Part No. 96900SL (Rev. D) Service Manual GreensmasterR 3200/3200--D Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Greensmaster 3200/3200--D. REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine.
Greensmaster 3200/3200–D
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 3 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . 5 – 7 Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . . 5 – 8 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 16 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 17 Testing . . . . . . . . . . . . . . . . . . . .
Greensmaster 3200/3200–D
Table Of Contents (continued) Cutting Units Wheels and Brakes Electrical System Hydraulic System Engine Cutting Units Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 3 General Information . . . . . . . . . . . . . . . . . . . . . . . . 8 – 4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .
Greensmaster 3200/3200–D
Chapter 1 Safety Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3 SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
While Operating 1. Do not run the engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could be deadly. 2. Sit on the seat when starting and operating the machine. 3. Check the operation of the interlock switches daily for proper operation (see Verify Interlock System Operation in Chapter 5 -- Electrical System). Replace any malfunctioning switches before operating the machine. 4. To start the engine: A. Sit on the seat, make sure cutting units are disengaged. B.
Maintenance and Service 2. Be sure entire machine is in good operating condition. Keep all nuts, bolts, screws and hydraulic fittings tight. 3. Make sure all hydraulic line connectors are tight,and all hydraulic hoses and lines are in good condition before applying pressure to the system. 4. Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks.
Safety and Instruction Decals Numerous safety and instruction decals are affixed to the traction unit. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog. Order replacements from your Authorized Toro Distributor. Safety Page 1 -- 4 Rev.
Safety On Seat Back (Part No. 95–0501) On Control Panel (GR3200) (Part No.
Safety Page 1 – 6 Greensmaster 3200/3200–D
Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Capscrew Markings and Torque Values – U.S. . . Capscrew Markings and Torque Values – Metric 1 2 2 2 3 3 3 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions Product Records and Maintenance Page 2 – 2 Greensmaster 3200/3200–D
Product Records and Maintenance Torque Specifications Greensmaster 3200/3200–D Page 2 – 3 Product Records and Maintenance
Single Point Adjust Cutting Unit Each cutting unit has (7) grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. IMPORTANT: Lubricating cutting units immediately after washing helps purge water out of bearings and increases bearing life. 1. Wipe each grease fitting with a clean rag. 2. Apply grease until pressure is felt against handle. IMPORTANT: Do not apply too much pressure or grease seals will be permanently damaged. Figure 4 3. Wipe excess grease away.
Product Records and Maintenance Page 2 – 6 Greensmaster 3200/3200–D
Maintenance Maintenance procedures and recommended service intervals for the Greensmaster 3200 and 3200–D are covered in the Operator’s Manuals. Refer to those publications when performing regular equipment maintenance. Product Records and Maintenance Page 2 – 6 Rev.
Chapter 3 Vanguard 3/LC Gasoline Engine INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Fuel Shutoff Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . 4 Filling Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Checking Cooling System . . . . . . .
Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the gasoline engine used in the Greensmaster 3200 mower. equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Briggs and Stratton Vanguard 3/LC Repair Manual.
Specifications Item Description Make / Designation Briggs and Stratton Vanguard 3/LC, Water–cooled, Gasoline, DM 700 G – 45 Number of Cylinders 3 Horse Power Governed to 18.5 HP @ 2800 RPM Torque kg–m (ft–lb) 4.91 (35.5) @ 2300 RPM Bore x Stroke mm (in.) 68 x 64 (2.68 x 2.52) Total Displacement cc (cu. in.) 677 (42.5) 8.6:1 Firing Order 1– 2–3 Dry Weight (approximate) kg (lb.) 85 (187) Fuel Unleaded Regular Grade Gasoline Fuel Capacity liters (gallons) 22.7 (6.
General Information Fuel Shutoff Valve These valves should be shut when removing the engine or placing the unit in long term storage. 1 Figure 1 1. Fuel shut off (under the fuel tank) Checking Engine Oil IMPORTANT: Check level of oil every 5 operating hours or daily. Change oil after every 50 hours of operation. Crankcase capacity is approximately 3.2 qts. (3.0 L) with filter. 1 1. Position machine on a level surface. 2. Remove dipstick and wipe it with a clean rag.
Fill Fuel Tank The engine runs on unleaded regular grade gasoline. Fuel tank capacity is approximately 6.0 gallons (22.7 L). 1 The Toro Company strongly recommends the use of fresh, clean, unleaded regular grade gasoline in Toro gasoline powered products. Unleaded gasoline burns cleaner, extends engine life, and promotes good starting by reducing the build–up of combustion chamber deposits. Leaded gasoline can be used if unleaded is not available.
Check Cooling System The cooling system is filled with a 50/50 solution of water and ethylene glycol antifreeze. Check level of the coolant at the beginning of each day before starting the engine. Capacity of cooling system is approximately 3.6 qts. (3.4 L). 1 CAUTION If engine has been running, pressurized hot coolant can escape when the radiator cap is removed and may cause burns. 2 1. Park machine on a level surface. 2. Check coolant level.
Adjustments Alternator Belt Adjustment Make sure belt is properly tensioned to assure the proper operation of the machine and prevent unnecessary wear. On new belts, check tension after 8 hours of operation. 2 1 The engine belt should be tensioned so it deflects 0.20 inch (5 mm) with a 2–3 pound (9 to 13 N) load applied midway between the crankshaft and alternator pulley. 1. Loosen bolts securing the alternator to the engine and adjusting bracket. Figure 6 1. Alternator 2.
Service and Repairs Servicing Air Cleaner Service air cleaner filter every 200 hours (more frequently in extreme dusty or dirty conditions). 5. Inspect new filter for shipping damage. Check sealing end of the filter. Do not install a damaged filter. 1. Check air cleaner body and hoses for damage which could possibly cause an air leak. Replace air cleaner body if damaged. 6. Insert new filter properly into the air cleaner body.
Cleaning Radiator and Screen To prevent the cooling system from overheating, the radiator screen and radiator must be kept clean. Check and clean screen and radiator daily. If necessary, clean any debris off these parts hourly. Clean these components more frequently in dusty and/or dirty conditions. 2 1. Release latches and remove radiator screen from the radiator support. 2. Remove fan shroud to access radiator corners. 1 CAUTION Figure 9 Use eye protection such as goggles when using compressed air 2.
Changing Engine Oil and Filter Change oil and filter initially after the first 8 hours of operation. Change oil every 50 hours and the filter every 100 hours thereafter. 1. Remove drain plug letting the oil flow into the drain pan. When the oil stops flowing, install drain plug. 2. Remove oil filter. Apply a light coat of clean oil to the new filter gasket. 2 3. Screw filter on by hand until the gasket contacts the filter adapter. Tighten filter from 1/2 to 3/4 of a turn further. Do not overtighten.
Replacing Spark Plugs Use a Briggs & Stratton Vanguard 3/LC #491053 or Champion RC12YC spark plug or equivalent. Correct air gap is 0.030 inch (0.76 mm). Remove plugs after every 100 operating hours and check condition. 1. Pull wires off the spark plugs. 2. Clean around spark plugs and remove plugs. IMPORTANT: Replace any cracked, fouled, or dirty spark plug. Do not sand blast, scrape, or clean electrodes because engine damage could result from grit entering the cylinder. Figure 14 1.
Muffler and Air Cleaner 9 4 7 14 11 10 13 8 12 10 4 4 3 27 4 26 2 25 5 24 17 19 20 6 19 18 21 RIGHT FRONT 22 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. Not used Air cleaner bracket Lock nut Cap screw Mounting band Air cleaner Muffler Spark arrestor Hot surface decal Vanguard 3/LC Gasoline Engine 10. 11. 12. 13. 14. 15. 16. 17. 18. Clamp Exhaust bracket Exhaust pipe Lock nut Nut Not used Not used Air cleaner hose Air cleaner hose Page 3 – 12 19. 20. 21. 22. 23. 24. 25. 26. 27.
Muffler Removal (Fig. 15) Air Cleaner Removal (Fig. 15) 1. Park machine on a level surface, lower the cutting units, stop the engine, engage parking brake, and remove the key from the ignition switch. 1. Park machine on a level surface, lower the cutting units, stop the engine, engage parking brake, and remove the key from the ignition switch. 2. Loosen hose clamps (19), and disconnect air cleaner hoses (17 and 18) from the air cleaner (6). CAUTION 3. Remove lock nut (24) from bolt (26).
Radiator 34 12 3 20 25 24 1 20 2 27 15 1 32 4 1 20 24 17 38 29 19 3 22 9 5 31 26 18 9 9 30 18 7 30 6 1 8 28 10 11 14 36 39 37 7 13 21 Figure 16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Hose clamp Radiator hose Barb hose fitting Radiator Upper cooler bracket Fan warning decal Cap screw Radiator support assembly Lock nut Screen Swell latch Radiator cap decal Lower cooler bracket Vanguard 3/LC Gasoline Engine 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Radiator Removal (Fig. 16) Radiator Installation (Fig. 16) 1. Park machine on a level surface, lower the cutting units, stop the engine, engage parking brake, and remove the key from the ignition switch. 1. Secure fan shroud (19) to radiator (4) with four cap screws (22), lock nuts (28), and flat washers (15). 2. Slide radiator (4) into the radiator support (8). Secure radiator to support with four cap screws (18) and lock nuts (9).
Fuel Tank 1 13 27 6 13 2 6 30 to 60 in–lb (35 to 69 kg–cm) 3 ANTISEIZE LUBRICANT 14 26 22 19 25 17 4 6 16 14 21 15 18 10 9 24 24 11 24 12 6 20 20 23 6 20 6 Figure 17 1. 2. 3. 4. 5. 6. 7. 8. 9. Fuel cap Gasoline fuel tank Grommet Flat washer Not used Cap screw Not used Not used Fuel shut–off fitting Vanguard 3/LC Gasoline Engine 10. 11. 12. 13. 14. 15. 16. 17. 18.
Fuel Tank Removal (Fig. 17) Fuel Tank installation (Fig. 17) 1. Park machine on a level surface, lower the cutting units, stop the engine, engage parking brake, and remove the key from the ignition switch. 1. Position fuel tank (2) to the mounting plate (13). A. Apply antiseize lubricant to the threads of the three cap screws (16). B. Secure fuel tank to the plate with three flat washers (4) and cap screws. DANGER Because gasoline is inflammable, caution must be used when storing or handling it.
Engine 27 30 28 19 11 15 18 31 14 19 28 33 15 16 18 43 51 34 29 21 20 37 31 46 32 40 15 19 17 26 15 24 2 5 25 8 16 6 7 41 42 7 17 35 44 36 37 15 18 4 20 49 45 31 15 21 16 30 45 39 46 50 13 3 1 26 45 9 7 21 20 15 38 47 48 16 Figure 18 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Engine Removal 1. Park machine on a level surface, lower the cutting units, stop the engine, engage parking brake, and remove the key from the ignition switch. PUMP INLET HOSE 2. Release lockup handle, and pivot steering arm and steering wheel all the way forward. Lift seat forward to gain access to the engine. 3. Remove console shroud from the control panel. 4. Drain fuel tank (see Fuel Tank Removal): Figure 19 CAUTION 4 The hydraulic fluid may be hot.
8. Remove fuel tank and hydraulic reservoir as follows: 1 A. Remove three cap screws (6) and two flat washers (14) securing tank mounting plate (13) to the support bracket (27) and frame (Fig. 17). 2 B. Disconnect expansion tank hose (25) from the radiator elbow (27) (Fig. 16). C. Disconnect hydraulic hose from welded fitting on the tube leading into rear bulkhead (Fig. 21). D. If the oil cooler is not installed, disconnect hydraulic hose from the hydraulic oil filter (Fig. 22). Figure 22 1.
12. Remove radiator as follows (Fig. 16): A. Remove alternator guard (29) from radiator support (8) and frame bracket. B. Disconnect breather hose (24) and radiator hose (17) from the radiator elbow (27). RELIEF VALVE C. Disconnect radiator hose (2) from the bottom of the water pump. D. Disconnect hose (37) from air cleaner at the radiator support (8). Remove hose from the machine CAPSCREWS E. Remove screen (10) from the radiator support. Figure 25 F.
15. Loosen cable clamp and remove choke cable from the clamp. Disconnect choke link from the choke lever (Fig. 28) CAUTION One person should operate the chain fall or hoist while the other person guides the engine out of the frame. 16. Disconnect the following electrical connections (Fig. 18): A. The black (negative) battery cable (36) and black wire harness ground (37) from below the oil filter. 22. Remove engine from the frame. B.
Engine Installation G. The green/blue wire to the oil pressure switch. 1. If the pump plate, backing plate, or engine mounts were removed from the engine, install them to the engine using Figure 18 as a guide. H. The black and white/black wires and connector to the fuel pump (39). I. The connector to the electric governor. .Secure main electrical harness to the frame with R–clamps (Fig. 29). CAUTION J. The blue and white wires and connector to the alternator.
F. Install alternator guard (29) to the radiator support (8) and frame bracket. 17. Install fuel tank and hydraulic reservoir as follows: A. Position mounting plate and tanks onto the frame. G. Make sure hoses are clear of rotating parts. Make sure cable ties and clamps securing hoses to the frame and supports are installed. B. If the oil cooler is not installed, Connect hydraulic hose to the hydraulic oil filter (Fig. 22). 13. Install fuel filter (39) to the front engine mount (13).
