toro 3000d groundskeeper

8/9/2019 toro 3000d groundskeeper

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Part No. 96890SL Rev. C

Service Manua

Groundsmaster

3000/3000DPreface

The purpose of this publication is to provide the servicetechnician with information for troubleshooting, testing,

and repair of major systems and components on theGroundsmaster 3000 and 3000D.

REFER TO THE TRACTION UNIT AND CUTTINGUNIT OPERATORS MANUALS FOR OPERATING,MAINTENANCE AND ADJUSTMENT INSTRUC-TIONS. Space is provided in Chapter 2 of this book toinsert the Operators Manuals and Parts Catalogs foryour machine. Replacement Operators Manuals are

available by sending complete Model and Serial Number to:

The Toro Company8111 Lyndale Avenue SouthBloomington, MN 55420

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

ING, or CAUTION, PERSONAL SAFETYThis safety symbol means DANGER, WARN-

INSTRUCTION. When you see this symbol,carefully read the instructions that follow.Failure to obey the instructions may result inpersonal injury.

NOTE: A NOTE will give general information about thcorrect operation, maintenance, service, testing or re

pair of the machine.

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


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Table Of Contents

Chapter 1 Safety

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 4

Chapter 2 Product Records and Maintenance

Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1Equivalents and Conversions . . . . . . . . . . . . . . . . 2 2Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 3

Maintenance Quick Reference Aid . . . . . . . . . . . . 2 4

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5Equipment Operationand Service History Reports . . . . . . . . . . . . . . . . 2 9

Chapter 3 Ford Gasoline Engine

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2General Information . . . . . . . . . . . . . . . . . . . . . . . . . 3 2

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 4FORD VSG411/413 ENGINE SERVICE MANUAL

Chapter 4 Peugeot Diesel Engine

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3

Chapter 5 Hydraulic System and Transaxle

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General Information . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . 5

Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . 5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 2SAUERSUNDSTRAND IHT SERVICE MANUAL

Chapter 6 Electrical System

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Troubleshooting (GM3000) . . . . . . . . . . . . . . . . . . 6 Troubleshooting (GM3000D) . . . . . . . . . . . . . . . . 6

Electrical System Quick Checks . . . . . . . . . . . . . . 6 Component Identification and Testing . . . . . . . . . . 6

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 6 3

Chapter 7 Rear Axle (2WD)

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 7


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Table of Contents (continued)

Chapter 9 84Cutting Units

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 9 7

Chapter 10 Contour 82Cutting Unit

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3

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

Chapter 11 72Cutting Units

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 11

Chapter 12 Electrical Diagrams

Groundsmaster 3000 . . . . . . . . . . . . . . . . . . . . . . 12 Groundsmaster 3000D . . . . . . . . . . . . . . . . . . 12 1


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Chapter 1

SafetyTable of Contents

SAFETYINSTRUCTIONS ...................... 1BeforeOperating ............................ 1WhileOperating ............................. 2

Safety Instructions

The GROUNDSMASTERR 3000 and 3000-D wastestedandcertifiedbyTOROforcompliancewiththeB71.41990 specificationsof theAmericanNationalStandardsInstitute.Althoughhazardcontrolandaccidentpreventionpartiallyaredependentuponthedesignandconfigurationofthemachine,thesefactorsarealsodependentupontheawareness,concern,andpropertrainingofthepersonnelinvolvedintheoperation,transport,maintenance,andstorageofthemachine.Improperuseormaintenanceofthemachinecanresultininjuryordeath.Toreducethepotentialforinjuryordeath,complywiththefollowingsafetyinstructions.

MaintenanceandService .....................SAFETYANDINSTRUCTIONDECALS..........

CAUTION

TO REDUCE THE POTENTIAL FOR INJURY

OR DEATH, COMPLY WITH THE FOLLOWINGSAFETY INSTRUCTIONS.


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7. Checkinterlockswitchesdailyforproperoperation.Donotrelyentirelyonsafetyswitches-shutoffengine

beforegettingoffseat.Ifaswitchfails,replaceitbefore

operatingthemachine.Theinterlocksystemisforyour

protection,so donotbypass it. Replaceall interlock

switcheseverytwoyears.Interlockswitchesshouldbe

adjustedso:

A. Enginecannotbestartedunlesstractionpedal

isreleased(neutralposition).

B.Enginestops ifoperator getsoffseatwhen

tractionpedalisdepressed.

C.PTOdisengagesifoperatorgetsoffseatwhen

PTOleverisENGAGED(onposition).

8. Fillfueltankwithdieselfuelbeforestartingtheen

gine.Avoidspillinganyfuel.Sincedieselfuelisflammable,handleitcarefully.

A.Useanapprovedfuelcontainer.

B.Donotfillfueltankwhenengineishotor

running.

C.Donotsmokewhilehandlingfuel.

D.Fillfueltankoutdoorsanduptoaboutone

inch(25mm)fromthetopofthetank,not

thefillerneck.E.Wipeupanyspilledfuel.

9. Sitontheseatwhenstartingtheengineandoperatingthemachine.

10. Always use seat beltand ROPS together. Make

sureseatislatched.

11. Beforestartingtheengine:

A.Engageparkingbrake.B.Makesuretractionpedalisinneutral.

C.Afterengineisstarted,releaseparkingbrake

andkeepfootofftractionpedal.Machinemustnot

move.Ifmovementisevident,theneutralreturnmechanismisadjustedincorrectly.Shutengine

offandadjustuntilmachinedoesnotmovewhen

tractionpedalisreleased.

12. Donotruntheengineinaconfinedareawithoutadequateventilation.Exhaustfumesarehazardousand

couldpossiblybedeadly.

13. Maximumseatingcapacityisoneperson.Therefore,nevercarrypassengers.

14. Thistractionunitisintendedtobeusedwithanim

plement. Refer to implement operators manual for

soundandvibrationinformationandrearweightrequire

ments.15. Check carefully for overhead clearances before

drivingunderanyobjects.

While Operating


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24. Donottouchengine,muffler,orradiatorwhileengineisrunningorsoonafterithasstopped.Theseareas

couldbehotenoughtocauseaburn.

25. Lowerthecuttingunitorotherattachedimplement

tothegroundandremovekeyfromswitchwhenever

machineisleftunattended.

26. Beforegettingofftheseat:

A. Movetractionpedaltoneutralpositionandremovefootfrompedal.

B.SettheparkingbrakeanddisengagethePTO

C.Shuttheengineoffandremovekeyfromigni

tionswitch.Waitforallmovementtostopbefogettingofftheseat.

Maintenance

27. Removekeyfromignitionswitchtopreventaccidentalstartingoftheenginewhenservicing,adjusting,

orstoringthemachine.

28. Ifmajorrepairsareeverneededorassistanceisde

sired,contactanAuthorizedTORODistributor.

29. Toreducepotentialfirehazard,keeptheenginefree

ofexcessivegrease,grass,leaves,andaccumulations

ofdirt.Neverwashawarmengineorelectricalconnec

tionswithwater.

30. Ifthecuttingunitdischargeareaeverplugs,disengagePTOandshutengineoffbeforeremovingtheob

struction.

31. Makesuremachineisinsafeoperatingconditionby

keepingnuts,bolts,andscrewstight.Checkattachmentmountinghardwareandallcuttingunitblademounting

boltsfrequentlytoassuretheyaretorquedtoproper

specifications.

32 Periodically inspect the roll bar and roll bar mount

Hydraulicfluidescapingunderpressurecanhavesufficientforcetopenetrateskinanddoseriousdamage.

fluidisejectedintotheskin,itmustbesurgicallyre

movedwithinafewhoursbyadoctorfamiliarwithth

formofinjuryorgangrenemayresult.

35. Beforedisconnectingorperforminganyworkonthhydraulicsystem,allpressureinsystemmustbere

lievedbystoppingengineandloweringimplementtoth

ground.

36. Iftheenginemustberunningtoperformmainte

nanceoranadjustment,keepclearofPTOshaft,cuttingunitblades,andothermovingparts.

37. Donotoverspeedtheenginebychangingthegovernorsettings.Toensuresafetyandaccuracy,haveaAuthorizedTORODistributorcheckmaximumengin

speedwithatachometer.

38. Enginemustbeshutoffbeforecheckingoilorad

dingoiltothecrankcase.


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Safety and Instruction Decals (Groundsmaster 3000)

ible,installanewdecal.Partnumbersarelistedbeloworinyourpartscatalog.

(Part No. 671710)

Thefollowingsafetyandinstructiondecalsaremountedonthetractionunit.Ifanydecalbecomesdamagedorilleg

On Side of Tool Box

Next to Right Side of Seat In Compartment Behind Control panel

(Part No. 935935) (Part No. 935933)

(Part No. 773100)

On Hood

ON FAN SHROUD


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Safety and Instruction Decals (Groundsmaster 3000D)

Thefollowingsafetyandinstructiondecalsaremountedonthetractionunit.Ifanydecalbecomesdamagedorilleg

ible,installanewdecal.Partnumbersarelistedbeloworinyourpartscatalog.

(Part No. 671710)

In Compartment Behind Control panel

On Side of Tool Box

Next to Right Side of Seat (Part No. 935932)

(Part No. 773100)

(Part No. 935934)

ON FAN SHROUD


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Safety and Instruction Decals (84ICutting Units)

Thefollowingsafetyandinstructiondecalsaremountedonthecuttingunit.Ifanydecalbecomesdamagedorillegible,

installanewdecal.Partnumbersarelistedbeloworinyourpartscatalog.

On Each Corner OfOn Front of Cutting Unit

Cutting Unit On Right & Left Covers (Part No. 688340)(Part No. 930299)(Part No. 438480)

On Gearbox BaseOn Front of Deck(Part No. 881270)

(Part No. 936697) On Deck Channels, Under Covers(Part No. 856410)


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On Front of Deck(Part No. 661340)

On Front Of Deck(Part No. 937824)

Replaces Decal Part No.

