Form No. 19239SL Rev C Greensmaster® eTriFlex 3360 and 3370 (Model 04580 and 04590) © 2020—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision Date A 06/2019 Initial Issue B 12/2019 Model 04590 information added C 10/2020 Modify battery file handling, battery storage, and wheel motor controller handling. Added battery service wire harness.
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Reader Comments Page 4 Greensmaster® eTriFlex 3360 and 3370 19239SL Rev C
Preface This service manual was written expressly for service technicians. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Toro Company has made every effort to make the information in this manual complete and correct. The purpose of this publication is to provide the service technician with information about troubleshooting, testing, and repairing major systems and components. This manual may also be specified for use on numerous products.
Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S.
Table of Contents Preface ................................................................................................................ 5 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Jacking Instructions ..................................................................................... 1–6 Safety and Instructional Decals .
Wire Harness Diagram – 3360 (continued) ...................................................A–8 Wire Harness Drawing – 3370 ......................................................................A–9 Wire Harness Diagram – 3370 ....................................................................A–10 Wire Harness Diagram – 3370 (continued)..................................................
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Think Safety First ............................................................................................................................... 1–3 Jacking Instructions ..............................................................................................................................
Safety Instructions DANGER This safety symbol means danger. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions could cause serious permanent injury, disability, or death. WARNING This safety symbol means warning. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions can result in serious injury. CAUTION This safety symbol means caution.
Think Safety First Toro Products are evaluated 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, hazard control and accident prevention are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine. Improper use or maintenance of the machine can result in injury or death.
Think Safety First (continued) Use only original equipment parts to ensure that important safety criteria are met. • Avoid injury to bystanders… Always clear the area of bystanders before starting or testing powered equipment. • Avoid injury due to projectiles… Always clear the area of any debris that could be picked up and thrown by the powered equipment. • Avoid modifications… Do not alter or modify any part unless it is a factory approved procedure.
Think Safety First (continued) Ensure fire extinguishers are serviced regularly, and replace any fire extinguishers that are discharged or in use beyond their expiration dates. – Class A fire extinguishers are for ordinary combustible materials such as paper, wood, cardboard, and most plastics. The numerical rating on these types of extinguishers indicates the amount of water it holds and the amount of fire it can extinguish. Geometric symbol (green triangle).
Jacking Instructions DANGER Mechanical or hydraulic jacks may fail to support the machine and cause a serious injury. • Use jack stands to support the raised machine. • Use only mechanical or hydraulic jacks to lift the machine. 1. Park the machine on a level surface, lower the cutting units, shut off the engine, remove the key from the key switch and unplug the 48V battery disconnect. 2.
g288440 Figure 2 1. Cutting unit pivot mount – supports left front of machine 2. Cutting unit pivot mount – supports right front of machine 3. Battery trays – supports rear of machine Safety and Instructional Decals Numerous safety and instructional decals are affixed to the traction unit and the cutting units of the Greensmaster 3360/3370. If any decal becomes illegible or damaged, replace it with a new decal. Part numbers are listed in your Parts Catalog and Operator’s Manual.
Safety: Safety and Instructional Decals Page 1–8 Greensmaster® eTriFlex 3360 and 3370 19239SL Rev C
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Overall Dimensions............................................................................................................................ 2–2 Engine (Model 04580 only) ................................................................................................................
Specifications Overall Dimensions g287052 Figure 3 Engine (Model 04580 only) Item Description Make/Designation Kawasaki, 4-cycle, V-Twin Cylinder, OHV, Air Cooled, Gasoline Engine - Model FS481V. Bore x Stroke 73 x 72 mm (2.87 x 2.83 inches) Total displacement 603 cc3 (36.8 in3) Mechanical Governor Carburetor Single-barrel, float controlled with fixed main jets Manual Choke Fuel Pump Pulse Type Fuel Refer to the Traction Unit Operator’s Manual Fuel tank capacity 18.5 L (4.
