Form No.
Revision History Revision Date Description -- 2012 A 02/2015 Updated Hydraulic chapter. B 02/2018 Updated Solenoids S3 and S4. Added revision history. C 04/2018 Revised bedknife installation procedure, added Universal Groomer chapter. Initial Issue. © THE TORO COMPANY 2018 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. 12190SL Rev. C Service Manual (Models 04530 and 04540) GreensmasterR TriFlexTM 3320/3420 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 Hybrid 3320 and 3420. REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
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Chapter 3 − Gasoline Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . Fuel Evaporative Control System . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . BRIGGS & STRATTON VANGUARD V−TWIN REPAIR MANUAL 3−2 3−3 3−4 3−7 3−8 OHV Chapter 7 − Chassis Specifications . . . . . . . . . . . . . . . .
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Chapter 9 − Belt Driven Groomer (Optional) Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . Chapter 10 − Universal Groomer (Optional) 9−2 9−3 9−4 9−6 9−7 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 Hybrid 3320 and 3420 machines have been tested and certified by TORO for compliance with existing safety standards and specifications. Although hazard control and accident prevention are partially 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 operator seat. 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: B. Verify that functional control lever is in neutral. C. Verify that parking brake is applied. A. Make sure cutting units are disengaged and have stopped rotating. 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, place functional control lever in the neutral position, 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 Hybrid 3320 and 3420 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 3320 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 Hybrid 3320 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 3320
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 3320 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 Grommet (2 used) Fuel hose (cannister to tank vent) Hose clamp (3 used) Carbon canister 8. 9. 10. 11. 12. 13. Bracket Flange nut (2 used) Fuel hose (cannister to engine) Fuel hose Fresh air filter R−clamp 14. 15. 16. 17. 18. 19.
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 RIGHT 16 14 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 Nut Worm clamp Cap screw R−clamp 13. 14. 15. 16. 17. 18. 19.
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 23 32 5 22 27 30 28 1 29 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 20 to 25 in−lb (2.3 to 2.8 N−m) 1 90 to 110 in−lb (10.2 to 12.4 N−m) Antiseize Lubricant FRONT RIGHT 170 to 200 in−lb (19.3 to 22.6 N−m) 19 2 21 7 23 3 24 15 16 10 6 20 25 4 8 22 9 8 14 5 11 12 17 25 to 38 ft−lb (34 to 51 N−m) 18 13 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.
2. Disconnect battery cables from battery. Disconnect negative battery cable first and positive cable last. 3 4 3. Close fuel shut−off valve on fuel tank. 2 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. 6.
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. 6. Position generator belt to the generator pulley attached to engine crankshaft and tension the belt (see Generator Belt (Greensmaster 3320) in the Service and Repairs section of Chapter 6 − Electrical System). 3.
Chapter 4 Diesel Engine Table of Contents Greensmaster 3420 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 gasoline engine used in the Greensmaster TriFlex Hybrid 3420 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. 1 4. Disassemble air cleaner as necessary (Fig. 4). 5. Check air cleaner housing and cover for damage that could cause possible air leaks. 2 3 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 Illustration from machine with serial number below 312000000 shown 5 6 7 11 10 1 8 9 2 16 17 11 12 15 13 14 3 Antiseize Lubricant 30 to 50 in−lb (3.4 to 5.6 N−m) 4 RIGHT 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.
Fuel Tank Installation (Fig. 6) DANGER Diesel fuel is flammable. Use caution when storing or handling it. Do not smoke while servicing the fuel tank. Do not fill fuel tank while engine is running or in an enclosed area. Always fill fuel tank outside and wipe up any spilled fuel before starting the engine. Store fuel in a clean, safety− approved container and keep the cap in place. 1. Install fitting assembly and shut−off valve into fuel tank if they were removed from tank (Fig. 7).
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.
Starter Motor 2 4 1 5 6 3 Figure 9 1. Starter motor 2. Flywheel plate Diesel Engine 3. Bell housing 4. Cap screw (2 used) Page 4 − 14 5. Lock washer (2 used) 6.
Starter Motor Removal (Fig. 9) 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 CAUTION The engine, radiator, exhaust system and hydraulic system may be hot. To avoid possible injury, allow machine to cool before working on the engine. 2. Disconnect battery cables from battery before removing the starter motor.
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 11 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.
3. Close fuel shut−off valve on fuel tank. 4. Remove air cleaner and air intake hose from machine (see Air Cleaner Removal in this section). 3 1 2 5. Remove radiator from machine (see Radiator Removal in this section). 6. Remove exhaust system from machine (see Exhaust System Removal in this section). 4 7. Remove starter motor from engine (see Starter Motor Removal in this section). 8. Disconnect fuel supply hose from the injector pump and fuel return hose from the #3 injector.
12.Remove tension on generator belt and remove belt from the generator pulley attached to engine (see Generator Drive Belt (Greensmaster 3420) in the Service and Repairs section of Chapter 6 − Electrical System). FRONT 3 CAUTION When removing engine assembly, make sure lift or hoist can safely support 190 lbs (86 kg). 4 13.Attach a suitable lift or hoist to engine. Support engine with lift or hoist to prevent engine from shifting or moving. 5 14.Remove fasteners that secure engine to machine: A.
16.Open fuel shutoff valve on fuel tank. Check tank and hoses for leaks. CAUTION When installing engine assembly, make sure lift or hoist can safely support 190 lbs (86 kg). 17.Fill cooling system with coolant. Check radiator and hoses for leaks. 18.Make sure that alternator belt tension is properly adjusted. 5. Attach a suitable lift or hoist to engine. IMPORTANT: Make sure to not damage the engine, fuel hoses, hydraulic lines, electrical harness or other parts while installing the engine. 6.
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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 Opening Electrical Circuit to Cutting Units . . . . . .
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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 Displacement (per revolution) Single section, positive displacement gear pump (Casappa) 0.30 in3 (4.95 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. 7) 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. 9) 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.
EXPANSION TANK OUT S1 LEAK IN DETECTOR VOLUME LEAK DETECTOR KIT (OPTIONAL) BREATHER LEFT FRONT (#2) (Extend to Lower) GEAR PUMP G1 SUCTION STRAINER OR2 .028 C4 .33 P S4 C1 T 1.44 4.0 GPM S1 S2 C5 110 − 150 PSI C 25 PSI 3000 PSI 3000 PSI LIFT CONTROL VALVE OR1 C2 RV 400 .037 PSI C3 OIL FILTER S3 OR3 .028 C6 70 − 100 PSI BYPASS VALVE C1 1.9 GPM HYDROSTAT A TOP PORT FORWARD 20.
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EXPANSION TANK LEAK DETECTOR VOLUME S1 OUT IN BREATHER LEAK DETECTOR KIT High Pressure Low Pressure (Charge) Return or Suction Flow SUCTION STRAINER LIFT CONTROL MANIFOLD .33 P S4 GEAR PUMP G1 OR2 .028 C1 T 3000 PSI 3000 PSI C BYPASS VALVE C1 P BOTTOM PORT B G1 G2 20.6 A FORWARD OPTIONAL 3WD B 4.5 1160 PSI L R T 10.3 E PORT BALL JOINT END STEERING CYLINDER ENGINE TOP PORT A POWER STEERING VALVE 70 to 100 PSI 1.9 GPM HYDROSTAT TRANSPORT = 17.
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 High Pressure Low Pressure (Charge) Return or Suction Flow Solenoids S1, S2, S3 and S4 in lift control manifold are shown in energized position. SUCTION STRAINER LIFT CONTROL MANIFOLD .33 P GEAR PUMP G1 S4 OR2 .028 S1 RIGHT FRONT (#3) T S3 110 − 150 PSI 3000 PSI 3000 PSI C 70 to 100 PSI P FORWARD R 20.6 B B A BOTTOM PORT OPTIONAL 3WD G1 4.
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 High Pressure Low Pressure (Charge) Return or Suction Flow Solenoids S1, S3 and S4 in lift control manifold are shown in energized position. SUCTION STRAINER LIFT CONTROL MANIFOLD .33 T S3 C5 110 − 150 PSI 3000 PSI 3000 PSI C C2 RV OR1 400 .037 PSI C3 25 PSI OR3 .028 C6 MOW = 6.7 GPM AT 3.8 MPH 1.44 S1 S2 RIGHT FRONT (#3) (Extend to Lower) 70 to 100 PSI P FORWARD R 20.
