Service Manual

ManualsBrandsToro ManualsRiding ProductsGreensmaster 3250-D

(Model 04383)

Part No. 00062SL (Rev. J)

Service Manual

Greensmaster

3250--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 3250--D (Model 04383).

REFER TO THE TRACTION UNIT AND CUTTING

UNIT OPERATOR’S MANUALS FOR OPERATING,

MAINTENANCE AND ADJUSTMENT INSTRUC-

TIONS. Space is provided in Chapter 2 of this book to

insert the Operator’s Manuals and Parts Catalogs for

your machine. Additional copies of the Operator’s

ManualsandParts Catalogare availableon theinternet

at www.Toro.com.

TheToroCompany reservestherighttochangeproduct

specifications or this publication without notice.

This safety symbol means DANGER, WARNING,

or CAUTION, PERSONAL SAFETY INSTRUC-

TION. When you see this symbol, carefully read

the instructions that follow. Failure to obey the

instructions may result in personal injury.

Note: A Note will give general information about the

correct operation, maintenance, service, testing, or re-

pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-

portantinstructionswhichmustbefollowed topre-

vent damage to systems or components on the

machine.

E The Toro Company -- 2000, 2003, 2004, 2005, 2006, 2007, 2009, 2012

Summary of content (308 pages)

PAGE 1
Part No. 00062SL (Rev. J) Service Manual (Model 04383) GreensmasterR 3250--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 3250--D (Model 04383). REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
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1 2 3 6 Chapter 3 -- Engine Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 3 General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 4 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 7 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . .
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Chapter 1 Safety Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . . Greensmaster 3250−D 2 2 3 4 4 Page 1 − 1 Rev.
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Safety Instructions The GREENSMASTER 3250--D was tested and certified by Toro for compliance with national and international standards as specified in the Operator’s Manual. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
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While Operating 11. Sit on the seat when starting and operating the machine. 12. 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. 13. To start the engine: A. Sit on the seat, make sure cutting units are disengaged. B. Verify that functional control lever is in neutral. 16.
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Maintenance and Service 26. Before servicing or making adjustments to the machine, stop the engine, remove key from switch to prevent accidental starting of the engine. 27. Be sure entire machine is in good operating condition. Keep all nuts, bolts, screws and hydraulic fittings tight. 28. Make sure all hydraulic line connectors are tight,and all hydraulic hoses and lines are in good condition before applying pressure to the system. 29.
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Chapter 2 Product Records and Maintenance Table of Contents 1 2 2 2 3 3 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
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Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 − 2 Rev.
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Torque Specifications These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
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Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in−lb in−lb N−cm 10 + 2 13 + 2 147 + 23 # 6 − 32 UNC # 6 − 40 UNF # 8 − 32 UNC 13 + 2 25 + 5 # 10 − 24 UNC 30 + 5 SAE Grade 8 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 5 or Stronger Nuts) in−lb N−cm in−lb N−cm 15 + 2 170 + 20 23 + 2 260 +
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Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 5 in−lb 640 + 60 N−cm 78 + 7 in−lb 885 + 80 N−cm M6 X 1.0 96 + 9 in−lb 1018 + 100 N−cm 133 + 13 in−lb 1500 + 150 N−cm M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m 27 + 2 ft−lb 36 + 3 N−m M10 X 1.
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Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3 ft--lb 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb Recommended Torque** 7/16 -- 20 UNF Grade 5 65 + 10 ft--lb 88 + 14 N--m 1/2 -- 20 UNF Grade 5 80 + 10 ft--lb 108 + 14 N--m M12 X 1.25 Class 8.
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Chapter 3 Engine INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . Fuel Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . Fill Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleed Fuel System . . . . . . . . . . . . . . . . . . . . . . . . .
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Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the diesel engine used in the Greensmaster 3250. ment is explained. However, the cost of the test 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.
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Specifications Item Briggs and Stratton Vanguard/Daihatsu, Water−cooled, Diesel, Model 522447 Number of Cylinders 3 Horsepower Governed to 14.5 + 0.5 HP @ 2600 RPM Torque kg−m (ft−lb) 4.76 (34.5) @ 2300 RPM Bore x Stroke mm (in.) 68 x 78 (2.68 x 3.07) Total Displacement cc (cu. in.) 850 (51.8) Compression Ratio 24.5:1 Firing Order 1− 2−3 Dry Weight (approximate) kg (lb.) 72 (159) Fuel No. 2 Diesel per ASTM D975 Fuel Capacity liters (gallons) 22.7 (6.
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General Information DANGER Because 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, hot, or when machine is 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 cap in place. Use diesel fuel for the engine only; not for any other purpose.
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Fill Fuel Tank The engine runs on No. 2 diesel fuel. Fuel tank capacity is approximately 6.0 gallons (22.7 L). 1 1. Clean area around fuel tank cap. 2. Remove fuel tank cap. 3. Fill tank to about one inch below the top of tank, (bottom of the filler neck). Do not overfill. Install cap. 4. Wipe up any fuel that may have spilled to prevent a fire hazard. Figure 3 1. Fuel cap Bleed Fuel System 1. Position machine on a level surface. Make sure fuel tank is at least half full. 2 Engine 1 2.
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Drain Water from Fuel Filter/Water Separator Any water accumulation should be drained from the fuel filter/water separator before each use or when warning light glows. 2 1 1. Position machine on a level surface and stop the engine. Note: Because the accumulated water will be mixed with diesel fuel, drain the fuel filter into a suitable container and dispose of properly. 3 2. Place a drain pan under the fuel filter. 3.
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Adjustments Adjust Alternator Belt 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 The engine belt should be tensioned so it deflects 0.20 inch (5 mm) with a 2 to 3 lbf (9 to 13 N) load applied midway between the crankshaft and alternator pulley. 1 1. Loosen bolts securing the alternator to the engine and adjusting bracket. 2. Adjust belt to proper tension and tighten bolts.
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Service and Repairs Service Air Cleaner Service air cleaner filter every 200 hours (more frequently in extreme dusty or dirty conditions). 2 1. Check air cleaner body and hoses for damage which could possibly cause an air leak. Replace air cleaner body if damaged. 2. Release latches securing the air cleaner cover to the air cleaner body. Separate cover from the body. Clean inside of air cleaner cover. 1 3. Gently slide filter out of the air cleaner body to reduce the amount of dust dislodged.
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Change Engine Oil and Filter Change oil and filter initially after the first 50 hours of operation, thereafter change oil every 50 hours and filter every 100 hours. However, change oil more frequently when engine is operated in extremely dusty or dirty conditions. 1. Remove drain plug letting the oil flow into the drain pan. When the oil stops flowing, install drain plug. 2 2. Remove oil filter. Apply a light coat of clean oil to the new filter gasket. 1 3.
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Muffler and Air Cleaner 15 26 18 9 6 19 1 5 19 RIGHT 21 17 FRONT 2 16 15 3 20 7 12 13 4 10 28 11 10 27 4 8 15 24 14 22 30 4 24 25 29 Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Pipe plug Air cleaner bracket Lock nut Cap screw Mounting bracket Air cleaner body Muffler Muffler shield Air inlet hood Clamp Engine 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Exhaust plate Exhaust pipe R−clamp Washer Flat washer Cap screw Air cleaner hose Lock nut Hose clamp Decal Page 3 − 10 21. 22. 23. 24. 25.
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Muffler Removal (Fig. 13) 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 clamp (19), and disconnect air cleaner hose (17) from the air cleaner body (6). CAUTION 3. Remove lock nut (18) from cap screw (16). 4.
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Radiator 3 24 25 34 12 1 15 2 20 20 18 35 1 27 16 1 17 19 20 24 18 3 22 24 4 5 9 7 31 23 9 9 18 35 1 30 6 28 10 8 11 14 32 7 13 21 Figure 17 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Hose clamp Radiator hose (to water pump) Barb hose fitting Radiator Upper cooler bracket Fan warning decal Washer head screw Radiator support assembly Lock nut Screen Swell latch Radiator cap decal Engine 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
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Radiator Removal (Fig. 17) Radiator 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. Secure fan shroud (19) to radiator (4) with four cap screws (22), lock nuts (28), and flat washers (31). 2. Slide radiator (4) into the radiator support (8). Secure radiator to support with four cap screws (18) and lock nuts (9).
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Fuel Tank 1 13 17 2 6 10 24 10 11 6 26 14 13 30 to 60 in−lb (3.4 to 7.8 N−m) 25 3 ANTISEIZE LUBRICANT 4 10 16 18 23 21 10 9 RIGHT 22 FRONT 19 27 6 20 23 6 Figure 18 1. 2. 3. 4. 5. 6. 7. 8. 9. Fuel cap Fuel tank Grommet Flat washer Not used Washer head screw Not used Not used Fuel shut−off fitting Engine 10. 11. 12. 13. 14. 15. 16. 17. 18. Hose clamp Fuel fitting Not used Mounting plate Flat washer Not used Cap screw Support Bracket Fuel hose Page 3 − 14 19. 20. 21. 22. 23. 24. 25.
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Fuel Tank Removal (Fig. 18) Fuel Tank installation (Fig. 18) 1. Park machine on a level surface, lower 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). DANGER B. Secure fuel tank to the plate with three flat washers (4) and cap screws. Diesel fuel is flammable.
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Engine 31 39 31 34 30 31 10 9 19 8 28 3 11 43 15 30 19 18 31 24 32 15 30 15 31 6 44 1 37 35 15 36 27 15 18 28 1 5 22 12 33 17 42 15 15 47 29 31 16 46 7 38 45 15 25 21 32 23 15 20 15 12 2 26 14 16 38 21 15 20 45 4 13 41 16 19 38 15 40 45 15 18 16 20 21 Figure 19 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
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Engine Removal PUMP INLET HOSE 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 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 20 CAUTION 4 The hydraulic fluid may be hot.
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10. 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 (17) and frame (Fig. 18). 2 B. Disconnect hydraulic hose to power steering from from the hydraulic reservoir. Make sure hose to gear pump is disconnected at the pump (Fig. 22). C. If the oil cooler is not installed, disconnect hydraulic hose from the hydraulic oil filter (Fig. 23). D.
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12. Separate relief valve from the pump plate by removing both cap screws flat washers, and lock nuts (Fig. 26). 1 13. Separate hydrostat from the pump plate as follows: A. Loosen both set screws securing the hydrostat shaft to the hub (Fig. 27). 2 CAUTION Use caution when removing the traction control mechanism. The extension spring is under tension and may cause personal injury during removal. Figure 26 1. Relief valve 2. Cap screw B.
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A. Attach a short section of chain between both engine mounts 17. Remove three flange lock nuts (20), flat washers (21), washers (45), and cap screws (19) securing the front engine mount (13) and rear engine mount (11) to the rubber mounts (18) (Fig. 19). B. Connect hoist or chain fall to center of chain. IMPORTANT: Make sure not to damage the engine, fuel and hydraulic lines, electrical harness, or other parts while removing the engine. CAUTION C. Slowly remove engine and mounts from the machine.
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Engine Installation F. The white/red 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 19 as a guide. G. Plug−in connector with white and green wires to the alternator. Also, grey wire with rubber cap. 7. Install hydrostat to the pump plate as follows: CAUTION CAUTION One person should operate the chain fall or hoist while the other person guides the engine into the frame.
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A. Position mounting plate and tanks onto the frame. 14. Connect hydraulic oil cooler if installed (Fig. 21). A. Connect tube and O−ring to hydraulic fitting on the hydraulic reservoir. B. Connect fuel hose coming from the fuel filter/water separator at the injector pump inlet (Fig. 24). C. Connect fuel hose to the injector pump that goes to the fuel tank (Fig. 24). Secure hoses to frame with clamps (19 and 20) (Fig. 18). B. Connect tube and O−ring to hydraulic fitting on the oil filter. 15.
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Clean 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. 3. If installed, lift oil cooler from supports. 1 CAUTION Figure 29 1. Screen 2.
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Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Check Hydraulic System Fluid . . . . . . . . . . . . . . . . . 4 Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic Hose and Tube Installation . . . . . . . . .
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This page is intentionally blank. Hydraulic System (Rev.
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Specifications Item Description Hydrostatic Transmission (P3) Maximum Pump Displacement (per revolution) Charge Pressure Variable displacement piston pump 1.24 in3 (20.3 cc) 100 to 150 PSI (6.9 to 10.3 bar) Gear Pump Front Section (P1) (cutting reels) Displacement (per revolution) Rear Section (P2) (steering/lift) Displacement (per revolution) 2 section, positive displacement gear type pump 0.55 in3 (9.0 cc) 0.31 in3 (5.