661340 for CE

On Rear of Deck(Part No. 666380)

On Rear Of Deck(Part No. 937828)


666380 for CE

On Each Castor Arm(Part No. 934894)


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Safety and Instruction Decals (Guardian 72IRecycler Cutting Unit)

Thefollowingsafetyandinstructiondecalsaremountedonthecuttingunit.Ifanydecalbecomesdamagedorillegible


On Front of Cutting UnitOn Each Corner Of On Left Caster Arm (Part No. 688340)Cutting Unit (Part No. 930299)(Part No. 438480)

On Gearbox Base

(Part No. 936697) On Deck Channels, Under Covers(Part No. 856410)


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Safety and Instruction Decals (Rear Discharge 72ICutting Unit)

Thefollowingsafetyandinstructiondecalsaremountedonthecuttingunit.Ifanydecalbecomesdamagedorillegible,


On Gearbox Base(Part No. 936697)




688340 for CE On Front Deck Hanger(Part No. 934690)


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666380 for CE




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Chapter 2

Product Records and MaintenanceTable of Contents

PRODUCTRECORDS......................... 1EQUIVALENTSANDCONVERSIONS ........... 2

DecimalandMillimeterEquivalents ............ 2U.S.toMetricConversions ................... 2

TORQUESPECIFICATIONS ................... 3CapscrewMarkingsandTorqueValuesU.S. .. 3

CapscrewMarkingsandTorqueValuesMetric . 3QUICKREFERENCEMAINTENANCEAID....... 4

Product Records

RecordinformationaboutyourGroundsmaster3000or

3000DontheOPERATIONANDSERVICEHISTORYREPORTform.Usethisinformationwhenreferringtoyourmachine.

LUBRICATION ................................TractionUnit ................................CuttingUnits ................................

OPERATIONANDSERVICEHISTORYREPORTS

InsertOperatorsManualsandPartsCatalogsforyou

Groundsmaster3000or3000Dattheendofthissection.


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Equivalents and Conversions


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Torque Specifications


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800 800


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Lubrication

Traction Unit

CAUTION

Before servicing or making adjustments to the

machine, stop engine and remove key from the

switch.

Themachinehasgreasefittingsthatmustbelubricatedregularly with No. 2 General Purpose Lithium Base

Grease. Ifmachine isoperatedundernormal condi-tions,lubricateallbearingsandbushingsafterevery50hoursofoperationorimmediatelyaftereverywashing.

Thegreasefittinglocationsandquantitiesare:

2 Wheel Drive Models onlySteeringcylinderballjoint,Rearaxletierod(2),Rearaxlepivot(1)RearSpindleShafts(2)(Fig.1).

4 Wheel Drive Models onlySteering cylinder balljoints,Rearaxletierod(2),Rearaxlepivot(1),DoubleCardanjoints(2ea.side)(Fig.2)andRearDrIveShaft(3)(Fig.3)

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

Figure3


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Cutting Units

Ifmachineisoperatedundernormalconditions,lubri

catecastorbearingsandbushingswithNo.2generalpurpose lithium base grease or molybdenum base

grease,afterevery8hoursofoperationordaily,whichevercomesfirst.Lubricatefittingsimmediatelyaftereverywashing,regardlessoftheintervallisted.

Guardian 84IRecyler Cutting Unit

CAUTION



switch.


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Rear Discharge 84ICutting Unit

Figure8

Contour 82ICutting Unit


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Guardian 72IRecycler Cutting Unit

Figure10

Rear Discharge 72ICutting Unit


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EQUIPMENTOPERATIONANDSERVICEHISTORYREPORTfor

GROUNDSMASTERR3000


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GroundsmasterR3000 Maintenance Schedule

Minimum Recommended Maintenance Intervals

LubricateAllGreaseFittings

InspectAirFilter

CheckBatteryLevel/CableConnections

CheckCuttingUnitGearboxOilLevel

CleanUnderCuttingUnitBeltCovers

CheckCuttingUnitDriveBeltAdjustment

} ChangeEngineOilandFilter

InspectCoolingSystemHoses

{

{

CheckGovernorOilLevel

ServiceAirFilter

ChangeFuelFilter

Maintenance Procedure

Every50hrs

Every100hrs

Every200hrs

Every800hrs

Maintenance Interval & Service

Every400hrs

A LevelService

B LevelService

C LevelService

CheckFan,GovernorandAlternatorBeltTension

TorqueWheelLugNuts

ServiceSparkArresterMuffler


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GroundsmasterR3000 Daily Maintenance Check List

UnitDesignation:__________

TOROID#:_____________

DailyMaintenance:(duplicatethispageforroutineuse)CheckpropersectionofOperatorsManualforfluidspecifications

MaintenanceCheck Itemb

Daily Maintenance Check For Week Of _________________

MON TUES WED THURS FRI SAT SUN

n SafetyInterlockOperation

n BrakeOperation

n EngineOil&FuelLevel

n CoolingSystemFluidLevel

n Radiator&ScreenforDebris

n UnusualEngineNoises

n UnusualOperatingNoises

n HydraulicSystemOilLevel

n HydraulicHosesforDamage

n

FluidLeaksn TirePressure

n InstrumentOperation

LubricateAllGreaseFittings1

TouchupDamagedPaint


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_____________

_______

_____________

_______

__________________________

________________________________

_____________

_______

_____________

_______

_____________

_______

_____________

_______

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_____________

_______

_____________

_______

Date:______

__________

every100hou

rs)

CService(every20

0hours)

(every800ho

urs)

eOilandFilter

gSystemHoses

aulicOil

aulicFilter

DServiceReq

uired

CheckGovernorOilLev

el

nceWorkO

rder

nofalldrivebelts

equired

TorqueWheelLugNuts

ServiceSparkArrestorM

uffler

AandBServiceRequired

O

therAnnualService&Specials

anFuelTank

eBearings

WheelToeIn

ReplaceMovingHoses

ReplaceSafetySwitches

CoolingSystemFlush/ReplaceFluid


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EQUIPMENTOPERATIONANDSERVICEHISTORYREPORTfor

GROUNDSMASTERR3000D


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GroundsmasterR3000D Daily Maintenance Check List

UnitDesignation:__________

TOROID#:_____________

DailyMaintenance:(duplicatethispageforroutineuse)CheckpropersectionofOperatorsManualforfluidspecifications

MaintenanceCheck Itemb

Daily Maintenance Check For Week Of _________________

MON TUES WED THURS FRI SAT SUN

n SafetyInterlockOperation

n BrakeOperation

n EngineOil&FuelLevel

n

CoolingSystemFluidLevel

DrainWater/FuelSeparator

n Radiator&ScreenforDebris

n UnusualEngineNoises1

n UnusualOperatingNoises

n HydraulicSystemOilLevel

n HydraulicHosesforDamage

n FluidLeaks

n TirePressure

n InstrumentOperation

LubricateAllGreaseFittings2

_


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____________________

____________________

___________________

_____________

___________________

_____________

_______________________________

____________________

____________________

____________________

____________________

_____________

_______

_______________________________

_______________________________

_______________________________

Date:______

__________

DServiceRequired

every100hou

rs)

CService(every20

0hours)

(every600ho

urs)

eOilandFilter

gSystemHose

s

iceRequired

ReplaceMovingHoses

ReplaceSafetySwitches

CoolingSystemFlush/ReplaceFluid

noteonMaint.S

ched.)

enoteonMaint.Sched.)

nanceWorkOrder

dAlternatorBeltTension

TorqueWheelLugNuts

AandBServiceRequired

gBelt

anFuelTank

arAxleBearing

s

WheelToeIn

O

therAnnualService&Specials

TimingBelt(seenoteo

nMaint.Sched.)


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General Information

TheengineusedintheGroundsmaster3000ismanufacuturedbyFordMotorCompany.OrderserviceandrepairpartsforFordenginesfromyoulocalFordPowerProductsDealer.SeetheFordVSG411/413EngineServiceManualforengineidentificationinformation.

Specifications

Item Specification

Make/Designation FordModelVSG411

FiringOrder 1243

IgnitionTiming DistributorlessIgnitionSystem(DIS)TimingcontrolledbyUniversalElectronicSparkControl(UESC)

SparkPlug MotorcraftAGSF22CorAGRF22orequivalent

SparkPlugGap 0.040in.(1.0mm)

CrankcaseOilCapacity 3.5U.S.qt.(3.25liter)includingfilter

OilServiceClassification APISG

OilViscosity Ambient temperature (single viscosity oil)10to+60_F SAE10+10_to+90_F SAE20Above+32_F SAE30Above+50_F SAE40

Ambient temperature (multiviscosity oil)Below+60_F SAE5W30


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Adjustments

Belt Adjustments

Checkconditionandtensionofbeltsafterevery100hoursofoperation. Replacebeltsasrequired.

Alternator Belt

Thealternatorbeltshouldbetensionedsowhenitispressedfirmlywiththumb,midwaybetweenpulleys,it

deflects.25inch(6.4mm).

1. Toadjustbelttension,loosenboltsecuringbraceto

engine,boltsecuringalternatortobraceandalternator

mountingbolt.

2. Rotatealternatorawayfromengine.

3. Holdalternatorinpositionafterproperbelttension

setting is achieved and tighten alternator and braceboltstosecureadjustment. Figure1

2

1

Cooling & Governor Fan Belts1. Cooling Fan Belt2. Governor Fan Belt

Thecoolingandgovernorfanbeltsbeltshouldbeten

sionedsowhentheyarepressedfirmlywiththumb,midwaybetweenpulleys,theydeflect.38inch(9.7mm).

1. Toadjustbelttension,loosenupperandlowernuts

securingidlerarmtofrontenginemount.

2. Pullout on idler armuntildesired belt tension is


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Governor Adjustment

1. Withengineshutoff,movethrottlecontroltoFASTpositionandopenhood.Checkbetweenthethrottlearmandthestoponthecarburetorbasetomakesurethere

is1/32(0.8mm).Ifgapisnotcorrect,adjustthrottlerodbyturningballjointendsuntilgapis1/32(0.8mm).Ifgapiscorrect,proceedtostep2.

Engine must be running so final adjust-

ment of the governor can be performed.guard against possible personal

hands, feet, face and other parts of the

body away from fan or other moving

parts.

WARNING

To

injury, engage parking brake and keep

2. StartengineandmovethrottletoSLOWposition.Allowenginetowarmuptonormaloperatingtemperature.

3. Rotatethrottlearmcloseduntilitcontactsstop.

4. Checkidlespeedandadjustcarburetoridlespeedscrew if necessary to attain 1350 + 50 rpm

9. Bumpthethrottleleverwithyourhandsoenginespeedsupmomentarily.Ifgovernorisworkingproperly,enginespeedshouldreturntonormalwithinoneortwo

surgesofthegovernor.Morethantwosurgesofthegovernorusuallyindicatesthantheantisurgescrewmustbeturnedinslightlymorethanitis.Whenadjustmentiscorrect,lockjamnutagainstgovernorbody.

