Form No.
Revision History Revision Date Description -- 2012 A 02/2018 Added revision history. B 04/2018 Revised bedknife installation procedure, added Universal Groomer chapter. C 06/2020 Added 2 schematics, 2 wire harnesses, reel restraining, universal groomer shaft repair Initial Issue. © THE TORO COMPANY 2020 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies).
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
NOTES _
Part No. 12186SL Rev. C Service Manual (Model 04384) 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 04384). REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
This page is intentionally blank.
Chapter 6 − Chassis Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 − 2 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 − 4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . Chapter 4 − Hydraulic System Specifications . . . . . . .
This page is intentionally blank.
Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
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.
1. Do not run the engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could be deadly. 2. Sit on the seat when starting and operating the machine. 3. Check the operation of the interlock switches daily for proper operation (see Verify Interlock System Operation in Chapter 5 − Electrical System). Replace any malfunctioning switches before operating the machine. 4. To start the engine: A. Sit on the seat, make sure cutting units are disengaged. B.
Maintenance and Service 1. Before servicing or making adjustments to the machine, stop the engine, remove key from switch to prevent accidental starting of the engine. 2. Be sure entire machine is in good operating condition. Keep all nuts, bolts, screws and hydraulic fittings tight. 3. Make sure all hydraulic line connectors are tight,and all hydraulic hoses and lines are in good condition before applying pressure to the system. 9. Do not overspeed the engine by changing governor settings.
Chapter 2 Product Records and Maintenance Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . .
Equivalents and Conversions 0.
Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. 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.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size # 6 − 32 UNC 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 − 40 UNF # 8 − 32 UNC 13 + 2 25 + 5 282 + 30 # 8 − 36 UNF # 10 − 24 UNC 18 + 2 30 + 5 339 + 56 # 10 − 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) SAE
Thread Size 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 1.5 38 + 4 ft−lb 52 + 5 N−m 53 + 5 ft−lb 72 + 7 N−m M12 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Recommended Torque 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.
Chapter 3 Diesel Engine Table of Contents Greensmaster 3250−D Page 3 − 1 Diesel Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel Shut−off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Adjust Throttle Control . . . . . . . . . . . . . . . . . . . .
This page is intentionally blank.
Specifications Item Description Make / Designation Kubota water−cooled, Diesel, Model D902−E3B Number of Cylinders 3 2.83” x 2.9” (72mm x 73.6mm) Total Displacement 54.8 in3 (898 cc) Compression Ratio 24.
General Information Information about specifications, maintenance, troubleshooting, testing and repair of the diesel engine used in the Greensmaster 3250−D is included in this chapter and the Kubota Workshop Manual, Diesel Engine, SM−E3B Series. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Kubota Workshop Manual. The use of some specialized test equipment is explained.
Adjustments Adjust Throttle Control Proper throttle operation is dependent upon proper adjustment of throttle control. Make sure throttle control is operating properly. NOTE: The throttle cable swivel should be positioned in the lowest hole in the speed control lever. 2. Check position of the engine speed control lever on fuel injection pump (Fig. 2). The speed control lever should be contacting the high speed screw when the throttle control lever is in the FAST position. 3.
Service and Repairs Air Cleaner 2 RIGHT 3 4 FRONT 1 5 9 11 10 6 7 8 9 Figure 4 1. 2. 3. 4. Air cleaner assembly Air inlet hood Mounting bracket Hose clamp (2 used) Diesel Engine 5. 6. 7. 8. Air cleaner hose Flange head screw R−clamp Cap screw (2 used) Page 3 − 6 9. Flange nut (4 used) 10. Air cleaner bracket 11.
Air Cleaner Removal (Fig. 4) 5 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. Remove air cleaner components as needed using Figure 4 as a guide. 3. Check air cleaner hose (item 5 in Fig. 4) for damage or wear. Replace hose if damage is found. 1 4. Disassemble air cleaner as necessary (Fig. 5). 5. Check air cleaner housing and cover for damage that could cause possible air leaks.
Exhaust System 17 6 2 1 2 3 4 16 15 12 14 13 2 3 5 11 10 2 2 RIGHT 9 3 6 FRONT 8 7 Figure 6 1. 2. 3. 4. 5. 6. Muffler Flat washer (10 used) Lock nut (4 used) Upper muffler mount Piston pump Cap screw (6 used) Diesel Engine 7. 8. 9. 10. 11. 12. Lower muffler mount Flange nut Engine mount Exhaust support Flange head screw Exhaust pipe Page 3 − 8 13. 14. 15. 16. 17.
Exhaust System Removal (Fig. 6) 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 CAUTION 2 2. Remove exhaust system components as needed using Figure 6 as a guide. Diesel Engine The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the muffler. 3 Exhaust System Installation (Fig. 6) 1. Make sure the engine is off.
Radiator 16 20 17 15 3 20 23 1 3 9 5 12 9 21 18 18 7 24 22 2 1 8 6 13 10 19 4 RIGHT 14 11 FRONT 7 21 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. Hose clamp (4 used) Lower radiator hose Hose connector (2 used) Radiator Upper cooler bracket Flat washer (4 used) Washer head screw (2 used) Radiator support 9. 10. 11. 12. 13. 14. 15. 16.
4. If machine is equipped with optional hydraulic oil cooler (Fig. 9), drain hydraulic reservoir and remove oil cooler (see Oil Cooler in the Service and Repairs section of Chapter 4 − Hydraulic System). B. Secure upper rear corner of radiator support to frame with flange head screw (item 18) and flange nut (item 9). C. Secure the upper front radiator support tab to the frame with washer head screw (item 7). 5. Remove the following hoses from the radiator: D.
Fuel Tank 1 32 RIGHT 15 2 FRONT 26 12 14 17 10 18 5 10 6 9 26 11 25 3 20 26 20 27 24 19 8 16 13 7 22 4 21 26 23 22 31 28 Antiseize Lubricant 30 to 60 in−lb (3.4 to 6.8 N−m) 6 29 30 22 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Fuel cap Fuel tank Flange bushing (3 used) Flat washer (3 used) Overflow tank (coolant) Washer head screw (4 used) Flange head screw (3 used) Fuel hose Straight fitting Hose clamp (2 used) Fuel fitting Diesel Engine 12. 13. 14. 15. 16. 17. 18. 19.
Fuel Tank Removal (Fig. 10) 1. Park machine on a level surface, lower cutting units, stop the engine, engage parking brake and remove the key from the ignition switch. 8. If necessary, remove shut−off valve and fitting assembly from fuel tank (Fig. 11). The nut and fitting have left hand threads. Fuel Tank Installation (Fig. 10) 1. Install fitting assembly and shut−off valve into fuel tank if they were removed from tank (Fig. 11). The nut and fitting have left hand threads. Diesel fuel is flammable.
Engine 6 7 RIGHT 9 FRONT 10 5 8 11 12 20 20 13 13 1 3 14 15 2 4 16 20 17 18 19 21 Figure 12 1. 2. 3. 4. 5. 6. 7. Engine assembly Ground harness Flange head screw Negative (−) battery cable Support bracket Engine mount Cap screw (3 used) Diesel Engine 8. 9. 10. 11. 12. 13. 14. Flange head screw (4 used) Flange head screw (6 used) Engine mount (3 used) Mount spacer (3 used) Flange head screw (2 used) Flange nut (10 used) Washer (3 used) Page 3 − 14 15. 16. 17. 18. 19. 20. 21.
Engine Removal (Fig. 12) 4 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 5 1 3 CAUTION 2 The engine, radiator, exhaust system and hydraulic system may be hot. To avoid possible injury, allow machine to cool before working on the engine. Diesel Engine 2. Close fuel shut−off valve on fuel tank. 3. Remove air cleaner and air intake hose from machine (see Air Cleaner in this section). 4.
Loctite #242 27 to 33 ft−lb (37 to 44 N−m) CAUTION 1 8 Support the hydraulic pump assembly when removing its supporting fasteners to prevent it from falling and causing damage or personal injury. 6 9. Support hydraulic pump assembly to prevent it from moving during engine removal. 3 4 FRONT Figure 16 When removing engine assembly, make sure lift or hoist can safely support 190 lbs (86 kg). 11. Attach a suitable lift or hoist to engine.
8. Connect all electrical harness connectors to engine using labels placed during engine removal. 9. Connect throttle cable to the swivel on injector pump speed control lever (Fig. 14). Adjust cable (see Adjust Throttle Control in the Adjustments section of this chapter). 13.Remove plugs placed during engine removal from fuel hoses. Connect fuel supply hose to the injector pump fitting and fuel return hose to the #3 injector fitting. Secure fuel hoses with hose clamps. 14.
Engine Bell Housing 1 Loctite #242 17 to 21 ft−lb (23 to 28 N−m) 6 2 4 3 FRONT 5 RIGHT Loctite #242 17 to 21 ft−lb (23 to 28 N−m) Figure 17 1. Engine 2. Flange head screw (5 used) 3. Bell housing 4. Coupling flange 5. Flange head screw (4 used) 6. Spring pin Removal (Fig. 17) Installation (Fig. 17) NOTE: The hydraulic pump assembly needs to be removed from engine before bell housing and coupling flange can be removed. 1.
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 . . . . . . . . . .
This page is intentionally blank.
Specifications Item Description Piston (Traction) Pump Maximum Pump Displacement (per revolution) Charge Pressure Variable displacement piston pump 1.24 in3 (20.3 cc) 100 to 150 PSI (7 to 10 bar) Gear Pump Front Section (cutting reels) Displacement (per revolution) Rear Section (steering/lift) Displacement (per revolution) 2 section, positive displacement gear pump 0.58 in3 (9.5 cc) 0.33 in3 (5.4 cc) Front Wheel Motors Displacement (per revolution) Orbital rotor motor 10.
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.
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. 1 2 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 rear side of the piston pump. Rotate valve 90o so the slot in the valve is vertical. Figure 2 1. Piston pump 2.
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.
Hydraulic Hose and Tube Installation (O−Ring Face Seal Fitting) 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. 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. 2.
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.
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.
Hydraulic System Page 4 − 10 EXPANSION TANK BREATHER LEAK IN DETECTOR VOLUME OUT OPTIONAL LEAK DETECTOR KIT G1 BACKLAP SWITCH (SW) MA P1 FC1 LC OR1 0.013 T PRV 550 PSI CENTER REEL (#1) FILTER .73 S1R1 SUCTION STRAINER OR2 0.060 MR MB LEFT FRONT REEL (#2) .73 .73 FRONT RIGHT REEL (#3) P2 OPTIONAL OIL COOLER 25 PSI G2 0.055” L2B CU #2 2.0” Bore 0.75” Rod 1.75” Stroke L1A S2 S3 GEAR PUMP .33 R2 400 PSI FC2 7.0 GPM L2A CU #1 2.0” Bore 0.75” Rod 2.56” Stroke .
Hydraulic System This page is intentionally blank.
Hydraulic System Page 4 − 12 EXPANSION TANK BREATHER LEAK IN DETECTOR VOLUME OUT OPTIONAL LEAK DETECTOR KIT G1 BACKLAP SWITCH (SW) MA P1 FC1 .73 LC OR1 0.013 T PRV 550 PSI CENTER REEL (#1) FILTER S1R1 SUCTION STRAINER OR2 0.060 MR MB LEFT FRONT REEL (#2) .73 .73 FRONT RIGHT REEL (#3) P2 OPTIONAL OIL COOLER 25 PSI G2 0.055” L2B CU #2 2.0” Bore 0.75” Rod 1.75” Stroke L1A S2 S3 GEAR PUMP .33 R2 400 PSI FC2 7.0 GPM L2A CU #1 2.0” Bore 0.75” Rod 2.56” Stroke .
Traction Circuits Forward Reverse The piston (traction) pump 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 piston pump 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.
Hydraulic System Page 4 − 14 Greensmaster 3250−D EXPANSION TANK BREATHER LEAK IN DETECTOR VOLUME OUT OPTIONAL LEAK DETECTOR KIT G1 BACKLAP SWITCH (SW) MA P1 FC2 LC OR1 0.013 T PRV 550 PSI CENTER REEL (#1) FILTER .73 S1R1 SUCTION STRAINER OR2 0.060 MR MB LEFT FRONT REEL (#2) .73 .73 FRONT RIGHT REEL (#3) P2 OPTIONAL OIL COOLER 25 PSI G2 0.055” L2B CU #2 L1A GEAR PUMP 7.0 GPM S2 .33 R2 400 PSI FC2 S3 L2A .58 L1A CU #1 1.