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General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Greensmaster 3250--D. Refer to that publication for additional information when servicing the machine. Check Hydraulic System Fluid The hydraulic system on the Greensmaster 3250--D is designed to operate on high quality hydraulic fluid. Refer to the Operator’s Manual for hydraulic fluid recommendations.
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Towing Traction Unit In case of emergency, the Greensmaster 3250--D can be towed for a short distance. However, Toro does not recommend this as a standard practice. IMPORTANT: Do not tow the machine faster than 2 to 3 mph because drive system may be damaged. If machine must be moved a considerable distance, transport it on a truck or trailer. 1. Locate by--pass valve on the hydrostat. Rotate valve 90o. 1 2 Figure 2 1. By--pass valve 2. Hydrostat Hydraulic System 2.
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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 and maintenance. These conditions can cause hose damage and deterioration. Some hoses are more susceptible to these conditions than others.
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Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The markings on the nut and fitting body will verify that the connection has been properly tightened. 2.
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Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port) Non--Adjustable Fitting (Fig. 6) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.) method. 2.
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Adjustable Fitting (Fig. 8) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is recommended that the O--ring be replaced any time the connection is opened. Lock Nut 3. Lightly lubricate the O--ring with clean hydraulic oil. Fitting threads should be clean with no lubricant applied. Back--up Washer 4. Turn back the lock nut as far as possible.
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Hydraulic System (Rev.
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Greensmaster 3250--D Page 4 -- 11 Hydraulic System (Rev.
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Hydraulic System (Rev.
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Greensmaster 3250--D Page 4 -- 13 Hydraulic System (Rev.
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Hydraulic System (Rev.
PAGE 53
Traction Forward and Reverse Forward Reverse The hydrostat (P3) 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.
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Hydraulic System (Rev.
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Raise and Lower Cutting Units (Serial Number Under 260999999) The gear pump (P2) is directly coupled to the hydrostat through gear pump (P1). It supplies hydraulic pressure for raising and lowering the cutting units, for the steering circuit, and for maintaining 100 to 150 PSI (6.9 to 10.3 bar) to the low pressure side of the traction circuit (charge pressure). The gear pump (P2) takes its suction from the hydraulic reservoir. Maximum circuit pressure is limited by relief valve (R5).
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Hydraulic System (Rev. I) Page 4 -- 18 Greensmaster 3250--D S1R1 (NOT ENERGIZED) (ENERGIZED) (ENERGIZED) (NOT ENERGIZED) High Pressure Low Pressure (Charge) Return or Suction Flow Greensmaster 3250--D Raise Cutting Units OPTIONAL 3WD TRACTION WHEEL MOTOR Schematic For Machine With Serial Number Above 270000000 Shown. Solenoids S2 and S3 are shown in the energized position. All other solenoids are shown as de--energized.
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Raise and Lower Cutting Units (Serial Number Above 270000000) During cutting unit hold (not raising or lowering) conditions, flow from the gear pump (P2) is by--passed through the steering control valve and de--energized solenoid valve (S2) directly to the hydrostat and the charge relief valve (R4). Flow then returns to the hydraulic reservoir. Raise Cutting Units When the cutting units are to be raised, solenoid valve (S2) is energized and blocks flow directly to the hydrostat.
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Hydraulic System (Rev.
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Mow and Backlap (Serial Number Under 260999999) 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 gear pump (P1) directly to the hydraulic reservoir. Mow With the engine running and the Functional Control and Raise/Lower/Mow levers positioned so the reels will turn (see Operator’s Manual), solenoid valve (S1) is energized.
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Hydraulic System (Rev. I) Page 4 -- 22 Greensmaster 3250--D S1R1 (ENERGIZED) High Pressure Low Pressure (Charge) Return or Suction Flow Greensmaster 3250--D Mow OPTIONAL 3WD TRACTION WHEEL MOTOR Schematic For Machine With Serial Number Above 270000000 Shown. Solenoid S1R1 is shown in the energized position. All other solenoids are shown as de--energized.
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Mow and Backlap (Serial Number Above 270000000) 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 relief valve (S1R1) in the hydraulic manifold is de--energized. The de--energized (S1R1) by--passes flow from the gear pump (P1) to the oil filter and hydraulic reservoir. Additionally, manifold pressure reducing valve (PRV) will remain seated to prevent the reel motors (and reels) from rotating.
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Hydraulic System (Rev.
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Right and Left Turn 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. Flow enters the steering control valve at Port (P) and goes through the spool valve, by--passing the steering cylinder. Flow leaves the control valve out port (PB) and continues through solenoid valve (S2) to the hydrostat.
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Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit -- TOR47009 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 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges. Use gauges as recommended in Testing section of this chapter.
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Hydraulic Test Fitting Kit -- TOR4079 This kit includes a variety of O--ring face seal fittings to enable you to connect test gauges into the system. TORO TEST FITTING KIT (NO. TOR4079) The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings. Figure 13 Measuring Container -- TOR4077 Hydraulic System Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only).
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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. Problem Possible Cause Hydraulic oil leaks from system. Fitting(s), hose(s), or tube(s) are loose or damaged. O--ring(s) or seal(s) are missing or damaged. Hydraulic fluid foams. Oil level in reservoir is low. Hydraulic system has wrong type of oil.
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Problem Possible Cause No traction exists in either direction. Parking brake is not released. Oil level in reservoir is low. Hydrostat by--pass valve is open. Charge pressure is low (see Charge Pressure Relief Valve (R4) Pressure Test). Traction pump (P3) or wheel motor(s) are worn or damaged (see Traction Drive Hydrostat (P3) Flow and Wheel Motor Efficiency Tests). Wheel motor will not turn. Brakes are binding. Key on wheel motor shaft is sheared or missing. Wheel motor is damaged.
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Problem Possible Cause Cutting units will not lift or lift slowly. Engine speed is too low. Reservoir oil level is low. Lift cylinder linkage is binding or broken. Lift cylinder bushings bind. Charge circuit pressure is low (see Charge Relief Valve (R4) Pressure Test). Implement relief valve (R5) is leaking or damaged (see Implement Relief Valve (R5) Pressure Test). Solenoid valve (S2) in hydraulic manifold is leaking or damaged.
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Problem Possible Cause The steering wheel can be turned without the rear wheel turning. The steering cylinder is worn. Steering response is too slow and heavy when trying to turn quickly. Oil supply to the steering control valve is insufficient. Turning steering wheel turns machine in the opposite direction. Hoses to the steering cylinder are reversed. Steering force (possibly to one side only) is insufficient. Hydraulic flow to steering control valve is low.
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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). 1. Clean machine thoroughly before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. Contamination will cause excessive wear of components.
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5. For issues with the cutting system, consider performing the following hydraulic tests: Mow Circuit Relief Valve (R1) Pressure Test Reel Motor Case Drain Flow Test Gear Pump (P1) Flow Test Hydraulic System 4.
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Traction Drive Hydrostat (P3) Flow Test (Using Tester with Flowmeter and Pressure Gauge) HOSE FROM UPPER FITTING M5 TRACTION WHEEL MOTORS M4 OPTIONAL REAR WHEEL MOTOR TESTER 3WD DUMP VALVE R4 FROM GEAR PUMP (P2) P3 High Pressure TO HYDRAULIC RESERVOIR Hydraulic System (Rev.
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Procedure for Traction Drive Hydrostat (P3) Flow Test 8. Start engine and move throttle to full speed (2750 + 50 RPM) position. This test measures hydrostat pump output (flow). During this test, pump load is created at the flowmeter using the adjustable load valve on the tester. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off.
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Wheel Motor Efficiency Test (Using Tester with Flowmeter and Pressure Gauge) HOSE FROM UPPER FITTING M5 TRACTION WHEEL MOTORS M4 CAP CAP OPTIONAL REAR WHEEL (3WD) MOTOR TESTER 3WD DUMP VALVE R4 FROM GEAR PUMP P3 High Pressure TO HYDRAULIC RESERVOIR HYDROSTAT Low Pressure Return or Suction Flow Hydraulic System (Rev. I) Page 4 -- 36 Rev.
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Note: Over a period of time, a wheel motor can wear internally. A worn motor may by--pass oil to its case drain causing the motor to be less efficient. Eventually, enough oil loss will cause the wheel motor to stall under heavy load conditions. Continued operation with a worn, inefficient motor can generate excessive heat, cause damage to seals and other components in the hydraulic system, and affect overall machine performance. 1.
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Charge Relief Valve (R4) Pressure Test (Using Pressure Gauge) M5 TRACTION WHEEL MOTORS M4 OPTIONAL REAR WHEEL MOTOR 3WD PUMP (P3) CHARGE PORT SCHEMATIC AND PICTURE ARE FROM A MACHINE WITH SERIAL NUMBER UNDER 220999999 DUMP VALVE FROM LIFT CIRCUIT TO REEL MOTOR CIRCUIT R4 TO STEERING AND LIFT CIRCUITS R5 P3 ENGINE RPM P1 P2 HYDROSTAT GEAR PUMP High Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev. I) Page 4 -- 38 Rev.
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Procedure for Charge Relief Valve (R4) Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. 2. Park machine on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. Make sure the hydraulic tank is full. 7. Shut off engine. 8.
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Gear Pump (P2) Flow and Implement Relief Valve (R5) Pressure Tests (Using Tester with Flowmeter and Pressure Gauge) RELIEF VALVE (R5) PUMP DISCHARGE FITTING PHOTO SHOWS RELIEF VALVE (R5) AS USED IN MACHINES WITH SERIAL NUMBER UNDER 220999999 TO REEL MOTOR CIRCUIT Hydraulic System TO STEERING AND LIFT CIRCUITS TESTER FROM LIFT CIRCUIT TO TRACTION CHARGE CIRCUIT R5 P1 P2 ENGINE RPM SCHEMATIC FROM MACHINE WITH SERIAL NUMBER UNDER 220999999 SHOWN GEAR PUMP FROM HYDROSTAT High Pressure Low Pressure Ret
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5. Open control valve on tester and shut off engine. CAUTION Before continuing further, read and become familiar with Precautions for Hydraulic Testing. Note: The implement relief valve (R5) is in series with charge relief valve (R4). (R4) pressure will affect (R5) pressure. 6. Implement relief valve (R5) pressure should be: 3. On gear pump (P2) (rear pump section), disconnect the hydraulic hose from the discharge fitting on the bottom of the pump. 4.
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Lower Cutting Units Relief Valve (R2) Pressure Test (Using Pressure Gauge) SCHEMATIC FROM MACHINE WITH SERIAL NUMBER UNDER 220999999 SHOWN TO AND FROM REEL MOTORS MA MB OPTIONAL RD1 VALVES S4 O1 FC1 R2 LC1 S3 L3B #3 L3A S2 #1 L1B R1 S1 LIFT CYLINDERS LOWER RAISE L2B T #2 L2A OIL FILTER FLOW CONTROL VALVE MANIFOLD BLOCK P1 PT ST P2 P V1 R5 T OIL COOLER (OPTIONAL KIT) R TESTER TO TRACTION CHARGE CIRCUIT L ENGINE RPM P1 PB P2 STEERING CONTROL VALVE GEAR PUMP FROM HYDROS
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Procedure for Lower Cutting Units Relief Valve (R2) Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. 2. Park machine on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. Make sure the hydraulic tank is full. CAUTION Before continuing further, read and become familiar with Precautions for Hydraulic Testing. 3.
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Gear Pump (P1) Flow Test (Using Tester with Flowmeter and Pressure Gauge) PUMP (P1) OUTLET TO HYDRAULIC MANIFOLD TO HYDRAULIC MANIFOLD SCHEMATIC FROM MACHINE WITH SERIAL NUMBER UNDER 220999999 SHOWN FROM LIFT CIRCUIT TESTER TO STEERING AND LIFT CIRCUITS TO TRACTION CHARGE CIRCUIT R5 P1 P2 ENGINE RPM GEAR PUMP High Pressure FROM HYDROSTAT Low Pressure Return or Suction Flow Hydraulic System (Rev.
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Procedure for Gear Pump (P1) Flow Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. 2. Park machine on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. Make sure the hydraulic tank is full. CAUTION Do not engage the cutting units when performing this test. 7. Start engine and move throttle to full speed (2750 + 50 RPM). 8.
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Mow Circuit Relief Valve (R1) Pressure Test (Using Tester with Flowmeter and Pressure Gauge) TO LEFT REEL MOTOR TO AND FROM REEL MOTORS SCHEMATIC FROM MACHINE WITH SERIAL NUMBER UNDER 220999999 SHOWN MA MB S4 RD1 OPTIONAL VALVES O1 R2 L3B S3 FC1 LC1 L3A S2 R1 L1B S1 TO HYDRAULIC RESERVOIR TO AND FROM LIFT CYLINDERS L2B T L2A P1 PT ST P2 MANIFOLD BLOCK FROM STEERING CIRCUIT High Pressure Low Pressure FROM GEAR PUMP (P1) Return or Suction Flow Hydraulic System (Rev.