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 S1 OUT IN BREATHER LEAK DETECTOR KIT 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. SUCTION STRAINER LIFT CONTROL MANIFOLD P .33 S4 GEAR PUMP G1 OR2 .028 C1 (Extend to Lower) C4 CENTER (#1) (Extend to Raise) LEFT FRONT (#2) RIGHT FRONT (#3) T 3000 PSI 3000 PSI C BYPASS VALVE C1 1.9 GPM 70 to 100 PSI P B G1 G2 20.
Right and Left Turn The gear pump is directly coupled to the piston (traction) pump. The gear pump 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. proportional to the amount of the turning on the steering wheel.
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 19 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
Lift/Lower Circuit Problems ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ
Steering Circuit Problems ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (see the Special Tools section in this Chapter). 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: 4. For problems with the steering and lift/lower circuit, consider performing one or more of the following tests: A. Steering/Lift Relief Valve Pressure. A. Charge Relief Valve Pressure. B. Lower Cutting Units Relief Valve (RV) Pressure. B. Piston (Traction) Pump Flow. C. Steering/Lift Circuit Gear Pump Flow. C. Wheel Motor Efficiency. D. Power Steering Valve.
Charge Relief Valve Pressure Test (Using Pressure Gauge) TO POWER STEERING VALVE FROM POWER STEERING AND LIFT CONTROL VALVES PRESSURE GAUGE HYDROSTAT C TO HYDRAULIC RESERVOIR A 10.3 1.44 BACK PORT B A RIGHT MOTOR A 1.9 GPM GEAR PUMP 10.3 ENGINE LEFT MOTOR .33 G2 B 70 to 100 PSI 110 − 150 PSI FRONT PORT TOP PORT 3000 PSI G1 3000 PSI 20.6 B FROM HYDRAULIC RESERVOIR C1 MOW = 6.7 GPM AT 3.8 MPH BYPASS VALVE 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. 4 2 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 TESTER HYDROSTAT C TO HYDRAULIC RESERVOIR A 10.3 1.44 GEAR PUMP BACK PORT B 10.3 RIGHT MOTOR A A ENGINE 1.9 GPM LEFT MOTOR .33 G2 B 70 to 100 PSI 110 − 150 PSI FRONT PORT TOP PORT 3000 PSI G1 3000 PSI 20.
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. 8. Move functional lever to the transport position. CAUTION Procedure for Piston (Traction) 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 and off. Make sure engine is off.
Wheel Motor Efficiency Test (Using Tester with Flowmeter and Pressure Gauge) TO POWER STEERING VALVE FROM POWER STEERING AND LIFT CONTROL VALVES TESTER HYDROSTAT C TO HYDRAULIC RESERVOIR A 10.3 1.44 GEAR PUMP BACK PORT B 10.3 RIGHT MOTOR A A ENGINE 1.9 GPM LEFT MOTOR .33 CAP G2 B 70 to 100 PSI 110 − 150 PSI FRONT PORT TOP PORT 3000 PSI CAP G1 3000 PSI 20.6 B C1 FROM HYDRAULIC RESERVOIR MOW = 6.7 GPM AT 3.8 MPH TRANSPORT = 17.
13.Slowly push traction pedal in forward direction until 1000 PSI (69 bar) is displayed on the tester pressure gauge. Make sure that wheel motor being tested is not rotating. 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 traction control assembly is adjusted to the neutral position. 5.
Steering/Lift Relief Valve Pressure Test (Using Pressure Gauge) CENTER (#1) (Extend to Raise) LEFT FRONT (#2) (Extend to Lower) RIGHT FRONT (#3) (Extend to Lower) STEERING CYLINDER 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 TO HYDRAULIC RESERVOIR A 10.3 1.44 A A BACK PORT 10.3 ENGINE 1.
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. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.
Lower Cutting Units Relief Valve (RV) Pressure Test (Using Pressure Gauge) CENTER (#1) (Extend to Raise) LEFT FRONT (#2) (Extend to Lower) RIGHT FRONT (#3) (Extend to Lower) STEERING CYLINDER 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 TO HYDRAULIC RESERVOIR 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: 10.If the lower relief valve pressure is incorrect, adjust lower cutting units relief valve on lift control manifold (Fig. 24) (see Adjust Manifold Relief Valves in the Adjustments section of this Chapter). Retest relief valve pressure after adjustment is performed. 1.
Steering/Lift Circuit Gear Pump Flow Test (Using Tester with Flowmeter and Pressure Gauge) CENTER (#1) (Extend to Raise) RIGHT FRONT (#3) (Extend to Lower) LEFT FRONT (#2) (Extend to Lower) STEERING CYLINDER 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 TESTER HYDROSTAT C TO HYDRAULIC RESERVOIR 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.
Adjustments Adjust Manifold Relief Valves The lift control manifold includes an adjustable relief valve. If adjustment of this valve is necessary, follow the following procedure. NOTE: Do not remove relief valve from the hydraulic manifold for adjustment. CAP 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. Always install and tighten the cap before pressurizing the system.
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. traction (piston) 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 9 27 to 31 ft−lb (37 to 42 N−m) Antiseize Lubricant 6 3 2 4 10 7 12 1 11 5 RIGHT 13 FRONT 8 Figure 34 1. 2. 3. 4. 5. Gear pump Flat washer (2 used) Socket head screw (2 used) Hydraulic fitting 90o hydraulic fitting 6. 7. 8. 9. Hose clamp O−ring Hydraulic hose (steering/lift supply) Suction (inlet) hose Removal (Fig. 34) 10. 11. 12. 13. O−ring O−ring Piston (traction) pump O−ring 3. Label all hose connections on gear pump for assembly purposes.
7. Mark hydraulic fitting orientation on bottom of pump to allow correct assembly. Remove hydraulic fittings and O−rings from gear pump. Discard removed O−rings. 5. Secure gear pump to the piston pump with two (2) socket head screws and flat washers. Torque screws from 27 to 31 ft−lb (37 to 42 N−m). 8. Support gear pump to prevent it from falling. Separate gear pump from the piston pump by removing two (2) socket head screws and flat washers. 6.
Gear Pump Service 12 9 11 10 8 6 5 2 1 16 15 14 13 9 4 3 7 3 33 ft−lb (45 N−m) 4 Figure 35 1. 2. 3. 4. 5. 6. O−ring Front cover Back−up seal Pressure seal Front thrust plate Drive shaft 7. 8. 9. 10. 11. Idler gear Rear thrust plate Dowel pin (4 used) O−ring Housing 12. 13. 14. 15. 16. End cover Cap screw (4 used) Washer (4 used) Shaft seal Retaining ring Gear Pump Disassembly (Fig. 35) NOTE: Disassemble gear pump for cleaning, inspection and seal replacement only.
4. Loosen the four (4) cap screws that secure pump assembly. NOTE: Pressure and back−up seals fit in grooves machined into thrust plates. Body O−rings fit in grooves machined in housing. 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 section. Be careful to not drop parts or disengage gear mesh.
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 26 14 27 22 12 25 23 1 Loctite #242 Loctite #242 9 30 29 28 RIGHT 27 FRONT PUMP ASSEMBLY FROM GREENSMASTER 3420 SHOWN Figure 38 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. 38) Assembly (Fig. 38) 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 removed components to traction neutral assembly using Figure 38 as a guide along with the following: CAUTION CAUTION 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. 2.
Piston (Traction) Pump 9 Antiseize Lubricant 27 to 31 ft−lb (37 to 42 N−m) 26 6 21 2 20 4 3 13 10 14 22 7 19 1 17 14 23 13 24 17 18 11 25 8 12 16 15 RIGHT FRONT PUMP ASSEMBLY FROM GREENSMASTER 3320 SHOWN 5 16 Figure 39 1. 2. 3. 4. 5. 6. 7. 8. 9. Gear pump Hardened washer (2 used) Socket head screw (2 used) Hydraulic fitting Hydraulic hose (traction reverse) Hose clamp O−ring Hydraulic hose (traction forward) Suction (inlet) hose 10. 11. 12. 13. 14. 15. 16. 17. 18.