Raise and Lower Cutting Units During cutting unit hold (not raising or lowering) conditions, flow from the gear pump (P2) is by−passed through the steering valve and de−energized solenoid valve (S2) in the hydraulic manifold directly to the traction charge circuit. Flow in excess of charge circuit requirements then returns to the gear pump inlet. Raise Cutting Units When the cutting units are to be raised, solenoid valve (S2) is energized and blocks flow directly to the traction charge circuit.
Hydraulic System Page 4 − 16 Greensmaster 3250−D EXPANSION TANK BREATHER LEAK IN DETECTOR VOLUME OUT OPTIONAL LEAK DETECTOR KIT G1 BACKLAP SWITCH (SW) MA P1 FC1 .73 SUCTION STRAINER LC OR1 0.013 T CENTER REEL (#1) FILTER S1R1 PRV 550 PSI OR2 0.060 MR MB LEFT FRONT REEL (#2) .73 .73 FRONT RIGHT REEL (#3) P2 OPTIONAL OIL COOLER 25 PSI G2 0.055” L2B CU #2 L1A S2 S3 GEAR PUMP .33 R2 400 PSI FC2 7.0 GPM L2A CU #1 .58 L1A 1.
Mow and Backlap With the engine running and the Functional Control and Raise/Lower/Mow levers positioned so the reels will not turn, solenoid relief valve (S1R1) in the hydraulic manifold is de−energized. The de−energized (S1R1) by−passes flow from the front section of the gear pump 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.
RIGHT TURN LEFT TURN Steering Cylinder Steering Cylinder L P STEERING VALVE R L 4.5 4.
Right and Left Turn With the steering wheel in the neutral position and the engine running, the spool valve in the steering valve is in the center position. Pump flow enters the steering valve at Port (P) and goes through the spool valve, by− passing the steering cylinder. Flow leaves the steering valve out port (E) to be available for the raise/lower and traction charge circuits.
Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges. Use gauges as recommended in Testing section of this chapter.
High Flow Hydraulic Filter Kit The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi−directional filtration which prevents filtered debris from being allowed back into the circuit regardless of flow direction. If a component failure occurs in the closed loop traction circuit, contamination from the failed part will remain in the circuit until removed.
Hydraulic Test Fitting Kit 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. Toro Part Number: TOR4079 Figure 15 Measuring Container Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only).
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.
Traction Circuit Problems ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Mow Circuit Problems ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Lift/Lower Circuit Problems ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ
Steering Circuit Problems ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
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 hydraulic system components.
3. For traction related problems (e.g. machine will not go up an incline), consider performing the following hydraulic tests: Charge Pressure Relief Valve Pressure Test Wheel Motor Efficiency Test Piston (Traction) Pump Flow Test 5. For issues with the cutting system, consider performing the following hydraulic tests: Mow Circuit Relief Valve (S1R1) Pressure Test Reel Motor Case Drain Flow Test Gear Pump (Front Section) Flow Test Hydraulic System 4.
Hydraulic System Page 4 − 30 EXPANSION TANK BREATHER LEAK IN DETECTOR VOLUME OUT OPTIONAL LEAK DETECTOR KIT G1 BACKLAP SWITCH (SW) MA P1 FC1 .73 LC OR1 0.013 T PRV 550 PSI CENTER REEL (#1) FILTER S1R1 SUCTION STRAINER OR2 0.060 MR MB LEFT FRONT REEL (#2) .73 .73 FRONT RIGHT REEL (#3) P2 OPTIONAL OIL COOLER 25 PSI G2 0.055” L2B CU #2 L1A S2 S3 GEAR PUMP .33 R2 400 PSI FC2 7.0 GPM L2A CU #1 .58 L1A 1.
The traction charge circuit is designed to replace loss of hydraulic fluid from the closed loop traction circuit. The charge relief valve pressure test will identify if charge pressure is correct. 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.
Wheel Motor Efficiency Test (Using Tester with Flowmeter and Pressure Gauge) TO STEERING VALVE ILLUSTRATION SHOWS TEST FOR LEFT FRONT MOTOR FROM CONTROL MANIFOLD PORT PT TO CONTROL MANIFOLD PORT P1 TESTER TRACTION PUMP TOP PORT CAP A BYPASS VALVE LEFT MOTOR RIGHT 10.3 10.3 CAP 3000 PSI GEAR PUMP .33 .58 1.24 MOTOR ENGINE RPM 3000 PSI 2710/1500 20.
5. If machine has 3 wheel drive, block up the rear wheel off the ground to allow flow through the rear wheel motor. 6. Chock front wheel being tested to prevent rotation of the wheel. 7. Thoroughly clean junction of hydraulic lines and fittings at the front wheel motor that is not being tested. Disconnect hydraulic lines from front wheel motor that is not being tested. Cap the disconnected hydraulic lines and plug ports in wheel motor. 8.
Piston (Traction) Pump Flow Test (Using Tester with Flowmeter and Pressure Gauge) TO STEERING VALVE FROM CONTROL MANIFOLD PORT PT TO CONTROL MANIFOLD PORT P1 TRACTION PUMP TESTER TOP PORT A BYPASS VALVE RIGHT LEFT MOTOR 10.3 10.3 MOTOR 3000 PSI GEAR PUMP .33 .58 1.24 ENGINE RPM 3000 PSI 2710/1500 20.6 70−100 PSI 110−150 PSI B OPTIONAL BOTTOM Procedure for Piston (Traction) Pump Flow Test This test measures piston pump output (flow).
5. Thoroughly clean junction of hydraulic hose and the upper hydraulic fitting on the front side of the piston pump (Fig. 20). Disconnect hose from the upper hydraulic fitting. 6. Install tester with pressure gauge and flow meter in series with the pump and the disconnected hose. Make sure flow control valve on the tester is fully open. 7. Make sure functional lever is in the transport position. 8. Start engine and move throttle to high idle speed (2710 + 50 RPM). CAUTION 13.
Hydraulic System Page 4 − 36 EXPANSION TANK BREATHER P1 FC1 LC OR1 0.013 T PRV 550 PSI FILTER S1R1 SUCTION STRAINER OR2 0.060 MR MB .73 CENTER REEL (#1) P2 OPTIONAL OIL COOLER 25 PSI G2 0.055” L2B CU #2 S2 S3 GEAR PUMP .33 R2 400 PSI .58 PT 0.055” 1.24 3000 PSI 3000 PSI CONTROL MANIFOLD ST Lower Raise 110−150 PSI TRACTION PUMP 4.0 GPM S4 0.055” L3B L3A L1A L1A CU #3 CU #1 FC2 7.
Procedure for Gear Pump (Rear Section) 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 Before continuing further, read and become familiar with Precautions for Hydraulic Testing. 3.
Hydraulic System Page 4 − 38 EXPANSION TANK BREATHER P1 FC1 LC OR1 0.013 T PRV 550 PSI FILTER S1R1 SUCTION STRAINER OR2 0.060 MR MB .73 CENTER REEL (#1) P2 OPTIONAL OIL COOLER 25 PSI G2 0.055” L2B CU #2 S2 S3 GEAR PUMP .33 R2 400 PSI .58 PT 0.055” 1.24 3000 PSI 3000 PSI CONTROL MANIFOLD ST Lower Raise 110−150 PSI TRACTION PUMP 4.0 GPM S4 0.055” L3B L3A L1A L1A CU #3 CU #1 FC2 7.
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. Make sure the hydraulic tank is full. CAUTION Before continuing further, read and become familiar with Precautions for Hydraulic Testing. 3. Measure and record charge relief valve pressure (see Charge Relief Valve Pressure Test in this section). 4.
Hydraulic System Page 4 − 40 EXPANSION TANK BREATHER P1 FC1 LC OR1 0.013 T PRV 550 PSI FILTER S1R1 SUCTION STRAINER OR2 0.060 MR MB .73 CENTER REEL (#1) P2 S2 S3 GEAR PUMP .33 R2 400 PSI .58 PT 0.055” 1.24 3000 PSI 3000 PSI CONTROL MANIFOLD ST Lower Raise 110−150 PSI TRACTION PUMP 4.0 GPM S4 0.055” L3B L3A L1A L1A CU #3 CU #1 FC2 7.0 GPM L2A OPTIONAL OIL COOLER 25 PSI G2 0.
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. Make sure the hydraulic tank is full. CAUTION Before continuing further, read and become familiar with Precautions for Hydraulic Testing. 3. Measure and record charge relief valve pressure (see Charge Relief Valve Pressure Test in this section). 4.
Hydraulic System Page 4 − 42 EXPANSION TANK BREATHER LEAK IN DETECTOR VOLUME OUT OPTIONAL LEAK DETECTOR KIT G1 BACKLAP SWITCH (SW) MA P1 FC1 .73 LC OR1 0.013 T PRV 550 PSI CENTER REEL (#1) FILTER S1R1 SUCTION STRAINER OR2 0.060 MR MB LEFT FRONT REEL (#2) .73 .73 FRONT RIGHT REEL (#3) L2A OPTIONAL OIL COOLER GEAR PUMP S2 S3 .33 R2 400 PSI L1A CU #1 FC2 TESTER P2 25 PSI 7.0 GPM G2 0.055” L2B CU #2 .58 L1A 1.
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. Watch pressure gauge carefully while slowly closing the flow control valve on the tester until 2000 PSI (138 bar) is obtained. 8. Flow gauge reading for a gear pump section in good condition should be approximately 6.
Hydraulic System Page 4 − 44 EXPANSION TANK BREATHER LEAK IN DETECTOR VOLUME OUT OPTIONAL LEAK DETECTOR KIT P1 FC1 .73 LC OR1 0.013 T PRV 550 PSI CENTER REEL (#1) FILTER S1R1 SUCTION STRAINER OR2 0.060 MR MB TESTER G1 BACKLAP SWITCH (SW) MA LEFT FRONT REEL (#2) .73 .73 FRONT RIGHT REEL (#3) P2 S2 S3 .33 R2 400 PSI FC2 L1A CU #1 GEAR PUMP L2A OPTIONAL OIL COOLER 25 PSI 7.0 GPM G2 0.055” L2B CU #2 .58 L1A 1.
Procedure for Mow Circuit Relief Valve (S1R1) 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. Make sure the hydraulic tank is full. CAUTION Before continuing further, read and become familiar with Precautions for Hydraulic Testing. 10.After recording relief pressure, disengage cutting units.
Reel Motor Case Drain Flow Test (Using Tester with Flowmeter and Pressure Gauge) CENTER MOTOR RETURN RIGHT MOTOR CASE DRAIN RIGHT MOTOR RETURN LEFT MOTOR CASE DRAIN CENTER MOTOR CASE DRAIN LEFT MOTOR RETURN CENTER MOTOR LEFT MOTOR RIGHT MOTOR ILLUSTRATION SHOWS TEST FOR RIGHT FRONT REEL MOTOR TESTER FRONT RIGHT REEL (#3) .73 MEASURING CONTAINER CENTER REEL (#1) CAP .73 .
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. 2. Park machine on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. CAUTION Before continuing further, read and become familiar with Precautions for Hydraulic Testing. 3. For the suspected faulty cutting reel motor, disconnect return hose from motor.
Steering Valve Test Steering Cylinder (CYLINDER ROD FULLY RETRACTED) PLUG L STEERING VALVE R TURNED FOR RIGHT TURN 4.
Procedure for Steering Valve Test 1 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. 2 3. Drive machine slowly in a figure eight on a flat level surface. A. There should be no shaking or vibration in the steering wheel or rear wheel. REMOVE THIS HOSE B.
Adjustments Adjust Manifold Relief Valve (R2) The hydraulic manifold includes an adjustable relief valve in the lift circuit (Fig. 29). If adjustment to this valve is necessary, follow the following procedure. FRONT NOTE: Do not remove relief valve from the hydraulic manifold for adjustment. WARNING 2 Never adjust the relief valve with the hydraulic system pressurized. Hydraulic oil may spray out of the valve with the cap off. Personal injury may result.
Hydraulic System This page is intentionally blank.
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. Drain and refill hydraulic system reservoir.
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 the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine.
Filtering Closed−Loop Traction Circuit Filtering of a closed−loop hydraulic system after a major component failure (e.g. piston (traction) pump or wheel motor) is a requirement to prevent debris from transmitting throughout the system. If a closed−loop hydraulic system filtering tool is not used to ensure system cleanliness, repeat failures, as well as subsequent damage to other hydraulic components in the affected system, will occur.
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 piston (traction) pump was rebuilt or replaced, make sure piston 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.