Chassis Item Description Front and Rear tire Standard = 19 x 10.50 x 8, 4 ply Smooth Optional = 20 x 10 x 8, 4 ply Turf Tread 83 to 110 kPa (12 to 16 psi) Wheel lug nut torque 95 to 122 N∙m (70 to 90 ft-lb) DPA Cutting Units Item Description Frame construction Precision machined die cast aluminum crossmember with two bolt-on die-cast aluminum side plates. Reel construction Reels are 53.3 cm (21 inches) in length and 12.7 cm (5 inch) in diameter.
DPA Cutting Units (continued) Item Description Cutting unit weight (approximate) 8 blade* = 32.7 kg (72 lb) 11 blade* = 34 kg (75 lb) 14 blade* = 35 kg (78 lb) *Cutting unit weights do not include a front roller. Options Refer to the Cutting Unit Parts Catalog or contact your local Authorized Toro Distributor for available cutting unit options. Universal Groomer (Optional) Item Description Grooming reel diameter 6 cm (2.
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These torque specifications for the installation and tightening of the fasteners will apply to all the fasteners which do not have a specific requirement identified in this Service Manual.
Calculating the Torque Values When Using a Drive-Adapter Wrench g205924 Figure 4 Torque Conversion Factor = A / B 1. Torque wrench 3. A (effective length of torque wrench) 2. Drive-adapter wrench (crowsfoot) 4. B (effective length of torque wrench and drive-adapter wrench) Using a drive-adapter wrench (e.g.
Identifying the Fastener g206089 Figure 5 Metric Bolts and Screws 1. Class 8.8 2. Class 10.9 g206088 Figure 6 Inch Series Bolts and Screws 1. Grade 1 2. Grade 5 3. Grade 8 Fasteners with a Locking Feature IMPORTANT If a fastener with a locking feature or previously applied thread locking compound is reused, clean the fastener threads and apply new thread locker to the fastener during installation. Locking features are designed to create friction and prevent a fastener from loosening.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 and 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, and Sems with Regular Height Nuts(SAE J995 Grade 2 or Stronger Nuts) #6 - 32 UNC #6 - 40 UNF 8 - 32 UNC 1 – 1.5 N·m (8 – 12 in-lb) 1 – 1.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) (continued) Note: The torque values must be reduced when installing the fasteners into threaded aluminum or brass. The specified torque value should be determined based on the aluminum or base material strength, fastener size, length of thread engagement, etc. Note: The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 6 – 7 N·m (51 – 63 in-lb) 8 – 10 N·m (70 – 86 in-lb) M6 X 1.0 10 – 12 N·m (86 – 106 in-lb) 13 – 16 N·m (119 – 147 in-lb) M8 X 1.25 23 – 28 N·m (17 – 21 ft-lb) 34 – 42 N·m (25 – 31 ft-lb) M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 14 – 18 N·m (120 – 160 in-lb) 7 – 9 N·m (61 – 85 in-lb) 5/16 - 18 UNC 20 – 28 N·m (180 – 250 in-lb) 14 – 18 N·m (125 – 165 in-lb) 3/8 - 16 UNC 34 – 61 N·m (25 – 45 ft-lb) 20 – 28 N·m (15 – 21 ft-lb) 1/2 - 13 UNC 81 – 122 N·m (60 – 90 ft-lb) 54 – 81 N·m (40 – 60 ft-lb) Thread Cutting Screws (Zinc Plated Steel) Type 1, Type 23 or Type F Thread Size Baseline Torque** No.
Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants, and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply. IMPORTANT Always follow manufacturers instructions when using or storing shop supplies.
Shop Supplies (continued) GASKET COMPOUND Used to create a seal between mating parts. Gasket compounds may be used with or without the presence of a pre-formed gasket. Gasket compounds may be solvent or silicone based, and cure when exposed to air or designed to cure in an air-less environment (anaerobic). Most gasket compounds are designed to be applied to clean surfaces free of oil, chemical residue and previously used gaskets or gasket compounds.
Special Tools Special tools for servicing Toro Commercial Products are available from your Toro Distributor. Some of these tools may have been supplied with your machine, are available as Toro parts, or may also be available from a local tool supplier. Multimeter Obtain this tool locally The meter can test the electrical components and circuits for current, resistance, or voltage. Note: Use a digital multimeter when testing the electrical circuits.