Piston Pump Removal (Fig. 39) 11. Remove gear pump from the piston pump (see Gear Pump Removal in this section). 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.
1. Make sure the flange surfaces of the gear pump and piston pump are thoroughly clean. 6. Insert coupling on pump shaft into coupling attached to engine and slide pump assembly to pump mount. Secure pump assembly to pump mount with two (2) cap screws (item 23) and flat washers (item 24). 2. Install gear pump to the piston pump (see Gear Pump Installation in this section). 7. Remove plugs that were placed during disassembly from hydraulic fittings and hoses. 3.
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Piston (Traction) Pump Service 36 37 21 20 19 17 23 22 18 REAR OF TRACTION UNIT 16 15 18 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 32 25 31 35 34 39 4 33 30 Figure 42 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. 43). 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 v 3 9 10 6 1 Figure 44 1. 2. 3. 4. Crush ring Shims Cover plate Housing 5. Swash plate (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. 44) 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 45 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. 45) 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 47 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 48 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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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 49 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. 49) 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 50 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. 50) Assembly (Fig. 50) 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 51 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 − 74 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. 51) 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 52 1. 2. 3. 4. 5. 6. Lift manifold Zero leak plug (5 used) Orifice (0.028) (ports C4 and C6) 90o hydraulic 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 52 uses several zero leak plugs.
Control Manifold Cartridge Valve Service CAUTION 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.
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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 53 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 − 80 11. 12. 13. 14. 15.
Removal (Fig. 53) 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 9 10 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 55 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 56 1. 2. 3. 4. Steering cylinder Frame Rear steering fork Jam nut (4 used) 5. Rear wheel spindle 6. Steering spindle 7. Rear wheel assembly Removal (Fig. 56) 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. 57). 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 58 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 − 86 10. 11. 12. 13.
Disassembly (Fig. 58) Assembly (Fig. 58) 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. 2. Mount cylinder in a vise by clamping vise on barrel ball joint location of cylinder. Use of a vise with soft jaws is recommended. 3. Using a pipe wrench, carefully remove both collars (item 2) from cylinder barrel. 4.
Hydraulic Reservoir 7 Illustration from diesel powered machine with serial number below 312000000 shown 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 v 15 6 18 21 30 to 38 ft−lb (41 to 51 N−m) 22 16 30 to 38 ft−lb (41 to 51 N−m) 23 Antiseize Lubricant 30 to 50 in−lb (3.4 to 5.6 N−m) 1 12 13 14 Figure 59 1. 2. 3. 4. 5. 6. 7. 8.
Installing Hydraulic Reservoir (Fig. 59) IMPORTANT: When installing tank cover and reservoir to machine, do not over−tighten cap screws. Threads in reservoir may become damaged. 3. Remove four (4) cap screws (item 7), flat washers (item 9), neoprene washers (item 8) and spacers (item 20) that secure tank cover to hydraulic reservoir. 1. Lubricate and place new O−rings onto all removed fittings and plugs. Install fittings and plugs into reservoir openings.
Leak Detector Tank (Machines Equipped with Optional 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 14 9 5 26 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.
Removal (Fig. 60) 2 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. 1 Figure 61 1. Gear pump 2. 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 Optional Turf GuardianTM Leak Detector System) Illustration from machine with serial number below 312000000 shown Antiseize Lubricant 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 11 110 to 140 in−lb (12.5 to 15.8 N−m) 24 Antiseize Lubricant 30 to 60 in−lb (3.4 to 6.
NOTE: The Turf GuardianTM Leak Detector System is optional on Greensmaster TriFlex Hybrid machines. Removal (Fig. 63) 1. Park machine on a level surface, set brake, lower cutting units and stop engine. Remove key from the ignition switch. Installation (Fig. 63) 1. If fittings were removed from solenoid valve manifold, lubricate and place new O−rings onto fittings. Install fittings into manifold openings.
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Chapter 6 Electrical System GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Toro Electronic Controller (TEC) . . . . . . . . . . . . . . 2 CAN−bus Communications . . . . . . . . . . . . . . . . . . . 2 Opening Electrical Circuit to Cutting Units . . . . . . 3 Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL SYSTEM OPERATION . . . . . . . . . . . . 4 12 Volt DC System Operation . . . .
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 service information. Toro Electronic Controller (TEC) Greensmaster TriFlex Hybrid 3320 and 3420 machines use a Toro Electronic Controller (TEC) to manage 12 volt machine electrical functions.
Opening Electrical Circuit to Cutting Units 1 CAUTION Before installing, removing or servicing the cutting units, separate the cutting unit power disconnect. This will prevent unexpected cutting unit operation. Before installing, removing or working on the cutting units, disconnect the cutting units from the electrical power supply by separating the cutting unit power disconnect couplers (Fig. 1). The couplers are located at the base of the rollover bar on the left side of the traction unit.
Electrical System Operation Greensmaster TriFlex Hybrid machines use two (2) separate electrical systems. Most machine functions operate on a typical 12 volt DC system. The second system exists to operate the electric cutting reels and is a 48 volt DC electrical system. Basic information about the two systems is included below.
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Turf GuardianTM Leak Detector System Operation (Optional Kit) NOTE: The Turf GuardianTM Leak Detector System is optional on Greensmaster TriFlex Hybrid machines. Before Start-Up (Cold Oil) With ignition switch OFF, solenoid valve is open. Before start-up, hydraulic fluid is at level mark of sight gauge (oil cold). Oil level sensor float is in raised position, keeping alarm circuit open.
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.
Battery Terminal Protector Aerosol spray that should be used on battery terminals, ring terminals and fork terminals to reduce corrosion problems. Apply terminal protector to the connection after the battery cable, ring terminal or fork terminal has been secured. Toro Part Number: 107−0392 Figure 8 Dielectric Lubricant/Sealant Dielectric gel should be used to prevent corrosion of un− sealed connection terminals.
Generator Rotor Tool Set The generator rotor tool set is required to remove and install the rotor from the generator housing. Tool set includes base plate, threaded shaft and handle (Fig. 11). 2 Toro Part Number: TOR6029 3 NOTE: For generator service procedures, see Generator Assembly Service in the Service and Repairs section of this chapter. 1 Generator Rotor Removal 1. Remove screws that secure generator cover. Do not remove cover from generator assembly. 2.
Cutting Reel Motor Rotor Tool Set The rotor tool set for the cutting reel motor is required to remove and install the rotor from the reel motor housing. Tool set includes base plate, threaded shaft and handle (Fig. 13). 2 Toro Part Number: TOR6028 3 NOTE: For cutting reel motor service procedures, see Cutting Reel Motor Service in the Service and Repairs section of this chapter. 1 Cutting Reel Motor Rotor Removal 1.
InfoCenter Display (Serial Number Above 312000000) The InfoCenter Display used on TriFlex Hybrid Greensmowers with serial number above 312000000 is a LCD device that is located on the console. The InfoCenter provides information for the machine operator during machine operation, provides electrical system diagnostic assistance for technicians and allows inputs for adjustable machine settings.
Main Information Screen The InfoCenter main information screen (Fig. 16) is displayed after the initial splash screen has been displayed for several seconds. During normal machine operation, the main information screen provides machine information for the operator. 8 9 6 1 180 The main information screen can be used to monitor engine coolant temperature, engine RPM, generator voltage, PTO speed and hour meter reading. The screen will also identify if the parking brake is applied.
Main Menu Screen The main menu screen can be accessed from the InfoCenter main information or splash screen by pressing and releasing the menu/back button (left button) on the display. Once to the main menu screen (Fig. 17), navigation to the five (5) different menu items can occur. Pressing the move to menu item button (center button) allows a different menu item to be highlighted. Selection of the highlighted item is completed by pressing the choose item button (right button).
Service Screen The service screen (Fig. 19) contains machine operational information including hours and counts. Values listed for service menu items cannot be changed. 1 Hours Key On: Engine Run: Transport: The options listed for hours include the following: 2 D Key On identifies the number of hours that the key switch has been in the RUN position. 92.5 Hours 88.4 Hours 3.7 Hours 5 D Engine Run identifies the number of hours that the engine has been running.