Gear Pump 7 7 1 16 17 13 14 2 12 11 8 4 9 5 10 3 RIGHT FRONT 6 15 Figure 33 1. 2. 3. 4. 5. 6. Pump inlet hose Gear pump Hydraulic fitting Hydraulic fitting O−ring O−ring Hydraulic System 7. 8. 9. 10. 11. 12. Hose clamp (2 used) O−ring O−ring Hydraulic hose O−ring Piston pump Page 4 − 56 13. 14. 15. 16. 17.
4. Secure gear pump to the piston pump with two (2) socket head screws and flat washers. Removal (Fig. 33) 5. Inspect threads and sealing surfaces of hydraulic fittings and hydraulic hose connectors. Replace any damaged or worn fittings or hoses. Before continuing further, read and become familiar with General Precautions for Removing and Installing Hydraulic System Components. 1.
Gear Pump Service 19 12 11 15 16 18 9 8 6 2 17 13 7 1 3 4 4 3 14 13 21 22 20 14 10 33 ft−lb (45 N−m) 5 Figure 35 1. 2. 3. 4. 5. 6. 7. 8. O−ring Front cover Back−up seal Pressure seal Thrust plate Drive shaft Idler gear Thrust plate 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Dowel pin O−ring Housing Coupler Back−up seal Pressure seal Thrust plate Drive gear Idler gear Thrust plate O−ring End cover Socket head screw (4 used) Washer (4 used) Gear Pump Disassembly (Fig.
6. Support the pump assembly and gently tap the pump housing with a soft face hammer to loosen the pump sections. Be careful to not drop parts or disengage gear mesh. Gear Pump Assembly (Fig. 35) IMPORTANT: Mark the relative positions of the gear teeth and the thrust plates so they can be assembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. NOTE: Pressure and back−up seals fit in grooves machined into thrust plates.
Piston (Traction) Pump Neutral Assembly 17 13 16 12 Antiseize Lubricant 28 18 25 8 15 11 7 27 30 1 10 19 22 RIGHT FRONT 6 25 20 29 23 33 26 5 2 29 4 32 14 14 24 3 34 9 21 25 36 40 39 2 42 35 31 38 37 41 Figure 37 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Disassembly (Fig. 37) 4 1. Park machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. 3 2. If necessary, remove muffler to allow disassembly of traction neutral assembly (Fig. 39). Refer to Exhaust System in the Service and Repairs section of Chapter 3 − Diesel Engine for additional information on muffler removal. 1 6 CAUTION The extension spring (item 17) is under tension and may cause personal injury during removal.
Piston (Traction) Pump 1 1 10 17 13 6 4 7 2 18 16 16 Loctite #242 27 to 33 ft−lb (37 to 44 N−m) 23 18 24 23 20 15 3 8 9 21 22 19 11 14 27 26 12 RIGHT 28 FRONT 21 7 5 27 25 Figure 40 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Hose clamp (2 used) O−ring 90o hydraulic fitting Gear pump Piston pump O−ring Flat washer (4 used) Coupler Key Pump inlet hose 11. 12. 13. 14. 15. 16. 17. 18. 19.
Piston Pump Removal (Fig. 40) 4 1. Park machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. 3 CAUTION Before continuing further, read and become familiar with General Precautions for Removing and Installing Hydraulic System Components. 2. Remove muffler to allow pump removal (Fig. 43). Refer to Exhaust System in the Service and Repairs section of Chapter 3 − Diesel Engine for additional information on muffler removal.
IMPORTANT: If fittings are going to be removed from piston pump, note position of fittings for assembly purposes. 13.If fitting removal from piston pump is necessary, mark hydraulic fitting orientation to allow correct assembly. Remove hydraulic fittings and O−rings from piston pump. Discard removed O−rings. 14.If necessary, remove the neutral assembly attached to the piston pump (see Piston (Traction) Pump Neutral Assembly in this section). Piston Pump Installation (Fig. 40) 1.
Hydraulic System This page is intentionally blank.
Piston (Traction) Pump Service 36 37 21 20 19 17 23 22 18 16 15 REAR OF TRACTION UNIT 41 14 15 4 8 38 27 40 24 9 13 29 28 11 5 12 26 7 39 6 8 3 10 2 28 1 38 30 4 6 31 31 35 34 32 39 25 4 33 30 Figure 44 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Key Drive shaft Bearing Cap screw (3 used per plate) Cover plate O−ring Shim kit (for crush ring replacement) Bearing cone Key Swash plate Rotating kit Gasket Valve plate Bearing Hydraulic System 15. 16. 17. 18. 19. 20. 21.
For repair of the piston pump, see Eaton, Medium Duty Piston Pump, Repair Information, Model 70160 Variable Displacement Piston Pump at the end of this chapter. 1 NOTE: The charge relief valve is attached to the piston pump back plate (shown in Fig. 45). The back plate must be removed to service the relief valve. 2 NOTE: The piston pump is equipped with relief valves (items 18 and 41) for both the forward and reverse direction.
Piston Pump Crush Ring Replacement 4 5 8 7 29 ft−lb (39 N−m) 2 v 3 9 10 6 1 Figure 46 1. 2. 3. 4. Crush ring Shims Cover plate Housing 5. Swash plate (control shaft) 6. Bearing cone 7. 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. 2.
Hydraulic System This page is intentionally blank.
Front Wheel Motors 250 to 400 ft−lb (339 to 540 N−m) 24 6 7 5 11 12 RH 15 LH 16 4 1 9 21 15 RH 16 LH 14 18 17 12 70 to 90 ft−lb (95 to122 N−m) 19 2 20 26 8 RIGHT Antiseize Lubricant 13 10 23 22 28 FRONT 25 3 27 Figure 47 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Lug nut (4 used per wheel) Wheel assembly Swivel clevis Cap screw (4 used per motor) Brake drum Wheel hub Drive stud (4 used per wheel) Backing plate Brake cam Retaining clip Hydraulic System 11. 12. 13. 14. 15. 16. 17. 18. 19.
Front Wheel Motor Removal (Fig. 47) Front Wheel Motor Installation (Fig. 47) 1. Park the machine on a level surface, lower the cutting units and stop the engine. Remove key from the ignition switch. 1. Position hydraulic wheel motor and brake bracket (item 14) to the frame. Make sure ports of motor face the rear of the machine. Secure motor and brake bracket to the frame with four (4) cap screws (item 4).
Rear Wheel Motor (If Equipped with 3WD) 18 15 16 3 20 4 17 19 14 70 to 90 ft−lb (95 to122 N−m) 80 to 100 in−lb (9 to 11 N−m) 23 25 26 100 ft−lb (135 N−m) 9 1 11 12 21 6 24 7 22 5 8 RIGHT FRONT 13 3 10 4 2 40 ft−lb (55 N−m) Figure 48 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 Mount spacer 10. 11. 12. 13. 14. 15. 16. 17. 18.
Hydraulic System This page is intentionally blank.
Wheel Motor Service 13 12 11 10 3 1 2 4 5 6 7 8 9 8 14 15 16 17 24 5 23 5 22 5 19 18 20 21 5 Figure 49 1. 2. 3. 4. 5. 6. 7. 8. Dirt seal Bearing Housing Back−up washer Seal ring Back−up washer Inner seal Thrust washer 9. 10. 11. 12. 13. 14. 15. 16. Thrust bearing Bearing Coupling shaft Thrust bearing Drive link Cap screw Commutator seal Commutator 17. 18. 19. 20. 21. 22. 23. 24.
Hydraulic System This page is intentionally blank.
Cutting Reel Motors 1 2 FRONT REEL MOTORS 3 3 20 9 18 5 4 23 16 15 22 29 14 21 7 25 30 19 29 7 6 30 17 24 17 11 12 7 10 8 RIGHT 6 13 14 28 13 15 27 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Cap screw Flat washer Tube clamp Lock nut Plug 90o Hydraulic fitting Hydraulic fitting Hydraulic fitting O−ring Bulkhead nut 26 27 FRONT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
4. Rotate the motor counterclockwise until the motor flanges are encircling the cap screws. Tighten two (2) cap screws to secure reel motor to cutting unit. 5. If hydraulic fittings are to be removed from reel motor, mark fitting orientation to allow correct assembly. Remove hydraulic fittings and O−rings from motor. Discard removed O−rings. 5. Remove caps and plugs from disconnected hydraulic hoses and motor fittings. 6. Inspect threads and sealing surfaces of fittings and motor ports.
Reel Motor Service 5 6 7 9 8 7 10 6 11 5 1 215 to 280 in−lb (24 to 32 N−m) 3 12 4 2 Figure 52 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 (4 used) Front flange Washer (if equipped) DIAGONAL MARK 2.
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. 54). 8. Carefully remove and discard O−rings, pressure seals and back−up rings (Fig. 55) from motor. Do not cause any damage to the machined grooves during the removal process.
Assembly 8. Install dowel pins in body. NOTE: When assembling the motor, check the identification marks made during disassembly to make sure the parts are properly aligned during assembly. 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. Install new shaft seal into front flange. 3.
Hydraulic System This page is intentionally blank.
Oil Cooler (If Equipped) 14 11 10 8 12 5 11 9 6 1 5 4 5 10 3 2 13 7 15 4 OIL FLOW 16 Figure 57 1. 2. 3. 4. 5. 6. Oil cooler Lower formed hose Upper formed hose Grommet (2 used) Hose clamp (4 used) Hydraulic tube 7. 8. 9. 10. 11. Hydraulic tube Hydraulic straight fitting 90o hydraulic fitting O−ring O−ring Removal (Fig. 57) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove key from the ignition switch.
4. Loosen hose clamps securing the formed hoses to the oil cooler. 9. Plug ends of the oil cooler. Clean exterior of the cooler. 5. Carefully pull oil cooler from the cooler brackets in the radiator support. Remove oil cooler from the formed hoses. Allow hoses and cooler to drain into a suitable container. 10.The oil cooler should be free of corrosion and excessive pitting of tubes. 6.
Lift Cylinders 11 RIGHT 20 19 FRONT 18 10 12 3 7 2 14 3 1 13 8 13 12 13 12 13 4 19 16 4 12 5 9 3 3 17 5 6 15 FRONT LIFT CYLINDER CENTER LIFT CYLINDER 11 Figure 58 1. 2. 3. 4. 5. 6. 7. Hydraulic hose Hydraulic hose O−ring Cotter pin Clevis pin Front lift arm Front lift cylinder (2 used) 8. 9. 10. 11. 12. 13. 14. Washer head screw Pivot pin Spacer Frame 90o Hydraulic fitting O−ring Spacer 15. 16. 17. 18. 19. 20.
Lift Cylinder Installation (Fig. 58) 1. If fittings were removed from lift cylinder, lubricate and place new O−rings onto fittings. Install fittings into cylinder openings making sure that fitting orientation is as noted during removal. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2. To secure front lift cylinder to frame: 4. Position clevis of the lift cylinder to the lift arm. Insert clevis pin (item 5) through the cylinder clevis and lift arm.
Lift Cylinder Service CENTER HYDRAULIC CYLINDER 1 11 7 6 2 40 ft−lb (54 N−m) 3 1. 2. 3. 4. 4 Barrel Shaft Nut Piston 5 5. 6. 7. 8. 8 9 10 12 Figure 59 T seal O−ring Rod seal Head 9. 10. 11. 12. O−ring Back−up ring Dust seal Internal collar FRONT HYDRAULIC CYLINDER 1 6 7 11 2 40 ft−lb (54 N−m) 3 4 5 8 9 10 12 Figure 60 1. 2. 3. 4. Barrel Shaft Nut Piston Hydraulic System 5. 6. 7. 8. T seal O−ring Rod seal Head 9. 10. 11. 12.
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 vise with soft jaws. Remove internal collar with a spanner wrench. 3. Extract shaft, head and piston by carefully twisting and pulling on the shaft.
Hydraulic Manifold 24 1 17 14 6 20 18 7 13 19 19 20 15 2 16 15 22 5 9 11 11 17 9 16 9 26 11 23 15 11 8 21 25 11 9 15 32 16 29 3 4 2 27 9 17 15 31 33 10 30 28 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Hydraulic manifold assembly Hydraulic adapter (2 used) Hydraulic tee fitting Hydraulic test fitting 90o hydraulic fitting 90o hydraulic fitting 90o hydraulic fitting Hydraulic straight fitting Hydraulic straight fitting (5 used) Dust cap O−ring 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 61) Installation (Fig. 61) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove key from the ignition switch. 1. If fittings were removed from manifold, lubricate and place new O−rings onto fittings. Install fittings into manifold openings making sure that fitting orientation is as noted during removal. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter).