Chapter 4 Perkins Diesel Engine Table of Contents Cleaning Radiator and Screen . . . . . . . . . . . . . . . Changing Engine Oil and Filter . . . . . . . . . . . . . . . Torquing Cylinder Head Bolts . . . . . . . . . . . . . . . . Replacing Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . Muffler and Air Cleaner . . . . . . . . . . . . . . . . . . . . . Muffler Removal and Installation . . . . . . . . . . . . . Air Cleaner Removal and Installation . . . . . . . . . Radiator . . . . . . . . . . . .
Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the diesel engine used in the Greensmaster 3200–D mower. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Special Tools section. The use of some specialized test equipment is explained.
Specifications Item Description Make / Designation Perkins, vertical in–line, 4–stroke, water–cooled Diesel, 103–07 KL 70373 Combustion Chamber IDI special swirl–combustion type Number of Cylinders 3 Horse Power 17.0 HP @ 3600 RPM Torque kg–cm (in–lb) 392 (340) @ 3600 RPM Bore x Stroke mm (in.) 67 x 64 (2.64 x 2.52) Total Displacement cc (cu. in.) 676 (41.23) Compression Ratio 24:1 Firing Order 1– 2–3 Dry Weight (approximate) kg (lb.) 64 (141) Grade No.
Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (Commercial Products). Some tools may be listed in the Greensmaster 3200–D Parts Catalog. Tools may also be available from a local supplier. Filter Cleaner Mix cleaner with water, and use solution to wash the Donaldson air cleaner element. Figure 1 Diesel Engine Compression Test Kit This 0 to 1000 PSI gauge allows testing and checking the general operating condition of the engine.
Nozzle Test Adapter This adapter is required to test the fuel injection nozzles in conjunction with the spray tester.
General Information Fuel Shutoff Valves These valves should be shut when removing the engine or placing the unit in long term storage. 1 1 Figure 6 1. Fuel shut off (under the fuel tank) Figure 5 1. Fuel shut off valve (on the fuel filter) Filling Fuel Tank The engine runs on No. 2 diesel fuel. The fuel tank capacity is approximately 6 gallons (22.7 L) 1 1. Clean area around fuel tank cap. DANGER Diesel fuel is flammable. Use caution when storing or handling it.
Checking Engine Oil IMPORTANT: Check level of oil every 5 operating hours or daily. Change oil after every 50 hours of operation. 1 Crankcase capacity is approximately 3.2 qts. (3.0 L) with filter. 1. Park machine on a level surface, engage parking brake, and lower cutting units. Allow engine to run for at least ten minutes to bring it to operating temperature, then shut off the engine. Figure 8 1. Dipstick 2. Remove dipstick and wipe it with a clean rag.
Adjustments Alternator Belt Adjustment Make sure belt is properly tensioned to assure proper operation of the machine and prevent unnecessary wear. On new belts, check tension after 8 hours operation. 1 The alternator belt should be tensioned so it deflects 0.20 inch (0.51 cm) with a 2 to 3 pound (8.9 to 13.3 N) load applied midway between the crankshaft and alternator pulley. 2 1. Loosen bolts securing alternator to engine and adjusting strap. 1 2. Adjust belt to proper tension and tighten bolts.
Throttle Adjustment 3 4 1 1 2 Perkins Diesel Engine 6 7 5 8 Figure 13 1. Throttle control cable 2. Lock nut 3. Cap screw 4. Throttle cable clamp 5. Lock nut 6. Shoulder screw Normally, adjustments to the engine speed settings are not necessary unless the throttle control cable, injection pump, or governor have been repaired, rebuilt, or replaced; or are they are not operating correctly. 7. Throttle tab 8. Governor lever 5. Install new wire and lead seal no the high–speed set bolt.
Low–Speed Adjustment (Fig. 13 and 14) 1. Make sure machine is parked on a level surface with the parking brake engaged and the cutting units lowered. Allow engine to run for at least ten minutes to bring it to operating temperature. 2. Position throttle control lever to the low idle position (against the stop plate). 3. Lift up seat to access the engine. Perkins Diesel Engine 4. Loosen cap screw and lock nut securing the throttle cable clamp to the throttle control cable and front engine mount. 5.
Service and Repairs Inspecting Fuel Filter Inspect fuel filter bowl daily for water or other contaminants. If water or other contaminants are present, they must be removed before commencing operation. 1. Close fuel shutoff valve above the filter. 1 DANGER Diesel fuel is flammable. Use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running or in an enclosed area.
Bleeding Fuel System 1. Park the machine on a level surface. Make sure fuel tank is at least half full. 2 1 DANGER Diesel fuel is flammable. Use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running or in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety–approved container, and keep the cap in place.
Servicing Air Cleaner Service air cleaner filter every 200 hours (more frequently in extreme dusty or dirty conditions). 1. Check air cleaner body for damage which could possibly cause an air leak. Replace cleaner body if damaged. 6. Insert new filter properly into air cleaner body. Make sure filter is sealed properly by applying pressure to outer rim of filter when installing. Do not press on flexible center of filter. 7. Reinstall cover and secure latches. 2.
Cleaning Radiator and Screen Keep radiator screen and radiator clean to prevent the cooling system from overheating. Check and clean both the screen and radiator daily. If necessary, clean any debris off these parts hourly. Clean these components more frequently in dusty and/or dirty conditions. 2 1. Release latches and remove radiator screen from the support. 2. Remove fan shroud to access radiator corners. CAUTION 1 Figure 19 Use eye protection such as goggles when using compressed air 1. Screen 2.
Torque Cylinder Head Bolts Check head bolt torque after the first 50 hours of operation, and every 400 hours thereafter. 1 1. Remove breather hose and cylinder head cover from engine. 2 2. Torque head bolts from 25 to 29 ft–lb (3.5 to 4.0 kg–m) using the sequence in Figure 23. 3. Install cylinder head cover and gasket. Torque cover screws from 7 to 9 ft–lb (1.0 to 1.2 kg–m). Install breather hose. Figure 22 2. Cylinder head cover Perkins Diesel Engine 1.
Muffler and Air Cleaner 9 4 7 12 13 14 10 11 8 4 25 26 10 4 28 3 2 25 15 5 16 24 17 19 20 19 6 RIGHT 18 21 FRONT 22 Figure 25 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Not used Air cleaner bracket Lock nut Cap screw Mounting band Air cleaner Muffler Muffler shield Hot surface decal Clamp Perkins Diesel Engine 11. 12. 13. 14. 15. 16. 17. 18. 19.
Muffler Removal Air Cleaner Removal 1. Park machine on a level surface, lower the cutting units, stop the engine, engage parking brake, and remove the key from the ignition switch. 1. Park machine on a level surface, lower the cutting units, stop the engine, engage parking brake, and remove the key from the ignition switch. 2. Loosen hose clamps (19), and disconnect air cleaner hoses (17 and 18) from the air cleaner (6). CAUTION 3. Remove lock nut (24) from bolt (15).
Radiator 12 30 25 20 37 28 1 24 RIGHT 2 20 3 FRONT 1 1 1 17 22 15 4 23 26 28 20 19 24 3 31 5 18 9 9 24 29 9 18 7 36 1 36 6 8 27 10 11 14 38 34 35 7 13 21 Figure 26 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Hose clamp Radiator hose (to water pump) Hydraulic barb fitting Radiator Upper cooler bracket Lower cooler bracket Cap screw Radiator support Lock nut Screen Swell latch Radiator cap decal Cooler lower bracket Perkins Diesel Engine 14. 15. 16. 17. 18. 19. 20.
Radiator Removal (Fig. 26) Radiator Installation (Fig. 26) 1. Park machine on a level surface, lower the cutting units, stop the engine, engage parking brake, and remove the key from the ignition switch. 1. Secure fan shroud (19) to radiator (4) with four cap screws (22), lock nuts (27), and flat washers (15). 2. Slide radiator (4) into the radiator support (8). Secure radiator to support with four cap screws (18) and lock nuts (9).
Fuel Tank 1 13 28 6 13 2 6 30 to 60 in–lb (35 to 69 kg–cm) 25 ANTISEIZE LUBRICANT 3 14 5 22 6 10 19 4 24 17 6 16 14 10 23 11 RIGHT 21 15 26 10 FRONT 12 18 27 10 9 Figure 27 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Diesel fuel cap Fuel tank Grommet Flat washer Expansion tank hose (from radiator) Cap screw Not used Not used Fuel shut–off fitting Hose clamp Perkins Diesel Engine 11. 12. 13. 14. 15. 16. 17. 18. 19.
Fuel Tank Removal (Fig. 27) Fuel Tank installation (Fig. 27) 1. Park machine on a level surface, lower the cutting units, stop the engine, engage parking brake, and remove the key from the ignition switch. 1. Position fuel tank (2) to the mounting plate (13). Be careful not to damage any fuel hoses. A. Apply antiseize lubricant to the threads of the three cap screws (16). B. Secure fuel tank to the plate with three flat washers (4) and cap screws. DANGER Diesel fuel is flammable.
Engine 12 44 46 34 49 7 19 45 RIGHT 36 19 11 16 15 15 FRONT 18 18 42 10 36 27 15 47 3 16 35 16 39 41 50 21 16 20 41 34 21 28 20 10 16 14 30 52 31 34 32 29 15 53 38 31 54 37 19 33 22 2 40 23 4 16 15 26 9 18 8 6 1 16 40 17 41 24 21 20 5 8 7 13 43 51 25 44 Figure 28 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Engine Removal 1. Park machine on a level surface, lower the cutting units, stop the engine, engage parking brake, and remove the key from the ignition switch. PUMP INLET HOSE 2. Release lockup handle, and pivot steering arm and steering wheel all the way forward. Lift seat forward to gain access to the engine. 3. Remove console shroud from the control panel. 4. Drain fuel tank (see Fuel Tank Removal): Figure 29 CAUTION 4 The hydraulic fluid may be hot.
8. Remove fuel tank and hydraulic reservoir as follows: 1 A. Remove three cap screws (6) and two flat washers (14) securing tank mounting plate (13) to the support bracket (28) and frame (Fig. 27). 2 B. Disconnect fuel hose (36) and expansion tank hose (50) from the support bracket (14). Disconnect fuel hose (35) from the number three fuel injector (Fig. 28). C. Disconnect expansion tank hose (25) from the radiator elbow (26) (Fig. 26). D.
10. Remove muffler as follows (Fig. 34): 7 5 A. Remove four cap screws and flat washers securing the exhaust plate to the engine exhaust manifold. 3 4 B. Remove muffler shield from the muffler and pump plate by removing four cap screws. 1 7 2 C. Remove two cap screws securing the muffler to the pump plate. 7 6 CAUTION Figure 34 1. 2. 3. 4. The muffler and muffler tube may be hot. To avoid possible burns, allow the exhaust system to cool before working on the muffler and muffler tube.
13. Separate relief valve from the pump plate by removing both cap screws flat washers, and lock nuts (Fig. 35). 14. Separate hydrostat from the pump plate as follows: RELIEF VALVE A. Loosen set screw securing the hydrostat shaft to the hub (Fig. 36). CAUTION CAPSCREWS Use caution when removing the lock nut from the pin. The extension spring is under tension and may cause personal injury during removal. Figure 35 B. Remove lock nut securing the pin and extension spring to the spring bracket.
15. Disconnect electrical connections from the following engine components (Fig. 28): A. The black (negative) battery cable (37) and Black wire harness ground (38) on the lower engine block. 18. Remove three whiz nuts (20), plate washers (21), and cap screws (19) securing the front engine mount (13) and rear engine mount (11) to the rubber mounts (18) (Fig. 28). CAUTION B. The red (positive) battery cable (39) and red wires and connector on the starter solenoid.
G. The blue and white wires and connector to the alternator. Engine Installation 1. If the pump plate, backing plate, or engine mounts were removed from the engine, install them to the engine using Figure 28 as a guide. 8. Install hydrostat to the pump plate as follows: CAUTION CAUTION Use caution when installing the lock nut to the pin. The extension spring is under tension and may cause personal injury during removal.
F. Connect fuel hose (36) and expansion tank hose (50) to the support bracket (14). Connect fuel hose (35) to the number three fuel injector (Fig. 28). 12. Install muffler as follows (Fig. 34): A. Secure muffler to the pump plate with two cap screws. G. Make sure hoses are secured to the frame and supports with cable ties and hose clamps. B. Install muffler shield to the muffler and pump plate with four cap screws. H. Connect fuel hose (36) to fuel filter (49) (Fig. 28). C.
Perkins Diesel Engine Page 4 – 30 Greensmaster 3200–D
Chapter 5 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 3 Check Hydraulic System Fluid . . . . . . . . . . . . . . . . . 5 Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 6 Check Hydraulic Lines and Hose . . . . . . . . . . . . . . .
Specifications Item Description Hydrostatic Transmission Maximum Operating Pressure Maximum Intermittent Pressure Maximum Rated Speed Rated Flow @ Maximum Rated Speed and Operating Pressure Charge Pressure Variable displacement piston pump 3000 PSI (207 bar) 5000 PSI (345 bar) 3600 RPM 17 GPM (64 LPM) 100 to 150 PSI (6.9 to 10.
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions, or mishandling during operation or maintenance. These conditions can cause damage or premature deterioration. Some hoses are more susceptible to these conditions than others. Inspect the hoses frequently for signs of deterioration or damage.
SAE Straight Thread O–Ring Port – Non–adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O–ring seal when this type of fitting shows signs of leakage. O–Ring 3. Lubricate the O–ring with a light coating of oil. 4. Install the fitting into the port and tighten it down full length until finger tight. Figure 3 5. Tighten the fitting to the correct flats from finger tight (F.F.F.T.). Size 4 (1/4 in.