Diagnostics Screen The diagnostics screen (Fig. 20) lists the various states of machine electrical components. The diagnostics screen should be used to check operation of machine switches and controls. For each of the diagnostics screen items, inputs, qualifiers and outputs are identified. The diagnostics screen includes the following: D Engine Run identifies machine requirements to allow the engine to run. Inputs indicate the state of the ignition switch.
About Screen The about screen (Fig. 21) identifies the machine model number, serial number and software revisions for the TEC controller, InfoCenter, reel motor controllers and generator controller. The about screen also lists the CAN−bus status. 1 About 04530 Model: 312000285 SN: TEC 5001: 120−6320G 2 To return to the main menu screen from the about screen, press the back button (left button). 5 3 5 4 3 Figure 21 4. Choose menu item 5. Back button Electrical System 1. About menu 2. About items 3.
Settings Screen The settings screen identifies the InfoCenter language and units (English or Metric). The settings screen also allows the operator to customize the backlight (brightness) and contrast settings for the InfoCenter display. 1 2 If either the backlight or contrast items are selected, the center button (−) or right button (+) can be used to change the display settings.
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Troubleshooting If the machine has any interlock switches by−passed, they must be reconnected for proper troubleshooting and safety. 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.
Retrieving Fault Codes Clearing 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: After the three (3) most recent fault codes have been retrieved, clearing of those faults can be completed using the following switch sequence: 1.
Fault Codes The list below identifies the fault codes that are generated by the TEC controller to identify an electrical system malfunction (fault) that occurred during machine operation. On machines with serial number below 312000000, the fault code will be retrieved using the diagnostic light (see Diagnostic Light (Serial Number Below 312000000) in this section).
Fault Description 4−3 Optional hydraulic oil temperature sensor is faulty (GR3420) 4−4 System voltage to generator and all cutting unit motors is insufficient (likely a 48V battery problem) 4−5 System voltage to generator and all cutting unit motors is excessive (e.g. incorrect batteries or charger problem) 4−6 Logic system voltage to generator and all cutting unit motors is excessive (e.g.
Fault Code (Lamp Flashes) Fault Description 9−7 System voltage to generator is insufficient (generator will be disabled) 9−8 Logic system voltage to #1 cutting unit motor is excessive (motor will be disabled) 9−9 Logic system voltage to #2 cutting unit motor is excessive (motor will be disabled) 10 − 1 Logic system voltage to #3 cutting unit motor is excessive (motor will be disabled) 10 − 2 High current logic system voltage to generator is excessive (generator will be disabled) 10 − 3 Temperat
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Hand Held 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 Hand Held 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 Hand Held 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.
Hand Held Diagnostic Display TEC Controller Inputs Hand Held 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) (Optional for Greensmaster 3320 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 Reel speed control (potentiometer) and circuit wiring OK: LED ON Reel speed control (potentiometer) and c
Verify Diagnostic Display Output Functions The Hand Held 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 Hand Held Diagnostic Display. 1. Park machine on a level surface, lower the cutting units, engage the parking brake and stop the engine. 2.
Hand Held Diagnostic Display Outputs Hand Held Diagnostic Display LED Operation START TEC output exists to energize starter solenoid (Greensmaster 3320) or starter relay (Greensmaster 3420): 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 (if equipped
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Starting Problems NOTE: Check Diagnostic Light (serial number below 312000000) or InfoCenter display (serial number above 312000000) for possible operator advisories or faults whenever diagnosing machine electrical problems. Problem Possible Causes Starter solenoid clicks, but starter will not crank (if solenoid clicks, problem is not in safety interlock system). 12VDC battery cables are loose or corroded. 12VDC battery ground to frame is loose or corroded. 12VDC battery is discharged or faulty.
Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. The fuel tank is empty. The fuel filter is plugged. Engine and/or fuel may be too cold. Wiring to start circuits is loose, corroded or damaged (see electrical schematic in Chapter 10 − Foldout Drawings). Engine or fuel system is malfunctioning (see Chapter 3 − Gasoline Engine or Chapter 4 − Diesel Engine). Kill relay or circuit wiring is faulty (Greensmaster 3320 machines).
General Run and Transport Problems NOTE: Check Diagnostic Light (serial number below 312000000) or InfoCenter display (serial number above 312000000) for possible operator advisories or faults whenever diagnosing machine electrical problems. Possible Causes Problem 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.
Cutting Unit Operating Problems NOTE: Check Diagnostic Light (serial number below 312000000) or InfoCenter display (serial number above 312000000) for possible operator advisories or faults whenever diagnosing machine electrical problems. Problem Possible Causes Cutting units will not raise. Wiring to raise circuit components is loose, corroded or damaged (see electrical schematic in Chapter 10 − Foldout Drawings).
Cutting Unit Operating Problems (Continued) Problem Possible Causes None of the cutting units run when lowered with the functional control lever in the MOW position. The cutting unit power disconnect couplers are not connected (see Opening Electrical Circuit to Cutting Units in the General Information section of this chapter). NOTE: Make sure to check for machine electrical fault to assist with troubleshooting.
Electrical System Quick Checks 12 Volt 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.
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. 29). 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. 31). 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. 36). 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 3320 with Serial Number Below 312000000) The engine oil pressure indicator light on Greensmaster 3320 machines with serial number below 312000000 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.
Indicator Lights (Greensmaster 3420 with Serial Number Below 312000000) 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.
Fuse Block (Greensmaster 3320) The fuse block on Greensmaster 3320 machines is attached to the frame under the operator seat (Fig. 41). Fuse Identification and Function 1 Use Figure 42 to identify each individual fuse and its correct amperage. Fuses for Greensmaster 3320 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 3420 with Serial Number Below 312000000) The fuse block on Greensmaster 3420 machines is attached to the frame under the operator seat (Fig. 43). 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 44 to identify each individual fuse and its correct amperage.
Fuse Block (Greensmaster 3420 with Serial Number Above 312000000) The fuse block on Greensmaster 3420 machines is attached to the frame under the operator seat (Fig. 45). 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 46 to identify each individual fuse and its correct amperage.
Electric Reel Drive System (48 Volt DC) Fuses Several fuses are used in the electric reel drive system for circuit protection. These fuses plug into fuse holders and are located under the side cover next to the operator seat. Fuse Identification and Function 2 Use Figures 47, 48 and 49 (if equipped) to identify the electric reel drive system fuses. 1 10 Amp Fuse (Fig. 47): Protects logic power supply circuits for the generator and electric reel motors.
Fusible Links The electrical system on Greensmaster TriFlex Hybrid 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. 3 2 1 Greensmaster 3320 machines (gasoline engine) use only two (2) of the harness fusible links. The fusible link harness on Greensmaster 3320 machines is connected to the starter solenoid (Fig. 50).
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.
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. 55). 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. 57). 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. 58). 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. 60). The switches are identical and are shown in Figure 61. The Toro Electronic Controller (TEC) monitors the operation of the joystick raise and lower switches. A.
Backlap Switch The backlap switch on Greensmaster TriFlex Hybrid machines is used to control cutting reel backlap operation. The Toro Electronic Controller (TEC) uses the backlap switch as an input to reverse cutting reel direction and also to prevent the cutting reels from raising during backlapping. The backlap switch is located under the operator seat (Fig. 62). 1 2 The rear of the backlap switch should be depressed for normal mow operation.
Electric Reel Contactor Greensmaster TriFlex Hybrid machines use the electric reel contactor to connect the generator, reel motors and the 48 volt battery pack. The contactor is energized by the generator controller. The electric reel contactor is located under the left side cover next to the operator seat (Fig. 65). Testing 1. Park machine on level surface, lower cutting units, stop engine, apply parking brake and remove key from ignition switch. 2.
Reel Speed Potentiometer (Serial Number Below 312000000) The reel speed potentiometer on Greensmaster TriFlex Hybrid machines with serial number below 312000000 controls the cutting reel speed. The TEC controller uses the potentiometer setting as an input to determine the necessary CAN−bus output to the cutting reel motor controllers for correct cutting reel speed. The reel speed potentiometer is located under the operator seat (Fig. 67). 1 2 Testing 1.
