Form No.
Revision History Revision Date -- 2012 A 02/2018 Updated Solenoids S3 and S4. Added revision history. B 04/2018 Revised bedknife installation procedure, added Universal Groomer chapter. C 07/2021 Updated Foldout Drawings. © THE TORO COMPANY 2021 Description Initial Issue 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.
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Part No. 12187SL Rev. C Service Manual (Models 04510 and 04520) GreensmasterR TriFlexTM 3300/3400 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 TriFlex 3300 and 3400. REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
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General Safety Instructions . . . . . . . . . . . . . . . . . . 1 -- 2 Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 5 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 6 General Information . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 3 Turf Guardian Leak Detector System Operation . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 6 Troubleshooting . . . . . . . . . . .
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Chapter 9 -- Belt Driver Groomer (Optional) Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . Chapter 10 -- Universal Groomer (Optional) 9 -9 -9 -9 -9 -- 2 3 4 6 7 Specifications . . . . . . . . . . . .
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Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
General Safety Instructions Greensmaster TriFlex 3300 and 3400 machines have been tested and certified by TORO for compliance with existing safety standards and specifications. 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. Sit on the seat when starting and operating the machine. 2. Before starting the engine: A. Sit on the seat, make sure cutting units are disengaged. 4. Do not touch engine, exhaust system components or radiator (if equipped) while engine is running or soon after it is stopped. These areas could be hot enough to cause burns. 5. Before getting off the seat: A. Make sure cutting units are disengaged. B. Verify that functional control lever is in neutral. B.
Maintenance and Service 1. The Traction Unit and Cutting Unit Operator’s Manuals provide information regarding the operation, general maintenance and maintenance intervals for your Greensmaster machine. Refer to these publications for additional information when servicing the machine. 2. Before servicing or making adjustments, lower cutting units, stop engine, apply parking brake and remove key from the ignition switch. 3.
Jacking Instructions Safety CAUTION When changing attachments, tires or performing other service, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands to support the raised machine.
Safety and Instruction Decals Numerous safety and instruction decals are affixed to the traction unit and the cutting units of Greensmaster TriFlex 3300 and 3400 machines. If any decal becomes illegible or damaged, install a new decal. Part numbers are listed in your Parts Catalog and Operator’s Manual. Order replacement decals from your Authorized Toro Distributor.
Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 0.
Torque Specifications These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual. The following factors shall be considered when applying torque: cleanliness of the fastener, use of a thread sealant (e.g.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in−lb in−lb N−cm 10 + 2 13 + 2 147 + 23 # 6 − 32 UNC # 6 − 40 UNF # 8 − 32 UNC 13 + 2 25 + 5 # 10 − 24 UNC 30 + 5 SAE Grade 8 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 5 or Stronger Nuts) in−lb N−cm in−lb N−cm 15 + 2 170 + 20 23 + 2 260 + 20
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 5 in−lb 640 + 60 N−cm 78 + 7 in−lb 885 + 80 N−cm M6 X 1.0 96 + 9 in−lb 1018 + 100 N−cm 133 + 13 in−lb 1500 + 150 N−cm M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m 27 + 2 ft−lb 36 + 3 N−m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Recommended Torque 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 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 Gasoline Engine Table of Contents Greensmaster 3300 Page 3 − 1 Gasoline Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 FUEL EVAPORATIVE CONTROL SYSTEM . . . . . . 4 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Choke Cable Adjustment . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Make / Designation Briggs and Stratton, 4−cycle, V−Twin Cylinder, OHV, Air Cooled, Gasoline Engine − Model 385447 Bore x Stroke 2.97” x 2.76” (75.5 mm x 70 mm) 38.3 in3 (627 cc) Total Displacement Governor Mechanical Governor Carburetor Float Feed, Two Barrel Fuel Pump Pulsating Crankcase Vacuum Fuel Unleaded, regular grade gasoline Fuel Tank Capacity 6.0 U.S. gallons (22.
General Information Information about specifications, maintenance, troubleshooting, testing and repair of the gasoline engine used in the Greensmaster TriFlex 3300 is included in this chapter and the Briggs & Stratton Vanguard V−Twin OHV Repair Manual. Service and repair parts for Briggs & Stratton Vanguard V-Twin OHV engines are supplied through your local local Toro distributor.
Fuel Evaporative Control System SERIAL NUMBER BELOW 312000000 CHECK VALVE TO INTAKE MANIFOLD FUEL TANK CARBON CANNISTER ENGINE FRESH AIR FILTER SERIAL NUMBER ABOVE 312000000 CARBON CANNISTER CHECK VALVE TO INTAKE MANIFOLD FUEL TANK CHECK VALVE FRESH AIR FILTER TO AIR CLEANER ENGINE Figure 1 Gasoline Engine Page 3 − 4 Greensmaster 3300
The function of the fuel evaporative control system is to collect and store evaporative emissions from the fuel tank and engine. The evaporate control system used on Greensmaster 3300 machines uses a carbon cannister to collect these evaporative emissions. Fuel vapors from the fuel tank are vented to the canister when the engine is not running. Vapors from the canister are consumed when the engine is running.
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Adjustments Choke Cable Adjustment 1. Park machine on a level surface, disengage and lower cutting units, move functional control lever to neutral (N), engage parking brake, stop the engine and remove the key from the ignition switch. Wait for all machine movement to stop. 2. Remove air cleaner cover and air filter from engine. 3. Move choke control on control panel while watching choke plate in carburetor. 4. If cable adjustment is needed, loosen cap screw and nut that secure choke cable clamp.
Service and Repairs Fuel Evaporative Control System (Serial Number Below 312000000) 1 2 8 7 9 6 4 19 11 6 4 10 19 6 5 12 14 13 19 15 19 16 3 17 RIGHT 18 FRONT Figure 3 1. 2. 3. 4. 5. 6. 7. Flange head screw (2 used) Tank mount plate Fuel hose (to engine intake manifold) Grommet (2 used) Fuel hose (cannister to tank vent) Hose clamp (3 used) Carbon canister Gasoline Engine 8. 9. 10. 11. 12. 13.
Removal (Fig. 3) 2 1. Park machine on a level surface, disengage and lower cutting units, move functional control lever to neutral (N), engage parking brake, stop the engine and remove the key from the ignition switch. Wait for all machine movement to stop. 1 DANGER 3 FRONT Figure 4 1. Carbon cannister 2. Hose to tank vent 3. Hose to engine 2. Access the carbon cannister under the fuel tank and between the rear frame sections.
Fuel Evaporative Control System (Serial Number Above 312000000) 8 1 1 14 7 6 21 31 29 30 9 6 14 12 28 27 29 29 32 11 2 24 4 5 10 3 22 20 35 13 20 3 34 14 18 29 15 25 26 18 33 16 14 RIGHT FRONT 23 25 19 17 14 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Flange head screw (2 used) Tank mount plate Washer head screw (2 used) Grommet (2 used) Washer head screw Hose clamp (2 used) Carbon cannister Cannister bracket Flange nut Worm clamp Cap screw R−clamp 13. 14. 15. 16. 17.
Removal (Fig. 5) Installation (Fig. 5) 1. Park machine on a level surface, disengage and lower cutting units, move functional control lever to neutral (N), engage parking brake, stop the engine and remove the key from the ignition switch. Wait for all machine movement to stop. 1. Install all removed components using Figure 5 as a guide. A. If either purge hose assembly (item 27) or tee hose assembly (item 28) was removed, make sure that installation is correct. B.
Fuel Tank 31 Illustration from machine with serial number below 312000000 shown 32 27 23 28 5 22 30 29 1 2 24 8 6 9 7 3 33 10 34 Antiseize Lubricant 30 to 50 in−lb (3.4 to 5.6 N−m) 11 6 35 10 4 12 14 5 3 10 5 13 18 15 19 25 26 RIGHT 16 10 14 20 10 21 FRONT 17 14 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Fuel Tank Removal (Fig. 7) Fuel Tank Installation (Fig. 7) 1. Park machine on a level surface, disengage and lower cutting units, move functional control lever to neutral (N), engage parking brake, stop the engine and remove the key from the ignition switch. Wait for all machine movement to stop. 1. Install fitting assembly and shut−off valve into fuel tank if they were removed from tank (Fig. 8). The nut and fitting have left hand threads. 2. Position fuel tank on the tank mount plate. 3.
Engine 90 to 110 in−lb (10.2 to 12.4 N−m) 20 to 25 in−lb (2.3 to 2.8 N−m) FRONT 1 Antiseize Lubricant RIGHT 25 to 38 ft−lb (34 to 51 N−m) 2 21 7 170 to 200 in−lb (19.3 to 22.6 N−m) 23 3 24 19 13 15 10 16 6 25 20 22 4 8 26 9 8 12 5 11 14 17 18 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. Engine assembly Spacer screw Muffler Muffler mount Cap screw (4 used) Flange nut (4 used) Muffler shield Hardened washer (8 used) Cap screw (4 used) 10. 11. 12. 13. 14. 15. 16. 17. 18.
2. Disconnect the negative (−) battery cable at the battery. 3 2 3. Close fuel shut−off valve on fuel tank. 4. Disconnect fuel hoses from the fuel filter outlet and the check valve near rear engine cylinder head (Fig. 10). Drain any fuel trapped in the fuel filter and fuel hose into a suitable container. 5. Disconnect choke and throttle control cables from engine. 7. Disconnect wire harness connectors from engine components: 4 Figure 10 1. Fuel filter 2. Check valve 3. Rear cylinder head 4.
Engine Installation (Fig. 9) 1. Make sure that all removed engine components are correctly installed to the engine. 2. If exhaust system components were removed from engine, attach removed components using Figure 9 as a guide. 3. Apply antiseize lubricant to engine crankshaft. Position square key (item 19) to crankshaft. IMPORTANT: Make sure to not damage the engine, fuel hose, hydraulic hoses, electrical harness, control cables or other parts while installing the engine. 4.
Chapter 4 Diesel Engine Table of Contents Greensmaster 3400 Page 4 − 1 Diesel Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Adjust Throttle Control . . . . . . . . . . . . . . . . . . . . . . . 5 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Make / Designation Kubota water−cooled, Diesel, Model D902−E3B Number of Cylinders 3 Bore x Stroke 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 TriFlex 3400 is included in this chapter and the Kubota Workshop Manual, Diesel Engine, SM−E3B Series. Service and repair parts for Kubota engines are supplied through your local local Toro distributor. If no parts list is available, be sure to provide your distributor with the Toro model and serial number.
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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. 1. Move throttle control lever on control console to FAST position. 2. Check position of the engine speed control lever on fuel injection pump (Fig. 1).
Service and Repairs Air Cleaner Assembly RIGHT 1 2 FRONT 3 7 4 5 6 6 8 9 Figure 3 1. Air inlet hood 2. Flat washer (2 used) 3. Cap screw (2 used) Diesel Engine 4. Mounting bracket 5. Air cleaner assembly 6. Hose clamp (2 used) Page 4 − 6 7. Flange nut (2 used) 8. Air intake hose 9.
Air Cleaner Removal (Fig. 3) 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 3 as a guide. 3. Check air intake hose (item 8) for damage or wear. Replace hose if damage is found. 4. Disassemble air cleaner as necessary (Fig. 4). 1 5. Check air cleaner housing and cover for damage that could cause possible air leaks. 2 Air Cleaner Installation (Fig.
Exhaust System FRONT RIGHT 3 13 15 11 17 4 13 5 9 8 14 7 6 16 10 16 3 13 2 6 12 1 18 Figure 5 1. 2. 3. 4. 5. 6. Engine assembly Muffler assembly Lock nut (4 used) Exhaust pipe Flange head screw Flange nut (4 used) Diesel Engine 7. 8. 9. 10. 11. 12. Lock washer (3 used) Exhaust plate Exhaust gasket Flange nut Flange nut Brace Page 4 − 8 13. 14. 15. 16. 17. 18.
Exhaust System Removal (Fig. 5) Exhaust System Installation (Fig. 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. 1. Make sure the engine is off. CAUTION 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. 2. Remove exhaust system components as needed using Figure 5 as a guide.
Fuel Tank 5 6 7 11 10 1 8 9 2 16 17 11 12 15 13 14 3 RIGHT Antiseize Lubricant 30 to 50 in−lb (3.4 to 5.6 N−m) 4 FRONT 3 Figure 6 1. 2. 3. 4. 5. 6. Fuel tank Tank mount plate Flange head screw (4 used) Clip (2 used) Fuel cap Fuel vent valve 7. 8. 9. 10. 11. 12. Grommet Bushing Elbow fitting Vent hose Hose clamp Flange bushing (4 used) 13. 14. 15. 16. 17. Flat washer (4 used) Cap screw (4 used) Return hose Hose clamp Fuel supply hose Fuel Tank Removal (Fig. 6) 1.
1. Install fitting assembly and shut−off valve into fuel tank if they were removed from tank (Fig. 7). The nut and fitting have left hand threads. CAUTION The muffler and exhaust manifold may be hot. Avoid possible burns, allow exhaust system to cool before working on the engine. DANGER 2. Position fuel tank on the tank mount plate. 3. Move fuel tank towards the rear of the machine and install return hose (item 15) to elbow fitting on front of tank. Secure hose with hose clamp. 4.
Radiator 20 25 23 24 20 7 16 8 5 3 6 1 20 16 16 6 2 17 22 21 4 18 19 16 20 14 16 8 9 13 10 12 11 15 RIGHT FRONT Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. Seal panel Radiator shroud Trim seal Fan assembly Radiator assembly Hose clamp (2 used) R−clamp (2 used) Clip (8 used) Stud (2 used) Diesel Engine 10. 11. 12. 13. 14. 15. 16. 17.
10.Disconnect fan wire connector from machine wire harness. Radiator Removal (Fig. 8) 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. 11. Support radiator assembly to prevent it from falling. 12.Remove four (4) flange nuts that secure front shroud to machine. Remove radiator assembly from machine. CAUTION 13.Remove components from radiator as necessary using Figure 8 as a guide.
