Toro Greenmaster 3000 Lawn Mower Manuals

Manuals and User Guides for Toro Greenmaster 3000 Lawn Mower. We have 1 Toro Greenmaster 3000 Lawn Mower manual available for free PDF download: Service Manual

Toro Greenmaster 3000 Service Manual (275 pages)

Toro Greenmaster 3000(-D) Mowers Service manual

Brand: Toro | Category: Lawn Mower | Size: 16.23 MB

Table of Contents
3
Safety
5
Before Operating
5
While Operating
6
While Doing Maintenance, Testing, Adjustments or Repair
7
Product Record and Manuals
9
Equivalent and Conversions
10
Decimal and Millimeter Equivalents
10
US to Metric Conversions
10
Torque Specifications
11
Maintenance Schedule
14
Minimum Recommended Maintenance Intervals
14
Daily Maintenance Check List
15
Kohler Engine
21
Specifications
21
Governor and Throttle Adjustment
22
Removing the Engine
23
Installing the Engine
23
Mitsubishi Diesel Engine
25
Mitsubishi Diesel Engine Specifications
27
Mitsubishi Diesel Engine - Tightening Torque
34
Special Tools
35
Mitsubishi Diesel Engine Adjustments
37
Valve Clearance
37
Engine Speed Adjustments
38
High Speed Adjustment
38
Idle Speed Adjustment
38
Throttle Linkage Adjustment
39
Mitsubishi Diesel Engine Troubleshooting
39
Glow Plug Test
42
Compression Test
43
Nozzle Tests
44
Injection Pressure Test
44
Chattering Test
44
Nozzle Leakage Test
44
Spray Test
45
Injection Pump Test
46
Injection Timing Test
47
Fuel Pump Test
48
Thermostat Test
48
Preparation for Engine Repair
49
Cylinder and Cylinder Block Overhaul
49
Engine Compression
49
External Engine Component Repair
50
Fan Belt Replacement
50
Alternator Removal and Installation
51
Starter Removal and Installation
51
Replacing And/Or Adjusting Engine Stop Solenoid
52
Glow Plug Replacement
53
Oil Pressure Switch Replacement
53
Thermostat Removal and Installation
53
Water Pump Service
54
Governor System Repairs
55
Governor Operation
55
Governor Inspection
56
Governor Service
57
Installation of Torque Spring Set
58
Assembly of Torque Spring Set
59
Fuel System Repairs
60
Bleeding the Fuel System
60
Bleeding Air from the Injectors
61
Fuel Pump Service
61
Injection Pump Service
62
Injection Pump Disassembly
63
Injection Pump Inspection
64
Injection Pump Assembly
64
Nozzle Service
65
Nozzle Removal and Disassembly
65
Nozzle Inspection and Cleaning
66
Nozzle Assembly and Testing
66
Nozzle Installation
66
Removing and Installing the Fuel Tank and Tank Base
67
Removing the Engine (Mitsubishi)
68
Installing the Engine (Mitsubishi)
69
Cylinder Head Overhaul
70
Cylinder Head Removal
70
Cylinder Head Service
71
Valve Guides
72
Valves
73
Valve Seats
73
Valve Springs
74
Rocker Arm and Rocker Shaft
74
Cylinder Head Assembly and Installation
75
Cylinder Block Overhaul
77
Gear Case and Oil Pump
77
Timing Gears and Camshafts
80
Piston and Connecting Rod
83
Crankshaft
87
Cylinder Block
90
Reboring Cylinder
90
Hydraulic System
91
Hydraulic System Specifications
92
Hydraulic Hose and Fitting Information
93
Hydraulic Fitting Installation
93
O-Ring Face Seal
93
SAE Straight Thread O-Ring Port (Non-Adjustable)
94
SAE Straight Thread O-Ring Port (Adjustable)
94
Hydraulic Flow Diagram
95
Traction No. 1 Position
95
Traction No. 2 Position
96
Traction, Reverse Position
97