10. Checklowandhighidlespeedtobesurethereisnochangefromtheinitialsetting.Ifhighidlespeedhasincreased,antisurgehasbeenturnedintothegovernortoofaranditmustbebackedout.Thenrepeattheentireadjustmentprocedure.

Note:IfthethrottlecontrolontheinstrumentpanelwillnotstayintheFASTpositionduringoperation,removethepanelcoverandtightenthenutatbaseofthrottleleverassembly.

1

23

4

5

S i d R i


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Service and Repairs

Check Engine Oil

Crankcasecapacityis31/2U.S.qt.(3.3liter)withfilter.1. Parkmachineonalevelsurface.Rotatehoodlatchfullycounterclockwiseandopenhood.

2. Removedipstickandwipeitwithacleanrag.Insert

dipstickintotubeandmakesureitisfullyseated.Re

movedipstickandchecklevelofoil.Iflevelofoilislow,

addenoughoiltoraiseleveltonotchindipstick.DONOTOVERFILL.

3. Installdipstickintotube.4. Ifoillevelislow,cleanareaaroundoilfillcap,re

movecapandaddoiluntillevelreachesFULLmarkon

dipstick.DONOTOVERFILL.

1

5. Theengineusesanyhighqualitydetergentoilhav- Figure 4

ing the American Petroleum InstituteAPIservice 1. Hood Latch

classificationSG.Oilviscosityweight mustbe se

lectedaccordingtoambienttemperature.Temperature/

viscosityrecommendationsare:

Single Viscosity Oils

Outside Temperature

10_Fto+60_F SAE10W

+10_Fto+90_F SAE20W20

1


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Change Engine Oil and Filter

Changeoilandfilterinitiallyafterthefirst50hoursofop

eration,thereafterchangeoilandfilterevery100hours.

1. Removedrainplug(Fig.7)andletoilflowintodrain

pan.Whenoilstops,installdrainplug.

2. Removeoilfilter(Fig.8).Applyalightcoatofcleanoiltothenewfiltersealbeforescrewingiton.DONOT

OVERTIGHTEN.

3. Addoiltocrankcase.Capacityis3.5U.S.quarts

(3.3liters)withfilter.RefertoCheckEngineOil.1

Figure 71. Drain Plug

1

Figure 81. Oil Filter


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Check Coolant

Capacityofsystemis9U.S.qt.(8.5liters).

Cleandebrisoffscreen, oilcoolerandradiatordaily,

hourlyifconditionsareextremelydustyanddirty;refer

toCleaningRadiatorandScreen.

Thecoolingsystemisfilledwitha50/50solutionofwaterandpermanentethyleneglycolantifreeze.Checklevel

ofcoolantatbeginningofeachdaybeforestartingthe

engine.

1. Parkmachineonalevelsurface.Rotatehoodlatch

fullycounterclockwiseandopenhood.

2. Checkcoolantlevel.CoolantshouldbeuptoCOLD

lineonreservetank,whenengineiscold.

1

COLD

HOT

CAUTION

If engine has been running, pressurized

if radiator cap is removed. Allow engineto cool at least 15 minutes or until the

radiator cap is cool enough to touch

hot coolant can escape and cause burns

without burning hand.

Figure 91. Reserve Tank


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Cooling System Service

1. Removing Debris Remove debris from rear

screen,oilcoolerand radiatordaily, cleanmore fre

quentlyindirtyconditions.

IMPORTANT: Never spray water onto a hot engine asdamage to engine may occur.

A. Turnengineoff and cleanhoodscreen thor

oughly.

B.Releasehoodlatchandraisehood.Cleanengine

areathoroughlyofalldebris.

C. Cleanbothsidesofoilcoolerandradiatorarea

thoroughlywithcompressedair.Do not use water.

1

D. Closehoodandsecurelatch. Figure 101. Rear Screen

Note:Donotusewatertocleanengineorelectrical

components,asdamagemayoccur.

2. Maintaining Cooling System Capacity of the

systemis9quarts(8.5liters). Alwaysprotectcooling

systemwitha50/50solutionofwaterandpermanent

ethylene glycol antifreeze. DO NOT USE WATER

ONLYINCOOLINGSYSTEM.

A. Afterevery100operatinghours, inspectandtightenhoseconnections.Replaceanydeteriorated

hoses.

2

1

Figure 11B. Afterevery2years,drainandflushthecooling

1. Oil Coolersystem.Addantifreeze (refer toCheck Cooling 2. RadiatorSystem)


43/242


44/242

Fuel System Service

Fuel Tank

Drainandcleanfueltankevery800hoursofoperationor

yearly,whichevercomesfirst.Also,drainandcleantank

iffuelsystembecomescontaminatedorifmachineistobestoredforanextendedperiod.Usecleanfueltoflush

outthetank.

Fuel Lines and Connections

Checklinesandconnectionsevery400hoursoryearly,

whichevercomesfirst.Inspectfordeterioration,dam

age,orlooseconnections.

DANGER

Because gasoline is flammable, caution mustbe used when storing or handling it. Do not fill

fuel tank while engine is running, hot, or when

filling the fuel tank to prevent the possibility of

an explosion. Always fill fuel tank outside andwipe up any spilled gasoline before starting

engine. Use a funnel or spout to prevent spil-

ling gasoline and fill tank to about 1 inch (25

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


45/242

Replacing Spark Plugs

Changesparkplugsafterevery400operatinghoursto

assureproperengineperformanceandreduceexhaust

emissionlevel.

CorrectsparkplugtouseisaMotorcraftAGSF22CorAGRF22orequivalent.

Recommendedairgapis.040(1.016mm).

Note:Thesparkplugusuallylastsalongtime;however,theplugshouldberemovedandcheckedwheneverthe

enginemalfunctions.

1. Cleanareaaroundsparkplugssoforeignmatter

cannotfallintocylinderwhensparkplugisremoved.

2. Pullsparkplugwiresoffsparkplugsandremove

plugsfromcylinderhead.

3. Checkconditionofsideelectrode,centerelectrode

andcenterelectrodeinsulatortoassurethereisnodam

age.

IMPORTANT: A cracked, fouled, dirty or otherwismalfunctioning spark plug must be replaced. Do no

sand blast, scrape, or clean electrodes by using wire brush because grit may eventually releas

from the plug and fall into the cylinder. The result i

usually a damaged engine.

4. Setairgapbetweencenterandsideofelectrodesa

.040(1.016mm).Installcorrectlygappedsparkplu

andtightenplugto1115ftlb.Iftorquewrenchisno

used,tightenplugfirmly.

5. Installsparkplugwires.

Check Governor Oil Level

Thegovernorisshippedwithoilinit,butthelevelofoilmustbecheckedafterevery250hoursofoperation.

1. Positionmachineonlevelsurfaceandshutengineoff.

2. Disengagehoodlatchandopenthehood.

3. Cleanareaaroundcheckplugongovernor.


46/242

Servicing Spark Arrestor Muffler

Every200hoursoperation,clearthemufflerofcarbon

buildup.

1. Removepipeplugfromcleanoutportatlowerside

ofmuffler.

CAUTION

Be careful while working around muffler as it

may be hot and could cause injury.

2. Startengine.Plugthenormalmufflerexitwithblock

ofwoodormetalplatesoexhaustflowwillbeforcedout

ofthecleanoutport.Continuetoblockexituntilcarbon

depositsceasecomingoutport.

CAUTION

Do not stand in line with the cleanout

port. Always wear safety glasses.


47/242

Chapter 4

Peugeot TUD5 Engine

Table of Contents

SPECIFICATIONS 2............................ FuelSystemService ........................ 1SPECIALTOOLS 3............................. PrimingFuelSystem........................ 1ADJUSTMENTS 8.............................. Frame,FuelTankandBattery ................ 1

BeltAdjustments 8............................ MufflerandRearBumper .................... 1SERVICEANDREPAIRS 9...................... Hood ..................................... 1

CheckEngineOil 9............................ FanBracketandDegasser .................. 1ChangeEngineOilandFilter 10................. CenterShroudandAirCleaner............... 2CheckCoolingSystem .......................11 RadiatorandCooler ........................ 2CoolingSystemService 12..................... Engine .................................... 2GeneralAirCleanerService 13................. PeugeotTUD5Overhaul,Checking,Tuning.... 2ServicingAirCleaner 13.......................

Specifications


48/242

Specifications

Item Specification

Make/Designation PeugeotTUD54cycle,inline,overheadcam,

liquidcooleddieselengineGovernorAdjustment Highidle2650+50RPM

LowIdle1500+100R{M

Oil SAE15W40CE

Oilcapacity 4.75U.S.qt.withfilter(4.5liters)

Coolant 50/50mixturewaterandPeugeotrecommendedantifreeze

(ToroPartNo.937213)

Coolantcapacity 11.5U.S.qt.(10.9liters)

Special Tools


49/242

Special Tools

Compression Test Kit (TOR3003A)

01000PSIGaugeallowstestingofdieselenginestocheckgeneraloperatingconditionofengine.

Kitcontains:

CaseGaugewithhoseGlowplugholeadapters

Figure3

Valve Spring Compression Tool (TOR4024T)

Useforremovingvalvesprings.


50/242

Injection Nozzle Tester (TOR463610)

Whenusedalongwiththeadapter,TOR437580,injec

tionnozzlesmaybeexaminedbyperformingthefollowingtests:

Injectionpressuretest.Chatteringtest.

Nozzleleakagetest.Spraytest.

Figure6

Digital Belt Tension Tool (TOR4075)

Toolisusedtoaccuratelyadjustthecamdrivebelttension.NOTE: This tool is not included in TOR4080 kit.

Order separately.


51/242

C h f Pi i S i T l (TOR4084)


52/242

Camshaft Pinion Setting Tool (TOR4084)

Toolisusedtoholdthecamshaftgearand/orinjector

pumpgearwhiletighteningthefasteners.

Figure12

Timing Pin Set (TOR4085)

Toolsetisusedtosetinjectionpumpenginetiming.