Engine FRONT 22 RIGHT 27 3 13 15 18 28 17 22 11 4 13 5 9 8 14 7 6 23 16 25 24 10 16 3 13 2 26 6 21 12 1 18 20 19 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Engine assembly Muffler assembly Lock nut (4 used) Exhaust pipe Flange head screw Flange nut (4 used) Lock washer (3 used) Exhaust plate Exhaust gasket Flange nut 11. 12. 13. 14. 15. 16. 17. 18. 19.
2. Close fuel shut−off valve on fuel tank. 3. Remove air cleaner and air intake hose from machine (see Air Cleaner Removal in this section). 3 2 4. Remove radiator from machine (see Radiator Removal in this section). 5. Remove exhaust system from machine (see Exhaust System Removal in this section). 6. Disconnect fuel supply hose from the injector pump and fuel return hose from the #3 injector. Drain any fuel trapped in the hoses into a suitable container.
1 CAUTION When removing engine assembly, make sure lift or hoist can safely support 190 lbs (86 kg). 2 11. Attach a suitable lift or hoist to engine. Support engine with lift or hoist to prevent engine from shifting or moving. 5 12.Remove fasteners that secure engine to machine: 3 A. Remove cap screw, spacer, snubbing washer and flange nut that secure engine support to engine mount (Fig. 14). 4 Figure 13 B.
IMPORTANT: Make sure to not damage the engine, fuel hoses, hydraulic lines, electrical harness or other parts while installing the engine. Also, make sure that hydraulic pump assembly does not shift location during engine installation. 5. Slowly move the engine assembly toward the hydraulic pump assembly to allow the pump coupling to slide into the engine coupling flange (Fig. 16). 6. Secure hydraulic pump assembly to bell housing on engine with two (2) cap screws and flat washers (Fig. 16). 13.
Engine Bell Housing 6 4 3 1 FRONT RIGHT 5 2 Figure 17 1. Engine 2. Flange head screw (5 used) 3. Bell housing 4. Coupling flange 5. Flange head screw (5 used) 6. Dowel pin (2 used) 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. If coupling flange was removed from engine flywheel, position flange to flywheel and align mounting holes.
Chapter 5 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Operator’s Manuals . . . . . . . . . . . . . . . . . . . . . . . . . 4 Check Hydraulic Fluid Level . . . . . . . . . . . . . . . . . . 4 Pushing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . 4 Relieving Hydraulic System Pressure . . . . . . . . . . 5 Traction Circuit Component Failure . . . . . . . . . . . . 5 Hydraulic Hoses . .
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Specifications Item Description Piston (Traction) Pump Maximum Pump Displacement (per revolution) Variable displacement piston pump (Eaton model 70160) 1.44 in3 (23.6 cc) Gear Pump Front Section Displacement (per revolution) Rear Section Displacement (per revolution) 2 section, positive displacement gear pump (Casappa) 0.58 in3 (9.5 cc) 0.33 in3 (5.4 cc) Charge Circuit Relief Pressure 110 to 150 PSI (7.6 to 10.
General Information Operator’s Manuals The Traction Unit and Cutting Unit Operator’s Manuals provide information regarding the operation, general maintenance procedures and maintenance intervals for your Greensmaster machine. Refer to these publications for additional information when servicing the machine. Check Hydraulic Fluid Level The hydraulic system on your Greensmaster machine is designed to operate on high quality hydraulic fluid. Check level of hydraulic fluid daily.
Relieving Hydraulic System Pressure Before disconnecting or performing any work on your Greensmaster hydraulic system, all pressure in the hydraulic system must be relieved. To relieve hydraulic pressure in the traction circuit, park machine on a level surface with the cutting units lowered and off. Turn ignition switch to OFF and allow engine to stop. If machine is parked on an incline or slope, pressure in the traction circuit WILL NOT be relieved.
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.
Page 5 − 10 EXPANSION TANK LEAK DETECTOR VOLUME IN BREATHER S1 OUT LEAK DETECTOR KIT SUCTION STRAINER OPTIONAL OIL COOLER G SW LEFT FRONT REEL (#2) RIGHT FRONT REEL (#3) P FC FRONT PORT MV PRV LC OR1 PORV T CENTER REEL (#1) OR2 M1 M2 FRONT PORT .73 .73 .73 .33 C1 110 − 150 PSI 3000 PSI 3000 PSI C MOW = 6.7 GPM AT 3.8 MPH 1.44 T C5 C2 RV OR1 400 .037 PSI C3 25 PSI S3 OR3 .028 C6 70 to 100 PSI P 1160 PSI 4.5 R G1 ENGINE T E 10.3 10.
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EXPANSION TANK LEAK DETECTOR VOLUME IN BREATHER S1 OUT LEAK DETECTOR KIT SUCTION STRAINER G SW LEFT FRONT REEL (#2) RIGHT FRONT REEL (#3) OPTIONAL OIL COOLER High Pressure Low Pressure (Charge) Return or Suction Flow All solenoids are shown as de−energized. Traction pedal is pressed for the forward direction. P FC FRONT PORT MV PRV LC OR1 PORV T CENTER REEL (#1) OR2 M1 M2 FRONT PORT .73 .73 .73 .33 C1 110 − 150 PSI 3000 PSI 3000 PSI C MOW = 6.7 GPM AT 3.8 MPH 1.
Traction Circuit The traction circuit piston pump is a variable displacement pump that is directly coupled to the engine. Pushing the traction pedal controls the variable displacement piston pump swash plate to create a flow of oil. This oil is directed to the wheel motors. Operating pressure on the high pressure side of the closed traction circuit loop is determined by the amount of load developed at the fixed displacement wheel motors.
EXPANSION TANK LEAK DETECTOR VOLUME IN BREATHER S1 OUT LEAK DETECTOR KIT SUCTION STRAINER G SW LEFT FRONT REEL (#2) RIGHT FRONT REEL (#3) OPTIONAL OIL COOLER High Pressure Low Pressure (Charge) Return or Suction Flow Solenoids S1, S2, S3 and S4 in lift control manifold are shown in energized position. P FC FRONT PORT MV PRV LC OR1 PORV T CENTER REEL (#1) OR2 M1 M2 FRONT PORT .73 .73 .73 .33 S2 C1 4.0 GPM P RIGHT FRONT (#3) T C5 MOW = 6.7 GPM AT 3.
Lower Cutting Units The lift control manifold includes four (4) electrically operated solenoid valves. Solenoid valve S1 causes circuit flow to by−pass the lift cylinders when de−energized and directs flow to the cylinders when energized. Directional solenoid valve S2 is used to direct oil flow to raise the cutting units when de−energized and lower them when energized.
EXPANSION TANK LEAK DETECTOR VOLUME IN BREATHER S1 OUT LEAK DETECTOR KIT SUCTION STRAINER G SW LEFT FRONT REEL (#2) RIGHT FRONT REEL (#3) OPTIONAL OIL COOLER High Pressure Low Pressure (Charge) Return or Suction Flow Solenoids S1, S3 and S4 in lift control manifold are shown in energized position. P FC FRONT PORT MV PRV LC OR1 PORV T CENTER REEL (#1) OR2 M1 M2 FRONT PORT .73 .73 .73 .33 C1 C5 MOW = 6.7 GPM AT 3.8 MPH 3000 PSI 3000 PSI C C2 RV OR1 400 .
Raise Cutting Units The lift control manifold includes four (4) electrically operated solenoid valves. Solenoid valve S1 causes circuit flow to by−pass the lift cylinders when de−energized and directs flow to the cylinders when energized. Directional solenoid valve S2 is used to direct oil flow to raise the cutting units when de−energized and lower them when energized.
EXPANSION TANK LEAK DETECTOR VOLUME IN BREATHER S1 OUT LEAK DETECTOR KIT SUCTION STRAINER G SW LEFT FRONT REEL (#2) RIGHT FRONT REEL (#3) OPTIONAL OIL COOLER High Pressure Low Pressure (Charge) Return or Suction Flow Pressure Reducing Valve (PRV) in mow control manifold is shown in energized position. P FC FRONT PORT MV PRV LC OR1 PORV T CENTER REEL (#1) OR2 M1 M2 FRONT PORT .73 .73 .73 .33 C1 110 − 150 PSI 3000 PSI 3000 PSI C MOW = 6.7 GPM AT 3.8 MPH 1.
Mow and Backlap The tandem gear pump is directly coupled to the piston (traction) pump. The front gear pump section supplies hydraulic flow for the mow circuit. The gear pump takes its suction from the hydraulic reservoir and supplies oil flow to the mow control manifold and to the cutting reel motors. Maximum circuit pressure is limited by the proportional relief valve (PRV) located in the mow control manifold.
EXPANSION TANK LEAK DETECTOR VOLUME IN BREATHER S1 OUT LEAK DETECTOR KIT SUCTION STRAINER G SW LEFT FRONT REEL (#2) RIGHT FRONT REEL (#3) OPTIONAL OIL COOLER High Pressure Low Pressure (Charge) Return or Suction Flow All solenoids are shown as de−energized. Power steering valve is positioned for a right turn. P FC FRONT PORT MV PRV LC OR1 PORV T CENTER REEL (#1) OR2 M1 M2 FRONT PORT .73 .73 .73 .33 C1 110 − 150 PSI 3000 PSI 3000 PSI C MOW = 6.7 GPM AT 3.8 MPH 1.
Right and Left Turn The tandem gear pump is directly coupled to the piston (traction) pump. The rear gear pump section supplies hydraulic flow for the steering circuit (priority flow), for raising and lowering the cutting units and for the traction charge circuit. The gear pump takes its suction from the hydraulic reservoir. Maximum circuit pressure of 1160 PSI (80 bar) is limited by the relief valve located in the power steering valve.
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 the Testing section of this chapter.
40 GPM Hydraulic Tester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 1. LOAD VALVE: A simulated working load is created in the circuit by turning the valve to restrict flow. 2. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure. 3.
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.
Measuring Container Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only). Measure efficiency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system. Toro Part Number: TOR4077 Figure 18 Wheel Hub Puller The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors.
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 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Mow Circuit Problems ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Lift/Lower Circuit Problems ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ
Steering Circuit Problems ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Hydraulic System This page is intentionally blank.
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). IMPORTANT: All obvious areas such as oil supply, filter, binding linkages, loose fasteners, improper adjustments, solenoid valve operation or electrical connections must be checked before assuming that a hydraulic component is the source of the problem.
3. For traction related problems (e.g. machine will not go up an incline), consider performing one or more of the following tests: 5. For issues with the mow circuit, consider performing one or more of the following tests: A. Mow Circuit Gear Pump Flow. A. Charge Relief Valve Pressure. B. Mow Circuit Relief Valve Pressure. B. Piston (Traction) Pump Flow. C. Reel Motor Case Drain Flow. C. Wheel Motor Efficiency.
Charge Relief Valve Pressure Test (Using Tester with Flowmeter and Pressure Gauge) TO POWER STEERING VALVE FROM POWER STEERING AND LIFT CONTROL VALVES PRESSURE GAUGE TO MOW CONTROL VALVE HYDROSTAT C A 10.3 1.44 BACK PORT B 10.3 A 1.9 GPM RIGHT MOTOR ENGINE A .58 G2 FRONT PORT 70 to 100 PSI 110 − 150 PSI B PUMP LEFT MOTOR GEAR .33 TOP PORT 3000 PSI G1 3000 PSI 20.6 B FROM HYDRAULIC RESERVOIR C1 MOW = 6.7 GPM AT 3.8 MPH TRANSPORT = 17.
10.If specification is not met, remove piston pump back plate assembly that contains the charge relief valve (see Piston (Traction) Pump Service in the Service and Repairs section of this chapter). Repair or replace relief valve components as necessary. 1 11. A dynamic charge pressure test can be performed as follows: A. Position machine so that a load can be placed on the traction system. For example, chain the machine to an immovable object or chock all drive wheels to prevent the machine from moving.
Piston (Traction) Pump Flow Test (Using Tester with Flowmeter and Pressure Gauge) TO POWER STEERING VALVE FROM POWER STEERING AND LIFT CONTROL VALVES TO MOW CONTROL VALVE TESTER HYDROSTAT C A 10.3 1.44 BACK PORT B 10.3 A RIGHT MOTOR ENGINE 1.9 GPM A .58 G2 FRONT PORT 70 to 100 PSI 110 − 150 PSI B PUMP LEFT MOTOR GEAR .33 TOP PORT 3000 PSI G1 3000 PSI 20.6 B C1 FROM HYDRAULIC RESERVOIR MOW = 6.7 GPM AT 3.8 MPH TRANSPORT = 17.
This test measures piston pump output (flow). During this test, pump load is created at the flowmeter using the adjustable load valve on the tester. 7. After installing tester, start engine and run at low idle speed. Check for hydraulic leakage and correct before proceeding with test. Procedure for Piston (Traction) Pump Flow Test: 8. Move functional lever to the transport position. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes.
Wheel Motor Efficiency Test (Using Tester with Flowmeter and Pressure Gauge) TO POWER STEERING VALVE WHEEL MOTOR EFFICIENCY TEST FOR RIGHT FRONT WHEEL MOTOR SHOWN FROM POWER STEERING AND LIFT CONTROL VALVES TO MOW CONTROL VALVE TESTER HYDROSTAT C A 10.3 1.44 BACK PORT B 10.3 A 1.9 GPM RIGHT MOTOR ENGINE A .58 CAP G2 FRONT PORT 70 to 100 PSI 110 − 150 PSI B PUMP LEFT MOTOR GEAR .33 TOP PORT 3000 PSI CAP G1 3000 PSI 20.6 B C1 FROM HYDRAULIC RESERVOIR MOW = 6.7 GPM AT 3.
14.Wheel motor internal leakage will be shown on flow meter in GPM. Flow should be less than 1.5 GPM for the tested wheel motor. Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 3. Read Precautions for Hydraulic Testing in this section. 4. Make sure the transmission is adjusted to the neutral position. 5.
Steering/Lift Relief Valve Pressure Test (Using Pressure Gauge) LEFT FRONT (#2) CENTER (#1) (Extend to Lower) (Extend to Raise) RIGHT FRONT (#3) STEERING CYLINDER (Extend to Lower) PORT BALL JOINT END L C4 C1 R C6 OR2 .028 OR3 .028 4.5 C5 S2 P OR1 C2 .037 RV 400 PSI S1 1160 PSI POWER STEERING VALVE S3 S4 T E C3 25 PSI LIFT CONTROL MANIFOLD G1 P T PRESSURE GAUGE HYDROSTAT C A 10.3 1.44 A A BACK PORT 10.3 ENGINE 1.9 GPM RIGHT MOTOR G2 B FORWARD LEFT MOTOR .
