Toro Greenmaster 3000

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Table of Contents3
Safety5
Before Operating5
While Operating6
While Doing Maintenance, Testing, Adjustments or Repair7
Product Record and Manuals9
Equivalent and Conversions10
Decimal and Millimeter Equivalents10
US to Metric Conversions10
Torque Specifications11
Maintenance Schedule14
Minimum Recommended Maintenance Intervals14
Daily Maintenance Check List15
Kohler Engine21
Specifications21
Governor and Throttle Adjustment22
Removing the Engine23
Installing the Engine23
Mitsubishi Diesel Engine25
Mitsubishi Diesel Engine Specifications27
Mitsubishi Diesel Engine - Tightening Torque34
Special Tools35
Mitsubishi Diesel Engine Adjustments37
Valve Clearance37
Engine Speed Adjustments38
High Speed Adjustment38
Idle Speed Adjustment38
Throttle Linkage Adjustment39
Mitsubishi Diesel Engine Troubleshooting39
Glow Plug Test42
Compression Test43
Nozzle Tests44
Injection Pressure Test44
Chattering Test44
Nozzle Leakage Test44
Spray Test45
Injection Pump Test46
Injection Timing Test47
Fuel Pump Test48
Thermostat Test48
Preparation for Engine Repair49
Cylinder and Cylinder Block Overhaul49
Engine Compression49
External Engine Component Repair50
Fan Belt Replacement50
Alternator Removal and Installation51
Starter Removal and Installation51
Replacing And/Or Adjusting Engine Stop Solenoid52
Glow Plug Replacement53
Oil Pressure Switch Replacement53
Thermostat Removal and Installation53
Water Pump Service54
Governor System Repairs55
Governor Operation55
Governor Inspection56
Governor Service57
Installation of Torque Spring Set58
Assembly of Torque Spring Set59
Fuel System Repairs60
Bleeding the Fuel System60
Bleeding Air from the Injectors61
Fuel Pump Service61
Injection Pump Service62
Injection Pump Disassembly63
Injection Pump Inspection64
Injection Pump Assembly64
Nozzle Service65
Nozzle Removal and Disassembly65
Nozzle Inspection and Cleaning66
Nozzle Assembly and Testing66
Nozzle Installation66
Removing and Installing the Fuel Tank and Tank Base67
Removing the Engine (Mitsubishi)68
Installing the Engine (Mitsubishi)69
Cylinder Head Overhaul70
Cylinder Head Removal70
Cylinder Head Service71
Valve Guides72
Valves73
Valve Seats73
Valve Springs74
Rocker Arm and Rocker Shaft74
Cylinder Head Assembly and Installation75
Cylinder Block Overhaul77
Gear Case and Oil Pump77
Timing Gears and Camshafts80
Piston and Connecting Rod83
Crankshaft87
Cylinder Block90
Reboring Cylinder90
Hydraulic System91
Hydraulic System Specifications92
Hydraulic Hose and Fitting Information93
Hydraulic Fitting Installation93
O-Ring Face Seal93
SAE Straight Thread O-Ring Port (Non-Adjustable)94
SAE Straight Thread O-Ring Port (Adjustable)94
Hydraulic Flow Diagram95
Traction No. 1 Position95
Traction No. 2 Position96
Traction, Reverse Position97
Reel Drive, Mowing Operation98
Reel Drive, Lower Cutting Units99
Reel Drive, Raising Cutting Units100
Power Steering, RH Turn101
Hydraulic Tester102
Seal Protector103
Seal Installer103
Detent Installation Tool103
Seal Installation Tool104
Assembly Studs104
Control Valve Spool Seal Installation Tools104
Hydraulic System Troubleshooting105
Slow Groundspeed in All Traction Selections106
Slow or no Ground Speed in No. 1 and Reverse No. 2 Appears Normal107
No Increase in Speed from No.1 to No.2108
One or more Cutting Units Slow or no Reel Drive Action109
All Reels Slow or will Not Turn110
Mow Pedal Won't Stay Engaged - Reels Slow down or Stop111
Cutting Unit(S) Drop During Transport112
Cutting Unit Lift too Slowly or Not at All113
Lift Pedal Binding114
Center (#1) Cutting Unit Operates in Raised Position114
Center (#1) Cutting Unit Drops before Front Cutting Units/Too Fast114
Steering Loss, Steering Wander or Free Play115
Testing116
Before Performing Hydraulic Tests116
Test Hook up No.1117
Test A: Traction Pump Flow117
Test B: Relief Valve Setting118
Test Hook up No.2119
Test A: Traction Motors Mechanical Drag119
Test B: Valve Bank Leakage120
Test C: Traction Motor Efficiency120
Test Hook up No.3121
Test A: Reel Drive Pump Efficiency121
Test Hook up No.4122
Test A: Reel Drive Motor Flow122
Test B: Reel Drive Relief Setting and Reel Motor Efficiency Procedure123
Test Hook No.5124
Test A: Steering Pump Flow124
Lift and Mow Pedal Height Adjustment125
Traction Pedal Adjustment126
Rear Camshaft Adjustment127
Repairs128
Reel Motor Removal and Installation128
Reel Motor Shaft Seal Replacement128
Reel Motor Repair129
Hydraulic Pump Removal and Installation130
Pump Repair131
Relief Valve Service133
Pump Service133
