.
7. Pull on spring loaded idlers and install wing belts.
2
Figure 19
1. Idler Pulley
2. Spring Tensioning Nut
3. Idler Pulley Locking Nut
8. Install belt covers to top of cutting unit.
Figure 20
Groundsmaster 3000/3000–D
Page 9 – 11 Rev. A
84 inch Cutting Units
Front Castor Fork Bushing Service
The castor forks have bushings pressed into the top and
bottom of the casting and after many hours of operation,
the bushings will wear. To check the bushings, move
castor fork back and forth and from side to side. If castor
spindle is loose around the bushings, bushings are worn
and must be replaced.
5
6
1. Start tractor and raise deck to highest possible posi­
tion and turn off engine.
2. Remove front snapper pins from castor arms and
slide castor wheel assembly out of castor arm tube.
3. Remove locknut from capscrew holding castor
wheel assembly between castor fork. Grasp castor
wheel and slide capscrew out of fork.
1
6
3
4
4. Remove retaining ring, washer and wave washer
securing castor shaft to castor fork. Remove shaft from
fork.
2
5. Insert pin punch into top or bottom of castor fork and
drive bushing out of fork. Repeat for other bushing.
Clean inside of forks to remove dirt.
6. Apply grease to inside and outside of new bushings.
Using a hammer and flat plate, drive bushings into fork.
7. Inspect castor shaft and fork for wear and replace if
damaged.
Figure 21
1. Front Castor Fork
2. Retaining Ring
3. Washer
4. Wave Washer
5. Castor Shaft
6. Bushings
8. Push castor shaft through bushings and fork and se­
cure with wave washer, washer and retaining ring.
9. Insert snapper pin into castor arm and through
groove in castor shaft at desired height–of–cut.
84 inch Cutting Units
Page 9 – 12
Groundsmaster 3000/3000–D
The castor wheel rotates on a high–quality roller bear­
ing. Even after many hours of use, provided that the
bearing was kept well–lubricated, bearing wear will be
minimal. However, failure to keep bearing lubricated will
cause rapid wear. A wobbly castor wheel usually indi­
cates a worn bearing.
84 inch
Cutting Units
Castor Wheel and Bearing Service
60 – 80 ft–lb
(8 – 11 Kgm)
1. Remove locknut from capscrew holding castor
wheel assembly between castor fork. Grasp castor
wheel and slide capscrew out of fork.
3. Remove bearing from wheel hub and allow spacer
to fall out. Remove bearing from opposite side of wheel
hub.
1
4. Check the bearings, spacer and inside of wheel hub
for wear. Replace defective parts as required.
5. To assemble the castor wheel, push bearing into
wheel hub. Slide spacer into wheel hub. Push other
bearing into open end of wheel hub to captivate the
spacer inside the wheel hub.
2
1
7. Install castor wheel assembly between castor forks
and secure in place with capscrew and locknut.
Figure 22
1. Bearing
2. Spacer
Groundsmaster 3000/3000–D
Page 9 – 13
84 inch Cutting Units
Cutter Blade Removal and Installation
The blade must be replaced if a solid object is hit, the
blade is out–of–balance or if the blade is bent. Always
use genuine TORO replacement blades to be sure of
safety and optimum performance. Never use replace­
ment blades made by other manufacturers because
they could be dangerous.
1. Raise cutting unit to highest position, shut the en­
gine off and engage the parking brake.
2
2. Remove hair pin cotters and clevis pins securing
height–of–cut straps to rear of deck.
3. Rotate front of deck upward and insert latch rod into
front hole (service position) in latch plate.
4. Grasp end of blade using a rag or thickly padded
glove. Remove blade bolt, anti–scalp cup and blade
from spindle shaft.
5. Install blade–sail facing (up) toward cutting unit–
with anti–scalp cup and blade bolt. Tighten blade bolt to
85–110 ft–lb (12 – 15 Kgm).
85 – 110 ft–lb
(12 – 15 Kgm)
1
Figure 23
1. Blade bolt
2. Anti–Scalp Cup
WARNING
Do not try to straighten a blade that is bent, and
never weld a broken or cracked blade. Always
use a new blade to assure continued safety
certification of the product.
84 inch Cutting Units
Page 9 – 14
Groundsmaster 3000/3000–D
Inspecting and Sharpening Blade
84 inch
Cutting Units
1. Raise cutting unit to highest position, shut the en­
gine off and engage the parking brake.
2. Remove hair pin cotters and clevis pins securing
height–of–cut straps to rear of deck.
3. Rotate front of deck upward and insert latch rod into
front hole (service position) in latch plate.
4. Examine cutting ends of the blade carefully, espe­
cially where the flat and curved parts of the blade meet
(Fig. 24–A). Since sand and abrasive material can wear
away the metal that connects the flat and curved parts of
the blade, check the blade before using the machine. If
wear is noticed (Fig. 24–B), replace the blade: refer to
Removing Cutter Blade.
DANGER
Figure 24
If blade is allowed to wear, a slot will form
between the sail and flat part of the blade
(Fig. 24–C). Eventually a piece of the blade
may break off and be thrown from under the
housing, possibly resulting in serious injury to
yourself or bystander.
5. Inspect cutting edges of all blades. Sharpen the cut­
ting edges if they are dull or nicked. Sharpen only the top
of the cutting edge and maintain the original cutting
angle for best performance (Fig. 25). The blade will re­
main balanced if same amount of metal is removed from
both cutting edges.
SHARPEN AT THIS
ANGLE ONLY
END VIEW
Figure 25
6. To check blade for being straight and parallel, lay
blade on a level surface and check its ends. Ends of
blade must be slightly lower than the center, and cutting
edge must be lower than the heel of the blade. This
blade will produce good quality of cut and require mini­
mal power from the engine. By contrast a blade that is
higher at the ends than the center, or if cutting edge is
higher than the heel, the blade is bent or warped and
must be replaced.
7. Install blade—sail facing (up) toward cutting unit–
with anti–scalp cup and blade bolt. Tighten blade bolt to
85–110 ft–lb (12 – 15 Kgm).
Groundsmaster 3000/3000–D
Page 9 – 15
84 inch Cutting Units
Blade Spindle Service
Removing Spindle Housing Assembly
1
1. Lower the cutting unit, shut the engine off and engage
the parking brake.
85 – 110 ft–lb
(12 – 15 Kgm)
2. Remove deck covers from top of cutting unit. Release
belt tension. Remove belt from spindle to be serviced.
Install seal with
lip facing IN
2
3
4
6
3. Start the engine and raise the cutting unit. Turn the
engine OFF and remove the key from the key switch.
Block up the cutting unit so it cannot fall accidentally.
7
8
5
4. Remove blade screw, flat washer, anti–scalp cup and
blade from spindle assembly.
5. Remove flange nuts and carriage bolts securing
spindle housing to deck. Slide spindle housing assem­
bly out the bottom of the cutting unit.
15
9
4
Install seal with
lip facing OUT
10
11
Disassembly
12
1. Remove lock nut retaining the spindle pulley on
spindle shaft. Slide pulley off of shaft.
2. Press the spindle shaft out of the spindle housing
using an arbor press. The bearing spacer remains on
the spindle shaft as the shaft is being removed.
13
85 – 110 ft–lb
(12 – 15 Kgm)
14
Figure 26
3. Remove seals from spindle housing.
4. Allow the bearings and small thick spacer to fall out
of the spindle housing.
5. Using a punch and hammer, drive both of the bearing
cups out of the spindle housing. Also drive the large
spacer out of the housing.
1. Grease fitting
2. Lock nut
3. Pulley
4. Oil seal
5. Spacer and bearing assy
6. Spacers – matched set
7. Lock nut
8. Spindle housing
9. Screw
10. Spindle shaft
11. Spindle shaft spacer
12. Blade
13. Anti–scalp cup
14. Blade screw
15. Flat washer
6. A large snap ring is still inside the spindle housing and
it should remain there because it cannot be easily
removed.
IMPORTANT: If new bearings will be installed into a
used spindle housing that has the original snap ring
installed, discard the large snap ring that came with
the bearings because it is not needed. However,
new bearings with their matched spacer and snap
ring must always be installed when the spindle
housing is being replaced. Replacement bearings
are sold only with a matched snap ring and spacer
set. These parts cannot be purchased separately.
Figure 27
84 inch Cutting Units
Page 9 – 16
Groundsmaster 3000/3000–D
IMPORTANT: If a new spindle housing is being used,
new bearings and matched snap ring set must be
installed; see step 1 below. Never use old bearings,
spacer, and snap ring with a new spindle housing.
If installing bearings into a used spindle housing
that still has a snap ring installed, use only new
bearings with cups and spacer – not the large snap
ring because it is not required; see step 2 below.
11. Slide pulley end of spindle assembly through hole in
cutting unit. Mount the spindle assembly in place with
the carriage bolts and flange nuts.
12. Install the belt and adjust belt tension.
13. Reinstall the belt covers.
1. Install large snap ring into groove in bore of spindle
housing. Make sure snap ring is seated in groove.
2. Using an arbor press, push large spacer into top of
spindle housing; tightly against snap ring. The spacer
must contact the snap ring to be sure of the correct
assembly of the parts.
3. Thoroughly oil the bearing cups. Use an arbor press
to push the bearing cups into the top and bottom of the
spindle housing. The top bearing cup must contact the
spacer that was installed in step 2, and the bottom
bearing cup must contact the snap ring. Make that the
assembly is correct by supporting the first cup and
pressing the second against it.
Figure 28
4. Apply a film of grease on lips of both seals. Pack the
bearing cones with grease.
5. Install bearing and seal into bottom of spindle
housing. BOTTOM SEAL MUST HAVE THE LIP
FACING OUT.
6. Check the spindle shaft to make sure it is free of burrs
and nicks that could possibly cut the seals. Thoroughly
lubricate both the shaft and seal lips.
7. Slide small, thick spacer into spindle housing, then
install bearing and seal into top of spindle housing. LIP
OF UPPER SEAL MUST FACE IN.
Figure 29
8. Slide bearing spacer onto spindle shaft. Carefully
slide spindle shaft through spindle housing. The bottom
seal and bearing spacer fit together when the spindle is
installed.
9. Attach a hand pump grease gun to grease fitting and
fill cavity with grease until grease starts to come out of
lower seal. NOTE: Pneumatic grease guns can produce
air pockets when filling large cavities.
10. Push pulley onto splines of spindle shaft and retain
the parts together with the large flat washer and nut.
Tighten the nut to 85 – 110 ft–lb (12 – 15 Kgm). Rotate
Groundsmaster 3000/3000–D
Page 9 – 17 Rev. A
Figure 30
84 inch Cutting Units
84 inch
Cutting Units
the spindle shaft to be sure that the shaft rotates freely.
Installing Spindle, Bearings and
Seals Into Spindle Housing
Correcting Cutting Unit Mismatch
If there is mismatch between the blades, the grass will
appear streaked when it is cut. This problem can be cor­
rected by making sure the blades are straight and all
blades are cutting on the same plane.
1. Position machine on a level surface on the shop
floor.
2. Release belt tension on belts.
3. Raise deck to transport position and lock transport
latch.
4. Position the tip of an outer blade and adjacent blade
tip as close together as possible at the intersection of the
two cutting chambers. Note the height of the outer blade
tip with respect to the adjacent blade tip.
5. Rotate outer blade 180_ and note the height of the
outer blade tip with respect to the adjacent blade tip. If
the relative height changed by more than 1/8 inch (3
mm) after rotating blade, then outer blade is bent and
should be replaced.
6. Repeat steps 4 and 5 until all pairs of adjacent
blades have been checked at both blade tips. Note the
relative difference in blade height at each blade inter­
section after replacing any bent blades. This height dif­
ference should be less than 1/8 inch (3 mm) for all
adjacent blades.
84 inch Cutting Units
7. Raise the height–of–cut to the highest position and
lower deck to the floor.
8. Rotate an outer blade until the tip is positioned near­
est to the skid on the side of the deck housing. Measure
the distance from the bottom of the blade to the floor. Re­
peat the measurement on the opposite side of the deck.
If the two distances differ by more than 1/4 inch (6 mm)
proceed to step 9 and add shims as instructed.
9. Remove capscrews, flatwashers, lockwashers and
nuts from outer spindle in the area where shims must be
added. To raise or lower the blade, add a shim, Part No.
3256–24, between spindle housing and bottom of cut­
ting unit. Continue to check alignment of blades and add
shims until tips of blades are within the required dimen­
sion.
IMPORTANT: Do not use more than three shims at
any one hole location. Use decreasing numbers of
shims in adjacent holes if more than one shim is
added to any one hole location.
10. Re–tension belts. Re–install belt covers.
Page 9 – 18
Groundsmaster 3000/3000–D
2
8
4
3
12
15
5
1
6
7
9:3
8
9:2
9
10
13
11
12
14
22
21
17
16
20
19
19:1
170 – 190 in–lb
(196 – 219 Kgcm)
Figure 31
1. Gearbox
2. Shroud
3. Lock nut
4. Drive shaft
5. Roll pin
6. Screw
7. Lock nut
8. Flat washer
Groundsmaster 3000/3000–D
9. Gearbox mount
9:2. Lube decal
9:3. Threaded insert
10. Rubber mount
11. Screw
12. Screw
13. Rubber bumper
14. Rivet
Page 9 – 19
15. Latch plate
16. Screw
17. Woodruff key
19. Taper lock bushing
19:1. Set screw
20. Gearbox pulley
21. Pop rivet
22. Serial plate
84 inch Cutting Units
84 inch
Cutting Units
Gearbox
4
15
14
13
2
16
12
1
17
9
4
11
5
3
5
2
18
20
21
7
19
8
10
6
22
23
2
Figure 32
1. Housing
2. Capscrew
3. Cap
4. Bearing cone
5. Bearing cup
6. R.H. gear
7. Bearing cup
8. Bearing cone
9. Spacer
10. Lower shaft
11. Upper seal
12. Cap
13. Gasket (.015)
14. Gasket (.005)
15. Gasket (.003)
16. Upper shaft
17. L.H. gear
18. Plug
19. Lower seal
20. Bearing cone
21. Bearing cup
22. Cap
23. Washer
Shaft End Play Adjustment
The lower shaft (Fig. 28, Item 10) and upper shaft (16)
should have a very small amount of bearing drag. If the
shaft turns hard, the cap (12) or (22) must be removed
and gaskets (13, 14, or 15) need to be added. If the shaft
has no bearing drag, or has end play, the cap must be
removed and gaskets taken out. The cap must be ad­
justed so the shaft has no end play and only a slight
amount of bearing drag.
84 inch Cutting Units
Page 9 – 20
Groundsmaster 3000/3000–D
84 inch
Cutting Units
Drive Shaft
2
4
8
5
7
3
6
Figure 33
2. Yoke
3. U–joint kit
4. Slip yoke shaft
Groundsmaster 3000/3000–D
5. Slip yoke tube
6. Yoke
Page 9 – 21
7. Grease fitting
8. Grease fitting
84 inch Cutting Units
84 inch Cutting Units
Page 9 – 22
Groundsmaster 3000/3000–D
Chapter 10
Contour 82 Cutting Unit
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Height of Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Deck Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 7
Grease Bearings and Bushings . . . . . . . . . . . . . . . . 7
Disconnect Cutting Unit from Traction Unit . . . . . . 8
Connect Cutting Unit to Traction Unit . . . . . . . . . . . 9
Front Castor Fork Bushing Service . . . . . . . . . . . . 10
Castor Wheel and Bearing Service . . . . . . . . . . . . . 11
Cutting Blade Removal and Installation . . . . . . . . 12
Inspecting and Sharpening Blades . . . . . . . . . . . . 13
Correcting Cutting Unit Mismatch . . . . . . . . . . . . . 14
Chamber Pivot Service . . . . . . . . . . . . . . . . . . . . . . 15
Lift Arm Ball Joint Installation . . . . . . . . . . . . . . . . . 18
Hydraulic Motor and Blade . . . . . . . . . . . . . . . . . . . 19
Blade Spindle Service . . . . . . . . . . . . . . . . . . . . . . . 20
Hydraulic Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 1
Groundsmaster 3000/3000–D
Page 10 – 1
Rev. C
Contour 82 Cutting Unit
Contour 82
Cutting Unit
Table of Contents
Specifications
Deck Configuration: Out front deck with a right hand
trim offset. Four individual chambers jointed for articulation. One blade per chamber.