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Procedure for Mow Circuit Relief Valve (R1) Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. 10. On machines with serial number above 270000000, system pressure should be from 2700 to 3300 PSI (186.3 to 227.7 bar). Record test results. A. If this specification is met, go to step 11. B. If specification is not met, open control valve on tester, shut off engine and remove solenoid relief valve (S1R1) on manifold (Fig.
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Reel Motor Case Drain Flow Test (Using Tester with Flowmeter and Pressure Gauge) RIGHT MOTOR CASE DRAIN REAR MOTOR CASE DRAIN LEFT MOTOR CASE DRAIN REAR MOTOR RETURN LEFT MOTOR RETURN RIGHT MOTOR RETURN M3 RIGHT MOTOR MEASURING CONTAINER M1 REAR MOTOR M2 LEFT MOTOR High Pressure Low Pressure TO HYDRAULIC RESERVOIR Hydraulic System (Rev. I) FROM MANIFOLD PORT MA Return or Suction TO MANIFOLD PORT MB Page 4 -- 48 Flow Rev.
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Procedure for Reel Motor Case Drain Flow Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. 9. After achieving 1000 PSI (69 bar), place disconnected motor case drain hose into a container graduated in ounces or milliliters (e.g. Toro #TOR4077) and collect hydraulic fluid for 15 seconds. After 15 seconds, remove hose end from container. 2.
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Steering Control Valve Test P PLUG R V1 STEERING CYLINDER (CYLINDER ROD FULLY EXTENDED) T L POWER STEERING VALVE (LEFT TURN) PB SCHEMATIC FROM MACHINE WITH SERIAL NUMBER UNDER 220999999 SHOWN High Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev.
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Procedure for Steering Control Valve Test 1. Make sure the hydraulic tank is full. 2. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. 3. Drive machine slowly in a figure eight on a flat level surface. REMOVE THIS HOSE A. There should be no shaking or vibration in the steering wheel or rear wheel. B.
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Adjustments Adjust 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 the bulkhead, tighten locknuts evenly, securing traction cable to the bulkhead. Do not twist cable. 1. Block up under the frame so one of the front wheels is off the floor. If machine is equipped with 3 wheel drive kit, raise and support rear wheel off the floor as well.
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Adjust Mowing Speed The machine is adjusted at the factory, but speed may be varied if desired. 1. Loosen jam nut on trunnion cap screw located on the traction control assembly. 2 2. Loosen nut securing the lock and mow brackets on pedal pivot. 1 3. Rotate trunnion cap screw clockwise to reduce mowing speed or counterclockwise to increase mowing speed. 4. Tighten jam nut on the trunnion cap screw and nut on the lock and mow brackets to lock adjustment. Check adjustment and re--adjust as required.
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Adjust Implement Relief Valve (R5) (Machine Serial Number Under 220999999) For machines with serial number under 220999999, the implement (lift/steering) relief valve (R5) (Figure 26) is adjustable. Note: The implement relief valve (R5) for machines with serial number over 230000000 is incorporated into the steering control valve and is not adjustable. WARNING CAP Never adjust the relief valve with the hydraulic system pressurized. Hydraulic oil will spray out of the valve with the cap off.
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Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting units or attachments, and stop engine. Remove key from the ignition switch 1. Check oil level in the hydraulic reservoir and add correct oil if necessary.
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Gear Pump 1 27 to 31 ft--lb (37 to 42 N--m) 13 7 14 2 11 12 5 3 8 6 4 15 9 10 1. 2. 3. 4. 5. Pump inlet hose Gear pump Hydraulic fitting Hydraulic fitting O--ring Hydraulic System (Rev. I) 6. 7. 8. 9. 10. Figure 28 O--ring Hose clamp O--ring O--ring Hydraulic hose Page 4 -- 56 11. 12. 13. 14. 15.
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Removal (Fig. 28) Installation (Fig. 28) 1. Make sure mounting and O--ring sealing surfaces on the gear pump and hydrostat are clean. CAUTION Before continuing further, read and become familiar with General Precautions for Removing and Installing Hydraulic System Components. 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting units, and stop engine. 2. Clamp pump inlet hose to prevent draining the hydraulic tank. 2.
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Gear Pump Service 1 8 12 18 11 10 17 9 5 3 12 6 14 16 12 10 8 13 19 9 7 2 12 4 Figure 29 1. 2. 3. 4. 5. 6. 7. Front plate Back plate Front body Back body Drive gear Front idler gear Back idler gear 8. 9. 10. 11. 12. 13. Back--up gasket Wear plate Pressure seal Cap screw O--ring Adapter plate 14. 15. 16. 17. 18. 19.
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Hydraulic System Start--up CAUTION Be careful when operating the cutting unit reels. Contact with the reel or other moving parts can result in personal injury. 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. 9. After the hydraulic system starts to show signs of fill, accomplish the following: 2.
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Hydrostatic Transmission 32 28 1 40 24 1 3 6 25 2 15 19 ILLUSTRATION FOR MACHINE WITH SERIAL NUMBER UNDER 220999999 SHOWN 47 Antiseize Lubricant 20 29 16 90 to 110 in--lb (10.2 to 12.4 N--m) Loctite #242 17 45 6 38 2 3 17 41 38 22 18 4 5 13 11 33 7 8 9 39 34 44 10 35 26 42 23 21 46 36 27 43 25 37 14 7 30 12 11 31 Figure 30 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
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Removal (Fig. 30) 6 2 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting units, and stop engine. 4 1 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. Note: The neutral system assembly can be removed from the hydrostat without complete disassembly. 2. Remove extension spring from the spring bracket (Fig. 31). 5 Figure 31 1. 2. 3.
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9. Pull gear pump (28) and connected hoses assemblies (27 and 38) away from the hydrostat (45) and secure. 10. Remove hose assemblies (25, 26, and 29) and O-rings (6 and 16) from the hydraulic fittings (3 and 17). Allow hoses to drain into a suitable container. 11. Remove hydraulic fittings (3 and 17) and O--rings (2 and 20) from the hydrostat (45). 12. Loosen both set screws (5) on the pump hub (4) enough to allow the hydrostat (45) shaft to be removed.
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Piston Pump Service 36 19 17 44 43 42 41 37 20 23 18 40 21 14 45 REAR OF TRACTION UNIT 22 16 15 15 4 24 8 27 9 49 48 46 47 13 26 28 12 11 5 Parts not listed in partlist are not serviced separately. 7 6 8 29 3 1 4 2 35 16 14 24 39 6 34 33 30 32 31 19 30 31 7 25 28 20 36 37 6 12 17 20 27 30 34 35 36 37 4 Figure 35 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
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Piston Pump Crush Ring Replacement 4 5 8 7 29 ft--lb (39 N--m) 2 3 9 10 v 6 1 Figure 36 1. 2. 3. 4. Crush ring Shims Cover plate Housing 5. 6. 7. Camplate (control shaft) Bearing cone Bearing cup Note: The shims replace the crush ring in the cover plate. If the camplate, cover plate, or housing is replaced during servicing of the pump, the old crush ring can not be used to make sure of proper preload. 1. Remove crush ring from the cover plate. Measure thickness of crush ring. 5.
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Change Hydraulic Oil and Filter Change hydraulic filter initially after the first 50 operating hours, thereafter change hydraulic oil and filter after every 800 hours. Contaminated oil looks milky or black when compared to clean oil. If oil becomes contaminated, flush hydraulic system (see Flush Hydraulic System). 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. Place drain pan under filter and remove filter.
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Wheel Motors 4 250 to 400 ft--lb (339 to 542 N--m) 3 24 6 5 7 12 11 30 1 RH 15 LH 16 8 9 32 15 RH 16 LH 14 18 2 13 17 12 19 70 to 90 ft--lb (95 to122 N--m) 20 26 29 10 RIGHT 23 FRONT 22 28 21 25 31 27 Figure 38 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Lug nut Tire Rim Valve stem Brake drum Wheel hub Drive stud Backing plate Brake cam Retaining clip Return spring 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
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Note: The brake assembly consists of return spring (11), brake cam (9), brake shoes (12), backing plate (8), and retaining clip (10). 3. Lubricate new O--rings (18) with clean hydraulic fluid. Install O--rings and hose assemblies (15 or 16) to the hydraulic fittings (17). Tighten hose connections. 6. Remove brake assembly from the brake bracket (14) by removing four cap screws (26) and lock nuts (29) from the backing plate (8) and brake bracket. Do not disassemble.
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18 16 20 3 4 15 17 19 14 70 to 90 ft--lb (95 to122 N--m) 9 1 11 80 to 100 in--lb (9.0 to 11.3 N--m) 23 21 6 24 7 RIGHT FRONT 22 5 8 13 10 3 4 12 30 ft--lb (41 N--m) 2 85 ft--lb (115 N--m) 25 Figure 39 1. 2. 3. 4. 5. 6. 7. 8. 9. Castor fork Hub and motor assembly Hydraulic hose Hydraulic hose Bearing Relube flangette Grease fitting Standard flangette Bearing tab 10. 11. 12. 13. 14. 15. 16. 17.
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5. Loosen both set screws (24) on bearing (5). Slide flangettes (6 and 8) and bearing (5) off the motor shaft. 6. Remove grease fitting (22) from the hydraulic motor and hub assembly (2). Remove four lug nuts (23) and wheel (25) from the hub drive studs. Note: For disassembly of the hub from the rear wheel motor, see Rear Wheel (3WD) Disassembly instructions in Chapter 6 -- Wheels and Brakes. Rear Wheel (3WD) Installation (Fig. 39) 5.
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Wheel Motor Service 12 13 11 10 3 1 4 5 6 7 8 9 8 14 2 15 16 17 24 5 23 Parts not listed in partlist are not serviced separately. 25 19, 20, 21 26 15, 16, 23 27 28 5 22 5 21 1, 4, 5, 6, 7, 15 19 20 5 2, 3, 8, 9, 10 18 Figure 40 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Dirt seal Bearing Housing Back--up washer Seal rings Back--up washer Inner seal Thrust washer Thrust bearing Bearing 11. 12. 13. 14. 15. 16. 17. 18. 19.
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Flush 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. 10.
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Implement Relief Valve (Machines with Serial Number Under 220999999) RELIEF VALVE 20 ft--lb (27 N--m) 11 13 12 14 10 7 9 8 4 15 6 3 1 3 LEFT 5 REAR 3 2 Figure 43 1. 2. 3. 4. 5. Hose assembly Hose assembly O--ring 90o hydraulic fitting Tee hydraulic fitting 6. 7. 8. 9. 10. Lock nut Cap screw Flat washer Mounting plate Relief valve body 11. 12. 13. 14. 15. Relief valve cartridge O--ring O--ring Back--up ring O--ring Removal 2. Label all hydraulic connections for reassembly. 1.
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Installation CAUTION 1. Lubricate new O--rings with clean hydraulic fluid. Install O--rings and hydraulic fittings to the valve body. 2. Secure valve body to the mounting plate with cap screws, flat washers, and lock nuts. 3. Install O--rings and hose assemblies to hydraulic fittings. Tighten hose connections. Disassembly 1. Unscrew relief valve cartridge from the relief valve body. Remove O--rings and back--up ring. 2.
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Reel Motors 1 2 3 3 20 31 18 4 23 5 16 15 22 14 21 29 7 29 7 30 25 19 30 17 6 8 10 11 12 24 7 11 17 27 13 15 26 6 14 28 RIGHT FRONT 13 27 28 8 FRONT REEL MOTORS Figure 44 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Cap screw Flat washer Tube clamp Lock nut Plug 90o Hydraulic fitting Hydraulic fitting Hydraulic fitting Not used Bulkhead nut Washer 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
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1 9 10 11 3 25 27 17 5 9 23 4 18 14 8 12 2 21 6 4 3 15 20 3 22 24 26 3 19 13 28 13 RIGHT FRONT 1 9 10 16 11 9 REAR REEL MOTOR 7 Bulkhead lock nut Bulkhead lock nut Hex washer head screw Hydraulic hose Reel motor Bulkhead bracket Hydraulic tube Hydraulic hose Washer Spacer 11. 12. 13. 14. 15. 16. 17. 18. 19. Grommet Hydraulic straight fitting 90o Hydraulic fitting Hose bracket Clamp Hydraulic hose O--ring O--ring O--ring 20. 21. 22. 23. 24. 25. 26. 27. 28.
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Reel Motor Service (Serial Number Under 220999999) 3 4 5 6 1 7 2 8 9 190 to 210 in--lb (21.5 to 23.7 N--m) 5 14 10 11 12 13 5 Figure 46 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 Disassembly (Fig. 46) 1. Make sure caps or plugs are in motor openings to prevent contamination. Clean motor with solvent.
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1. Remove all nicks and burrs from all parts with an emery cloth. CAUTION Use eye protection such as goggles when using compressed air. 2. Clean all parts with solvent. Dry all parts with compressed air. 3. Inspect drive shaft and idler gear assemblies. A. Bushing points and seal areas should be free of excessive excessive wear and rough surfaces. B. Gear faces should be free of excessive scoring and wear. Note: Make sure idler gear is installed into the gear pocket opposite the external drain port. 3.
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Reel Motor Service (Serial Number Over 230000000) 6 5 7 9 8 7 10 5 11 6 1 215 to 280 in--lb (24 to 32 N--m) 3 12 4 2 Figure 47 1. 2. 3. 4. Rear cover Drive gear Seal Tab washer 5. 6. 7. 8. Pressure seal Back--up ring O--ring Body Disassembly 1. Plug motor ports and clean the outside of the motor thoroughly. After cleaning, remove plugs and drain any oil out of the motor. 9. 10. 11. 12. Idler gear Cap screw Front flange Washer (if equipped) DIAGONAL MARK 2.
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IMPORTANT: Mark the relative positions of the gear teeth and the bearing blocks so they can be reassembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. 1 7. Place the motor on its side and push on the rear bearing block to remove the bearing block and gear set (Fig. 49). 8. Carefully remove and discard O--rings, pressure seals, and back--up rings (Fig. 50) from motor. Do not cause any damage to the machined grooves during the removal process.
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Reassembly 8. Install dowel pins in body. NOTE: When reassembling the motor, check the identification marks made during disassembly to make sure the parts are properly aligned during reassembly. IMPORTANT: Do not dislodge O--rings, pressure seals, or back--up rings during final assembly. 1. Lubricate O--rings, pressure seals, back--up gaskets, and seal grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic oil. 2.