Hydraulic Manifold Service 25 ft−lb (34 N−m) 26 18 26 2 21 14 16 29 60 in−lb (6.7 N−m) 29 21 20 ft−lb (27 N−m) 60 in−lb (6.7 N−m) 20 ft−lb (27 N−m) 25 ft−lb (34 N−m) 15 13 11 2 10 17 6 12 6 20 ft−lb (27 N−m) 40 ft−lb (54 N−m) 7 20 ft−lb (27 N−m) 7 4 25 ft−lb (34 N−m) 1 9 VIEW FROM BELOW 7 6 3 6 9 6 6 19 6 22 1 6 UP 20 24 5 23 20 ft−lb (27 N−m) 20 ft−lb (27 N−m) 6 6 20 ft−lb (27 N−m) 8 8 PLUG TORQUE 7 4 SAE #4: 165 in−lb (18.
NOTE: The hydraulic manifold shown in Figure 62 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.
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. Rotary Cartridge Valve 1. Remove rotary handle from valve (Fig. 63): 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.
Mow/Backlap Spool (Fig. 64) 1 1. Make sure manifold is clean before removing the mow/backlap spool. 2 4 Loctite 603 3 2. Remove mow/backlap spool from manifold: 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. 6 5 B. Remove lower retaining ring from mow/backlap spool. Raise mow/backlap spool to allow access to retaining ring on upper end of spool.
Steering Valve 28 29 1 20 to 26 ft−lb (28 to 35 N−m) 2 5 8 3 4 10 6 11 7 12 21 4 22 19 27 26 9 17 15 33 14 32 13 24 31 30 20 25 18 15 23 12 13 11 10 16 Antiseize Lubricant Figure 65 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Knob Lockup handle Lockup spacer Friction disc (2 used) Steering wheel Steering wheel nut Flange head screw (4 used) Flat washer Cap screw Cap screw (2 used) Flat washer (2 used) Hydraulic System 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove key from the ignition switch. CAUTION Before continuing further, read and become familiar with General Precautions for Removing and Installing Hydraulic System Components. 2. Remove screw (item 29) and then steering wheel cap (item 28) from the steering wheel. 3. While routing hydraulic hose to machine, position steering valve to steering mount.
Steering Valve Service 14 13 11 16 15 12 11 7 8 10 9 6 25 5 26 v 4 3 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 67 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. 29.
Hydraulic System This page is intentionally blank.
Steering Cylinder 1 CYLINDER ASSEMBLY 65 to 85 ft−lb (88 to 115 N−m) 2 3 26 27 28 30 17 32 21 24 22 25 22 19 20 18 28 27 3 23 4 33 19 65 to 85 ft−lb (88 to 115 N−m) 17 18 26 31 16 13 15 36 35 14 29 12 6 5 34 7 8 9 10 RIGHT FRONT 8 7 6 29 11 Figure 68 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Removal (Fig. 68) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove key from the ignition switch. A. Block front wheels. Jack up rear wheel off the ground by the frame. Support the frame with the rear wheel off the ground. B. Remove lock nut (item 16), bolt (item 5), rear spindle spacers (item 29) and rear wheel assembly from the castor fork.
Steering Cylinder Service 2 4 12 v 8 14 12 13 1 3 7 9 10 6 5 11 Figure 69 1. 2. 3. 4. 5. Rod Wiper Seal Head (non−ball joint end) Backup ring 6. 7. 8. 9. 10. O−ring Wear ring Barrel Back−up ring Seal 11. 12. 13. 14. Wear ring Retaining ring Piston Head (ball joint end) NOTE: The steering cylinder design does not allow removal of the piston (item 13) from the rod.
Disassembly (Fig. 69) Assembly (Fig. 69) 1. Pump oil out of cylinder into a drain pan by slowly moving rod in and out of cylinder bore. Plug ports and clean outside of cylinder. NOTE: The seal kit includes several O−rings, backup rings and wear rings that cannot be accessed on the Greensmaster 3250−D steering cylinder due to cylinder design. 1. Identify components from seal kit that are to be used in cylinder repair. Put a coating of clean hydraulic oil on all new seals, back−up rings and O−rings. 2.
Hydraulic Reservoir 5 18 32 20 24 17 18 3 6 25 Antiseize Lubricant 30 to 60 in−lb (3.4 to 6.8 N−m) 2 29 16 14 11 4 28 1 19 13 12 31 15 16 22 9 23 10 30 26 7 21 27 8 9 23 Figure 70 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Strainer 90o hydraulic fitting Fuel tank clamp Washer head screw (2 used) Tank cap Hydraulic tank Hydraulic straight fitting Oil filter assembly Hydraulic barb fitting Oil filter mount O−ring 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
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. 73). PUMP INLET HOSE 6. Remove three (3) washer head screws that secure the mounting plate (item 29) to the frame. Two screws are located on the top of the plate at the front corners of the hydraulic tank. The third screw is in front of the castor fork and below the plate. 7.
Turf GuardianTM Leak Detector System (If Equipped) 2 1 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 37 28 32 35 12 31 36 100 to 125 in−lb (11.3 to 14.1 N−m) 30 to 60 in−lb (3.4 to 6.8 N−m) 17 to 21 ft−lb (23 to 28 N−m) 13 30 29 14 15 16 16 26 28 6 7 17 27 7 18 25 19 20 24 21 18 39 23 22 9 10 Figure 74 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Removal (Fig. 74) 3 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove key from the ignition switch. 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 75 1. Cap screw 2. Flat washer 3. Cover plate 4.
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 cap screw. 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. 76). 8.
Chapter 5 Electrical System Table of Contents Greensmaster 3250−D Solenoid Valve Coils . . . . . . . . . . . . . . . . . . . . . . . . Neutral and Mow Sensors . . . . . . . . . . . . . . . . . . . Parking Brake Sensor . . . . . . . . . . . . . . . . . . . . . . Backlap Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick Raise and Lower Switches . . . . . . . . . . . Safety Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow Relay . . . . . . . . . . . . . . . . . .
This page is intentionally blank.
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. Electrical Drawings Electrical System The electrical schematic and other electrical drawings for the Greensmaster 3250−D are located in Chapter 9 − Foldout Drawings.
Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The multimeter can test electrical components and circuits for current, resistance or voltage. Obtain this tool locally. 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.
Dielectric Gel Dielectric gel should be used to prevent corrosion of connection terminals. To ensure complete coating of terminals, liberally apply gel to both component and wire harness connector, plug connector to component, unplug connector, reapply gel to both surfaces and reconnect harness connector to component. Connectors should be thoroughly packed with gel for effective results.
Troubleshooting 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. For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and components used on this machine (see electrical schematic and other electrical drawings in Chapter 9 − Foldout Drawings).
Starting Problems (continued) Problem Possible Causes Engine cranks (but should not) with the functional control lever in the MOW or TRANSPORT position. Neutral sensor is out of adjustment. Neutral sensor or circuit wiring is faulty. Interlock relay or circuit wiring is faulty. Engine cranks, but does not start. Wiring to start circuits is loose, corroded or damaged (see Electrical Schematic in Chapter 9 − Foldout Drawings). Run relay or circuit wiring is faulty.
General Run and Transport Problems Problem Possible Causes Engine kills when the Functional Control Lever is in the MOW or TRANSPORT position with the operator in the seat. Operator is sitting too far forward on the seat (seat switch not depressed). Seat switch or circuit wiring is faulty. Parking brake switch or circuit wiring is faulty. Battery does not charge. Wiring to charging circuit components is loose, corroded or damaged (see Electrical Schematic in Chapter 9 − Foldout Drawings).
Cutting Unit Operating Problems Problem Possible Causes Cutting units run (but should not) when Joystick relay or circuit wiring is faulty. raised. Solenoid valve S1R1 or circuit wiring is faulty. Mow relay or circuit wiring is faulty. Mow sensor or circuit wiring is faulty. Cutting units do not run when lowered with the Functional Control Lever in the MOW or NEUTRAL position. Fuse F1 (10 ampere) or fuse block is faulty. Solenoid valve S1R1 or circuit wiring is faulty.
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 (16o to 37o C). 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 negative battery post. Voltage Measured Battery Charge Level 12.68 V (or higher) Fully charged (100%) 12.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check). NOTE: For engine component testing information, refer to the Kubota Workshop Manual. CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.
Fuse Block Fuses can be removed to check continuity. The test meter should read less than 1 ohm. F1 F2 Fuses supply power to the following (Fig. 8): F3 1. Fuse F1 (top) (10 ampere) supplies power to the run and mow relays. 2. Fuse F2 (10 ampere) supplies power to the raise and lower relays. F1 3. Fuse F3 (15 ampere) supplies power to terminal B of the ignition switch. F2 F3 4. Fuse F4 is available for optional accessories. A maximum 15 ampere fuse should be used in this position.
Warning Light Cluster Glow Plug Indicator Light 3 The glow plug indicator light should come on when the ignition switch is placed in the RUN position prior to placing the ignition switch in START. The light should stay lit for approximately six (6) seconds while the ignition switch is left in the RUN position. 2 4 High Temperature Warning Light If the engine coolant temperature reaches 220oF (105oC) (approximate), the high temperature warning light will come on and the engine will shut down.
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 Testing 3 1. Make sure the engine is off. Remove seat from the support assembly by removing four (4) lock nuts from the seat bolts. 1 1 2. Disconnect wire harness connector from the seat switch. 3.
Lower Reels Time Delay The lower reels time delay is a solid state timer. Upon the application of power, the load is energized and the time delay is started. After six (6) seconds the load is de−energized. The time delay is attached to a bracket under the control console (Fig. 13). Testing 1. Connect voltmeter across test load and test load to timer. Connect 12VDC source to timer and load. Make sure to observe polarity. After six (6) seconds, there should be no voltage across the load. 2.
Diode Circuit Boards The Greensmaster 3250−D electrical system uses two (2) diode circuit boards that are inserted into wire harness connectors. Each of these circuit boards contain four (4) diodes. The diodes are used for circuit protection from inductive voltage spikes and for safety circuit logic. D A Apply dielectric grease (Toro part number 107−0342) to circuit board contacts whenever the circuit board is installed into the wire harness.
Solenoid Valve Coils The Greensmaster hydraulic control manifold uses several hydraulic solenoid valve coils for system control. When the solenoid coils are energized, hydraulic valve shift occurs to control hydraulic circuit flow. Testing of the coils can be done with the coil installed on the hydraulic valve. 3 1 4 Testing 2 NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter may display a small resistance value (usually 0.
Neutral and Mow Sensors The neutral and mow sensors are used to determine when the functional control lever is in the NEUTRAL or MOW position. These sensors are identical and are normally open reed sensors. They close when the actuator comes in close proximity to the sensor. The sensors are attached to the functional control lever bracket under the console panel (Fig. 18). The actuator is attached to the functional control lever. 3 1 Testing 2 1. Make sure the engine is off.
Parking Brake Sensor The parking brake sensor is normally closed and opens when the operator applies the parking brake. If the functional control lever is moved out of the NEUTRAL position and the parking brake is applied, the engine will stop running. The sensor and its electrical connector are located directly under the operator floor plate (Fig. 20). Testing 1 2 3 1. Park machine on level surface, lower cutting units, stop engine, apply parking brake and remove key from ignition switch. 5 6 7 2.
Backlap Switch The backlap switch is a normally open ball switch that is in the normal, open state when the backlap lever is in the mow position. When the backlap lever is in the backlap position, the switch closes. The backlap switch is attached to the front of the hydraulic control manifold located under the operator seat (Fig. 21). Testing 2 20 ft−lb (27 N−m) 1. Park machine on level surface, lower cutting units, stop engine, apply parking brake and remove key from ignition switch. 5 3.
Joystick Raise and Lower Switches The joystick raise and lower switches are located on the joystick assembly that is attached to the control console. The rear switch is used to lower the cutting units and the front switch to raise them (Fig. 22). The switches are identical and are shown in Figure 23. 1 Testing 3 1. Park machine on level surface, lower cutting units, stop engine, apply parking brake and remove key from ignition switch. FRONT 2.
Safety Relays Several safety relays are used on Greensmaster 3250−D machines. The relays are attached to frame brackets under the operator seat (Figs. 24 and 25). A tag on the wire harness connector can be used to identify the relays. 1 2 3 Relay Testing 1. Disconnect wire harness connector from relay that is to be tested. NOTE: Use illustration in Figure 26 to identify relay terminals. 2. Verify coil resistance between terminals 86 and 85 with a multimeter (ohms setting).
Glow Relay When energized by the glow plug controller, the glow relay allows electrical current to the engine glow plugs. The glow relay is attached to a frame bracket near the fuse block (Fig. 27) and is connected to the wire harness with a four (4) wire connector (Fig. 28). 1 2 4 Relay Testing 3 1. Disconnect wire harness connector from glow relay. 2. To allow easier access to relay terminals, either loosen fasteners that secure relay to bracket or remove relay from bracket. 3.