Cutting Width: 82 inches (2.1 m).
Chamber Housing: 12 GA. steel, 4.5 inch (114 mm)
deep, welded construction and reinforced with 10 GA
high strength formed plates.
Height–of–Cut (HOC): 1 inch (25 mm) to 4 inch (102
mm) by 1/4 inch (6 mm) increments.
Blade Size: Four 22 inch (559 mm) long by 2.50 inch (64
mm) wide by .25 inch (6 mm) thick heat treated steel with
formed parallel sails.
Blade Overlap: 2 inch (51 mm) in the flat configuration.
Blade Drive: Hydraulic drive via a PTO driven high efficiency gear pump on the traction unit integrated hydrostatic transaxle (IHT). Four integrated spindle motors
operated in a series configuration through SAE–10
(.625) high pressure wear resistant hoses with high density polyethylene protective tubing. Spindle motor is a
high efficiency pressure balanced gear motor with a direct drive to the spindle shaft operating in a constant wet
lubrication on two Teflon coated journal bearings.
Welded blade retainers mounted through a tapered joint
with a 2 inch (51 mm) high outer shield to protect spindle
seals. Hydraulic braking valve set to 600 PSI (41 Bar) to
achieve a complete blade stopping time of 5 seconds
from full engine (PTO) speed.
Blade Speed: 15,724 feet (4,793 m) per minute tip
speed (2730 rpm spindle speed) at 2795 rpm on diesel
models and 3275 on gas models.
Suspension & Castor Wheels: Five front castors and
three rear castors, consisting of 8 inch (203 mm) pneumatic wheels with sealed ball bearings. One rear link
suspended from the right lift arm. Hydraulic counter balance and lift system designed integral with deck for maximum floatation.
Anti–Scalp Features: 11 inch (279 mm) diameter anti
scalp cups located .75 inch (19 mm) below each blade.
Adjacent chambers pivot freely about two independent
60 opposed hinges down –20 and up +20. 1 inch
(25 mm) diameter anti–scalp/wear skids located on
each outside chamber.
Discharge: Evenly dispersed rear discharge between
the outside width of the deck with partial recycling rear
baffles.
Lift/Transport: Stainless steel cables from outside
chambers to nearest lift arm actuated via a lever on the
lift arms. Complete deck is lifted via the traction unit lift
system.
Counter–Balance: Recommended operating counter
balance pressure of 125 PSI (9 Bar) set by an adjustable
counter balance valve on the traction unit.
Overhang/Trim: Deck is offset to the right of the traction
unit to provide overhang of 21 inch (533 mm) on the right
and 8.25 inch (210 mm) on the left with deck in a flat configuration. Uncut circle is 16 inch (406 mm) on right with
no brakes.
Covers: No complete deck covers required. Hydraulic
hoses to be covered per ANSI/ISO standards.
Connect/Disconnect: Use existing GM 3000 style of
quick attach lift arm system. For ease of cleaning and
maintaining oil cleanliness, the hydraulic lines use flush
face quick couplers for pressure supply line, return line,
braking sense line, and motor case drain line.
Sound Levels: Operator ear to be 90 dBA per SAE
measuring standards.
Safety: Deck and traction unit to comply with ANSI
B71.4–1990 and CE compliance.
Productivity: Mows up to 4.6 acre (1.86 hectare) per
hour at 5.5 mph (9 km/hr)
Approach Angle: Minimum approach angle (for trailering) of 11.5 at highest HOC setting.
Weight: 745 lbs (338 Kg).
Specifications and design subject to change without notice.
Contour 82 Cutting Unit
Page 10 – 2
Groundsmaster 3000/3000–D
Adjustments
The height–of–cut is adjustable from 1 to 4 inches (25 to
102 mm) in 1/4 inch (6 mm) increments.
2
1. Start the engine and raise the cutting unit so height–
of–cut can be changed. Stop engine after cutting unit is
raised.
3
Front Castor Wheels
4
Contour 82
Cutting Unit
Height of Cut Adjustment
1. Remove H.O.C. cap from spindle shaft and slide
spindle out of front castor arm. Slide spacers onto
spindle shaft to get desired height–of–cut.
4
2. Push castor spindle through front castor arm install
remaining spacers onto spindle and install HOC cap to
secure assembly.
1
Figure 2
1.
2.
3.
4.
Front castor wheel
H.O.C. Cap
Spacer
Washer
Figure 3
Groundsmaster 3000/3000–D
Page 10 – 3
Contour 82 Cutting Unit
Rear Castor Wheels
1
1. Remove hairpin cotter and cotter pin securing rear
castor pivot arm to deck bracket.
2. Align the pivot arm holes with selected height–of–
cut bracket holes in the deck frame, install cotter pin and
secure with hairpin cotter.
Figure 4
1. Rear Castor Pivot
Figure 5
Contour 82 Cutting Unit
Page 10 – 4
Groundsmaster 3000/3000–D
Rear Deck Chain
1. Remove hair pin cotter and clevis pin securing
height–of–cut chain to chamber bracket.
2. Mount height–of–cut chain to desired height–of–cut
hole with clevis pin and hair pin cotter.
3. Verify deck pitch on No. 3 chamber. Refer to Adjusting Deck Pitch.
Contour 82
Cutting Unit
1
Figure 6
1. Height–of–Cut chain
Figure 7
Groundsmaster 3000/3000–D
Page 10 – 5
Contour 82 Cutting Unit
Deck Pitch Adjustment
Deck pitch is the difference in height–of–cut from the
front of the blade plane to the back of the blade plane.
For the Contour 82, TORO recommends a blade pitch of
7/16 inch (11 mm). That is the back of the blade plane is
7/16 inch (11 mm) higher than the front.
1. Position machine on a level surface on shop floor.
2. Set deck to the desired height–of–cut.
3. Rotate No. 3 chamber blade so it points straight forward.
1
4. Using a short ruler, measure from floor to front tip of
blade. Then, measure from floor to rear tip of blade.
5. Subtract the front dimension from rear dimension to
calculate your pitch.
6. To adjust pitch, start traction unit and raise deck to
highest possible position and turn off engine.
7. Loosen jam nuts on top or bottom of Height–of–Cut
chain U–bolt.
Figure 8
1. Height–of–Cut chain
8. Adjust other set of nuts to raise or lower rear of No. 3
chamber and attain correct deck pitch.
9. Tighten jam nuts.
10. Lower deck.
Contour 82 Cutting Unit
Page 10 – 6
Groundsmaster 3000/3000–D
Service and Repairs
CAUTION
Grease Bearings and Bushings
The cutting unit must be lubricated regularly. If machine
is operated under normal conditions, lubricate castor
bearings and bushings with No. 2 general purpose lithium base grease or molybdenum base grease, after every 50 hours of operation. Lubricate fittings immediately
after every washing, regardless of the interval listed.
1. The cutting unit has (19) bearings and bushings that
must be lubricated, and these lubrication points are:
front castor shaft bushings (5), chamber pivots (12) and
right and left push arm ball joints (2).
Figure 9
Groundsmaster 3000/3000–D
Page 10 – 7
Contour 82 Cutting Unit
Contour 82
Cutting Unit
To prevent accidental starting of the engine,
while performing maintenance, shut engine off
and remove key from ignition switch.
Disconnect Cutting Unit from Traction Unit
Note: Implements are heavy and may require two
people to handle.
1. Start traction unit and raise deck to highest possible
position and turn off engine.
2. Remove hair pin cotter and clevis pin securing
height–of–cut chain to rear height–of–cut brackets on
chamber 3.
1
3. Rotate ignition key to run position and move lift lever
forward to lower cutting unit.
4. Raise seat and open needle valve. This allows lift
arms to float freely.
5. Remove hair pin cotter and clevis pin securing latch
cover to lift arm .
Figure 11
6. Loosen release lever by rotating it counterclockwise.
1. Needle Valve
7. Pivot release lever upward and remove shaft latch
from slot in traction unit lift arm.
5
1
8. Disconnect hydraulic line quick couplers from traction unit.
3
9. Stay clear of lift arms and move deck away from
traction unit allowing lift arms to fall.
10. Secure hair pin cotter and clevis pin to height–of–
cut chain for storage.
2
4
11. Close needle valve
Figure 12
1. Latch Cover
2. Release Lever
3. Shaft latch
4. Traction Unit Lift Arm
5. Machined Surface
1
Figure 10
1. Height–of–Cut chain
Figure 13
Contour 82 Cutting Unit
Page 10 – 8
Groundsmaster 3000/3000–D
Connect Cutting Unit to Traction Unit
1. Center traction unit in front of cutting unit on any flat
hard surface.
3. Adjust lift arms heights making sure that the machined surface on top of each traction unit lift arm is parallel to ground (Fig. 12). (Raise or lower lift arm casting
by pushing up or down from behind the front tires or using wrench in front of traction unit)
Contour 82
Cutting Unit
2. Raise seat and open needle valve. This allows lift
arms to float freely.
1
4. Check for dirt and debris on mating parts and clean
as required.
5. Turn castor wheels so they point straight forward.
6. Secure first lift arm assembly to traction unit as follows:
Figure 14
A. Remove hair pin cotter and clevis pin securing
latch cover to lift arm.
1. Height–of–Cut chain
B. Pivot release lever upward.
C. Slide cutting unit lift arm onto traction unit lift
arm, inserting shaft latch into slot in traction unit
lift arm.
Note: If latch does not fall into slot in traction unit
lift arm, raise or lower lift arm casting by pushing
up or down from behind the front tires.
1
D. Pivot release lever downward and tighten se-
curely by rotating clockwise.
7. Install other lift arm on traction unit by rotating deck
towards traction unit, aligning lift arm to traction unit arm
and repeating step 5. If latch does not fall into slot in traction unit lift arm the arms are not lined up.
Figure 15
A. If lift arms on traction unit are not at the correct
height for deck arms to slide on, push up or down
on lift arm castings from behind the front tires until
deck arm line up and slide on.
1. Needle Valve
B. If lift arms on deck do not line up side to side.
Rotate castor wheels side ways so deck moves
side to side easier. Move deck side to side until lift
arms line up and slide on.
8. Move deck from side to side to check for tightness
and re–tighten latches, if required.
5
1
3
2
4
9. Install latch covers to lift arms and secure with clevis
pins and hair pin cotters.
10. Clean hydraulic coupler with a clean rag and connect hydraulic lines to traction unit.
Figure 16
11. Close needle valve and lower seat.
12. Start traction unit and raise deck to highest possible
position and turn off engine.
1. Latch Cover
2. Release Lever
3. Shaft latch
4. Traction Unit Lift Arm
5. Machined Surface
13. Align height–of–cut chain on chamber 3 with hole
for desired height–of–cut, install clevis pin and secure
with hair pin cotter.
Groundsmaster 3000/3000–D
Page 10 – 9
Contour 82 Cutting Unit
Front Castor Fork Bushing Service
The castor forks have bushings pressed into the top and
bottom of the chamber and after many hours of operation, the bushings will wear. To check the bushings,
move castor fork back and forth and from side to side. If
castor spindle is loose around the bushings, bushings
are worn and must be replaced.
1
1. Lock transport levers, raise cutting unit to highest
position, shut the engine off and engage the parking
brake.
2
2. Remove front height–of–cut caps from castor forks
and slide castor wheel assembly out of castor arm tube.
3. Insert pin punch into top or bottom of chamber and
drive bushing out. Repeat for other bushing. Clean inside of bushing hubs to remove dirt.
2
Figure 17
1. Castor arm tube
2. Bushing
4. Apply grease to inside and outside of new bushings.
Using a hammer and flat plate, drive bushings into
chamber housing.
5. Inspect castor shaft and fork for wear and replace if
damaged.
6. Push castor shaft through bushings and secure with
height–of–cut caps
Contour 82 Cutting Unit
Page 10 – 10
Groundsmaster 3000/3000–D
Castor Wheel and Bearing Service
1. Lock transport levers, raise cutting unit to highest
position, shut the engine off and engage the parking
brake.
60 – 80 ft–lb
(8 – 11 Kgm)
1
2
Contour 82
Cutting Unit
2. Remove locknut from capscrew holding castor
wheel assembly between front castor fork (Fig. 18) or
rear castor pivot arm (Fig. 19) Grasp castor wheel and
slide capscrew out of fork or pivot arm.
2. Remove bearing from wheel hub and allow bearing
spacer to fall out. Remove bearing from opposite side of
wheel hub.
3. Check the bearings, spacer and inside of wheel hub
for wear. Replace defective parts.
4. To assemble the castor wheel, push bearing into
wheel hub. Slide bearing spacer into wheel hub. Push
other bearing into open end of wheel hub to captivate the
bearing spacer inside the wheel hub.
5. Install castor wheel assembly between castor fork
and secure in place with capscrew and locknut. Torque
to 60 – 80 ft–lb (8 – 11 Kgm).
3
4
Figure 18
1. Castor wheel
2. Front Caster Fork
3. Bearing (2)
4. Bearing spacer
3
2
4
1
60 – 80 ft–lb
(8 – 11 Kgm)
Figure 19
1. Castor wheel
2. Rear Caster Pivot Arm
Groundsmaster 3000/3000–D
Page 10 – 11
3. Bearing (2)
4. Bearing Spacer
Contour 82 Cutting Unit
Cutting Blade Removal and Installation
The blade must be replaced if a solid object is hit, the
blade is out–of–balance or if the blade is bent. Always
use genuine TORO replacement blades to be sure of
safety and optimum performance. Never use replacement blades made by other manufacturers because
they could be dangerous.
1. Lock transport levers, raise cutting unit to highest
position, shut the engine off and engage the parking
brake.
3
2
85 – 110 ft–lb
(12 – 15 Kgm)
2. Grasp end of blade using a rag or thickly padded
glove. Remove blade bolt, anti–scalp cup and blade
from spindle shaft.
3. Install blade (sail facing (up) toward cutting unit)
with anti–scalp cup and blade bolt. Tighten blade bolt to
85–110 ft–lb (12 – 15 Kgm).
1
Figure 20
1. Blade bolt
2. Anti–Scalp Cup
3. Blade
WARNING
Do not try to straighten a blade that is bent, and
never weld a broken or cracked blade. Always use
a new blade to assure continued safety certification of the product.
Contour 82 Cutting Unit
Page 10 – 12
Groundsmaster 3000/3000–D
Inspecting and Sharpening Blade
1. Lock transport levers, raise cutting unit to highest
position, shut the engine off and engage the parking
brake.
Contour 82
Cutting Unit
2. Examine cutting ends of the blade carefully, especially where the flat and curved parts of the blade meet
(Fig. 21–A). Since sand and abrasive material can wear
away the metal that connects the flat and curved parts of
the blade, check the blade before using the machine. If
wear is noticed (Fig. 21–B), replace the blade: refer to
Removing Cutter Blade.
DANGER
If blade is allowed to wear, a slot will form
between the sail and flat part of the blade
(Fig. 21–C). Eventually a piece of the blade
may break off and be thrown from under the
housing, possibly resulting in serious injury to
yourself or bystander.
3. Inspect cutting edges of all blades. Sharpen the cutting edges if they are dull or nicked. Sharpen only the top
of the cutting edge and maintain the original cutting
angle for best performance (Fig. 22). The blade will remain balanced if same amount of metal is removed from
both cutting edges.