Toro Electronic Controller (TEC) Greensmaster TriFlex Hybrid 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 operator seat (Fig. 70).
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. On machines equipped with the optional 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. Testing of the coils can be done with the coil installed on the hydraulic valve.
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). 4. Using a multimeter (ohms setting), measure resistance between the two (2) connector terminals on the solenoid valve coil. The resistance for the solenoid coils is identified below: Resistance S1, S3 and S4 (lift) 8.
Main Power, Electric Cutting Reels Enable, Charge Circuit (Greensmaster 3320), Glow (Greensmaster 3420) and Fan (Greensmaster 3420) Relays The Greensmaster TriFlex Hybrid electrical system includes several identical, four (4) terminal relays for current control. Most of these relays are located under the right side cover next to the operator seat (Fig. 74). The electric cutting reels enable relay is located under the left side cover next to the operator seat (Fig. 75).
3. Measure coil resistance between terminals 85 and 86 with a multimeter (ohms setting) (Fig. 76). Resistance should be approximately 72 ohms. 6. After testing is completed, secure relay to bracket and connect wire harness electrical connector to relay. 7. Install right side cover next to operator seat. Electrical System 4. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85.
Kill (Greensmaster 3320) and Start (Greensmaster 3420) Relays The Greensmaster TriFlex Hybrid electrical system includes a five (5) terminal relay for current control. The kill relay is used only on Greensmaster 3320 machines. The start relay is used only on Greensmaster 3420 machines. These relays are located under the right side cover next to the operator seat (Fig. 77) and can be identified by a tag near the relay wire harness connector.
CAN−bus Termination Resistors System communication between electrical components on Greensmaster Hybrid TriFlex machines is accomplished on two (2) CAN−bus communication systems. Two (2) specially designed, twisted cables form the bus for both of the networks used on the Hybrid machines. These wires provide the data pathways between machine components. At the ends of the twisted pair of bus cables are 120 ohm termination resistors. The resistors plug into the wire harness in the following areas: A.
Electric Reel Circuit Protection Diode The Greensmaster TriFlex Hybrid electric reel circuit includes a diode that is used for circuit protection from voltage spikes when the electric reel contactor is de−energized. The diode plugs into the E−Reels wire harness under the left side cover next to the operator seat (Fig. 80). Protection Diode Test The protection diode (Fig. 81) can be tested using a digital multimeter (diode test or ohms setting) and the table to the right. 2 1 Figure 80 1.
Location ID Module The location ID module exists in the electric cutting reels circuit to identify the location of the three (3) cutting reel motors. This module allows such machine features as raising the center cutting unit slightly later than the front cutting units. The location module plugs into the E−Reels wire harness under the left side cover next to the operator seat (Fig. 82). Testing 1.
Cutting Reel Motors The three (3) cutting reel motors are identical 48 VDC, brushless, permanent magnet motors. Each motor has its own integral invertor and on−board controller. Because the cutting reel motors used on the machine are identical, motors from different cutting units can be exchanged. If the problem follows a motor to the new cutting unit, the motor is likely the issue.
Starter Solenoid (Greensmaster 3320) Testing NOTE: Before disconnecting and testing starter solenoid, test the TEC controller outputs with the Hand Held Diagnostic Display (see Hand Held Diagnostic Display in the Troubleshooting section of this chapter) or InfoCenter Display (see InfoCenter Display in this chapter). If the Diagnostic or InfoCenter Display verifies that the TEC outputs are functioning correctly, consider that a problem with the starter solenoid or circuit wiring may exist.
Fuel Pump (Greensmaster 3420) The fuel pump on Greensmaster 3420 machines is secured to the radiator assembly with an r−clamp (Fig. 89). The Toro Electronic Controller (TEC) energizes the fuel pump when the ignition switch is in either the RUN or START position. 1 4 IMPORTANT: When testing fuel pump, make sure that pump is not operated without fuel. 2 3 DANGER Because diesel fuel is flammable, use caution when handling it. Do not smoke while testing the fuel pump.
Fuel Solenoid (Greensmaster 3420) The fuel solenoid used on Greensmaster 3420 machines must be energized for the diesel engine to run. The fuel solenoid is mounted to the injection pump on the engine (Fig. 90). 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 3420) The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 91). 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 3420) The Greensmaster 3420 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 wire harness in the engine area (see Greensmaster 3420 Wire Harness Drawing in Chapter 10 − Foldout Drawings). 2 Diode Test 3 The diode (Fig. 93) can be individually tested using a digital multimeter (diode test or ohms setting) and the table to the right. 1 Figure 93 1. Diode 2.
Turf GuardianTM Leak Detector Oil Level Sensor (If Equipped) NOTE: The Turf GuardianTM Leak Detector System is optional on Greensmaster TriFlex Hybrid machines. 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: The Turf GuardianTM Leak Detector System is optional on Greensmaster TriFlex Hybrid machines. 4 3 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. 1 Testing 1. Park machine on level surface, lower cutting units, stop engine, apply parking brake and remove key from ignition switch.
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 system are to: A. Prevent the engine from cranking or starting unless the functional control lever is in NEUTRAL. B.
12 Volt Battery Care 1. Battery electrolyte level must be properly maintained. The top of the battery must be kept clean. lf the machine is stored in a location where temperatures are extremely high, the battery will discharge more rapidly than if the machine is stored in a location where temperatures are cool. 3. Battery cables must be tight on battery terminals to provide good electrical contact.
12 Volt 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 3320 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. 98 or 99) 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 retainer. Replace battery if cracked or 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. If the battery has been charged, apply a 150 amp load for fifteen (15) seconds to remove the surface charge.
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.
Electric Reel Drive System (48 Volt DC) Battery Pack Service 4 3 5 2 6 1 7 8 15 16 17 9 14 10 11 13 12 18 19 RIGHT FRONT 20 Figure 100 1. 2. 3. 4. 5. 6. 7. Flange nut (8 used) Battery jumper wire (3 used) Foam strip (2 used) Battery clamp Flange head screw (8 used) Flange nut (3 used) Retaining nut (3 used) Electrical System 8. 9. 10. 11. 12. 13. 14.
The batteries used in the TriFlex electric reel drive system are valve regulated, sealed lead acid batteries. The batteries are maintenance free with no provision for checking or adjusting electrolyte level. The batteries are equipped with a low pressure venting system designed to release excess gas pressure and then automatically reseal. A low self discharge rate prevents deterioration of battery performance during non−use or storage. 1 5 4 5 Battery Pack Removal (Fig. 100) 2 1.
Battery Pack Service Battery Pack Storage Clean the battery pack with clean water and a towel. Do not use solvents or chemicals to clean the battery pack. There are no special procedures or precautions for battery storage less than six (6) months. However, storage above 70oF (21oC) will significantly reduce battery life. Cold temperatures are not an issue during storage and actually will reduce the battery self−discharge rate.
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Generator Drive Belt (Greensmaster 3320) Removal (Fig. 103) 1. Park machine on a level surface, lower cutting units, stop engine, apply parking brake and remove key from ignition switch. 7 6 2. Disconnect the cutting units from the electrical power supply by separating the cutting unit power disconnect couplers (see Opening Electrical Circuit to Cutting Units in the General Information section of this chapter). This will prevent unexpected cutting unit operation.
6. Remove generator belt from pulleys and machine. Loctite #242 27 to 33 ft−lb (37 to 44 N−m) 1 7. Inspect generator belt and replace belt if worn or damaged. 11 Installation (Fig. 103) 7 6 1. Position generator belt to engine, generator and idler pulleys. 2 2. Secure pump assembly to pump mount (Fig. 105): 3 8 4 A. Carefully insert coupling on pump shaft into coupling attached to engine and slide pump assembly to pump mount.
Generator Drive Belt (Greensmaster 3420) Removal (Fig. 106) 1. Park machine on a level surface, lower cutting units, stop engine, apply parking brake and remove key from ignition switch. 2. Disconnect the cutting units from the electrical power supply by separating the cutting unit power disconnect couplers (see Opening Electrical Circuit to Cutting Units in the General Information section of this chapter). This will prevent unexpected cutting unit operation.