F t S l I t ll (TOR4087)


53/242

Front Seal Installer (TOR4087)

Toolisusedtoinstallthecrankshaftfrontseal.

Figure15

Camshaft Seal Installer (TOR4088)

Toolisusedtoinstallthecamshaftseal.

Adjustments


54/242

j

CAUTION



switch.

Engine Belts

Checkconditionandtensionofbeltsafterevery100hoursofoperation(Fig.17).Replacebeltsasrequired.

Alternator Belt

1. Propertensionwillallow1/8in.(3.2mm)deflection

onthebeltmidwaybetweenthepulleys,whenpressed

firmlywiththumb.

2. Ifdeflectionexceeds1/8in.(3.2mm),loosenalter

nator mountingbolts. Adjust belttensionandtighten

mountingbolts.Checkdeflectionofbeltagaintoassure

tensioniscorrect.

Fan Belt 2

1

1. Propertensionwillallow3/8in.(9.5mm)deflection Figure17onthebeltmidwaybetweenthepulleys,whenpressed

1. Fan Beltfirmlywiththumb. 2. Alternator belt

2 If deflection exceeds 3/8 in (9 5 mm) loosen pulley

Service and Repairs


55/242

CAUTION



switch.

Check Engine Oil

Crankcasecapacityis4.75U.S.qt.(4.5liters)withfilter.

1. Parkmachineonalevelsurface.Rotatehoodlatch

fullycounterclockwiseandopenhood.

2. Removedipstickandwipeitwithacleanrag.Insert

dipstickintotubeandmakesureitisfullyseated.Re

movedipstickandchecklevelofoil.Iflevelofoilislow,

addenoughoiltoraiseleveltonotchindipstick.DONOTOVERFILL.

3. Ifoillevelislow,cleanareaaroundoilfillcap,re

movecapandaddSAE15W40CEoiluntillevelreach

esFULLmarkondipstick.DONOTOVERFILL.4. Installoilfillcap.

1

5. Closehoodandsecurelatch. Figure181. Hood Latch



56/242


Changeoilandfilterinitiallyafterthefirst50hoursofop

eration,thereafterchangeoilandfilterevery100hours.

1. Removedrainplug(Fig.20)andletoilflowintodrain

pan.Whenoilstops,installdrainplugandnewplugseal,PartNo.747850.

2. Removeoilfilter(Fig.21).Applyalightcoatofclean

oiltothenewfiltersealbeforescrewingiton.DONOT

OVERTIGHTEN.

3. Add15W40CEoiltocrankcase.Capacityis4.75

quartswithfilter.

1

Figure201. Drain Plug

Check Cooling System


57/242

Check Cooling System

Checkcoolingsystemiflowwaterlevellightilluminates.

1. Park machine ona level surface.Release hood

latchandopenhood.

2. Removedegassertankcapandcheckcoolantlev

el.Coolant level should be up to or above tabs In de-

gasser tank, when engine is cold.

If engine has been running, pressurized

if degasser cap is removed. Allow engine

to cool at least 15 minutes or until thedegasser cap is cool enough to touch

CAUTION

Figure22

1

Capacityofsystemis11.5qts.(10.9l).

hot coolant can escape and cause burns

without burning hand.

1. Degasser Tank

3. Ifcoolantislow,removedegassertankcapandadda50/50mixtureofwaterandPeugeotrecommended

antifreeze(ToroPartNo.937213).DO NOT USE WA-

TER ONLY OR ALCOHOL/METHANOL BASE COOL-

ANTS.

4 I ll d k



58/242


1. Removing Debris Remove debris from rear

screen,oilcoolerand radiatordaily, cleanmore fre

quentlyindirtyconditions.

IMPORTANT: Never spray water onto a hot engine asdamage to engine may occur.

A. Turnengineoff and cleanhoodscreen thor

oughly.

B.Releasehoodlatchandraisehood.Cleanengine

areathoroughlyofalldebris.

C. Cleanbothsidesofoilcoolerandradiatorarea

thoroughlywithcompressedair.Do not use water.

D. Closehoodandsecurelatch.Note:Donotusewatertocleanengineorelectrical

components,asdamagemayoccur.

1

2. Maintaining Cooling System Capacity of the Figure23

systemis11.5quarts.Alwaysprotectcoolingsystem1. Rear Screen

with a 50/50 solution of water and Peugeot recom

mendedantifreeze(PartNo.937213).DONOTUSE

WATERONLYINCOOLINGSYSTEM.

A. Afterevery100operatinghours, inspectandtightenhoseconnections.Replaceanydeteriorated

hoses.

B. Afterevery2years,drainandflushthecooling

system. Addantifreeze(refertoCheckCooling

System)

2

1

General Air Cleaner Maintenance


59/242

General Air Cleaner Maintenance

1. Inspectaircleanerafterevery50hoursofoperation.

Morefrequentindustyordirtyconditions.

2. Checkaircleanerbodyfor damagewhichcould

possibly cause an air leak. Replace a damaged aircleanerbody.

3. Servicetheaircleanerfilterevery400hours(more

frequentlyinextremedustyordirtyconditions).Donot

overserviceairfilter.

4. Besurecoverissealingaroundaircleanerbody.

CAUTION

cleaner assembly in place and latched proper-

ly or a damaged air cleaner Debris entering en-

gine can cause engine failure.

Never operate machine without complete air

Servicing the Air Cleaner

1. Releaselatchessecuringaircleanercovertoair

cleanerbody.Separatecoverfrombody.Cleaninsideof

aircleanercover.

2. Gentlyslidefilter(Fig.26)outofaircleanerbodyto

reducetheamountofdustdislodged.Avoidknockingfil

teragainstaircleanerbody.

3. Inspectfilteranddiscardifdamaged.Donotwashorreuseadamagedfilter.

Washing Method

A. Prepareasolutionoffiltercleanerandwater

andsoakfilterelementabout15minutes.Referto

di ti filt l t f l t i 2

1

Fuel System Service


60/242

Fuel System Service

Drainandcleanfueltankevery800hoursofoperationor

iffuelsystembecomescontaminatedorifmachineistobestoredforanextendedperiod.Usecleanfueltoflush

outthetank.

DANGER

Because diesel fuel is highly flammable,

Do not smoke while filling the fuel tank. Donot fill fuel tank while engine is running,

hot, or when machine is in an enclosed

area. Always fill fuel tank outside and wipeup 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.

Figure27

1. Fuel Filter2. Drain Screw3. Primer plunger

3

2

1

Fuel Tank

yearly,whichevercomesfirst.Also,drainandcleantank

use caution when storing or handling it.

Fuel Lines and Connections

Checklinesandconnectionsevery400hoursoryearly,

whichevercomesfirst.Inspectfordeterioration,dam

age,orlooseconnections.

Priming Fuel System


61/242

g y

IMPORTANT: The fuel system may need to be

primed when a new engine is started for the first

time, if it runs out of fuel or if maintenance is

performed on the fuel system.

1. Unlatchandraisehood.

2. Inserta3/16inch (5mm)hoseoverbleedscrew

andrunotherendintoacontainertocatchfuel.

3. Loosenfuelfilter/waterseparatorbleedscrew(Fig.

28)afewturns.Pumpprimingplungeruntilasteadystreamoffuelcomesoutofholeinbleedscrew.When

fuelstopsfoaming,tightenthebleedscrewduringthe

downstrokeoftheprimingplunger.Wipeupanyspilled

1

2

fuel. Figure28

4. Pumpprimingplungeruntilresistanceisfelt.Tryto 1. Primer Plunger 2. Bleed Screw

startengine.Ifenginedoesnotstartrepeatstep3.

Frame, Fuel Tank and Battery


62/242

, y

36

37

38

39

1

2

3

4

56

78

910

16

17

18

21

22

23 24 25 26

27

11 1213

1415

44

28

19

35

2019

41

42

43

26

Muffler and Bumper


63/242

p

1 2

3

4 5

7

8

9

6

10

11

12

1

Hood


64/242

2

4

3

67

8

9

12

1314

17

19

18

1

5

11

20

Center Shroud and Air Cleaner


65/242

1

2

3 4 5

6

7

8

9

10

11

1213

20

1415

21

25

23

24

28

27

26

29

30

Fan Bracket and Degasser


66/242

1 2 3

5

6

7 89

10

16

17

18

19

11

12

13

14

20

22

21

2 23

Radiator and Cooler


67/242

33

1

23

4

5

7

8

9

10

18 19

20

5

2223242526

1112

13

4

34

35

36 37

38

39

13

40

4143

42 14

15

13

44

Fan clearanceminimum .18 inch (5 mm)

Pipe threadsealant

Pipe threadsealant

Engine


68/242

1

2

3

4

5

6

7

8 9 11

17 18

19

20

21

22

2324

25

26

27

2829

30

12

49

1415

16

2

4

41

34

3134

33

24

42

43

10

44

42

34

3624

47

13

50

32

2928

Peugeot TUD5 Overhaul, Checking Tuning


69/242

See the Peugeot Citroen Moteurs TUD5 Overhaul,

Checking,Tuningmanualfordetailedserviceinformation.SeetheToroPartsCatalogforpartsindentification.

RefertotheSpecial ToolsliststartingonPage43oftheToroGroundsmaster3000/3000DServiceManual.

ThetoolnumbersreferredtointhePeugeotmanualarePeugeotnumbers,whichTorodoesnotuse.

UsetheTOROlubrication,maintenanceandfluidrecommendationsiftheyaredifferentfromtheinformation

inthePeugeotmanual.


70/242

Chapter 5


71/242

p

Hydraulic System and Transaxle

Table of Contents

SPECIFICATIONS 2............................ SERVICEANDREPAIRS ..................... 2

GENERALINFORMATION 3..................... CheckTirePressure ........................ 2PushingorTowingTractionUnit 3............... CheckWheelNutTorque .................... 2HydraulicHoses 3............................. CheckHydraulicFluid....................... 2HydraulicFittingInstallation 3................... ChangeHydraulicOilandFilter .............. 2

HYDRAULICSCHEMATICS 6.................... TractionControlLinkage..................... 2HYDRAULICCOMPONENTS 8................... BrakeLinkage ............................. 2SPECIALTOOLS 9............................. Driveshafts ................................ 2

TESTING ....................................11 LiftArms .................................. 2ChargePressureTest 12....................... SteeringControl ............................ 2ForwardTractionTest 13....................... RemovingHydraulicSystemComponents ..... 3ReverseTractionTest 13....................... ManifoldBlock ............................. 3ImplementReliefPressureTest 14.............. CartridgeValves............................ 3CounterbalancePressureTest 15............... LiftCylinder................................ 3

SteeringCircuitTest 16........................ SteeringCylinder ........................... 3AuxiliaryHydraulicPumpEfficiencyTest 17....... AuxiliaryHydraulicPump .................... 3

ADJUSTMENTS 20............................. TransaxleService .......................... 3TractionPedalLinkage 20...................... SAUERSUNDSTRANDIHTSERVICEMANUALServiceBrakes 20.............................