Figure 21
SHARPEN AT THIS
ANGLE ONLY
END VIEW
Figure 22
4. To check blade for being straight and parallel, lay
blade on a level surface and check its ends. Ends of
blade must be slightly lower than the center, and cutting
edge must be lower than the heel of the blade. This
blade will produce good quality of cut and require minimal power from the engine. By contrast a blade that is
higher at the ends than the center, or if cutting edge is
higher than the heel, the blade is bent or warped and
must be replaced.
5. Install blade retainer, blade (sail facing (up) toward
cutting unit) with anti–scalp cup and blade bolt. Tighten
blade bolt to 85–110 ft–lb (12 – 15 Kgm).
Groundsmaster 3000/3000–D
Page 10 – 13
Contour 82 Cutting Unit
Correcting Cutting Unit Mismatch
If there is mismatch between the blades, the grass will
appear streaked when it is cut. This problem can be corrected by making sure the blades are straight and all
blades are cutting on the same plane.
1. Raise the height–of–cut to the highest position and
lower deck to the floor.
2. Position machine on a level surface on the shop
floor.
3. Shut engine off and engage the parking brake. Unlock transport levers.
4. Position the tip of an outer blade and adjacent blade
tip as close together as possible at the intersection of the
two cutting chambers. Note the height of the outer blade
tip with respect to the adjacent blade tip.
5. Rotate outer blade 180 and note the height of the
outer blade tip with respect to the adjacent blade tip. If
the relative height changed by more than 1/8 inch (3
mm) after rotating blade, then outer blade is bent and
should be replaced.
Note: When the blade cutting tips are rotated to their
closest point, the blade in the forward chamber should
be .20 ".13 inch (5 + 3 mm) above the blade of the more
rearward chamber. This is caused by the tilting of each
motor spindle in each individual chamber. The blade
rake is accomplished by titling each spindle rather that
tilting the entire deck. Even with this “apparent mismatch”, the after cut appearance will not show a mismatch because each chamber overlaps the adjacent
chamber by 2 inch (51 mm).
Contour 82 Cutting Unit
6. Repeat steps 3 and 4 until all pairs of adjacent
blades have been checked at both blade tips. Note the
relative difference in blade height at each blade intersection after replacing any bent blades. This height difference should be less than 1/8 inch (3 mm) for all
adjacent blades.
7. Rotate an outer blade until the tip is positioned toward the side of the deck housing. Measure the distance
from the bottom of the blade to the floor. Repeat the
measurement on the opposite side of the deck. If the two
distances differ by more than 1/4 inch (6 mm) proceed to
step 8 and add shims as instructed.
8. Remove capscrews, flatwashers, lockwashers and
nuts from outer spindle in the area where shims must be
added. To raise or lower the blade, add a shim, Part No.
3256–24, between spindle housing and bottom of cutting unit. Continue to check alignment of blades and add
shims until tips of blades are within the required dimension.
IMPORTANT: Do not use more than three shims at
any one hole location. Use decreasing numbers of
shims in adjacent holes if more than one shim is
added to any one hole location.
Page 10 – 14
Groundsmaster 3000/3000–D
Chamber Pivot Service
If cutting unit chamber pivot assemblies should ever
have to be separated for service or repair, use the following procedure.
1
1. Pivot assembly dis–assembly.
A. Remove capscrews and nut from pivot cast-
ing.
Contour 82
Cutting Unit
B. Loosen capscrew locking eccentric cam in
place.
C. Using a 1/2 inch (13 mm) diameter drive pin,
drive pilot pin 3/8 inch (10 mm) to 1/2 inch (13 mm)
into pivot casting.
D. Slide pivot assembly out of chamber housing.
2. Ball joint removal from pivot assembly
Figure 23
1. Chamber pivots
A. Remove the lock nuts from the ball joint studs.
B. Separate span casting from ball joints, Using
an expansion fork and soft (lead) hammer.
3
C. Slide tapered sleeve out of span casting. and
save this part.
D. Remove retaining rings from back side of ball
joints.
E. Using a press, push ball joints out of pivot cast-
ing. The front (top) ball joint should be removed
first.
2
6
4
7
1
4
5
Figure 24
1.
2.
3.
4.
Groundsmaster 3000/3000–D
Page 10 – 15
Pivot casting
Pivot pin
Eccentric cam
Ball joint
5. Span casting
6. Tapered sleeve
7. Pivot spacer (2)
Contour 82 Cutting Unit
3. Pivot assembly re–assemble.
A. Press ball joints into pivot casting. Bottom ball
joint first.
3
B. Insert and orientate grease fittings to face upward.
C. Install retaining rings on back side of ball
joints.
D. Clean any debris, oil, or dirt from tapered joints
on span casting and tapered sleeve. Any nicks
should be filed off.
E. Install pivot casting into chamber housing with
spacer plate on top and bottom of pivot casting.
2
6
F. Install pilot pin into 5/8 inch (16 mm) diameter
“pivot” hole and drive flush with top surface of
chamber housing.
4
G. Install eccentric cam through assembly with
identification mark facing forward. Use a small
amount of anti–seize compound on the diameter
interface between eccentric cam and pivot casting.
7
H. Install 7/16 inch grade 8 fasteners (and thick
washers) and tighten assembly such that eccentric cam can still rotate pivot casting in chamber
housing.
I. Install span casting over ball joints in pivot
casting.
J. Use a soft mallet, tap tapered sleeve into place
in top ball joint position.
1
4
5
Figure 25
1.
2.
3.
4.
Pivot casting
Pivot pin
Eccentric cam
Ball joint
5. Span casting
6. Tapered sleeve
7. Pivot spacer (2)
K. Torque ball joints as follows:
IMPORTANT: Failure to torque ball joints as follows can result in premature wear of ball joints
due to pre–load applied to ball joint sockets.
Bottom ball joint nut
Top ball joint nut
Bottom ball joint nut
Top ball joint nut
50 ft–lbs (7 Kgm)
50 ft–lbs (7 Kgm)
125 ft–lbs (17 Kgm)
125 ft–lbs. (17 Kgm)
NOTE: It is NOT recommended to use slotted
nuts on ball joints due to the need to over tighten
or back–off slotted nuts and to align cross holes
for use with a cotter pin.
Contour 82 Cutting Unit
Page 10 – 16
Rev. A
Groundsmaster 3000/3000–D
4. Adjustment of Chamber Pivots.
A. Set deck to its maximum height of cut: 4 inches
(102 mm).
3
B. Place the deck on a level surface with the lock
and lift cables in the unlocked position.
D. Use two 1–1/4 inch wrenches on the eccentric
cam to rotate simultaneously. Verify that identification mark on top of each eccentric cam is facing
forward.
2
E. Rotate adjacent blades until cutting edge tips
are aligned directly across from each other as
shown in figure 27.
6
4
F. Rotation of outboard eccentric cam will primarily effect blade gap and inboard eccentric cam will
primarily effect chamber front alignment.
7
G. Rotate eccentric cam’s until blade tips are
touching each other and chamber fronts are
aligned parallel.
H. Apply a small force (10–15 lbs / 5–7 Kg) to
back of chambers. Be sure non–rotating rear castors are free to slide along floor. This will remove
any back–lash in system.
I. Rotate outboard eccentric cam until blade tips
are .25 .03 inches (6 + 1 mm) apart.
J. Tighten capscrew against eccentric cam’s.
Secure jam nut against the threaded “C” shaped
wall.
1
4
5
Figure 26
1.
2.
3.
4.
Pivot casting
Pivot pin
Eccentric cam
Ball joint
5. Span casting
6. Tapered sleeve
7. Pivot spacer (2)
Front Part Of Blade
Sail
K. Secure 7/16 grade 8 capscrews and nut on
pivot casting and tighten to a torque of 80 ft–lbs
(11 Kgm). in the following order:
1. Capscrew and nut through the eccentric cam.
2. Capscrew without pilot pin.
3. Capscrew with pilot pin (pivot point of casting).
1/4 inch (6 mm)
Figure 27
Groundsmaster 3000/3000–D
Page 10 – 17
Contour 82 Cutting Unit
Contour 82
Cutting Unit
C. Tighten capscrew against the eccentric cam,
then, back off 1/2 turn.
Lift Arm Ball Joint Installation
Lift arm ball joints have been adjusted at the factory. The
proper setting of left hand ball joint is 1.75 inch (45 mm)
from end of lift arm to center of tapered stud (Fig. 28).
The proper setting of right hand ball joint is 2.09 inch (53
mm) from end of lift arm to center of tapered stud (Fig.
29). These distances can be adjusted if deck alignment
to traction unit is off or if the deck rubs against traction
tires.
140 ft–lb (19 Kgm)
then continue tightening
until slot in nut aligns
with cotter pin hole
1.75 in. (45 mm)
1
Figure 28
1. Left ball joint
2.09 in. (53 mm)
1
140 ft–lb (19 Kgm)
then continue tightening
until slot in nut aligns
with cotter pin hole
Figure 29
1. Right ball joint
Contour 82 Cutting Unit
Page 10 – 18
Groundsmaster 3000/3000–D
Hydraulic Motor and Blade
5
1
6
2
Contour 82
Cutting Unit
7
3
4
8
9
10
85 – 110 ft–lb
(12 – 15 Kgm)
11
12
Figure 30
1. Motor
2. O–ring
3. Spindle Assy
4. Support plate
Groundsmaster 3000/3000–D
5. Screw
6. Washer
7. Locknut
8. Screw
Page 10 – 19 Rev. C
9. Blade
10. Anti scalp cup
11. Hardended washer
12. Blade screw
Contour 82 Cutting Unit
Blade Spindle Service
Disassembly
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
6
131 to 159 ft–lb
(178 to 216 N–m)
2
Chamfer side down
2. Remove two cap screws that secure hydraulic motor
to the cutting unit. Remove hydraulic motor and O–ring
from deck (Fig. 30).
4
8
1
10
3. Start the engine and raise the cutting unit. Stop engine and remove key from the ignition switch. Block up
the cutting unit so it cannot fall accidentally. If required
for easier service, remove cutting unit (see Disconnect
Cutting Unit From Traction Unit).
7
9
4. Remove cutting blade, anti–scalp cup and bolt (see
Cutting Blade Removal and Installation).
12
4
8
5
5. Remove cap screws and lock nuts securing spindle
housing to deck. Remove spindle assembly. Remove
spindle plate from under deck (Fig. 30).
3
6. Loosen and remove spindle nut from top of spindle
shaft (Fig. 31).
7. Press the spindle shaft out of the spindle housing using an arbor press. The shaft spacer remains on the
spindle shaft as the shaft is being removed.
8. Remove seals from spindle housing.
Figure 31
1.
2.
3.
4.
5.
6.
Spindle housing
Seal spacer
Spindle shaft
Oil seal
Shaft spacer
Spindle nut
7.
8.
9.
10.
11.
12.
Grease fitting
Bearing
Spacer ring
Spacer set (2 piece)
Bearing
Large snap ring
9. Allow the bearings, inside spacer and spacer ring to
fall out of the spindle housing.
10.Using a punch and hammer, drive both of the bearing
cups out of the spindle housing. Also drive the large
spacer out of the housing.
11. The large snap ring should remain inside the spindle
housing because it is difficult to remove.
Contour 82 Cutting Unit
Page 10 – 20
Rev. C
Groundsmaster 3000/3000–D
IMPORTANT: If new bearings will be installed into a
used spindle housing that has the original large
snap ring installed, discard the snap ring that came
with the new bearings because it is not necessary
to replace the original snap ring. However, new
bearings with their matched spacer set and snap
ring must always be installed when the spindle
housing is being replaced. Replacement bearings
are sold only with a matched snap ring and spacer
set. These parts cannot be purchased separately.
1. If large snap ring was removed, or if replacing the
spindle housing, install snap ring into spindle housing
groove. Make sure snap ring is seated in groove.
IMPORTANT: If bearings are being replaced, make
sure to use the large spacer, inside spacer, and
spacer ring that are included in new bearing set.
11. Install spindle housing and spindle plate to deck with
cap screws and lock nuts. Notches on housing and plate
should be aligned to front of deck.
12.Install cutting blade, anti–scalp cup and bolt (see
Cutting Blade Removal and Installation). Tighten blade
bolt from 85 to 110 ft–lb (115 to 149 N–m).
13.Position O–ring to top of spindle housing. Install hydraulic motor to the cutting unit with two cap screws.
IMPORTANT: When greasing spindles, grease
passes into the center of the shaft and out to fill the
bearing cavity of the housing. If grease does not
come out of lower seal when greasing, check lubrication hole in spindle shaft for obstruction.
14.Attach a hand pump grease gun to either grease fitting and fill housing cavity with grease until grease starts
to come out of lower seal. NOTE: Pneumatic grease
guns can produce air pockets when filling large cavities.
2. Using an arbor press, push large spacer into top of
spindle housing. The spacer should fit tightly against the
snap ring.
3. Thoroughly oil the bearing cups. Using an arbor
press, push the bearing cups into the top and bottom of
the spindle housing. The top bearing cup must contact
the spacer previously installed, and the bottom bearing
cup must contact the snap ring. Make sure that the assembly is correct by supporting the first bearing cup and
pressing the second against it (Fig 32).
PRESS
4
3
1
2
5
6
4. Pack the bearing cones with grease. Apply a film of
grease on lips of seals.
5. Install lower bearing and seal into bottom of spindle
housing. Note: The bottom seal must have the lip facing
out (down) (Fig. 33).
Figure 32
1. Bearing cups
2. Large snap ring
3. Large spacer
6. Slide spacer ring and inside spacer into spindle
housing, then install upper bearing and seal into top of
housing. Note: The upper seal must have the lip facing
out (up) (Fig. 33).
4. Arbor press
5. Support
6. Arbor press base
2
7. Inspect the spindle shaft to make sure it is free of
burrs or nicks that could possibly damage the seals.
Also, make sure that lubrication hole in shaft is clean.
Lubricate the shaft with grease.
8. Install spindle spacer onto shaft. Carefully slide
spindle shaft through spindle housing. The bottom seal
and spindle spacer fit together when the spindle is
installed fully.
1
9. Install seal spacer with chamfer side down (Fig. 32).
10.Thread spindle nut onto shaft and tighten nut from
131 to 159 ft–lb (178 to 216 N–m).
Groundsmaster 3000/3000–D
Figure 33
1. Bottom seal installation
Page 10 – 21 Rev. C
2. Upper seal installation
Contour 82 Cutting Unit
Contour 82
Cutting Unit
Assembly
Hydraulic Assembly
1
2:1
2
2:2
1:1
3
4
4:1
5
Hydraulic Flow Direction
Inlet
Outlet
Case drain
2
6:2
6
6:1
7
8
12:1
12
11
11:1
11
11:1
11:2
9:2
10
9
9:1
Figure 34
1. Hose
1:1 O–ring
2. Hydraulic fitting
2:1. O–ring
2:2. O–ring
3. Coupler
4. Hose
5. Coupler
6. Hydraulic fitting
6:1. O–ring
6:2. O–ring
7. Hose
8. Hose
9. Hydraulic fitting
10. Hose
11. Tee
11:1. O–ring
11:2. O–ring
12. Hydraulic fitting
12:1. O–ring
NOTE: See Chapter 5 – Hydraulic System for hydraulic
test information.
Contour 82 Cutting Unit
Page 10 – 22
Rev. C
Groundsmaster 3000/3000–D
Chapter 11
72I Cutting Units
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport Latch Adjustment . . . . . . . . . . . . . . . . . . .
Height of Cut Adjustment . . . . . . . . . . . . . . . . . . . . .
Skid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Anti–Scalp Roller Adjustment (Rear Discharge) . .
Gage Wheel Adjustment (Guardian Recycler) . . .
Deck Pitch Adjustment . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Check Gear Box Lubricant . . . . . . . . . . . . . . . . . . . .