The steering/lift relief valve pressure test should be performed to make sure that the relief pressure for the steering and lift circuits is correct. Procedure for Steering/Lift Relief Valve Pressure Test: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. 2. Park machine on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. Make sure the hydraulic tank is full.
Lower Cutting Units Relief Valve (RV) Pressure Test (Using Pressure Gauge) LEFT FRONT (#2) CENTER (#1) (Extend to Lower) (Extend to Raise) RIGHT FRONT (#3) STEERING CYLINDER (Extend to Lower) PORT BALL JOINT END L C4 C1 R C6 OR2 .028 OR3 .028 4.5 C5 S2 P OR1 C2 .037 RV 400 PSI S1 1160 PSI POWER STEERING VALVE S3 S4 T E C3 25 PSI LIFT CONTROL MANIFOLD P G1 T PRESSURE GAUGE HYDROSTAT C A 10.3 1.44 A A BACK PORT 10.3 ENGINE 1.
The lower cutting units relief valve (RV) pressure test should be performed to make sure that the relief pressure for lowering the cutting units is correct. Procedure for Lower Cutting Units Relief Valve (RV) Pressure Test: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. 2. Park machine on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. Make sure the hydraulic tank is full.
Steering/Lift Circuit Gear Pump Flow Test (Using Tester with Flowmeter and Pressure Gauge) LEFT FRONT (#2) CENTER (#1) (Extend to Lower) (Extend to Raise) RIGHT FRONT (#3) STEERING CYLINDER (Extend to Lower) PORT BALL JOINT END L C4 C1 R C6 OR2 .028 OR3 .028 4.5 C5 S2 P OR1 C2 .037 RV 400 PSI S1 1160 PSI POWER STEERING VALVE S3 S4 T E C3 25 PSI LIFT CONTROL MANIFOLD P G1 T TESTER HYDROSTAT C A 10.3 1.44 A A BACK PORT 10.3 ENGINE 1.
The steering/lift circuit gear pump flow test should be performed to make sure that the steering, lift and traction charge circuits have adequate hydraulic flow. Procedure for Steering/Lift Circuit Gear Pump 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.
Power Steering Valve Test STEERING CYLINDER (CYLINDER ROD FULLY EXTENDED) BALL JOINT END PORT PLUG L R STEERING WHEEL ROTATED FOR LEFT TURN 4.
NOTE: This steering test procedure will be affected by incorrect rear tire pressure, binding in the hydraulic steering cylinder, extra weight on the vehicle and/or binding of the steering fork assembly. Make sure that these items are checked before proceeding with any hydraulic testing procedure. Procedure for Power Steering Valve Test: 1. Make sure the hydraulic tank is full. CAUTION Prevent personal injury and/or damage to equipment.
Mow Circuit Gear Pump Flow Test (Using Tester with Flowmeter and Pressure Gauge) RIGHT FRONT REEL (#3) .73 FRONT PORT FRONT PORT CENTER REEL (#1) .73 .73 LEFT FRONT REEL (#2) FRONT PORT TO POWER STEERING VALVE M1 M2 TESTER SW MV OPTIONAL OIL PORV COOLER LEAK DETECTOR KIT OR1 FC LEAK OR2 GEAR PUMP DETECTOR VOLUME LC IN PRV OUT .33 .
The mow circuit gear pump flow test should be performed to make sure that the mow circuit has adequate hydraulic flow. Procedure for Mow Circuit Gear Pump 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. 7. Move throttle so engine is running at high idle speed.
Mow Circuit Relief Pressure Test (Using Tester with Flowmeter and Pressure Gauge) RIGHT FRONT REEL (#3) .73 FRONT PORT TO LEFT REEL MOTOR FRONT PORT CENTER REEL (#1) .73 .73 LEFT FRONT REEL (#2) TESTER FRONT PORT TO POWER STEERING VALVE SW M1 M2 MV OPTIONAL OIL PORV COOLER LEAK DETECTOR KIT OR1 FC LEAK OR2 GEAR PUMP DETECTOR VOLUME LC IN PRV OUT .33 .
The mow circuit relief valve pressure test should be performed to make sure that the relief pressure for the mow circuit is correct. 10.As relief valve opens, system pressure should be from 2700 to 3300 PSI (186 to 227 bar). Record test results. Procedure for Mow Circuit Relief Valve Pressure Test: 11. Disengage cutting units. Open control valve on tester and shut off engine. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. 12.
Reel Motor Case Drain Flow Test (Using Tester with Flowmeter and Pressure Gauge) 3 2 1 4 1. Left motor case drain hose 2. Left motor return hose 3. Right motor case drain hose 4. Right motor return hose 5. Center motor return hose 6. Center motor case drain hose 6 5 RIGHT FRONT REEL (#3) TESTER .73 MEASURING CONTAINER FRONT PORT FRONT PORT CENTER REEL (#1) CAP .73 .
Procedure for Reel Motor Case Drain Flow Test: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. 9.
Adjustments Adjust Manifold Relief Valves Both the lift and mow control manifold include an adjustable relief valve. If adjustment of either of these valves is necessary, follow the following procedure. NOTE: Do not remove relief valve from the hydraulic manifold for adjustment. 1 WARNING Never adjust the relief valve with the hydraulic system pressurized. Hydraulic oil may spray out of the valve when the cap is off. Personal injury may result.
Adjust Traction Control Assembly Proper control of the traction circuit is accomplished by the traction pedal, cables and piston (traction) pump neutral assembly. Adjustments to these components may be required for correct operation. Use the following information and the illustrations in the right column when adjusting the traction control on your Greensmaster.
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, disengage and lower cutting units, move functional control lever to neutral (N), engage parking brake and stop the engine. Remove the key from the ignition switch. Wait for all machine movement to stop before getting off machine. 1.
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). 8. Disconnect appropriate electrical component(s) to prevent the engine from starting: A. On machines with gasoline engine, disconnect both spark plug wires from spark plugs. IMPORTANT: Flush hydraulic system when changIng from petroleum base hydraulic fluid.
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 1. After the hydraulic system components have been properly installed and if the piston pump was rebuilt or replaced, make sure piston pump housing is at least half full of clean hydraulic oil. 2. Make sure all hydraulic connections and lines are secured tightly. 3. Make sure hydraulic reservoir is full. Add correct oil if necessary. Drain, flush and refill hydraulic system reservoir and change oil filter if component failure was severe or system is contaminated. 4.
Gear Pump 27 to 31 ft−lb (37 to 42 N−m) 9 6 2 3 4 10 7 15 1 14 13 12 17 5 11 16 RIGHT FRONT 8 Figure 38 1. 2. 3. 4. 5. 6. Gear pump Flat washer (2 used) Socket head screw (2 used) Hydraulic fitting 90o hydraulic fitting Hose clamp 7. 8. 9. 10. 11. 12. O−ring Hydraulic hose (mow supply) Suction (inlet) hose O−ring Hydraulic hose (steering/lift supply) O−ring 13. 14. 15. 16. 17. 90o hydraulic fitting O−ring Piston (traction) pump O−ring O−ring 3.
7. Mark hydraulic fitting orientation to allow correct assembly. Remove hydraulic fittings and O−rings from gear pump. Discard removed O−rings. NOTE: A case drain exists in the piston (traction) pump and a suction port is near the input shaft of the gear pump (Fig. 39). When the gear pump is removed from the piston pump, plug piston pump case drain hole to prevent draining the piston pump. 8. Support gear pump to prevent it from falling.
Gear Pump Service 19 15 11 16 18 12 9 8 6 2 22 21 17 14 13 20 14 13 4 3 10 33 ft−lb (45 N−m) 7 1 3 4 5 Figure 40 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. Dowel pin O−ring Housing Coupler Back−up seal Pressure seal Thrust plate 16. 17. 18. 19. 20. 21. 22. Drive gear Idler gear Thrust plate O−ring End cover Socket head screw (4 used) Washer (4 used) Gear Pump Disassembly (Fig.
4. Loosen the four (4) socket head screws that secure pump assembly. 5. Remove pump from vise and remove fasteners. 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. 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. 7.
Piston (Traction) Pump Neutral Assembly 4 200 to 250 in−lb (23 to 28 N−m) 18 8 6 24 3 10 17 2 16 5 15 19 11 21 20 Antiseize Lubricant Antiseize Lubricant 13 17 7 17 14 27 26 22 12 25 23 Loctite #242 1 Loctite #242 9 30 29 28 RIGHT 27 FRONT PUMP ASSEMBLY FROM GREENSMASTER 3400 SHOWN Figure 42 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Cable support (diesel shown) Plate Flat washer Cap screw Mount (3 used) Washer (3 used) Pump lever Lock nut (3 used) Cap screw (3 used) Eccentric stud 11.
Disassembly (Fig. 42) GR3300 GEAR PUMP SHOWN 1. Park machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove key from the ignition switch. 3 2 4 CAUTION 5 The torsion spring (item 14) is under tension and may cause personal injury during removal. Use caution when removing the spring from the pump neutral assembly. 1 2. Remove components from traction neutral assembly as needed using Figure 42 as a guide. Figure 43 1. Traction control cable 2.
Piston (Traction) Pump 27 to 31 ft−lb (37 to 42 N−m) 9 26 2 3 21 6 20 4 13 14 10 22 19 7 1 17 14 13 12 17 5 11 16 23 24 18 25 8 29 28 27 15 RIGHT FRONT PUMP ASSEMBLY FROM GREENSMASTER 3300 SHOWN 30 27 Figure 44 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Gear pump Hardened washer (2 used) Socket head screw (2 used) Hydraulic fitting 90o hydraulic fitting Hose clamp O−ring Hydraulic hose (mow supply) Suction (inlet) hose O−ring 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Piston Pump Removal (Fig. 44) 1. Park 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 in this section. 12.Separate gear pump from the piston pump (see Gear Pump Removal in this section).
Piston Pump Installation (Fig. 44) 1. Make sure the flange surfaces of the gear pump and piston pump are thoroughly clean. IMPORTANT: A case drain exists in the piston (traction) pump and a suction port is near the input shaft of the gear pump (Fig. 47). Before the gear pump is installed to the piston pump, make sure that plugs placed in either of these ports are removed. Failure to remove plugs will cause excessive pressure in the piston pump and damage seals. 2.
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Piston (Traction) Pump Service 36 37 21 20 19 17 23 22 18 16 15 REAR OF TRACTION UNIT 41 14 15 4 8 40 24 38 27 9 13 29 28 11 5 12 26 7 39 6 8 3 10 2 28 1 4 38 30 6 31 39 32 25 31 35 34 4 33 30 Figure 48 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 (traction) pump, see Eaton, Medium Duty Piston Pump, Repair Information, Model 70160 Variable Displacement Piston Pump at the end of this chapter. 1 2 NOTE: The charge relief valve is attached to the piston pump back plate (Fig. 49). The back plate must be removed to service the relief valve. NOTE: The piston (traction) pump is equipped with relief valves for both the forward and reverse direction.
Piston Pump Crush Ring Replacement 4 5 8 7 29 ft−lb (39 N−m) 2 3 v 9 10 6 1 Figure 50 1. 2. 3. 4. Crush ring Shims Cover plate Housing 5. Camplate (control shaft) 6. Bearing cone 7. Bearing cup 5. Install washers and cap screws to the cover plate and housing. Torque cap screws to 29 ft−lbs (39 N−m). Piston Pump Crush Ring Replacement (Fig. 50) NOTE: The shims (item 2) replace the crush ring (item 1) in the cover plate.
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Front Wheel Motors 13 14 15 65 to 85 ft−lb (89 to 115 N−m) 16 17 12 6 4 1 3 11 2 10 8 5 7 9 RIGHT 250 to 400 ft−lb (339 to 540 N−m) FRONT Figure 51 1. 2. 3. 4. 5. 6. Wheel assembly Wheel hub Brake drum Wheel stud (4 per wheel) Brake assembly (LH shown) Cap screw (4 per brake) 7. 8. 9. 10. 11. 12. Lock nut Cap screw (4 per motor) Lug nut (4 per wheel) Brake lever tab Hydraulic motor (LH shown) Woodruff key Front Wheel Motor Removal (Fig. 51) 1.
7. Remove lock nut and brake drum assembly. Locate and retrieve woodruff key (item 12). 8. Remove four (4) cap screws that secure brake assembly to wheel motor. Remove brake assembly. If brake service is required, see Brake Service in the Service and Repairs section of Chapter 7 − Chassis. 9. Thoroughly clean hydraulic line ends and fittings on wheel motor to prevent hydraulic system contamination. 10.Label hydraulic connections at wheel motor for assembly purposes. 5.
Rear Wheel Motor (Optional 3WD) 17 250 to 400 ft−lb (339 to 540 N−m) 15 19 16 12 19 13 4 FRONT 14 19 RIGHT 5 21 10 11 3 18 9 22 65 to 85 ft−lb (89 to 115 N−m) 23 7 8 6 1 75 ft−lb (101 N−m) 2 20 75 ft−lb (101 N−m) Figure 53 1. 2. 3. 4. 5. 6. 7. 8. Wheel motor Motor plate Wheel hub Lock nut Lug nut (4 used) Socket head screw (2 used) Cap screw (2 used) Lock nut (2 used) Hydraulic System 9. 10. 11. 12. 13. 14. 15. 16.
1. Park 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 in this section. 2. Loosen, but do not remove, rear wheel lug nuts (item 5) and lock nut (item 4). Loosen lock nut at least two (2) turns. 3. Chock both front wheels to prevent the machine from moving.
Wheel Motor Service 14 15 13 12 11 10 9 7 16 5 2 3 8 8 45 to 55 ft−lb (61 to 75 N−m) 8 6 4 1 Figure 54 1. 2. 3. 4. 5. 6. Dirt seal Housing Back−up ring Back−up washer Shaft seal Coupling shaft 7. 8. 9. 10. 11. Drive link Seal ring (5 used) Thrust bearing Wear plate Rotor assembly NOTE: The wheel motors used on your Greensmaster have the same basic construction. The left wheel motor(s) has a yellow sticker on the port side of the stator. The right wheel motor(s) has a reverse timed manifold. 12.