Check Hydraulic System Fluid The hydraulic system is designed to operate on antiwear hydraulic fluid. The machine’s reservoir is filled at the factory with Mobil 424 hydraulic fluid. Check level of hydraulic fluid before engine is first started and daily thereafter (see Specifications for capacity). IMPORTANT: Two groups of hydraulic fluid are specified to allow optimal operation of the machine in a wide range of temperatures encountered.
Checking Fluid Level 1 1. Position machine on a level surface. Make sure machine has cooled down so fluid is cold. 2 2. Remove cap from reservoir and check level of fluid. The fluid should be up to bottom of screen in filler neck. 3. If fluid level is low, slowly fill reservoir with appropriate hydraulic fluid until level reaches bottom of screen. DO NOT OVERFILL. IMPORTANT: To prevent system contamination, clean top of hydraulic fluid containers before puncturing.
Greensmaster 3200/3200–D Page 5 – 7 Rev.
Hydraulic Flow Diagrams Traction Forward and Reverse Forward Reverse The hydrostat is driven directly by the engine. The traction circuit of the hydraulic system acts essentially as a closed loop. Taking its suction directly from the return side of the wheel motors of the traction circuit, the hydrostat supplies oil flow to the wheel motors through the supply side of the traction circuit. The traction circuit operates essentially the same in reverse as it does in the forward direction.
Greensmaster 3200/3200–D Page 5 – 9 Hydraulic System P3 HYDROSTAT 3025 HIGH IDLE (DIESEL) 2300 RPM MOW OR TRANSPORT 2800 RPM MOW OR TRANSPORT (GASOLINE) 1500 LOW IDLE R4 BY–PASS VALVE OPTIONAL 3WD TRACTION WHEEL MOTOR M4 M5 TRACTION WHEEL MOTORS R5 P1 P1 Hydraulic System OIL COOLER (OPTIONAL KIT) ENGINE RPM OIL FILTER T S1 R1 LC1 O1 RD1 M1 S2 P2 S3 OPTIONAL VALVES PT ST MB GEAR PUMP P2 FC1 MA M2 M3 REEL MOTORS PB T P V1 MANIFOLD BLOCK R2 S4 L2A L2B L1B L3A
Raise and Lower Cutting Units Raise Lower The gear pump (P2) is directly coupled to the hydrostat through gear pump (P1). It supplies hydraulic pressure for raising and lowering cutting units and maintaining 100 to 150 PSI (6.9 to 10.0 bar) to the low pressure side of the traction circuit (charge pressure). The pump takes its suction from the hydraulic reservoir. Circuit operation for lowering the lift cylinders is similar to raising them.
Greensmaster 3200/3200–D Page 5 – 11 Hydraulic System P3 HYDROSTAT 1500 LOW IDLE 3025 HIGH IDLE 2300 RPM MOW OR TRANSPORT (DIESEL) 2800 RPM MOW OR TRANSPORT (GASOLINE) R4 BY–PASS VALVE OPTIONAL 3WD TRACTION WHEEL MOTOR M4 M5 TRACTION WHEEL MOTORS R5 OIL COOLER (OPTIONAL KIT) P1 P1 Hydraulic System ENGINE RPM OIL FILTER T S1 R1 LC1 O1 RD1 M1 S2 P2 S3 OPTIONAL VALVES PT ST MB GEAR PUMP P2 FC1 MA M2 M3 REEL MOTORS PB T P V1 MANIFOLD BLOCK R2 S4 L2A L2B L1B L3A
Mow and Backlap Mow The gear pump (P1) is directly coupled to the the hydrostat which is driven directly by the engine. Taking its suction directly from the hydraulic reservoir, the gear pump supplies oil flow to the manifold block and to the reel motors. With the engine running and the Functional Control and Raise/Lower/Mow levers positioned so the reels will not turn (see Operator’s Manual), solenoid valve (S1) is de–energized. S1 by–passes flow from the reel motors directly to the hydraulic reservoir.
Greensmaster 3200/3200–D Page 5 – 13 Hydraulic System P3 HYDROSTAT 3025 HIGH IDLE (DIESEL) R5 S1 P1 P1 R1 LC1 O1 RD1 M1 S2 P2 S3 OPTIONAL VALVES PT ST MB REEL MOTORS GEAR PUMP P2 FC1 MA M2 Hydraulic System ENGINE RPM OIL FILTER T OIL 2300 RPM MOW OR TRANSPORT COOLER 2800 RPM MOW OR TRANSPORT (OPTIONAL KIT) (GASOLINE) 1500 LOW IDLE R4 BY–PASS VALVE OPTIONAL 3WD TRACTION WHEEL MOTOR M4 M5 TRACTION WHEEL MOTORS M3 PB T P V1 MANIFOLD BLOCK R2 S4 L2A L2B L1B L3A
Right and Left Turn Right The gear pump (P2) is directly coupled to the hydrostat through gear pump (P1). It supplies hydraulic pressure to the steering control valve for turning the rear wheel and maintaining 100 to 150 PSI (6.9 to 10.0 Bar) to the low pressure side of the traction circuit. The pump takes its suction from the hydraulic reservoir. With the steering wheel in the neutral position (rear wheel positioned straight ahead) and the engine running, the spool valve is in the center position.
Greensmaster 3200/3200–D Page 5 – 15 Hydraulic System P3 HYDROSTAT 3025 HIGH IDLE (DIESEL) 2300 RPM MOW OR TRANSPORT 2800 RPM MOW OR TRANSPORT (GASOLINE) 1500 LOW IDLE R4 BY–PASS VALVE OPTIONAL 3WD TRACTION WHEEL MOTOR M4 M5 TRACTION WHEEL MOTORS R5 P1 P1 Hydraulic System OIL COOLER (OPTIONAL KIT) ENGINE RPM OIL FILTER T S1 R1 LC1 O1 RD1 M1 S2 P2 S3 OPTIONAL VALVES PT ST MB GEAR PUMP P2 FC1 MA M2 M3 REEL MOTORS PB T P V1 MANIFOLD BLOCK R2 S4 #2 #3 STEERING C
Special Tools Order these tools from your Toro Distributor. Some tools may also be available from a local supplier. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each, 1000, 5000 and 10000 PSI gauges. Use gauges as recommended in Testing section of this chapter.
Troubleshooting The charts that follow contain information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the Testing section of this Chapter for precautions and specific test procedures.
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Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks. (See the Special Tools section in this Chapter.) WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved by stopping the engine and lowering or supporting the cutting units or other implements.
5. Completely open load valve in the hydraulic tester (when using tester with pressure and flow capabilities) to minimize the possibility of damaging components. 6. Install fittings finger tight and far enough to insure that they are not cross–threaded before tightening them with a wrench. 9. Check the traction pedal linkage for improper adjustment, binding,or broken parts. 10. All hydraulic tests should be made with the hydraulic oil at normal operating temperature. Hydraulic System 7.
TEST NO. 1: Hydrostat Flow (P3) RIGHT UPPER FITTING FRONT M5 TRACTION WHEEL MOTORS HYDRAULIC HOSE M4 TESTER DUMP VALVE R4 FROM GEAR PUMP P3 TO HYDRAULIC RESEROIR HYDROSTAT High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 5 – 22 Rev.
Procedure for Hydrostat Flow (P3) Check: 2. Make sure machine is parked on a level surface with the cutting units lowered and off. Make sure engine is off. CAUTION Use extreme caution when taking gauge readings. The front tire on the ground will be trying to move the machine forward. 3. Read Precautions for Hydraulic Testing. 14. Slowly push traction pedal into fully forward position. 4. Make sure that traction pedal is adjusted to the neutral position (see Traction Pedal in the Adjustments Section).
TEST NO.
Procedure for Charge Relief Valve (R4) Pressure Check: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 5. Operate engine at full speed. A. Units with a diesel engine (3025 " 50 RPM). B. Units with a gasoline engine (2800 " 28 RPM). 6. Make sure hydraulic oil is at operating temperature. 2. Make sure machine is parked on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. 7.
TEST NO. 3: Gear Pump (P2) Flow and Implement Relief Valve (R5) Pressure T–CONNNECTOR PUMP DISCHARGE TO REEL MOTOR CIRCUIT TESTER TO STEERING AND LIFT CIRCUITS R5 P1 TO TRACTION CHARGE CIRCUIT P2 ENGINE RPM GEAR PUMP FROM TRACTION CHARGE AND CASE DRAIN CIRCUIT High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 5 – 26 Rev.
Procedure for Gear Pump (P2) Flow Check: Procedure for Implement Relief Valve (R5) Pressure Check: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Make sure machine is parked on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. 3. Read Precautions for Hydraulic Testing. CAUTION Do not allow pressure to exceed 1200 PSI. 1. Fully open control valve on the tester. 4.
TEST NO.
Procedure for Gear Pump (P1) Check: 7. Make sure tester load valve is fully open before starting the engine. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Make sure machine is parked on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. 3. Read Precautions for Hydraulic Testing. 4. Disconnect hose connection on the reel drive pump leading to port P1 on the hydraulic manifold. 5.
TEST NO. 5: Manifold Relief Valve (R1) Pressure TO REEL MOTOR CIRCUIT TO LEFT REEL MOTOR TO AND FROM REEL MOTORS MA MB S4 RD1 OPTIONAL VALVES O1 R2 S3 L3B FC1 LC1 L3A S2 R1 L1B S1 TO AND FROM LIFT CYLINDERS TO OIL FILTER L2B T L2A P1 PT ST P2 MANIFOLD BLOCK FROM STEERING CIRCUIT FROM GEAR PUMP Hydraulic System Page 5 – 30 Rev.
Procedure for Manifold Relief Valve (R1) Pressure Check: CAUTION 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Make sure machine is parked on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. Keep away from reels during test to prevent personal injury from the rotating reel blades. 8. Start engine and move throttle to full speed. Engage the cutting units. 3.
TEST NO. 6: Manifold Relief Valve (R2) Pressure HOSE TO PORT P2 S1 S3 S2 S4 TO AND FROM REEL MOTORS MA MB RD1 S4 OPTIONAL VALVES TO HYDRAULIC RESERVOIR O1 R2 L3B S3 FC1 LC1 #3 L3A R1 S2 #1 L1B S1 L2B #2 T L2A P2 P1 MANIFOLD BLOCK PT ST TO HYDROSTAT FROM GEAR PUMP Hydraulic System FROM STEERING CONTROL VALVE Page 5 – 32 Rev.
Procedure for Manifold Relief Valve (R2) Pressure Check: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Make sure machine is parked on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. 8. Watch pressure gauge carefully while holding the Raise/Lower – Mow Control lever at RAISE until the manifold relief opens. Relief pressure should be 300 PSI. Release lever and shut off engine.
TEST NO.
Procedure for Reel Motor Case Drain Check: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Make sure machine is parked on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. 3. Read Precautions for Hydraulic Testing. 4. For the suspected bad motor, disconnect return hose from motor that is used for mowing operation. 5.
TEST NO.
Procedure for Steering Control Valve Check: 1. Make sure the hydraulic tank is full. 2. Start engine. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 3. Drive machine slowly in a figure eight on a flat level surface. LEFT TURN RIGHT TURN A. There should be no shaking or vibration in the steering wheel or rear wheel. B.
Adjustments Adjusting Transmission for Neutral If the machine “creeps” when the traction control pedal is in the neutral position, the neutral return mechanism must be adjusted. E. From each side of bulkhead, tighten locknuts evenly, securing traction cable to bulkhead. Do not twist cable. 1. Block up under the frame so one of the front wheels is off the floor. Note: If cable tension exists when in neutral, machine may creep when the functional control lever is moved to the Mow or Transport position. 2.
Adjusting Cutting Unit Lift and Drop The machine’s cutting unit lift/drop circuit has a flow control valve which is preset at the factory to about 3 turns open. An adjustment may be required to compensate for differences in hydraulic oil temperatures, mowing speeds, etc. If an adjustment is required proceed as follows: Note: Allow hydraulic oil to reach full operating temperature before adjusting flow control valve. 2 1 1.
Adjusting Manifold Relief Valves (R1 and R2) The hydraulic reel and lift circuits are equipped with relief valves. These valves are preset at the factory to 2400 PSI (R1) and 150 PSI (R2), but an adjustment may be required if the setting proves to be off after testing (see TESTING). If an adjustment is required proceed as follows: CAP WARNING Never adjust the relief valve with the hydraulic system pressurized. Hydraulic oil may spray out of the valve with the cap off. Personal injury may result.
Hydraulic System Greensmaster 3200/3200–D Page 5 – 41 Hydraulic System
Service and Repairs Hydrostatic Transmission 1 24 20 1 19 3 29 28 2 30 22 29 25 29 21 47 31 4 36 23 5 11 31 31 10 31 18 32 27 8 9 34 17 16 26 32 15 19 35 33 7 45 38 37 14 13 46 37 39 9 7 12 11 42 41 40 44 25 39 31 43 31 Figure 16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Removal (Fig. 16) 1 4 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting units, and stop engine. 5 2 3 CAUTION Use caution when removing the lock nut from the pin. The extension spring is under tension and may cause personal injury during removal. 6 Figure 17 Note: The neutral system assembly can be remove from the hydrostat without complete disassembly. 1. 2. 3. Lock nut Pin Extension spring 4. 5. 6. 2.
11. Pull gear pump (28) and connected hoses assemblies (23 and 27) away from the hydrostat (16) and secure. 12. Remove hose assemblies (25, 26, and 35) and O– rings (30 and 32) from the hydrostat (16). Allow hoses to drain into a suitable container. Plug open hose connections to prevent contamination. 13. Remove hydraulic fittings (3 and 17) and O–rings (29 and 34) from the hydrostat (16). Plug open ports on the hydrostat to prevent contamination. 14.