Reel Drive, Mowing Operation
98
Reel Drive, Lower Cutting Units
99
Reel Drive, Raising Cutting Units
100
Power Steering, RH Turn
101
Hydraulic Tester
102
Seal Protector
103
Seal Installer
103
Detent Installation Tool
103
Seal Installation Tool
104
Assembly Studs
104
Control Valve Spool Seal Installation Tools
104
Hydraulic System Troubleshooting
105
Slow Groundspeed in All Traction Selections
106
Slow or no Ground Speed in No. 1 and Reverse No. 2 Appears Normal
107
No Increase in Speed from No.1 to No.2
108
One or more Cutting Units Slow or no Reel Drive Action
109
All Reels Slow or will Not Turn
110
Mow Pedal Won't Stay Engaged - Reels Slow down or Stop
111
Cutting Unit(S) Drop During Transport
112
Cutting Unit Lift too Slowly or Not at All
113
Lift Pedal Binding
114
Center (#1) Cutting Unit Operates in Raised Position
114
Center (#1) Cutting Unit Drops before Front Cutting Units/Too Fast
114
Steering Loss, Steering Wander or Free Play
115
Testing
116
Before Performing Hydraulic Tests
116
Test Hook up No.1
117
Test A: Traction Pump Flow
117
Test B: Relief Valve Setting
118
Test Hook up No.2
119
Test A: Traction Motors Mechanical Drag
119
Test B: Valve Bank Leakage
120
Test C: Traction Motor Efficiency
120
Test Hook up No.3
121
Test A: Reel Drive Pump Efficiency
121
Test Hook up No.4
122
Test A: Reel Drive Motor Flow
122
Test B: Reel Drive Relief Setting and Reel Motor Efficiency Procedure
123
Test Hook No.5
124
Test A: Steering Pump Flow
124
Lift and Mow Pedal Height Adjustment
125
Traction Pedal Adjustment
126
Rear Camshaft Adjustment
127
Repairs
128
Reel Motor Removal and Installation
128
Reel Motor Shaft Seal Replacement
128
Reel Motor Repair
129
Hydraulic Pump Removal and Installation
130
Pump Repair
131
Relief Valve Service
133
Pump Service
133
Control Valve Removal and Installation
134
Relief Valve Removal and Installation
134
Control Valve Spool Seal Replacement
135
Front (Chain Link) Side
135
Rear (Bonnet) Side
135
Control Valve Internal Seal Replacement
136
Control Valve No.1 Spool Detent Replacement
137
Control Valve No.4 Spool Detent Replacement
138
Lift Cylinder Removal and Installation
139
No.1 (Center) Lift Cylinder
140
No.2 and 3 Lift Cylinders
141
Lift Cylinder Repair - No.1 (Center)
142
Lift Cylinder Repair - No.2 and 3 (Left and Right)
143
Wheel Motor Removal and Installation
144
Wheel Motor Shaft Seal And/Or Shaft Replacement - Nichols Gray
145
Wheel Motor Repair - Nichols-Gray
146
Steering Cylinder Removal and Installation
147
Steering Cylinder Repair
148
Steering Valve Removal and Installation
149
Electrical System
151
Wiring Schematics
152
Continuity Tester
154
Volt - Ohm - Amp Meter
154
Skin-Over Grease
155
Electrical System Troubleshooting
156
Verify Interlock Operation
158
Verify Interlock Operation (3000-D)
162
Electrical System Testing
163
Ignition Key Switch Test
163
Seat Switch Test
164
Traction (Neutral) Switch Test
164
Mow/Lift Switch Test
165
Interlock Module Switch
165
Safety Relay and Capacitor (Time Delay) Test
166
High Temperature Shut-Down Relay Test
166
Glow Relay Switch
167
Battery Testing
167
Terminal Voltage Test
167
Indicator Lights Testing
167
Hourmeter Test
168
Temperature Gauge Test
168
High Temperature Shut-Down Switch Test