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Hydraulic System This page is intentionally blank. Greensmaster 3250--D Page 4 -- 81 Hydraulic System (Rev.
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Oil Cooler (If Equipped) 11 10 8 9 10 7 3 OIL FLOW 12 13 11 1 6 14 4 5 2 Figure 52 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. 52) 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 Radiator screen Upper cooler bracket Lower cooler bracket 2.
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7. Plug ends of the oil cooler. Clean exterior of the cooler. 8. The oil cooler should be free of corrosion and excessive pitting of tubes. Installation (Fig. 52) 1. Make sure formed hoses and openings of the oil cooler are clean. 4. Remove clamps that where used to prevent drainage from the formed hoses. 5. Fill hydraulic tank (see Check Hydraulic System Fluid). 6. Start machine. Run machine at idle for 3 to 5 minutes to circulate hydraulic fluid and remove any air trapped in the system.
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Lift Cylinders 4 10 12 3 7 2 1 11 13 8 13 14 12 3 9 14 5 6 HYDRAULIC CYLINDER Figure 53 1. 2. 3. 4. 5. Hose assembly Hose assembly O--ring Cotter pin Clevis pin 6. 7. 8. 9. 10. Lift arm Hydraulic cylinder Cap screw Ram pivot pin Spacer Front Cylinder Removal (Fig. 53) 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. Frame 90o Hydraulic fitting O--ring Washer 5.
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12 11 10 10 HYDRAULIC CYLINDER 2 15 5 16 17 9 6 7 18 14 18 13 4 1 8 3 Figure 54 Hose assembly Hose assembly O--ring 90o hydraulic fitting Orificed hydraulic fitting Cotter pin 7. 8. 9. 10. 11. 12. Clevis pin Lift arm Hydraulic cylinder Retaining ring Cylinder pin Frame Rear Cylinder Removal (Fig. 54) 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.
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Lift Cylinder Service REAR HYDRAULIC CYLINDER 1 6 7 11 2 24 to 30 ft--lb (33 to 41 N--m) 3 1. 2. 3. 4. 4 5 Barrel Shaft Nut Piston 5. 6. 7. 8. 8 Uni--ring O--ring Rod seal Head 9 10 12 Figure 55 9. 10. 11. 12. O--ring Back--up ring Dust seal Internal collar FRONT HYDRAULIC CYLINDER 1 6 7 11 2 24 to 30 ft--lb (33 to 41 N--m) 3 4 5 8 9 10 12 Figure 56 1. 2. 3. 4. Barrel Shaft Nut Piston Hydraulic System (Rev. I) 5. 6. 7. 8.
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1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. IMPORTANT: Prevent damage when clamping the hydraulic cylinder into a vise; clamp on the clevis only. Do not close vise enough to distort the barrel. 2. Mount lift cylinder in a vice. Remove internal collar with a spanner wrench. 3. Extract shaft, head, and piston by carefully twisting and pulling on the shaft.
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Hydraulic Manifold 4 1 2 14 7 13 21 6 10 24 15 30 22 28 5 29 9 16 19 23 25 20 8 27 26 32 16 31 17 15 11 31 2 4 18 3 ILLUSTRATION FOR MACHINE WITH SERIAL NUMBER UNDER 260999999 SHOWN 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Hydraulic manifold assembly Hydraulic straight fitting Hydraulic fitting O--ring 90o Hydraulic fitting 90o Hydraulic fitting 90o Hydraulic fitting Hydraulic straight fitting Hydraulic straight fitting 45o Hydraulic fitting Hydraulic T--fitting 12. 13. 14. 15.
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Removal (Fig. 57) 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. IMPORTANT: Before disconnecting any hydraulic fittings from the hydraulic manifold block, make sure the position of each fitting is observed and matchmarked to ensure it is oriented properly on the manifold. 6. Disconnect hydraulic fittings and O--rings from the manifold. CAUTION Installation (Fig.
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Hydraulic Manifold Service (Serial Number Under 260999999) 19 15 in--lb (1.7 N--m) PLUG TORQUE 1 1 35 ft--lb (47 N--m) SAE #4: 9 to 11 ft--lb (12 to 14 N--m) SAE #6: 16 to 18 ft--lb (22 to 24 N--m) SAE #8: 43 to 46 ft--lb (58 to 62 N--m) SAE #10: 60 to 62 ft--lb (81 to 84 N--m) 19 15 in--lb (1.
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Solenoid Operated Cartridge Valves (Fig. 58) C. Torque cartridge valve using a deep socket to 35 ft--lb (47 N--m). 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 (1.7 N--m). 2. Remove nut securing solenoid to the cartridge valve. Slide solenoid and both O--rings off the valve.
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Hydraulic Manifold Service (Serial Number Over 270000000) 20 ft--lb (27 N--m) 26 25 ft--lb (34 N--m) 18 2 25 ft--lb (34 N--m) 15 13 11 2 60 in--lb (6.7 N--m) 21 14 16 29 26 29 21 20 ft--lb (27 N--m) 60 in--lb (6.7 N--m) 10 17 6 12 6 20 ft--lb (27 N--m) 40 ft--lb (54 N--m) 7 7 4 165 in--lb (18.6 N--m) 198 in--lb (22 N--m) 1 9 VIEW FROM BELOW 7 8 41 ft--lb (55 N--m) 3 6 9 6 6 19 6 22 1 6 UP 20 24 5 23 20 ft--lb (27 N--m) 8 6 120 in--lb (13.
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NOTE: The hydraulic manifold shown in Figure 59 uses several zero leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening. The zero leak plugs also have an O--ring to provide a secondary seal. If zero leak plug removal is necessary, lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug: the impact will allow plug removal with less chance of damage to the socket head of the plug.
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Rotary Cartridge Valves IMPORTANT: Use care when installing the rotary cartridge valve. Slight bending or distortion of the stem tube can cause binding and malfunction. Make sure that deep well socket fully engages the valve base. 1. Remove rotary handle from valve (Fig. 60): A. Loosen two (2) set screws that secure handle cap. B. Lubricate cartridge threads with clean hydraulic oil. Thread rotary cartridge valve carefully into the manifold port. The valve should go in easily without binding.
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Mow/Backlap Spool (Fig. 61) 1 1. Remove mow/backlap spool from manifold: 2 4 A. Remove backlap switch from manifold before removing mow/backlap spool. Remove dowel pin and ball from manifold port after switch is removed. Remove and discard O--ring from switch. Loctite 603 3 6 B. Remove lower retaining ring from mow/backlap spool. Raise mow/backlap spool to allow access to retaining ring on upper end of spool. Remove upper retaining ring. 5 C.
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Flow Control and Backlap Valves (If Equipped on Serial Number Under 260999999) 16 14 17 15 18 12 3 35 ft--lb (47 N--m) 4 5 19 6 21 20 22 23 24 26 35 ft--lb (47 N--m) 25 7 13 8 2 1 11 10 9 35 ft--lb (47 N--m) 27 Figure 62 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.
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Flow Control and Two Position Directional Valves (Fig. 62) 6. Reinstall the cartridge valve (7 or 13): A. Lubricate new O--ring and backup ring of seal kit (8 or 11) with clean hydraulic oil and install. The O-ring and backup ring of seal kit must be arranged properly on the cartridge valve (7 or 13) for proper operation and sealing. CAUTION Before continuing further, read and become familiar with General Precautions for Removing and Installing Hydraulic System Components. 1. Remove knob assembly: B.
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Logic Cartridge Valves (Fig. 62) CAUTION CAUTION Before continuing further, read and become familiar with General Precautions for Removing and Installing Hydraulic System Components. 1. Remove logic cartridge valve (10) and seal kit (9). 2. Visually inspect the port in the manifold (27) for damage to the sealing surfaces, damaged threads, and contamination. Use eye protection such as goggles when using compressed air. 4. Clean logic cartridge valve (10) using clean mineral spirits.
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Rear Lift Cylinder Flow Control Valve 8 HYDRAULIC CYLINDER 7 6 5 4 1 2 FLOW CONTROL VALVE 3 Figure 63 1. 2. 3. Hose assembly O--ring 90o Hydraulic fitting 4. 5. 6. O--ring Flow control valve O--ring 7. 8. 90o Hydraulic fitting Hydraulic cylinder Removal Hydraulic System 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.
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Steering Control Valve 1 2 ILLUSTRATION FOR MACHINE WITH SERIAL NUMBER UNDER 220999999 28 3 27 4 5 10 6 35 ft--lb (47 N--m) 11 7 12 26 21 8 4 19 20 37 34 35 22 9 17 29 36 14 10 13 33 24 32 18 31 30 15 29 12 11 25 23 13 Antiseize Lubricant 16 Figure 65 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
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Removal (Fig. 65) 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. ILLUSTRATION FOR MACHINE WITH SERIAL NUMBER FROM 230000001 TO 270999999 2 CAUTION 1 Before continuing further, read and become familiar with General Precautions for Removing and Installing Hydraulic System Components. Antiseize Lubricant 2. Remove screw (28) and steering wheel cap (27) from the steering wheel (5). 3 3.
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Installation (Fig. 65) 1. Install removed hose assemblies and O--rings to the steering control valve. Install removed hydraulic fittings and O--rings to the control valve. 2. Install steering column assembly to the steering control valve. 3. While routing hydraulic hoses to machine, position steering control valve into the steering cover assembly. Secure control valve to steering arm cover with cap screws. 4.
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Hydraulic System This page is intentionally blank. Greensmaster 3250--D Page 4 -- 103 Hydraulic System (Rev.
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Steering Control Valve Service (Serial Number Under 220999999) BOTTOM 5 1 6 2 INNER RACE 8 3 15 12 13 14 4 OUTER RACE 7 10 GEAR WHEEL 16 9 11 18 to 27 ft--lb (24 to 37 N--m) 20 RIM 16 21 17 18 22 19 18 to 27 ft--lb (24 to 37 N--m) Figure 68 1. 2. 3. 4. 5. 6. 7. 8. Dust seal Housing Ball Threaded bushing O--ring/kin--ring Bearing assembly Ring Spool 9. 10. 11. 12. 13. 14. 15. Cross pin Spring set Sleeve Cardan shaft O--ring Distributor plate Gear wheel set Disassembly (Fig. 68) 1.
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Note: The cross pin can be seen through the open end of the spool. 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. 69). Note: The outer race of the bearing assembly may stick in the housing. Make sure race is removed from the housing. CROSS PIN 8. Remove ring and bearing assembly from the spool.
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4. Install ring over the sleeve. Make sure ring is able to rotate free of the springs. OUTER RACE 5. Insert cross pin into the spool and sleeve (Fig. 69). NEEDLE BEARING 6. Install bearing assembly onto the spool and sleeve (Fig. 72). 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. 73 and 74).
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16. Secure special screw with new washer into the hole shown (Fig. 76 and 77). 17. Secure remaining screws with washers into control valve. Torque all screws in a criss--cross pattern from 18 to 27 ft--lb (24 to 37 N--m). SPECIAL SCREW 18. Install dust seal carefully into the housing. Figure 76 SPECIAL SCREW Hydraulic System Figure 77 Greensmaster 3250--D Page 4 -- 107 Hydraulic System (Rev.
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Steering Control Valve Service (Serial Number From 230000000 to 270999999) 1 27 28 5 4 8 26 3 24 2 19 19 23 29 30 7 6 25 20 22 21 150 in--lb (17 N--m) 9 10 17 18 16 15 14 13 12 11 140 to 160 in--lb (16 to 18 N--m) Figure 78 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Steering valve housing Dust seal O--ring Spool Spring retaining ring Pin Sleeve Centering springs/spacers Cap screw End cap 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
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8. Put the thrust bearing and races into the housing. The thrust bearing goes between the two races (Fig. 79). CAUTION The centering springs are under tension. Remove the retaining ring carefully. IMPORTANT: Do not damage the dust or quad seals when installing the spool and sleeve assembly. 10.Remove the spring retaining ring and centering springs from the spool. 9. Apply a light coating of clean hydraulic fluid to the spool and sleeve assembly and slide carefully the assembly into the housing.
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Steering Control Valve Service (Serial Number Over 280000000) 14 13 11 16 15 12 11 7 8 10 9 6 25 5 3 26 v 4 27 2 29 24 28 23 22 21 18 1 20 17 18 19 20 to 24 ft--lb (27 to 33 N--m) 18 Figure 80 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Plug Plug Spring Relief valve Dust seal T port Housing R port E port Shaft seal 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Thrust washer Bearing Cross pin Ring Sleeve Spool Cardan shaft O--ring Distribution plate Outer gearwheel 21. 22. 23. 24. 25. 26. 27. 28.
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Hydraulic System This page is intentionally blank. Greensmaster 3250--D Page 4 -- 111 Hydraulic System (Rev.
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Steering Cylinder CYLINDER ASSEMBLY 2 65 to 85 ft--lb (88 to 115 N--m) 1 3 27 26 28 30 24 21 32 31 25 17 22 22 19 18 20 28 27 3 4 23 33 19 15 17 18 65 to 85 ft--lb (88 to 115 N--m) 26 37 16 39 36 35 38 29 34 6 7 5 8 9 RIGHT FRONT HUB ASSEMBLY 10 12 14 13 8 7 6 29 WHEEL ASSEMBLY 11 Figure 81 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
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Removal (Fig. 81) 1. Before removing any parts from the hydraulic system, park machine on a level surface, set brake, lower cutting units, and stop engine. CAUTION Before continuing further, read and become familiar with General Precautions for Removing and Installing Hydraulic System Components. CAUTION Support rear wheel to prevent dropping and causing personal injury while removing hex nut. Use two people to remove steering cylinder. 8.
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Steering Cylinder Service 9 10 14 11 13 12 10 11 9 5 2 5 6 4 3 8 7 3 4 2 6 1 SERIAL NUMBER BELOW 260999999 Figure 82 1. 2. 3. 4. 5. Seal kit Rod wiper U--cup Back--up ring O--ring 6. 7. 8. 9. 10. Wear ring Piston ring O--ring Set screw Threaded cap 11. 12. 13. 14. Head Piston Barrel Rod 4 12 v 15 12 16 13 3 14 7 2 3 7 5 6 8 9 10 6 2 5 11 1 SERIAL NUMBER ABOVE 270000000 Figure 83 1. 2. 3. 4. 5. 6.
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Disassembly (Figs. 82 and 83) Assembly (Figs. 82 and 83) IMPORTANT: To prevent damage when clamping cylinder barrel in a vise, clamp only on pivot end. Do not clamp the vise jaws against the shaft surface. NOTE: Due to steering cylinder design for serial numbers above 270000000, the seal kit may include several O--rings, backup rings and wear rings that cannot be accessed. 2. Mount cylinder in a vise by clamping vise on center mounting location of cylinder.