36 19 18 17 14 13 15 37 20 22 21 38 16 23 12 4 5 6 9 7 10 11 20 19 24 17 18 15 8 DRIVE END 3 8 28 2 1 35 34 31 30 33 31 32 30 7 27 26 25 29 4 Key Drive shaft Bearing Screw Cover seal Shaft seal Washer Thrust bearing Key Cam plate Rotating kit assembly Gasket Valve plate 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. Disassembly 1. Position pump into a vise with protected jaws so the drive end is pointed up. Clamp onto the mounting flange of the hydrostat. 2.
B. Position the housing assembly (29) end of the pump up and lower the shaft (2) through the hole in the table or workbench. Allow rotating parts kit (11) to rest on the table. VALVE PLATE END PINS C. Remove rotating parts kit (11) by lifting away the housing assembly (29) and shaft (2). 8. The rotating parts kit (11) can be disassembled as follows (see Fig. 22): WASHER SPRING WASHER RETAINER RETAINING RING SPIDER PISTON BLOCK A.
3. Inspect backplate assembly (16) (Fig. 21). 0.070 to 0.080 in. (1.78 to 2.03 mm) A. Bearing needles must remain in bearing cage and move freely. Verify that bearing height on the numbered end meets the proper dimension (Fig. 23). 0.105 to 0.115 in. (2.67 to 2.92 mm) BEARING HEIGHT ROLL PIN HEIGHT B. Check that the roll pin is tight and meets the proper height in (Fig. 23). C. Replace entire assembly as a unit. Figure 23 4. Inspect camplate assembly (10) (Fig. 21).
F. Compress spring by tightening the nut onto the cap screw. Install the retaining ring into the piston block. G. Unscrew the nut and remove washer and cap screw from the piston block. H. Install spider pivot onto the three pins, and place the spider on the spider pivot. I. Insert piston assemblies through the spider and into the piston block with the piston shoes resting on the spider. 10. Set rotating kit assembly (11) on a working surface with the piston shoes facing up.
Hydraulic System Start–up 10. Make sure traction pedal is in neutral and the cutting unit switch is off. Start engine and run it at low idle. The charge pump should pick up oil and fill the hydraulic system. If there is no indication of fill in 30 seconds, stop the engine and determine the cause. 1. After the hydraulic system components have been properly installed and if the traction pump was rebuilt or replaced, make sure traction pump housing is at least half full of clean hydraulic oil.
Wheel Motors 22 23 14 24 3 4 27 1 20 28 5 7 8 6 30 2 9 25 31 10 4 16 26 19 29 RIGHT 13 FRONT 12 18 11 15 21 32 17 Figure 26 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Lug nut Tire Brake drum Return spring Woodruff key Brake bracket Hose assembly (RH) Hose assembly (LH) 45 Fitting Hydraulic wheel motor Flat washer Hydraulic System 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Front Wheel Motor Removal (Fig. 26) 1. Before removing any parts from the hydraulic system, park the machine on a level surface, engage the parking brake, lower the cutting units, and stop the engine. CAUTION 10. Put caps or plugs on disconnected hoses and motor ports to prevent contamination. 11. Remove four cap screws (20) from brake bracket (6) and hydraulic wheel motor (10). Remove motor from the frame. Front Wheel Motor Installation (Fig.
17 15 19 17 14 16 1 18 16 13 10 8 20 23 6 4 22 21 5 12 7 RIGHT 25 9 3 26 26 11 FRONT 2 24 Figure 26 1. 2. 3. 4. 5. 6. 7. 8. 9. Castor fork Hydraulic motor & hub assembly Hydraulic hose Hydraulic hose Bearing Relube flangette Standard flangette Bearing tab Cap screw 10. 11. 12. 13. 14. 15. 16. 17. 18. Lock nut Socket head screw Lock nut Cable tie Tube clamp Cover plate Cap screw Lock nut Clamp bracket Rear Wheel (3WD) Removal (Fig. 26) 1.
5. Position hydraulic motor and hub assembly (2), flangettes (6 and 7) with bearing (5), and wheel (24) into the castor fork (1). Make sure hose fittings on the motor face the rear. 5. Loosen both set screws (22) on bearing (5). Slide flangettes (6 and 7) and bearing (5) off the motor shaft. 6. Remove grease fitting (25) from the hydraulic motor and hub assembly (2). Remove four lug nuts (23) and wheel (24) from the hub drive studs. Rear Wheel (3WD) Installation (Fig. 26) 6.
12 13 11 10 3 1 6 7 5 4 8 89 14 2 15 16 17 5 5 5 24 5 23 22 21 20 18 19 Figure 28 1. 2. 3. 4. 5. 6. 7. 8. Dirt & water seal Bearing Housing Back–up washer Seal ring Back–up washer Inner seal Thrust washer 9. 10. 11. 12. 13. 14. 15. 16. Thrust bearing Bearing Coupling shaft Thrust bearing Drive link Cap screw Commutator seal Commutator 17. 18. 19. 20. 21. 22. 23. 24. Woodruff key Wear plate Rotor Vane Stator Manifold Commutator ring End cover assembly Wheel Motor Disassembly (Fig.
13. Remove coupling shaft (11); push on the output end of the shaft. CAUTION 14. Remove inner seal (7) and back–up washers (4 and 6) from the housing by working them around the unseated thrust washers (8) and thrust bearing (9) (Fig. 32). Do not remove the thrust washer. Use eye protection such as goggles when using compressed air 5. Remove commutator (16) and commutator seal (15).
Wheel Motor Inspection (Fig. 28) 1. Inspect bolts (14) for damaged threads and sealing rings under the bolt head. Replace if damaged (Fig. 33). Note: A polished pattern (not scratches) on the cover from rotation of the commutator (16) is normal. Discoloration would indicate excess fluid temperature, thermal shock, or excess speed and require system investigation for cause and close inspection of end cover, commutator, manifold, and rotor set.
8. Inspect the wearplate (18) for cracks, peening, and scoring. A polished pattern on the wear plate from rotor rotation is normal. Replace as necessary. 9. Inspect drive link (13) for cracks and worn or damaged splines. No perceptible lash (play) should be noted between mating spline parts of the rotor (19) or coupling shaft (11). Replace as necessary (Fig. 36). 10. Inspect thrust bearing (12) for wear, peening, corrosion and a full complement of retained rollers. Replace as necessary. 11.
Wheel Motor Reassembly (Fig. 28) 1. Lubricate all seals and seal rings with clean hydraulic oil before assembly. WARNING Since they are flammable, be extremely careful when using any solvent. Even a small explosion or fire could cause injury or death. Figure 40 CAUTION Use eye protection such as goggles when using compressed air 2. Wash all parts in a clean petroleum–based solvent before assembly. Blow parts dry with compressed air. 3.
8. Install thrust bearing (12) onto the end of coupling shaft (11). 9. Apply a small amount of clean petroleum jelly to a new seal ring (5) and insert it into the housing (3) seal ring groove. Note: One or two alignment studs screwed finger tight into housing (18) bolt holes, approximately 180 degrees apart, will facilitate the assembly and alignment of components as required in the following procedures. The studs can be made by cutting off the heads of 3/8–24 UNF 2A bolts so they are 0.5 inch (12.
E. Grasp the output end of coupling shaft (11) with locking pliers or other appropriate turning device. Rotate coupling shaft, drive link (13), and rotor (19) to seat the rotor and the assembled vanes (20) into the stator (21). This rotation should create the necessary clearance to assemble the seventh or remaining vanes. Use minimum force when assembling the remaining vane (s). F. Remove the two assembled bolts (14) if used to retain stator and wear plate.
Changing Hydraulic Oil and Filter Change hydraulic filter initially after the first 50 operating hours, thereafter change hydraulic oil and filter after every 800 hours. If oil becomes contaminated, contact your local TORO distributor because the system must be flushed. Contaminated oil looks milky or black when compared to clean oil. HOSE Note: If oil is not going to be drained, disconnect and plug hydraulic line going to filter. 1. Clean area around filter mounting area.
Hydraulic Gear Pump 1 13 7 14 2 15 12 10 3 8 5 11 4 9 6 Figure 49 1. 2. 3. 4. 5. Pump inlet hose Gear pump Hydraulic fitting Hydraulic fitting Hydraulic T–fitting 6. 7. 8. 9. 10. Hose assembly Hose clamp O–ring O–ring O–ring Removal (Fig. 49) 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting units, and stop engine. O–ring Hydrostat Hex socket screw Flat washer O–ring 3.
Installation (Fig. 49) 1. Make sure mounting and O–ring sealing surfaces on the gear pump and hydrostat are clean. 2. Replace all O–rings with new ones. Apply clean hydraulic oil to all O–rings. 6. Inspect threads and sealing surfaces of hydraulic fittings and hydraulic hose connector. Replace any damaged or worn fittings or connector. 7. Install O–rings into gear pump. Install fittings and tighten to positions noted during removal. 3. Place O–ring on the gear pump. 8.
1 18 8 11 10 17 9 5 3 12 15 6 14 16 19 13 7 4 2 Figure 50 1. 2. 3. 4. 5. 6. 7. Front plate Back plate Front body Back body Drive gear Front idler gear Back idler gear Hydraulic System 8. 9. 10. 11. 12. 13. Back–up gasket Wear plate Pressure seal Cap screw O–ring Adapter plate Page 5 – 64 14. 15. 16. 17. 18. 19.
Disassembly (Fig. 50) SCRIBE MARK 1. Make sure caps or plugs are in motor openings to prevent contamination. Clean motor with solvent. 2. Make a scribe mark diagonally across the front plate, body, adapter plate, body, and back–up plate for reassembly purposes (Fig. 51). IMPORTANT: Use extreme caution when using a vise to hold the gear pump. Do not over tighten. Parts may be distorted. 3. Secure gear pump in a vise with the shaft end up. Remove eight cap screws and four washers from the pump. Figure 51 4.
5. Inspect front plate, back plate, and adapter plate as follows: OIL GROOVE A. Inside diameter of all bushings should not exceed 0.755 inch (19.2 mm). B. Bushings in the front plate should extend 0.126 inch (3.20 mm) from the plate surface. C. Bushings on the wear plate side of the adapter plate should extend 0.126 inch (3.20 mm) from the plate surface. OIL GROOVE FRONT PLATE D. Scoring on the face of the back plate or the back plate side of the adapter plate should not exceed 0.0015 inch (0.
Implement Relief Valve LEFT 10 7 REAR RELIEF VALVE 4 1 5 13 15 14 16 12 RELIEF VALVE 8 9 11 2 3 12 4 6 4 Hose assembly Hose assembly Hose assembly O–ring 90_ hydraulic fitting Tee hydraulic fitting 7. 8. 9. 10. 11. Lock nut Cap screw Flat washer Mounting plate Relief valve body 12. 13. 14. 15. 16. O–ring Relief valve cartridge O–ring O–ring Back–up ring Removal 3. Label all hydraulic connections for reassembly. 1.
Installation CAUTION 1. Remove caps or plugs from disconnected hoses. 2. Lubricate new O–rings with clean hydraulic fluid. Install O–rings and hydraulic fittings to the valve body. 3. Secure valve body to the mounting plate with cap screws, flat washers, and lock nuts. 4. Install O–rings and hose assemblies to hydraulic fittings. Tighten hose connections. Disassembly Use eye protection such as goggles when using compressed air 4.
Reel Motors 1 2 3 3 20 4 23 18 5 16 15 22 21 29 7 29 7 30 25 19 30 17 11 6 10 11 12 24 26 7 27 13 6 8 15 17 14 28 RIGHT FRONT 13 8 Hydraulic System 14 28 27 Figure 55 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Cap screw Flat washer Tube clamp Lock nut Plug 90_ Hydraulic fitting Hydraulic fitting Hydraulic fitting Not used Bulkhead nut Greensmaster 3200/3200–D 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
1 9 RIGHT FRONT 4 36 2 8 4 25 12 24 9 26 10 35 6 1 22 9 2728 3 11 27 3 14 17 34 33 32 3 15 9 10 11 13 27 7 31 19 18 30 16 23 29 22 13 23 5 20 21 Figure 56 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Bulkhead nut Bulkhead nut Cap screw Hose assembly Reel motor Bulkhead bracket Hydraulic tube Hose assembly Washer Spacer Rubber grommet Hydraulic fitting 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
3. Remove caps or plugs in motor openings and hose assemblies. 6. Make sure hose connections are clean. Inspect threads and sealing surfaces of connections. Replace any worn or damaged connections. 4. Apply clean hydraulic oil to all O–rings. 7. Install reel motor to the cutting unit (see Cutting Unit Removal and Installation in Chapter 7– Cutting Units). 8. Secure hose connection to the proper hydraulic fitting on the reel motor. Repeat this step for the remaining hose connections. Hydraulic System 5.
3 4 5 6 1 7 2 8 9 5 14 10 11 12 13 5 Figure 57 1. 2. 3. 4. 5. Hex socket head screw Washer Dowel pin Cover assembly Needle bearing 6. 7. 8. 9. 10. Idler gear assembly Drive shaft assembly Seal ring Load plate assembly Body assembly 11. 12. 13. 14. Spacer Shaft seal Retaining ring Dowel pin Disassembly (Fig. 57) CAUTION 1. Make sure caps or plugs are in motor openings to prevent contamination. Clean motor with solvent. IMPORTANT: Use extreme caution when using a vise to hold the motor.
3. Remove hex socket head screws and washers from the cover assembly and body assembly. 4. Separate cover assembly from body assembly by tapping lightly on the drive shaft with a plastic hammer; do not pry apart. 5. Remove load plate assembly from the drive shaft and idler gear assemblies. Discard load plate assembly. 6. Remove seal ring from the body assembly. Discard seal ring. Assembly (Fig. 57) 1. Coat new seal ring lightly with petroleum jelly.