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Cutting Reel Motors 14 3 2 15 7 9 13 10 8 4 5 6 12 7 5 6 11 1 Figure 55 1. 2. 3. 4. 5. Reel motor Hose assembly Hose assembly Hose assembly 90o hydraulic fitting (2 per motor) 6. 7. 8. 9. 10. O−ring O−ring Hydraulic fitting O−ring O−ring Removal (Fig. 55) 1. Park machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove key from the ignition switch. 11. 12. 13. 14. 15.
7. 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. 8. Inspect threads and sealing surfaces of fittings and motor ports. Replace components if damage is found. Installation (Fig. 55) 1. If fittings were removed from reel motor, lubricate and place new O−rings onto fittings.
Cutting Reel Motor Service 9 1 10 16 5 17 15 13 18 7 14 8 19 4 11 18 ft−lb (25 N−m) 6 3 12 2 Figure 59 1. 2. 3. 4. 5. 6. 7. Body Front cover Front thrust plate Rear thrust plate Drive gear Idler gear Socket head screw (4 used) 8. 9. 10. 11. 12. 13. Flat washer (4 used) Lock washer (4 used) O−ring Pressure seal Pressure seal Dust seal 14. 15. 16. 17. 18. 19. Shaft seal Retaining ring Back−up seal Back−up seal Back−up washer Dowel pin (2 used) Disassembly (Fig. 59) 1.
6. Carefully remove body from front cover. Lift body straight up to remove. Make sure the rear thrust plate remains on the drive and idler gear shafts. Remove and discard O−ring from the body. Locate and retrieve dowel pins (item 19). IMPORTANT: Note position of the open and closed side of the thrust plates before removing. Also, identify thrust plates (front and rear) with a marker for proper assembly.
Assembly (Fig. 59) NOTE: When assembling the motor, check the marker line on each part to make sure the parts are properly aligned during assembly. 1. Lubricate O−rings, pressure seals, back−up seals and thrust plate grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic oil. 2. Install new seals into front cover (Fig. 61): 7. Lubricate the idler gear shaft with clean hydraulic oil.
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Mow Control Manifold 3 2 4 1 2 5 2 6 7 RIGHT FRONT Figure 63 1. Mow control manifold 2. O−ring 3. Hydraulic tube 4. Hydraulic tube 5. Hydraulic hose 6. Hydraulic hose 7. Flange head screw (2 used) NOTE: The ports on the mow control manifold are marked for easy identification of components. Example: PRV is the proportional relief valve and T is the return port (see Hydraulic Schematic to identify the function of the hydraulic lines and cartridge valves at each port location).
Removal (Fig. 63) Installation (Fig. 63) 1. Park machine on a level surface, engage parking brake, lower cutting units and stop the engine. 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 (Fig. 64). Properly tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2.
Mow Control Manifold Service 6 60 in−lb (6.7 N−m) FRONT 7 9 8 25 ft−lb (34 N−m) 7 VIEW FROM BELOW 5 10 4 11 20 ft−lb (27 N−m) 12 40 ft−lb (54 N−m) 16 20 ft−lb (27 N−m) 2 13 3 14 6 8 25 ft−lb (34 N−m) 17 7 18 2 2 1 19 15 20 ft−lb (27 N−m) 17 23 VIEW FROM ABOVE 22 21 20 FRONT 20 ft−lb (27 N−m) Figure 65 1. 2. 3. 4. 5. 6. 7. 8.
NOTE: The ports on the mow control manifold are marked for easy identification of components. Example: PRV is the proportional relief valve and T is the return port (see Hydraulic Schematic to identify the function of the hydraulic lines and cartridge valves at each port location). 2. To install rotary handle: IMPORTANT: Make sure that flow control cartridge valve is properly secured in manifold before installing rotary handle to valve. A.
Mow/Backlap Spool (Fig. 67) 1 1. To remove mow/backlap spool from manifold: 2 A. Remove backlap switch from manifold before removing mow/backlap spool (Fig. 65). Remove shim and ball from manifold port after switch is removed. Remove and discard O−ring from switch. 3 4 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. Remove upper retaining ring. Loctite 603 C.
Control Manifold Cartridge Valve Service Before continuing further, read and become familiar with General Precautions for Removing and Installing Hydraulic System Components in this section. 1. Make sure the control manifold is clean before removing the cartridge valve from the control manifold. 2. If cartridge valve is solenoid operated, remove nut securing solenoid coil to the cartridge valve. Carefully slide coil off the valve. IMPORTANT: Use care when handling the cartridge valve.
Lift Cylinders 1 12 11 4 8 2 21 6 14 15 16 6 20 19 15 17 5 13 16 21 16 10 22 3 7 14 4 14 RIGHT 2 18 FRONT 21 23 9 Figure 68 1. 2. 3. 4. 5. 6. 7. 8. Lift control manifold Hydraulic lift cylinder (#2 and #3 CU) Hydraulic lift cylinder (#1 CU) Tapered pin (2 used) Hydraulic hose Lock nut (2 used) Hydraulic hose Flange nut Hydraulic System 9. 10. 11. 12. 13. 14. 15. 16.
Lift Cylinder Removal (Fig. 68) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. 8. If hydraulic fittings are to be removed from lift cylinder, mark fitting orientation to allow correct assembly. Remove hydraulic fittings and O−rings from cylinder. Discard removed O−rings. 9. Inspect threads and sealing surfaces of fittings and lift cylinder ports. Replace components if damage is found. CAUTION Lift Cylinder Installation (Fig.
Lift Cylinder Service FRONT LIFT CYLINDER SHOWN 2 7 9 8 10 11 13 1 3 4 6 5 12 40 ft−lb (54 N−m) 3 1 6 7 4 12 5 8 10 11 9 2 13 Figure 69 1. 2. 3. 4. 5. Barrel Retaining ring Lock nut Wear ring Piston seal 6. 7. 8. 9. O−ring Piston O−ring Back−up ring 10. 11. 12. 13. Head seal Dust seal Head Shaft NOTE: The center lift cylinder (#1 cutting unit) has less stroke than the front lift cylinders (#2 and #3 cutting units) which are identical.
Disassembly (Fig. 69) Assembly (Fig. 69) 1. Remove the oil from the lift cylinder by slowly pumping the cylinder shaft while holding the cylinder over a drain pan. Plug both ports and clean the outside of the cylinder. 1. Make sure all lift cylinder parts are clean before assembly. 2. Coat new seal kit components with clean hydraulic oil. IMPORTANT: Prevent damage when clamping the lift cylinder in a vise; clamp on the rear mounting flange only. Do not close vise on the barrel. A.
Lift Control Manifold 22 6 10 2 7 5 6 24 1 3 4 23 6 9 11 17 21 12 14 6 3 4 2 13 6 18 8 15 2 16 20 19 RIGHT FRONT Figure 70 1. 2. 3. 4. 5. 6. 7. 8. Lift control manifold 90o hydraulic fitting (3 used) O−ring O−ring 45o hydraulic fitting O−ring O−ring O−ring Hydraulic System 9. 10. 11. 12. 13. 14. 15. 16. 90o hydraulic fitting O−ring Hydraulic hose Hydraulic hose Tee fitting 45o hydraulic fitting Hydraulic hose Flange head screw (2 used) Page 5 − 96 17. 18. 19. 20. 21. 22. 23.
WARNING If lift manifold is attached to machine, make sure that cutting units are fully lowered before loosening hydraulic lines or cartridge valves from lift manifold. If cutting units are raised as components are loosened in manifold, cutting units may drop unexpectedly. Removal (Fig. 70) 1. Park machine on a level surface, engage parking brake, lower cutting units and stop the engine. 2. Remove right side cover next to operator seat to allow access to lift control manifold.
Lift Control Manifold Service 8 60 in−lb (6.7 N−m) 10 10 9 60 in−lb (6.7 N−m) 11 9 9 8 12 7 6 13 20 ft−lb (27 N−m) 14 5 VIEW FROM BELOW 4 2 1 3 25 ft−lb (34 N−m) UP 17 3 2 15 20 ft−lb (27 N−m) 16 20 ft−lb (27 N−m) 2 20 ft−lb (27 N−m) 20 ft−lb (27 N−m) Figure 71 1. 2. 3. 4. 5. 6. Lift manifold Zero leak plug (5 used) Orifice (0.028) (ports C4 and C6) 90o fitting Solenoid valve (port S2) Solenoid valve (port S4) Hydraulic System 7. 8. 9. 10. 11. 12.
NOTE: The ports on the lift control manifold are marked for easy identification of components. Example: S1 is the solenoid valve and P is the supply port (see Hydraulic Schematic to identify the function of the hydraulic lines and cartridge valves at each port location). CAUTION Before continuing further, read and become familiar with General Precautions for Removing and Installing Hydraulic System Components in this section. NOTE: The hydraulic manifold shown in Figure 71 uses several zero leak plugs.
Power Steering Valve 4 6 5 3 1 14 15 2 9 20 to 26 ft−lb (28 to 35 N−m) 7 13 13 8 14 12 10 11 Antiseize Lubricant RIGHT FRONT Figure 72 1. 2. 3. 4. 5. Steering wheel cap Hex nut Flat washer Screw Flange head screw (2 used) Hydraulic System 6. 7. 8. 9. 10. Steering wheel Button head screw (6 used) Tinnerman nut (6 used) Flange head screw (4 used) Power steering valve Page 5 − 100 11. 12. 13. 14. 15.
Removal (Fig. 72) 2. Position power steering valve to steering mount. 1. Park machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove key from the ignition switch. 3. Using labels placed during control valve removal, lubricate new O−rings and connect hydraulic hoses to power steering valve. Tighten hose connections (see Hydraulic Hose and Tube Installation in the General Information section of this chapter).
Power Steering Valve Service 16 15 14 13 11 12 11 7 8 10 9 6 25 5 26 v 4 3 27 2 29 24 28 23 22 21 18 1 20 20 to 24 ft−lb (27 to 33 N−m) 18 17 18 19 Figure 74 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.
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Steering Cylinder 60 to 80 ft−lb (82 to 108 N−m) 2 4 60 to 80 ft−lb (82 to 108 N−m) 10 9 8 9 7 3 8 1 5 4 RIGHT FRONT 6 Figure 75 1. 2. 3. 4. Steering cylinder Frame Rear steering fork Jam nut (4 used) 5. Rear wheel spindle 6. Steering spindle 7. Rear wheel and tire Removal (Fig. 75) 2. Operate all hydraulic controls to relieve hydraulic system pressure. 1. Park machine on a level surface, engage the parking brake, lower the cutting units and stop the engine.
5. Remove hose assemblies and O−rings from hydraulic fittings at the cylinder. Allow hoses to drain into a suitable container. 6. Put clean caps or plugs on disconnected hoses and fittings to prevent contamination. 7. Remove caps and plugs from disconnected hoses and fittings. 8. Lubricate new O−rings and connect hydraulic hoses to steering cylinder (Fig. 76). Tighten hose connections (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 7.
Steering Cylinder Service 1 2 9 3 10 11 12 4 13 5 2 6 7 8 7 6 5 4 Figure 77 1. 2. 3. 4. 5. Shaft Collar Head (ball joint end) Dust seal Shaft seal Hydraulic System 6. 7. 8. 9. O−ring and backup ring Wear ring Piston seal Dowel pin Page 5 − 106 10. 11. 12. 13.
Disassembly (Fig. 77) Assembly (Fig. 77) 1. Pump oil out of cylinder into a drain pan by slowly moving shaft in and out of cylinder bore. Plug ports and clean outside of cylinder. 1. Put a coating of clean hydraulic oil on all new seals, back−up rings, wear rings and O−rings. IMPORTANT: To prevent damage when clamping cylinder barrel in a vise, clamp only on ball joint location. Do not clamp the vise jaws against the cylinder barrel or shaft surface. 2.
Hydraulic Reservoir (Machines Equipped with Turf GuardianTM Leak Detector System) 17 to 21 ft−lb (23 to 28 N−m) 110 to 140 in−lb (12.5 to 15.8 N−m) 6 Antiseize Lubricant 30 to 50 in−lb (3.4 to 5.6 N−m) 7 29 70 to 80 ft−lb (95 to 108 N−m) 8 1 2 3 41 4 30 3 5 27 31 9 11 10 18 35 19 20 28 19 39 21 35 36 25 12 33 34 16 13 26 40 35 33 19 14 17 to 21 ft−lb (23 to 28 N−m) 32 22 35 17 37 38 35 15 23 24 19 21 Antiseize Lubricant 30 to 50 in−lb (3.4 to 5.
1. Park machine on a level surface, set brake, lower cutting units and stop 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 in this section. 2. Disconnect oil level sensor wire connector from machine wire harness. 3. Remove leak detector tank (see Leak Detector Tank Removal in this section). 4.
Hydraulic Reservoir (Machines Not Equipped with Turf GuardianTM Leak Detector System) Illustration from machine with serial number below 312000000 shown 7 Antiseize Lubricant 30 to 50 in−lb (3.4 to 5.6 N−m) 9 8 4 19 11 3 10 30 to 38 ft−lb (41 to 51 N−m) 17 to 21 ft−lb (23 to 28 N−m) 5 20 6 70 to 80 ft−lb (95 to 108 N−m) 18 2 27 17 21 26 v 15 6 30 to 38 ft−lb (41 to 51 N−m) 25 16 24 23 22 17 to 21 ft−lb (23 to 28 N−m) 1 12 Antiseize Lubricant 30 to 50 in−lb (3.4 to 5.
Removing Hydraulic Reservoir (Fig. 80) 1. Park machine on a level surface, set brake, lower cutting units and stop engine. Remove key from the ignition switch. 13.Clean hydraulic reservoir and reservoir components with clean solvent. Inspect reservoir for leaks, cracks or other damage. Installing Hydraulic Reservoir (Fig. 80) IMPORTANT: When installing reservoir cover and reservoir to machine, do not over−tighten cap screws. Threads in reservoir may become damaged.