Control Valve Removal and Installation134
Relief Valve Removal and Installation134
Control Valve Spool Seal Replacement135
Front (Chain Link) Side135
Rear (Bonnet) Side135
Control Valve Internal Seal Replacement136
Control Valve No.1 Spool Detent Replacement137
Control Valve No.4 Spool Detent Replacement138
Lift Cylinder Removal and Installation139
No.1 (Center) Lift Cylinder140
No.2 and 3 Lift Cylinders141
Lift Cylinder Repair - No.1 (Center)142
Lift Cylinder Repair - No.2 and 3 (Left and Right)143
Wheel Motor Removal and Installation144
Wheel Motor Shaft Seal And/Or Shaft Replacement - Nichols Gray145
Wheel Motor Repair - Nichols-Gray146
Steering Cylinder Removal and Installation147
Steering Cylinder Repair148
Steering Valve Removal and Installation149
Electrical System151
Wiring Schematics152
Continuity Tester154
Volt - Ohm - Amp Meter154
Skin-Over Grease155
Electrical System Troubleshooting156
Verify Interlock Operation158
Verify Interlock Operation (3000-D)162
Electrical System Testing163
Ignition Key Switch Test163
Seat Switch Test164
Traction (Neutral) Switch Test164
Mow/Lift Switch Test165
Interlock Module Switch165
Safety Relay and Capacitor (Time Delay) Test166
High Temperature Shut-Down Relay Test166
Glow Relay Switch167
Battery Testing167
Terminal Voltage Test167
Indicator Lights Testing167
Hourmeter Test168
Temperature Gauge Test168
High Temperature Shut-Down Switch Test168
Temperature Gauge Sender Test169
Fuel Stop (ETR) Solenoid Test170
Checking Starter Pinion Gap171
Starter No-Load Test171
Magnetic Switch (Solenoid) Attraction Test172
Magnetic Switch (Solenoid) Holding Test172
Magnetic Switch (Solenoid) Return Test172
Alternator Regulated Voltage Test173
Alternator Output Test173
Diode (Glow Plug)173
Electrical System Repairs174
General Safety Interlock Switch Service174
Seat Switch Replacement and Adjustment174
Traction (Neutral) Switch Replacement and Adjustment175
Mow/Lift Switch Replacement and Adjustment176
Wiring Harness Service176
Starter Service - Disassembly and Inspection177
Starter Assembly and Adjustment180
Alternator Disassembly and Inspection181
Alternator Assembly184
Battery Service185
Steering and Brakes187
Electrical System Adjustments188
Steering Cable Adjustment188
Brake Adjustment189
Steering Cable Replacement190
Brake Service192
Brake Disassembly192
Brake Reassembly193
4 Bolt Adjust Cutting Units195
4 Bolt Adjust Cutting Units Specifications196
Roller Bearing Replacement Tool197
Plastic Plug197
Handle Assembly198
Bedknife Screw Tool198
4 Bolt Adjust Cutting Units Troubleshooting199
4 Bolt Adjust Cutting Units Set up and Adjustment201
Reel Bearing Service and Adjustment202
Bedknife to Reel Adjustment203
Leveling Rear Roller to Reel204
Height of Cut205
Front Roller Scraper Adjustment206
Comb Adjustment206
Shield Height Adjustment207
Top (Cut Off) Bar Adjustment207
Pull Frame Adjustment208
4 Bolt Adjust Cutting Units Repairs209
Cutting Unit Removal and Installation209
Reel Lapping210
Bedbar Removal and Installation211
Bedknife Replacement212
Preparing Reel for Grinding212
Reel Removal and Bearing Replacement213
Lift Bail Replacement214
Single Point Adjust Cutting Units215
Single Point Adjust Cutting Units Specifications217
Single Point Adjust Cutting Units - Special Tools218
Mclube218
Single Point Adjust Cutting Units Troubleshooting220
Factors Affecting Quality of Cut220
Single Point Adjust Cutting Units Set up and Adjustments222
Bedknife to Reel Contact223
Parallel Bedknife to Reel225
Height of Cut Adjustment229
Top (Cut-Off) Bar Adjustment231
Single Point Adjust Cutting Units Repairs233
Removal and Installation of Cutting Unit233
Bedbar Removal/Installation234
Bedbar Bushing Replacement236
Replacement of Bedknife237
Preparing Cutting Unit for Reel Grinding237
Reel Removal/Bearing Replacement238
Bedknife Adjustment Knob Bearing Service239
Replacement of Lift Bail240
Grooming Reel Cutting Units241
Grooming Reel Cutting Units Specifications243
Grooming Reel Cutting Units - Special Tools244
Grooming Reel Cutting Units Troubleshooting246
Factors Affecting Grooming248
Grooming Reel Mechanical Problems249
Grooming Reel Cutting Units Set up and Adjustments250
Groomer Reel Depth Adjustment258
Groomer Reel Drive Belt Adjustment259
Grooming Reel Cutting Units Repairs261
Groomer Reel Blade Service268
Groomer Reel Drive Belt Replacement268
Groomer Reel Removal and Bearing Service269
Groomer Reel Clutch Service270
Bedknife to Reel Adjustment Knob Bearing Service272

Toro Greenmaster 3000 - Page 153

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