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Manuals
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Toro Manuals
Lawn Mower
Greenmaster 3000
Service manual
Toro Greenmaster 3000 Service Manual
Toro greenmaster 3000(-d) mowers service manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Safety
Before Operating
While Operating
While Doing Maintenance, Testing, Adjustments or Repair
Product Record and Manuals
Equivalent and Conversions
Decimal and Millimeter Equivalents
US to Metric Conversions
Torque Specifications
Maintenance Schedule
Minimum Recommended Maintenance Intervals
Daily Maintenance Check List
Kohler Engine
Specifications
Governor and Throttle Adjustment
Removing the Engine
Installing the Engine
Mitsubishi Diesel Engine
Mitsubishi Diesel Engine Specifications
Mitsubishi Diesel Engine - Tightening Torque
Special Tools
Mitsubishi Diesel Engine Adjustments
Valve Clearance
Engine Speed Adjustments
High Speed Adjustment
Idle Speed Adjustment
Throttle Linkage Adjustment
Mitsubishi Diesel Engine Troubleshooting
Glow Plug Test
Compression Test
Nozzle Tests
Injection Pressure Test
Chattering Test
Nozzle Leakage Test
Spray Test
Injection Pump Test
Injection Timing Test
Fuel Pump Test
Thermostat Test
Preparation for Engine Repair
Cylinder and Cylinder Block Overhaul
Engine Compression
External Engine Component Repair
Fan Belt Replacement
Alternator Removal and Installation
Starter Removal and Installation
Replacing And/Or Adjusting Engine Stop Solenoid
Glow Plug Replacement
Oil Pressure Switch Replacement
Thermostat Removal and Installation
Water Pump Service
Governor System Repairs
Governor Operation
Governor Inspection
Governor Service
Installation of Torque Spring Set
Assembly of Torque Spring Set
Fuel System Repairs
Bleeding the Fuel System
Bleeding Air from the Injectors
Fuel Pump Service
Injection Pump Service
Injection Pump Disassembly
Injection Pump Inspection
Injection Pump Assembly
Nozzle Service
Nozzle Removal and Disassembly
Nozzle Inspection and Cleaning
Nozzle Assembly and Testing
Nozzle Installation
Removing and Installing the Fuel Tank and Tank Base
Removing the Engine (Mitsubishi)
Installing the Engine (Mitsubishi)
Cylinder Head Overhaul
Cylinder Head Removal
Cylinder Head Service
Valve Guides
Valves
Valve Seats
Valve Springs
Rocker Arm and Rocker Shaft
Cylinder Head Assembly and Installation
Cylinder Block Overhaul
Gear Case and Oil Pump
Timing Gears and Camshafts
Piston and Connecting Rod
Crankshaft
Cylinder Block
Reboring Cylinder
Hydraulic System
Hydraulic System Specifications
Hydraulic Hose and Fitting Information
Hydraulic Fitting Installation
O-Ring Face Seal
SAE Straight Thread O-Ring Port (Non-Adjustable)
SAE Straight Thread O-Ring Port (Adjustable)
Hydraulic Flow Diagram
Traction No. 1 Position
Traction No. 2 Position
Traction, Reverse Position
Reel Drive, Mowing Operation
Reel Drive, Lower Cutting Units
Reel Drive, Raising Cutting Units
Power Steering, RH Turn
Hydraulic Tester
Seal Protector
Seal Installer
Detent Installation Tool
Seal Installation Tool
Assembly Studs
Control Valve Spool Seal Installation Tools
Hydraulic System Troubleshooting
Slow Groundspeed in All Traction Selections
Slow or no Ground Speed in No. 1 and Reverse No. 2 Appears Normal
No Increase in Speed from No.1 to No.2
One or more Cutting Units Slow or no Reel Drive Action
All Reels Slow or will Not Turn
Mow Pedal Won't Stay Engaged - Reels Slow down or Stop
Cutting Unit(S) Drop During Transport
Cutting Unit Lift too Slowly or Not at All
Lift Pedal Binding
Center (#1) Cutting Unit Operates in Raised Position
Center (#1) Cutting Unit Drops before Front Cutting Units/Too Fast
Steering Loss, Steering Wander or Free Play
Testing
Before Performing Hydraulic Tests
Test Hook up No.1
Test A: Traction Pump Flow
Test B: Relief Valve Setting
Test Hook up No.2
Test A: Traction Motors Mechanical Drag
Test B: Valve Bank Leakage
Test C: Traction Motor Efficiency
Test Hook up No.3
Test A: Reel Drive Pump Efficiency
Test Hook up No.4
Test A: Reel Drive Motor Flow
Test B: Reel Drive Relief Setting and Reel Motor Efficiency Procedure
Test Hook No.5
Test A: Steering Pump Flow
Lift and Mow Pedal Height Adjustment
Traction Pedal Adjustment
Rear Camshaft Adjustment
Repairs
Reel Motor Removal and Installation
Reel Motor Shaft Seal Replacement
Reel Motor Repair
Hydraulic Pump Removal and Installation
Pump Repair
Relief Valve Service
Pump Service
Control Valve Removal and Installation
Relief Valve Removal and Installation
Control Valve Spool Seal Replacement
Front (Chain Link) Side
Rear (Bonnet) Side
Control Valve Internal Seal Replacement
Control Valve No.1 Spool Detent Replacement
Control Valve No.4 Spool Detent Replacement
Lift Cylinder Removal and Installation