Fusible Links The electrical system on Greensmaster 3250−D machines includes a harness with three (3) fusible links for machine circuit protection (Fig. 29). The fusible link harness is connected to the engine starter motor B+ terminal. The fusible link harness connects the machine wire harness to the positive (+) battery terminal. An additional fusible link is included in the wire harness. This fusible link connects the starter terminal to the engine fuel solenoid pull coil.
Glow Controller The glow controller is attached to a bracket under the control console (Fig. 30). NOTE: When troubleshooting the glow controller, refer to electrical drawings in Chapter 9 − Foldout Drawings. 5. If any of the conditions in Step 3 are not met or electrical power to terminal 1 exists and any of the other conditions in Step 4 are not met: Controller Operation A. Verify continuity of the circuitry from the battery to the glow relay and glow plugs (see Chapter 9 − Foldout Drawings). 1.
High Temperature Shutdown Switch The high temperature shutdown switch is located on the thermostat housing near the alternator (Fig. 32). The high temperature shutdown switch has a yellow/red wire connected to it. 1 CAUTION 2 Make sure engine is cool before removing the temperature switch. 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. 33). Figure 32 1. Temperature switch 2.
Oil Pressure Switch The engine oil pressure switch is located on the engine near the alternator (Fig. 34). The oil pressure switch is a normally closed switch that opens with pressure. 1 The oil pressure switch should open at approximately 7 PSI (48.3 kPa). Testing 2 NOTE: Refer to Kubota Workshop Manual, Diesel Engine, 05−E3B Series for information regarding engine lubrication system and testing. 1. Turn the ignition switch to the RUN position.
Fuel Pump The fuel pump on Greensmaster 3250−D machines is secured to the radiator assembly with an r−clamp (Fig. 35). The fuel pump is energized when the ignition switch is in either the RUN or START position. 4 FROM TANK IMPORTANT: When testing fuel pump, make sure that pump is not operated without fuel. DANGER 2 Because diesel fuel is flammable, use caution when handling it. Do not smoke while testing the fuel pump. Do not test fuel pump while engine is hot.
Fuel Solenoid The fuel solenoid used on Greensmaster 3250−D machines must be energized for the diesel engine to run. The fuel solenoid is mounted to the injection pump on the engine (Fig. 36). The fuel solenoid is energized when the ignition switch is in either the RUN or START position. The fuel solenoid includes two (2) coils for operation: the pull coil and the hold coil. When the ignition switch is turned to START, the fuel solenoid pull coil is energized and the solenoid plunger retracts.
Turf GuardianTM Leak Detector System (If Equipped) Operation The leak detector system is designed to assist in the early detection of hydraulic oil system leaks. If the oil level in the main tank is lowered by 4 to 5 ounces, the level switch in the leak detection tank will close. After a 1 second delay, the alarm will sound alerting the operator. Expansion of oil from the normal heating of the hydraulic oil during machine operation will cause oil to transfer into the leak detection tank.
Test Operation 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. 2. Release leak detector switch. 3. Remove cover plate from leak detector. Remove plug from valve assembly. CLEAN ROD OR SCREWDRIVER VALVE ASSEMBLY PLUG REMOVED SOLENOID RETURN VALVE CLOSED 4. Insert clean rod or screw driver into valve assembly and gently push down on switch float (Fig. 40).
RED/WHITE + − RED VALVE SOLENOID TEST SWITCH + BLACK GRAY LEVEL SWITCH RED YELLOW CONNECTOR − 1 SEC. DELAY TIMER AUDIO ALARM BLACK YELLOW + − BLACK/WHITE 270 OHM RESISTOR LEAK DETECTOR CIRCUIT BLACK Figure 41 Components can be tested by isolating them from the rest of the circuit and individually testing the suspected component. 6 5 Delay Timer This is a solid state device with no moving parts. Upon the application of power, the time delay is initiated.
Electrical System This page is intentionally blank.
Service and Repairs NOTE: See the Kubota Workshop Manual for engine 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. Prevent the engine from cranking or starting unless the functional control lever is in NEUTRAL. B.
Battery Storage If the machine will be stored for more than thirty (30) days: 3. Leave cables disconnected if the battery is stored on the machine. 1. Make sure ignition switch is in the OFF position. Remove the battery and charge it fully (see Battery Service in this section). 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 2. Either store battery on a shelf or on the machine. 5.
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. Battery Specifications BCI Group Size 26 540 Amp Cranking Performance at 0oF (−17.8oC) 80 Minute Reserve Capacity at 80oF (26.7oC) Electrolyte Specific Gravity (fully charged): from 1.250 to 1.280 Electrolyte Specific Gravity (discharged): 1.240 3.
B. Temperature correct each cell reading. For each 10oF (5.5oC) above 80oF (26.7oC) add 0.004 to the specific gravity reading. For each 10oF (5.5oC) below 80oF (26.7oC) subtract 0.004 from the specific gravity reading. Cell Temperature 100oF Cell Gravity ADD (20o above 80oF) Correction to 80oF 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.
Battery 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.
Chapter 6 Chassis Table of Contents Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Front Wheels and Brakes . . . . . . . . . . . . . . . . . . . . 4 Rear Wheel (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rear Wheel (If Equipped with 3WD) . . . . . . . . .
Specifications Item Description Front tire pressure, 19 x 10.50 x 8 (2 ply) 8 to 12 PSI (55 to 83 kPa) Rear tire pressure, 19 x 10.
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. Special Tools Wheel Hub Puller The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors.
Service and Repairs Front Wheel and Brakes 250 to 400 ft−lb (339 to 540 N−m) 24 6 7 5 12 11 RH 15 LH 16 4 1 9 21 15 RH 16 LH 14 18 17 12 70 to 90 ft−lb (95 to122 N−m) 19 2 20 26 8 Antiseize Lubricant RIGHT 13 10 23 28 22 FRONT 25 3 27 Figure 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Lug nut (4 used per wheel) Wheel assembly Swivel clevis Cap screw (4 used per motor) Brake drum Wheel hub Drive stud (4 used per wheel) Backing plate Brake cam Retaining clip 11. 12. 13. 14. 15. 16. 17. 18. 19.
5. Make sure that lock nut (item 24) on wheel motor shaft is loosened at least two (2) turns. Use hub puller (see Special Tools in this chapter) to loosen brake drum assembly from wheel motor. 6. Make sure that wheel hub bore and wheel motor shaft are thoroughly cleaned. Install woodruff key (item 21) to the wheel motor shaft. Slide brake drum assembly over shaft and key. 6. Remove lock nut and brake drum assembly. Locate and retrieve woodruff key (item 21). 7.
Rear Wheel (2WD) 1 65 to 85 ft−lb (88 to 115 N−m) 2 3 26 27 28 30 17 32 21 24 22 25 22 20 19 18 28 27 3 23 70 to 90 ft−lb (95 to 122 N−m) 4 33 19 65 to 85 ft−lb (88 to 115 N−m) 17 18 26 31 16 13 15 36 35 14 29 12 6 5 34 7 8 9 RIGHT 10 FRONT 8 7 6 29 11 Figure 4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Removal (Fig. 4) 3 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove key from the ignition switch. 6 1 3 1 2. Chock both front wheels to prevent the machine from moving. 3. Use a jack or hoist to lift rear wheel off the ground and then place appropriate jackstands beneath the frame to support the raised machine. 5. Remove wheel and hub assembly from the castor fork. 6.
Rear Wheel (If Equipped with 3WD) 18 15 16 3 20 4 17 19 14 70 to 90 ft−lb (95 to122 N−m) 80 to 100 in−lb (9 to 11 N−m) 26 25 23 100 ft−lb (135 N−m) 9 1 11 12 21 6 24 7 22 5 RIGHT FRONT 8 13 3 10 4 2 40 ft−lb (55 N−m) Figure 6 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 Mount spacer Chassis 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 6) Installation (Fig. 6) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove key from the ignition switch. 1. Slide wheel assembly onto the drive studs. Secure wheel to wheel hub assembly with four (4) lug nuts (item 23). Torque lug nuts evenly in a crossing pattern to a torque from 70 to 90 ft−lb (95 to 122 N−m). 3. Chock both front wheels to prevent the machine from moving. 4.
Rear Wheel Hub and Motor Assembly (If Equipped with 3WD) 12 9 8 5 6 11 9 10 10 12 6 1 3 2 4 7 11 Figure 7 1. 2. 3. 4. Hydraulic motor 45_ Hydraulic fitting O−ring O−ring 5. 6. 7. 8. Hub Clutch roller bearing (4 used) Drive stud (4 used) Grease fitting Disassembly (Fig. 7) The following procedures assume the rear wheel hub and motor assembly has been removed from the machine (see Rear Wheel (If Equipped with 3WD) in this section).
Assembly (Fig. 7) 3 1. If removed, press new drive studs (item 7) into the wheel hub fully to the shoulder of the stud flange. 2. If removed, press roller clutch bearings (item 6) into the hub as follows (Fig. 9): 2 NOTE: Arrow on the side of the clutch roller bearings must point to the long side end of the hub (Fig. 9). A. Press three (3) roller bearings into flange end of the hub. The outer edge of the third bearing must be flush with the recessed edge within the hub. 1 B.
Rear Castor Fork 1 65 to 85 ft−lb (88 to 115 N−m) 2 3 26 27 28 30 17 32 21 24 22 25 22 20 19 18 28 27 3 23 70 to 90 ft−lb (95 to 122 N−m) 4 33 19 65 to 85 ft−lb (88 to 115 N−m) 18 17 26 31 16 13 15 36 35 14 29 12 6 5 34 7 8 9 10 RIGHT FRONT 8 7 6 29 11 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Removal (Fig. 10) Installation (Fig. 10) 1. Park machine on a level surface. Make sure engine is off. Engage parking brake and block front wheels. 1. If bearing cups (item 28) were removed from frame, press new cups into the castor fork pivot housing with the thick side of the cups facing each other. Make sure that cups are pressed fully to shoulder of frame housing. 3. Remove rear wheel assembly from the castor fork (see Rear Wheel (2WD) or Rear Wheel (If Equipped with 3WD) in this section). 4.
Front Lift Arms 9 RIGHT FRONT 7 6 5 4 10 5 11 14 3 12 15 14 13 23 2 22 1 2 22 21 20 11 21 12 20 19 11 11 24 17 16 25 26 27 18 8 28 67 to 83 ft−lb (91 to 112 N−m) Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Front lift frame Bushing Grease fitting Lift arm Bushing Grease fitting Cotter pin Cap screw Lift cylinder Clevis pin Chassis 11. 12. 13. 14. 15. 16. 17. 18. 19.
Disassembly 1. Park machine on a level surface. Make sure engine is off and parking brake is engaged. 67 to 83 ft−lb (91 to 112 N−m) 5 2 1 2. Remove cutting unit from front lift arm. 4 3 3. Disassemble front lift arm as needed using Figures 11 and 12 as guides. 6 Assembly 3 1. Assemble front lift arm using Figures 11 and 12 as guides. A. If clevis (item 16 in Fig. 11) was removed from front lift frame, torque cap screw from 67 to 83 ft−lb (91 to 112 N−m). B. If pull frame (item 1 in Fig.
Center Lift Arm 100 to 150 ft−lb (136 to 203 N−m) 13 4 5 3 6 2 7 1 8 33 2 12 9 11 34 10 22 11 12 24 23 22 25 10 21 24 20 15 26 RIGHT 9 9 18 19 17 14 27 28 29 FRONT 30 67 to 83 ft−lb (91 to 112 N−m) 15 18 31 16 9 32 Figure 13 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Center lift arm Bushing Torsion spring Cotter pin Lift cylinder Clevis pin Grease fitting Pivot tube Cap screw Jam nut Flange bushing Thrust washer Chassis 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Disassembly 1. Park machine on a level surface. Make sure engine is off and parking brake is engaged. 67 to 83 ft−lb (91 to 112 N−m) 5 2 1 2. Remove center cutting unit from lift arm. 4 3 3. Disassemble center lift arm as needed using Figures 13 and 14 as guides. 6 Assembly 3 1. If lift frame (item 25 in Fig. 13) was removed from machine: A. Adjust eccentric bushings (item 22 in Fig. 13) as needed so that lift frame is level when the lift frame is in the raised position. B.
This page is intentionally blank.