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Hydraulic Reservoir 5 18 24 20 17 15 3 18 15 6 25 2 14 30 to 60 in--lb (3.4 to 6.8 N--m) 29 16 11 1 4 28 19 13 12 16 9 22 23 10 21 26 7 27 8 9 23 Figure 84 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Hydraulic barb fitting Hydraulic straight fitting Fuel tank clamp Hex washer head screw Tank cap Hydraulic tank Hydraulic straight fitting Oil filter assembly Hydraulic barb fitting Oil filter mount 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
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5. Remove cap screw and flat washer securing the console shroud to the hydraulic tank. Remove both cap screws and flat washers securing the console shroud to the lower panel (Fig. 87). 6. Remove three hex head screws and flat washers securing the mounting plate (29) to the frame. Two screws are located on the top of the plate at the front corners of the fuel tank. The third screw is in front of the castor fork and below the plate. PUMP INLET HOSE 7.
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Leak Detector 1 2 3 9 17 to 21 ft--lb (23 to 28 N--m) 4 10 33 8 5 38 7 6 11 5 9 34 35 10 28 37 35 36 12 32 100 to 125 in--lb (11.3 to 14.1 N--m) 13 31 30 to 60 in--lb (3.4 to 6.8 N--m) 17 to 21 ft--lb (23 to 28 N--m) 30 29 14 15 16 16 26 28 6 7 17 27 7 18 25 19 20 24 18 21 39 23 22 9 10 Figure 88 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
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Removal (Fig. 88) 3 1. Before removing any parts from the hydraulic system, park machine on a level surface, set brake, lower cutting units, and stop engine. 1 2 5 4 CAUTION Before continuing further, read and become familiar with General Precautions for Removing and Installing Hydraulic System Components. 2. Place clean container, large enough to collect 2 gallons (7.6 liters), under the oil filter assembly to collect hydraulic oil. Figure 89 1. 2. 3. 4.
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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. 90). 8.
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Chapter 5 Electrical System Table of Contents Functional Control Lever Reed Switches and Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Backlap Switch (If Equipped) . . . . . . . . . . . . . . . . Leak Detector (Optional) . . . . . . . . . . . . . . . . . . . . Warning Light Cluster . . . . . . . . . . . . . . . . . . . . . . . High Temperature Shutdown Switch . . . . . . . . . . Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . Lower Reels Time Delay . . . . . . . . .
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Electrical Schematics The electrical schematic and other electrical drawings for the Greensmaster 3250−D are located in Chapter 8 − Electrical Diagrams. Electrical System (Rev.
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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.
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Troubleshooting 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. If the machine has any interlock switches by−passed, they must be reconnected for proper troubleshooting and safety.
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Starting Problems (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 − Engine). Engine and fuel may be too cold. Neutral sensor is out of adjustment, faulty, or short circuited.
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General Run and Transport Problems 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.
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Cutting Unit Operating Problems 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 NEUTRAL 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.
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Electrical System Quick Checks Battery 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 60o to 100o 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 12.68 V (or higher) Fully charged (100%) 12.
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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 Briggs and Stratton Vanguard/Daihatsu Repair Manual for 3 Cylinder Water−Cooled Diesel Engines for additional component testing information.
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Safety Relays Two styles of safety relays have been used on Greensmaster 3250−D machines. Later production machines (after serial number 250000000) have a different relay terminal arrangement than relays on earlier machines (Fig. 4). Relay operation is identical regardless of terminal layout. 87 87A 86 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.
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Seat Switch The seat 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. 2 1. Make sure the engine is off. Remove seat from the support assembly by removing four lock nuts from the seat bolts. 3 2. Disconnect electrical connector from the seat switch. 3.
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Functional Control Lever Reed Switches and Actuator Both reed switches are normally open. They close when the actuator comes in close proximity to the switch. These switches are used to sense the Functional Control Lever in either the NEUTRAL or MOW position. 3 1. Make sure the engine is off. Disconnect electrical connectors to both switches. Check continuity of both switches by connecting a multimeter (ohms setting) across the connector terminals. 1 2 2.
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Leak Detector (Optional) 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.
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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. 15).
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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 16 Components can be tested by isolating them from the rest of the circuit and individually testing the suspected component. 6 5 This is a solid state device with no moving parts. Upon the application of power, the time delay is initiated.
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Warning Light Cluster Two styles of warning light clusters have been used on the Greensmaster 3250--D. On machines with serial number below 250000000, the four warning lights are included in one component (Fig. 18). On machines with serial number above 250000000, the four warning lights are included in two components (Fig. 20).
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High Temperature Shutdown Switch The high temperature shutdown switch is located on the water pump, which is located on the rear end of the engine block. The high temperature shutdown switch has a yellow/red wire connected to it (Fig. 20). 2 CAUTION Make sure engine is cool before removing the temperature switch. 1 1. Lower coolant level in the engine and remove the temperature switch. 2. Put switch in a container of oil with a thermometer and slowly heat the oil (Fig. 21). Figure 20 1.
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Oil Pressure Switch 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. 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 white/red wire from the switch and ground it to the engine block. 2 3. If the lamp comes on the switch is bad. 4.
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Lower Reels Time Delay 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. 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. TIME DELAY 2. Disconnect timer from 12VDC source and test load.
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Diode Circuit Boards 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.
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Solenoid Valve Coils 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. Subtract this value from from the measured value of the component you are testing. 1. Make sure engine is off. Disconnect solenoid valve electrical connector. 2 1 2. Apply 12VDC source directly to the solenoid.
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Glow Relay When energized, the glow relay allows electrical current to the engine glow plugs. Two styles of glow relays have been used on the Greensmaster 3250--D. On machines with serial number below 250000000, two of the four relay connections are secured with screws (Fig. 33). Machines with serial number above 250000000 use relays that are connected to the wire harness with a four wire connector (Fig. 34). GLOW RELAY 1.
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Service and Repairs Note: See the Briggs and Stratton Vanguard/Daihatsu Repair Manual for 3 Cylinder Water−Cooled Diesel Engines for more component repair information. Verify Interlock System Operation CAUTION The interlock switches are for the operator’s protection; do not disconnect them. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before operating the machine. The purposes of the interlock switches are to: A.
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Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. CAUTION 1 When working with batteries, use extreme caution to avoid splashing 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 34 1.
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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. Cell Temperature 100 F Cell Gravity ADD (20 above 80 F) Correction to 80 F 1.245 0.008 1.253 C. If the difference between the highest and lowest cell specific gravity is 0.050 or greater or the lowest cell specific gravity is less than 1.225, charge the battery.
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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 Follow the manufacturer’s instructions when using a battery charger. Note: Using specific gravity of the battery cells is the most accurate method of determining battery condition. 1.
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Chapter 6 Chassis Table of Contents Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Rear Wheel (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rear Wheel (3WD) . . . . . . . . .
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Specifications Item Description Front tire pressure, 19 x 10.50 x 2 ply 8 to 12 PSI, (0.55 to 0.83 bar) Rear tire pressure, 19 x 10.50 x 2 ply 8 to 15 PSI, (0.55 to 1.04 bar) Wheel lug nut torque 70 to 90 ft−lb, (95 to 122 N−m) Special Tools Wheel Hub Puller − TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors. Figure 1 Chassis (Rev.
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Adjustments Brake Adjustment CAUTION 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. 3 5 6 1 Note: The brake adjustment rods are located on each side of the machine. Adjust each brake equally. 1. While driving the machine, depress the brake pedal. Both wheels should lock equally. 2 2. Park machine on a level surface. Make sure engine is off. 4 3.
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Service and Repairs Rear Wheel (2WD) 2 1 3 26 27 28 30 31 25 17 24 21 32 22 22 19 18 20 28 27 3 4 23 33 70 to 90 ft−lb (95 to122 N−m) 19 17 18 26 15 37 16 39 36 35 38 34 29 5 6 7 8 9 HUB ASSEMBLY 10 RIGHT 8 7 FRONT 12 13 6 14 29 WHEEL ASSEMBLY 11 Figure 3 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Slotted hex nut Cotter pin Steering washer Castor fork Bolt Oil seal Bearing cone Bearing cup Wheel hub Grease fitting Drive stud Tire Rim Chassis (Rev. D) 14. 15. 16. 17. 18.
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Removal (Fig. 3) 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 (12), rim (13), and valve stem (14) with cap. The hub assembly consists of the wheel hub (9), oil seals (6), bearing cones (7), bearing cups (8), grease fitting (10), and drive studs (11). 3. Remove lock nut (16) from bolt (5).
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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 slotted 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. 3. Install wheel and hub assemblies into the castor fork (4). Insert bolt (5) into motor adapter plate (34) mounting hole.
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Rear Wheel (3WD) 18 16 20 3 4 15 17 19 14 9 1 11 80 to 100 in−lb (9.0 to 11.3 N−m) 23 21 6 24 7 RIGHT 22 5 8 13 10 3 4 FRONT 12 30 ft−lb (41 N−m) 85 ft−lb (115 N−m) 2 25 Figure 5 Castor fork Hub and motor assembly Hydraulic hose Hydraulic hose Bearing Relube flangette Grease fitting Standard flangette Bearing tab 10. 11. 12. 13. 14. 15. 16. 17. Cap screw Lock nut Hex socket head screw Lock nut Cable tie Tube clamp Cover plate Cap screw 18. 19. 20. 21. 22. 23. 24. 25.
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9 6 8 5 12 6 9 11 10 10 11 12 1 3 2 4 7 1. 2. 3. 4. Hydraulic motor 45_ Hydraulic fitting O−ring O−ring 5. 6. 7. 8. Figure 6 9. 10. 11. 12. Hub Clutch roller bearing Drive stud Grease fitting Disassembly (Fig. 6) 1. Remove grease seal (12) and snap ring (12) from the long end of hub (5). Thrust washer Washer Snap ring Grease seal OUTER BEARING EDGE MUST BE FLUSH WITH EDGE 2. Remove washer (10), two thrust washers (9), and hub (5) from the hydraulic motor (1) shaft.
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Installation (Fig. 5) 1. Secure wheel (25) to the four drive studs of the hydraulic motor and hub assembly (2) with four lug nuts (23). Torque nuts from 70 to 90 ft−lb (95 to 122 N−m). 2. Reinstall grease fitting (22) into hydraulic motor and hub assembly (2) so it points away from the wheel (25). 5. Secure hydraulic motor and hub assembly (2) loosely to the left inside of the castor fork (1) with both socket head screws (12) lock nuts (13). 6.
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Front Wheel and Brake 4 250 to 400 ft−lb (339 to 542 N−m) 3 24 6 7 5 12 11 RH 15 LH 16 30 8 1 9 32 15 RH 16 LH 14 18 2 17 13 70 to 90 ft−lb (95 to122 N−m) 12 19 20 26 29 10 RIGHT 23 28 22 FRONT 21 31 25 27 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Lug nut Tire Rim Valve stem Brake drum Wheel hub Drive stud Backing plate Brake cam Retaining clip Return spring Chassis (Rev. D) 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
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Removal (Fig. 8) 2 1. Park machine on a level surface. Make sure engine is off. Make sure brake is in the OFF position. 2. Block front and rear of wheels not being jacked up. Lift front wheel off the ground using a jack, and place blocks beneath the frame under the hydraulic wheel motor (20). 3. Remove lug nuts (1), tire (2) and rim (3), and bearing plate (13). Loosen but do not remove lock nut (24) from hydraulic wheel motor (20) shaft.
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Front Lift Arms 9 7 6 5 8 4 8 10 5 11 14 3 12 15 14 13 23 2 22 16 22 1 2 21 20 21 12 20 16 19 16 18 24 17 29 25 26 30 27 28 67 to 83 ft−lb (91 to 112 N−m) Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Front lift frame Bushing Grease fitting Lift arm Bushing Grease fitting Cotter pin Flat washer Lift cylinder Clevis pin Chassis (Rev. D) 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