No.1 (Center) Lift Cylinder
No.2 and 3 Lift Cylinders
Lift Cylinder Repair - No.1 (Center)
Lift Cylinder Repair - No.2 and 3 (Left and Right)
Wheel Motor Removal and Installation
Wheel Motor Shaft Seal And/Or Shaft Replacement - Nichols Gray
Wheel Motor Repair - Nichols-Gray
Steering Cylinder Removal and Installation
Steering Cylinder Repair
Steering Valve Removal and Installation
Electrical System
Wiring Schematics
Continuity Tester
Volt - Ohm - Amp Meter
Skin-Over Grease
Electrical System Troubleshooting
Verify Interlock Operation
Verify Interlock Operation (3000-D)
Electrical System Testing
Ignition Key Switch Test
Seat Switch Test
Traction (Neutral) Switch Test
Mow/Lift Switch Test
Interlock Module Switch
Safety Relay and Capacitor (Time Delay) Test
High Temperature Shut-Down Relay Test
Glow Relay Switch
Battery Testing
Terminal Voltage Test
Indicator Lights Testing
Hourmeter Test
Temperature Gauge Test
High Temperature Shut-Down Switch Test
Temperature Gauge Sender Test
Fuel Stop (ETR) Solenoid Test
Checking Starter Pinion Gap
Starter No-Load Test
Magnetic Switch (Solenoid) Attraction Test
Magnetic Switch (Solenoid) Holding Test
Magnetic Switch (Solenoid) Return Test
Alternator Regulated Voltage Test
Alternator Output Test
Diode (Glow Plug)
Electrical System Repairs
General Safety Interlock Switch Service
Seat Switch Replacement and Adjustment
Traction (Neutral) Switch Replacement and Adjustment
Mow/Lift Switch Replacement and Adjustment
Wiring Harness Service
Starter Service - Disassembly and Inspection
Starter Assembly and Adjustment
Alternator Disassembly and Inspection
Alternator Assembly
Battery Service
Steering and Brakes
Electrical System Adjustments
Steering Cable Adjustment
Brake Adjustment
Steering Cable Replacement
Brake Service
Brake Disassembly
Brake Reassembly
4 Bolt Adjust Cutting Units
4 Bolt Adjust Cutting Units Specifications
Roller Bearing Replacement Tool
Plastic Plug
Handle Assembly
Bedknife Screw Tool
4 Bolt Adjust Cutting Units Troubleshooting
4 Bolt Adjust Cutting Units Set up and Adjustment
Reel Bearing Service and Adjustment
Bedknife to Reel Adjustment
Leveling Rear Roller to Reel
Height of Cut
Front Roller Scraper Adjustment
Comb Adjustment
Shield Height Adjustment
Top (Cut Off) Bar Adjustment
Pull Frame Adjustment
4 Bolt Adjust Cutting Units Repairs
Cutting Unit Removal and Installation
Reel Lapping
Bedbar Removal and Installation
Bedknife Replacement
Preparing Reel for Grinding
Reel Removal and Bearing Replacement
Lift Bail Replacement
Single Point Adjust Cutting Units
Single Point Adjust Cutting Units Specifications
Single Point Adjust Cutting Units - Special Tools
Mclube
Single Point Adjust Cutting Units Troubleshooting
Factors Affecting Quality of Cut
Single Point Adjust Cutting Units Set up and Adjustments
Bedknife to Reel Contact
Parallel Bedknife to Reel
Height of Cut Adjustment
Top (Cut-Off) Bar Adjustment
Single Point Adjust Cutting Units Repairs
Removal and Installation of Cutting Unit
Bedbar Removal/Installation
Bedbar Bushing Replacement
Replacement of Bedknife
Preparing Cutting Unit for Reel Grinding
Reel Removal/Bearing Replacement
Bedknife Adjustment Knob Bearing Service
Replacement of Lift Bail
Grooming Reel Cutting Units
Grooming Reel Cutting Units Specifications
Grooming Reel Cutting Units - Special Tools
Grooming Reel Cutting Units Troubleshooting
Factors Affecting Grooming
Grooming Reel Mechanical Problems
Grooming Reel Cutting Units Set up and Adjustments
Groomer Reel Depth Adjustment
Groomer Reel Drive Belt Adjustment
Grooming Reel Cutting Units Repairs
Groomer Reel Blade Service
Groomer Reel Drive Belt Replacement
Groomer Reel Removal and Bearing Service
Groomer Reel Clutch Service
Bedknife to Reel Adjustment Knob Bearing Service
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Rev. B
, 2002
Table of
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Table of Contents
Troubleshooting
Throttle Linkage Adjustment
39
Hydraulic System Troubleshooting
105
Electrical System Troubleshooting
156
4 Bolt Adjust Cutting Units Troubleshooting
199
Single Point Adjust Cutting Units Troubleshooting
220
Grooming Reel Cutting Units Troubleshooting
246
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Summary of Contents for Toro Greenmaster 3000
Page 1
Rev. B , 2002...
Page 202
Use Loctite 271 on spline nut threads. Rev. B...
Page 213
Use Loctite 271 on spline nut threads. Rev. B...
Page 224
Use Loctite 271 on spline nut threads. Rev. B...
Page 238
Use Loctite 271 on spline nut threads. Rev. B...
Page 252
Use Loctite 271 on spline nut threads. Rev. B...
Page 267
Use Loctite 271 on spline nut threads.
This manual is also suitable for:
Greenmaster 3000-d
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