Leak Detector Tank (Machines Equipped with Turf GuardianTM Leak Detector System) Antiseize Lubricant 30 to 50 in−lb (3.4 to 5.6 N−m) Illustration from machine with serial number below 312000000 shown 17 to 21 ft−lb (23 to 28 N−m) 40 to 50 ft−lb (55 to 67 N−m) 6 12 7 1 2 3 13 3 4 8 26 14 9 5 15 10 18 11 19 20 19 21 11 25 23 11 110 to 140 in−lb (12.5 to 15.8 N−m) 24 Antiseize Lubricant 30 to 60 in−lb (3.4 to 6.7 N−m) 16 17 19 40 to 50 ft−lb (55 to 67 N−m) 22 19 21 11 Figure 81 1.
Removal (Fig. 81) 2 1. Park machine on a level surface, set brake, lower cutting units and stop engine. Remove key from the ignition switch. 1 CAUTION Before continuing further, read and become familiar with General Precautions for Removing and Installing Hydraulic System Components in this section. GR3300 GEAR PUMP SHOWN Figure 82 1. Gear pump 2. Pump inlet hose 2. Place a clean container, large enough to collect two (2) gallons (7.6 liters), under the pump assembly to collect hydraulic oil. 4 3.
4. Connect overflow hose (item 4) to leak detector tank barb and secure with hose clamp (item 3). 5. Apply antiseize lubricant to the end threads of the four (4) cap screws (item 6) used to secure leak detector tank to hydraulic reservoir. IMPORTANT: Do not over−tighten cap screws when securing leak detector tank to hydraulic reservoir. Threads in reservoir may become damaged. NOTE: Monitor hydraulic fluid level in leak detector tank window.
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Leak Detector Solenoid Valve Assembly (Machines Equipped with Turf GuardianTM Leak Detector System) Illustration from machine with serial number below 312000000 shown 30 to 50 in−lb (3.4 to 5.6 N−m) 17 to 21 ft−lb (23 to 28 N−m) 40 to 50 ft−lb (55 to 67 N−m) 6 12 7 1 3 13 3 4 8 2 14 9 5 15 10 18 11 19 20 19 21 11 25 23 11 24 110 to 140 in−lb (12.5 to 15.8 N−m) 16 30 to 60 in−lb (3.4 to 6.7 N−m) 17 19 22 40 to 50 ft−lb (55 to 67 N−m) 19 21 11 Figure 84 1. 2. 3. 4. 5. 6. 7. 8. 9.
Removal (Fig. 84) 1. Park machine on a level surface, set brake, lower cutting units and stop 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 in this section. 2. Remove leak detector tank (see Leak Detector Removal in this section). 3. Clean junction of tank hose (item 22) at solenoid valve fitting (item 21).
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Chapter 6 Electrical System GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Toro Electronic Controller (TEC) . . . . . . . . . . . . . . 3 CAN−bus Communications . . . . . . . . . . . . . . . . . . . 3 TURF GUARDIANTM LEAK DETECTOR SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . .
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General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Greensmaster machine. Refer to that publication for additional information when servicing the machine. Electrical Drawings The electrical schematic and wire harness drawings for Greensmaster TriFlex 3300 and 3400 machines are located in Chapter 10 − Foldout Drawings.
Turf GuardianTM Leak Detector System Operation The Turf GuardianTM Leak Detector System oil level sensor closely monitors the hydraulic fluid level in the main hydraulic reservoir. The sensor is open when the sensor float is in the raised position and closed when the float is in the lowered position. NOTE: Greensmaster 3300 machines are equipped with the Turf GuardianTM Leak Detector System. On Greensmaster 3400 machines, the Leak Detector System is optional.
Leak Alert! If hydraulic fluid leaks during operation, the fluid level in the main hydraulic tank drops. This causes the oil level sensor float to lower, closing the alarm circuit. The alarm will sound and the console indicator light will illuminate after a one (1) second time delay.
Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The meter can test electrical components and circuits for current, resistance or voltage. 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.
Skin−Over Grease Special non−conductive grease which forms a light protective skin which helps waterproof electrical switches and contacts. Toro Part Number: TOR50547 Figure 8 Battery Terminal Protector Aerosol spray that should be used on battery terminals to reduce corrosion problems. Apply terminal protector after the battery cable has been secured to the battery terminal.
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 wire harness drawings in Chapter 10 − Foldout Drawings).
Retrieving Fault Codes All machine fault codes are retained in the TEC controller memory. The three (3) most recent fault codes that have occurred within the last forty (40) hours of operation can be retrieved using the diagnostic light. To retrieve these fault codes from the controller memory, perform the following switch sequence: 1. Operator seat should be UNOCCUPIED. 2. Place functional control lever in the TRANSPORT position. 3.
Clearing Fault Codes 2. Operator seat should remain UNOCCUPIED. After fault codes have been retrieved, clearing of those faults can be completed using the following switch sequence: 3. Move backlap valve on mow control manifold to the BACKLAP position. 4. Move joystick to the RAISE position. 1. Place machine switches in fault retrieval (see above). The diagnostic light should be displaying the fault codes. Electrical System 5.
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Diagnostic Display Your Greensmaster is equipped with a Toro Electronic Controller (TEC) which controls machine electrical functions. The controller monitors various input switches (e.g. ignition switch, seat switch, etc.) and energizes outputs to actuate solenoids or relays for the requested machine function. 2 1 For the controller to properly control the machine, each of the input switches, output solenoids and relays must be connected and functioning properly.
5. The “INPUTS DISPLAYED” LED, on lower right column of the Diagnostic Display, should be illuminated. If the green “OUTPUTS DISPLAYED” LED is illuminated, press the toggle button on the Diagnostic Display to change to “INPUTS DISPLAYED” LED. 6. The Diagnostic Display will illuminate the LED associated with each of the inputs when that input is in the position identified on the Diagnostic Display overlay. Individually, change the position of each of the inputs (i.e. sit on seat, move joystick, etc.
Diagnostic Display TEC Controller Inputs Diagnostic Display LED Operation JOYSTICK LOWER Joystick moved to lower (forward) position: LED ON Joystick NOT moved to lower position: LED OFF LEAK DETECTOR (LD) (Greensmaster 3300 machines only) Leak detector switch closed (oil level is low): LED ON Leak detector switch open (oil level is OK): LED OFF ELECTRIC REEL SPEED Not used on Greensmaster 3300 or 3400 machines.
Verify Diagnostic Display Output Functions The Diagnostic Display has the ability to detect which output solenoids or relays are turned on by the TEC controller. This is a quick way to determine if a machine malfunction is electrical or hydraulic. NOTE: An open output (e.g. an unplugged connector or a broken wire) cannot be detected with the Diagnostic Display. 1. Park machine on a level surface, lower the cutting units, engage the parking brake and stop the engine. 2.
Diagnostic Display Outputs Diagnostic Display LED Operation START TEC output exists to energize starter solenoid (Greensmaster 3300) or starter relay (Greensmaster 3400): LED ON No TEC output to starter solenoid or starter relay: LED OFF ETR (DSL) RTR (Gas) TEC output exists to energize engine run components (see NOTE below): LED ON No TEC output to engine run components: LED OFF GLOW (DSL) LD LAMP TEC output exists to energize leak detector indicator light and alarm (Greensmaster 3300) or glow plug
Starting Problems Problem Possible Causes Starter solenoid clicks, but starter will not crank (if solenoid clicks, problem is not in safety interlock system). Battery cables are loose or corroded. Battery ground to frame is loose or corroded. Battery is discharged or faulty. Wiring at starter is loose or faulty. Starter mounting bolts are loose or not supplying a sufficient ground. Starter solenoid is faulty. Starter motor is faulty. Nothing happens when start attempt is made.
Starting Problems (continued) Problem Possible Causes Engine cranks (but should not) with the functional control lever in the MOW or TRANSPORT position. Neutral switch is out of adjustment or is faulty. Engine cranks, but does not start. The fuel tank is empty. Circuit wiring for neutral switch is loose, corroded or damaged. The fuel filter is plugged. Engine and/or fuel may be too cold.
General Run and Transport Problems Problem Possible Causes Engine kills when the functional control lever is in the Operator is sitting too far forward on the seat (seat MOW or TRANSPORT position with the operator in the switch not depressed). seat. Parking brake is engaged. Parking brake switch is out of adjustment or is faulty. Parking brake switch wiring is loose, corroded or damaged. Seat switch is faulty. Seat switch wiring is loose, corroded or damaged. Battery does not charge.
Cutting Unit Operating Problems Problem Possible Causes Cutting units run (but should not) when raised. Mow switch is faulty or out of adjustment. A hydraulic problem exists (see Chapter 5 − Hydraulic System). The TEC Controller is faulty. Cutting units do not run when lowered with the functional control lever in the MOW position. Wiring to run/mow/backlap circuit components is loose, corroded or damaged (see electrical schematic in Chapter 10 − Foldout Drawings). Fuse or fuse block is faulty.
TEC Logic Chart (Greensmaster 3300) Each line of the following chart identifies the necessary component position (INPUTS) in order for the TEC controller to energize the appropriate OUTPUTS for machine operation.
TEC Logic Chart (Greensmaster 3400) Each line of the following chart identifies the necessary component position (INPUTS) in order for the TEC controller to energize the appropriate OUTPUTS for machine operation.
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.
Adjustments Parking Brake Switch The parking brake switch is a normally open proximity switch that mounts to the frame bracket used to attach the parking brake lever assembly (Fig. 17). The sensing plate for the brake switch is a tab on the parking brake lever assembly. The Toro Electronic Controller (TEC) monitors the operation of the parking brake switch.
Neutral and Mow Switches The neutral and mow switches are normally open proximity switches that mount to the console assembly (Fig. 17). The sensing plate for these switches is a tab on the functional control lever. The Toro Electronic Controller (TEC) monitors the operation of the neutral and mow switches. 3 2 When the functional control lever is in the neutral position, the tab on the lever is positioned near the target end of the neutral switch causing the switch to close.
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 appropriate engine service manual (Briggs & Stratton Repair Manual or Kubota Workshop Manual).
Ignition Switch (Serial Number Above 312000000) The ignition (key) switch is located on the control panel and has three (3) positions: STOP, RUN and START (Fig. 24). The Toro Electronic Controller (TEC) monitors the operation of the ignition switch. NOTE: The engine can only be started when the functional control lever is in the NEUTRAL position and either the seat is occupied or the parking brake is engaged. Also, the TEC controller limits engine cranking time to thirty (30) seconds. 6.
Engine Oil Pressure Indicator Light (Greensmaster 3300) The engine oil pressure indicator light should come on when the ignition switch is in the RUN position with the engine not running. Also, it should illuminate with the engine running if the engine oil pressure drops to an unsafe level. 1 IMPORTANT: If the oil pressure indicator light is illuminated with the engine running, shut off the engine immediately.
Indicator Lights (Greensmaster 3400) Charge Indicator Light The charge indicator light should come on when the ignition switch is in the RUN position with the engine not running. Also, it should illuminate with an improperly operating charging circuit while the engine is running. 3 Engine Oil Pressure Light 2 The engine oil pressure light should come on when the ignition switch is in the RUN position with the engine not running.
Hour Meter 1. Park machine on a level surface, lower cutting units, engage parking brake and stop engine. Remove key from ignition switch. 2. Remove console cover from console assembly to gain access to hour meter (see Control Console Disassembly in the Service and Repairs section of Chapter 7 − Chassis). 1 2 3. Disconnect machine wire harness electrical connector from the hour meter. 4. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter. 5.
Fuse Block (Greensmaster 3300) The fuse block on Greensmaster 3300 machines is attached to the frame under the operator seat (Fig. 31). Fuse Identification and Function 1 Use Figure 32 to identify each individual fuse and its correct amperage. Fuses for Greensmaster 3300 machines have the following function: 2 Right Fuse 1 (2 Amp): Protects TEC logic and ignition switch power supply circuits. Right Fuse 2 (7.
Fuse Block (Greensmaster 3400 with Serial Number Below 312000000) The fuse block on Greensmaster 3400 machines is attached to the frame under the operator seat (Fig. 33). In addition to the fuses in the fuse block, a 50 amp maxi−fuse is included in the wire harness. This fuse protects the engine cooling fan circuit and resides in a fuse holder under the right side cover next to operator seat. 1 2 Fuse Identification and Function Use Figure 34 to identify each individual fuse and its correct amperage.
Fuse Block (Greensmaster 3400 with Serial Number Above 312000000) The fuse block on Greensmaster 3400 machines is attached to the frame under the operator seat (Fig. 35). In addition to the fuses in the fuse block, a 50 amp maxi−fuse is included in the wire harness. This fuse protects the engine cooling fan circuit and resides in a fuse holder under the right side cover next to operator seat. 1 2 Fuse Identification and Function Use Figure 36 to identify each individual fuse and its correct amperage.
Fusible Links The electrical system on TriFlex Greensmaster machines include a harness with three (3) fusible links for machine circuit protection. This fusible link harness connects the machine wire harness to the positive (+) battery terminal. Greensmaster 3300 machines (gasoline engine) use only two (2) of the harness fusible links. The fusible link harness on Greensmaster 3300 machines is connected to the starter solenoid (Fig. 37).
Seat Switch The seat switch is normally open and closes when the operator is on the seat. If the Functional Control Lever is moved out of neutral (neutral switch opens) and the operator raises out of the seat, the engine will stop. The seat switch and its electrical connector are located directly under the seat (Fig. 40). 1 Testing 1. Park machine on level surface, lower cutting units, stop engine, apply parking brake and remove key from ignition switch. 3 2.
Neutral and Mow Switches The neutral and mow switches are normally open proximity switches that mount to the console assembly (Fig. 42). The sensing plate for these switches is a tab on the functional control lever. The Toro Electronic Controller (TEC) monitors the operation of the neutral and mow switches. B. The mow switch LED should be illuminated only when the functional control lever is in the mow position.
Parking Brake Switch The parking brake switch is a normally open proximity switch that mounts to the frame bracket used to attach the parking brake lever assembly (Fig. 43). The sensing plate for the brake switch is a tab on the parking brake lever assembly. The Toro Electronic Controller (TEC) monitors the operation of the parking brake switch. When the parking brake is not applied, the tab on the parking brake lever is positioned near the target end of the parking brake switch so the switch is closed.