Oil Cooler 11 9 10 7 8 10 3 OIL FLOW 12 13 11 1 6 5 14 4 2 Figure 58 1. 2. 3. 4. 5. Oil cooler Lower formed hose Upper formed hose Grommet Hose clamp 6. 7. 8. 9. 10. Tube assembly Tube assembly Hydraulic fitting Hydraulic fitting O–ring Removal (Fig. 58) 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting units, and stop engine. 11. 12. 13. 14. O–ring Radiator screen Upper cooler bracket Lower cooler bracket 4.
5. Remove clamps that where used to prevent drainage from the formed hoses. Installation (Fig. 58) 1. Make sure formed hoses and openings of the oil cooler are clean. 6. Fill hydraulic tank (see Check Hydraulic System Fluid). 2. Remove plugs from oil cooler openings. 3. Hang oil cooler onto cooler brackets while attaching the formed hoses to the cooler. Secure hoses by tightening the hose clamps. 7. Start machine.
Lift Cylinders 10 12 3 2 7 4 1 11 13 8 13 12 3 9 5 6 HYDRAULIC CYLINDER Figure 59 1. 2. 3. 4. 5. Hose assembly Hose assembly O–ring Cotter pin Clevis pin 6. 7. 8. 9. Lift arm Hydraulic cylinder Cap screw Ram pivot pin 10. 11. 12. 13. Spacer Frame 90_ Hydraulic fitting O–ring 5. Remove cotter pin from the clevis pin. Pull clevis pin from the hydraulic cylinder and lift arm. Front Cylinder Removal (Fig. 59) 1.
11 12 10 10 2 9 17 3 16 5 13 13 HYDRAULIC CYLINDER 6 15 7 13 14 3 13 1 4 8 Figure 60 Hose assembly Hose assembly O–ring 90_ hydraulic fitting Hydraulic fitting Cotter pin 7. 8. 9. 10. 11. 12. Clevis pin Lift arm Hydraulic cylinder Retaining ring Cylinder pin Frame 13. 14. 15. 16. 17. O–ring Flow control valve Hydraulic union fitting 90_ hydraulic fitting O–ring 6. Support hydraulic cylinder to prevent it from dropping. Rear Cylinder Removal (Fig. 60) 1.
5 4 3 2 8 11 9 7 12 1 6 10 4 3 8 REAR HYDRAULIC CYLINDER 2 7 6 5 Figure 61 1. 2. 3. 4. Barrel Uni–ring O–ring PDF seal 5. 6. 7. 8. O–ring Back–up washer Retaining ring Dust seal 5 9. 10. 11. 12. Lock nut Shaft Piston Head 6 4 3 2 11 8 9 7 1 12 10 3 FRONT HYDRAULIC CYLINDER 2 4 5 8 6 7 Figure 62 1. 2. 3. 4. Barrel Uni–ring O–ring PDF seal Hydraulic System 5. 6. 7. 8. O–ring Back–up washer Retaining ring Dust seal Page 5 – 78 9. 10. 11. 12.
Front and Rear Cylinder Disassembly Front and Rear Cylinder Reassembly 1. Remove oil from the hydraulic cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1. Coat new O–rings, Uni–rings, PDF seal, back–up washer, and dust seal with with clean hydraulic oil. Install Uni–ring and O–ring to the piston. Install PDF seal, O–ring, and back–up washer to the head.
Rear Lift Cylinder Flow Control Valve HYDRAULIC CYLINDER 8 7 6 5 FLOW CONTROL VALVE 4 1 2 3 Figure 63 1. 2. 3. Hose assembly O–ring 90_ hydraulic fitting 4. 5. 6. O–ring Flow control valve O–ring Removal 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting units, and stop the engine. CAUTION 7. 8. 90_ hydraulic fitting Hydraulic cylinder 2.
Flushing Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky or black or contains metal particles). IMPORTANT: Flush hydraulic system when changIng from petroleum base hydraulic fluid. Operate machine under normal operating conditions for at least four (4) hours before draining. 1. Park machine on a level surface. Lower cutting units, stop engine, and engage parking. 9.
Hydraulic Manifold 21 7 10 22 13 15 16 2 17 1 14 6 20 21 23 5 19 18 34 16 9 23 17 36 23 21 27 28 8 29 11 32 23 21 3 31 30 23 35 21 23 36 21 26 24 16 25 RIGHT 33 FRONT 12 5° 30° 65° Figure 67 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
2. Install hydraulic fittings and their respective O–rings to the manifold assembly, and orient them as follows: Removal (Fig. 67) 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting units, and stop the engine.
19 1 1 19 3 18 2 17 23 1 20 22 4 16 20 8 17 21 9 5 16 6 4 20 7 5 20 15 4 4 5 5 14 6 7 6 5 5 4 4 11 13 10 20 12 7 7 6 6 Figure 68 1. 2. 3. 4. 5. 6. 7. 8. 20 watt solenoid N.O. cartridge (Ports S1 & S2) 4Way/2Position cartridge (Port S3) Plug O–ring Plug O–ring 2000 PSI relief cartridge (Port R1) 9. 10. 11. 12. 13. 14. 15. 16. N.C. cartridge (Port S4) Plug O–ring Manifold body 150 PSI relief cartridge (Port R2) Orifice plug Cavity plug O–ring 17. 18. 19. 20. 21. 22. 23.
C. Torque cartridge valve using a deep socket to 35 ft–lb (4.8 kg–m). Solenoid Operated Cartridge Valves (Fig. 68) 1. Make sure the manifold is clean before removing the valve (s). D. Make sure a new O–ring is at each end of the solenoid coil. Install solenoid coil to the cartridge valve. Apply ”Loctite 242” or equivalent to the threads of the valve. Torque nut to 15 in–lb (17 kg– cm). 2. Remove nut securing solenoid to the cartridge valve. Slide solenoid and both O–rings off the valve.
Backlap Kit 16 17 15 18 19 21 6 14 12 5 20 22 23 24 3 26 25 4 7 13 2 8 1 11 10 9 27 Figure 69 1. 2. 3. 4. 5. 6. 7. 8. 9. Backlap bracket N.O. ball switch Socket head screw Flat washer Detent kit Indicator kit Directional cartridge valve (Port RD1) Seal kit Seal kit 10. 11. 12. 13. 14. 15. 16. 17. 18. Logic cartridge (Port LC1) Seal kit Detent kit Flow control cartridge (Port FC1) Jumper wire Harness Relay Knob Jam nut 19. 20. 21. 22. 23. 24. 25. 26. 27.
B. Thread valve carefully into the applicable port (RD1 or FC1). The valve should go in easily without binding. Torque valve to 35 ft–lb (4.8 kg–m). Flow Control and Two Position Directional Valves (Fig. 69) 1. Remove knob assembly: 7. Reinstall knob assembly: B. Slide off applicable indicator plate (6 or 19) being careful not to lose springs (20 or 21). Remove spring. C. Loosen set screw (23) and slide detent plate (22) off the applicable cartridge valve (7 or 13) stem. D.
Logic Cartridge Valves (Fig. 69) CAUTION 1. Make sure the manifold (27) is clean before removing logic cartridge valve (10) and seal kit (9). Remove cartridge valve. 2. Visually inspect the port in the manifold (27) for damage to the sealing surfaces, damaged threads, and contamination. 3. Visually inspect logic cartridge valve (10) for damaged sealing surfaces and contamination. A.
Hydraulic System Greensmaster 3200/3200–D Page 5 – 89 Hydraulic System
Steering Control Valve 1 28 2 3 27 4 6 5 10 11 7 12 26 21 8 4 19 22 20 37 34 35 9 17 29 36 14 10 13 33 24 32 18 31 30 29 15 12 11 25 23 13 16 Figure 70 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Knob Lockup handle Lockup spacer Friction disc Steering wheel Steering wheel nut Socket head screw Lockup spacer Socket head screw Cap screw Flat washer Bushing Socket head screw Hydraulic System 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
Removal (Fig. 70) 1. Before removing any parts from the hydraulic system, park the machine on a level surface, engage the parking brake, lower the cutting units, and stop the engine. 13. Remove hose assemblies (30, 31, and 32) and O– rings (29 and36) from the steering control valve (23). Remove hydraulic fittings (17) and O–rings (29) from the control valve. Plug ports to prevent contamination. 14. Remove both cap screws (18) and steering column assembly (15) from the steering control valve (23).
6. Connect hose assembly (31) with O–ring to T–fitting on the end of the gear pump (Fig. 72). Installation (Fig. 70) 1. Remove caps or plugs from the disconnected, fittings, and ports. 7. Connect hose assembly (32) with O–ring to the rear hydraulic fitting on the steering cylinder (Fig. 73). 2. Install steering column assembly (15) and both cap screws (18) to the steering control valve (23). 8. Connect hose assemblies (33 and 34) with O–rings (35) to hydraulic fittings (17). 3.
5. Remove distributor plate from the control valve and O–ring from housing. 6. Screw out threaded bushing from the control valve. Remove remove valve from the vise and shake out the ball. Note: The cross pin can be seen through the open end of the spool. CROSS PIN 7. Make sure cross pin is kept horizontal in the spool and sleeve. Remove sleeve, ring, and bearing from the housing by pressing the spool out the housing bottom (Fig. 75). Note: The outer race of the bearing assembly may stick in the housing.
4. Install ring over the sleeve. Make sure ring is able to rotate free of the springs. 5. Insert cross pin into the spool and sleeve (Fig. 75). 6. Install bearing assembly onto the spool and sleeve (Fig. 78). OUTER RACE NEEDLE BEARING INNER RACE 7. Coat new O–ring/kin–ring lightly with petroleum jelly. Install ring carefully into the inner bore of the housing so that they fit snuggly in place (Fig. 79 and 80).
16. Secure special screw with new washer into the hole shown (Fig. 82 and 83). 17. Secure remaining screws with washers into control valve. Torque all screws in a criss–cross pattern from 18 to 27 ft–lb (2.4 to 3.7 kg–m). SPECIAL SCREW 18. Install dust seal carefully into the housing.
Steering Cylinder CYLINDER ASSEMBLY 4 6 11 5 1 2 8 3 2 14 3 4 9 5 12 12 7 8 10 13 Figure 84 1. 2. 3. 4. 5. Hose assembly O–ring Hydraulic fitting Jam nut Ball joint 6. 7. 8. 9. 10. Frame Steering cylinder Retaining ring O–ring Wheel Removal (Fig. 84) 1. Before removing any parts from the hydraulic system, park machine on a level surface, set brake, lower cutting units, and stop engine. CAUTION 11. 12. 13. 14. Lock nut Bolt Spacer Castor fork 2.
Installation (Fig. 84) 4. Gain access to front ball joint. A. Remove three cap screws and flat washers securing the fuel tank base plate to frame. Two screws are on the top of the plate at the front corners of the tank. The third screw is in front of the castor fork and below the plate. 1. f the rear ball joint was removed, accomplish the following: B. Tilt fuel tank base up by lifting at the right of the machine to gain access to the top of the jam nuts and ball joint. Prop up tank securely. B.
Hydraulic Reservoir 35 18 15 34 5 6 24 20 17 3 15 18 36 14 2 11 27 25 26 1 32 16 30 13 33 19 31 12 16 29 4 9 22 10 23 7 21 28 29 8 29 9 v 23 Figure 85 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Hydraulic barb fitting Hydraulic fitting Fuel tank clamp Cap screw Hydraulic oil clamp Hydraulic tank Hydraulic fitting Oil filter assembly Hydraulic barb fitting Oil filter mount Mounting plate Flat washer 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Removing Hydraulic Reservoir (Fig. 85) 1. Before removing any parts from the hydraulic system, park machine on a level surface, set brake, lower cutting units, and stop engine. PUMP INLET HOSE CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the ignition switch in RUN and the engine OFF. Return ignition switch to OFF when pressure has been relieved. Remove key from the ignition switch. Figure 86 1 2.
2. Place antiseize lubricant into all four inserts at the bottom of the hydraulic tank (6). Position tank onto the mounting plate (11). Inspecting Reservoir Parts (Fig. 85) 1. Clean tank and filler screen with solvent. 2. Inspect tank for leaks, cracks, or other damage. 3. Replace hydraulic hoses if worn or leaking. 4. Make sure cap screws are secure. If loose, remove and reinstall cap screws with ”Loctite 242” or equivalent. 5. Make sure all bracket fasteners are tight.
Hydraulic System Greensmaster 3200/3200–D Page 5 – 101 Hydraulic System
Leak Detector 9 10 1 2 3 33 4 8 5 38 7 6 11 5 9 34 35 10 28 37 12 32 35 13 31 36 30 16 29 14 15 16 26 6 28 7 17 27 7 18 25 19 20 24 18 21 39 23 22 9 10 Figure 89 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Clamp Lock nut Delay timer Cover plate Audio alarm assembly Hydraulic barb fitting O–ring Pipe plug Cap screw Flat washer Leak detection tank Cap screw Flat washer Hydraulic System 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Removal (Fig. 89) 1. Before removing any parts from the hydraulic system, park machine on a level surface, set brake, lower cutting units, and stop engine. 4. Clean mating surfaces of block and fill neck with a clean, dry rag. Carefully place new O–ring over fill neck boss (Fig. 91). 5. Route wire harness through access hole in hydraulic tank. Align valve assembly with fill neck. Secure valve to hydraulic tank fill neck with four capscrews (Fig. 91).