Replace Gear Box Lubricant . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
3
3
4
5
6
6
7
8
8
8
9
Disconnecting Cutting Unit from Traction Unit . . 10
Connecting Cutting Unit to Traction Unit . . . . . . . . 11
Install Lift Arm Ball Joints . . . . . . . . . . . . . . . . . . . . . 11
Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . 12
Front Castor Fork Service . . . . . . . . . . . . . . . . . . . 13
Castor Wheel and Bearing Service . . . . . . . . . . . . 14
Cutter Blade Removal and Installation . . . . . . . . . 15
Inspecting and Sharpening Blade . . . . . . . . . . . . . 16
Blade Spindle Service . . . . . . . . . . . . . . . . . . . . . . . 17
Cutting Unit Mismatch . . . . . . . . . . . . . . . . . . . . . . . 19
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 1
Groundsmaster 3000/3000–D
Page 11 – 1
72 inch Cutting Units
72 inch
Cutting Units
Table of Contents
Specifications
Type: 72 inch (1.8 m) width of cut, 3 blades.
Height Of Cut: 1 to 5 inches (25 to 127 mm) adjustable
in 1/2 inch (13 mm) increments. Front adjustment is with
snapper pin and grooves in castor shaft. Rear adjust­
ment is with hanger brackets and pin.
Construction: Housing is made of 12 gauge steel and
reinforced with 2–1/2 inch x 10 gauge angle.
Cutter Drive: Gear box mounted on cutting unit is driven
by PTO shaft. Power is transmitted to the blades by one
hex B section belt. Spindle shafts are 1–1/4 inch (32
mm) diameter and supported by two externally sealed,
greaseable, tapered roller bearings.
Blades: Three 25.18 in. (716 mm) long, .25 in. (6 mm)
thick, heat–treated steel. Patent Pending.
Suspension & Castor Wheels: Two front castors, con­
sisting of 10 in. (254 mm) pneumatic wheel and tire as­
sembly with sealed ball bearings. Rear of deck is
suspended from lift arms with adjustable deck rake. Hy­
draulic counter balance and lift system designed inte­
gral with deck for maximum flotation.
Anti–scalp Features: Anti–scalp cup located on each
blade. Two gauge wheels. Adjustable skid on each end
of deck.
Deck Covers: 16 gauge steel covers.
Quick Attach System: Tapered joint with over center
adjustable tensioning latch.
Weight: Rear Discharge 545 lbs. (247 Kg). Guardian
Recycler 555 lbs. (252 Kg).
Specifications and design subject to change without notice.
72 inch Cutting Units
Page 11 – 2
Rev. A
Groundsmaster 3000/3000–D
Adjustments
Transport Latch Adjustment
1. Start tractor and raise deck to highest possible posi­
tion and turn off engine.
2
2. Loosen (2) flange head capscrews securing latch
plate to side of gearbox.
3. Rotate latch rod downward from front of traction
unit.
1
4. Insert latch rod into rear hole (transport position) in
latch plate.
6. Loosen latch plate flange head capscrews and ad­
just latch plate position if required.
7. Tighten flange head capscrews securing latch plate
to gearbox.
Figure 2
(Rear Discharge)
1. Latch Plate
2. Latch Rod
8. Remove hair pin cotters and clevis pins securing
height–of–cut chains to rear of deck.
9. Remove latch rod from rear hole in latch plate.
2
1
Figure 3
(Guardian Recycler)
1. Latch Plate
2. Latch Rod
Groundsmaster 3000/3000–D
Page 11 – 3
72 inch Cutting Units
72 inch
Cutting Units
5. Rotate front of deck upward and insert latch rod into
front hole (service position) in latch plate.
Height of Cut Adjustment
The height–of–cut is adjustable from 1 to 5 inches (25 to
127 mm) in 1/2 inch (13 mm) increments.
1. Start engine and raise cutting. Stop engine after cut­
ting unit is raised.
1
2. Remove front snapper pins from castor arms and
slide castor wheel assembly up or down.
3. Insert snapper pin into castor arm and through
groove in castor shaft to get desired height–of–cut.
4. Remove hair pin cotter and clevis pin securing
height–of–cut chain to rear of deck.
5. Mount height–of–cut chain to desired height–of–cut
hole with clevis pin and hair pin cotter.
Figure 4
1. Snapper Pin
6. When using 1 inch (25 mm) height–of–cut, move
skids and gage wheels to the highest holes.
Figure 5
1
Figure 6
1. Height–of–Cut chain
Figure 7
72 inch Cutting Units
Page 11 – 4
Groundsmaster 3000/3000–D
Skid Adjustment
1. Adjust skids by loosening flange nuts, positioning as
desired and re–tightening flange nuts.
1
72 inch
Cutting Units
2
Figure 8
(Rear Discharge)
1. Skid
2. Flange nut
1
2
Figure 9
(Guardian Recycler)
1. Skid
2. Flange nut
Groundsmaster 3000/3000–D
Page 11 – 5
72 inch Cutting Units
Gage Wheel Adjustment (Rear Discharge Cutting Unit)
Note: If cutting unit is to be used in the 1 inch (25 mm)
height–of–cut setting, cutting unit gage wheels must be
positioned in highest position.
1. Adjust gage wheels by loosening locking hub, posi­
tioning gage wheel support at desired height and re–
tightening locking hub. Make sure gage wheel support
pins are positioned in holes in deck.
2
3
1
Figure 10
1. Gage wheel
2. Gage wheel support
3. Locking hub
Anti–scalp Roller Adjustment (Guardian Recycler Cutting Unit)
Note: If cutting unit is to be used in the 1 or 1–1/2 inch
(25 or 38 mm) height–of–cut setting, cutting unit rollers
must be repositioned in the top bracket holes.
To adjust front and rear rollers:
1. Remove cotter pins securing roller shafts to under­
side of deck.
2. Slide shafts out of lower bracket holes, align rollers
with top holes and install shafts.
3. Install cotter pins to secure assemblies.
72 inch Cutting Units
Page 11 – 6
Groundsmaster 3000/3000–D
Deck Pitch Adjustment
Deck pitch is the difference in height–of–cut from the
front of the blade plane to the back of the blade plane.
TORO recommends a blade pitch of .25 inches (6 mm).
That is the back of the blade plane is .25 inches (6 mm)
higher than the front.
2
1. Position machine on a level surface on shop floor.
2. Set deck to the desired height–of–cut.
1
3. Rotate (1) blade so it points straight forward.
4. Using a short ruler, measure from floor to front tip of
blade. Then, measure from floor to rear tip of blade.
6. To adjust pitch, start tractor and raise deck to highest possible position and turn off engine.
Figure 11
1. Height–of–Cut chain
2. U–bolt
7. Loosen jam nuts on top or bottom of Height–of–Cut
chain U–bolt.
8. Adjust other set of nuts to raise or lower rear of deck
and attain correct deck pitch.
9. Tighten jam nuts.
10. Lower deck.
Groundsmaster 3000/3000–D
Page 11 – 7
72 inch Cutting Units
72 inch
Cutting Units
5. Subtract the front dimension from rear dimension to
calculate your pitch.
Service and Repairs
CAUTION
To prevent accidental starting of the engine,
while performing maintenance, shut engine off
and remove key from ignition switch.
Check Gear Box Lubricant
The gear box is designed to operate with SAE 80–90 wt.
gear lube. Although the gear box is shipped with lubri­
cant from the factory, check the level before operating
the cutting unit. Change lubricant in gear box initially
after 50 hours of operation.
1. Position the machine and cutting unit on a level sur­
face.
2. Remove check plug from side of gear box and make
sure lubricant is up to bottom of hole. If level of lubricant
is low, remove fill plug on top of gear case and add
enough lubricant to bring it up to bottom of hole in side.
1
2
Figure 12
1. Filler Plug
2. Check Plug
Replace Gear Box Lubricant
The gear box lubricant must be changed initially, after
the first 400 hours of operation, and thereafter every
1600 hours of operation.
1. Position the machine and cutting unit on a level sur­
face.
2. Loosen fixed idler pulley locking nut.
3. Loosen spring tensioning nut as required and re­
move belt.
4. Remove (4) locknuts securing gearbox mount to
deck.
5. Remove belt from pulley.
6. Remove check plug from side of gear box and tip
gear box assembly allowing lubricant to drain from gear
box.
7. Reinstall belt to pulley.
8. Reinstall gear box assembly to deck
9. Remove fill plug on top of gear case and add SAE
80–90 wt. gear lube until level is up to bottom of hole in
side.
10. Reinstall check plug to side of gear box and fill plug
to top of gear case.
11. Re–tension belt. Refer to Replacing Drive Belts.
72 inch Cutting Units
Page 11 – 8
2
1
3
Figure 13
1. Gear Box Mount
2. Filler Plug
3. Check Plug
Groundsmaster 3000/3000–D
Grease Bearings, Bushings and Gear Box
The cutting unit must be lubricated regularly. If machine
is operated under normal conditions, lubricate castor
bearings and bushings with No. 2 general purpose lithium base grease or molybdenum base grease, after every 8 hours of operation or daily, whichever comes first.
Lubricate fittings immediately after every washing, regardless of the interval listed.
1. The cutting unit has bearings and bushings that
must be lubricated, and these lubrication points are:
front castor shaft bushings (2), blade spindle bearings
(3), gage wheels (2), idler arm pivot and right and left
push arm ball joints (Fig. 14).
2. Position the machine and cutting unit on a level surface and lower cutting unit. Remove check plug from
side of gear box and make sure lubricant is up to bottom
of hole. If level of lubricant is low, remove fill plug on top
of gear case and add SAE 80–90 wt. gear lube until level
is up to bottom of hole in side.
72 inch
Cutting Units
1
2
Figure 14
1. Filler Plug
2. Check/Drain Plug
Groundsmaster 3000/3000–D
Page 11 – 9
72 inch Cutting Units
Disconnect Cutting Unit From Traction Unit
Note: Implements are heavy and may require two
people to handle.
1. Start tractor and raise deck to highest possible position and turn off engine.
2. Rotate ignition key to run position and move lift lever
forward to lower cutting unit.
1
3. Remove hair pin cotters and clevis pins securing
height–of–cut chains to rear height–of–cut brackets.
4. Raise seat and open needle valve. This allows lift
arms to float freely.
5. Remove hair pin cotter and clevis pin securing latch
cover to lift arm .
Figure 15
1. Height–of–Cut Chain
6. Loosen release lever by rotating it counterclockwise.
7. Pivot release lever upward and remove shaft latch
from slot in traction unit lift arm.
8. Pull rearward on lock collar to release drive shaft
coupler from tractor.
1
9. Stay clear of lift arms and move deck away from
tractor allowing lift arms to fall.
10. Secure hair pin cotter and clevis pin to height–of–
cut chains for storage.
11. Close needle valve
Figure 16
1. Needle Valve
5
1
3
2
4
Figure 17
1. Latch Cover
2. Release Lever
3. Shaft latch
72 inch Cutting Units
Page 11 – 10
4. Traction Unit Lift Arm
5. Machined Surface
Groundsmaster 3000/3000–D
Connect Cutting Unit to Traction Unit
2. Raise seat and open needle valve. This allows lift
arms to float freely.
3. Adjust lift arms heights making sure that the ma­
chined surface on top of each traction unit lift arm is par­
allel to ground (Fig. 17). (Raise or lower lift arm casting
by pushing up or down from behind the front tires or us­
ing wrench in front of tractor)
4. Check for dirt and debris on mating parts and clean
as required.
5. Turn castor wheels so they point straight forward.
6. Secure first lift arm assembly to traction unit as fol­
lows:
A. Remove hair pin cotter and clevis pin securing
latch cover to lift arm.
B. Pivot release lever upward.
7. Install other lift arm on tractor by rotating deck to­
wards tractor, aligning lift arm to tractor arm and repeat­
ing step 5. If latch does not fall into slot in traction unit lift
arm the arms are not lined up.
A. If lift arms on traction unit are not at the correct
height for deck arms to slide on, push up or down
on lift arm castings from behind the front tires until
deck arm lines up and slides on.
B. If lift arms on deck do not line up side to side.
Rotate castor wheels side ways so deck moves
side to side easier. Move deck side to side until lift
arms line up and slide on.
8. Move deck from side to side to check for tightness
and re–tighten latches, if required.
9. Install latch covers to lift arms and secure with clevis
pins and hair pin cotters.
10. Connect drive shaft to traction unit.
11. Close needle valve and lower seat.
C. Slide cutting unit lift arm onto traction unit lift
arm, inserting shaft latch into slot in traction unit
lift arm.
12. Start tractor and raise deck to highest possible posi­
tion and turn off engine.
Note: If latch does not fall into slot in traction unit
lift arm, raise or lower lift arm casting by pushing
up or down from behind the front tires.
13. Align height–of–cut chains with hole for desired
height–of–cut, install clevis pin and secure with hair pin
cotter.
D. Pivot release lever downward and tighten se­
curely by rotating clockwise.
Install Lift Arm Ball Joints
1. Adjust ball joint in each lift arm assembly until a dimension of 2.75 inches (70 mm) from end of lift arm to
center of ball joint is attained.
140 ft–lb (19 Kgm)
then continue tightening
until slot in nut aligns
with cotter pin hole
1
2.75 in. (70 mm) 2
Figure 18
1. Ball Joint
2. Lift Arm
Groundsmaster 3000/3000–D
Page 11 – 11 Rev. A
72 inch Cutting Units
72 inch
Cutting Units
1. Center traction unit in front of cutting unit on any flat
hard surface.
Drive Belt Replacement
The blade drive belt, tensioned by the spring loaded
idler, is very durable. However, after many hours of use,
the belt will show signs of wear. Signs of a worn belt are:
squealing when belt is rotating, blades slipping when
cutting grass, frayed edges, burn marks and cracks. Re­
place the belt if any of these conditions are evident.
2
1
1. Lower cutting unit to the shop floor. Remove belt
covers from top of cutting unit and set covers aside.
2. Unhook spring from idler arm bracket to release belt
tension. Remove cotter pin and clevis pin securing idler
arm bracket to idler arm.
3
3. Remove (2) capscrews and nuts securing front of
gear box plate to deck channels.
Figure 19
4. Loosen (2) capscrews and nuts securing rear of
gear box plate to deck channels and raise front of gear
box plate to access belt.
1. Spring
2. Idler Arm
3. Idler Arm Bracket
5. Remove old belt from around spindle pulleys and
thru idler pulley assembly.
6. Route new belt around spindle pulleys and thru idler
pulley assembly, as shown in figure 21.
7. Reposition gear box plate on deck channels while
routing belt around gear box pulley. Mount gear box
plate to deck channels with capscrews and nuts pre­
viously removed.
8. Reinstall idler arm bracket to idler arm with cotter pin
and clevis pin. Hook spring onto idler arm bracket. To as­
sure there is proper tension on drive belt, spring should
be extended to a length of approximately 7.00 inch (178
mm). If spring is not extended to this length, relocate
spring rod to a new mounting holes further away from
from belt.
1
2
Figure 20
1. Gear Box Plate
2. Capscrews & Nuts
9. Reinstall belt covers.
Figure 21
72 inch Cutting Units
Page 11 – 12
Groundsmaster 3000/3000–D
Front Castor Fork Bushing Service
5
6
1. Start tractor and raise deck to highest possible posi­
tion and turn off engine.
2. Remove front snapper pins from castor arms and
slide castor wheel assembly out of castor arm tube.
3. Remove locknut from capscrew holding castor
wheel assembly between castor fork. Grasp castor
wheel and slide capscrew out of fork.
1
6
3
4
4. Remove retaining ring, washer and wavey washer
securing castor shaft to castor fork. Remove shaft from
fork.
2
5. Insert pin punch into top or bottom of castor fork and
drive bushing out of fork. Repeat for other bushing.
Clean inside of forks to remove dirt.
6. Apply grease to inside and outside of new bushings.
Using a hammer and flat plate, drive bushings into fork.
7. Inspect castor shaft and fork for wear and replace if
damaged.