Generator Rotor Tool K-Line Part No. TOR6029 The starter/generator rotor tool is recommended to safely remove and install the starter/generator rotor from the housing/stator assembly. The tool includes the base plate, threaded shaft and handle. 3WD Motor Rotor Tool Toro Part No. 139–8420 The 3WD motor rotor tool is recommended to remove and install the rotor from the optional 3WD motor housing. The tool includes the puller hub, threaded shaft, handle and four screws.
Lithium-Ion Battery Service Wire Harness Toro Part No. 122–1947 Use with Model 04590 machines to identify a failing battery, or determine if the SC8: lithium-ion battery controller or battery interface harness is working correctly. The lithium–ion battery service wire harness may also be used to bypass a failing battery or battery interface harness, allowing you to move the machine or (depending on distance and battery condition) drive it back to the shop for repair.
Cutting Performance Paper Toro Part No. 125–5610 (300 strips) Cutting performance paper is used to test the cutting reel performance after adjusting the reel to bedknife clearance. Reel Drive Shaft K-Line Part No. TOR4112 Use the drive shaft for rotating the reel during cutting unit adjustment or any time the cutting unit motor is removed. Reel Thread Repair Taps 15/16–16 Right-Hand Thread – Toro Part No. 137–0926 15/16–16 Left-Hand Thread – Toro Part No.
Angle Indicator and Magnetic Mount Angle Indicator: Toro Part No. 131–6828 Magnetic Mount: Toro Part No. 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. 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. g223327 Figure 8 1. 2.
Diameter/Circumference Measuring Tape K-Line Part No. TOR6023 Spring steel measuring tape for accurately measuring the circumference and outside diameter of cutting reel and other spherical components. Tape calibration is in fixed inch readings (no adjustments). Roller Rebuilding Tools The following combination of washers and spacers can be used to install bearings and seals into the front and rear rollers (2 each required).
Cutting Unit Motor Rotor Tool K-Line Part No. TOR6028 The cutting unit motor rotor tool is recommended to remove and install the rotor from the cutting unit motor housing. The tool includes the puller hub, threaded shaft, handle and four screws. Drive Shaft Removal Tool Toro Part No. 137–0920 Use to remove the optional Universal Groomer drive shaft from the reel if the drive shaft hex is damaged. Adapter Wrench Toro Part No.
Chapter 3 Troubleshooting Table of Contents GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems ............................. 3–2 Operator Advisories............................................................................................................................... 3–3 Dialogue Messages ............................................................................................................................... 3–5 Machine Faults ........................................
GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems 1. Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue 2. Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis • Narrow down the focus of the problem 3.
Operator Advisories Operator advisories are automatically displayed by the InfoCenter when a machine function is prevented and additional action is required. Typically, an advisory can be eliminated with a change in machine controls by the operator. For example; if the operator attempts to drive the machine when the manual parking brake is engaged, an advisory is identified on the InfoCenter Display that the manual parking brake needs to be in disengaged. An advisory will not be logged into any fault log.
Operator Advisories (continued) Advisory Number Advisory Name B2304 (Model 04590 Only) BATTERY TEMPERATURE LOW Battery Temp Low | Warm machine B2305 (Model 04590 Only) BATTERY TEMPERATURE HIGH Battery Temp High | Cool machine B2408 CUTTING UNIT LOWER DENIED Function switch in HIGH Lower Denied | Set function switch to LOW B2503 PTO DENIED Fault(s) Active PTO Denied | Resolve active faults B2509 PTO DENIED Out of seat PTO Denied | Seat B250B (Model 04580 Only) PTO DENIED Engine not runn
Dialogue Messages When the machine is being calibrated, dialog messages appear in the InfoCenter. These messages are intended to instruct you through the calibration process. Refer to the following table for a list of each dialog message: Message Number Greensmaster® eTriFlex 3360 and 3370 InfoCenter Message 1 Return pedal to neutral 4 Move pedal to max forward and hold 5 Max forward calibration passed 9 Max forward calibration failed.