IMPORTANT: Do not over tighten cap screw. Threads in tank may become damaged. 6. Locate plugged 2–pin connector with yellow/orange and black wires in main tractor harness. Attach leak detector harness. Secure leak detector harness to underside of leak detection tank with R–clamp and capscrew. 7. Remove plug from top of the valve assembly. Carefully fill float cavity to the top of the threads. Replace and tighten fill plug. Clean up any spilled oil (Fig. 91). 8.
Chapter 6 Electrical System Table of Contents COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Valve Coils . . . . . . . . . . . . . . . . . . . . . . . . Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reed Switch and Actuator . . . . . . . . . . . . . . . . . . . Backlap Switch . . . . . . . . . . . . . . . . . .
IG Electrical System – + #3 YELLOW/RED YEL/BLUE Page 6 – 2 1C 1F RED 3F 92–5720 SOLID STATE CONTROLLER 2S RED/BLACK 1A 1J GROUND 2K 1M OUTPUTS RED 2L BLACK YELLOW/RED A GREEN CAN (+) CAN (–) BLACK/WHITE ORANGE/WHITE ENGINE SPEED SWITCH GREEN/WHITE BACKLAP SWITCH (OPTION) ORANGE/RED ENGINE SPEED SIGNAL RED HIGH TEMP.
IG Greensmaster 3200/3200–D – + #3 YELLOW/RED YEL/BLUE Page 6 – 3 1D 1E 3H 1F RED 3F 92–5720 SOLID STATE CONTROLLER 2S 1A GROUND 2K 1M OUTPUTS RED 2L BLACK YELLOW/RED A GREEN CAN (+) CAN (–) BLACK/WHITE ORANGE/WHITE ENGINE SPEED SWITCH GREEN/WHITE BACKLAP SWITCH (OPTION) ORANGE/RED ENGINE SPEED SIGNAL RED HIGH TEMP.
Electrical System IG CHARGING – + #3 YELLOW/RED YEL/BLUE Page 6 – 4 1D 1E 3H 1F RED 3F 92–5720 SOLID STATE CONTROLLER 2S 1A 1J GROUND 2K 1M OUTPUTS RED 2L BLACK YELLOW/RED A CAN (+) CAN (–) BLACK/WHITE ORANGE/WHITE ENGINE SPEED SWITCH GREEN/WHITE BACKLAP SWITCH (OPTION) ORANGE/RED ENGINE SPEED SIGNAL RED HIGH TEMP.
Page 6 – 5 ALTERNATOR HOUR METER YELLOW S B – 12 V 40 AMP THERMAL BREAKER #1 + BLUE WHITE BLACK OIL F D GREEN RED GREEN/BLUE BATT GLOW C E B WHITE WHITE BLUE RED RED OFF 2 A Electrical System BLACK BLUE ORANGE RED YELLOW SAFETY RELAY (R8) BLACK BLACK START RELAY (R4) VIOLET/RED BROWN GLOW RELAY BLACK ORANGE/RED YELLOW ”X1” OR RED WARNING LIGHT CLUSTER OIL PRESSURE SENOR D4 ORANGE VIOLET ON 1 40 AMP THERMAL BREAKER #2 WATER RED RED/VIOLET 3 TIMER 6
ALTERNATOR HOUR METER YELLOW S 12 V BLACK GREEN/BLUE 3 ON 1 ORANGE A OIL PRESSURE SENOR ”X1” BLACK YELLOW SAFETY RELAY (R8) BLACK BLACK START RELAY (R4) VIOLET/RED BROWN GLOW RELAY BLACK ORANGE/RED YELLOW RED WARNING LIGHT CLUSTER 40 AMP THERMAL BREAKER #2 OR VIOLET D4 OFF AFTER 6 SECONDS OFF 2 WATER RED F OIL BATT GLOW C D E GREEN RED RED BLACK BLACK RED B WHITE BLUE WHITE WHITE BLUE BLACK TIMER 6 SEC RED/VIOLET 40 AMP THERMAL BREAKER #1 + VOLTAGE REG
S Page 6 – 7 HOUR METER 40 AMP THERMAL BREAKER #1 + BLUE WHITE BLACK C BATT E F OIL D GREEN GREEN/BLUE GLOW B WHITE WHITE RED RED A OIL PRESSURE SENOR WARNING LIGHT CLUSTER ORANGE/RED YELLOW SAFETY RELAY (R8) BLACK BLACK START RELAY (R4) VIOLET/RED BROWN Electrical System RED ”X1” OR VIOLET D4 GLOW RELAY BLACK BLACK ORANGE YELLOW 40 AMP THERMAL BREAKER #2 WATER RED RED ON 1 OFF AFTER 6 SECONDS OFF 2 RED/VIOLET 3 TIMER 6 SEC BLACK BLACK BLACK VOLTAGE REG
Page 6 – 8 HOUR METER YELLOW ALTERNATOR 12 V S 40 AMP THERMAL BREAKER #1 + BLUE WHITE OIL D GREEN C GREEN/BLUE F BATT GLOW BLACK E B WHITE WHITE BLUE RED RED RED A OIL PRESSURE SENOR WARNING LIGHT CLUSTER ORANGE/RED ”X1” OR RED YELLOW 40 AMP THERMAL BREAKER #2 WATER RED D4 BLUE ORANGE RED YELLOW SAFETY RELAY (R8) BLACK BLACK START RELAY (R4) VIOLET/RED BROWN GLOW RELAY BLACK ORANGE VIOLET ON 1 OFF 2 RED/VIOLET 3 TIMER 6 SEC BLACK BLACK BLACK VOLTAGE RE
Page 6 – 9 ALTERNATOR HOUR METER YELLOW S 12 V 40 AMP THERMAL BREAKER #1 + BLUE WHITE BLACK GREEN/BLUE F OIL BATT GLOW C D E GREEN RED B WHITE WHITE BLUE RED RED BLACK OFF 2 YELLOW OIL PRESSURE SENOR WARNING LIGHT CLUSTER BLACK BLACK BLUE ORANGE RED YELLOW SAFETY RELAY (R8) BLACK START RELAY (R4) VIOLET/RED BROWN GLOW RELAY Electrical System ”X1” OR RED ORANGE/RED A D4 ORANGE VIOLET ON 1 40 AMP THERMAL BREAKER #2 WATER RED RED/VIOLET 3 TIMER 6 SEC
Page 6 – 10 ALTERNATOR HOUR METER YELLOW S 12 V 40 AMP THERMAL BREAKER #1 + BLUE WHITE OIL BATT GLOW C GREEN/BLUE F BLACK D E GREEN RED B WHITE WHITE BLUE RED RED 3 TIMER 6 SEC OFF 2 YELLOW OIL PRESSURE SENOR WARNING LIGHT CLUSTER ”X1” OR RED ORANGE/RED A D4 RED BLUE ORANGE YELLOW SAFETY RELAY (R8) BLACK BLACK START RELAY (R4) VIOLET/RED BROWN GLOW RELAY BLACK BLACK ORANGE VIOLET ON 1 40 AMP THERMAL BREAKER #2 WATER RED RED/VIOLET BLACK BLACK BLACK V
Page 6 – 11 ALTERNATOR HOUR METER YELLOW S 12 V 40 AMP THERMAL BREAKER #1 + BLUE WHITE TIMER 6 SEC OFF 2 OIL BATT GLOW C GREEN/BLUE F BLACK D E GREEN RED YELLOW OIL PRESSURE SENOR WARNING LIGHT CLUSTER BLACK YELLOW SAFETY RELAY (R8) BLACK BLACK START RELAY (R4) VIOLET/RED BROWN GLOW RELAY Electrical System ”X1” OR RED ORANGE/RED A D4 ORANGE VIOLET ON 1 40 AMP THERMAL BREAKER #2 WATER RED RED/VIOLET 3 BLACK B WHITE WHITE BLUE RED RED BLACK BLACK VOLTAGE
Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: Toro recommends the use of a DIGITAL Volt– Ohm–Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter.
Toro Automated Control ElectronicsE Diagnostic Tool (GR3200) Diagnostic ACEE Display The diagnostic display is connected to the wiring harness connector located under the seat to help the user verfiy correct electrical functions of the machine (Fig. 3 and 4).
Troubleshooting (GR3200) For all electrical problems, use ACE Troubleshooting Guide. The handheld Diagnostic ACE display allows electrical problems to be found quickly. If any interlock switches are by–passed, they must be reconnected for proper troubleshooting and safety. ACE Troubleshooting Guide (GR3200) Diagnostic Light 1 The GR 3200 is equipped with a diagnostic light that indicates if the Electronic Controller Unit (ECU) is functioning correctly.
turn on, check all wiring and connections to switch and/ or check switch with an ohm meter. Replace any defective switches and repair any defective wiring. Retrieving Stored Faults (Fig. 6) 1. Turn ignition switch to OFF. Connect Diagnostic ACE to the harness connector of the ECU. Verify Output Function (Fig. 6) The Diagnostic ACE also has the ability to detect which output solenoids or relays are turned on. This is a quick way to determine if a machine malfunction is electrical or hydraulic. 1.
For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Wiring Schematics section of this chapter). If the machine has any interlock switches by–passed, they must be reconnected for proper troubleshooting and safety. Starting Problems (GR3200) Problem Possible Causes Starter solenoid clicks, but starter will not crank (if solenoid clicks, the problem is not with the ECU or its inputs). Battery charge is low.
Starting Problems (GR3200) (continued) Problem Possible Causes Engine cranks, but does not fire. Wiring to start circuits (see Wiring Schematics) is loose, corroded, or damaged. The ECU is faulty. The ignition components (ignitor module, speed sensor, ignition coils, and spark plugs) are faulty. Fuel valve solenoid, fuel pump, or electric governor is faulty. Engine or fuel system is malfunctioning (see Chapter 3 – Daihatsu Engine).
General Run and Transport Problems (GR3200) Problem Possible Causes Operator is sitting too far forward on the seat (seat Engine kills when the functional control lever is in the MOW or TRANSPORT position with the operator in the switch not depressed). seat. Seat switch, mow senor, or neutral sensor is faulty or out of adjustment. Seat switch wiring is loose, corroded, or damaged. The ECU is faulty Engine overheated. Battery does not charge.
Troubleshooting (GR3200–D) For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Wiring Schematics section of this chapter). CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage.
Starting Problems (GR3200–D) (continued) Problem Possible Causes Engine cranks, but does not start. Wiring to start circuits (see Wiring Schematics) is loose, corroded, or damaged. Diode D5 circuit is open. Run relay or high temperature relay is faulty. High temperature switch is shorted. ETR solenoid is faulty. Glow plugs are faulty. Engine or fuel system is malfunctioning (see Chapter 4 – Perkins Engine). Engine and fuel may be to cold.
General Run and Transport Problems (GR3200–D) Problem Possible Causes Engine kills when the Functional Control Lever is in the Operator is sitting too far forward on the seat (seat MOW or TRANSPORT position with the operator in the switch not depressed). seat. Seat hinge, support pin, or spring binding is preventing the seat switch from closing. Seat switch is faulty or out of adjustment. Seat switch wiring is loose, corroded, or damaged. Battery does not charge.
Cutting Unit Operating Problems (GR3200–D) Problem Possible Causes Cutting units run (but should not) when raised. Joy stick relay R7 is faulty or shorted. Solenoid valve S1 is faulty. Mow relay is faulty or shorted. Mow sensor is shorted. Cutting units do not run when lowered with the Functional Control Lever in the MOW or NEU position. Wiring to run/mow/backlap circuits (see Wiring Schematics) components is loose, corroded, or damaged. Fuse block or fuse is faulty. Solenoid valve S1 is faulty.
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Set the multimeter to the DC volts setting. The battery should be at a temperature of 60_ to 100_ F. The ignition key should be off and all accessories turned off. Connect the positive (+) meter lead to the positive battery post and the negative (–) meter lead the the negative battery post. Voltage Measured Battery Charge Level 12.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check). Note: See the Perkins 100 Series Workshop Manual for more component testing information. CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.
Electrical Relays 1. Verify coil resistance between terminals 86 and 85 with a multimeter (ohms setting). Resistance should be from 80 to 90 ohms. There should be continuity between terminals 87A and 30. 86 87A 87 87 87A 86 2. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85. 85 30 85 30 3.
Seat Switch This switch is normally open and closes when the operator is on the seat. If the neutral switch or traction interlock switch is open when the operator raises out of the seat, the engine will stop. The switch and its electrical connector are located directly under the seat. I 1. Make sure the engine is off. Remove seat from the support assembly by removing four lock nuts from the seat bolts. a . 2. Disconnect electrical connector from the switch. 3.
Backlap Switch The backlap switch is located on the hydraulic manifold (when the Backlap Kit is installed). It is normally open and closes when the backlap knob is turn clockwise to the backlap position. 2 3 1. With the engine off, disconnect electrical connector. 1 2. Check the continuity of the switch by connecting a multimeter (ohms setting) across the connector terminals. 3. Turn the backlap knob clockwise to the backlap position while watching the multimeter.
40 Ampere Thermal Breaker This device operates as a thermal overload. After the device trips, time should be allowed for it to cool and reset. 1. Verify continuity between the two terminals. THERMAL BREAKER 2. Replace if necessary. Figure 16 THERMAL BREAKER Figure 15 Figure 17 Fuse Block Fuses can be removed to check continuity, The test meter should read less than 1 ohm. For the GR3200, fuses supply power tho the following (Fig. 18): 1.