Chapter 7 DPA Cutting Units Table of Contents DPA Cutting Units SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Cutting Unit Operator’s Manual . . . . . . . . . . . . . . . 3 Supporting Cutting Unit when Servicing . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FACTORS THAT CAN AFFECT CUTTING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Figure 1 Frame Construction: Precision machined die cast aluminum cross member with two (2) bolt−on cast aluminum side plates. Bedknife Adjustment: Dual screw adjustment to the reel; detents corresponding to 0.0007 inch (0.018 mm) bedknife movement for each indexed position. Reel Construction: Reels are 21 inches (53.3 cm) in length and 5 inch (12.7 cm) in diameter. High strength, low alloy steel blades are thru hardened and impact resistant.
General Information Cutting Unit Operator’s Manual The Cutting Unit Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for the DPA cutting units on your Greensmaster 3250−D machine. Additionally, if optional kits have been installed on the cutting units (e.g. rear roller brush), the installation instructions for the kit includes set−up and operation information. Refer to those publications for additional information when servicing the cutting units.
Special Tools Special tools for servicing Toro Commercial Products are available from your Toro Distributor. Some of these tools may have been supplied with your machine or are available as Toro parts. Gauge Bar Assembly Use gauge bar to verify height−of−cut adjustment. Toro Part Number: 108−6715 Used for Height−of− Cut adjustment Figure 3 Bedknife Screw Tool This screwdriver−type bit is made to fit Toro bedknife attaching screws. Use this bit with a torque wrench to secure the bedknife to the bedbar.
Roller Bearing Installation Tools Washers and spacer used to install bearings and seals into front and rear rollers (Fig. 6). Seal installation washer: 107−8133 Seal installation spacer: 107−3505 Bearing installation washer: 104−6126 As an alternative to using washers and spacers listed above, a special tool set is available that can be used for roller bearing and seal installation (Fig. 7).
Bedknife Top Angle Indicator and Mount Toro Part Numbers: 131−6828 and 131−6829 Because the top grind angle on bedknives is critical for edge retention, and therefore after− cut appearance, Toro has developed these service tools for accurately measuring the top grind angle on all bedknives. 1 2 3 Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar. 1.
Factors That Can Affect Cutting Performance 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.
Factor Possible Problem/Correction Reel and bedknife sharpness A reel and/or bedknife that has rounded cutting edges or “rifling” (grooved or wavy appearance) cannot be corrected by tightening the bedknife to reel contact. Grind cutting reel to remove taper and/or rifling. Grind bedknife to sharpen and/or remove rifling. The most common cause of rifling is bedknife to reel contact that is too tight.
Factor Possible Problem/Correction Roller condition and roller type Make sure rollers rotate freely. Repair roller bearings as necessary. See Roller Service in the Service and Repairs section of this chapter. Refer to Cutting Unit Operator’s Manual for roller options. A variety of cutting unit accessories are available that can be used to enhance aftercut appearance. Refer to Operator’s Manual for a listing of available accessories.
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 cutting unit suspension 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.
Leveling Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel). If the side plates are disassembled or as the cutting reel wears, a limited amount of side plate adjustment is possible to make sure that the cutting unit is properly aligned. 2 2 1 1. Place the assembled cutting unit on a surface plate. 2. Make sure that bedknife is properly adjusted to cutting reel. 3.
Service and Repairs Backlapping DANGER 2 TO AVOID PERSONAL INJURY OR DEATH: D Never place hands or feet in the reel area while the engine is running. D When backlapping, run engine at idle speed only. 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.
9. To make an adjustment to the cutting units while backlapping, disengage the PTO with the joystick and turn the engine OFF. Wait for all machine movement to stop. After adjustments have been completed, repeat steps 5 through 8. 3 4 10.When the backlapping operation is completed, stop the engine and remove the key from the ignition switch. Run a file across the front face of the bedknife. This will remove any burrs or rough edges that may have built up on the cutting edge. 11.
Bedbar Assembly 200 to 250 in−lb (23 to 28 N−m) 1 17 16 2 3 190 to 240 in−lb (22 to 27 N−m) 6 13 7 12 11 Antiseize Lubricant 4 9 8 15 RIGHT 14 FRONT 18 16 5 17 10 Figure 17 1. 2. 3. 4. 5. 6. Bedbar Bedknife Screw (13 used) Bedbar adjuster screw (2 used) Bedbar adjuster shaft (2 used) Cap screw (2 used) 7. 8. 9. 10. 11. 12. Detent (2 used) Wave washer (2 used) Retaining ring (2 used) Lock nut (2 used) Washer (2 used) Compression spring (2 used) Bedbar Removal (Fig. 17) 1.
6. Position one (1) metal washer (item 17) and one (1) plastic washer (item 16) between bedbar and each cutting unit side plate (Fig. 18). Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when handling the bedbar. 7. Remove bedbar assembly from cutting unit. 8. Inspect nylon bushings (item 15) and rubber bushings (item 14) in side plates for wear or damage. Remove bushings and replace if necessary. Bedbar Installation (Fig. 17) 1.
Bedknife Replacement and Grinding Bedknife Removal 1. Remove bedbar from cutting unit (see Bedbar Removal in this section). 2 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special Tools in this chapter). Discard screws. Remove bedknife from the bedbar (Fig. 19). 3. See bedknife grinding information on the following pages. Bedknife Installation 1. Use scraper to remove all rust, scale and corrosion from bedbar surface. Lightly oil bedbar surface before installing bedknife.
Bedknife Grinding Bedknife Grinding Specifications (see Fig. 22) Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar. Follow the bedknife grinding specifications provided (Fig. 21). Grind only enough so the top surface of the bedknife is true (Fig. 22).
Bedbar Adjuster Service 1 Antiseize Lubricant 3 2 11 6 7 10 9 8 5 RIGHT 5 FRONT 4 Figure 24 1. 2. 3. 4. Bedbar assembly Compression spring Lock nut Bedbar adjuster shaft DPA Cutting Units 5. 6. 7. 8. Flange bushing Cap screw Detent Wave washer Page 7 − 18 9. Retaining ring 10. Bedbar adjuster screw 11.
Removal (Fig. 24) Installation (Fig. 24) 1. Remove lock nut (item 3), compression spring (item 2) and washer (item 11) from bedbar adjuster screw. 1. If detent (item 7) was removed, secure detent to cutting unit side plate with cap screw. 2. Remove bedbar (see Bedbar Removal in this section). 2. If flange bushings (item 5) were removed, align key on bushing to slot in frame and install bushings. NOTE: Bedbar adjuster shaft (item 4) has left−hand threads. 3.
Reel Assembly 210 to 240 in−lb (24 to 27 N−m) 8 12 4 9 13 10 210 to 240 in−lb (24 to 27 N−m) 5 11 1 5 5 5 4 2 Grease OD surface 6 RIGHT Grease OD surface FRONT 14 11 7 15 3 16 Figure 25 1. 2. 3. 4. 5. 6. Crossmember LH side plate Flange head screw (2 used) Shoulder bolt (2 used per side plate) Flange nut (2 used per side plate) Cutting reel assembly 7. 8. 9. 10. 11.
Reel Assembly Removal (Fig. 25) 90 to 110 ft−lb (123 to 149 N−m) (Right Hand Threads) 5 CAUTION 90 to 110 ft−lb (123 to 149 N−m) (Left Hand Threads) Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when removing the cutting reel. 3 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. 6 1 7 2.
8. Support cutting reel to prevent it from shifting or falling. 9. Remove shoulder bolts (item 4) and flange nuts (item 5) that secure the LH side plate to the cutting unit crossmember. Remove the LH side plate from the reel shaft, rollers, bedbar and cutting unit crossmember. 1 90 to 110 ft−lb (122 to 149 Nm) 2 3 4 10.Carefully slide the cutting reel assembly (with flocked seals, reel bearings and reel nuts) from the RH side plate. Reel Assembly Installation (Fig. 25) 1.
NOTE: The parallel position of the rear roller to the cutting reel is controlled by the precision machined crossmember and side plates of the cutting unit. If necessary, the cutting unit side plates can be loosened and a slight adjustment can be made to parallel the rear roller with the cutting reel (see Leveling Rear Roller in the Set−Up and Adjustments section of this Chapter). 14.Install cutting unit to the machine. DPA Cutting Units 12.Install new O−ring (item 12) on weight (item 10).
Reel Assembly Service 4 3 2 5 90 to 110 ft−lb (123 to 149 N−m) (Right Hand Threads) 2 3 4 1 RIGHT FRONT 90 to 110 ft−lb (123 to 149 N−m) (Left Hand Threads) 6 Figure 29 1. Cutting reel 2. Flocked seal (2 used) 3. Bearing (2 used) 4. Plug (2 used) 5. Reel nut (RH thread) 6. Reel nut (LH thread) NOTE: The reel nuts (items 5 and 6) are different. The reel nut with left hand threads (item 6) has a black finish and has notches on the head.
Disassembly of Cutting Reel (Fig. 29) 1. Remove reel nuts (items 5 and 6) from cutting reel. The black reel nut (item 6) has LH threads and is installed in end of reel shaft identified with a groove that is just inside of reel spider (Fig. 30). 3 1 2. Slide bearings from reel shaft. 3. Note orientation of flocked seals for assembly purposes. Remove seals from reel shaft. 2 Inspection of Cutting Reel (Fig. 29) Figure 30 1.
Preparing Reel for Grinding NOTE: Before grinding a cutting reel, make sure that all cutting unit components are in good condition. Depending on type of grinder used, faulty cutting unit components can affect grinding results. Reel Grinding Specifications NOTE: When grinding, be careful to not overheat the cutting reel blades. Remove small amounts of material with each pass of the grinder. 1.
DPA Cutting Units This page is intentionally blank.
Front Roller Removal (Fig. 32) 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 cutting unit from the machine and place on a level working surface. Use appropriate support to raise front roller from work surface. Antiseize Lubricant 4 3. Loosen cap screw (item 1) that secures the front roller shaft to each front height−of−cut arm. 4.
Rear Roller Removal (Fig. 34) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 4 5 2. Remove the cutting unit from the machine and place on a level working surface. Place support blocks under bedbar to raise rear roller from work surface. 3. Loosen two (2) flange nuts that secure the rear roller shaft to each rear roller shaft retainer. 2 4.
Roller Service 1 7 6 5 4 25 to 30 ft−lb (34 to 41 N−m) 2 5 4 25 to 30 ft−lb (34 to 41 N−m) 6 7 3 Figure 35 1. Wiehle roller 2. Smooth roller 3. Roller shaft 4. Ball bearing 5. Seal 6. V−ring 7. Bearing lock nut 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 screw in place with jam nut. While retaining shaft, remove bearing lock nut from each end of roller shaft. 2 3 4 5 6 2.
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. 37). 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.
Rear Roller Brushes (Optional) 1 2 Figure 41 1. Rear roller brush for cutting units with or without a belt driven groomer There are two different types of rear roller brush kits for Greensmaster 3250−D cutting units. The earlier type of kit is designed to fit on cutting units with or without a belt driven groomer. A later type of kit is designed to fit on cutting units with or without a universal groomer.
Servicing the Rear Roller Brush (with or without a belt driven groomer) Antiseize Lubricant 70 to 80 in−lb (8 to 9 N−m) 12 130 to 140 in−lb (15 to 16 N−m) 1 2 12 10 11 6 21 14 22 23 5 17 3 12 26 7 19 8 20 9 18 4 13 15 100 ft−lb (136 N−m) 25 8 16 24 RIGHT Figure 42 1. 2. 3. 4. 5. 6. 7. 8. 9. Cover Drive belt Drive pulley Pulley driver Cap screw Idler pulley assembly Cover plate Flange nut (5 used) Drive plate 10. 11. 12. 13. 14. 15. 16. 17. 18.
CAUTION 1 kg (2 lb) Contact with the reel or other cutting unit parts can result in personal injury. Use heavy gloves when handling the cutting reel. 6 mm (1/4 inch) Replacing the Roller Brush Element 1. Remove the cutting unit from the machine and place it on a level work surface. 2. Loosen the set screw in the bearing locking collar on right side of brush shaft. Figure 43 3.
2 3 G. To install the pulley driver, insert a long−handled pry bar through the front of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move. 4 1 H. Move the pry bar against the weld side of the reel support plate closest to the pulley driver. IMPORTANT: The pulley driver and drive adapter have left−hand threads. Turn the pulley driver or drive adapter counterclockwise to tighten. I.
11. Tighten the roller brush bearing locking collars. A. Slide the locking collars outward onto the bearing collars. Rotate the locking collars by hand in the direction of normal brush rotation until the collars are tight on the shaft. B. Using the blind hole in the bearing locking collar as an impact point, lock each collar by striking it with a punch in the normal direction of the brush rotation. C. Tighten the set screw in the locking collars to secure the bearing assembly to the brush shaft.