Figure 22
1. Front Castor Fork
2. Retaining Ring
3. Washer
4. Wavey Washer
5. Castor Shaft
6. Bushings
8. Push castor shaft through bushings and fork and se­
cure with wavey washer, washer and retaining ring.
9. Insert snapper pin into castor arm and through
groove in castor shaft at desired height–of–cut.
Groundsmaster 3000/3000–D
Page 11 – 13
72 inch Cutting Units
72 inch
Cutting Units
The castor forks have bushings pressed into the top and
bottom of the casting and after many hours of operation,
the bushings will wear. To check the bushings, move
castor fork back and forth and from side to side. If castor
spindle is loose around the bushings, bushings are worn
and must be replaced.
Castor Wheel and Bearing Service
The castor wheel rotates on a high–quality roller bear­
ing. Even after many hours of use, provided that the
bearing was kept well–lubricated, bearing wear will be
minimal. However, failure to keep bearing lubricated will
cause rapid wear. A wobbly castor wheel usually indi­
cates a worn bearing.
60 – 80 ft–lb
(8 – 11 Kgm)
1. Remove locknut from capscrew holding castor
wheel assembly between castor fork. Grasp castor
wheel and slide capscrew out of fork.
2. Remove bearing from wheel hub and allow spacer
to fall out. Remove bearing from opposite side of wheel
hub.
1
3. Check the bearings, spacer and inside of wheel hub
for wear. Replace defective parts as required.
2
4. To assemble the castor wheel, push bearing into
wheel hub. Slide spacer into wheel hub. Push other
bearing into open end of wheel hub to captivate the
spacer inside the wheel hub.
1
5. Install castor wheel assembly between castor forks
and secure in place with capscrew and locknut.
Figure 23
1. Bearing
2. Spacer
72 inch Cutting Units
Page 11 – 14
Groundsmaster 3000/3000–D
Cutter Blade Removal
The blade must be replaced if a solid object is hit, the
blade is out–of–balance or if the blade is bent. Always
use genuine TORO replacement blades to be sure of
safety and optimum performance. Never use replace­
ment blades made by other manufacturers because
they could be dangerous.
1. Raise cutting unit to highest position, shut the en­
gine off and engage the parking brake.
2
2. Remove hair pin cotters and clevis pins securing
height–of–cut chains to rear of deck.
1
85 – 110 ft–lb
(12 – 15 Kgm)
4. Grasp end of blade using a rag or thickly padded
glove. Remove blade bolt, anti–scalp cup and blade
from spindle shaft.
5. Install blade–sail facing (up) toward cutting unit–
with anti–scalp cup and blade bolt. Tighten blade bolt to
85–110 ft–lb (12 – 15 Kgm).
Figure 24
1. Blade bolt
2. Anti–Scalp Cup
WARNING
Do not try to straighten a blade that is bent, and
never weld a broken or cracked blade. Always
use a new blade to assure continued safety
certification of the product.
Groundsmaster 3000/3000–D
Page 11 – 15
72 inch Cutting Units
72 inch
Cutting Units
3. Rotate front of deck upward and insert latch rod into
front hole (service position) in latch plate.
Inspecting and Sharpening Blade
1. Raise cutting unit to highest position, shut the en­
gine off and engage the parking brake.
2. Remove hair pin cotters and clevis pins securing
height–of–cut chains to rear of deck.
3. Rotate front of deck upward and insert latch rod into
front hole (service position) in latch plate.
4. Examine cutting ends of the blade carefully, espe­
cially where the flat and curved parts of the blade meet
(Fig. 25–A). Since sand and abrasive material can wear
away the metal that connects the flat and curved parts of
the blade, check the blade before using the machine. If
wear is noticed (Fig. 25–B), replace the blade: refer to
Removing Cutter Blade.
DANGER
Figure 25
If blade is allowed to wear, a slot will form
between the sail and flat part of the blade
(Fig. 25–C). Eventually a piece of the blade
may break off and be thrown from under the
housing, possibly resulting in serious injury to
yourself or bystander.
SHARPEN AT THIS
ANGLE ONLY
END VIEW
5. Inspect cutting edges of all blades. Sharpen the cut­
ting edges if they are dull or nicked. Sharpen only the top
of the cutting edge and maintain the original cutting
angle for best performance (Fig. 26). Make sure blade is
balanced after sharpening.
Figure 26
6. To check blade for being straight and parallel, lay
blade on a level surface and check its ends. Ends of
blade must be slightly lower than the center, and cutting
edge must be lower than the heel of the blade. This
blade will produce good quality of cut and require mini­
mal power from the engine. By contrast a blade that is
higher at the ends than the center, or if cutting edge is
higher than the heel, the blade is bent or warped and
must be replaced.
7. Install blade—sail facing (up) toward cutting unit–
with anti–scalp cup and blade bolt. Tighten blade bolt to
85–110 ft–lb (12 – 15 Kgm).
72 inch Cutting Units
Page 11 – 16
Groundsmaster 3000/3000–D
Blade Spindle Service
Removing Spindle Housing Assembly
1
2
1. Lower the cutting unit, shut the engine off and engage
the parking brake.
85 – 110 ft–lb
(12 – 15 Kgm)
2. Remove deck covers from top of cutting unit. Release
belt tension. Remove belt from spindle to be serviced.
Install seal with
lip facing IN
3
4
5
3. Start the engine and raise the cutting unit. Turn the
engine OFF and remove the key from the key switch.
Block up the cutting unit so it cannot fall accidentally.
6
7
15
8
4. Remove blade screw, flat washer, anti–scalp cup and
blade from spindle assembly.
Install seal with
lip facing OUT
72 inch
Cutting Units
5. Remove flange nuts and carriage bolts securing
spindle housing to deck. Slide spindle housing assem­
bly out the bottom of the cutting unit.
9
4
14
10
Disassembly
1. Remove lock nut retaining the spindle pulley on
spindle shaft. Slide pulley off of shaft.
2. Press the spindle shaft out of the spindle housing
using an arbor press. The bearing spacer remains on
the spindle shaft as the shaft is being removed.
11
12
85 – 110 ft–lb
(12 – 15 Kgm)
13
Figure 27
3. Remove seals from spindle housing.
4. Allow the bearings and small thick spacer to fall out
of the spindle housing.
5. Using a punch and hammer, drive both of the bearing
cups out of the spindle housing. Also drive the large
spacer out of the housing.
1. Grease fitting
2. Lock nut
3. Pulley
4. Oil seal
5. Spacers – matched set
6. Screw
7. Flat washer
8. Spindle housing
9. Nut
10. Spacer
11. Blade
12. Anti–scalp cup
13. Blade screw
14. Spindle shaft
15. Spindle bearing assy
(includes item 5)
6. A large snap ring is still inside the spindle housing and
it should remain there because it cannot be easily
removed.
IMPORTANT: If new bearings will be installed into a
used spindle housing that has the original snap ring
installed, discard the large snap ring that came with
the bearings because it is not needed. However,
new bearings with their matched spacer and snap
ring must always be installed when the spindle
housing is being replaced. Replacement bearings
are sold only with a matched snap ring and spacer
set. These parts cannot be purchased separately.
Figure 28
Groundsmaster 3000/3000–D
Page 11 – 17
72 inch Cutting Units
IMPORTANT: If a new spindle housing is being used,
new bearings and matched snap ring set must be
installed; see step 1 below. Never use old bearings,
spacer, and snap ring with a new spindle housing.
If installing bearings into a used spindle housing
that still has a snap ring installed, use only new
bearings with cups and spacer – not the large snap
ring because it is not required; see step 2 below.
11. Slide pulley end of spindle assembly through hole in
cutting unit. Mount the spindle assembly in place with
the carriage bolts and flange nuts.
12. Install the belt and adjust belt tension.
13. Reinstall the belt covers.
1. Install large snap ring into groove in bore of spindle
housing. Make sure snap ring is seated in groove.
2. Using an arbor press, push large spacer into top of
spindle housing; tightly against snap ring. The spacer
must contact the snap ring to be sure of the correct
assembly of the parts.
3. Thoroughly oil the bearing cups. Use an arbor press
to push the bearing cups into the top and bottom of the
spindle housing. The top bearing cup must contact the
spacer that was installed in step 2, and the bottom
bearing cup must contact the snap ring. Make that the
assembly is correct by supporting the first cup and
pressing the second against it.
Figure 29
4. Apply a film of grease on lips of both seals. Pack the
bearing cones with grease.
5. Install bearing and seal into bottom of spindle
housing. BOTTOM SEAL MUST HAVE THE LIP
FACING OUT.
6. Check the spindle shaft to make sure it is free of burrs
and nicks that could possibly cut the seals. Thoroughly
lubricate both the shaft and seal lips.
7. Slide small, thick spacer into spindle housing, then
install bearing and seal into top of spindle housing. LIP
OF UPPER SEAL MUST FACE IN.
Figure 30
8. Slide bearing spacer onto spindle shaft. Carefully
slide spindle shaft through spindle housing. The bottom
seal and bearing spacer fit together when the spindle is
installed.
9. Attach a hand grease gun to grease fitting and fill cavity with grease until grease starts to come out of lower
seal. NOTE: Pneumatic grease guns can cause air
pockets when filling large cavities with grease.
10. Push pulley onto splines of spindle shaft and retain
the parts together with the large flat washer and nut.
Tighten the nut to 85 – 110 ft–lb (12 – 15 Kgm). Rotate
72 inch Cutting Units
Page 11 – 18 Rev. A
Figure 31
Groundsmaster 3000/3000–D
84 inch
Cutting Units
the spindle shaft to be sure that the shaft rotates freely.
Installing Spindle, Bearings and
Seals Into Spindle Housing
Correcting Cutting Unit Mismatch
1. Using a 3 foot (1 m) long carpenters level, find a lev­
el surface on the shop floor.
2. Raise height–of–cut to the highest position: refer to
Adjusting Height–Of–Cut.
3. Lower cutting unit onto flat surface. Remove covers
from top of cutting unit.
4. Unhook spring from idler arm bracket to release belt
tension.
5. Rotate blades until the ends face forward and back­
ward. Measure from floor to front tip of cutting edge and
remember this dimension. Then rotate same blade so
opposite end is forward and measure again. The differ­
ence between dimensions must not exceed 1/8 of an
inch (3 mm). If dimension exceeds 1/8 of an inch (3 mm),
replace the blade because it is bent. Make sure to mea­
sure all blades.
Groundsmaster 3000/3000–D
6. Compare measurements of outer blades with the
center blade. Center blade must not be more than 3/8 of
an inch lower than the outer blades. If center blade is
more than 3/8 of an inch (9 mm) lower than the outer
blades. proceed to step 7 and add shims between
spindle housing and bottom of cutting unit.
7. Remove capscrews, flatwashers, lockwashers and
nuts from outer spindle in the area where shims must be
added. To raise or lower the blade, add a shim, Part No.
3256–24, between spindle housing and bottom of cut­
ting unit. Continue to check alignment of blades and add
shims until tips of blades are within the required dimen­
sion.
IMPORTANT: Do not use more than three shims at
any one hole location. Use decreasing numbers of
shims in adjacent holes if more than one shim is
added to any one hole location.
8. Hook spring onto idler arm bracket. Reinstall belt
covers.
If there is mismatch between the blades, the grass will
appear streaked when it is cut. This problem can be cor­
rected by making sure the blades are straight and all
blades are cutting on the same plane.
Page 11 – 19
72 inch Cutting Units
72 inch
Cutting Units
If there is mismatch between the blades, the grass will
appear streaked when it is cut. This problem can be cor­
rected by making sure the blades are straight and all
blades are cutting on the same plane.
Gearbox
27
29
3
4
5
28
6
1
2
1
25
7
8
26
21 22
24
9
23
10
11
20
12
19
17
18
13
14
7
15
16
170 – 190 in–lb
(196 – 219 Kgcm)
16:1
Figure 32
1. Screw
2. Latch plate
3. Flat washer
4. Gear box
5. Screw
6. Shield
7. Nut
8. Flat washer
9. Rubber mount
10. Screw
72 inch Cutting Units
11. Rivet
12. Rubber bumper
13. Belt
14. Flat washer
15. Gear box pulley
16. Taper lock bushing
16:1. Screw
17. Torque decal
18. Blade bolt decal (Europe)
19. Gearbox mount
Page 11 – 20
20. Screw
21. Safety decal
22. CE decal
23. Lube decal
24. Woodruff key
25. Gear box bracket
26. Lock nut
27. Roll pin
28. Screw
29. Drive shaft
Groundsmaster 3000/3000–D
4
15
14
13
2
16
12
1
17
9
4
11
5
3
5
2
72 inch
Cutting Units
18
20
21
7
19
8
10
6
22
23
2
Figure 33
1. Housing
2. Capscrew
3. Cap
4. Bearing cone
5. Bearing cup
6. R.H. gear
7. Bearing cup
8. Bearing cone
9. Spacer
10. Lower shaft
11. Upper seal
12. Cap
13. Gasket (.015)
14. Gasket (.005)
15. Gasket (.003)
16. Upper shaft
17. L.H. gear
18. Plug
19. Lower seal
20. Bearing cone
21. Bearing cup
22. Cap
23. Washer
Shaft End Play Adjustment
The lower shaft (Fig. 28, Item 10) and upper shaft (16)
should have a very small amount of bearing drag. If the
shaft turns hard, the cap (12) or (22) must be removed
and gaskets (13, 14, or 15) need to be added. If the shaft
has no bearing drag, or has end play, the cap must be
removed and gaskets taken out. The cap must be ad­
justed so the shaft has no end play and only a slight
amount of bearing drag.
Groundsmaster 3000/3000–D
Page 11 – 21
72 inch Cutting Units
Drive Shaft
2
4
8
5
7
3
6
Figure 34
2. Yoke
3. U–joint kit
4. Slip yoke shaft
72 inch Cutting Units
5. Slip yoke tube
6. Yoke
Page 11 – 22
7. Grease fitting
8. Grease fitting
Groundsmaster 3000/3000–D
Chapter 12
Electrical Diagrams
Table of Contents
3
3
4
5
6
7
8
9
Groundsmaster 3000–D Electrical Schematics,
Wiring Diagrams, and Harness Drawings . . . . . . 10
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . 10
Start Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Run Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Wiring Diagram (Rear Section) . . . . . . . . . . . . 13
Wiring Diagram (Front Section) . . . . . . . . . . . . 14
Harness Drawing (Rear Section) . . . . . . . . . . . 15
Harness Drawing (Front Section . . . . . . . . . . . 16
Electrical
Diagrams
Groundsmaster 3000 Electrical Schematics,
Wiring Diagrams, and Harness Drawings . . . . . . .
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . .
Start Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Run Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram (Rear Section) . . . . . . . . . . . . .
Wiring Diagram (Front Section) . . . . . . . . . . . . .
Harness Drawing (Rear Section) . . . . . . . . . . . .
Harness Drawing (Front Section . . . . . . . . . . . .