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. 45). The switches are identical and are shown in Figure 46. The Toro Electronic Controller (TEC) monitors the operation of the joystick raise and lower switches. 7. Replace joystick switch if necessary. 8.
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 bottom of the hydraulic mow control manifold located under the left side cover next to operator seat (Fig. 47).
Hydraulic Solenoid Valve Coils The Greensmaster hydraulic control manifolds use several hydraulic solenoid valve coils for system control. The lift manifold includes four (4) solenoid valves and the mow manifold includes a single solenoid valve. On machines equipped with the Turf GuardianTM Leak Detector, the leak detector manifold includes a single solenoid valve. When the solenoid coils are energized, hydraulic valve shift occurs to control hydraulic circuit flow.
NOTE: Solenoid coil resistance should be measured with solenoid at approximately 68oF (20oC). Resistance may be slightly different than listed at different temperatures. Typically, a failed solenoid coil will either be shorted (very low or no resistance) or open (infinite resistance). 2 4. Using a multimeter (ohms setting), measure resistance between the two (2) connector terminals on the solenoid valve coil.
Main Power, Charge Circuit (Greensmaster 3300), Glow (Greensmaster 3400) and Fan (Greensmaster 3400) Relays The Greensmaster TriFlex electrical system includes several identical, four (4) terminal relays for current control. The relays are located under the right side cover next to the operator seat (Fig. 52). Relays can be identified by a tag near the relay wire harness connector. 4. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85.
Kill (Greensmaster 3300) and Start (Greensmaster 3400) Relays The Greensmaster TriFlex electrical system includes a five (5) terminal relay for current control. The kill relay is used only on Greensmaster 3300 machines. The start relay is used only on Greensmaster 3400 machines. These relays are located under the right side cover next to the operator seat (Fig. 54) and can be identified by a tag near the relay wire harness connector.
Toro Electronic Controller (TEC) Greensmaster TriFlex machines use a Toro Electronic Controller (TEC) to monitor the condition of various switches (inputs) and then direct electrical power output to allow certain machine functions. The controller is attached to the frame under the right side cover next to operator seat (Fig. 56). 1 2 Inputs from the ignition, neutral, parking brake, seat, joystick, mow, backlap and engine oil pressure are all monitored by the TEC controller.
CAN−bus Termination Resistors System communication between electrical components on Greensmaster TriFlex machines is accomplished on a CAN−bus communication system. Two (2) specially designed, twisted cables form the bus for the electrical system. These wires provide the data pathways between machine components. At the ends of the twisted pair of bus cables are 120 ohm termination resistors.
Turf GuardianTM Leak Detector Oil Level Sensor (If Equipped) NOTE: Greensmaster 3300 machines are equipped with the Turf GuardianTM Leak Detector System. On Greensmaster 3400 machines, the Leak Detector System is optional. 1 The leak detector oil level sensor closely monitors the hydraulic fluid level in the main hydraulic reservoir. The sensor is open when the sensor float is in the raised position and closed when the float is in the lowered position.
Turf GuardianTM Leak Detector Alarm (If Equipped) NOTE: Greensmaster 3300 machines are equipped with the Turf GuardianTM Leak Detector System. On Greensmaster 3400 machines, the Leak Detector System is optional. Machines equipped with the Turf GuardianTM Leak Detector System include an alarm that sounds if a hydraulic leak is detected by the system. The alarm is attached to the outside of the control console assembly. 4 3 1 2 Figure 62 Testing 1.
Starter Solenoid (Greensmaster 3300) The starter solenoid used on Greensmaster 3300 machines allows current flow from the battery to the engine starter motor when energized. This solenoid is energized by the TEC controller when the ignition switch is in the START position. The starter solenoid is attached to the left side of the rear frame beneath the hydraulic oil reservoir (Fig. 63). Testing 7. Replace starter solenoid if necessary. 8.
Fuel Pump (Greensmaster 3400 machines) The fuel pump on Greensmaster 3400 machines is secured to the radiator assembly with an r−clamp (Fig. 65). The Toro Electronic Controller (TEC) energizes the fuel pump when the ignition switch is in either the RUN or START position. 7. Fuel collected in the graduated cylinder should be approximately 16 fl oz (475 ml) after fifteen (15) seconds. IMPORTANT: When testing fuel pump, make sure that pump is not operated without fuel. 9.
Fuel Solenoid (Greensmaster 3400 machines) The fuel solenoid used on Greensmaster 3400 machines must be energized for the diesel engine to run. The fuel solenoid is mounted to the injection pump on the engine (Fig. 66). The Toro Electronic Controller (TEC) energizes the fuel solenoid 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.
Temperature Sender (Greensmaster 3400 machines) The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 67). 6. Replace temperature sender if specifications are not met. 7. Install temperature sender to the water flange. The resistance of the temperature sender reduces as the engine coolant temperature increases.
Diode Assembly (Greensmaster 3400) The Greensmaster 3400 wire harness contains a diode that is used for circuit protection from voltage spikes when the engine starter solenoid is de−energized. The diode plugs into the wiring harness in the engine area (see Greensmaster 3400 Wire Harness Drawing in Chapter 10 − Foldout Drawings). 2 Diode Test 3 1 The diode (Fig. 69) can be tested using a digital multimeter (diode test or ohms setting) and the table to the right. Figure 69 1. Diode 2.
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Service and Repairs Verify Interlock System Operation CAUTION The interlock switches are for the operator’s protection; do not disconnect them. Check the operation of the switches daily to assure the interlock system is operating. If a switch is defective, replace it 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. 9 GREENSMASTER 3300 6 2 7 5 CAUTION 1 When working with batteries, use extreme caution to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries.
Battery Inspection and Maintenance Battery Installation (Fig. 70 or 71) 1. Perform following inspections and maintenance: IMPORTANT: To prevent possible electrical problems, install only a fully charged battery. A. Check for cracks caused by overly tight or loose hold−down rod. Replace battery if cracked and leaking. B. Check battery terminal posts for corrosion. Use a terminal brush or steel wool to clean corrosion from the battery terminal posts.
Battery Testing 1. Conduct a hydrometer test of the battery electrolyte. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. A. Measure the specific gravity of each cell with a hydrometer. Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm− up the hydrometer. At the same time take the temperature of the cell. B. Temperature correct each cell reading. For each 10oF (6oC) above 80oF (27oC) add 0.004 to the specific gravity reading.
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 battery charger manufacturer’s instructions when using a battery charger. NOTE: Using specific gravity of the battery cells is the most accurate method of determining battery condition. 1.
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Chapter 7 Chassis Table of Contents Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manuals . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Parking Brake Adjustment . . . . . . . . . . . . . . . . . . . . 5 SERVICE AND REPAIRS . . . . . . . . . . .
Specifications Item Description Front tire pressure (19 x 10.50 x 8) (4 ply) 12 to 16 PSI (83 to 110 kPa) Rear tire pressure (19 x 10.
General Information Operator’s Manuals Chassis The Traction Unit and Cutting Unit Operator’s Manuals provide information regarding the operation, general maintenance procedures and maintenance intervals for your Greensmaster TriFlex machine. Refer to these publications 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 the hydraulic wheel motors used on Greensmaster TriFlex machines. Toro Part Number: TOR4097 Figure 1 Grease Fitting This grease fitting can be used to allow the frame tube to be filled with grease after service of the rear steering fork.
Adjustments Parking Brake Adjustment 1. Park 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. With parking brake engaged, measure the distance between the centers of the two (2) pins that secure the brake spring to the brake lever and the equalizer bracket. This distance should be from 6.120” to 6.240” (156 to 158 mm) (Fig. 3). 2 3.
Service and Repairs Wheels 3 1 2 1 65 to 85 ft−lb (89 to 115 N−m) RIGHT 2 FRONT Figure 5 1. Front wheel Chassis 2. Lug nut (4 used per wheel) Page 7 − 6 3.
Removal (Fig. 5) Installation (Fig. 5) 1. Park machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove key from the ignition switch. 1. Install wheel and secure with four (4) lug nuts. 2. Lower machine to ground. 2. Chock wheels to prevent machine from shifting. WARNING 3. Loosen, but do not remove, lug nuts. Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury.
Brake Service 13 14 15 65 to 85 ft−lb (89 to 115 N−m) 16 17 12 6 4 3 11 1 2 10 8 5 9 7 RIGHT 250 to 400 ft−lb (339 to 540 N−m) FRONT Figure 6 1. 2. 3. 4. 5. 6. Wheel assembly Wheel hub Brake drum Wheel stud (4 per wheel) Brake assembly (LH shown) Cap screw (4 per brake) 7. 8. 9. 10. 11. 12. Lock nut Cap screw (4 per motor) Lug nut (4 per wheel) Brake lever tab Hydraulic motor (LH shown) Woodruff key Removal (Fig. 6) 1.
NOTE: If desired, the complete brake assembly can be removed from the machine for disassembly (see step 11 below). 10.Install front wheel assembly (see Wheel Installation in this section). 11. Lower machine to ground. 9. Remove shoe springs from brake shoes (Fig. 8). 10.Remove shoe hold down cups and springs. Remove brake shoes and hold down pins from backing plate (Fig. 8). 11. If necessary, remove backing plate from machine by removing four (4) cap screws (item 6). 12.
Brake Cables 24 3 9 25 15 18 4 2 21 13 14 8 6 10 11 1 22 12 17 16 20 22 19 23 7 RIGHT FRONT 5 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. Handle grip Brake lever assembly LH cover Shoulder screw (2 used) Brake assembly (LH shown) Rubber bumper Clevis pin (2 used) Extension spring Screw Chassis 10. 11. 12. 13. 14. 15. 16. 17. Pin Equalizer bracket Retaining ring (3 used) Proximity sensor Flange nut (2 used) Cotter pin RH brake cable bracket RH brake cable Page 7 − 10 18. 19. 20. 21. 22. 23. 24.
Brake Cable Removal (Fig. 9) Brake Cable Installation (Fig. 9) 1. Park machine on a level surface, lower cutting units, stop engine and remove key from the ignition switch. Make sure that parking brake is not applied. 1. Using notes taken during brake cable removal, route brake cable onto machine. Make sure that parking brake is not applied. 2. Chock front wheels to prevent machine from moving. 2. Connect brake cable to equalizer bracket at brake lever: 3.
Rear Wheel Spindle Assembly 13 65 to 85 ft−lb (89 to 115 N−m) 4 7 16 5 2 12 1 14 3 6 4 8 9 10 RIGHT See text for tightening procedure FRONT 11 15 Figure 10 1. 2. 3. 4. 5. 6. Lug nut (4 used) Wheel spindle Seal Bearing cone (2 used) Wheel hub Bearing cup (2 used) Chassis 7. 8. 9. 10. 11. Wheel stud (4 used) Tab washer Jam nut Retainer Dust cap Page 7 − 12 12. 13. 14. 15. 16.
Disassembly (Fig. 10) 1. Park machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove key from the ignition switch. IMPORTANT: The lip of the seal must be toward the bearing. The seal should be pressed in so it is flush with the end of the wheel hub. 6. Lubricate the inside of a new seal and press it into the wheel hub with the seal lip toward the bearing. 2. Chock front wheels to prevent machine from shifting. 3.
Rear Steering Fork 60 to 80 ft−lb (82 to 108 N−m) 29 27 28 25 180 to 216 in−lb (21 to 24 N−m) 26 16 30 26 23 31 25 22 20 22 60 to 80 ft−lb (82 to 108 N−m) 21 24 23 20 16 13 4 19 65 to 85 ft−lb (89 to 115 N−m) 7 5 12 2 14 3 17 18 6 4 RIGHT 8 9 10 FRONT 1 11 15 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Lug nut (4 used) Wheel spindle Seal Bearing cone (2 used) Wheel hub Bearing cup (2 used) Wheel stud (4 used) Tab washer Jam nut Retainer Dust cap 12. 13. 14. 15. 16. 17. 18.
5. Jack up rear of machine and support machine with jack stands (see Jacking Instructions in Chapter 1 − Safety). 6. Remove rear wheel assembly (see Wheel Removal in this section). 7. Remove two (2) jam nuts (item 16) that secure steering cylinder rod end to the rear steering fork. Separate steering cylinder rod end from the steering fork. 8.
Control Console 5 RIGHT 6 FRONT 4 9 7 3 16 15 8 17 1 12 14 18 13 19 20 10 21 22 11 2 Figure 12 1. 2. 3. 4. 5. 6. 7. 8. Console Console cover Hour meter Arm rest Knob Lever boot Joystick rod Jam nut Chassis 9. 10. 11. 12. 13. 14. 15. Washer head screw (2 per control) Joystick assembly Lock nut (2 per control) Screw (7 used) Flange nut (4 used) Carriage screw (2 used) Alarm (if equipped) Page 7 − 16 16. 17. 18. 19. 20. 21. 22.
Disassembly (Fig. 12) 27 1. Park machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove key from the ignition switch. 1 31 32 25 2. Remove screws (item 12) that secure console cover (item 2) to console. Lower cover to allow access to console components. 29 3. Remove components from control console as needed using Figure 12 as a guide. 30 5 28 23 17 16 24 15 4. Disassemble functional control lever assembly as needed using Figure 13 as a guide.
Tank Mount Plate Assembly GREENSMASTER 3300 GREENSMASTER 3400 1 7 2 3 8 3 9 4 5 10 11 6 10 RIGHT FRONT Figure 15 1. 2. 3. 4. Tank mount plate assembly (GR3300) Suction hose (to gear pump) Flange head screw (2 used) Flat washer (2 used) 5. 6. 7. 8. Flange head screw (2 used) Frame (GR3300) Tank mount plate assembly (GR3400) Suction hose (to gear pump) NOTE: For access to fasteners that secure hydraulic reservoir and fuel tank and also to access machine components at rear of machine (e.g.
Raise Tank Mount Plate Assembly 1. Park machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove key from the ignition switch. 2. Locate and remove four (4) screws that secure tank mount plate to frame. 3. Carefully lift tank mount plate assembly (hydraulic reservoir, fuel tank and tank mount plate) up from machine. Take care to not damage fuel lines, hydraulic hoses or electrical components as assembly is raised.