Servicing the Rear Roller Brush (with or without a universal groomer) 6 7 8 9 10 34 33 11 12 RIGHT 10 13 FRONT 14 15 15 5 10 12 2.3 to 2.
Drive components for the rear roller brush are located on the opposite side of the cutting unit from the hydraulic cutting reel motor. Figure 47 shows components used when the brush drive is on the left side of the cutting unit. 4 3 2 1 CAUTION Contact with the reel or other cutting unit parts can result in personal injury. Use heavy gloves when handling the cutting reel. Replacing the Roller Brush Element Refer to Fig. 47 for this procedure. 1.
4 3 2 Note: Install all flocked seals with the flocked surface against the bearing. 1 135 to 150 N·m (100 to 110 ft−lb) 8. Install a flocked seal and the retaining ring onto the brush shaft. 9. Install the brush and RH bearing bracket assembly. 10.Install the drive pulley. IMPORTANT: The brush drive belt may fail prematurely if the pulleys are not properly aligned. 11. Using a straight edge, determine the number of spacers necessary under the driven pulley to align the pulleys.
This page is intentionally blank.
Chapter 8 Belt Driven Groomer (Optional) Table of Contents Specifications ....................................................................................................................................... 8–2 Belt Driven Groomer (Optional).......................................................................................................... 8–2 General Information ..............................................................................................................................
Specifications Belt Driven Groomer (Optional) Item Description Grooming reel diameter 6 cm (2.375 inches) Groomer blade type Spring Steel: 42 steel blades with 1/2 inch blade spacing. Carbide: 42 steel blades with 1/2 inch blade spacing. Thin blade: 82 steel blades with 1/4 inch blade spacing. A soft or stiff groomer brush can be installed in place of the grooming reel. Groomer mounting The groomer is mounted to the cutting unit side plates.
General Information Installation Instructions The Installation Instructions for the groomer provides information regarding the set-up, operation, general maintenance procedures, and maintenance intervals for the groomer assembly on your Greensmaster machine. Refer to the Installation Instructions for additional information when servicing the groomer assembly. Grooming Performance There are a number of factors that can affect the performance of grooming.
Troubleshooting Problem The groomer reel does not rotate. Possible Causes Correction Seized grooming reel or idler bearing(s) in groomer side plate(s). Identify and replace faulty bearing(s). Broken or damaged drive belt idler spring. Replace idler . The groomer drive belt is worn, broken or damaged. If the belt slips, it probably is worn and must be replaced. Repair or replace belt if necessary.
Special Tools Special tools for servicing Toro Commercial Products are available from your Toro Distributor. Some of these tools may have been supplied with your machine, are available as Toro parts, or may also be available from a local tool supplier. Reel Thread Repair Taps 15/16–16 Right-Hand Thread – Toro Part No. 137–0926 15/16–16 Left-Hand Thread – Toro Part No. 137–0927 Use to clean or repair the internal threads of cutting unit reels.
Service and Repairs The groomer drive assembly is located on the opposite side of the cutting unit from the cutting unit hydraulic motor. Replacing the Groomer Drive Belt 1. Park the machine on a clean and level surface, lower the cutting units completely to the ground, stop the engine, engage the parking brake and remove the key from the ignition switch. 2.
Replacing the Groomer Drive Belt (continued) IMPORTANT Make sure that the drive belt is centered on the pulleys and correctly aligned with pulley grooves after installation. 5. Install a new drive belt to the drive pulley, idler pulley and the driven pulley observing correct belt routing. 6. Secure the belt cover to the machine with three lock nuts. 7.
The Groomer Plate Assemblies g229416 Figure 3 1. Lock nut (4 each) 11. Bushing (2 each) 21. Lock nut (2 each) 2. Drive cover 12. Spring washer (2 each) 22. Plow bolt (2 each) 3. Drive belt 13. Lock nut (2 each) 23. Grooming reel assembly 4. Drive pulley 14. Support plate assembly 24. O-ring 5. Shoulder bolt (2 each) 15. Groomer arm – LH 25. Front roller assembly 6. Extension spring 16. Tabbed washer (2 each) 26. Motor adapter 7. Drive plate assembly 17.
Removing the Drive Plate (continued) 4. Remove the groomer drive cover and drive belt. 5. Loosen and remove the drive pulley from the cutting reel: A. Tip up the cutting unit to access the bottom of the reel. g325691 Figure 4 1. Drive pulley 3. Unwelded side of reel support plate 2. Reel shaft 4. Pry bar B. Insert a long-handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit.
Removing the Drive Plate (continued) IMPORTANT If the groomer drive assembly is installed on the left side of the cutting unit, the drive pulley has left-hand threads. Turn the pulley driver or drive adapter clockwise to loosen. If the groomer drive assembly is installed on the right side of the cutting unit, the drive pulley has right-hand threads. Turn the pulley driver or drive adapter counterclockwise to loosen. D. Rest the handle of the pry bar against the front roller and loosen the drive pulley. E.
Removing the Drive Plate (continued) g229543 Figure 6 1. Driven pulley 2. Idler pulley 3. Idler arm extension spring 11. Remove the idler arm extension spring. 12. Remove the two shoulder bolts that secure the drive plate assembly to the cutting unit and remove the groomer drive plate assembly. Locate and retrieve the shim. 13. Inspect the seals, bushings and bearings in the drive plate, support plate and groomer arms for wear or damage. Replace components as needed.
Removing the Support Plate (continued) g229554 Figure 7 1. Pinch bolt 4. Spring washer 2. 3. Groomer reel Lock nut 5. Groomer arm – RH 5. Remove the lock nut and spring washer that secure the RH groomer arm to the drive plate assembly. Note: To speed cutting unit setup after installing the groomer reel, do not change the height adjustment bolt or the groomer adjuster setting. 6. Remove the lock nut, tabbed washer and plow bolt that secure the RH groomer arm assembly to the cutting unit side plate.
Servicing the Drive and Support Plates g229556 Figure 8 1. Drive plate 9. Reel hub 2. Support plate 10. Idler pulley 3. Retaining ring 11. Bearing (2 each) 4. Bushing (2 each) 12. Retaining ring 5. Spacer 13. Flange nut 6. Idler arm 14. Shaft seal (3 each) 7. Spacer 15. Shaft bearing (3 each) 8. O-ring 16. Expansion plug 1. Remove the retaining ring and separate the reel hub, spacers and idler arm from the drive plate. 2. Replace idler pulley bearings if necessary. 3.
Servicing the Drive and Support Plates (continued) g229557 Figure 9 1. Drive plate 6. Inner shaft seal 2. Support plate 7. Bearing 3. 4. Outer shaft seal Outer bearing 8. 9. Seal Expansion plug 5. Inner bearing IMPORTANT Bearings should be installed with extended inner races toward center of plate. Apply pressure equally to inner and outer bearing races when installing bearings. Seals should be installed with the face of the seal toward the outside of the plate. 6.
Installing the Support Plate (continued) the cutting unit side plate with two socket head screws and lock nuts. Make sure the groomer reel and the support plate rotate freely after installation. 5. Insert the front roller into the LH groomer arm. 6. Install the RH groomer arm: A. Apply anti-seize lubricant to the shoulder of the groomer arm lift rod. B. Position the groomer arm over the front roller, through the support plate bushing and against the cutting unit side plate.
Installing the Drive Plate (continued) 5. Carefully fit the drive plate assembly onto the groomer shaft and into the pilot bore of the cutting unit side plate. Secure the drive plate to the cutting unit side plate with two shoulder bolts. Make sure the groomer reel, the drive plate and the idler arm rotate freely after installation. 6. Install the idler arm extension spring. g229543 Figure 11 1. Driven pulley 2. Idler pulley 3. Idler arm extension spring 7.
Installing the Drive Plate (continued) g229452 Figure 12 1. 2. Pinch bolt Groomer reel 3. 4. Lock nut Spring washer 5. Groomer arm – LH D. Secure the groomer arm to the drive plate with the spring washer and lock nut. 10. Center the front roller in the cutting unit and tighten both pinch bolts. 11. Install the drive pulley: A. Insert a long-handled pry bar through the front of the cutting unit.
Installing the Drive Plate (continued) IMPORTANT If the groomer drive assembly is installed on the left side of the cutting unit, the drive pulley has left-hand threads. Turn the drive pulley counterclockwise to tighten. If the groomer drive assembly is installed on the right side of the cutting unit, the drive pulley has right-hand threads. Turn the drive pulley clockwise to tighten. C.
The Groomer Reel Removing the Groomer Reel 1. Remove the groomer drive plate; refer to Removing the Drive Plate (page 8–8). 2. Carefully pull the grooming reel from the support plate on the right side of the cutting unit. 3. Retrieve and discard the O-ring from the support plate end of the groomer reel shaft. Servicing the Groomer Reel g229531 Figure 14 1. Groomer reel shaft 4. Spacer – thin (82 each) 7. Midpoint 2. Groomer blade (42 each) 5. Locknut (2 each) 8. Centered on shaft 3.
Servicing the Groomer Reel (continued) Note: New lock nuts have an insert to prevent the lock nut from loosening. If a used lock nut is being installed, apply a medium strength thread locker (Loctite #242 or equivalent) to the threads of the lock nut. A. Install a lock nut on one end of the groomer reel shaft. B. Install a single 12 mm (0.46 inch) spacer against the lock nut. Then, place the first blade against the spacer installed. Note: For standard 13 mm (1/2 inch) spacing, fit two 5.6 mm (0.
The Groomer Arm Assemblies g229587 Figure 15 1. Groomer arm – LH 11. Cap screw 2. Flange nut 12. Bushing 3. Grooved pin 13. Wave washer 4. E-ring 14. Adjuster 5. Lift rod 15. Drive plate 6. 7. Lock screw Bushing (2 each) 16. 17. Lock nut Spring washer 8. Lift arm assembly 18. Bushing 9. Detent spring 19. Plastic plug 10.
Installing the Groomer Arms (continued) A. Install the lock screw before installing the grooved pin. The grooved pin is used to retain the lock screw. B. Apply anti-seize lubricant to the threads of the lift rods before installing the adjusters. 2. Apply anti-seize lubricant to the shoulder of the groomer arm lift rods and the shoulder of the lift arm studs. 3. Position either groomer arm through the drive plate bushing and against the cutting unit side plate.
The Grooming Brushes (Optional) g229598 Figure 16 1. Spiral brush 2. Spiral brush shaft 3. J-bolt (2 each) 4. Lock nut (2 each) 7. Grooming brush shaft 5. O-ring 8. Roll pin (2 each) 6. Grooming brush The optional grooming brush attaches to the groomer in place of the groomer reel. The grooming brush is removed and installed from the groomer in the same manner as the groomer reel; refer to The Groomer Reel (page 8–19). The grooming brush elements or shafts can be serviced separately.
Belt Driven Groomer (Optional): Service and Repairs Page 8–24 Greensmaster® 3250-D 12186SL Rev C
Chapter 9 Universal Groomer (Optional) Table of Contents Specifications ....................................................................................................................................... 9–2 Universal Groomer............................................................................................................................. 9–2 General Information ..............................................................................................................................
Specifications Universal Groomer Item Description Grooming reel diameter 6 cm (2.375 inches) Groomer blade type Spring Steel: 40 steel blades with 1/2 inch blade spacing. Carbide: 40 steel blades with 1/2 inch blade spacing. Thin blade: 81 steel blades with 1/4 inch blade spacing. The groomer brush can be installed in place of grooming reel. Groomer mounting The groomer is mounted to the cutting unit side plates.
General Information Installation Instructions The Installation Instructions for the groomer provides information regarding the set-up, operation, general maintenance procedures, and maintenance intervals for the groomer assembly on your Greensmaster machine. Refer to the Installation Instructions for additional information when servicing the groomer assembly.
Troubleshooting Grooming Performance There are a number of factors that can affect the performance of grooming. These factors vary for different golf courses and from fairway to fairway. It is important to inspect the turf frequently and vary the grooming practice with turf needs. IMPORTANT Improper or overaggressive use of the groomer (e.g., too deep or too frequent grooming) may cause unnecessary stress on the turf leading to severe turf damage. Use the groomer carefully.
Groomer Reel Mechanical Problems Problem The groomer reel does not rotate. The turf is damaged or has uneven grooming. Greensmaster® 3250-D 12186SL Rev C Possible Causes Correction The groomer drive is in neutral. Engage the groomer drive to forward or reverse. The groomer drive gears are damaged or seized. Repair the groomer drive. The groomer is set too aggressively. Refer to groomer Installation Instructions for groomer set-up information. The groomer reel blades are bent, damaged, or missing.