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Disassembly (Fig. 10) 5 1. Park machine on a level surface. Make sure engine is off and brake is set. 1 2 67 to 83 ft−lb (91 to 112 N−m) 4 3 2. Remove cutting unit from front lift arm (see Operator’s Manual). 6 3. Disassemble front lift arm as needed using Figures 10 and 11 as guides. 3 Assembly (Fig. 10) 1. Assemble front lift arm using Figures 10 and 11 as guides. A. If clevis (item 29) was removed from front lift frame, torque cap screw from 67 to 83 ft−lb (91 to 112 N−m). B.
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Center Lift Arm 100 to 150 ft−lb (136 to 203 N−m) 36 4 5 3 3 37 2 6 7 1 8 35 2 12 9 11 10 34 11 22 12 24 23 22 25 10 21 20 24 15 13 13 18 19 26 17 14 27 28 29 30 15 18 31 16 33 67 to 83 ft−lb (91 to 112 N−m) 32 Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Center lift arm Bushing Flat washer Cotter pin Lift cylinder Clevis pin Grease fitting Pivot tube Cap screw Jam nut Flange bushing Thrust washer Cap screw Chassis (Rev. D) 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
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Disassembly (Fig. 12) 5 1. Park machine on a level surface. Make sure engine is off and brake is set. 1 2 67 to 83 ft−lb (91 to 112 N−m) 4 3 2. Remove center cutting unit from lift arm (see Operator’s Manual). 6 3. Disassemble center lift arm as needed using Figures 12 and 13 as guides. 3 Assembly (Fig. 10) 1. If lift frame (item 25) was removed from machine: A. Adjust eccentric bushings (item 22) as needed so that lift frame is level when the lift frame is in the raised position. B.
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This page is intentionally blank. Chassis (Rev.
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Chapter 7 SPA and 4−Bolt Cutting Units Table of Contents Backlapping (Units with Backlap/Variable Reel Speed Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rollers and Bedbar Assembly (Single Point Adjust Cutting Units) . . . . . . . . . . Rear Roller and Height−of−Cut Adjuster Removal and Installation . . . . . . . . . . . . . . . . . . Front Roller Removal and Installation . . . . . . . . . Bearing Replacement for Standard Rear Roller ........................................
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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). SPA and 4−Bolt Cutting Units (Rev. A) Maintenance procedures for both cutting units are the same, except where noted.
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Specifications 4−BOLT ADJUST UNIT SINGLE POINT ADJUST UNIT Figure 14 Reel Construction: Reels are 5 inches (13cm) in diameter, 21 inches (53.3 cm) in length. High carbon steel blades are welded to 5 stamped steel spiders and heat treated to RC 48−54 hardness. The reel is ground for diameter, concentricity, and back grind. Reel Bearings: Two double row ball bearings, (30 mm I.D.) are press fitted onto the reel shaft. An inverted seal pressed onto reel shaft.
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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.
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Special Tools Order special tools from your Toro Distributor. Some tools may have been supplied with your mower or available as TORO parts. Some tools may also be available from a local supplier. Gauge Bar Assembly Used to verify height--of--cut. Toro Part No. 13--8199. Figure 3 Backlapping Brush Assembly -- TOR299100 Used to apply lapping compound to cutting units while keeping the operator’s hands at a safe distance from the rotating reel.
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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 19 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.
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Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the 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.
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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.
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Adjustments 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. Slowly rotate reel in the reverse direction listening for reel−to−bedknife contact.
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Adjust Bedknife Parallel to Reel (Single Point Adjust Cutting Units) 1. If the cutting unit is not removed from the machine, remove reel motor from the cutting unit and cutting unit from lift arm (see Cutting Unit Removal and Installation). 2. Position cutting unit on a level surface. 3. Make sure reel contact is removed by turning the bedknife adjuster counterclockwise (Fig. 9). 4. Position cutting unit with the front roller up (Fig. 10). C.
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Adjust Bedknife Parallel to Reel (4--Bolt Adjust Cutting Units) 1. If the cutting unit is not removed from the machine, remove reel motor from the cutting unit and cutting unit from lift arm (see Cutting Unit Removal and Installation). 2 IMPORTANT: Use only a 13mm wrench, 3 to 6 inches (7.5 to 15 cm) in length, when adjusting the hex head screws. A longer wrench will provide too much leverage and may cause distortion of the mounting plate (Fig. 11). 3 2.
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Adjust and Level Front Roller to Reel 1. If the cutting unit is not removed from the machine, remove reel motor from the cutting unit and cutting unit from lift arm (see Cutting Unit Removal and Installation). 1 3 Note: Make sure leveling plate covers the full length of reel blades. Three blades must contact the plate. 2. Position cutting unit on a cutting leveling plate or a known flat and level surface. 2 3.
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Adjust Attitude There are four positions for the front roller brackets. Position 1: The least aggressive position is used for very soft and tender turf, or the highest height− of−cut (Fig. 27). Height−of−Cut (HOC) Range − 1/8 to 1−1/32 inch (3.2 to 26mm) Note: The top frame hole and top bracket hole will yield Position 2 (standard position). Position 2: The standard position is used for most conditions (Fig. 28). HOC Range − 3/32 to 15/16 inch (2.
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4. Position both front brackets as follows: 3 2 Note: The top side plate hole and top bracket hole should yield Position 2 (standard setting). A. Insert eccentric bolt (shoulder bolt) through one of the two positions in the figure 8 hole in the frame and one of the top holes of the front bracket (Fig. 31) so the point on the bracket is at the desired position. 4 B. Screw lock nut onto the eccentric bolt (shoulder bolt). C. Insert carriage screw through the bottom hole of the frame and front bracket.
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Adjust Height−of−Cut Note: Cutting units will deliver differing effective height−of−cuts depending on their configuration. In fact, effective cutting height may be influenced by any of the following factors: turf conditions, roller profiles, cutting unit attitude, cutting unit accessories, weight of cutting units, and bedknife profile. Therefore benchsetting a cutting unit does not equal the effective (actual) height− of−cut you achieve.
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Adjust Front Roller Brush/Scraper 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Loosen socket head screws securing the clamp blocks to the roller shaft. Note: Secure one end of the brush assembly at a time to simplify the following steps. 3. Adjust aggressiveness of the brush/scraper as follows: A. Bristles touching the adjusting gauge bar gives you an aggressive setting. B.
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Service and Repairs Cutting Unit Removal and Installation IMPORTANT: When sharpening, setting height-ofcut, or performing other maintenance procedures on the cutting units, store the cutting unit reel motors in support tubes on the frame to prevent damage to the hoses. Do not raise suspension to transport position when the reel motors are in the holders in the traction unit frame. Damage to the motors or hoses could result. 3 Removal 1.
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Installation Note: New cutting units are shipped with the counter weight mounted to left end and drive coupler mounted in the right end of cutting unit. 1 1. If a cutting unit is to be mounted in the right front position, proceed as follows (Fig. 39): A. Remove both flange head screws and lockwashers securing the counter weight to the left end of cutting unit. Remove counter weight. B. Remove snap ring securing the drive coupler in the right bearing housing. Remove drive coupler. C. Apply No.
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Backlapping (Units without Backlap/Variable Reel Speed Kit) Top Face CAUTION Relief Angle Be careful when backlapping the reel because contact with the reel or other moving parts can result in personal injury. 1. Remove reel motors from the cutting units and cutting units from the lift arms and pull frame (see Cutting Unit Removal and Installation). Remove Burr Front Face Front Angle Figure 27 2.
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Backlapping (Units with Backlap/Variable Reel Speed Kit) DANGER 2 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. 1.
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Rollers and Bedbar Assembly (Single Point Adjust Cutting Units) 37 36 35 34 57 25 29 28 27 26 24 39 38 33 58 10 25 24 23 32 52 31 11 33 54 30 40 8 48 ‘ 50 2 55 21 15 17 18 14 13 22 12 11 49 48 47 42 56 11 41 49 53 20 19 51 10 46 9 16 3 46 4 8 7 6 5 43 1 44 45 Front roller assembly Bedbar and bushing Bedbar Bedknife Special screw Ball stud Lock washer Front bracket Cap screw Flanged bushing Lock nut Flat washer Pivot hub (LH) Flange head nut Cap screw Bracket positio
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Rear Roller and Height−of−Cut Adjuster Removal and Installation Note: Figure 42 shows the Rollers and Bedbar Assembly for a Single Point Adjust (SPA) cutting units. Both the SPA and 4−Bolt cutting units a similar in construction. Roller and Height−of−Cut (H−O−C) Adjuster replacement procedures are the same for each unit. Installation (Fig. 42) 1. Place cutting unit on a level working surface. 2.
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Front Roller Removal and Installation Removal 6 4 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. If removing the cutting unit, remove reel motor from the cutting unit and the cutting unit from lift arm (see Cutting Unit Removal and Installation).
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Bearing Replacement for Standard Rear Roller 1 6 3 2 5 6 4 1 4 6 1.495 to 1.525 inch (3.797 to 3.874 cm) 3 5 Figure 45 1. Roller tube 2. Shaft 3. Shield washer 4. Retaining Ring 5. Grease fitting 6. Bearing B. Make sure dimension of 1.495 to 1.525 inch (3.797 to 3.874 cm) between washer and the end of shaft is maintained. Removal 1. Clean inside of the roller tube around the shaft and shield washer. Both ends of the roller tube should be free of dirt and debris. C.
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Bearing Replacement for Standard Front and Full Front Rollers 5 5 3 4 4 1 2 BEARING RECESS 1 3 STANDARD FRONT ROLLER ILL USTRATED 2 Figure 46 3. Shaft 4. Retaining Ring 5. Grease fitting Removal 1. Clean inside of roller tube around the shaft and bearing. Both ends of the roller tube should be free of dirt and debris. 2. Secure roller tube tube in a vise keeping it level. 3. Remove retaining rings from the both ends of the shaft. 4.
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Bearing Replacement for Wiehle Rear Roller 3 2 1 BEARING AND ROLLER SURFACE MUST BE FLUSH 1 3 2 Figure 47 1. Wiehle roller 2. Machine bearing Note: This procedure is for the Wiehle Rear Roller Kit (Model 04488) only. The Toro part number for the roller is 94−8150. Remove Bearings Note: Use bearing replacement tool kit to remove the roller bearings (see Special Tools). 3. Grease fitting Install New Bearings 1. Make sure bearing cavity of Wiehle roller is clean and free of dirt. Apply No.
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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. 48). 3 3. Remove hex head flange screw (39), flat washer (38), and quad ring (37) from the bedbar (3) on the right side of the unit (Fig. 42). 5 4 4. Remove both pivot screws (30) from the pivot housing (28) and frame.
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Bedknife Adjuster Service (Single Point Adjust Cutting Unit) Removal (Fig. 42) 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 2. Remove both pivot screws (30) from the pivot housing (28). Replace plastic bushings (31) if worn or damaged. 4 3. Unscrew adjuster (29) from the bedbar pivot (50). Disassembly (Fig. 50) 7 1.
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Rollers and Bedbar Assembly (4−Bolt Adjust Cutting Units) 20 21 35 23 22 16 30 19 23 17 32 33 24 34 6 16 13 12 11 19 18 31 10 15 14 29 25 9 29 RIGHT 8 26 27 28 FRONT 5 1 3 6 7 4 Figure 51 Front roller assembly Not used Special screw (13 used) Bedknife Bedbar Front bracket Lock washer Ball stud Cap screw Wheel bolt Shoulder bolt Bracket position decal 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Cap screw Cap screw Height−of −cut collar Lock nut Height−of−cut adj.
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Bedbar Removal and Installation (4−Bolt Adjust Cutting Units) Removal 1 1. Position cutting unit on a clean level surface to allow access to the bedbar and rear roller. 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. 52). 3. Remove bottom hex head screw from each bedbar adjustment bracket located on both sides of the frame (Fig.
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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. 40). 3. Use scraper to remove all rust, scale and corrosion from bedbar surface before installing bedknife. 3 Replacement 1. Make sure bedbar threads are clean. Use new screws. Apply anti--seize lubricant to the screws before installing. Figure 40 1. Screw 2.
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Preparing a Reel for Grinding Note: Check to make sure the reel bearings are in good condition before grinding a reel. 4. 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).
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Reel Assembly 12 10 17 29 13 28 27 23 21 20 27 25 30 22 19 18 31 15 32 24 14 16 12 13 10 11 9 8 RIGHT 7 1 3 2 FRONT 4 5 4 6 Figure 58 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Reel Shield rod Reel frame Flat washer Cap screw Hex head flange screw Counter weight Tapered lock nut Lube fitting Bearing housing Flat wire spring 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