Leak Detector Operation The leak detector system is designed to assist in the early detection of hydraulic oil system leaks. If the oil level in the main tank is lowered by 4 to 5 ounces, the level switch in the leak detection tank will close. After a 1 second delay, the alarm will sound alerting the operator. Expansion of oil from the normal heating of the hydraulic oil during machine operation will cause oil to transfer into the leak detection tank.
Test Operation CLEAN ROD OR SCREWDRIVER 1. Place ignition switch in the ON position. DO NOT START ENGINE. Move leak detector switch downward and hold. After the one second time delay elapses, the alarm should sound. VALVE ASSEMBLY PLUG REMOVED SOLENOID RETURN VALVE CLOSED 2. Release leak detector switch. 3. Remove cover plate from leak detector. Remove plug from valve assembly. 4. Insert clean rod or screw driver into valve assembly and gently push down on switch float (Fig. 23).
RED/WHT CONNECTOR + RED VALVE SOLENOID – TEST SWITCH BLACK BLACK CONNECTOR GRAY YELLOW CONNECTOR LEVEL SWITCH + 1 SEC. DELAY TIMER – RED RED AUDIO ALARM – + 270 OHM RESISTOR YELLOW LEAK DETECTOR CIRCUIT BLACK BLK/WHT BLACK Figure 24 Components can be tested by isolating them from the rest of the circuit and individually testing the suspected component. 6 5 Delay Timer This is a solid state device with no moving parts. Upon the application of power, the time delay is initiated.
Warning Light Cluster (GR 3200) Note: Individual light bulbs can be tested by removing them from the lighting cluster and applying 12 VDC to their wiring terminals. Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running. Also, it should light with the engine running when the oil pressure drops below 4 PSI (0.3 kg/cm2).
40 Ampere Charging System (GR 3200) The alternator is belt driven and internally regulated (Fig. 28). Note: Prior to testing the charging system, make sure the V–belt to the alternator is in good operation condition and adjusted properly (see Belt Adjustment in Chapter 3 – Daihatsu Engine). Test Equipment Briggs and Stratton recommends using their digital multimeter and shunt.
Temperature Sender (GR 3200) The switch is located on the side of the water pump. There is a blue wire attached to the switch. CAUTION 1 Allow the engine to cool to a safe temperature before removing the temperature sender from the engine. 1. Lower the coolant level in the engine and remove the high temperature sender. 2. Allow enough time so the temperature switch can cool to room temperature of 70_F (21_C). Figure 31 1.
High Temperature Switch (GR 3200–D) The switch is located on top of the water pump. The pump is between the fan pulley assembly and the cylinder head. There is a blue wire attached to the switch (Fig. 32). 1 1. Lower the coolant level in the engine and remove the high temperature shutdown switch. 2. Put the switch in a container of oil with a thermometer and slowly heat the oil (Fig. 33). CAUTION Figure 32 1.
Warning Light Cluster (GR 3200–D) Note: Individual light bulbs can be tested by removing them from the lighting cluster and applying 12 VDC to their wiring terminals. Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running. Also, it should light with the engine running when the oil pressure drops below 4 PSI (0.3 kg/cm2).
Oil Pressure Switch (GR 3200–D) The switch is located on the front cylinder head above the injection pump and governor assembly. It is a normally closed switch and opens with pressure. The operating range for the switch is 2.8 to 5.7 PSI (0.2 to 04 kg/cm2 ). 1 Testing with the engine off 1. Turn the ignition switch to ON. The oil pressure lamp should be on. 2. If the lamp is not on, disconnect the brown wire from the switch and ground it to the engine block. 3. If the lamp comes on the switch is bad.
Glow Plug and Lower Reels Timer (GR 3200–D) This is a solid state timer. Upon the application of power, the load is energized and the time delay is started. After 6 seconds the load is de–energized. + – INPUT VOLTAGE 1. Connect voltmeter across test load and test load to timer. Connect 12VDC source to timer and load. Make sure to observe polarity. After 6 seconds, there should be no voltage across the load. LOAD 2. Disconnect timer from 12VDC source and test load.
Diode Circuit Board (GR 3200–D) Each circuit board contains four diodes. The diodes are used for circuit protection from inductive voltage spikes and for safety circuit logic. Diode D8 is not used. D2 D6 D4 Diode D1 D8 D3 This diode prevents current flow to solenoid S3 when solenoids S2 and S4 are energized through lower relay R6. D7 D1 D5 Diode D2 DIODE DIAGRAM This diode prevents current flow to solenoid S4 when solenoids S2 and S3 are energized through Raise relay R5.
ETR Solenoid (GR 3200–D) The ETR solenoid must be energized for the engine to run. It is mounted on the engine block next to the injection pump and has a blue and a blue/white wire attached to it. 1 In Place Testing Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads.
27 Ampere Charging System (GR 3200–D) The alternator is belt driven and externally regulated. There are four terminals on the alternator electrical connector (Fig. 46 and 47). ALTERNATOR Note: Prior to testing the charging system, make sure the V–belt to the alternator is in good operation condition and adjusted properly (see Belt Adjustment in Chapter 4 – Perkins Engine). Test Equipment A digital multimeter and shunt are recommended for testing the charging system.
2. Test continuity of the alternator windings by setting the multimeter to the ohms scale. Read all combinations between the sky blue and white wires (criss–cross) on the connector from the alternator. BLACK LEAD NEGATIVE BATTERY CABLE RED LEAD A. Two measurements should be 0.1 ohms. B. Two measurements should be O/L. 3. Check insulation resistance between lead wires and alternator casing. A. Make sure test lead makes good contact with the alternator casing. Figure 49 B.
Service and Repairs NOTE: See the Perkins 100 Series Workshop Manual or Briggs and Stratton Vanguard 3/LC Repair Manual for more component repair information. Verify Interlock System Operation 1. Sit on the seat, engage parking brake, and move Functional Control Lever to NEUTRAL. Try to depress traction pedal. If the pedal does not depress, the interlock system is operating correctly. Correct problem if not operating properly.
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extend. Additionally, battery and electrical component failure can be prevented. 1 CAUTION When working with batteries, use extreme caution to avoid slashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries. 2 Figure 51 1.
B. Temperature correct each cell reading. For each 10_F (5.5_C) above 80_F (26.7_C) add 0.004 to the specific gravity reading. For each 10_F (5.5_C) below 80_F (26.7_C) subtract 0.004 from the specific gravity reading. Example: Cell Temperature 100_F Cell Gravity ADD (20_ above 80_F) Correction to 80_F H. Using the table below, determine the minimum voltage for the cell temperature reading. Minimum Voltage 1.245 0.008 1.253 C. If the difference between the highest and lowest cell specific gravity is 0.
Charging To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is available in most shops. CAUTION Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to 60_F (15.5_ C) before connecting to a charger. Charge the battery in a well–ventilated place to dissipate gases produced from charging.
Chapter 7 Wheels and Brakes Table of Contents SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Rear Wheel (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rear Wheel (3WD) . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Front Wheel and Brake . . . . . . . . . . . . . . . . . . . . . 10 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Wheels & Brakes SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ADJUSTMENTS . . . .
Specifications Item Description Front tire pressure 8 to 12 PSI, (0.55 to 0.83 bar) Rear tire pressure 8 to 15 PSI, (0.55 to 1.04 bar) Wheel lug nut torque Wheels and Brakes 40 to 50 ft–lb, (5.5 to 6.
Adjustments Brake Adjustment CAUTION 3 Before and after adjusting the brakes, always check the brakes in a wide open area that is flat and free of other persons and obstructions. 5 6 1 1. While driving the machine, depress the brake pedal. Both wheels should lock equally. 2. Park machine on a level surface. Make sure engine is off. 2 4 3. Remove cotter pin and clevis pin from the clevis and brake pedal tab. Figure 1 4. Loosen jam nut on the brake rod. 1. Cotter pin 2. Clevis pin 3. Clevis 5.
Service and Repairs Rear Wheel (2WD) 2 22 17 1 3 18 19 21 PIVOT HOUSING 16 10 15 13 12 11 31 15 33 19 18 3 4 30 32 8 12 10 11 9 17 HUB ASSEMBLY 5 20 24 25 26 6 27 28 26 25 7 23 24 29 20 WHEEL ASSEMBLY Figure 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Hex nut Cotter pin Steering washer Castor fork Bolt Wheel hub Tire Lug nut Lock nut Ball joint 90_ grease fitting Wheels and Brakes 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Removal (Fig. 2) 1. Park machine on a level surface. Make sure engine is off. Set brake and block front wheels. 4 2. Jack up and secure the rear wheel off the ground. 1 Note: The wheel assembly consists of the tire (7), rim (23), and valve stem (29) with cap. The hub assembly consists of the wheel hub (6), shaft seal (24), bearing cone (25), bearing cup (26), grease fitting (27), and drive stud (28). 3. Remove lock nut (9) from bolt (5).
D. Place second bearing cone on the castor fork shaft with the wide edge up. Place remaining steering washer on top of the bearing cone. E. Run hex nut (1) onto castor fork shaft until drag is felt while rotating the castor fork. Back–off hex nut to align the hole to the slot. Install and secure cotter pin (2) into the shaft. F. Secure ball joint (10) to the castor fork (4) with both jam nuts (17). G. Secure fuel tank base plate to the frame with three hex head screws and flat washers.
Rear Wheel (3WD) 17 15 19 3 4 14 16 1 18 13 10 8 20 23 6 22 21 5 12 7 25 9 RIGHT 11 FRONT 2 24 Figure 4 Castor fork Hydraulic motor & hub assembly Hydraulic hose Hydraulic hose Bearing Relube flangette Standard flangette Bearing tab Hex head screw 10. 11. 12. 13. 14. 15. 16. 17. Lock nut Socket head screw Lock nut Cable tie Tube clamp Cover plate Hex head screw Lock nut 18. 19. 20. 21. 22. 23. 24. 25.
1 2 3 4 5 6 7 5 4 3 2 11 1 10 8 9 12 Figure 5 1. 2. 3. 4. Grease seal Retaining ring Washer Thrust washer 5. 6. 7. 8. Clutch roller bearing Grease fitting Hub Hydraulic motor Disassembly (Fig. 5) 9. 10. 11. 12. O–ring 45_ hydraulic fitting O–ring Drive stud OUTER BEARING EDGE MUST BE FLUSH WITH EDGE 1. Remove grease seal (1) and retaining ring (2) from the long end of hub (7). 2. Remove washer (3), two thrust washers (4), and hub (7) from the hydraulic motor (8) shaft.
Installation (Fig. 4) 1. Secure wheel (24) to the four drive studs of the hydraulic motor and hub assembly (2) with four lug nuts (23). Torque nuts from 45 to 55 ft–lb, (6.2 to 7.6 kg–m). 5. Secure hydraulic motor and hub assembly (2) loosely to the left inside of the castor fork (1) with both socket head screws (11) lock nuts (12). 6. Secure flangettes (6 and 7) with bearing (5) loosely to the right inside of the castor fork (1). 2.
Front Wheel and Brake 22 23 14 24 3 4 27 1 20 7 8 28 5 6 30 2 9 31 25 10 4 16 26 19 29 RIGHT 13 FRONT 12 18 11 15 21 17 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Lug nut Tire Brake drum Return spring Woodruff key Brake bracket Hose assembly (RH) Hose assembly (LH) 45_ Fitting Hydraulic wheel motor Flat washer 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Brake rod Brake lever Lock nut Jam nut Hex head screw Hex head screw Lock nut Lock nut Hex head screw Swivel clevis Removal (Fig. 7) 1.
Installation (Fig. 7 and 8) 2 1. Secure backing plate (28) to the brake bracket (6) with the four hex head screws (16) and lock nuts (19). 2. Position both brake shoes (27) on the backing plate (28). Insert return springs (4) into the holes of both brake shoes (27). 3. Install brake cam (26) into the backing plate (28) and brake lever (13). Secure cam to the lever with the retaining clip (29). 3 1 4. Make sure that wheel hub bore and wheel motor shaft are thoroughly cleaned.
Wheels and Brakes Page 7 – 12 Greensmaster 3200/3200–D
Chapter 8 Cutting Units Cutting Units Table of Contents INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Lift Roller Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Grass Basket Removal and Installation . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TROUBLESHOOTING . . . . . . . . . .
Introduction There are two different types of cutting units covered in this chapter: the Single Point Adjust and 4–Bolt Adjust. Both units are similar in design and construction. However, each unit has different bedbars with different methods of bedknife adjustment (see Specifications). Cutting Units Maintenance procedures for both cutting units are the same, except where noted. If a chapter subheading does not specify a particular type of cutting unit, the procedure can be used for both types of units.
Cutting Units Specifications 4–BOLT ADJUST SINGLE POINT ADJUST Figure 1 Height–of–Cut (HOC): The cutting height is adjusted on the rear roller by two vertical screws which are held by two locking capscrews. The bench HOC range is 3/32 inch to 1–1/32 inches (2.4 mm to 26.2 mm). The effective HOC may vary depending on turf conditions and the bedknife installed. Options: Micro Cut Bedknife Low Cut Bedknife High Cut Bedknife Fairway Bedknife Part No. 93–4262 Part No. 93–4264 Part No. 94–6392 Part No.
General Information Lift Roller Position The cutting unit comes with its lift roller installed in the top position. The position of the roller may be changed as follows: 1 1. Remove hex head screw and lock nut from the lift roller and frame. 2 2. Position lift roller to the proper hole on the frame. Insert hex head screw through the frame and roller. Lower Hole – for increased transport height. Upper Hole – standard transport height so the cutting unit is level when it touches down upon lowering. 3.