Special Tools Special tools for servicing Toro Commercial Products are available from your Toro Distributor. Some of these tools may have been supplied with your machine, are available as Toro parts, or may also be available from a local tool supplier. Reel Thread Repair Taps 15/16–16 Right-Hand Thread – Toro Part No. 137–0926 15/16–16 Left-Hand Thread – Toro Part No. 137–0927 Use to clean or repair the internal threads of cutting unit reels. Drive Shaft Removal Tool Toro Part No.
Syringe – 50cc (2 ounce) Toro Part No. 137-0872 Aids in accurately filling the optional Universal Groomer gear box with oil.
Service and Repairs The groomer gear box assembly is located on the opposite side of the cutting unit from the cutting unit hydraulic motor. g227930 Figure 17 1. Gear box assembly 3. Groomer reel 5. Weight 2. Idler assembly 4. Height adjuster assembly (2 each) 6. Flat head screw (2 each) CAUTION Never work on the groomer with the engine running. Always stop the engine, remove the key from the ignition switch and wait for all machine movement to stop before working on the groomer.
The Gear Box Assembly g251181 Figure 18 1. Gear box assembly 4. Clevis pin 2. Drive shield 5. Input shaft 3. Cotter pin 6. Shim (left side groomer drive only) The groomer gear box assembly is located on the opposite side of the cutting unit from the cutting unit hydraulic motor. Removing the Gear Box Assembly IMPORTANT The groomer gear boxes for front left and center (rear) cutting units are installed on the left side of the cutting unit.
Removing the Gear Box Assembly (continued) 4. Install a 5/16–18 X 5/8 inch square head set screw (Toro p/n 1-803022) in the end of the drive shaft and tighten to 13 N·m (120 in-lb); refer to Figure 19. 5. Remove the cotter pin and clevis pin from the height adjustment rod at the front of the groomer gear box. Discard the cotter pin. 6. Tip up the cutting unit to access the bottom of the reel to remove the drive shaft assembly. g324486 Figure 19 1. 5/16–18 X 5/8 inch square head set screw 4.
Removing the Gear Box Assembly (continued) IMPORTANT You must use a 6-point socket with a heavy wall to remove the gear box from the reel. Do not use an impact wrench. Groomer gear boxes installed on the left side of the cutting unit use a left hand thread; turn the drive shaft clockwise to remove the gear box. Groomer gear boxes installed on the right side of the cutting unit use a right hand thread; turn the drive shaft counterclockwise to remove the gear box. 9.
Removing the Gear Box Assembly (continued) C. Slide the thrust washer, ring gear and bushing from the gear box housing. D. Slide the sun gear, and planet gears and bushings from the pins on the gear box housing. E. Remove the retaining ring from the drive shaft. F. Slide the groomer housing assembly from the drive shaft. G. Tip up the cutting unit to access the bottom of the reel to remove the drive shaft assembly. g324522 Figure 21 1. Damaged input shaft assembly 4.
Removing the Gear Box Assembly (continued) J. Use the drive shaft removal tool on the large flats of the drive shaft assembly; refer to Drive Shaft Removal Tool (page 9–6). IMPORTANT The drive shaft for groomer gear boxes installed on the left side of the cutting unit use a left hand thread; turn the drive shaft clockwise to loosen. The drive shaft for groomer gear boxes installed on the right side of the cutting unit use a right hand thread; turn the drive shaft counterclockwise to loosen. K.
Servicing the Gear Box g251182 Figure 22 1. Drive adapter 15. Thrust washer 29. Ring gear 2. Input shaft 16. O-ring 30. Flange bushing 3. O-ring (3 each) 17. O-ring 31. Sun gear 4. V-ring 18. Dowel pin (2 each) 32. Bearing 5. Oil seal 19. Drain/fill plug (4 each) 33. Planet gear (3 each) 6. Groomer housing 20. Straight bushing (2 each) 34. Flange bushing (3 each) 7. Ball bearing (2 each) 21. Detent ball 35. Locknut 8. Retaining ring 22. Detent spring 36.
Servicing the Gear Box (continued) 1. Remove the drain/fill plug and drain the oil from the gear box. 2. Remove the 4 socket-head screws and separate the gear box cover and housing. Remove and discard the cover gasket. 3. Slide the sun gear, ring gear, and planet gears from the pins on the gear box housing. 4. Continue to disassemble the gear box as necessary. 5.
Installing the Gear Box Assembly Refer to Figure 18 for this procedure. 1. Apply medium strength thread locking compound (Loctite 243 or equivalent) to the threads in the reel and allow the thread locking compound to cure for 15 minutes before continuing this procedure. 2. For cutting units with the groomer drive assembly on the left side, fit the shim (item 6 in Figure 18) over the input shaft. 3. Insert a long-handled pry bar through the front of the cutting unit.
Installing the Gear Box Assembly (continued) IMPORTANT You must use a 6-point socket with a heavy wall to install the gear box to the reel. Do not use an impact wrench. 6. Tighten the drive shaft assembly from 135 to 150 N∙m (100 to 110 ft-lb). 7. Remove the square head set screw from the end of the drive shaft. 8. Install the clevis pin and a new cotter pin to secure the height adjustment rod to the front of the groomer gear box. 9.
The Idler Assembly g251183 Figure 24 1. Socket-head screw (2 each) 2. 3. Motor adapter 9. Stub shaft 10. Flocked seal (2 each) 11. Bearing 4. Bushing 12. Retaining ring 5. Idler arm 13. Flange nut 6. O-ring 14. Clevis pin 7. Lock nut (2 each) 15. Cotter pin 8. Shield 16. Collar The groomer idler assembly is located on the opposite side of the groomer gear box. Removing the Idler Assembly 1.
Installing the Idler Assembly (continued) A. Press the bushing into a groomer plate until the bushing is centered in the idler arm bore. B. Press the bearing into the idler arm so that the bearing contacts the shoulder in idler arm bore and install the bearing retaining ring. C. Install the bearing shields with the flocked side of the shield toward the bearing. D. Insert the stub shaft through the shields and bearing.
The Groomer Reel g228732 Figure 25 1. Shaft clamp (4 each) 3. Bolt (4 each) 2. Jam nut (4 each) 4. Groomer reel Remove the groomer reel to replace individual groomer blades or replace the shaft. The groomer reel can be reversed to provide additional blade life. Removing the Groomer Reel 1. Park the machine on a clean and level surface, lower the cutting units completely to the ground, set the parking brake, and remove the key from the key switch.
Servicing the Groomer Reel g251184 Figure 26 1. 5. Groomer reel shaft Rounded edge 2. Groomer blade (40 each) 6. Midpoint 3. Spacer (39 each) 7. Centered on shaft 4. Locknut (2 each) Inspect the groomer reel blades frequently for any damage and wear. Straighten the bent blades. Either replace the worn blades or reverse the individual blades to put the sharpest blade edge forward.
Servicing the Groomer Reel (continued) D. When all the blades have been installed, install the second lock nut onto the shaft. Center the blades and spacers on the shaft by adjusting the lock nuts. E. Use the through holes in shaft to prevent the shaft from rotating and tighten the second lock nut to 42 to 48 N∙m (31 to 35 ft-lb). After tightening the lock nut, spacers should not be free to rotate and the groomer blades should be centered on the shaft. 7.
The Height Adjuster Assembly g251185 Figure 27 1. Clevis pin 11. Pinch bolt 2. Cotter pin 12. Height-of-cut bracket 3. Tabbed washer 13. Quick up lever 4. Lock nut 14. Groomer pin 5. Bumper 15. Quick up cover 6. Plow bolt 16. Detent spring 7. Height adjustment rod 17. Button-head screw 8. Flange nut 18. Height adjuster knob 9. Washer (2 each) 19. Height adjustment bolt 10.
Disassembling the Height Adjuster (continued) 6. Disassemble the height adjuster assembly as necessary. 7. Replace components that are worn or damaged. Assembling the Height Adjuster 1. Apply anti-seize lubricant to the upper threads of the adjustment rod and lower threads of the height adjusters. Assemble the height adjuster assembly. 2. If both the height adjusters are removed, fit 1 height adjuster assembly to the cutting unit side plate and secure it with a plow bolt, tabbed washer and lock nut.
The Grooming Brush (Optional) g229629 Figure 29 1. Spiral brush 4. Lock nut (2 each) 2. Brush shaft 5. Grooming brush 3. J-bolt (2 each) 6. Roll pin (2 each) The optional grooming brush attaches to the groomer in place of the groomer reel. The grooming brush is removed and installed from the groomer in the same manner as the groomer reel; refer to The Groomer Reel (page 9–20). The grooming brush element or shaft can be serviced separately.
Universal Groomer (Optional): Service and Repairs Page 9–26 Greensmaster® 3250-D 12186SL Rev C
Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations.........................................................................................................A–2 Hydraulic Schematic ..........................................................................................................................A–3 Electrical Circuit Diagrams – Crank Circuits (typical)..........................................................................
Electrical Drawing Designations Note: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire harness diagram (e.g., SP01 is splice number 1). Wire Color The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter.
Hydraulic Schematic g327656 Greensmaster 3250-D Model 04384, Drawing 121-9527 Rev A, Sheet 1 of 1 12186SL Rev C Page A–3
Electrical Circuit Diagrams – Crank Circuits (typical) g327658 Page A–4 12186SL Rev C Greensmaster 3250-D, Drawing 120-6307 Rev A, Sheet 1 of 6
Electrical Circuit Diagrams – Run Circuits (typical) g327662 Greensmaster 3250-D, Drawing 120-6307 Rev A, Sheet 2 of 6 12186SL Rev C Page A–5
Electrical Circuit Diagrams – Raise Cutting Units Circuits (typical) g327661 Page A–6 12186SL Rev C Greensmaster 3250-D, Drawing 120-6307 Rev A, Sheet 3 of 6
Electrical Circuit Diagrams – Lower Cutting Units Circuits (typical) g327659 Greensmaster 3250-D, Drawing 120-6307 Rev A, Sheet 4 of 6 12186SL Rev C Page A–7
Electrical Circuit Diagrams – Mow Circuits (typical) g327660 Page A–8 12186SL Rev C Greensmaster 3250-D, Drawing 120-6307 Rev A, Sheet 5 of 6
Electrical Circuit Diagrams – Backlap Circuits (typical) g327657 Greensmaster 3250-D, Drawing 120-6307 Rev A, Sheet 6 of 6 12186SL Rev C Page A–9
Electrical Schematic (serial numbers before 315000000) g327664 Page A–10 12186SL Rev C Greensmaster3250-D Model 04384 (serial numbers before 315000000), Drawing 120-6307 Rev A, Sheet 1 of 1
Electrical Schematic (serial numbers 315000000 to 407100000) g327665 Greensmaster 3250-D Model 04384 (serial numbers 315000000 to 407100000), Drawing 122-0517 Rev A, Sheet 1 of 1 12186SL Rev C Page A–11
Electrical Schematic (serial numbers above 407100000) g327666 Page A–12 12186SL Rev C Greensmaster 3250-D Model 04384 (serial numbers above 407100000), Drawing 122-1391 Rev A, Sheet 1 of 1
Main Wire Harness Drawing (serial numbers below 315000000) g327750 Greensmaster 3250-D Model 04384 (serial numbers below 315000000), Drawing 120-6306 Rev E, Sheet 1 of 2 12186SL Rev C Page A–13
Main Wire Harness Diagram (serial numbers below 315000000) g327749 Page A–14 12186SL Rev C Greensmaster 3250-D Model 04384 (serial numbers below 315000000), Drawing 120-6306 Rev E, Sheet 2 or 2
Main Wire Harness Drawing (serial numbers 315000000 to 407100000) g327989 Greensmaster 3250-D Model 04384 (serial numbers 315000000 to 407100000), Drawing 122-0149 Rev D, Sheet 1 of 2 12186SL Rev C Page A–15
Main Wire Harness Diagram (serial numbers 315000000 to 407100000) g327988 Page A–16 12186SL Rev C Greensmaster 3250-D Model 04384 (serial numbers 315000000 to 407100000), Drawing 122-0149 Rev D, Sheet 2 of 2
Main Wire Harness Drawing (serial numbers above 407100000) g327991 Greensmaster 3250-D Model 04384 (serial numbers above 407100000), Drawing 122-1392 Rev A, Sheet 1 of 2 12186SL Rev C Page A–17
Main Wire Harness Diagram (serial numbers above 407100000) g327990 Page A–18 12186SL Rev C Greensmaster 3250-D Model 04384 (serial numbers above 407100000), Drawing 122-1392 Rev A, Sheet 2 of 2