Installation (Fig. 106) CAUTION 1. Position generator belt to engine and generator pulleys. 2. Secure pump assembly to bell housing (Fig. 107): A. Carefully insert coupling on pump shaft into coupling attached to engine and slide pump assembly to bell housing. Take care to not damage hydraulic hoses, traction control cable or other components as pump assembly is installed. B. Secure pump assembly to bell housing with two (2) cap screws and flat washers. Be careful when rotating the idler bracket.
Generator Assembly (Greensmaster 3320) 26 25 33 32 FRONT RIGHT 33 7 2 8 9 1 10 3 11 9 30 27 6 15 4 5 34 17 18 31 19 29 12 29 13 28 1 14 23 21 2 16 22 20 24 90 to 110 in−lb (10.2 to 12.4 N−m) Figure 108 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Square key (2 used) Square head screw (4 used) Engine pulley Pump coupling Screw (4 used) Generator belt Grease fitting Retaining ring Washer (2 used) Idler bracket Torsion spring Idler pulley 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Removal (Fig. 108) Installation (Fig. 108) 1. Park machine on a level surface, lower cutting units, stop engine, apply parking brake and remove key from ignition switch. 1. If removed, install generator pulley to generator shaft: 3. To allow access to generator assembly, remove tank mount plate assembly from machine (see Tank Mount Plate Assembly in the Service and Repairs section of Chapter 7 − Chassis). 4. Remove generator drive belt (see Generator Drive Belt (Greensmaster 3320) in this section). A.
Generator Assembly (Greensmaster 3420) 18 12 19 16 32 20 14 24 30 26 28 13 23 10 30 7 17 22 6 15 11 21 31 5 1 9 31 8 29 7 RIGHT 24 4 FRONT 2 27 25 33 3 70 to 80 in−lb (8.0 to 9.0 N−m) 90 to 110 in−lb (10.2 to 12.4 N−m) Figure 109 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Generator assembly Square key Generator pulley Square head screw (2 used) Generator plate Flange head screw (5 used) Washer (2 used) Torsion spring Idler bracket Retaining ring Grease fitting 12. 13. 14. 15. 16. 17.
3. To allow access to generator assembly, remove tank mount plate assembly from machine (see Tank Mount Plate Assembly in the Service and Repairs section of Chapter 7 − Chassis). 4. Remove generator drive belt (see Generator Drive Belt (Greensmaster 3420) in this section). 5. Disconnect wire harness connector from generator assembly. CAUTION Support generator assembly when removing it to prevent it from falling and causing personal injury. Assembly weighs approximately 50 pounds (23 kg). 6.
Generator Assembly Service 8 170 to 190 in−lb (19.3 to 21.3 N−m) 70 to 80 in−lb (8.0 to 9.0 N−m) 6 20 to 26 ft−lb (28 to 35 N−m) 7 9 10 75 in−lb (8.5 N−m) 11 2 12 5 13 24 23 14 4 15 to 25 in−lb (1.8 to 2.8 N−m) 15 3 16 2 17 1 22 20 to 26 ft−lb (28 to 35 N−m) 21 18 8 70 to 80 in−lb (8.0 to 9.0 N−m) 20 19 Figure 110 1. 2. 3. 4. 5. 6. 7. 8. Generator assembly Plug (2 used) Flocked seal Wave washer Retaining ring Cap screw (2 used) Flat washer (2 used) Washer head screw (6 used) 9. 10.
6. Remove cap screws (item 6), flat washers (item 7) and flange nuts (item 10) that secure controller to generator assembly. Lift controller from generator. Remove and discard O−ring (item 24). C. Remove cover from rotor assembly. Remove O− rings and wave washer from cover. Discard O−rings. D. Remove and discard O−ring from housing groove in bearing bore. NOTE: If controller (item 9) damage exists, controller replacement is necessary. Internal controller components are not available separately. E.
Assembly (Fig. 110) B. Position woodruff key (item 22) into slot on rotor shaft. 1. Make sure that all generator components are cleaned before assembly. 2. Install internal generator assembly components (Fig. 111): A. If bearings were removed from rotor assembly, install new bearings onto rotor shaft. Make sure that new bearings are fully pressed onto rotor shaft. B. If isolator was removed, lubricate new gasket with dielectric lubricant (see Special Tools in this chapter) and install to isolator.
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Cutting Reel Motor 7 6 5 4 1 RIGHT 2 FRONT 3 Figure 112 1. O−ring 2. Retaining ring (2 used) 3. Cutting reel motor 4. Motor mount 5. Cutting Unit 6. Motor clamp 7. Motor cable NOTE: If electrical problems exist with a cutting reel motor, a fault should have occurred that would be indicated by a flashing diagnostic light on the console (serial number below 312000000) or fault indicator on the InfoCenter (serial number above 312000000).
4. Locate and unplug two (2) electrical connectors from motor cable to machine wire harness. 1 5. Route motor cable out of wire form on cutting unit suspension. 3 6. Remove cutting reel motor from the cutting unit: A. Push the motor clamp out of the slots on the motor mount toward the cutting unit sideplate (Fig. 114). B. Slide cutting reel motor from cutting unit (Fig. 115). 7. If necessary, remove two (2) retaining rings that secure motor mount (item 4) to reel motor. Remove motor mount from motor.
Cutting Reel Motor Service 2 3 4 6 1 14 10 5 7 8 12 8 35 to 45 in−lb (4 to 5 N−m) 9 13 4 5 11 7 1 35 to 45 in−lb (4 to 5 N−m) Figure 117 1. 2. 3. 4. 5. Torx head screw (12 used) Motor cover O−ring Wave washer (2 used) Bearing (2 used) 6. 7. 8. 9. 10. Rotor Bearing (2 used) O−ring (2 used) Housing/controller/cable assembly O−ring 11. 12. 13. 14. Output gear Gearbox cover Shaft seal O−ring NOTE: If motor housing, controller or cable damage occurs, cutting reel motor replacement is necessary.
7. Remove motor cover and wave washer (item 4) from rotor assembly. Remove and discard O−rings (items 14 and 3) from cover. 8. Remove and discard O−ring (item 8) from motor housing. IMPORTANT: Make sure to not damage the gearbox cover counter bore when removing the shaft seal from the cover. 9. Carefully remove shaft seal from gearbox cover. Discard removed seal. 10.If necessary, remove bearings from output gear (item 11) and rotor (item 6). Discard bearings if removed. 11.
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Chapter 7 Chassis Table of Contents Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manuals . . . . . . . . . . . . . . . . . . . . . . . . . 3 Opening Electrical Circuit to Cutting Units . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Parking Brake Adjustment . . . . . . . . . . . . .
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 The Traction Unit and Cutting Unit Operator’s Manuals provide information regarding the operation, general maintenance procedures and maintenance intervals for your Greensmaster TriFlex Hybrid machine. Refer to these publications for additional information when servicing the machine. Opening Electrical Circuit to Cutting Units 1 CAUTION Before installing, removing or servicing the cutting units, separate the cutting unit power disconnect.
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 Hybrid machines. Toro Part Number: TOR4097 Figure 2 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. 4). 2 3.
Service and Repairs Wheels 3 1 2 1 65 to 85 ft−lb (89 to 115 N−m) RIGHT 2 FRONT Figure 6 1. Front wheel Chassis 2. Lug nut (4 used per wheel) Page 7 − 6 3.
Removal (Fig. 6) Installation (Fig. 6) 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 542 N−m) FRONT Figure 7 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. 7) 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. 9). 10.Remove shoe hold down cups and springs. Remove brake shoes and hold down pins from backing plate (Fig. 9). 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 RIGHT 7 FRONT 5 Figure 10 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) Parking brake switch Flange nut (2 used) Cotter pin RH brake cable bracket RH brake cable Page 7 − 10 18. 19. 20. 21. 22. 23.
Brake Cable Removal (Fig. 10) Brake Cable Installation (Fig. 10) 1. Park machine on a level surface, lower cutting deck (or implement), 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 11 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. 11) 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 ft−lb (244 to 292 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 12 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.
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 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 13 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. 13) 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 13 as a guide. 30 5 28 23 17 16 24 15 4. Disassemble functional control lever assembly as needed using Figure 14 as a guide.