Specifications


72/242

Item Specification

Transaxle SauerSundstrandIHTM15ChargePressure: 80130PSI(5.59Bar)

ImplementReliefPressure: 1,0001,100PSI(6976Bar)

TractionForwardPressure:6,200PSI(428Bar)maximumTractionreversepressure:5,000PSI(345Bar)maximum

ManifoldBlock Torologiccartridge,elec./hyd.,solenoidactuatedRecommendedCounterbalancePressure:

84inchdecks: 220PSI(15Bar)72inchdecks: 220PSI(15Bar)

Contour82deck: 100150PSI(710Bar)Brush: 225PSI(16Bar)

Blower: 7080PSI(56Bar)

ImplementReliefPressure(Model30724Hyd.Kit):

1,0001,100PSI(6976Bar)SteeringControl EatonSeries2steeringcontrolunitwithpowerbeyond

HydraulicFluid Mobil424(seeCheck Hydraulic FluidinServiceandRepairs

sectionofthischapterforalternatives)

HydraulicFluidCapacity Approximately12U.S.qts.(11.4liters)

General Information


73/242

Pushing or Towing Traction Unit

Inanemergency,thetractionunitcanbepushedor

towed.However,Torodoesnotrecommendthisasstandardprocedure.

IMPORTANT: Do no push or tow the traction unitfaster than 10 mph (16 km/hr). If traction unit must

be moved a considerable distance, transport it on a

truck or trailer.

1. Locatetowingleveronrightsideofaxleassembly.

2. Removecotterpinandclevispinsecuringlevertoplateonsideofaxle.

3. Pivotleverrearwarduntilholeisalignedwithrear Figure1holeinplate.Securelevertorearholewithcotterpinand 1. Towing Leverclevispinpreviouslyremoved.

1

4. After completion of towing operation, pivot lever

backtooriginalposition andresecure.


74/242

SAE Straight Thread ORing Port Nonadjustable

1.Makesureboththreadsandsealingsurfacesarefreeof burrs nicks scratches or any foreign material


75/242

ofburrs,nicks,scratches,oranyforeignmaterial.

2.AlwaysreplacetheOringsealwhenthistypeoffit-tingshowssignsofleakage.

3.LubricatetheOringwithalightcoatingofoil.

4.Installthefittingintotheportandtightenitdownfulllengthuntilfingertight.

5.Tightenthefittingtothecorrectflatsfromfingertight

(F.F.F.T.). Figure4

Size F.F.F.T.

4(1/4in.nominalhoseortubing) 1.00+.256(3/8in.) 1.50+.258(1/2in.) 1.50+.2510(5/8in.) 1.50+.2512(3/4in.) 1.50+.2516(1in.) 1.50+.25

SAE Straight Thread ORing Port Adjustable

1.Makesureboththreadsandsealingsurfacesarefreeofburrs,nicks,scratches,oranyforeignmaterial.

2.AlwaysreplacetheOringsealwhenthistypeoffit-tingshowssignsofleakage. Lock Nut

ORing

S2

Hydraulic Schematic


76/242

LIFT/LOW

ER

CONTROL

LIFT

SOLENOIDS

S1

S2

ON

OFF

L

P

B

P

RT

STEERIN

GCYLINDER

S

CYL1

CYL2

2.5BORE

3.5STROKE

1ROD

N1

S1

LC1

75220P

SI

P

S

OIL

COOLER

OU

T

LIFT/

COUNTER

BALANCE

MANIFOLD

1.625BO

RE

7.00STR

OKE

.625ROD

HOLD

OFF

OFF

OFF

ON

ADJORIFICE

STD.187

C3

P3

P2

T3

T1

T2

G1

T

LIFTCYLINDERS

LOWER

/FLOAT

Hydraulic Schematic

CK PLER

TRVOI

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


77/242

RT

INGCYLINDER

S2

CYL1

CYL2

2.5BORE

3.5STROKE

1ROD

N1

S1

G1

1000PSI

OUT

BORE

TROKE

OD

LC1

75220PSI

P

T2

T1

5PSI

C3

SUNDSTRANDIHT

ID

LE

1650RPM

LOADED1560RPM

QUICK

COUPLER

CCW

INPUT

33CC

ADJORIFICE

STD.187

3625

PSI

1750

PSI

1750

PSI

1750

PSI

1750

PSI

600PSI

OIL

COOLER

18CC

18CC

18CC

18CC

QUIC

COU

QUICK

COUPLER

IH

RESE

LIFT/

COUNTERBALANCE

MANIFOLD

SOLENO

IDS

LIFT/LOWER

CONTROL

A

M1

M2

M3

M4

LIFT

HOLD

ON

OFF

OFF

OFF

OFF

ON

S1

S2

PB

LIFTCYLINDERS

AUXFILTER

BRAKINGVALVE

DECKMOTORS

EDMOTOROPTION

DETAIL

LOWER/FLOAT


78/242

Special Tools

NOTE:OrderspecialtoolsfromtheTORO SPECIAL


79/242

pTOOLS AND APPLICATIONS GUIDE (COMMERCIAL

PRODUCTS).Sometoolsmayalsobeavailablefromalocalsupplier.

Hydraulic Pressure Test Kit TOR47009

Useto takevariouspressurereadingsfor diagnostictests.Quickdisconnectfittingsprovidedattachdirectlytomatingfittingsonmachinetestportswithouttools.Ahigh pressurehose isprovided for remote readings.Containsoneeach:1000PSI(70Bar),5000PSI(350Bar) and10000PSI(700Bar)gauges.Usegaugesas

recommendedinTestingsectionofthischapter.

Figure7

Hydraulic Test Fitting Kit TOR4079

ThiskitincludesavarietyofOringFacesealfittingsto

enableyoutoconnecttestgaugesintothesystem.

Hydraulic Tester With Pressure and Flow Capabilities TOR214678


80/242

Figure10

Testing

Themosteffectivemethodforisolatingproblemsinthe 1.Thoroughlycleanthemachinebeforedisconnectin


81/242

hydraulicsystemisbyusinghydraulictestequipmentsuchaspressuregaugesandflowmetersinthecircuitsduring various operational checks. (See the SpecialToolssectioninthisChapter.)

CAUTION

dures could result in damage to gauge andpossible personal injury from leaking hot oil.

Failure to use gauges with recommended

pressure (psi) rating as listed in test proce-

Before Performing Hydraulic Tests

Allobviousareassuchasoilsupply,filter,bindinglinkage,loosefasteners,orimproperadjustmentsmustbecheckedbeforeassumingthatahydrauliccomponentisthesourceoftheproblembeingexperienced.

Before disconnecting or performing any work

WARNING

on the hydraulic system, all pressure in the

or disassembling any hydraulic components. Alwaykeepinmindtheneedforcleanlinesswhenworkingonhydraulicequipment.

2.Putcapsorplugsonanyhydrauliclinesleftopenoexposedduringtestingorremovalofcomponents.

3.Theenginemustbeingoodoperatingcondition.Usa tachometer when making a hydraulic test.Engin

speedcanaffecttheaccuracyofthetesterreadings.

4.Topreventdamagetotesterorcomponents,theinleandtheoutlethosesmustbeproperlyconnected,an

notreversed(testerwithpressureandflowcapabilities

5.Tominimizethepossibilityofdamagingcomponents

completelyopenloadvalveinhydraulictester(whenuingtesterwithpressureandflowcapabilities).

6.Installfittingsfingertight,farenoughtoinsureththeyarenotcrossthreaded,beforetighteningwith

wrench.

7.Position thetesterhosesso thatrotatingmachinpartswillnotmakecontactwiththemandresultinhosortesterdamage.

8 Check the oil level in the reservoir

IMPORTANT: Test ports on the transaxle are paintedclosed. Opening the ports will loosen the paint.

Make sure dirt or paint particles do not fall into theopen port.


82/242

p p

Charge Pressure Test

NOTE:SeeSauerSundstrandIHTServiceManualformoreinformation.

Usea500or1,000PSI(35or70Bar)testgauge.

Specification:80to130PSI(5.5to9Bar)

1.Makesurehydraulicoilisatnormaloperatingtemper-aturebyoperatingthemachineforapproximately10

minutes.

2.Lowercuttingunit,engageparkingbrakeandstoptheengine.

3.Removetheplugfromthechargepressureportandinstalla500or1,000PSI(35or70Bar)pressuregaugewithextensionhose.

4.Starttheengineandmovethethrottlecontrolallthe

wayforward.Takepressurereadingwithmachinestationary.Alsotakeapressurereadingwhileoperatingthemachineinforwardandreverse.Totestinforwardandreverse,engagethebrakesandpushthetractionpedalforward,thenreverse.

1

Figure11

1. Charge pressure port

Forward Traction Test

NOTE: See SauerSundstrand IHT Service Manual for NOTE: When you move the traction pedal to creat


83/242

NOTE:SeeSauer SundstrandIHTServiceManualfor

moreinformation.

Usea10,000PSI(700Bar)gauge.

Specification:6,200PSI(428Bar)maximum

1.Makesurehydraulicoilisatnormaloperatingtemper-aturebyoperatingthemachineforapproximately10minutes.


3.Removetheplugfromtheforwardtractionpressureportandinstalla10,000PSI(700Bar)pressuregauge

withextensionhose.

4.On4WDmachines,raisetheimplementandengagethetransportswitchsotheIHToperateswithlesstorquetothewheels.Engagetheparkingbrake,andruntheengineatfullspeed.Slowlypushthetractionpedalforward

andlistenforengagementoftheeasyridevalve.Contin

uetopushthetractionpedalandreadthegauge.