Special Tools Some tools may have been supplied with your mower or available as TORO parts. Some tools may also be available from a local supplier. Cutting Units OTC (Owatonna Tool Company) supplies special tools for servicing Toro Commercial Products. The TORO SPECIAL TOOLS AND APPLICATIONS GUIDE shows service tool applications. Gauge Bar Assembly Used to verify height–of–cut. Toro Part No. 13–8199.
Bearing Replacement Tool Kit – TOR238900A The puller is used to remove the bearings from the Wiehle Rear Roller kit (Model 04488) rollers only. A driving tube is used to install bearings into the roller. A drill bushing is used to drill into bearing shafts without a removal hole. Figure 8 Plastic Plug This cap is used for placement into the bearing housing when the reel motor is removed. It prevents dirt and debris from entering the housing. Toro Part No. 2410–30.
Troubleshooting cutting unit. It is important to remember that the lower the height–of–cut, the more critical these factors are. See Adjustments and Service and Repairs sections for detailed adjustments and repair information. Cutting Units There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions.
Factor Possible Problem/Correction Bedknife attitude Set attitude (angle) as recommended. See Leveling Front Roller to Reel and Attitude Adjustments. Rear roller adjustment Check and adjust as necessary. The rear roller must be leveled so it is parallel with the reel for proper height–of–cut setting. See Height–of–Cut Adjustment. Height–of–cut “Effective” or actual height–of–cut depends on the cutting unit weight and turf conditions.
Adjustments CAUTION Cutting Units Never work on a machine with the engine running. Always stop the engine and remove the key from the ignition switch first. Daily Adjustments (Single Point Adjust Cutting Units) Prior to each day’s mowing, or as required, each cutting unit must be checked to verify proper bedknife–to–reel contact. This must be performed even though quality of cut is acceptable. 1 1. Lower cutting units onto a hard surface, shut off engine, and remove the key from the ignition switch. 2.
Daily Adjustments (4–Bolt Adjust Cutting Units) Prior to each day’s mowing, or as required, each cutting unit must be checked to verify proper bedknife–to–reel contact. This must be performed even though quality of cut is acceptable. 1. Lower cutting units onto a hard surface, shut off engine, and remove the key from the ignition switch. 2. Slowly rotate reel in the reverse direction listening for reel–to–bedknife contact.
A. Park machine on a clean and level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. C. Should the reel be unable to cut the paper, it will be necessary to either backlap or regrind the cutting unit to achieve the sharp edges needed for precision cutting. Refer to Toro Reel Sharpening Manual, Form No. 80–300PT. B. Remove reel motor from the cutting unit and cutting unit from lift arm (see Cutting Unit Removal and Installation). 7.
Bedknife to Reel Parallel Adjustment (4–Bolt Adjust Cutting Units) 1. If the cutting unit is not removed from the machine, A. Park machine on a clean and level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1 3 B. Remove reel motor from the cutting unit and cutting unit from lift arm (see Cutting Unit Removal and Installation). IMPORTANT: Use only a M13 wrench, 3 to 6 inches (7.5 to 15 cm) in length, when adjusting the hex head screws.
Leveling Front Roller to Reel Adjustment 1. If the cutting unit is not removed from the machine, 1 A. Park machine on a clean and level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. B. Remove reel motor from the cutting unit and cutting unit from lift arm (see Cutting Unit Removal and Installation). Cutting Units 3 2 Note: Make sure leveling plate covers the full length of reel blades. Three blades must contact the plate. 2.
Attitude Adjustment Note: There are four positions for the front roller brackets. A more aggressive setting will increase grass removal and provide a cleaner cut, but may cause increased scalping and marking (Fig. 16). 2 1 Position 1: Least aggressive; used for very soft and tender turf or the highest height–of–cut. Position 2: Standard position; used for most conditions. Position 3: More aggressive; used on firm turf.
Height–of–Cut Adjustment 1. If the cutting unit is not already removed from the machine, Cutting Units A. Park machine on a clean and level surface, lower the cutting units, stop the engine, engage parking brake, and remove key from the ignition switch. B. Remove reel motor from the cutting unit and cutting unit from lift arm (see Cutting Unit Removal and Installation). 2.
Service and Repairs Cutting Unit Removal and Installation Removal 1. Park machine on a clean and level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 3 Note: When sharpening, setting height–of–cut, or performing other maintenance procedures on the cutting units, store cutting unit reel motors in the support tubes on the front of the frame to prevent damage to the hoses. 2.
6. Install hydraulic motor to bearing housing as follows (Fig. 2 3. Slide the cutting unit under the pull frame while hooking the lift roller onto lift arm (Fig. 21). A. Coat spline shaft of the motor with clean No. 2 multipurpose lithium base grease. 4. Connect center ball joint on pull frame to the carrier frame (Fig. 21). B. Install motor by rotating the motor clockwise so the motor flanges clear the flange head screws. 5. Remove the plastic cap from the bearing housing. C.
Backlapping (Units without Backlap/Variable Reel Speed Kit) Top Face CAUTION Remove Burr Relief Angle Be careful when backlapping the reel because contact with the reel or other moving parts can result in personal injury. Front Face Front Angle 1. Remove reel motors from the cutting units and cutting units from the lift arms and pull frame (see Cutting Unit Removal and Installation). Figure 23 2.
Backlapping (Units with Backlap/Variable Reel Speed Kit) DANGER TO AVOID PERSONAL INJURY OR DEATH: D Never place hands or feet in the reel area while the engine is running. D While backlapping, the reels may stall and then restart. D Do not attempt to restart reels by hand or foot. D Do not adjust reels while the engine is running. D If a reel stalls, stop engine before attempting to clear the reel. D Reel motors are connected in series, moving one motor moves the other two.
Rollers and Bedbar Assembly (Single Point Adjust Cutting Units) 28 27 47 48 29 26 20 21 96 54 19 37 18 13 36 36 37 23 45 39 37 43 8 40 23 16 55 14 56 39 8 30 22 4 22 32 12 5 33 11 34 52 57 46 46 44 2 35 15 41 9 17 57 6 RIGHT 58 FRONT 1 3 7 8 51 4 55 56 53 50 49 Figure 25 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Front Roller Removal and Installation Removal Cutting Units 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. Note: The front roller can be removed with the cutting unit either attached to the lift arm or removed from the lift arm. Determine your maintenance needs. 2.
2. If both front brackets were removed, position bracket as follows (Fig. 27): 3. Place roller shaft into the front bracket. Slide second front bracket on the other end of roller. Secure bracket as in step 2. (Fig. 27). A. Insert eccentric bolt (shoulder bolt) through the top hole on the frame and one of the top holes of the front bracket so the point on the bracket is at the desired position number on the decal (Fig. 28). 4. Apply Loctite 242 or equivalent to the cap screw threads.
Removal (Fig. 25) Installation (Fig. 25) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Place cutting unit on a level working surface. Note: The rear roller can be removed with the cutting unit either attached to the lift arm or removed from the lift arm. Determine your maintenance needs. 2. If the H–O–C adjusters (21) or H–O–C adjustment brackets (39) were removed, reinstall brackets as follows: A.
Roller Bearing Replacement (All Rollers except Wiehle Rear Roller) 5 4 1 2 5 BEARING RECESS 4 3 3 1 2 Figure 29 1. Shaft 2. Bearing 3. Roller tube 4. Grease fitting 5. Retaining Ring Removal ROLLER 1. Clean inside of roller around the shaft and bearing. Both ends of the roller should be free of dirt and debris. Full Rear TORO PART NO. 93–2465 Narrow Wiehle 94–8171 Full Front 94–3478 Wide Wiehle 93–2468 2. Secure roller tube in a vise keeping it level.
Wiehle Rear Roller Bearing Replacement Note: This procedure is for the Wiehle Rear Roller Kit (Model 04488) only. 2 1 3 Cutting Units Remove Bearings Note: Use the bearing replacement tool kit to remove the roller bearings (see Special Tools). Note: It is recommended to replace bearings at both ends of the roller after bearing failure. 1. If a hole is not on the bearing shaft, use drill bushing (supplied with bearing replacement kit) to drill a hole in the bearing shaft. 2.
Bedbar Removal and Installation (Single Point Adjust Cutting Units) Removal 2 1. Remove rear roller (see Rear Roller Removal and Installation). 1 2. Loosen both flange lock nuts securing the hex head flange screw to the frame tab (Fig. 31). 3 3. Remove hex head flange screw (28), flat washer (27), and quad ring (29) from the bedbar (2) on the right side of the unit (Fig. 25). 5 4 4. Remove both pivot screws (14) from the pivot housing (13) and frame.
Cutting Units Greensmaster 3200/3200–D Page 8 – 27 Cutting Units
Rollers and Bedbar Assembly (4–Bolt Adjust Cutting Units) 30 31 10 12 34 16 15 9 11 12 20 8 13 11 5 15 20 17 35 7 36 37 14 6 15 3 37 RIGHT 38 35 36 19 32 33 FRONT 4 1 2 18 29 Figure 33 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Wiehle roller Bedbar Hex head screw Front bracket Shoulder bolt Wheel bolt Height–of–cut (H–O–C) tab Height–of–cut (H–O–C) adjustment bracket Roller tube Height–of–cut (H–O–C) adjuster Carriage screw Lock nut Cutting Units 13. 14. 15. 16. 17. 18. 19. 20.
Bedbar Removal and Installation (4–Bolt Adjust Cutting Units) Removal 2. Remove rear roller (see Rear Roller Removal and Installation). 3 2 Note: The top hex head screws should remain in the adjustment brackets. This will allow for an easier adjustment of the bedbar when it is reinstalled (Fig. 34). 3. Remove bottom hex head screw from each bedbar adjustment bracket located on both sides of the frame (Fig. 34). 4. Remove both wheel bolts (6) from each end of the bedbar (2) and frame (Fig. 33).
Bedknife Replacement and Grinding Removal 2 1. Remove bedbar from frame (see Bedbar Removal). 1 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special Tools). Discard screws. Remove bedknife from the bedbar (Fig. 35). 3. Use a scraper to remove all rust, scale and corrosion from bedbar surface before installing new bedknife (Fig. 36). 3 4. Install bedbar to frame (see Bedbar Installation). Replacement Figure 35 1. Screw 2. Bedbar 3. Bedknife 1.
Bedknife Adjuster Service (Single Point Adjust Cutting Unit) Removal 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove both pivot screws (14) from the pivot housing (13). Replace plastic bushings (16) if worn or damaged (Fig. 25). Cutting Units 2 4 3. Unscrew adjustor (20) from the bedbar pivot (34) (Fig. 25). 7 Disassembly (Fig. 39) 1.
Reel and Shields Assembly (Single Point Adjust Cutting Unit) 26 10 27 20 2 8 19 7 21 31 4 3 5 6 32 34 18 16 22 33 7 8 34 9 10 11 12 RIGHT 13 17 25 FRONT 30 1 15 29 28 Figure 40 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Reel Frame Lock nut Lift roller Roller spacer Hex head screw Grease seal Bearing Flat wire spring Bearing housing Grease fitting Taper nut 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Reel and Bearing Removal and Installation 1. Remove reel motor from the cutting unit and the cutting unit from lift arm (see Cutting Unit Removal and Installation). A. Check reel shaft for bending and distortion by placing the shaft ends in V–blocks. Replace reel if necessary. 2. Place cutting unit on a level working surface. B. Check reel blades for bending or cracking. Replace reel if necessary. 3. Remove front grass shield (18) from spring pins (22) and shield rod (25). C.
4. Install left bearing housing (10) as follows: Installation (Fig. 40) Note: If bearings (8) where removed, grease seals (7) should be replaced. Both bearings should be replaced as a set. A. Insert bearing housing (10) into the left sideplate of the frame over the bearing (8). Make sure the grease fitting (11) is facing up. 1. If bearings (8) and grease seals (7) were removed from the reel shaft (1), install seals and bearings to the shaft as follows: B.
Preparing a Reel for Grinding 3. After completing the grinding process: A. Install parts removed to mount cutting unit into grinder. 1. Remove bedbar assembly (see Bedbar Removal and Installation). B. Install bedbar assembly (see Bedbar Removal and Installation). 2. Remove parts as necessary to mount cutting unit into grinder (e.g., front roller, front roller brackets). Note: The cutting unit must be aligned so the grinding wheel will travel parallel to the reel shaft.
Rear Roller Scraper Removal and Installation 7 8 6 1 4 6 5 9 3 4 2 RIGHT 1 FRONT 2 10 9 Figure 44 1. 2. 3. 4. Flange head nut Hex head screw Bracket (LH) Height–of–cut adjustment bracket 5. Torsion spring (LH) 6. Scraper 7. Bracket (RH) 8. Torsion spring (RH) 9. Lock nut 10. Height–of–cut tab Removal Installation 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1.
Reel and Shields Assembly (4–Bolt Adjust Cutting Unit) 10 32 28 20 8 3 7 21 19 2 4 Cutting Units 27 5 6 33 35 18 16 23 34 22 35 RIGHT 7 8 9 10 11 12 13 17 1 FRONT 26 30 29 31 15 Figure 45 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Reel Frame Lock nut Lift Roller Roller spacer Hex head screw Grease seal Bearing Flat wire spring Bearing housing Grease fitting Taper Nut 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Lubrication Single Point Adjust cutting units have seven grease fittings and 4–Bolt units have six fittings. Each grease fitting must be lubricated regularly with No. 2 multipurpose lithium base grease. The grease fitting locations are: the bedknife pivot hub (Single Point Adjust only, (Fig. 46)), both reel bearings, and two on both the front and rear roller. IMPORTANT: Lubricate cutting units immediately after washing helps purge water out of bearings and increases bearing life.
Commercial Products FORM 96–900–SL E The Toro Company – 1997 Printed in U.S.A.