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Reel and Bearing Removal and Installation Removal (Fig. 58) 3 1. Remove reel motor from the cutting unit and the cutting unit from lift arm (see Cutting Unit Removal and Installation). 2. Place cutting unit on a level working surface. 3. Remove shield rod (2) from frame by removing both cap screws (5) and flat washers (4). 4. Remove front roller from the cutting unit (see Front Roller Removal and Installation).
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Installation (Fig. 58) Note: If bearings (12) where removed, grease seals (13) should be replaced. Both bearings should be replaced as a set. Press bearing to here. 1. If bearings (12) and grease seals (13) were removed from the reel shaft (1), install seals and bearings to the shaft as follows: 1 A. Pack both bearings with No. 2 multipurpose lithium base grease. Bearing Surface B. Clean bearing surfaces of reel shaft. Apply antiseize lubricant to both bearing surfaces (Fig. 60). Press seal to here.
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Rear Roller Scraper Removal and Installation 7 8 6 1 4 6 5 9 3 4 2 RIGHT 1 FRONT 2 10 9 Figure 61 1. 2. 3. 4. Flange head nut Hex head screw Bracket (LH) Height−of−cut adjustment bracket 8. Torsion spring (RH) 9. Lock nut 10. Height−of−cut tab 5. Torsion spring (LH) 6. Scraper 7. Bracket (RH) 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.
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Front Roller Brush/Scraper Removal and Installation Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Loosen and remove cap screws securing each end of the roller shaft to the front roller brackets. 3. Remove capscrews and locknuts securing the left front roller bracket to the side plate. 4. Remove front roller from both roller brackets 5. Slide clamp block off each end of the roller shaft.
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This page is intentionally blank. SPA and 4−Bolt Cutting Units (Rev.
PAGE 239
Chapter 7.1 Dual Point Adjust Cutting Units Table of Contents 2 3 5 5 7 7 8 8 8 Bedbar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Bedbar Removal and Installation . . . . . . . . . . . . . . 11 Bedbar Adjuster Service . . . . . . . . . . . . . . . . . . . . 12 Bedknife Replacement and Grinding . . . . . . . . . . 13 Reel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Reel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Left Side Plate Service . .
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Specifications DUAL POINT ADJUST UNIT Figure 1 Height−of−Cut (HOC): Cutting height is adjusted on the front roller by two vertical screws and held by two locking capscrews. Standard bench height of cut range is .062 inch (1.6 mm) to .375 inches (9.5 mm) depending on type of bedknife installed. Bench height of cut range with the High Height of Cut Kit installed is .285 inch (7 mm) to 1 inch (25 mm). Effective HOC may vary depending on turf conditions, type of bedknife, rollers and attachments installed.
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Special Tools Order special tools from your Toro Distributor. Some tools may have been supplied with your mower or available as TORO parts. Some tools may also be available from a local supplier. Gauge Bar Assembly Used to verify height--of--cut. Toro Model Number: 13--8199 Figure 2 Backlapping Brush Assembly Used to apply lapping compound to cutting units while keeping the operator’s hands at a safe distance from the rotating reel.
PAGE 242
Bearing and Seal Installer (TOR4105) Used to install bearings and seals into front and rear rollers that have a threaded roller shaft. NOTE: TOR4105 is an alternative to using washers and spacers listed above. Figure 6 Inner Grease Seal Installation Washer Inner grease seal installation washer Toro Part Number 104-0532 This washer is used when replacing the reel bearing inner grease seal. It enables pressing the grease seal to a depth of .104 in. (2.64 mm) below the surface of the cutting unit side plate.
PAGE 243
Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the cutting unit. It is important to remember that the lower the height−of−cut, the more critical these factors are.
PAGE 244
Factor Possible Problem/Correction Bedknife to reel adjustment Check bedknife to reel contact daily. The bedknife must have light contact across the entire reel. No contact will dull the cutting edges. Excessive contact accelerates wear of both edges. Quality of cut is adversely affected by both conditions (see Bedknife to Reel Adjustment in the Cutting Unit Operator’s Manual). Slightly dull cutting edges may be corrected by backlapping (see Backlapping in this chapter of this manual).
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Set Up and Adjustments Characteristics If a cutting unit is determined to be out of adjustment, complete the following procedures in the specified order to adjust the cutting unit properly. CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop engine and remove key first. The dual knob bedknife−to−reel adjustment system incorporated in this cutting unit simplifies the adjustment procedure needed to deliver optimum mowing performance.
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Service and Repairs Hydraulic Reel Motor IMPORTANT: When performing maintenance procedures on the cutting units, store the cutting unit reel motors in support tubes on the frame to prevent damage to the hoses. Do not raise suspension to transport position when the reel motors are in the holders in the traction unit frame. Damage to the motors or hoses could result. Inspection Removal 1. Coat spline shaft of the motor with clean No. 2 multipurpose lithium base grease. 1.
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Backlapping (Units with Optional Backlap/Variable Reel Speed Kit) DANGER 2 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. Move functional control lever to the Neutral/Backlap position. IMPORTANT: Do not attempt to rotate the directional valve knob when the machine or reels are running. 3. Raise seat and rotate directional valve knob fully clockwise to the backlap position. 4.
PAGE 248
Bedbar Assembly 15 6 4 5 15 9 10 1 5 2 3 16 4 4 17 5 8 7 11 190 to 240 in−lbs (21 to 27 Nm) 14 12 Antiseize Lubricant 13 Figure 12 1. 2. 3. 4. 5. 6. Side plate Rubber bushing Flange bushing Washer (plastic) Washer (metal) Bedbar 7. 8. 9. 10. 11. 12. Dual Point Adjust Cutting Units (Rev. D) Bedbar pivot bolt Flange nut Flange nut Shim Spacer Retainer Page 7.1 − 10 13. 14. 15. 16. 17.
PAGE 249
Bedbar Removal and Installation ÂÂÂÂ ÇÇÇÇ ÂÂÂÂÇÇÇÇ ÂÂÂÂ ÇÇÇÇ ÂÂÂÂ ÂÂÂÂ ÂÂÂÂ ÂÂÂÂ ÂÂÂÂÇÇÇÇ ÂÂÂÂÇÇÇÇ ÂÂÂÂ 6 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 the basket from the cutting unit carrier frame. 3. Disconnect the drive motor from the cutting unit. 4. Disconnect the cutting unit from the pull link. 5.
PAGE 250
Bedbar Adjuster Service 9 6 8 5 7 4 3 2 12 11 10 2 1 15 to 20 ft−lbs (20 to 27 Nm) Figure 14 1. 2. 3. 4. Adjuster shaft Flange bushing Cutting unit frame Wave washer 5. 6. 7. 8. 9. 10. 11. 12. Jam nut Adjuster screw Detent Lock washer Cap screw Washer Spring Lock nut Removal (Fig. 14) Installation (Fig. 14) 1. Remove bedbar (see Bedbar Removal in this section of this manual). 1.
PAGE 251
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. 15). 3. Use scraper to remove all rust, scale and corrosion from bedbar surface before installing bedknife. 3 Replacement 1. Make sure bedbar threads are clean. Use new screws. Apply clean SAE 30 oil to the screws before installing. Figure 15 1. Screw 2.
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Reel Assembly 21 24 20 23 19 22 8 9 10 17 11 12 25 13 18 3 16 2 13 #2 General Purpose Grease 17 to 20 ft−lbs (23 to 27 Nm) 14 12 15 6 1 7 4 RIGHT 5 FRONT 8 2 #2 General Purpose Grease 9 3 Figure 18 1. 2. 3. 4. 5. 6. 7. 8. 9. Reel Speedi sleeve V−ring Drive coupler Retaining ring Left side plate assembly Shoulder bolt Bearing lock nut Outer grease seal 10. 11. 12. 13. 14. 15. 16. 17. Dual Point Adjust Cutting Units (Rev.
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Reel Removal (Fig. 18) 1. Remove reel motor from the cutting unit (see Hydraulic Reel Motor Removal in this chapter). 2. Remove the 2 capscrews securing the counter weight to the side plate (Fig. 19). Remove the counter weight. 1 3. Remove the bedbar assembly (see Bedbar Removal in this chapter). Note: Depending on tools available, it may be necessary to remove the reel motor adapter plate before removing the left end bearing lock nut (8). 4.
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Left Side Plate Service (Fig. 18) Right Side Plate Service (Fig. 18) 1. Remove the inner grease seal (13) and outer grease seal (9) from the side plate (6). 1. Remove the inner grease seal (13) and outer grease seal (9) from the side plate (10). 2. Remove the retaining ring (14) securing the bearing in the side plate. Remove the bearing (12). Inspect the bearing to insure that it spins freely and has minimal axial play. The bearing balls must be free of deformation and scoring.
PAGE 255
Reel Service (Fig. 18) 3 Note: Install new reel components on each end of the reel shaft that mates with newly serviced side plate components. 1. Remove the retaining ring (5) and the drive coupler (4) from the end of the reel shaft. 2. Remove the V−ring (3) from the reel shaft. 2 1 3. Using a flat blade screw driver or similar tool, remove the speedi sleeve (2) from the reel shaft. Figure 21 Note: Replacement Seal Kit (Toro Part No.
PAGE 256
Reel Installation (Fig. 18) IMPORTANT: Wipe any excess grease from the inner grease seals (13) where the reel shaft V−rings (3) make contact. The V−rings should run dry. 1. Slide the left hand side plate (6) onto the reel shaft. Make sure the reel shaft threads do not damage the grease seals in the side plate. 2. Apply a film of No. 2 general purpose grease to the reel shaft threads and install the left side reel bearing locknut (8). 3. Slide the right hand side plate (10) onto the reel shaft.
PAGE 257
Preparing a Reel for Grinding Note: Check to make sure the reel bearings are in good condition before grinding a reel. 4. 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).
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PAGE 259
Front Roller Removal and Installation Removal (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. 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. 6 2. Loosen cap screws securing the roller shafts to each front bracket. 4 5 2 3.
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Roller Service (Roller Shaft with Circlip) 4 v 1 2 3 6 5 Figure 26 1. 2. Roller seal Spiral retaining ring 3. 4. Roller bearing Rear roller body 5. 6. Seal Removal Roller shaft Front roller body .188 in. dia (2) 1. Make a seal removal tool from a 1/4 x 3 x 3 in. (.63 x 7.6 x 7.6 cm) piece of steel as shown (Fig. 27). 2. Slide seal removal over roller end of roller shaft. 3. Use the tool as a template to locate, mark, and drill two 7/64 in. diameter holes in the outer face of the seal. .625 in.
PAGE 261
Bearing Removal 2 Note: Replace both roller bearings as a set after a bearing failure. 3 1 1. Remove the roller seals (see Roller Seal Removal in this chapter of this manual). 2. Remove both spiral retaining rings from the roller shaft. 5 Note: Roller bearings have a press fit into the roller body and a slip fit on the roller shaft. 3. Loosely secure roller body in a vise. Lightly tap one end of the roller shaft with a plastic hammer to drive the shaft and one of the bearings from the roller body.
PAGE 262
Roller Service (Threaded Roller Shaft) 1 7 6 5 4 2 4 5 6 7 3 Figure 29 1. 2. 3. Wiehle roller Smooth roller Roller shaft 4. 5. Ball bearing Seal 6. 7. Disassembly 1 1. To hold roller shaft for bearing lock nut removal, install a 3/8−24 UNF 2B screw into threaded end of roller shaft and secure in place with jam nut. While retaining shaft, remove bearing lock nut from each end of roller shaft. 2 V−ring Bearing lock nut 3 4 5 6 2. Remove v−ring from each end of roller. 3.
PAGE 263
Note: Special tool TOR4105 (see Special Tools) can be used instead of washers and spacer when installing bearings and seals in roller. 2 3 1 4 2. Position a new bearing, black assembly washer (see Special Tools) and original lock nut onto each end of the roller shaft (Fig. 31). 3. Tighten nuts until the bearings are seated into each end of the roller. 4. Remove nut and black assembly washer from each end of the roller.
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PAGE 265
Chapter 7.2 Groomer (DPA Cutting Unit) Table of Contents 2 3 3 4 4 5 6 6 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 7 Groomer Belt Replacement . . . . . . . . . . . . . . . . . . . 7 Groomer Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Groomer Reel Service . . . . . . . . . . . . . . . . . . . . . . . 11 Groomer Reel Bearing Replacement . . . . . . . . . 12 Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Lift Arm Assembly . . . . . . .
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Specifications MOUNTING: The groomer is mounted to the Dual Point Adjust (DPA) cutting reel bearing housings and frame. REEL CONSTRUCTION: 2.375 inch (6 cm) diameter, 41 steel blades with 1/2 inch blade spacing. Blade spacing can be adjusted to 1/4 inch or 3/4 inch by altering the position of blade spacers on the groomer. GROOMER PENETRATION: From .410 inch (10.4 mm) above ground level to 0.125 inch (3.2 mm) below ground level, at mowing HOC range of .062 to .296 inch (1.6 to 7.5 mm).
PAGE 267
General Information Groomer Position IMPORTANT: Before changing groomer position, make certain that the reel drive is in the disengaged position and that the cutting reel is not rotating. To place the groomer reel in the raised, non−grooming position, remove the lock screw and rotate the lift arm to raise the groomer reel. Install the lock screw to retain the groomer reel in the non−grooming position (Fig. 1).
PAGE 268
Troubleshooting Factors Affecting Grooming There are a number of factors that can affect the performance of grooming. These factors vary for different golf courses and from green to green. It is important to inspect the turf frequently and vary the grooming practice with turf needs. It is important to remember that factors affecting quality of cut also affect grooming performance.
PAGE 269
Groomer Reel Mechanical Problems Problem Possible Causes Correction The groomer reel rotates when it is in the raised, transport position. The groomer reel should rotate whenever the cutting reel is engaged. Normal operation. No rotation of the groomer reel. Seized groomer reel or idler bearing(s) in groomer side plate(s). Identify and replace faulty bearing(s). Broken or damaged idler spring. Replace spring. The groomer belt is worn, broken or If the belt slips, it probably is worn damaged.