Tank Mount Plate Assembly GREENSMASTER 3320 GREENSMASTER 3420 1 7 2 3 8 3 9 4 5 10 11 6 10 RIGHT FRONT Figure 16 1. 2. 3. 4. Tank mount plate assembly (GR3320) Suction hose (to gear pump) Flange head screw (2 used) Flat washer (2 used) 5. 6. 7. 8. Flange head screw (2 used) Frame Tank mount plate assembly (GR3420) 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 (Fig. 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. 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 18 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. 18) Assembly (Fig. 18) 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 18 as a guide. 2. Disconnect the cutting units from the electrical power supply by separating the cutting unit power disconnect couplers (see Opening Electrical Circuit to Cutting Units in the General Information section of this chapter). 2.
Cutting Unit Suspension Assembly 16 85 to 115 in−lb (9.6 to 12.9 N−m) 19 17 85 to 115 in−lb (9.6 to 12.9 N−m) 18 19 20 16 6 21 5 8 9 2 15 7 14 11 13 12 4 1 55 to 60 ft−lb (75 to 81 N−m) RIGHT 10 3 FRONT Figure 19 1. 2. 3. 4. 5. 6. 7. Suspension assembly (3 used) Flange screw (3 per suspension) Basket Clevis pin (3 used) Cotter pin (3 used) Washer (3 used) LH spring retainer (3 used) 8. 9. 10. 11. 12. 13. 14.
2. Disconnect the cutting units from the electrical power supply by separating the cutting unit power disconnect couplers (see Opening Electrical Circuit to Cutting Units in the General Information section of this chapter). This will prevent unexpected cutting unit operation. Installation (Fig. 19) 1. Make sure that all suspension components are correctly assembled. 3. Remove grass basket and cutting unit from suspension assembly (see Traction Unit Operator’s Manual). 2.
Cutting Unit Suspension Service 9 15 11 14 12 4 67 to 83 ft−lb (91 to 112 N−m) 1 3 3 9 21 20 15 10 21 13 4 24 22 15 18 16 17 4 25 19 23 3 2 5 RIGHT 8 FRONT 7 8 6 26 14 9 15 Figure 20 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.
Disassembly (Fig. 20) 1. If cutting unit suspension is attached to machine: A. 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 B. Disconnect the cutting units from the electrical power supply by separating the cutting unit power disconnect couplers (see Opening Electrical Circuit to Cutting Units in the General Information section of this chapter). This will prevent unexpected cutting unit operation. 2.
C. If lift plate (item 12) was removed from A−arm, secure lift plate with two (2) flange head screws (item 13). Torque screws from 67 to 83 ft−lb (91 to 112 N−m). CAUTION Be careful when assembling the suspension counterbalance system. The counterbalance spring is under heavy load and may cause personal injury. E. If stabilizer springs were removed from suspension assembly, move and support suspension assembly so that upper a−arm has stabilizer spring attachment hole positioned 5.710” (145.
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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 24 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 Opening Electrical Circuit to Cutting Units . . . . . . 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 Hybrid 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 4 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. 7). 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. 8).
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. Also, disconnect the cutting unit power coupler to make sure that cutting unit motors can not be unexpectedly engaged.
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 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.
8. To make an adjustment to the cutting units while backlapping, disengage the PTO with the joystick and turn the engine OFF. Wait for all machine movement to stop. After cutting unit adjustments have been completed, repeat steps 5 through 8. NOTE: If the backlap enable switch is not returned to the forward (mow) position after backlapping, the cutting units will not function properly. 2 1 9. When the backlapping operation is completed, stop the engine and remove the key from the ignition switch.
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.
Bedbar Adjuster Service 1 Antiseize Lubricant 3 2 11 6 7 10 9 8 5 RIGHT 5 FRONT 4 Figure 19 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 − 16 9. Retaining ring 10. Bedbar adjuster screw 11.
Removal (Fig. 19) Installation (Fig. 19) 1. Remove lock nut (item 3), compression spring (item 2) and washer (item 11) from bedbar adjuster screw. 1. If detent (item 7) was removed, secure detent to cutting unit side plate with cap screw. 2. Remove bedbar (see Bedbar Removal in this section). 2. If flange bushings (item 5) were removed, align key on bushing to slot in frame and install bushings. NOTE: Bedbar adjuster shaft (item 4) has left−hand threads. 3.
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. 20). 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. 23) 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. 22). Grind only enough so the top surface of the bedknife is true (Fig. 23).
Reel Assembly 19 210 to 240 in−lb (24 to 27 N−m) 20 8 4 9 13 10 12 210 to 240 in−lb (24 to 27 N−m) 5 11 1 5 5 3 5 4 2 7 Grease OD surface 15 6 RIGHT Grease OD surface 14 3 11 FRONT 7 16 17 18 Figure 25 1. 2. 3. 4. 5. 6. 7. 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 Pitch arm (2 used) 8. 9. 10. 11. 12. 13. 14.
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. If cutting unit is equipped with an optional groomer or rear roller brush, remove drive components for those options from cutting unit.
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). 2. Slide bearings from reel shaft. IMPORTANT: The reel shaft bearing journals are painted. Proper bearing fit on the reel shaft includes having the paint on the shaft to ensure correct bearing clearance.
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 electric reel motor from the cutting unit (see Cutting Reel Motors in the Service and Repairs section of Chapter 6 − Electrical 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 bracket. 2 4.
Roller Service 1 7 6 5 4 25 to 30 ft−lb (34 to 41 N−m) 2 5 4 25 to 30 ft−lb (34 to 41 N−m) 6 7 3 Figure 35 1. Wiehle roller 2. Smooth roller 3. Roller shaft 4. Ball bearing 5. Seal 6. V−ring 7. Bearing lock nut Disassembly 1 1. To hold roller shaft for bearing lock nut removal, install a 3/8−24 UNF 2B screw into threaded end of roller shaft and secure screw in place with jam nut. While retaining shaft, remove bearing lock nut from each end of roller shaft. 2 3 4 5 6 2.
NOTE: Special tool TOR4105 (see Special Tools) can be used instead of washers and spacer when installing bearings and seals in roller. 2 3 1 4 2. Position a new bearing, black assembly washer (see Special Tools) and original lock nut onto each end of the roller shaft (Fig. 37). 3. Tighten nuts until the bearings are seated into each end of the roller. 4. Remove nut and black assembly washer from each end of the roller.
Rear Roller 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 Opening Electrical Circuit to Cutting Units . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 Factors Affecting Grooming . . . . . . . . . . . . . . . . . . . 4 Grooming Reel Mechanical Problems . . . . . . . . . .
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 Hybrid 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 Cutting Unit Operator’s Manual for adjustment procedures for the cutting units 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. Disconnect the cutting units from the electrical power supply by separating the cutting unit power disconnect couplers (see Opening Electrical Circuit to Cutting Units in the General Information section of this chapter).
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. 7). 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. 7). 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 8 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. Remove groomer drive cover (item 2) and groomer drive belt (item 3) from groomer drive (see Groomer Belt Replacement in this section). 5 Belt Driven Groomer (Optional) 2 6. Loosen cap screws (item 10) that secure front roller shaft to groomer arms. 7. Remove lock nut (item 13) and spring washer (item 12) that secure RH groomer arm lift rod to RH drive plate assembly. Location of these items are shown in Figure 9. 8.
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 (24 to 28 N−m) 120 in−lb (13.5 N−m) Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
7. Remove the two (2) idler gears (43T and 47T) from the RH drive plate assembly (Fig. 13). The bearings are pressed into the gears. 8. Loosen cap screws (item 7) that secure front roller shaft to groomer arms. 1 3 9. Remove lock nut and spring washer that secure RH groomer arm lift rod to RH drive plate assembly (Fig. 14). 10.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.
4. Apply light coating of grease to O−ring on RH drive plate assembly pivot hub and pilot bore of cutting unit side plate. 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. 10.Insert front roller into LH groomer arm assembly. 11.
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. 16) 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. 17) 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. 3 2. Disconnect the cutting units from the electrical power supply by separating the cutting unit power disconnect couplers (see Opening Electrical Circuit to Cutting Units in the General Information section of this chapter). This will prevent unexpected cutting unit operation. 2 1 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. 20). Tighten lock nut. 2 3 D. Position motor mount to groomer support plate (Fig. 19).