NOTE:Whenyou move the tractionpedal tocreat

pressure,moveitashortdistancefirstandwaitforchangeinsoundbeforemovingthepedalfurther.Thchangeinsoundindicatesthattheeasyridevalveha

closed.

1

Figure12

1. Forward traction pressure port

Reverse Traction Test

NOTE: See SauerSundstrand IHT Service Manual for NOTE: When you move the traction pedal to creat


84/242

Counterbalance Pressure Test and Adjustment

Usea500or1,000PSI(35or70Bar)testgauge.


85/242

, ( ) g g

Recommend counterbalance pressure:

84 inch decks: 220PSI(15Bar)

72 inch decks: 220PSI(15Bar)Contour 82 deck: 100150PSI(710Bar)Brush: 225PSI(16Bar)Blower: 7080PSI(56Bar)


minutes.

2.Lowercuttingunit,engageparkingbrakeandstopthe

engine.

1

2

Figure17

3.Installa500or1,000PSI(35or70Bar)pressure 1. Test Port2. Counterbalance valve

gaugewithquickconnectadapteronthetestport.

4.Starttheengineandmovethethrottlecontrolallthewayforward.Readthegauge.Donotraisetheimplementwhentestingcounterbalancepressure.Movethe

liftleverforwardtomakesuretheliftsystemisinthefloatposition.

Steering Circuit Test

Thesteeringandimplementliftcircuitsareconnectedin 2.Lowercuttingunit,engageparkingbrakeandstopthe


86/242

g p

series.Iftheimplementliftoperatescorrectly,thesteeringvalvehasadequateflowandpressure.

Cylinder Test

This test checks the steering cylinder for internalbypass,andassumesthatthesteeringvalveisworkingcorrectly.TheSteeringValveTestwilldetermineifthesteeringvalveisfaulty.

1.Makesurehydraulicoilisatnormaloperatingtemper-aturebyoperatingthemachineforapproximately10minutes.


3.Install ateefittinganda 5,000PSI(350Bar) testgaugeontotherightsidesteeringcylinderfitting.UsepartsfromTOR4079testfittingkitorthefollowingToroparts:

Cap(340117)Plug(340116)Tee(340115)Quickconnectfitting(865480)

4.Starttheengineandmovethethrottlecontrolallthe

g g g p g p

engine.

3.Disconnecttheteefromthecylinder.Installacapon

thecylinderandaplugontheopenteeport.

4.Starttheengineandmovethethrottlecontrolalltheway forward. Gently rotate the steering wheel whileobserving the pressure gauge. If the pressure nowincreasesto1,100PSI(76Bar),thecylinderhasadamagedinternalseal.Repairorreplacethecylinder.Ifthe

pressuredoesnotincreasebyrotatingineitherdirection,repairorreplacethesteeringvalve.

1

Figure18

1. Right side steering cylinder fitting

Auxiliary Hydraulic Pump Efficiency Test (Model 30726 Hydraulic Kit)

Awornordamagedpumpwillbypassoilandmakethe


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pumplessefficient.Eventually,enoughbypassingwilloccurtocausethecuttingunitstotostallinheavycuttingconditions.Continuedoperationwithaworn,inefficient

pumpcangeneratealotofheatandcausedamagetosealsandothercomponentsinthehydraulicsystem.

Useatesterwithpressureandflowcapabilities.

Specification:Minimum12GPM(45liter/min.)at2,500PSI(173Bar)


minutes.


3.Disconnectthelargepressurehosefromthecoupleratthepump.Disconnectthelargereturnhosefromthe

coupleratthereturnfilter.Installthetesterbetweenthepumpoutletandfilterinlet.

IMPORTANT: Make sure the oil flow indicator on theflow meter shows that the oil will flow from thepump, through the tester and into the return filter.Make sure the flow control valve is open beforestarting the engine

Figure201. 45 degree fitting2. Quick coupler nipple3. Pump4. Splined coupler

5. Flush faced coupler6. Pump supply hose7. Hose bracket8. Square Oring

1

3

2

4

5 67

8

Flow

Thispageisblank.


88/242

Thispageisblank.


89/242


90/242

Service and Repairs

Wheel and Tires


91/242

Check Tire Pressure Check Wheel Nut Torque

Thetiresareoverinflatedforshipping.Therefore,releasesomeoftheairtoreducethepressure.Correctairpressureinthefrontandreartiresis15psi(1Bar).

IMPORTANT: Maintainevenpressureinalltirestoas

sureagoodqualityofcutandpropermachineperformance.DONOTUNDERINFLATE.

Kgm) after 1-4 hours of operation and again

after 10 hours of operation and every 200

WARNING

Torque wheel nuts to 7080 ftlb (1011

hours thereafter. Failure to maintain proper

torque could result in failure or loss of wheel

and may result in personal injury.

Lubrication

Themachinehasgreasefittingsthatmustbelubricatedregularly with No. 2 General Purpose Lithium BaseGrease. Ifmachine isoperatedundernormal conditions,lubricateallbearingsandbushingsafterevery50hours ofoperationorimmediatelyaftereverywashing.

IntermediateDriveShaft(3)(Fig.25),4WDRearDrIveShaft(3)(Fig.26),PedalPivots(5),Tractionpedal(In

t b d fl l t ) (1) (Fi 27) d Lift

Check Hydraulic Fluid

Thehydraulicsystemisdesignedtooperateonanti

wear hydraulic fluid The machines reservoir is filled at


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wearhydraulicfluid.Themachinesreservoirisfilledat

the factory with approximately 12 U.S. quarts (11.4

liters)ofMobil424hydraulicfluid. Check level of hy-

draulic fluid before engine is first started and dailythereafter.

1. Positionmachineonalevelsurface,raisetheimple

ment,andstoptheengine.

2. Unscrewdipstickcapfromthefillerneckandwipeitwithacleanrag.Screwdipstickcapfingertightontofiller

neck.Unscrewthedipstickandchecklevelofoil.Iflevel

isnotuptoFULLmarkondipstick,addenoughoilto

raiseleveltomark.DONOTOVERFILL.

3. Screwdipstickfillercapfingertightontofillerneck.

4. Lowertheimplement.

The following fluids are recommended for use:

ISO type 46/68 antiwear hydraulic fluid

Mobil MobilFluid424

Amoco Amoco1000

InternationalHarvester HyTran

Texaco TDHShell DonaxTD

UnionOIl Hydraulic/TractorFluid

Chevron TractorHydraulicFluid

BP Oil BP HYD TF

1

Figure291. Dipstick cap

Change Hydraulic Oil and Filter

Thehydraulicsystemoilandfiltermustbechangedini

tially at 200 hours and thereafter every 800 hours of op


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tiallyat200hoursandthereafterevery800hoursofop

eration or seasonally, whichevercomes first. NOTE:

Changeoilandfiltersevery400hoursifequippedwith

Model30726HydraulicKit.Thehydraulicsystemisdesignedtooperateonantiwearhydraulicfluid.Themachines reservoir is filled at the factory with

approximately12U.S.quarts(11.4liters)ofMobil424

hydraulicfluid(SeeCheckHydraulicOilinthissection

forrecommendedfluids). Check level of hydraulic

fluid before engine is first started and daily thereaf- Figure31ter. 1. Drain plug

1

1. Startengine,parkmachineonalevelsurface,lower

implementtotheshopfloor,settheparkingbrake,andshutengineoff.

2. Cleanareaarounddipstickcapand remove cap

fromaxlefillertube.

3. Toeaseaccesstoaxlehousingdrainplug,implementmayberemovedfromtractionunit.

4. Removedrainplugfrom axlehousingandallowoil

toflowintodrainpan.

5. Cleanareaaroundhydraulicoilfilterandremovefilter.NOTE:AlsoreplacefilterforModel30726Hydraulic

Kit.

1

Figure326 Lubricate new filter seal and install filter 1 H d li Filt

Traction Control Linkage

1 2 3 4 5 6 726


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1 2 3 4 5 6 7

8

910

1619

20

21

22

23

24

25

11

13

14

15

26

12

Brake Linkage


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1

3

4 5

6

7

89

11

16

17

8

18

19

1

2021

23

24

29

30

31

10

12

13

14

15

2

13

33

32

7

22

34

34

Driveshafts


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23

4

5

6

7

8

9

10

16

1718

11

12

13

14

1

19

15

2021

Neverseez


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Steering Control

30 31


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1

2

3

45 6

78

9 10

16

17

18

19

20

21

22

23

24

25

27

28

11

12

13

14

15

3

29

6

30 31

35 45 ftlb

(5 6 Kgm)

#4Tube


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#1#2

#3

#4

#5

#3Tube

#2Tube

#1Tube

#5Tube

Removing Hydraulic System Components

1.Thoroughlycleanthemachinebeforedisconnecting,

removingordisassemblinganyhydrauliccomponents.

2.Afterrepairs,checkcontrollinkageforproperadjust

ment,bindingorbrokenparts.


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Always keep inmind the need for cleanliness whenworkingonhydraulicequipment.

2.Putcapsorplugsonanyhydrauliclinesorfittingsleftopenorexposed.

3.Putlabelsondisconnectedhydrauliclinesandhosesforproperinstallationafterrepairsarecompleted.

After Repair or Replacement of Components

1.Checkoillevelinhydraulicreservoirandaddcorrect

oilifnecessary.Drainandrefillhydraulicsystemreservoirandchangeoilfilterifcomponentfailurewassevereorsystemiscontaminated.

3.Afterdisconnectingorreplacinganyhydrauliccomponents,operatemachinefunctionsslowlyuntilairis

outofsystem.

4.Checkforhydraulicoilleaks.Shutoffengineandcorrectleaksifnecessary.Checkoillevelinhydraulicreservoirandaddcorrectoilifnecessary.


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Cartridge Valves

1.Clean valve block toprevent contamination when

valvecartridgeisremoved.

Cartridge Installation

1 Lubricate all o rings with clean hydraulic oil


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2.Removecartridgevalve:

A.Removenutfromsolenoid.

B.Removesolenoidcoilandoringateachendofsolenoidcoil.

C.Useadeepsockettoremovecartridgevalve.

NOTE:Usecarewhenhandlingvalvecartridges,becauseslightbendingordistortionofstemtubecancausebindingandmalfunction.