Groundsmaster 3000/3000–D
Page 12 – 1
Electrical Diagrams
Electrical Diagrams
Page 12 – 2
Groundsmaster 3000/3000–D
FLOAT/HOLD
SOLENOID (SV2)
LIGHT
ALTERNATOR
PINK
RED
BLUE
WHITE
BLUE
VIOLET
LIFT LEVER
POSITION
Y
FLOAT/HOLD
DIODE (D2)
SWITCH
VIOLET
SV1
SV2
LIFT
ON
OFF
HOLD
OFF
OFF
LOWER/FLOAT
OFF
ON
DIODE (D8)
1
VIOLET
+
1
VIOLET
WHITE
4
ANTI–DIESELING
VALVE
SOLENOID
HI TEMP
SWITCH
GRAY
6
7
HI TEMP
8
PINK
WHITE
ENGINE
COOLANT
TEMPERATURE
SENSOR (ECT)
5
R
LIGHT
LIFT/XBAL
SOLENOID (SV1)
PINK
GRAY
HI TEMP
OIL
PRESSURE
SWITCH
OVERRIDE
GREEN
OPTIONAL
CRUISE CONTROL
R
SWITCH
PINK
PINK
PINK
PINK
TAN
TAN
CRUISE
SEAT
RELAY
VIOLET
DIODE (D6)
SWITCH
3
TAN
5
G
IGNITION
SWITCH
START
S
GREEN
GRAY
TAN
10A
20A
CRUISE COIL
SWITCH
DIODE (D1)
A
DECK
CAPACITOR
X
TAN
BLUE
ENGINE
SHUTDOWN
DELAY
RELAY
ORANGE
SEAT
CAPACITOR
PTO
RELAY
VIOLET
S
RED
TAN
BRAKE
GREEN
Y
RUN
TAN
TAN
SERVICE
START
I
B
6
GREEN
NEUTRAL
SWITCH
2
SWITCH
LIGHT
BROWN
GREEN
GREEN
BROWN
BLUE
PINK
DISTRIBUTORLESS
IGNITION
COIL
BROWN
RELAY
STARTER
CRUISE
RELAY
TAN
9
12
VIOLET
PTO
SWITCH
2
5
1
4
VIOLET
DIODE (D3)
SEAT SWITCH
WHITE
BROWN
ORANGE
7.5A
YELLOW
20A
RED
PINK
SWITCH
11
B
DIODE (D5)
LIFT/XBAL
RELAY
10
RED
IMPLEMENT
FLOAT
RELAY
PINK
BLUE
BROWN
UNIVERSAL ELECTRONIC SPARK CONTROL
3
50A
VARIABLE
RELUCTANCE
SENSOR (VRS)
WHITE
2
YELLOW
+
BLUE
HOUR
METER
ORANGE
ORANGE
BATTERY
TEMP
GAUGE
TAN
OTHER
CIRCUITS
S
G
FUEL
GAUGE
OFF
NONE
NONE
RUN
B+I+A
X+Y
START
B+I+S
–
I
BLUE
I
+
TEMP
SENDER
TERMINAL
CONTINUITY
ORANGE
ORANGE
–
VIOLET
PTO COIL
IGNITION SWITCH
POSITION
12 VOLTS
VIOLET
FUEL
SENDER
S
G
Groundsmaster 3000
Electrical Schematic
All relays and solenoids
are shown as de–energized.
All ground wires are black.
Page 12 – 3
–
FLOAT/HOLD
SOLENOID (SV2)
LIGHT
ALTERNATOR
PINK
RED
BLUE
WHITE
BLUE
VIOLET
LIFT LEVER
POSITION
Y
FLOAT/HOLD
DIODE (D2)
SWITCH
VIOLET
+
1
PINK
WHITE
ENGINE
COOLANT
TEMPERATURE
SENSOR (ECT)
SWITCH
GRAY
HI TEMP
8
R
LOWER/FLOAT
OFF
ON
DIODE (D5)
LIFT/XBAL
PINK
GRAY
HI TEMP
OIL
PRESSURE
SWITCH
OVERRIDE
RELAY
SWITCH
GREEN
OPTIONAL
CRUISE CONTROL
R
CRUISE
RELAY
TAN
9
PINK
PINK
PINK
TAN
TAN
CRUISE
SEAT
RELAY
VIOLET
DIODE (D6)
SWITCH
3
TAN
5
G
BLUE
PINK
DISTRIBUTORLESS
GREEN
IGNITION
COIL
BROWN
SWITCH
S
10A
Y
RUN
NEUTRAL
TAN
A
X
BLUE
ENGINE
SHUTDOWN
DELAY
RELAY
ORANGE
SEAT
CAPACITOR
PTO
RELAY
VIOLET
SWITCH
VIOLET
PTO
SWITCH
2
5
1
4
VIOLET
DIODE (D3)
7.5A
YELLOW
SEAT SWITCH
WHITE
BROWN
ORANGE
20A
20A
CRUISE COIL
DECK
CAPACITOR
GREEN
GREEN
GRAY
TAN
TAN
SWITCH
DIODE (D1)
S
RED
TAN
BRAKE
START
TAN
6
GREEN
I
B
2
SERVICE
GREEN
IGNITION
START
BROWN
SWITCH
LIGHT
BROWN
RELAY
RED
OFF
LIGHT
BROWN
7
12
B
OFF
SOLENOID (SV1)
11
RED
HOLD
PINK
6
10
STARTER
OFF
LIFT/XBAL
WHITE
HI TEMP
SWITCH
ON
IMPLEMENT
FLOAT
RELAY
PINK
BLUE
WHITE
4
5
VIOLET
PINK
50A
UNIVERSAL ELECTRONIC SPARK CONTROL
3
LIFT
VIOLET
ANTI–DIESELING
VALVE
SOLENOID
VARIABLE
RELUCTANCE
SENSOR (VRS)
SV2
DIODE (D8)
1
2
SV1
YELLOW
+
BLUE
HOUR
METER
ORANGE
ORANGE
BATTERY
TEMP
GAUGE
OTHER
CIRCUITS
S
G
FUEL
GAUGE
OFF
NONE
NONE
RUN
B+I+A
X+Y
START
B+I+S
–
I
BLUE
I
+
TAN
TERMINAL
CONTINUITY
ORANGE
ORANGE
–
VIOLET
PTO COIL
IGNITION SWITCH
POSITION
12 VOLTS
VIOLET
S
G
Groundsmaster 3000
Start Circuits
TEMP
SENDER
FUEL
SENDER
Circuit Current
Logic Direction
All ground wires are black.
Page 12 – 4
–
FLOAT/HOLD
SOLENOID (SV2)
LIGHT
ALTERNATOR
PINK
RED
BLUE
WHITE
BLUE
VIOLET
LIFT LEVER
POSITION
Y
FLOAT/HOLD
DIODE (D2)
SWITCH
VIOLET
+
1
WHITE
VIOLET
4
PINK
WHITE
ENGINE
COOLANT
TEMPERATURE
SENSOR (ECT)
HI TEMP
SWITCH
7
HI TEMP
8
R
SWITCH
LOWER/FLOAT
OFF
ON
DIODE (D5)
LIFT/XBAL
PINK
GRAY
HI TEMP
OIL
PRESSURE
SWITCH
OVERRIDE
GREEN
OPTIONAL
CRUISE CONTROL
R
SWITCH
PINK
PINK
PINK
TAN
TAN
CRUISE
SEAT
RELAY
VIOLET
DIODE (D6)
SWITCH
3
TAN
5
G
BLUE
PINK
GREEN
IGNITION
SWITCH
START
BROWN
S
GREEN
GRAY
TAN
A
DIODE (D1)
X
10A
TAN
BLUE
ENGINE
SHUTDOWN
DELAY
RELAY
VIOLET
SWITCH
7.5A
BROWN
SEAT SWITCH
YELLOW
+
BLUE
HOUR
METER
ORANGE
ORANGE
BATTERY
TEMP
GAUGE
I
TAN
+
–
2
5
1
4
VIOLET
VIOLET
DIODE (D3)
VIOLET
PTO COIL
IGNITION SWITCH
POSITION
TERMINAL
CONTINUITY
OTHER
CIRCUITS
ORANGE
ORANGE
S
G
FUEL
GAUGE
OFF
NONE
NONE
RUN
B+I+A
X+Y
START
B+I+S
–
I
BLUE
12 VOLTS
PTO
RELAY
PTO
YELLOW
ORANGE
20A
20A
SWITCH
VIOLET
ORANGE
SEAT
CAPACITOR
WHITE
CRUISE COIL
DECK
CAPACITOR
S
RED
TAN
BRAKE
GREEN
Y
RUN
TAN
TAN
SERVICE
START
I
B
6
GREEN
NEUTRAL
SWITCH
2
SWITCH
LIGHT
BROWN
GREEN
DISTRIBUTORLESS
IGNITION
COIL
BROWN
RELAY
STARTER
CRUISE
RELAY
TAN
9
12
RED
OFF
SOLENOID (SV1)
11
B
OFF
LIGHT
RELAY
10
RED
HOLD
LIFT/XBAL
BROWN
GRAY
6
OFF
PINK
WHITE
5
ON
IMPLEMENT
FLOAT
RELAY
PINK
BLUE
PINK
50A
UNIVERSAL ELECTRONIC SPARK CONTROL
3
LIFT
VIOLET
ANTI–DIESELING
VALVE
SOLENOID
VARIABLE
RELUCTANCE
SENSOR (VRS)
SV2
DIODE (D8)
1
2
SV1
S
G
Groundsmaster 3000
Run Circuits
TEMP
SENDER
FUEL
SENDER
Circuit Current
Logic Direction
All ground wires are black.
Page 12 – 5
–
P3
P4
FLOAT/HOLD LIFT/XBAL
COIL
COIL
STARTER
J12
J8
B
P7
PTO
COIL
P6
SEAT
SWITCH
B
1
2
A
P8
SERVICE
BRAKE
B
A
WIRE IDENTIFICATION
B
W26
W32
W30
W31
W6
W11
W32
W29
ALTERNATOR
P9
LABEL
W1
W2
W3
W4
W5
W6
W7
W8
W9
W10
W11
W16
W17
W18
W19
W20
W21
W22
W24
W25
W26
W27
W28
W29
W30
W31
W32
W33
W28
W27
W26
W25
W24
W10
W22
W21
S1
W18
W33
A
W20
J13
A
W19
2
B
W18
1
W17
A
W16
P10
FORD
ECM
B
W9
W33
P12
CHARGE
CIRCUIT
PROTECTION
A
P5
NEUTRAL
SWITCH
W9
W30
W8
J9
COLOR
BLU
BLK
TAN
GRY
WHT
WHT
GRY
PNK
TAN
WHT
BLK
TAN
VIO
BLK
PNK
BLK
GRN
GRN
YEL
VIO
BLK
BRN
BRN
TAN
BLK
BLK
RED
RED
AWG
18
16
18
18
16
16
18
18
18
18
16
16
18
18
18
18
16
16
18
18
18
18
18
18
18
14
10
10
TYPE
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
ROUTE
J1, P2––C
J2, J11
J3, P2––B
J4, P1––G
J5, P1––H
J5, P10––1
J6, P2––G
J7, P1––B
P9, J8
P6––1, P2––E
J2, P10––2
J8, P1––E
P3––A, P1––K
P3–B, S1
P4––A, P2––A
P4––B, S1
P5––A, P1––F
P5––B, P2––D
P6––2, P1––A
P7––A, P1––C
P7––B, S1
P8––A, P1––D
P8–B, P2––F
J9, P1––J
J10, S1
J11, S1
J13, P12––A
J12, P12––B
CRUISE
CONTROL
J10
J7
OIL
PRESSURE J6
SWITCH
W7
W6
CARB
SOLENOID
J5
HIGH
TEMP
SWITCH
J4
TEMP
SENDER
FUEL
SENDER
J3
J2
J1
W5
W4
W3
W11
W31
W2
W2
J11
GROUND
W1
B
C
D
E
F
W7
W10
A
W28
W22
P1 HARNESS INTERFACE
K
W1
J
W3
H
W19
W29
G
W17
W5
F
W4
E
W21
D
W16
C
W27
B
W25
W8
W24
A
G
H
Groundsmaster 3000
Wiring Diagram (Rear Section)
P2 HARNESS INTERFACE
Page 12 – 6
P5 DIODE
PACK
1
3
1
W10
3
W33
2
2
4
5
J15
J16
W46
W55
W28
W11
W60
W15
W60
W29
W59
W42
W61
2
3
W34
W32
W18
W31
W30
W29
5
W35
6
W63
7
W54
8
W64
P10
CRUISE
SWITCH
E3
W27
E4
W26
E5
W25
W24
8
4
W22
7
3
W21
6
2
W6
5
1
W16
B
START
RELAY
F1
W19
F2
F5
W18
W14
W17
F4
W16
G1
W15
W13
W14
W8
G2
PTO
RELAY
G5
G4
STARTER ”B” TERMINAL
2
W66
3
W46
4
W67
5
LABEL
W1
W2
W3
W4
W5
W6
W7
W8
W9
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
W28
W29
W30
W31
W32
W33
W34
W35
W36
W37
W38
W39
W40
W41
W42
W43
W44
W45
W46
W47
W48
W49
W50
W51
W52
W53
W54
W55
W56
W57
W58
W59
W60
W61
W62
W63
W64
W65
W66
W67
W69
W70
W71
W72
W73
W74
W75
W76
W77
W78
W79
W80
COLOR
BLU
GRN
BLK
BLK
ORN
BLU
YEL
BLK
BRN
BRN
TAN
VIO
VIO
BLK
VIO
GRY
BRN
BLK
TAN
RED
WHT
GRN
PNK
PNK
GRY
BRN
WHT
WHT
BLU
VIO
VIO
BLK
VIO
GRN
TAN
TAN
BLK
TAN
TAN
VIO
PNK
PNK
BLK
BLK
BLK
PNK
ORN
TAN
BLK
ORN
BLU
BLK
ORN
BLK
PNK
GRN
VIO
PNK
BLU
TAN
BRN
GRN
TAN
BLK
GRY
BLK
WHT
BRN
VIO
PNK
YEL
BLK
BLK
GRN
RED
RED
ORN
RED
RED
AWG
16
18
18
18
18
16
18
18
18
18
18
18
18
18
18
16
18
18
16
10
18
16
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
16
18
18
18
18
18
18
18
16
18
18
18
18
18
18
18
18
18
18
10
16
16
16
16
TYPE
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
ROUTE
P4––J4, P4––H4
P4––J5, J5
P4––J2, J4
P4––J2, P4––H2
P4––J1, P6––A
P4––H4, P4––2
P6––X, J3
P4––H2, P4––G2
P4––H1, P3––E
P4––H1, P9––1
P4––G4, P9––5
P4––G5, P3––C
P4––G5, P4––G1
P4––G2, P4––F2
P4––G1, P9––4
P4––F4, P4––1
P4––F5, P6––S
P4––F2, P4––C5
P4––F1, P1––E
P4––1234, J1
P4––3, P2––E
P4––4, P1––F
P4––E1, P4––E2
P4––E2, P7––1
P4––E5, P1––G
P4––E4, P11––2
P4––E3, P1––H
P4––E3, J15
P4––C1, P8––1
P4––C2, P5––B
P4––C2, P4––C4
P4––C5, P4––B5
P4––C4, P8––3
P4––B1, P10––5
P4––B2, P10––6
P4––B2, P4––B4
P4––B5, P5––E
P4––B4, P5––A
P5––A, P1––J
P5––B, P1––K
P5––D, P2––A
P5––D, P7––3
P5––E, P5––G
P5––G, P5––H
P5––H, J8
J16, P11––4
J6, J9
J7, P2––B
J8, J11
J9, J12
J10, P2––C
J11, J13
J12, P6––A
J13, P10––8
J14, J16
P6––B, P2––D
P6––Y, P4––H5
J14, P7––1
P7––2, P8––1
P9––2, P9––5
P10––2, P2––F
P10––3, P10––5
P10––6, P10––7
P10––8, J17