Cutting Unit Suspension Crossarm Assembly 12 13 4 9 8 14 3 10 1 7 11 6 2 4 3 5 RIGHT 4 2 11 4 FRONT Figure 17 1. 2. 3. 4. 5. Crossarm Flange bushing (4 used) Link (4 used) Lock nut (4 used) LH crossarm mount 6. 7. 8. 9. 10. RH crossarm mount Pivot pin (2 used) Lever (2 used) Spring (2 used) Pivot pin (2 used) 11. 12. 13. 14.
Disassembly (Fig. 17) Assembly (Fig. 17) 1. Park machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove key from the ignition switch. 1. Assemble crossarm assembly using Figure 17 as a guide. 2. Remove grass basket from suspension assembly. 3. Remove cutting unit from suspension assembly (see Traction Unit Operator’s Manual). 2. Install cutting unit to suspension assembly (see Traction Unit Operator’s Manual). 3. Install grass basket. 4.
Cutting Unit Suspension Assembly 6 8 5 9 15 7 2 14 11 13 12 4 1 55 to 60 ft−lb (75 to 81 N−m) RIGHT 10 FRONT 3 Figure 18 1. 2. 3. 4. 5. Suspension assembly (3 used) Flange screw (3 per suspension) Basket Clevis pin (3 used) Cotter pin (3 used) 6. 7. 8. 9. 10. Washer (3 used) LH spring retainer (3 used) Lift cylinder RH stabilizer spring LH stabilizer spring 11. 12. 13. 14. 15.
Removal (Fig. 18) 7 FRONT CUTTING UNIT 1. Park machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove key from the ignition switch. 8 85 to 115 in−lb (9.6 to 12.9 N−m) 1 2. Remove grass basket from suspension assembly. 9 2 3. Remove cutting unit from suspension assembly (see Traction Unit Operator’s Manual). 6 3 4. If front suspension assembly is to be removed, remove front wheel (see Wheel Removal in this section).
Cutting Unit Suspension Service 9 15 11 14 67 to 83 ft−lb (91 to 112 N−m) 12 4 1 3 3 9 21 20 15 10 21 13 4 22 24 4 15 18 16 17 4 25 19 23 3 2 5 RIGHT 8 FRONT 15 8 6 7 26 14 9 Figure 21 1. 2. 3. 4. 5. 6. 7. 8. 9. Pivot mount Lower A−arm Ball joint (6 used) Retaining ring (6 used) Striker plate Pop rivet (2 used) Steering stop Flange head screw (5 used) Clamp (6 used) 10. 11. 12. 13. 14. 15. 16. 17. 18.
B. Use 3/8” drive breaker bar in tensioner arm square drive hole to hold tensioner arm in place so that clevis pin can be removed. C. Remove clevis pin and allow counterbalance springs to relax. 3 2. Disassemble suspension assembly as required using Figure 21 as a guide. 1 NOTE: Medium strength Loctite #609 retaining compound is applied to ball joint housing during assembly. Localized heat around the ball joint housing will allow easier ball joint removal from A−arm. 2 Figure 22 Assembly (Fig. 21) 1.
Frame Assembly 100 to 110 ft−lb (136 to 149 N−m) 1 13 12 55 to 60 ft−lb (75 to 81 N−m) 11 9 2 14 4 5 55 to 60 ft−lb (75 to 81 N−m) 3 5 10 9 RIGHT 6 8 9 FRONT 7 9 Figure 25 1. 2. 3. 4. 5. ROPS assembly Cap screw (4 used) RH side casting Lock nut (4 used) Flange head screw (8 used) 6. 7. 8. 9. 10. LH side casting Step Step plate Washer head screw (9 used) Frame assembly 11. 12. 13. 14.
Chapter 8 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 TriFlex 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.
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 1 1. Place the assembled cutting unit on a surface plate. 2 2. Make sure that bedknife is properly adjusted to cutting reel. 3.
Service and Repairs Backlapping DANGER 2 1 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.
11. Repeat procedure for all cutting units to be backlapped. DANGER Reels may stall while backlapping. Do not attempt to restart reels by hand or touch reels while backlapping. Stop engine and turn reel speed adjustment knob one position toward ”9.” 8. If reels stall or become erratic while backlapping, stop backlapping by disengaging the PTO with the joystick. Once the reels have stopped, move the reel speed selector knob one position closer to “9.
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). CAUTION 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 8 − 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: 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 3 5 2 4 7 Grease OD surface 15 6 RIGHT Grease OD surface FRONT 14 3 11 7 16 17 18 Figure 25 1. 2. 3. 4. 5. 6. Crossmember LH side plate Washer 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. 12.
Reel Assembly Removal (Fig. 25) 5 CAUTION 90 to 110 ft−lb (123 to 149 N−m) (Left Hand Threads) 3 2 6 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1 7 2. Remove the cutting unit from the machine and place cutting unit on a flat work area. 3. Remove two (2) cap screws and nuts that secure weight (item 10) to the RH side plate. Remove weight from the cutting unit. Remove and discard O−ring from weight. 4.
6. Install shoulder bolts (item 4) and flange nuts (item 5) to secure the LH side plates to the crossmember. Torque the shoulder bolts from 210 to 240 in−lb (24 to 27 N−m). 7. Position crosslink to pitch arms and secure with washer head screws (item 3). 8. If bearing lock nut (RH threads) and reel nut (LH threads) were loosened during cutting reel service, put a block of wood between the cutting reel blades to prevent the reel from rotating.
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Reel Assembly Service 5 3 2 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 27 1. Cutting reel 2. Flocked seal (2 used) DPA Cutting Units 3. Bearing (2 used) 4. Plug Page 8 − 24 5. Bearing lock screw (RH thread) 6.
Disassembly of Cutting Reel (Fig. 27) 1. Remove bearing lock screw (item 5) and reel nut (item 6) from cutting reel. Reel nut has LH threads and is in end of reel shaft identified with a groove that is just inside of reel spider (Fig. 28). 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. 27) Figure 28 1. Inspect reel bearings to insure that they spin freely and have minimal axial play.
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.
Reel Motor Adapter Removal 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove the hydraulic reel motor from the cutting unit (see Cutting Reel Motors in the Service and Repairs section of Chapter 5 − Hydraulic System). Move motor to storage location on front of cutting unit suspension assembly. 4 3. Remove reel motor adapter from cutting unit side plate using Fig. 30 as a guide. 4.
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 6 5 4 25 to 30 ft−lb (34 to 41 N−m) 2 5 7 4 6 7 25 to 30 ft−lb (34 to 41 N−m) 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 Brush (Optional) 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 FRONT Figure 41 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.
Disassembly (Fig. 41) 20 to 25 in−lb (2.3 to 2.8 N−m) 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 1 A. Loosen set screw in the bearing locking collar on left side of brush shaft. B. Using blind hole in bearing locking collar as an impact point, unlock collar by striking it with a punch in the opposite direction of brush rotation. C.
IMPORTANT: The brush drive belt may fail prematurely if the pulleys are not properly aligned. 4. Check alignment of pulleys with a straight edge placed along the outer face of the pulleys (Fig. 43). The outer faces of the drive, driven and idler pulleys should be aligned. If necessary to align pulleys, loosen locking collars on brush bearings and move brush assembly until pulleys are aligned. Once pulleys are aligned, secure brush with bearing locking collars.
Belt Driven Groomer (Optional) Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 Factors Affecting Grooming . . . . . . . . . . . . . . . . . . . 4 Grooming Reel Mechanical Problems . . . . . . . . . . 5 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications MOUNTING: The groomer is mounted to the DPA cutting unit side plates. GROOMING REEL CONSTRUCTION: 2.375 inch (6 cm) diameter, 41 steel blades with 1/2 inch blade spacing. Blade spacing can be adjusted to 1/4 inch or 3/4 inch by altering the number and position of blade spacers on the groomer. Grooming reel is available with either steel or carbide tipped blades. Groomer brush can be installed in place of grooming reel. GROOMER HEIGHT SETTING: From 0.030 to 0.620 inch (0.8 to 15.
Belt Driven Groomer (Optional) General Information Installation Instructions The Installation Instructions for the groomer provide information regarding the operation, general maintenance procedures and maintenance intervals for the groomer assembly on your Greensmaster TriFlex machine. Refer to this publication for additional information when servicing the groomer assembly.
Troubleshooting Factors Affecting Grooming There are a number of factors that can affect the performance of grooming. These factors vary for different golf courses and from green to green. It is important to inspect the turf frequently and vary the grooming practice with turf needs. It is important to remember that factors affecting quality of cut also affect grooming performance.
Problem Possible Causes Correction The grooming reel rotates when it is The grooming reel should rotate in the raised, transport position (for- whenever the cutting reel is enward rotating groomer drive). gaged. Normal operation. No rotation of the grooming reel (forward rotating groomer drive). 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 spring.
Adjustments CAUTION Never work on the cutting unit with the engine running. Always stop the engine and remove the key from the ignition switch before working on the mower. NOTE: See the Groomer installation instructions for adjustment procedures for the groomer on your Greensmaster. Height/Depth of Groomer Adjustment NOTE: Grooming is performed above the soil level. When adjusting groomer height/depth, groomer blades should never penetrate the soil. FORWARD ROTATING GROOMER SHOWN 1.
Belt Driven Groomer (Optional) Service and Repairs Groomer Belt Replacement (Forward Rotating Groomer Drive) 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition switch. 1 2. If equipped, remove rear roller brush from cutting unit (see Rear Roller Brush Removal in the Service and Repairs section of Chapter 8 − DPA Cutting Units). 3.
Groomer Cover (Counter Rotating Groomer Drive) On TriFlex machines with the counter rotating groomer, the groomer cover includes a handle which engages and disengages the groomer drive. When the handle is rotated toward the front of the machine, the groomer is engaged. 4 2 Removal 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition switch. 1 2.
Installation A. Install new O−ring into groove of shaft. 1 B. Apply antiseize lubricant to shaft surface that is below the retaining ring groove. 3 C. Slide shaft up through bore of cover and secure with thrust washer and retaining ring. Position shaft in cover so that cam point of shaft is located away from the gasket surface (Fig. 6). D. Install plunger detent into groomer cover so that end of plunger if from flush to 0.020” (0.5 mm) extending from cover surface (Fig. 6). 2 E.
Grooming Reel (Forward Rotating Groomer Drive) 100 ft−lb (135 N−m) 26 25 8 6 17 14 15 22 18 23 4 1 19 7 11 12 13 27 5 1 2 13 3 12 11 Antiseize Lubricant 20 16 21 24 9 RIGHT 17 to 21 ft−lb (24 to 28 N−m) 10 FRONT Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. Lock nut (4 used) Drive cover Groomer drive belt Drive pulley Shoulder bolt (2 used) Spring RH drive plate assembly Groomer shim RH groomer arm assembly 10. 11. 12. 13. 14. 15. 16. 17. 18.
5. Loosen cap screws (item 10) that secure front roller shaft to groomer arms. 5 2 7. Remove lock nut (item 21), special washer (item 16) and plow bolt (item 22) that secure RH groomer arm assembly to RH drive plate assembly. Do not change height−of−cut screw adjustment. Remove RH groomer arm assembly from cutting unit. Belt Driven Groomer (Optional) 6. Remove lock nut (item 13) and spring washer (item 12) that secure RH groomer arm lift rod to RH drive plate assembly.
8. Secure driven pulley to grooming reel shaft with lock nut (item 1). Torque lock nut from 17 to 21 ft−lb (24 to 28 N−m). NOTE: To prevent cutting reel from turning when installing drive pulley (item 4), block reel with piece of wood. 9. Secure drive pulley (item 4) to cutting reel shaft. Torque pulley to 100 ft−lb (135 N−m). 10.Insert front roller into LH groomer arm assembly. 11. Make sure that bushing (item 11) is installed in RH drive plate assembly. 12.
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Grooming Reel (Counter Rotating Groomer Drive) 10 120 in−lb (13.5 N−m) 125 ft−lb (170 N−m) 18 33 27 24 17 10 21 22 30 12 7 32 11 31 31 20 8 Antiseize Lubricant 19 18 14 24 1 13 4 5 23 15 16 3 7 6 13 9 2 26 29 25 2 9 28 17 to 21 ft−lb (23 to 28 N−m) 120 in−lb (13.5 N−m) Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
8. Remove lock nut and spring washer that secure RH groomer arm lift rod to RH drive plate assembly (Fig. 13). 9. Remove HOC nut (item 2), HOC washer (item 9) and plow bolt (item 31) that secure RH groomer arm assembly to RH drive plate assembly. Do not change height− of−cut screw adjustment. Remove RH groomer arm assembly from cutting unit. 1 3 10.Remove front roller from cutting unit.
5. Carefully slide RH drive plate onto grooming reel shaft taking care to not damage seals in drive plate. Position drive plate to the support plate on the cutting unit frame and secure with four (4) button head screws (item 30). Make sure that drive plate rotates freely after installation. 6. Install driven gear (item 14) onto grooming reel shaft: A. Apply light coating of grease to hub on driven gear (item 14). B.
Inspect grooming reel blades frequently for damage and wear. Straighten bent blades with a pliers. Replace blades that are worn or damaged. 200 to 250 in−lb (23 to 28 N−m) 6 Carbide tipped grooming blades (Fig. 15) should be replaced if the carbide tip is worn, loose or missing. Also, if the blade is eroded around the carbide insert, the blade should be replaced. Grooming blades without a carbide tip (Fig. 16) should be replaced if worn or damaged.
Grooming Reel Bearing Replacement Bearing Removal 4 1. Park machine on a clean, level surface. Lower cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition switch. 5 3 2. Remove the cutting unit from the machine and place cutting unit on a flat work area. 3.
2. Install LH support plate to left side of cutting unit: COUNTER ROTATING GROOMER A. Apply antiseize lubricant to threads of LH groomer arm lift rod. 3 B. Position support plate to cutting unit making sure that LH groomer arm lift rod is positioned through bushing in support plate. 2 C. Place spring washer and lock nut on lift rod threads (Fig. 19). Tighten lock nut. 2 3 D. Position motor mount to groomer support plate (Fig. 18).