3.Visuallyinspectportinblockfordamagetosealing

areas,damagedthreadsorcontamination.

4.Visuallyinspectcartridgefordamagedsealsandcontamination.

A.Orings and backup rings must be arrangedproperlyonthevalveforproperoperationandsealing.Replaceanydamagedseals.

B.Contaminationmaycausevalvestostickorhangup. Contamination can become lodged in smallvalveorificesorsealareasonpoppettypevalves

i lf i

1.Lubricatealloringswithcleanhydraulicoil.

2.Carefullythreadcartridgeintotheportbyhand.Valve

cartridgeshouldgoineasilywithoutbinding.

3.Useatorquewrenchanddeepsockettotightencartridgevalvestoatorqueof35ftlb(5Kgm).Excessivetorquemaycausethespooltobindandmalfunction.

NOTE: Use care when handling solenoid valve cartridgesbecauseslightbendingordistortionofstemtubecancausebindingandmalfunction.

4.Installsolenoidcoil.Makesurethereisanoringat

eachendofthecoil.ApplyLoctite242orequivalenttothreadsofstemtubebeforeinstallingnut.Tightennuttoatorqueof15inlb(17Kgcm).

5.Ifproblemstillexists,removevalveandcleanagain

orreplacevalve.

Lift Cylinder


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1

2

3

4

5

9

6

7

8

1011

1312

14

15

Steering Cylinder


104/242

1 23

4

56

78

910

16

19

11

1213

14

15

Auxiliary Hydraulic Pump (Model 30726 Hydraulic Kit)


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1

23

4

5

6

7

8

16

17

18

19

11

12

13

14

15

8

15:215:1

8:1

8:2

12:2

12:1 11:1

8:1

8:2

Transaxle Service

Toro recommended fluids andmaintenance intervals

maybedifferentthanthoselistedintheSauerSunds-trand IHT Service Manual When doing maintenance or

SomeofthecomponentsshownintheSauerSunds-

trandIHTServiceManualmaynotbeusedontheToroapplication See your Toro Parts Catalog for more in-


106/242

trandIHTServiceManual.Whendoingmaintenanceorserviceonthetransaxle,usetheTororecommendedfluidsandmaintenanceintervals.

application.SeeyourToroPartsCatalogformore in-formation.

12

34

5

6

7

8

1516

17

10

11

12

13

14

28

26

27

29

30

9 Brake rotor must be

45 50 ftlb(6 7 Kgm)

free of paint, grease,oil or other contamination

Chapter 6

Electrical System


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Electrical System

Table of Contents

ELECTRICAL SCHEMATICS, WIRING DIAGRAMS,ANDHARNESSDRAWINGS ................. 2

SPECIALTOOLS ............................. 3TROUBLESHOOTING(Groundsmaster3000) .... 4

StartingProblems(GM3000) ................. 4GeneralRun&TransportProblems(GM3000) . 5

CuttingUnitOperatingProblems(GM3000) .... 5TROUBLESHOOTING(Groundsmaster3000D).. 6StartingProblems(GM3000D) .............. 6GeneralRun&TransportProblems(GM3000D)7

CuttingUnitOperatingProblems(GM3000D) . 7ELECTRICALSYSTEMQUICKCHECKS ........ 8

BatteryTest(OpenCircuitTest) ............... 8GlowPlugSystemTest(GM3000D) .......... 8

COMPONENTIDENTIFICATIONANDTESTING.. 9

IgnitionSwitch .............................. 9DiodeCircuitBoards ....................... 10

NeutralSwitch ..............................11SeatSwitch ................................11Hydraulic Valve Solenoids 12

50AmpereThermalBreaker(GM3000D) .... 1FuelStopSolenoid(GM3000D) ............ 1InjectionAdvanceSolenoid(GM3000D) ..... 1Alternator(GM3000D) .................... 1

TemperatureSender(GM3000D) ........... 2TemperatureGauge(GM3000D) ........... 2

OilPressureSwitch(GM3000D) ............ 2TemperatureSendingUnit(GM3000D) ...... 2TransportSolenoid(GM3000D) ............ 2GlowPlugs(GM3000D) ................... 2H2OinFuelSensor(GM3000D) ............ 2CoolantLevelSensor(GM3000D) .......... 2IndicatorLightsandCircuits(GM3000D) .... 2FordEngine(VSG411)ElectricalComponentLoca

tions(GM3000) .......................... 2

TemperatureGauge(GM3000) .............. 3Thermistor(GM3000) ...................... 3

OilPressureSwitch(GM3000) .............. 3HighTemperatureSwitch(GM3000) ......... 3Anti dieseling Valve Solenoid (GM 3000) 3

Electrical Schematics, Wiring Diagrams,and Harness Drawings

Allelectricalschematics,diagrams,anddrawingsforboth the Groundsmaster 3000 and Groundsmaster3000 D l d i Ch 14 El i l Di


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3000D are located in Chapter 14 Electrical Diagrams.

Special Tools

Orderspecialtoolsfromthe TORO SPECIAL TOOLS SometoolsmayalsobeavailablefromalocalsupplierAND APPLICATIONS GUIDE (COMMERCIAL PROD-UCTS).


109/242

Multimeter

Themetercantestelectricalcomponentsandcircuitsforcurrent,resistance,orvoltage.

NOTE:TororecommendstheuseofaDIGITALVoltOhmAmpmultimeterwhentestingelectricalcircuits.Thehighimpedance(internalresistance)ofadigitalmeterinthevoltagemodewillmakesurethatexcesscurrent is not allowed through the meter. This excesscurrentcancausedamagetocircuitsnotdesignedtocarryit.

Figure1

SkinOver Grease

Specialnonconductivegreasewhichformsalightprotectiveskinwhichhelpswaterproofelectricalswitchesandcontacts.

Troubleshooting(Groundsmaster 3000)

CAUTION

For effective troubleshooting and repairs, you musthaveagoodunderstandingoftheelectricalcircuitsandcomponentsusedonthismachine(seeWiringSchematicssectionofthischapter).


110/242

Remove all especially rings andwatches, before doing any electrical trouble-

cables unless the test requires battery voltage.

jewelry,

shooting or testing. Disconnect the battery

Ifthemachinehasanyinterlockswitchesbypassed,

theymustbereconnectedforpropertroubleshootingandsafety.

Starting Problems

Problem Possible Causes

Startersolenoidclicks,butstarterwillnotcrank

(ifsolenoidclicks,theproblemisnotwiththeIgnitionmoduleoritsinputs).

Batterychargeislow.

Batterycablesarelooseorcorroded.

Batterygroundtoengineislooseorcorroded.

Wiringatstarterisfaulty.

Startersolenoidisfaulty.

Startermountingboltsarelooseornotsupplyingasufficientgroundforsolenoid.

Starterisfaultycausingincompletecircuitforsolenoid.

Nothinghappenswhenastartattemptismade. Wiringtostartcircuits(seeWiringSchematics)isloose, corroded, or damaged.

General Run and Transport Problems (Groundsmaster 3000)


Enginekillswhenthetractionpedalispositionedto Operatorissittingtoofarforwardontheseat(seat


111/242

g p peitherforwardorreverse.

p g (switchnotdepressed).

Wiringtoseatandshutdowndelaycircuits(seeWiringSchematics)isloose,corroded,ordamaged.

2amperefuse,seatswitch,orseatrelayisfaulty.

Diode(D1)orshutdowndelayrelayisfaulty.

20amperefusetoseatrelayisblown.

Batterydoesnotcharge. Wiringtothechargingcircuit(seeWiringSchematics)componentsisloose,corroded,ordamaged.

Voltageregulator/alternatorisfaulty.

50amperefuseisopen.

Batteryisdead.

Cutting Unit Operating Problems (Groundsmaster 3000)


Cuttingunitdoesnotengage. WiringtoPTOcircuit(seeWiringSchematics)components is loose corroded or damaged

Troubleshooting(Groundsmaster 3000D)

CAUTION

For effective troubleshooting and repairs, you musthaveagoodunderstandingoftheelectricalcircuitsandcomponentsusedonthismachine(seeWiringSchematicssectionofthischapter).


112/242

Remove all especially rings andwatches, before doing any electrical trouble-

cables unless the test requires battery voltage.

jewelry,

shooting or testing. Disconnect the battery

Ifthemachinehasanyinterlockswitchesbypassed,

theymustbereconnectedforpropertroubleshootingandsafety.

Starting Problems


Startersolenoidclicks,butstarterwillnotcrank

(ifsolenoidclicks,theproblemisnotwiththeIgnitionmoduleoritsinputs).

Batterychargeislow.

Batterycablesarelooseorcorroded.

Batterygroundtoframeislooseorcorroded.

Wiringatstarterisfaulty.

Startersolenoidisfaulty.

Startermountingboltsarelooseornotsupplyingasufficientgroundforsolenoid.

Starterisfaultycausingincompletecircuitforsolenoid.

Nothinghappenswhenastartattemptismade. Wiringtostartcircuits(seeWiringSchematics)isloose,corroded,ordamaged.

General Run and Transport Problems (GM 3000D)


Enginekillswhenthetractionpedalispositionedtoeither forward or reverse

Operatorissittingtoofarforwardontheseat(seatswitch not depressed)


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eitherforwardorreverse. switchnotdepressed).

Wiringtoseatandshutdowndelaycircuits(seeWiringSchematics)isloose,corroded,ordamaged.

7.5amperefuse,seatswitch,orseatrelayisfaulty.

Diode(D1)orshutdowndelayrelayisfaulty.

20amperefusetoseatrelayisopen.

Batterydoesnotcharge. Wiringtothechargingcircuit(seeWiringSchematics)componentsisloose,corroded,ordamaged.

Voltageregulator/alternatorisfaulty.

80amperefuseisopen.

Batteryisdead.

Cutting Unit Operating Problems (GM 3000D)


Cuttingunitdonotengage. WiringtoPTOcircuit(seeWiringSchematics)componentsisloose,corroded,ordamaged.

Electrical System Quick Checks

Battery Test (Open Circuit Test)

Note: Thistestprovidesarelativeconditionofthebat Voltage Measured Battery Charge Level


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tery.Loadtestingofthebatterywillprovideadditionalandmoreaccurateinformation.

1. Thebatterytemperatureshouldbefrom60_to100_

F.The ignitionkeyshouldbeoffand allaccessoriesturnedoff.