Idler Assembly (Forward Rotating Groomer Drive) 7 5 6 4 3 2 1 8 11 9 10 12 Figure 25 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 27 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. 27) 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. 29): 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 31 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. 31) 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. 1. Assemble lift arm using Figure 31 as a guide. 2. Disconnect the cutting units from the electrical power supply by separating the cutting unit power disconnect couplers (see Opening Electrical Circuit to Cutting Units in the General Information section of this chapter). This will prevent unexpected cutting unit operation.
Groomer Brush 3 1 2 5 20 to 25 in−lb (2.3 to 2.8 N−m) 3 4 20 to 25 in−lb (2.3 to 2.8 N−m) 2 Figure 32 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 Table of Contents Greensmaster 3320/3420 Page 11 − 1 Foldout Drawings HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL SCHEMATICS Greensmaster 3320 (Serial Number Below 312000000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Greensmaster 3320 (Serial Number Above 312000000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Greensmaster 3420 (Serial Number Below 312000000) . . . . . . . . . . . . . . . . . . . . . . . . .
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 L C4 C1 R C6 POWER STEERING VALVE OR3 .028 OR2 .028 4.5 S3 S4 1160 PSI C5 S2 RV 400 PSI S1 OR1 .037 P C2 T E C3 OIL FILTER 25 PSI G1 P LIFT CONTROL VALVE T 4.0 GPM C MOW = 6.7 GPM AT 3.8 MPH TRANSPORT = 17.
CAN−TRAK DISPLAY (FUTURE PRODUCTION) (TO E−REELS HARNESS) Greensmaster 3320 Electrical Schematic (Serial Number Below 312000000) Page 11 − 4
CAN−TRAK DISPLAY (TO E−REELS HARNESS) Greensmaster 3320 Electrical Schematic (Serial Number Above 312000000) Page 11 − 5
CAN−TRAK DISPLAY (FUTURE PRODUCTION) (TO E−REELS HARNESS) Greensmaster 3420 Electrical Schematic (Serial Number Below 312000000) Page 11 − 6
CAN−TRAK DISPLAY (TO E−REELS HARNESS) Greensmaster 3420 Electrical Schematic (Serial Number Above 312000000) Page 11 − 7
(60 A 58 V) (10 A 58 V) REEL SPEED POTENTIOMETER (SERIAL NUMBER BELOW 312000000) Greensmaster 3320/3420 E−Reels Electrical Schematic (Serial Number Below 315000000) Page 11 − 8
Greensmaster 3320/3420 E−Reels Electrical Schematic (Serial Number Above 315000000) Page 11 − 9
(OPTIONAL KIT) (OPTIONAL KIT) (NOT USED ON GR3320) (NOT USED ON GR3320) (OPTIONAL KIT) Greensmaster 3320 Wire Harness Drawing (Serial Number Below 312000000) Page 11 − 10 (FUTURE PRODUCTION)
PINK BLACK PINK BLACK WHITE BLACK BLACK WHITE BLACK YELLOW RED BLACK BLACK PINK BLACK BLACK BLACK BLACK RED BLACK BLACK PINK BLACK PINK (NOT USED) BLACK BLUE BLACK PINK BLACK BLACK RED RED (NOT USED) 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/BLACK BLACK BLUE GRAY BLACK ORANGE YELLOW BLACK YELLOW GRAY PINK BLACK TAN/BLACK ORANGE RED GREEN ORANGE BROWN/WHITE BLUE GRAY V
(OPTIONAL KIT) (OPTIONAL KIT) (NOT USED) (NOT USED) (OPTIONAL KIT) (NOT USED) (NOT USED) (OPTIONAL KIT) Greensmaster 3320 Wire Harness Drawing (Serial Number Above 312000000) Page 11 − 12
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 (NOT USED) BLUE BLACK PINK BLACK BLACK RED RED (NOT USED) BLACK BROWN (NOT USED) PINK (NOT USED) BLACK BLACK BLACK GRAY/BLACK YELLOW BROWN VIOLET TAN/BLACK PINK BLUE BLACK RED/BLACK BLUE GRAY PINK BLACK GREEN/BLACK ORANGE/BLK BLACK BLUE GRAY BLACK ORANGE YELLOW BLACK YELLOW GRAY PINK BLACK TAN/BLACK ORANGE RED GREEN ORANGE BRO
(OPTIONAL) (NOT USED) (NOT USED) (FUTURE PRODUCTION) Greensmaster 3420 Wire Harness Drawing (Serial Number Below 312000000) Page 11 − 14
BLACK BLACK WHITE BLACK WHITE BLACK BLACK PINK BLACK BLACK BLACK BLACK BLACK BLACK PINK BLACK PINK (NOT USED) BLACK BLUE BLACK PINK BLACK BLACK RED RED RED PINK WHITE PINK (NOT USED) 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 ORA
(OPTIONAL) (NOT USED) (NOT USED) (NOT USED) (NOT USED) (NOT USED) Greensmaster 3420 Wire Harness Drawing (Serial Number Above 312000000) Page 11 − 16
BLACK BLACK WHITE BLACK WHITE BLACK BLACK PINK BLACK BLACK BLACK BLACK (NOT USED) BLACK BLACK PINK BLACK PINK BLACK (NOT USED) BLUE BLACK PINK BLACK BLACK RED RED RED PINK WHITE PINK (NOT USED) BLACK BROWN BLACK RED/BLACK BLACK BLACK PINK PINK WHITE BLACK RED/BLACK (NOT USED) 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 BLA
Greensmaster 3320/3420 E−Reels Wire Harness Drawing (Serial Number Below 312000000) Page 11 − 18
YELLOW GREEN YELLOW GREEN YELLOW GREEN YELLOW GREEN YELLOW GREEN RED BLACK WHITE TAN YELLOW GREEN RED BLACK YELLOW GREEN WHITE RED BLACK WHITE YELLOW YELLOW GREEN YELLOW GREEN GRAY GREEN YELLOW BLACK RED BLACK WHITE BLUE YELLOW GREEN RED/WHITE BLACK/WHITE YELLOW GREEN YELLOW GREEN RED RED BLACK RED BLACK BLACK PINK BLUE VIOLET GRAY BLACK BROWN BROWN WHITE WHITE BLACK WHITE BLACK YELLOW RED Greensmaster 3320/3420 E−Reels Wire Harness Diagram (Serial Number Below 312000000) Page 1
Greensmaster 3320/3420 E−Reels Wire Harness Drawing (Serial Number From 312000000 To 314999999) Page 11 − 20
YELLOW GREEN YELLOW GREEN YELLOW GREEN YELLOW GREEN YELLOW GREEN RED BLACK WHITE TAN YELLOW GREEN RED BLACK YELLOW GREEN WHITE RED BLACK WHITE YELLOW YELLOW GREEN YELLOW GREEN GRAY GREEN YELLOW BLACK RED BLACK WHITE BLUE YELLOW GREEN RED/WHITE BLACK/WHITE YELLOW GREEN YELLOW GREEN RED RED BLACK RED BLACK BLACK PINK VIOLET BROWN BROWN WHITE BLACK WHITE WHITE BLACK YELLOW RED Greensmaster 3320/3420 E−Reels Wire Harness Diagram (Serial Number From 312000000 To 314999999) Page 11 − 2
Greensmaster 3320/3420 E−Reels Wire Harness Drawing (Serial Number Above 315000000) Page 11 − 22
YELLOW GREEN YELLOW GREEN YELLOW GREEN RED RED RED BLACK WHITE TAN YELLOW GREEN RED BLACK YELLOW GREEN WHITE RED BLACK WHITE YELLOW GREEN YELLOW YELLOW GREEN YELLOW GREEN GREEN YELLOW BLACK RED BLACK WHITE BLUE YELLOW GREEN RED/WHITE BLACK/WHITE YELLOW GREEN YELLOW GREEN YELLOW GREEN RED BLACK BLACK BLACK PINK BLACK VIOLET BROWN WHITE WHITE BROWN RED RED RED WHITE BLACK YELLOW RED Greensmaster 3320/3420 E−Reels Wire Harness Diagram (Serial Number Above 315000000) Page 1
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