Idler Assembly (Forward Rotating Groomer Drive) 7 5 6 4 3 2 1 8 11 9 10 12 Figure 24 1. 2. 3. 4. Pivot hub Spacer Idler bracket Spacer Belt Driven Groomer (Optional) 5. 6. 7. 8. RH drive plate O−ring Retaining ring Grease fitting Page 9 − 20 9. 10. 11. 12.
The groomer drive side plate assembly incorporates the idler system for tensioning the groomer drive belt. The idler system uses a spring to maintain proper belt tension. 5 2 4 Belt Driven Groomer (Optional) 1 Removal 1. Park machine on a clean, level surface. Lower cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition switch. 2.
Idler Assembly (Counter Rotating Groomer Drive) 1 9 8 12 7 2 10 11 6 3 4 5 Figure 26 1. 2. 3. 4. RH drive plate Adjustment cam Spacer Idler bracket 5. 6. 7. 8. Spacer Reel hub Retaining ring O−ring The groomer RH drive plate assembly incorporates the idler system for engaging the groomer gear drive. Disassembly (Fig. 26) 1. Park machine on a clean, level surface. Lower cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition switch. 2.
3. Check adjustment of adjustment cam (Fig. 28): 4 A. Rotate idler bracket so the bracket stop is against the adjustment cam. Belt Driven Groomer (Optional) 2 B. While holding bracket stop against the cam, measure the distance between the idler gear bearing surfaces on the idler bracket and the drive plate. This distance should be 1.484” (37.7 mm). C. If distance is incorrect, loosen flange nut that secures adjustment cam to drive plate. Rotate the adjustment cam until distance is correct.
Lift Arm Assembly 1 14 2 13 15 11 7 12 16 10 8 Antiseize Lubricant 9 7 6 3 4 17 Antiseize Lubricant 18 5 Antiseize Lubricant Figure 30 1. 2. 3. 4. 5. 6. HOC groomer arm (LH shown) Flange nut Grooved pin E−ring Groomer lift rod Lock screw Belt Driven Groomer (Optional) 7. 8. 9. 10. 11. 12. Bushing Lift arm assembly (LH shown) Detent spring Spring washer Cap screw Bushing Page 9 − 24 13. 14. 15. 16. 17. 18.
Assembly (Fig. 30) 1. Remove flange nut (item 2) that secures lift arm to HOC groomer arm. Remove lock nut (item 16) and spring washer (item 17) that secure lift arm to side plate. Loosen lock screw (item 6) completely. 1. Assemble lift arm using Figure 30 as a guide. 2. Remove flange nut (item 2) that secures lift arm assembly to HOC groomer arm. Remove lock nut (item 16) and spring washer (item 17) that secure lift arm assembly to side plate. Loosen lock screw (item 6) completely. 3.
Groomer Brush 3 1 2 5 20 to 25 in−lb (2.3 to 2.8 N−m) 3 20 to 25 in−lb (2.3 to 2.8 N−m) 4 2 Figure 31 1. Groomer brush shaft 2. Lock nut 3. J−bolt 4. Groomer brush 5. O−ring The groomer brush attaches to the groomer drive in place of the grooming reel. Removal and installation of the groomer brush uses the same procedure as removal and installation of the grooming reel (see Grooming Reel in this section).
Chapter 10 Universal Groomer (Optional) Table of Contents Specifications ..................................................................................................................................... 10–2 Universal Groomer........................................................................................................................... 10–2 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. Grooming Performance There are a number of factors that can affect the performance of grooming.
Troubleshooting Problem The groomer reel does not rotate. The turf is damaged or has uneven grooming. Universal Groomer (Optional): General Information 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.
Service and Repairs g227930 Figure 1 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 2 1. Gear box assembly 4. Clevis pin 2. Drive shield 5. Input shaft 3. Cotter pin 6. Shim 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 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. 2.
Removing the Gear Box Assembly (continued) C. Continue to unscrew the input shaft and remove the gear box from the cutting unit. D. Retrieve the shim (item 6 in Figure 2). Servicing the Gear Box g251182 Figure 3 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.
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. CAUTION Use the 1−3/8 inch flats on the input shaft to prevent the input shaft from rotating during drive adapter removal and installation.
Installing the Gear Box Assembly 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. 2. Safely prevent the reel from rotating by blocking the cutting reel with a piece of wood near one of the reel spiders. IMPORTANT All of the groomer gear boxes for this machine are installed on the left side of the cutting unit.
The Idler Assembly g251183 Figure 4 1. Socket-head screw (2 each) 2. 9. 10. Stub shaft Flocked seal (2 each) 3. Motor adapter 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 1. If the shields, bearing, or bushing was removed from the idler arm: 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 5 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 6 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 7 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 9 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 10–12). The grooming brush element or shaft can be serviced separately.
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Chapter 11 Foldout Drawings ELECTRICAL DRAWING DESIGNATIONS . . . . . . . 2 HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL SCHEMATICS Greensmaster 3300 (Serial Number Below 312000000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Greensmaster 3300 (Serial Numbers 312000001 to 314000000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Greensmaster 3300 (Serial Numbers 314000001 to 316000000) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
LEFT FRONT (#2) 2” Bore 3/4” Rod 2.05” Stroke (Extend to Lower) CENTER (#1) 2” Bore 3/4” Rod 2.05” Stroke (Extend to Raise) RIGHT FRONT (#3) 2” Bore 3/4” Rod 2.05” Stroke (Extend to Lower) STEERING CYLINDER 1.5” Bore 3/4” Rod 6.19” Stroke PORT BALL JOINT END RIGHT FRONT REEL (#3) .73 L FRONT PORT R CENTER REEL (#1) FRONT PORT .73 C4 C1 C6 .73 POWER STEERING VALVE OR3 .028 OR2 .028 4.5 LEFT FRONT REEL (#2) FRONT PORT S4 S3 1160 PSI C5 S2 RV 400 PSI S1 OR1 .
(NOT USED ON GR3300) CAN--TRAK DISPLAY (NOT USED ON GR3300) (NOT USED ON GR3300) Greensmaster 3300 Electrical Schematic (Serial Number Below 312000000) Page 11 -- 4 (NOT USED ON GR3300)
(NOT USED ON GR3300) CAN--TRAK DISPLAY (NOT USED ON GR3300) (NOT USED ON GR3300) Greensmaster 3300 Electrical Schematic (Serial Numbers 312000001 to 314000000) (NOT USED ON GR3300) Page 11 -- 5
121--6561 Rev C Greensmaster 3300 Electrical Schematic (Serial Numbers 314000001 to 316000000) Page 11 -- 6
122--0654 Rev A Greensmaster 3300 Electrical Schematic (Serial Numbers 316000001 to 403410000) Page 11 -- 7
Page 11 -- 8 122--1395 Rev B Greensmaster 3300 Electrical Schematic (Serial Numbers above 403410001)
(NOT USED ON GR3400) CAN--TRAK DISPLAY (NOT USED ON GR3400) (NOT USED ON GR 3400) Greensmaster 3400 Electrical Schematic (Serial Number Below 312000000) (NOT USED ON GR3400) Page 11 -- 9
(NOT USED ON GR3400) CAN--TRAK DISPLAY (NOT USED ON GR3400) (NOT USED ON GR 3400) Greensmaster 3400 Electrical Schematic (Serial Number 312000001 to 314000000) (NOT USED ON GR3400) Page 11 -- 10
121--6562 Rev B Greensmaster 3400 Electrical Schematic (Serial Numbers 314000001 to 316000000) Page 11 -- 11
122--0653 Rev A Greensmaster 3400 Electrical Schematic (Serial Numbers 316000001 to 403420000) Page 11 -- 12
122--1393 Rev A Greensmaster 3400 Electrical Schematic (Serial Numbers above 403420001) Page 11 -- 13
(NOT USED ON GR3300) (NOT USED ON GR3300) (NOT USED ON GR3300) (NOT USED ON GR3300) Greensmaster 3300 Wire Harness Drawing (Serial Number Below 312000000) Page 11 -- 14
PINK BLACK PINK BLACK WHITE BLACK BLACK WHITE BLACK YELLOW RED BLACK BLACK PINK BLACK BLACK BLACK BLACK RED BLACK BLACK PINK BLACK PINK BLACK BLUE BLACK PINK BLACK BLACK RED RED (NOT USED ON GR3300) BLACK BROWN PINK BLACK BLACK BLACK GRAY/BLACK YELLOW BROWN VIOLET TAN/BLACK PINK BLUE BLACK RED/BLACK BLUE GRAY PINK BLACK GREEN/BLACK ORANGE/BLACK BLACK BLUE GRAY BLACK ORANGE YELLOW BLACK YELLOW GRAY PINK BLACK TAN/BLACK ORANGE RED GREEN ORANGE BROWN/WHITE BLUE GRAY VIO
(NOT USED ON GR3300) (NOT USED ON GR3300) (NOT USED ON GR3300) (NOT USED ON GR3300) Greensmaster 3300 Wire Harness Drawing (Serial Numbers 312000001 to 316000000) Page 11 -- 16
PINK BLACK PINK BLACK WHITE BLACK BLACK WHITE BLACK YELLOW RED BLACK BLACK PINK BLACK BLACK BLACK BLACK RED BLACK BLACK PINK BLACK PINK BLACK BLUE BLACK PINK BLACK BLACK RED RED (NOT USED ON GR3300) BLACK BROWN PINK BLACK BLACK BLACK GRAY/BLACK YELLOW BROWN VIOLET TAN/BLACK PINK BLUE BLACK RED/BLACK BLUE PINK GRAY BLACK GREEN/BLACK ORANGE/BLK BLACK BLUE GRAY BLACK ORANGE YELLOW BLACK YELLOW GRAY PINK BLACK TAN/BLACK ORANGE RED GREEN ORANGE BROWN/WHITE BLUE GRAY VIOLE
122--0652 Rev B Wire Harness Drawing Greensmaster 3300 (Serial Numbers 316000001 to 403410000) CV Page 11 -- 18
122--0652 Rev B Wire Harness Drawing Greensmaster 3300 (Serial Numbers 316000001 to 403410000) Page 11 -- 19
122--1396 Rev B Wire Harness Drawing Greensmaster 3300 (Serial Numbers 403410001 to 406000000) CV Page 11 -- 20
122--1396 Rev B Wire Harness Diagram Greensmaster 3300 (Serial Numbers 403410001 to 406000000) Page 11 -- 21
122--1736 Rev A Wire Harness Drawing Greensmaster 3300 (Serial Numbers above 406000001) CV Page 11 -- 22
122--1736 Rev A Wire Harness Diagram Greensmaster 3300 (Serial Numbers above 406000001) Page 11 -- 23
(NOT USED ON GR3400) (NOT USED ON GR3400) (NOT USED ON GR3400) (NOT USED ON GR3400) Greensmaster 3400 Wire Harness Drawing (Serial Number Below 312000000) Page 11 -- 24
BLACK BLACK WHITE BLACK WHITE BLACK BLACK PINK BLACK BLACK BLACK BLACK BLACK BLACK PINK BLACK PINK BLACK BLUE BLACK PINK BLACK BLACK RED RED RED PINK WHITE PINK (NOT USED ON GR3400) BLACK BROWN BLACK RED/BLACK BLACK BLACK PINK PINK WHITE BLACK RED/BLACK WHITE BLACK FUSIBLE LINK BLACK BLACK BLACK BLACK ORANGE GRAY GRAY/BLACK YELLOW BLUE BROWN VIOLET TAN/BLACK GRAY PINK BROWN/WHITE RED/BLACK BLACK PINK GRAY BLACK WHITE GREEN/BLACK ORANGE/BLACK BLACK BLUE GRAY BLACK ORANG
(NOT USED ON GR3400) (NOT USED ON GR3400) (NOT USED ON GR3400) (NOT USED ON GR3400) Greensmaster 3400 Wire Harness Drawing (Serial Numbers 312000000 to 314000000) Page 11 -- 26
BLACK BLACK WHITE BLACK WHITE BLACK BLACK PINK BLACK BLACK BLACK BLACK BLACK BLACK PINK BLACK PINK BLACK BLUE BLACK PINK BLACK BLACK RED RED RED PINK WHITE PINK (NOT USED ON GR3400) BLACK BROWN BLACK RED/BLACK BLACK BLACK PINK PINK WHITE BLACK RED/BLACK WHITE BLACK FUSIBLE LINK BLACK BLACK BLACK BLACK ORANGE GRAY GRAY/BLACK YELLOW BLUE BROWN VIOLET TAN/BLACK GRAY PINK BROWN/WHITE RED/BLACK BLACK PINK GRAY BLACK WHITE GREEN/BLACK ORANGE/BLACK BLACK BLUE GRAY BLACK ORANG
122--0248 Rev B Wire Harness Drawing Greensmaster 3400 (Serial Numbers 314000001 to 316000000) CV Page 11 -- 28
122--0248 Rev B Wire Harness Diagram Greensmaster 3400 (Serial Numbers 314000001 to 316000000) Page 11 -- 29
122--0651 Rev B Wire Harness Drawing Greensmaster 3400 (Serial Numbers 316000001 to 316000500) CV Page 11 -- 30
122--0651 Rev B Wire Harness Diagram Greensmaster 3400 (Serial Numbers 316000001 to 316000500) Page 11 -- 31
122--0862 Rev D Wire Harness Drawing Greensmaster 3400 (Serial Numbers 316000501 to 403420000) CV Page 11 -- 32
122--0862 Rev D Wire Harness Diagram Greensmaster 3400 (Serial Numbers 316000501 to 403420000) Page 11 -- 33
122--1394 Rev B Wire Harness Drawing Greensmaster 3400 (Serial Numbers 403420000 to 405700000) CV Page 11 -- 34
122--1394 Rev B Wire Harness Diagram Greensmaster 3400 (Serial Numbers 403420000 to 405700000) Page 11 -- 35
122--1735 Rev A Wire Harness Drawing Greensmaster 3400 (Serial Numbers above 405700001) CV Page 11 -- 36
122--1735 Rev A Wire Harness Diagram Greensmaster 3400 (Serial Numbers above 405700001) Page 11 -- 37
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