P11––1, P2––G
P11––3, J2
P11––5, P3––H
P1––D, P3––E
P1––C, P3––C
P1––B, P3––A
P1––A, J3
J2, P3––F
P3––F, J4
P3––D, J5
P4––1234, P4––5678
P4––5, P13––B
P4––6, P13––A
P4––7, P12
P4––8, J18
W65
F
OIL PRESSURE SWITCH
W61
E
SERVICE BRAKE
W21
D
SEAT SWITCH
W56
C
NEUTRAL SWITCH
W51
B
FUEL SENDER
W48
A
TEMPERATURE SENDER
P1 HARNESS INTERFACE
K
W41
J
LIFT/XBAL COIL
H
W40
G
FLOAT/HOLD COIL
F
W39
E
CRUISE COIL
D
W27
C
FUEL STOP SOLENOID
B
W25
INPUT
POWER
A
TEMPERATURE SWITCH
SEAT
CAPACITOR
J1
W22
J2
NEUTRAL SWITCH
J3
W19
A
STARTER ”S” TERMINAL
P3 DIODE
PACK
B
W69
D
W70
C
E
PTO COIL
F
W71
G
ALTERNATOR ”D” TERM
DECK
CAPACITOR
H
W72
J4
W20
J5
W66
W73
W1
W72
W7
J4
W71
J5
W4
W3
W2
W70
W12
J2
W75
W69
W9
W73
W74
W5
W67
J1
H5
GROUND
W74
W3
W75
W2
ENGINE
SHUTDOWN
DELAY
RELAY
H4
W8
W4
W57
W6
W1
H2
J17
W13
W12
W11
W10
W9
SEAT SWITCH
SEAT
RELAY
1
W26
6
P11
WARNING
LIGHT CLUSTER
SERVICE BRAKE
H1
W65
W23
E1
W64
A
1
HI TEMP
OVERRIDE
P9
PTO SWITCH
W62
W20
P13
IMPLEMENTS
Y
W59
W24
W58
W77
X
W57
W78
B
W7
W79
A
WIRE IDENTIFICATION
P8
FLOAT/
HOLD SW
E2
W76
P12
S
W5
J18
LIGHT
KIT
J14
J13
P7
LIFT/XBAL
SWITCH
W28
HIGH
COOLANT
TEMP
RELAY
W80
J12
W53
W17
W58
W55
P4
CONVENIENCE
CENTER
J11
J10
W54
C1
J9
P6
IGNITION SWITCH
W52
W53
W50
C2
J8
W52
W49
C5
J7
W51
W50
W47
IMPLEMENT
FLOAT
RELAY
J6
METER
HOUR
W44
W43
W38
W36
W37
W32
W36
W35
W34
W33
W31
H
W49
W45
C4
G
W48
B1
F
W47
B2
E
W45
CRUISE
RELAY
D
W37
W42
W41
B5
C
W40
W30
W39
B4
B
FUEL
GAUGE
W56
A
TEMP
GAUGE
G
H
Groundsmaster 3000
Wiring Diagram (Front Section)
P2 HARNESS INTERFACE
Page 12 – 7
J6
P3
FLOAT/HOLD
SOLENOID
OIL
PRESSURE
BA
BA
P5
NEUTRAL
SWITCH
AB
P7
PTO
COIL
P6
SEAT
SWITCH
CARB
SOLENOID
1
2
J5
”S1”
W18
W20
W26
W30
W31
GROUND
J11
BA
LIFT/XBAL
SOLENOID
P4
ALTERNATOR
J7
J13
P9
BA
TEMP
SWITCH
J4
SERVICE
BRAKE
SWITCH
P8
J10
J9
CRUISE
COIL
J3
TEMP
SENDER
CHARGE
CIRCUIT
PROTECTION
A B
P12
1
P10
2
FORD
ECM
FUEL
SENDER
STARTER
J1
J2
A
B
C
D
H
G
F
E
A
B
C
D
E
+ + + + +
+ + + + +
J12
P13
HARNESS INTERFACE
+ + + +
+ + + +
J8
B A
K
J
H
G
F
Groundsmaster 3000
Harness Drawing (Rear Section)
P2
P1
Page 12 – 8
5
6
3
1
2
4
7
8
5
5
F
1
4
1
3
4
3
2
E
2
4
3
1
5 1
G
5
INPUT
POWER
J1
CONVENIENCE CENTER
P4
4
3
2
D
2
H
5
5
2
Y
S
2
1
HOUR
METER
3 2
6
1
K
B 5
4
J
2
J3
J12
+
+
X
5
P6
P9
2 3
5
4
1
3
J2
J5
+
3
FLOAT/HOLD
SWITCH 1
4
4
J4
C
5
SEAT
CAPACITOR
1 +
+
B
+
3
1
4
1
3
A
4
DECK
CAPACITOR
PTO
SWITCH
2
IGNITION
SWITCH
WARNING
LIGHT
CLUSTER
6
P11
12
J13
J14
3 4 5 6
3
2
3
A
1
2
ACCESSORY
P8
IMPLEMENT
BA
J18
P13
P12
LIGHT
KIT
LIFT/XBAL
SWITCH
J17
2
3
GROUND
P7
H
G
F
E
D
C
B
A
++++++++
++++++++
DIODE
PACK
H
G
F
E
D
C
B
A
J15
P5
P3
P2
DIODE
PACK
P1
E F G H
F G H J K
+ + + +
+ + + +
+ + + + +
+ + + + +
D C B A
E D C B A
J16
HIGH
TEMPERATURE
OVER–RIDE
HARNESS
INTERFACE
J6
J7
J8
TEMPERATURE
GAUGE
J9
J10
J11
3
6
2
5
1
4
8
7
1
CRUISE
SWITCH
P10
FUEL
GAUGE
Groundsmaster 3000
Harness Drawing (Front Section)
Page 12 – 9
LIGHT
DIODE (D2)
RED
BLUE
WHITE
PINK
VIOLET
FLOAT/HOLD
SOLENOID (SV2)
Y
ALTERNATOR
LIFT LEVER
POSITION
FLOAT/HOLD
SWITCH
SV1
SV2
LIFT
ON
OFF
HOLD
OFF
OFF
LOWER/FLOAT
OFF
ON
VIOLET
BLUE
DIODE (D8)
FUEL STOP
SOLENOID
VIOLET
1
BLUE
RED
2
PREHEATING
UNIT
VIOLET
BLUE
WHITE
TEMP SENDER
BLUE
WHITE
3
IMPLEMENT
FLOAT
RELAY
PINK
PINK
PINK
HIGH
TEMP
SWITCH
TAN
4
DIODE (D5)
LIFT/XBAL
SWITCH
LIFT/XBAL
SOLENOID (SV1)
LIGHT
GREEN
R
80A
OIL PRESSURE
SWITCH
OPTIONAL
CRUISE CONTROL
WHITE
WHITE
3
WHITE
GRAY
GLOW
PLUGS
6
GRAY
R
LIGHT
BROWN
Y
5
BLUE
HI TEMP
OVERRIDE
SWITCH
7
R
1
2
GREEN
H20 IN FUEL
SENSOR
WHITE
CRUISE
RELAY
TAN
PINK
PINK
TAN
ORANGE
RED
9
PINK
ORANGE
PINK
3
HIGH
COOLANT
TEMP
RELAY
8
1
2
TAN
COOLANT LEVEL
SENSOR
R
SEAT
RELAY
VIOLET
TAN
TAN
ORANGE
BROWN
BROWN
S
START
B
STARTER
10A
20A
S
CRUISE
SWITCH
GRAY
TAN
7.5A
20A
PTO
RELAY
VIOLET
BLUE
ENGINE
SHUTDOWN
DELAY
RELAY
ORANGE
2
YELLOW
BROWN
YELLOW
WHITE
CRUISE COIL
GREEN
SEAT
CAPACITOR
BLUE
RED
RED
LIGHT
DECK
CAPACITOR
X
A
G
WHITE
DIODE (D1)
RUN
NEUTRAL
SWITCH
IGNITION
SWITCH
TAN
Y
ORANGE
GREEN
GRAY
TAN
RED
TAN
RED
I
B
SERVICE
BRAKE
SWITCH
6
TAN
GREEN
START
RELAY
2
BROWN
BROWN
GREEN
PINK
INJECTION ADVANCE
VIOLET
50A THERMAL
BREAKER
BLUE
DIODE (D6)
5
3
PTO
SWITCH
VIOLET
DIODE (D3)
5
1
4
VIOLET
BLUE
VIOLET
DECK
POSITION
SWITCH
SEAT SWITCH
PTO COIL
+
12 VOLTS
ORANGE
ORANGE
B+I+A
X+Y
–
START
B+I+S
–
S
+
ORANGE
I
S
G
TRANSPORT
SWITCH
FUEL
GAUGE
TEMPERATURE
GAUGE
HOURMETER
NONE
I
FUEL
SENDER
YELLOW
G
3
G
GRAY
TEMP
SENDING
UNIT
TRANSPORT
RELAY
YELLOW
2
5
6
LIGHT
DIODE (D7)
YELLOW
RUN
NONE
OTHER
CIRCUITS
BLUE
OFF
TERMINAL
CONTINUITY
VIOLET
IGNITION SWITCH
POSITION
ORANGE
BATTERY
YELLOW
PINK
TRANSPORT
SOLENOID
Groundsmaster 3000–D
Electrical Schematic
All relays and solenoids
are shown as de–energized.
All ground wires are black.
2. ALL GROUND WIRES ARE BLACK
Page 12 – 10
–
LIGHT
DIODE (D2)
RED
WHITE
PINK
BLUE
VIOLET
FLOAT/HOLD
SOLENOID (SV2)
Y
ALTERNATOR
LIFT LEVER
POSITION
FLOAT/HOLD
SWITCH
SV1
SV2
LIFT
ON
OFF
HOLD
OFF
OFF
LOWER/FLOAT
OFF
ON
VIOLET
BLUE
DIODE (D8)
FUEL STOP
SOLENOID
VIOLET
1
BLUE
RED
2
PREHEATING
UNIT
VIOLET
BLUE
WHITE
TEMP SENDER
BLUE
WHITE
3
IMPLEMENT
FLOAT
RELAY
PINK
PINK
PINK
HIGH
TEMP
SWITCH
TAN
4
DIODE (D5)
LIFT/XBAL
SWITCH
LIFT/XBAL
SOLENOID (SV1)
LIGHT
GREEN
R
80A
OIL PRESSURE
SWITCH
OPTIONAL
CRUISE CONTROL
WHITE
WHITE
3
WHITE
GRAY
PLUGS
GLOW
6
GRAY
R
LIGHT
BROWN
Y
5
BLUE
HI TEMP
OVERRIDE
SWITCH
7
R
1
2
GREEN
H20 IN FUEL
SENSOR
WHITE
CRUISE
RELAY
TAN
PINK
PINK
TAN
ORANGE
RED
9
PINK
ORANGE
PINK
3
HIGH
COOLANT
TEMP
RELAY
8
1
2
TAN
COOLANT LEVEL
SENSOR
R
SEAT
RELAY
VIOLET
TAN
TAN
ORANGE
BROWN
S
START
GREEN
RED
RED
7.5A
20A
CRUISE COIL
GREEN
GRAY
TAN
X
PTO
RELAY
VIOLET
BLUE
ENGINE
SHUTDOWN
DELAY
RELAY
ORANGE
2
YELLOW
BROWN
BLUE
LIGHT
DECK
CAPACITOR
SEAT
CAPACITOR
WHITE
G
WHITE
CRUISE
SWITCH
Y
ORANGE
10A
B
20A
S
RED
A
TAN
DIODE (D1)
RUN
NEUTRAL
SWITCH
IGNITION
SWITCH
GREEN
GRAY
TAN
RED
TAN
STARTER
I
B
START
RELAY
SERVICE
BRAKE
SWITCH
BROWN
6
2
BROWN
TAN
BROWN
GREEN
PINK
INJECTION ADVANCE
VIOLET
50A THERMAL
BREAKER
BLUE
DIODE (D6)
5
3
YELLOW
PTO
SWITCH
1
VIOLET
DIODE (D3)
5
4
VIOLET
BLUE
VIOLET
DECK
POSITION
SWITCH
SEAT SWITCH
PTO COIL
+
12 VOLTS
ORANGE
ORANGE
B+I+A
X+Y
–
START
B+I+S
–
S
+
ORANGE
I
S
G
TRANSPORT
SWITCH
FUEL
GAUGE
TEMPERATURE
GAUGE
HOURMETER
NONE
I
FUEL
SENDER
YELLOW
G
G
GRAY
TEMP
SENDING
UNIT
TRANSPORT
RELAY
YELLOW
3
5
2
6
LIGHT
DIODE (D7)
YELLOW
RUN
NONE
OTHER
CIRCUITS
BLUE
OFF
TERMINAL
CONTINUITY
VIOLET
IGNITION SWITCH
POSITION
ORANGE
BATTERY
YELLOW
Groundsmaster 3000–D
Crank Circuits
PINK
Circuit Current
Logic Direction
All ground wires are black.
TRANSPORT
SOLENOID
Page 12 – 11
–
LIGHT
DIODE (D2)
RED
BLUE
WHITE
PINK
VIOLET
FLOAT/HOLD
SOLENOID (SV2)
Y
ALTERNATOR
LIFT LEVER
POSITION
FLOAT/HOLD
SWITCH
SV1
SV2
LIFT
ON
OFF
HOLD
OFF
OFF
LOWER/FLOAT
OFF
ON
VIOLET
BLUE
DIODE (D8)
RED
FUEL STOP
SOLENOID
VIOLET
1
BLUE
2
PREHEATING
UNIT
VIOLET
BLUE
WHITE
TEMP SENDER
BLUE
WHITE
3
IMPLEMENT
FLOAT
RELAY
PINK
PINK
PINK
HIGH
TEMP
SWITCH
TAN
4
DIODE (D5)
LIFT/XBAL
SWITCH
LIFT/XBAL
SOLENOID (SV1)
LIGHT
GREEN
R
80A
OIL PRESSURE
SWITCH
OPTIONAL
CRUISE CONTROL
WHITE
WHITE
3
WHITE
GRAY
PLUGS
GLOW
6
GRAY
R
LIGHT
BROWN
Y
5
1
HI TEMP
OVERRIDE
SWITCH
7
R
2
GREEN
H20 IN FUEL
SENSOR
BLUE
WHITE
CRUISE
RELAY
TAN
PINK
PINK
TAN 2
ORANGE
RED
9
PINK
ORANGE
PINK
3
HIGH
COOLANT
TEMP
RELAY
8
1
TAN
COOLANT LEVEL
SENSOR
R
SEAT
RELAY
VIOLET
TAN
TAN
ORANGE
BROWN
50A THERMAL
BREAKER
BLUE
2
BROWN
DIODE (D6)
5
3
6
TAN
G
LIGHT
WHITE
GREEN
PINK
RUN
NEUTRAL
SWITCH
IGNITION
SWITCH
RED
TAN
X
ENGINE
SHUTDOWN
DELAY
RELAY
ORANGE
7.5A
2
BROWN
YELLOW
WHITE
PTO
RELAY
VIOLET
BLUE
SEAT
CAPACITOR
YELLOW
BLUE
20A
RED
STARTER
A
ORANGE
B
10A
20A
S
RED
GREEN
Y
GRAY
GREEN
GRAY
TAN
RED
TAN
I
B
CRUISE COIL
DECK
CAPACITOR
START
GREEN
CRUISE
SWITCH
DIODE (D1)
S
START
RELAY
SERVICE
BRAKE
SWITCH
BROWN
TAN
BROWN
VIOLET
INJECTION ADVANCE
PTO
SWITCH
1
VIOLET
DIODE (D3)
5
4
VIOLET
BLUE
VIOLET
DECK
POSITION
SWITCH
SEAT SWITCH
PTO COIL
+
12 VOLTS
B+I+A
NONE
X+Y
B+I+S
–
S
+
–
START
TEMPERATURE
GAUGE
HOURMETER
I
G
TRANSPORT
SWITCH
FUEL
GAUGE
S
I
FUEL
SENDER
YELLOW
G
G
GRAY
TEMP
SENDING
UNIT
TRANSPORT
RELAY
YELLOW
3
5
2
6
LIGHT
DIODE (D7)
YELLOW
RUN
NONE
OTHER
CIRCUITS
BLUE
OFF
TERMINAL
CONTINUITY
VIOLET
IGNITION SWITCH
POSITION
ORANGE
ORANGE
ORANGE
ORANGE
BATTERY
YELLOW
Groundsmaster 3000–D
Run Circuits
PINK
TRANSPORT
SOLENOID
Circuit Current
Logic Direction
All ground wires are black.