168
Temperature Gauge Sender Test
169
Fuel Stop (ETR) Solenoid Test
170
Checking Starter Pinion Gap
171
Starter No-Load Test
171
Magnetic Switch (Solenoid) Attraction Test
172
Magnetic Switch (Solenoid) Holding Test
172
Magnetic Switch (Solenoid) Return Test
172
Alternator Regulated Voltage Test
173
Alternator Output Test
173
Diode (Glow Plug)
173
Electrical System Repairs
174
General Safety Interlock Switch Service
174
Seat Switch Replacement and Adjustment
174
Traction (Neutral) Switch Replacement and Adjustment
175
Mow/Lift Switch Replacement and Adjustment
176
Wiring Harness Service
176
Starter Service - Disassembly and Inspection
177
Starter Assembly and Adjustment
180
Alternator Disassembly and Inspection
181
Alternator Assembly
184
Battery Service
185
Steering and Brakes
187
Electrical System Adjustments
188
Steering Cable Adjustment
188
Brake Adjustment
189
Steering Cable Replacement
190
Brake Service
192
Brake Disassembly
192
Brake Reassembly
193
4 Bolt Adjust Cutting Units
195
4 Bolt Adjust Cutting Units Specifications
196
Roller Bearing Replacement Tool
197
Plastic Plug
197
Handle Assembly
198
Bedknife Screw Tool
198
4 Bolt Adjust Cutting Units Troubleshooting
199
4 Bolt Adjust Cutting Units Set up and Adjustment
201
Reel Bearing Service and Adjustment
202
Bedknife to Reel Adjustment
203
Leveling Rear Roller to Reel
204
Height of Cut
205
Front Roller Scraper Adjustment
206
Comb Adjustment
206
Shield Height Adjustment
207
Top (Cut Off) Bar Adjustment
207
Pull Frame Adjustment
208
4 Bolt Adjust Cutting Units Repairs
209
Cutting Unit Removal and Installation
209
Reel Lapping
210
Bedbar Removal and Installation
211
Bedknife Replacement
212
Preparing Reel for Grinding
212
Reel Removal and Bearing Replacement
213
Lift Bail Replacement
214
Single Point Adjust Cutting Units
215
Single Point Adjust Cutting Units Specifications
217
Single Point Adjust Cutting Units - Special Tools
218
Mclube
218
Single Point Adjust Cutting Units Troubleshooting
220
Factors Affecting Quality of Cut
220
Single Point Adjust Cutting Units Set up and Adjustments
222
Bedknife to Reel Contact
223
Parallel Bedknife to Reel
225
Height of Cut Adjustment
229
Top (Cut-Off) Bar Adjustment
231
Single Point Adjust Cutting Units Repairs
233
Removal and Installation of Cutting Unit
233
Bedbar Removal/Installation
234
Bedbar Bushing Replacement
236
Replacement of Bedknife
237
Preparing Cutting Unit for Reel Grinding
237
Reel Removal/Bearing Replacement
238
Bedknife Adjustment Knob Bearing Service
239
Replacement of Lift Bail
240
Grooming Reel Cutting Units
241
Grooming Reel Cutting Units Specifications
243
Grooming Reel Cutting Units - Special Tools
244
Grooming Reel Cutting Units Troubleshooting
246
Factors Affecting Grooming
248
Grooming Reel Mechanical Problems
249
Grooming Reel Cutting Units Set up and Adjustments
250
Groomer Reel Depth Adjustment
258
Groomer Reel Drive Belt Adjustment
259
Grooming Reel Cutting Units Repairs
261
Groomer Reel Blade Service
268
Groomer Reel Drive Belt Replacement
268
Groomer Reel Removal and Bearing Service
269
Groomer Reel Clutch Service
270
Bedknife to Reel Adjustment Knob Bearing Service
272

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