PAGE 270
Adjustments CAUTION Never work on the cutting unit with the engine running. Always stop the engine and remove the key from the ignition switch before working on the mower. Note: See Cutting Unit Operator’s Manual for adjustment procedures for the cutting units on the Greensmaster 3250−D. Height/Depth of Groomer Adjustment Note: Grooming is performed above the soil level. When adjusting groomer height/depth, groomer blades should never penetrate the soil. 1 2 1.
PAGE 271
Service and Repairs Groomer Belt Replacement 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition switch. 1 2 2. If equipped, remove rotating rear roller brush from cutting unit. 3. Remove two (2) lock nuts that secure groomer belt cover, then remove cover (Fig. 4). 3 4. Pivot idler pulley by placing a 12mm wrench on pulley nut and rotating idler bracket to relax belt tension.
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Groomer Reel 100 to 120 in−lbs (11.3 to 13.5 N−m) 19 18 15 16 17 14 13 12 20 Antiseize Lubricant 21 22 11 23 Loctite #242 24 10 25 27 7 27 28 60 to 80 ft−lbs (81 to 108 N−m) 100 in−lbs (11.3 N−m) 9 8 26 6 5 3 31 4 2 1 25 RIGHT 30 29 FRONT 23 24 32 17 100 to 120 in−lbs (11.3 to 13.5 N−m) 34 35 20 33 36 1 37 Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
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6. Remove lock nut (item 25) and spring washer (item 24) that secure drive side groomer arm lift rod to drive side plate (Fig. 7). 3 7. Remove lock nut (item 35), tab washer (item 34) and plow bolt (item 27) that secure drive side groomer arm assembly to drive side plate. Do not change height−of− cut screw adjustment. Remove drive side groomer arm assembly from cutting unit. 4 8. Remove front roller assembly from cutting unit.
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5. Carefully place drive side plate onto groomer shaft taking care not to damage seals in side plate. Position side plate to the cutting unit frame and secure with two shoulder nuts (item 8). 13.Apply antiseize lubricant to threads of lift arm assembly stud on groomer arm. Install spring washer (item 24) and lock nut (item 25) to secure drive side groomer arm assembly to groomer side plate (Fig. 7). 6. Apply grease to drive pulley splines and pulley hub taking care not to get grease on belt surface.
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Groomer Reel Service Disassembly (Fig. 10) 200 to 250 in−lbs (22.6 to 28.3 N−m) Inspect groomer reel blades frequently for damage and wear. Straighten bent blades with a pliers. Either replace worn blades or reverse worn blades on the groomer shaft to put the sharpest blade edge forward (Fig. 11). Blades that are rounded to the midpoint of the blade tip must be replaced or reversed for best groomer performance. 2 3 1 4 1. Remove groomer reel (see Groomer Reel Removal in this section). 2.
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Groomer Reel Bearing Replacement 6 2 3 5 4 2 3 3 Seal lip (toward center of cutting unit) Seal lip (toward center of cutting unit) 5 7 Seal lip (toward center of cutting unit) 2 6 1 Figure 13 1. Drive side plate (LH shown) 2. Oil seal 3. Groomer reel bearing 4. Grease fitting 5. Bushing Note: The groomer reel drive is located on the opposite side of the cutting unit from the cutting reel hydraulic motor. Figure 13 shows the groomer reel drive from the left side of the cutting unit.
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Bearing Installation 2 1. Install new bearings in both side plate assemblies (Fig. 13): 1 3 4 A. Slide new bearings into non−drive side plates. Position extended inner race of bearings toward center of side plate housing. B. Press new bearings into drive side plates applying pressure to outer bearing race only. Position extended inner race of bearings toward center of side plate housing. C. Install new seals into side plates.
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Idler Assembly 6 8 7 14 7 Seal lip (toward center of cutting unit) Seal lip (toward center of cutting unit) 5 6 3 2 1 10 11 4 12 9 13 Figure 16 1. 2. 3. 4. 5. Lock nut Flat washer Retaining ring Idler bearing Idler pulley 6. 7. 8. 9. 10. 11. 12. 13. 14. Seal Bearing Grease fitting Groomer drive side plate (LH shown) Pivot hub The groomer drive side plate assembly incorporates the idler system for tensioning the groomer drive belt.
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Lift Arm Assembly 1 14 2 13 11 15 7 12 10 8 Antiseize Lubricant 9 7 6 16 3 4 17 Antiseize Lubricant 18 5 Antiseize Lubricant Figure 18 HOC groomer arm (LH shown) Flange nut Grooved pin E−ring Groomer lift rod Lock screw 7. 8. 9. 10. 11. 12. Bushing Lift arm assembly (LH shown) Detent spring Spring washer Cap screw Bushing 13. 14. 15. 16. 17. 18. Wave washer Groomer adjuster Side plate (LH shown) Lock nut Spring washer Bushing Disassembly Assembly 1.
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Groomer Brush 3 4 3 2 20 to 25 in−lbs (2.3 to 2.8 N−m) 1 20 to 25 in−lbs (2.3 to 2.8 N−m) 2 Figure 19 1. Groomer brush shaft 2. Lock nut 3. J−bolt 4. Groomer brush The groomer brush attaches to the groomer drive in place of the groomer reel. Removal and installation of the groomer brush uses the same procedure as removal and installation of the groomer reel (see Groomer Reel in this section).
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Chapter 8 Electrical Diagrams Table of Contents Greensmaster 3250−D Page 8 − 1 Rev. H Electrical Diagrams ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . 3 Serial Number Below 210000000 . . . . . . . . . . . . . 3 Serial Number Between 210000000 and 230000600 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Serial Number Between 230000600 and 240999999 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Serial Number Between 250000000 and 250999999 . . . . . . . . . . . . . . . .
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Y DAIHATSU GLOW PLUG CONTROLLER 5 1 4 VIO R D6 R FUSELINK 2 IGNITION SWITCH B+ R/W RUN RELAY (R1) D5 GN/BK R GY/W HIGH TEMP SWITCH 86 Y/R OPTIONAL BACKLAP RELAY (R9) Y FUSELINK 1 87 85 BN FUSELINK 3 87a 30 86 BK 2 HIGH TEMP RELAY (R2) GLOW PLUGS 87 6 3 (−) 30 (+) BU/W GLOW RELAY 85 BATTERY ETR SOLENOID (PART OF INJECTION PUMP) HIGH TEMP OVERRIDE SWITCH Y RED 85 86 85 87a 85 BK 86 30 87a OFF RUN START BU/BK OR/BK R Start MOW RELAY (R3) 87 30 87 Y/BK
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Page 8 − 4 Rev. H BK BLACK R RED BU BLUE T TAN BN BROWN GY GRAY GN GREEN OR ORANGE PK PINK VIO W Y SP VIOLET WHITE YELLOW SPLICE FUSIBLE LINK Greensmaster 3250−D (Serial Number Between 210000000 and 230000600) Electrical Schematic All relays and solenoids are shown as de−energized.
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BK BLACK R BU BLUE T BN BROWN GY GRAY GN GREEN OR ORANGE PK PINK VIO W Y SP RED TAN VIOLET WHITE YELLOW SPLICE FUSIBLE LINK Greensmaster 3250−D (Serial Number Between 230000600 and 240999999) Electrical Schematic All relays and solenoids are shown as de−energized. Page 8 − 5 Rev.
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BK BLACK R RED BU BLUE T TAN BN BROWN GY GRAY GN GREEN OR ORANGE PK PINK VIO W Y SP VIOLET WHITE YELLOW SPLICE FUSIBLE LINK Greensmaster 3250−D (Serial Number Between 250000000 and 250999999) Electrical Schematic All relays and solenoids are shown as de−energized. Page 8 − 6 Rev.
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BK BLACK R RED BU BLUE T TAN BN BROWN GY GRAY GN GREEN OR ORANGE PK PINK VIO W Y SP VIOLET WHITE YELLOW SPLICE FUSIBLE LINK Greensmaster 3250−D (Serial Number Between 260000000 and 260999999) Electrical Schematic All relays and solenoids are shown as de−energized. Page 8 − 7 Rev.
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BK BLACK R RED BU BLUE T TAN BN BROWN GY GRAY GN GREEN OR ORANGE PK PINK VIO W Y SP VIOLET WHITE YELLOW SPLICE FUSIBLE LINK Greensmaster 3250−D (Serial Number Above 270000000) Electrical Schematic All relays and solenoids are shown as de−energized. Page 8 − 8 Rev.
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Y DAIHATSU GLOW PLUG CONTROLLER 5 1 4 VIO R GN/BK FUSELINK 2 IGNITION SWITCH B+ R/W RUN RELAY (R1) D5 D6 R R GY/W HIGH TEMP SWITCH 86 Y/R OPTIONAL BACKLAP RELAY (R9) Y FUSELINK 1 87 85 BN FUSELINK 3 87a 30 86 BK 2 HIGH TEMP RELAY (R2) GLOW PLUGS 87 6 3 (−) 30 (+) BU/W GLOW RELAY 85 BATTERY ETR SOLENOID (PART OF INJECTION PUMP) HIGH TEMP OVERRIDE SWITCH Y RED 85 86 85 87a 85 BK 86 30 87a OFF RUN START BU/BK OR/BK R Start MOW RELAY (R3) 87 30 87 Y/B
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Y DAIHATSU GLOW PLUG CONTROLLER 6 2 5 1 4 R HIGH TEMP RELAY (R2) GLOW PLUGS 87 3 VIO 87a 30 87 85 30 (−) 86 (+) BU/W GLOW RELAY 85 BATTERY ETR SOLENOID (PART OF INJECTION PUMP) HIGH TEMP OVERRIDE SWITCH Y GY/W HIGH TEMP SWITCH 86 Y/R OPTIONAL BACKLAP RELAY (R9) BK Y BN FUSELINK 3 D6 R GN/BK FUSELINK 2 IGNITION SWITCH FUSELINK 1 R B+ R/W RUN RELAY (R1) D5 RED 85 86 85 87a 85 BK 86 30 87a OFF RUN START BU/BK OR/BK R Start MOW RELAY (R3) 87 30 87 Y/BK B
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Y DAIHATSU GLOW PLUG CONTROLLER 6 2 5 1 4 R HIGH TEMP RELAY (R2) GLOW PLUGS 87 3 VIO 87a 30 87 85 30 (−) 86 (+) BU/W GLOW RELAY 85 BATTERY ETR SOLENOID (PART OF INJECTION PUMP) HIGH TEMP OVERRIDE SWITCH Y GY/W HIGH TEMP SWITCH 86 Y/R OPTIONAL BACKLAP RELAY (R9) BK Y BN FUSELINK 3 D6 R RUN RELAY (R1) D5 GN/BK FUSELINK 2 FUSELINK 1 IGNITION SWITCH R B+ R/W RED 85 86 85 87a 85 BK 86 30 87a OFF RUN START BU/BK OR/BK R Start MOW RELAY (R3) 87 30 87 Y/BK B
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Y DAIHATSU GLOW PLUG CONTROLLER 6 2 5 1 4 R HIGH TEMP RELAY (R2) GLOW PLUGS 87 3 VIO 87a 30 87 85 30 (−) 86 (+) BU/W GLOW RELAY 85 BATTERY ETR SOLENOID (PART OF INJECTION PUMP) HIGH TEMP OVERRIDE SWITCH Y GY/W HIGH TEMP SWITCH 86 Y/R OPTIONAL BACKLAP RELAY (R9) BK Y BN FUSELINK 3 D6 R GN/BK FUSELINK 2 IGNITION SWITCH FUSELINK 1 R B+ R/W RUN RELAY (R1) D5 RED 85 86 85 87a 85 BK 86 30 87a OFF RUN START BU/BK OR/BK R Start MOW RELAY (R3) 87 30 87 Y/BK B
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Y DAIHATSU GLOW PLUG CONTROLLER 6 2 5 1 4 R HIGH TEMP RELAY (R2) GLOW PLUGS 87 3 VIO 87a 30 87 85 30 (−) 86 (+) BU/W GLOW RELAY 85 BATTERY ETR SOLENOID (PART OF INJECTION PUMP) HIGH TEMP OVERRIDE SWITCH Y GY/W HIGH TEMP SWITCH 86 Y/R OPTIONAL BACKLAP RELAY (R9) BK Y BN FUSELINK 3 D6 R GN/BK FUSELINK 2 FUSELINK 1 IGNITION SWITCH R B+ R/W RUN RELAY (R1) D5 RED 85 86 85 87a 85 BK 86 30 87a OFF RUN START BU/BK OR/BK R Start MOW RELAY (R3) 87 30 87 Y/BK
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Y DAIHATSU GLOW PLUG CONTROLLER 6 2 5 1 4 R HIGH TEMP RELAY (R2) GLOW PLUGS 87 3 VIO 87a 30 87 85 30 (−) 86 (+) BU/W GLOW RELAY 85 BATTERY ETR SOLENOID (PART OF INJECTION PUMP) HIGH TEMP OVERRIDE SWITCH Y GY/W HIGH TEMP SWITCH 86 Y/R OPTIONAL BACKLAP RELAY (R9) BK Y BN FUSELINK 3 D6 R RUN RELAY (R1) D5 GN/BK FUSELINK 2 FUSELINK 1 IGNITION SWITCH R B+ R/W RED 85 86 85 87a 85 BK 86 30 87a OFF RUN START BU/BK OR/BK R Start MOW RELAY (R3) 87 30 87 Y/BK B
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2 1 3 4 5 RELAY #4 P14 SEAT SWITCH P3 HYD SOLENOID #2 P5 BA ALTERNATOR HYD SOLENOID #4 P4 BA 2 1 J4 P2 DIODE CONNECTOR 2 P9 HYD SOLENOID #3 P7 HYD SOLENOID #1 P8 5 4 3 1 2 P13 RELAY #3 5 4 3 1 2 P12 RELAY #2 5 4 3 1 2 P11 RELAY #1 LOWER TIMER J16 J17 J18 2 1 3 OPTIONAL LIGHTS J7 BACKLAP KIT J5 HG FE D C BA HIGH TEMP J8 OVERIDE J9 P34 WATER IN FUEL LIGHT 2 1 NEUTRAL MOW SENSOR SENSOR P15 P16 AB BA J6 AB WARNING LIGHT P18 CLUSTER BA P10 RAISE JOYSTICK 1 2 P19 3 BACKLAP SWITCH J
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P2 J4 B+ P3 1 2 W4 W1 OIL PRESSURE P33 W6 W3 SP2 W3 W10 P5 A B W13 W14 W17 W12 SP3 P4 A B P7 A B W23 W29 W27 P9 A B H G F W34 W35 W32 W33 W31 BACKLAP BACKLAP KIT SWITCH DIODE CONNECTOR #2 P8 A B W24 W21 HYDRAULIC SOLENOID #1 E P10 D C B A J5 A B W36 W50 W45 RELAY #1 P11 RELAY #2 P12 W49 30 85 87A 87 86 J3 B+ HYDRAULIC SOLENOID #3 30 85 87A 87 86 J2 B+ HYDRAULIC SOLENOID #2 W41 W42 J1 B+ HYDRAULIC SOLENOID #4 W14 W15 W44 W43 P1 SEAT SWITCH ALTERNATOR
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RELAY #4 RELAY #3 RELAY #2 RELAY #1 HYD SOL #2 ALTERNATOR STARTER B+ HYD SOL #3 HYD SOL #1 HYD SOL #4 RELAY #8 RELAY #7 GLOW PLUG CONTROLLER RELAY #6 GLOW PLUGS RELAY #5 Greensmaster 3250−D (Serial Number Between 210000000 and 230000600) Electrical Harness Drawing Page 8 − 18 Rev.
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GLOW PLUG CONTROLLER Greensmaster 3250−D (Serial Number Between 210000000 and 230000600) Wiring Diagram Page 8 − 19 Rev.
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START RELAY MOW RELAY HIGH TEMP RELAY HYD SOL #6 RUN SAFETY RELAY HYD SOL #2 STARTER B+ ALTERNATOR HYD SOL #4 HYD SOL #3 HYD SOL #1 START SAFETY RELAY JOYSTICK RELAY LOWER RELAY GLOW PLUG CONTROLLER GLOW PLUGS RAISE RELAY Greensmaster 3250−D (Serial Number Between 230000600 and 240999999) Electrical Harness Drawing Page 8 − 20 Rev.
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GLOW PLUG CONTROLLER Greensmaster 3250−D (Serial Number Between 230000600 and 240999999) Wiring Diagram Page 8 − 21 Rev.
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START RELAY MOW RELAY HIGH TEMP RELAY HYD SOL S6 HIGH TEMP OVERRIDE RUN SAFETY RELAY HYD SOL S2 STARTER B+ WATER IN FUEL LIGHT ALTERNATOR HYD SOL S4 HYD SOL S1 HYD SOL S3 STARTER B+ OIL PRESSURE ALT ”L” BACKLAP SWITCH OVERTEMP GLOW RESISTOR STARTER START SAFETY RELAY FUSEBLOCK JOYSTICK RELAY LOWER RELAY GLOW PLUG CONTROLLER GLOW PLUGS RAISE RELAY GLOW RELAY BACKLAP RELAY Greensmaster 3250−D (Serial Number Between 250000000 and 250999999) Electrical Harness Drawing Page 8 − 22 Rev.
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GLOW PLUG CONTROLLER Greensmaster 3250−D (Serial Number Between 250000000 and 250999999) Wiring Diagram Page 8 − 23 Rev.
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START RELAY MOW RELAY HIGH TEMP RELAY HYD SOL S6 HIGH TEMP OVERRIDE RUN SAFETY RELAY HYD SOL S2 ALTERNATOR WATER IN FUEL LIGHT STARTER B+ HYD SOL S4 HYD SOL S3 HYD SOL S1 STARTER B+ OIL PRESSURE ALT ”L” BACKLAP SWITCH OVERTEMP GLOW RESISTOR STARTER START SAFETY RELAY FUSEBLOCK JOYSTICK RELAY LOWER RELAY GLOW PLUG CONTROLLER GLOW PLUGS RAISE RELAY GLOW RELAY BACKLAP RELAY Greensmaster 3250−D (Serial Number Between 260000001 and 260999999) Electrical Harness Drawing Page 8 − 24 Rev.
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GLOW PLUG CONTROLLER Greensmaster 3250−D (Serial Number Between 260000001 and 260999999) Wiring Diagram Page 8 − 25 Rev.
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Greensmaster 3250−D (Serial Number Above 270000000) Electrical Harness Drawing Page 8 − 26 Rev.
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Greensmaster 3250−D (Serial Number Above 270000000) Wiring Diagram Page 8 − 27 Rev.
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