Page 12 – 12
–
P19
CHARGE
CIRCUIT
PROTECTION
P16
FLOAT/HOLD
COIL
STARTER
P11
SEAT
SWITCH
P12
PTO
COIL
A
A
1
A
B
2
P13
SERVICE
BRAKE
B
A
B
W32
W31
W30
W29
W28
W27
W26
W24
W14
W22
THERMAL
BREAKER
W30
W37
S3
W13
W45
J5
B
W25
W18
B
P18
NEUTRAL
SWITCH
W24
W17
A
P17
LIFT/XBAL
COIL
W23
W16
J8
W22
W49
J7
W21
3
W20
2
W19
1
W14
B
W49
A
W48
J6
WIRE IDENTIFICATION
P6
COOLANT
LEVEL
SENSOR
W33
A
P5
INJECTION
ADVANCE
1
2
J14
W34
W10
B
P14
DECK
POSITION
SWITCH
W15
W48
W36
J9
ALTERNATOR
CRUISE
CONTROL
W12
J4
W37
J10
W38
P4
OIL
PRESSURE
SWITCH
1
2
W11
W39
J3
W8
W3
S2
W10
GLOW
PLUGS
W15
W18
W9
W40
W40
W20
W47
W41
2
W8
W16
W46
W39
P3
THERMISTER
1
W4
1
W7
2
W6
W42
W9
W5
J1
W4
FUEL
SENDER
W43
W38
W2
P1
WATER
IN FUEL
SENDER
3
W3
2
W2
1
W1
4
P7
PRE/POST
HEAT RELAY
5
TYPE
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
ROUTE
P1––1, P10––A
P1––2, J1
P1––3, S2
J1, S1
J2, P9––C
P2––2, P8––G
P2––1, P9––B
P3––1, P7––2
J3, J12
J3, P5––1
P4––2, P9––G
J4, P8––B
J5, J11
J6, J7
P5––2, S2
P6––1, S1
P6––2, P9––H
P6––3, S2
J8, P8––E
J8, P7––4
P16––A, P8––K
P16––B, S3
P17––A, P9––A
P17––B, S3
P18––A, P8––F
P18–B, P9––D
P11––1, P9––E
P11––2, P8––A
P12––A, P8––C
P12––B, S3
P13––A, P8––D
P13––B, P9––F
P14–A, P10––E
P14––B, P10––D
J9, P8––J
J10, S3
J10, P15––B
P7–1, S1
P7––3, S2
P7––5, P10––B
P7––7, S1
P15––A, P10––F
J13, S1
J13, S3
P3––2, S1
S2, P8––H
J14, P19––A
J7, P19––B
7
S1
W13
J2
3
AWG
18
18
18
18
18
18
18
18
8
16
18
18
8
8
16
18
18
18
16
18
18
18
18
18
16
16
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
14
14
18
16
10
10
W44
P2
TEMP
SWITCH/
SENDER
2
COLOR
BLU
BLK
WHT
BLK
BLU
GRY
VIO
BLU
ORN
ORN
GRY
PNK
RED
RED
WHT
BLK
TAN
WHT
TAN
TAN
VIO
BLK
PNK
BLK
GRN
GRN
WHT
YEL
BLU
BLK
BRN
BRN
GRY
BRN
WHT
BLK
BLK
BLK
WHT
GRN
BLK
PNK
BLK
BLK
BLK
WHT
RED
RED
6
W42
W46
1
LABEL
W1
W2
W3
W4
W5
W6
W7
W8
W9
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
W28
W29
W30
W31
W32
W33
W34
W36
W37
W38
W39
W40
W41
W42
W43
W44
W45
W46
W47
W48
W49
J11
J12
A
B
P15
TRANSPORT
COIL
W44
W45
D
E
W43
C
W33
B
W34
A
W41
H
W1
P9 HARNESS INTERFACE
G
W17
F
W11
E
W32
D
W27
C
W26
B
W5
A
W7
K
W23
J
W21
H
W36
P8 HARNESS INTERFACE
G
W47
F
W6
E
W25
D
W19
C
W31
B
W29
W12
W28
A
J13
GROUND
Groundsmaster 3000–D
Wiring Diagram (Rear Section)
F
P10 HARNESS INTERFACE
Page 12 – 13
WIRE IDENTIFICATION
P5
DIODE
PACK
A
2
3
1
P1
PTO SWITCH
3
1
2
4
5
J15
J16
W69
W62
W28
W11
W68
W15
W68
W85
W67
E5
1
W38
TEMP
RELAY
Y
W34
W66
E4
X
W47
HIGH
COOLANT
B
W66
W24
W65
E3
A
W64
D1
S
W7
D2
J14
W63
D5
J13
W5
W60
W17
W65
W62
TRANSPORT
RELAY
J12
W61
D4
J11
J10
W59
W60
W57
C1
J9
W59
W56
C2
W51
FUEL GAUGE
J8
W58
C5
W50
J7
W57
W54
IMPLEMENT
FLOAT
RELAY
W49
J6
H
W56
W52
C4
G
W55
B1
F
W54
W53
B2
TEMP GAUGE
E
W52
CRUISE
RELAY
D
P4
IGNITION SWITCH
HI TEMP
OVERRIDE
SWITCH
W70
2
W48
B5
C
W47
W46
W45
W33
W44
W35
W43
B4
W42
W40
W41
W37
W40
W39
W72
W38
W36
B
HOUR
METER
P2
FLOAT/HOLD
SWITCH
P3
LIFT/XBAL
SWITCH
W71
W72
W39
W73
W37
W32
W36
W35
W34
W33
W31
W32
W18
W31
W30
P6 CONVENIENCE CENTER
ACCESSORY
W74
W29
W95
P15
W94
LIGHT
KIT
W93
7
3
6
2
5
1
P16
B
IMPLEMENTS
START
RELAY
F1
F2
F5
F4
G1
PTO
RELAY
G2
G5
G4
W78
1
2
W78
4
5
W21
W81
6
W6
W16
1
STARTER ”B” TERMINAL
W53
4
P11
WARNING
LIGHT CLUSTER
5
W16
W84
6
W15
W13
W14
W8
W13
W12
W11
W10
W9
W48
W41
GROUND
A
D
INTERFACE
E
F
E
F
P9 HARNESS INTERFACE
G
W81
D
W79
C
W70
B
W21
A
W63
K
W58
J
W55
P8 HARNESS INTERFACE
H
W46
G
W44
F
W43
E
W27
D
W25
C
W22
B
W19
A
W10
J1
INPUT
POWER
W86
J2
SEAT
CAPACITOR
P10
HARNESS
WIRE IDENTIFICATION (Cont.)
W87
J3
W88
A
W20
B
W83
C
W89
W88
W7
D
W87
E
DIODE PACK
W86
F
P7
W12
G
W90
W85
W9
W89
W91
DECK
CAPACITOR
H
C
W67
W45
W2
J4
B
W75
W4
W3
J5
W82
LOW COOLANT
OIL PRESSURE SWITCH
SERVICE BRAKE
SEAT SWITCH
NEUTRAL SWITCH
FUEL SENDER
TEMPERATURE SENDER
LIFT/XBAL COIL
FLOAT/HOLD COIL
W5
CRUISE COIL
W4
W64
W6
W1
FUEL STOP SOLENOID
W8
W1
J17
W84
W80
J4
3
W18
W14
W17
W91
J5
2
W83
TEMPERATURE SWITCH
J2
W82
W19
W3
W90
W2
SHUTDOWN
DELAY
RELAY
P12
WARNING
LIGHT CLUSTER
W80
NEUTRAL SWITCH
ENGINE
3
W69
W22
STARTER ”S” TERMINAL
J1
8
W26
SERVICE BRAKE
H4
7
W79
W25
W24
ALTERNATOR ”D” TERM
H5
P13
TRANSPORT
SWITCH
W26
SEAT SWITCH
SEAT
RELAY
H2
5
W74
PTO COIL
H1
3
6
W77
W20
A
8
W30
W23
4
7
2
W76
W29
W28
W27
W92
8
6
P14
CRUISE
SWITCH
W75
E1
W96
5
W61
E2
J18
3
H
LABEL
W86
W87
W88
W89
W90
W91
W92
W93
W94
W95
W96
COLOR
VIO
PNK
YEL
BLK
GRN
BLK
RED
RED
ORN
RED
RED
AWG
18
18
18
18
18
18
10
16
16
16
16
TYPE
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
ROUTE
P8––C, P7––C
P8––B, P7––A
P8––A, J3
J2, P7––F
P7––D, J5
P7––F, J4
P6––1234, P6–5678
P6––5, P16––B
P6––6, P16––A
P6––7, P15
P6––8, J18
LABEL
W1
W2
W3
W4
W5
W6
W7
W8
W9
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
W28
W29
W30
W31
W32
W33
W34
W35
W36
W37
W38
W39
W40
W41
W42
W43
W44
W45
W46
W47
W48
W49
W50
W51
W52
W53
W54
W55
W56
W57
W58
W59
W60
W61
W62
W63
W64
W65
W66
W67
W68
W69
W70
W71
W72
W73
W74
W75
W76
W77
W78
W79
W80
W81
W82
W83
W84
W85
COLOR
BLU
GRN
BLK
BLK
ORN
BLU
YEL
BLK
BRN
BRN
TAN
VIO
VIO
BLK
VIO
GRY
BRN
BLK
TAN
RED
WHT
GRN
PNK
PNK
GRY
BRN
WHT
WHT
ORN
YEL
YEL
BLK
YEL
BLU
VIO
VIO
BLK
VIO
TAN
TAN
BLK
TAN
TAN
VIO
YEL
PNK
PNK
BLK
BLK
BLK
BLK
BLK
ORN
ORN
VIO
BLK
ORN
BLU
BLK
ORN
BLK
PNK
GRN
VIO
PNK
BLU
BRN
TAN
PNK
BRN
GRN
GRN
TAN
BLK
GRY
ORN
YEL
BLK
GRY
WHT
TAN
GRN
BLK
BLU
BRN
AWG
16
18
18
18
18
16
18
18
18
18
18
18
18
18
18
16
18
18
16
10
18
16
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
16.
18
18
18
18
18
18
18
18
18
18
18
18
18
18
16
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
TYPE
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
GPT
ROUTE
P6––J4, P6––H4
P6––J5, J5
P6––J2, J4
P6––J2, P6––H2
P6––J1, P4––A
P6––H4, P6––2
P4––X, J3
P6––H2, P6––G2
P6––H1, P7––E
P6––H1, P8––D
P6––G4, P1––5
P6––G5, P7––C
P6––G5, P6––G1
P6––G2, P6––F2
P6––G1, P1––4
P6––F4, P6––1
P6––F5, P4––S
P6––F2, P6––D5
P6––F1, P8––E
P6––1234, J1
P6––3, P9––E
P6––4, P8––F
P6––E1, P6––E2
P6––E2, P3––1
P6––E5, P8––G
P6––E4, P12––2
P6––E3, P8––H
P6––E3, J15
P6––D1, P13––5
P6––D2, P13––6
P6––D2, P6––D4
P6––D5, P6––C5
P6––D4, P5––C
P6–C1, P2––1
P6––C2, P5––B
P6––C2, P6––C4
P6––CS, P6––B5
P6––C4, P2––3
P6––B2, P14––6
P6––B2, P6––B4
P6––B5, J17
P6––B4, P5––A
P5––A, P8––J
P5––B, P8––K
P5––C, P1O––F
P5––D, P9––A
P5––D, P3––3
P5––E, J17
P5––E, P5––F
P5––F, P5––G
P5–G, P5––H
P5––H, J8
J6, P11––4
J6, J9
J7, P9–B
J8, J11
J9, J12
J10, P9––C
J11, J13
J12, P4––A
J13, P14––8
J14, J16
P4––B, P9––D
P4––Y, P6––H5
J14, P3––1
P3––2, P2––1
P1––1, P10––D
P1––2, P1––5
J16, P12––4
P14––2, P9–F
P14––3, P14––5
P14––5, P6–B1
P14––6, P14––7
P14––8, P13––8
P13––2, P10––E
P13––3, P13––5
P13––6, P13––7
P13––8, P12––3
P12––1, P9––G
P12––5, P7–H
P12––6, P9––H
P11––2, P10––B
P11––3, J2
P11––6, P10––A
P1––1, P7––E
Groundsmaster 3000–D
Wiring Diagram (Front Section)
Page 12 – 14
P18
NEUTRAL
SWITCH
P16
FLOAT/HOLD
SOLENOID
P12
PTO
COIL
BA
BA
AB
THERMAL
BREAKER
J6
J7
X
X
X
X
X
X
X
X
X
X
X
X
X
X
P11
SEAT
SWITCH
J5
1
STARTER
2
J8
”S3”
D
W22
J3
GLOW
PLUGS
BA
W24
J13
GROUND
W30
W37
1 2
W45
P17
LIFT/XBAL
SOLENOID
AB
P2
TEMPERATURE
SWITCH
SENDER
P14
DECK
POSITION
SWITCH
P15
TRANSPORT
SOLENOID
P19
CHARGE
CIRCUIT
PROTECTION
P13
SERVICE
BRAKE
SWITCH
AB
BA
2 1
P5
INJECTION
ADVANCE
2 1
A B
P3
THERMISTER
3 2 1
J10
CRUISE
COIL
J9
P6
LOW
COOLANT
LEVEL
”S1”
B A
W4
P20
W16
W39
W42
W44
W46
”S2”
W3
W15
1 2 3 4 5 6 7
W18
J4
W40
ALTERNATOR
P1
WATER
IN
FUEL
W47
3 2 1
J14
P7
PREHEATING
UNIT
J11
PREHEATING
UNIT
2 1
J12
P4
OIL
PRESSURE
FUEL
SENDER
J1
J2
P8
P9
P10
HARNESS
INTERFACE
A
B
C
D
H
G
F
E
A
B
C
D
E
+ + + + +
+ + + + +
F
E
D
+ + + +
+ + + +
+ + +
+ + +
A
B
C
K
J
H
G
F
Groundsmaster 3000–D
Harness Drawing (Rear Section)
Page 12 – 15
5
6
7
8
J18
ACCESSORY
1
2
3
4
5
5
E
4
1
3
F
1
3
4
2
25
5
D
4
1
G
3
1
3
4
2
2 5
5
PTO
SWITCH
2
B
Y
S
1
3
2
25
A
1 +
+
3
4
+
+
+
4
5
B
1
4
J
SEAT
CAPACITOR
J2
J3
IGNITION
SWITCH
+
C
4
1
H
1
3
HOUR
METER
2
2
5
6
1
4
K
1 2 3 4 5 6
J13
J12
P12
P11
3
4
DECK
CAPACITOR
J4
J5
WARNING
LIGHT
CLUSTER
WARNING
LIGHT
CLUSTER
1 2 3 4 5 6
5
X
P1
P4
J14
3
6
P2
FLOAT/HOLD
SWITCH
1
2 3
3
A
2
3
1
2
BA
P16
IMPLEMENT
P15
KIT
LIGHT
P3
LIFT/XBALD
SWITCH
J1
INPUT
POWER
2
3
1
J17
GROUND
P7
P5
P13
TRANSPORT
SWITCH
DIODE
PACK
P9
D E F
E F G H
F G H J K + + + +
+ + + + +
+ + + +
+ + + + +
D C B A
E D C B A
++
++
++
DIODE
PACK
H
G
F
E
D
C
B
A
++++++++
++++++++
H
G
F
E
D
C
B
A
P10
C B A
P8
J15
J16
HIGH TEMPERATURE
OVER-RIDE
J6
J7
J8
TEMPERATURE
GAUGE
J9
J10
FUEL
GAUGE
J11
3
6
3
6
2
5
2
5
1
4
1
4
8
7
8
7
P14
CRUISE
SWITCH
Groundsmaster 3000–D
Harness Drawing (Front Section)
HARNESS-INTERFACE
Page 12 – 16

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