2. SetmultimetertotheDCvoltssetting.4. Recordvoltage.

3. Connectpositive(+)meterleadtothepositivebatterypostandnegative()meterleadtothethenegative

batterypost.

g y g

12.68V(orhigher) Fullycharged(100%)

12.45V 75%charged

12.24V 50%charged

12.06V 25%charged

11.89V 0%charged

Glow Plug System Test (GM 3000D)

Thisfast,simpletestcanhelpyoudetermineaglowplugsystemsintegrityandoperation.Runthistestanytimehardstarting(cold)isencounteredonthedieselengine.

Tool(s)required:Digitalmultimeterand/orAC/DC

currenttransducer(HallEffect).

1. Properlyconnectcurrenttransducertothedigital

multimeter.Setmultimeteronthepropervoltsscale(re

GLOWPLUGSGLOWPLUGS

Component Identification and Testing

Foraccurateresistanceand/orcontinuitychecks,electricallydisconnectthecomponentbeingtestedfromthecircuit(e.g.unplugtheignitionswitchconnectorbeforedoingacontinuitycheck).

CAUTION

Wh i l i l f i


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When testing electrical components for continu-ity with a multimeter (ohms setting), make sure

that power to the circuit has been disconnected.

Ignition Switch

The ignition (key) switch has three positions (OFF,STARTandRUN).Theterminalsaremarkedasshown.Thecircuitryoftheignitionswitchisshowninthechart.Withtheuseofacontinuitytester,theswitchfunctions

maybetestedtodeterminewhetherallcircuitsarebeingcompletedwhilethekeyismovedtoeachposition.

T

O

OR

A

B

I

X

S

Y

Figure4

POSITIONCONTINUITYAMONGTERMINALS

OTHERCIRCUITSMADE

Diode Circuit Boards

Eachcircuitboardcontainsfourdiodes.Thediodesare

D2usedforcircuitprotectionfrominductivevoltagespikes,batterychargingindication,andforsafetycircuitlogic.

D4D6

DiodesD4andD8arenotused.


116/242

DIODE

D8OntheGM3000wiringdiagram,thediodecircuitcards D3

adesignatedP3andP5.OntheGM3000Dwiringdia- D7grams,thediodecircuitcardsaredesignatedP7and D1P5.

D5

Diode D1

Directscurrentflowfromthedeckcapacitortothedeckrelaywhentheseatrelayisdeenergizedtoprovidea1seconddelay.

A B C D E F G H

DIAGRAM

Figure6

Diode D2

Providescurrentflowlogicforthechargingcircuitlight.

Diode D3

Prevents a negative spike from damaging the PTOswitchbyallowingagroundpathforthePTOrelayandPTOcoilwhentheydeenergize.

Diode D4

DIODE

P3orP7 P5

CIRCUITBOARDS

Figure7

Thiscomponentisnotused.


117/242

Hydraulic Valve Solenoids

The hydraulicvalve solenoidsare located belowtheseatandonthehydraulicmanifoldblock.

Note: Priortotakingsmallresistancereadingswitha

1


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digitalmultimeter,shortthetestleadstogether.Themeter will display a small resistance value (usually0.5ohmsorless).Thisresistanceisduetotheinternalre

sistanceofthemeterandtestleads.Subtractthisvaluefromfromthemeasuredvalueofthecomponentyouaretesting.

1. Makesureengineisoff.Disconnectsolenoidvalveelectricalconnector.

2

2. Apply12VDCsourcedirectlytothesolenoid.Listen Figure11forsolenoidtoswitchon.Removevoltagesource. 1. Electrical connector 2. Solenoid

3. Measureresistancebetweenthetwoconnectorterminals. The resistance should be approximately 7.2

ohms.

Hour Meter

1. Removeelectricalconnectionsfrommeter.

2. Connect the positive (+) terminal of a 12 VDC

sourcetothepositiveterminalofthehourmeter.

Cruise Control Coil (Optional)

Thecruisecontrolcoilislocatedbelowtheseat.

Note: Priortotakingsmallresistancereadingswithadigitalmultimeter,shortthetestleadstogether.Theme


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ter will display a small resistance value (usually0.5

ohmsorless).Subtractinternalresistanceofthemeterandtestleadsfromthemeasuredvalueofthecompo

nentyouaretesting.

1. Makesureengineisoff.Disconnectblueandvioletwirestothecoil.

2. Apply12VDCsourcedirectlytothecoilwires.Listenforcoiltopullinclutchplate.

CRUISECONTROLCOIL

3. Measureresistancebetweenthetwocoilwires.The Figure13resistanceshouldbefrom3.6to4.0ohms.

PTO (Clutch) Coil

ThePTO(clutch)coilislocatedinsidetheIHTtransmission.Theelectricalconnectortothecoilisbelowtheseat.

Note: Priortotakingsmallresistancereadingswithadigitalmultimeter,shortthetestleadstogether.Theme

ter will display a small resistance value (usually0.5ohmsorless).Subtractinternalresistanceofthemeter

CONNECTORTOPTOCOIL

Fuel Sender

Thesenderislocatedontopofthefueltankinsidethecentershroudarea.

1. Removebluewireandblackgroundwirefromthed

GROUNDWIRE


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sender.

2. Removeremainingscrewsandlockwashersfromthesenderandfueltank.

3. Remove sender and gasket from the fuel tank.Cleananyfuelfromthesender.

Note: Beforetakingsmallresistancereadingswitha

BLUEWIRE

Figure15digitalmultimeter,shorttestleadstogether.Themeterwilldisplayasmallresistancevalue.Thisinternalresis

tanceofthemeterandtestleadsshouldbesubtractfromthemeasuredvalueofthecomponent.

4. Checkresistanceofthesenderwithamultimeter.Resistancewiththefloatinthefullpositionshouldbe27.5to39.5ohms.Resistancewiththefloatintheemptypositionshouldbe240to260ohms.

Figure16

FULLPOSITION

EMPTYPOSITION

Relays and Fuses

Therelaysandfusesandarelocatedinthecompartmentthatisrearofthecontrolpanel(Fig.18).Thereisan80amperefuse(50ampereontheGM3000)locatedbythealternator(Fig.22).

87


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Relay Testing

1. Verifycoilresistancebetweenterminals86and85withamultimeter(ohmssetting).Resistanceshouldbefrom75to95ohms.Thereshouldbecontinuitybetweenterminals87Aand30.

2. Connectmultimeter(ohmssetting) leadstorelay

30

87A

8

6

8

5

30 85 86 87 87A

Figure19terminals30and87.Groundterminal86andapply+12VDCtoterminal85.Therelayshouldmakeandbreak

continuitybetweenterminals30and87as12VDCisappliedandremovedfromterminal85.

3. Disconnectvoltagefromterminal85andmultimeterleadfromterminal87.

4. Connectmultimeter(ohmssetting)leadtorelayter

minal30and87A.Apply+12VDCtoterminal85.Therelayshouldbreakandmakecontinuitybetweentermi

nals30and87Aas12VDCisappliedandremovedfromterminal85.

RelayandFuseLocation(Groundsmaster3000)

Figure20

5. Disconnectvoltageandmultimeterleadsfromrelayterminals

50 Ampere Thermal Breaker (GM 3000D)

Thisdeviceoperatesasa thermaloverload.Afterthedevicetrips,timeshouldbeallowedforittocoolandreset.Itislocatednearthestarter.

1 Verify continuity between the two terminals Conti


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1. Verifycontinuitybetweenthetwoterminals.Continuityshouldbeless than 1 ohm.

THERMAL

BREAKER

Figure23


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Injection Advance Solenoid (GM 3000D)

Theinjectionadvancesolenoidislocatedontopoftheinjectorpump,whichisontherightsideoftheengine.Itshastwoblackwiresconnectedtoit.Onewireleadstoaconnectorwithorangeandwhitewires.Theotherwire is grounded to the injector pump The solenoid is


124/242

wireisgroundedtotheinjectorpump.Thesolenoidispoweredfromtheorange(top)wire(Fig.52).

In Place Testing

Note: Priortotakingsmallresistancereadingswitha

digitalmultimeter,shortthetestleadstogether.Themeter will display a small resistance value (usually0.5ohmsorless).Thisresistanceisduetotheinternalresistanceofthemeterandtestleads.Subtractthisvaluefromfromthemeasuredvalueofthecomponentyouare

testing.

1. Removewireclipfromtheconnectoranddisconnectconnector.

2. Usingadigitalmultimeter,attachoneleadtothelug

ofthegroundwire.Connectotherleadtothepinintheconnector that isattached tothe injectorpump.Theorangewireontheharnessconnectorpowersthesole

noid.

3. Theresistanceshouldbeabout 14.6 ohms.

Live testing

SOLENOID

GROUNDWIRE

CONNECTOR

Alternator (GM 3000D)

Thealternatorisbeltdrivenwithainternalregulator.Itislocatedonthebottomrightendoftheengine.Ifeitherthealternatorortheregulatorisdamaged,theentireunitmustbereplaced(Fig.28).


125/242

Note: Priortotestingthechargingsystem,makesure

thepolyVbelttothealternatorisingoodoperationconditionandadjustedproperly(seeBeltAdjustmentin

Chapter4PeugeotDieselEngine).

Test Equipment

Useashuntcapableofhandlingatleast70ampere.Also,adigitalmultimeterwithahighimpedancemillivoltscale(withatleast300mvrange)canbeusedincon

junctionwiththeshunt(Fig.29).

Testing for DC Current Output (Fig. 30)

Note: Follow the manufacturers instructions whenusingaDCshunt.

1. Makesureengineisoff.

IMPORTANT: To perform this test properly, the bat-

tery must not be fully charged. See Battery Test inthe Electrical Quick Checks section.

2. InstalltheDCshuntonthenegativeterminalofthe

Figure28

Temperature Sender (GM 3000D)

Thetemperaturesenderislocatedonthetoprightsideofthewateroutletbox.Ithasagreenconnectorwithblueandblackwires.Thesendersuppliesasignaltotheglowcontrolunit(Fig.31).

TEMPSENDER


126/242

CAUTION

1. Lowerthecoolantlevelintheengineandremove

thethermistorfromthewaterpump.

Make sure engine is cool and coolant system isdepressurized before removing the thermistor.

Figure312. Putthesen

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