Message Number InfoCenter Message 504 Is the Cutting Unit installed? Continue? 1100 Traction diagnostic messages enabled 1101 Steering diagnostic messages enabled Troubleshooting: Battery Charger Error and Fault Codes Page 3–6 Greensmaster® eTriFlex 3360 and 3370 (Model 04590) 19239SL Rev C
Machine Faults Machine faults are generated by the machine controllers to identify an electrical system malfunction (fault) that occurs during machine operation. The fault IDs conform to SAE J2012 standards. When a fault occurs, a red warning light will illuminate and a code for the active fault will appear on the InfoCenter display. Faults can be viewed via the InfoCenter Faults screen. The fault code includes the number of the controller that generated the fault.
Machine Faults (continued) Fault ID Fault Title C0528 Steering Position Sensor - Not Responding C0529 Steering Position Sensor Signal Correlation Fault C1013 Engine Run Output - Short to Battery C1014 Engine Run Output – Overcurrent C1015 Engine Run Output - Open Circuit Fault Controller(s) Condition/Circuit Additional Notes Affected Description SC7 SC7 T1 T1 T1 The controller does not see a change in the steering position sensor when comparing steering motor commands and steering sensor movemen
Machine Faults (continued) Fault ID Fault Title C1023 Parking Brake Disengage Output - Short to Battery C1024 Parking Brake Disengage Output Overcurrent C1025 Parking Brake Disengage Output - Open Circuit C10C4 Steering Feedback Output Overcurrent Fault Controller(s) Condition/Circuit Additional Notes Affected Description T1 T1 T1 T1 Greensmaster® eTriFlex 3360 and 3370 Low current detected on parking brake disengage output. Indicates a short to a high (+) source.
Machine Faults (continued) Fault ID Fault Title C10C5 Steering Feedback Output - Open Circuit C10E3 48V Logic Enable Relay Output - Short to Battery C10E4 48V Logic Enable Relay Output Overcurrent C10E5 48V Logic Enable Relay Output - Open Circuit C1801 Cutting Unit Motor - High Temp Shutdown Fault Controller(s) Condition/Circuit Additional Notes Affected Description T1 T1 T1 T1 T2, T3, T4 Open circuit detected on steering feedback output. Low current detected on logic relay output.
Machine Faults (continued) Fault ID Fault Title C180C Cutting Unit Motor - High Temp Warning C1811 Cutting Unit Motor Controller - High Temp Shutdown C181C Cutting Unit Motor Controller - High Temp Warning Fault Controller(s) Condition/Circuit Additional Notes Affected Description Service Actions T2, T3, T4 1. Let the machine cool off. 2. Check the reel to bedknife contact and the condition of the cutting unit. 3. Reduce the reel speed.
Machine Faults (continued) Fault ID Fault Title C1822 Cutting Unit Motor - Stall Fault Controller(s) Condition/Circuit Additional Notes Affected Description Service Actions T2, T3, T4 1. Check the cutting unit and the motor for mechanical resistance. 2. Check the bedknife adjustment and the condition of the reel. 3. Try spinning the motor without a load. If it doesn't spin, replace and program the motor (contact an Authorized Toro Distributor for assistance). 1. Cycle the key switch. 2.
Machine Faults (continued) Fault ID Fault Title C1851 Cutting Unit Motor Bus Voltage - High Fault Controller(s) Condition/Circuit Additional Notes Affected Description Service Actions T2, T3, T4 PTO is disabled. 1. Note: If more than one Bus Voltage - High fault is reported, go to fault U1511 and follow the listed service actions. Swap cutting reel motors between cutting units.
Machine Faults (continued) Fault ID Fault Title C1912 Lift/Lower Motor - Stall C1919 Lift/Lower Motor - Position Error C1921 Lift/Lower Motor Logic Voltage High C1922 Lift/Lower Motor Logic Voltage Low C1931 Lift/Lower Motor Bus Voltage High Fault Controller(s) Condition/Circuit Additional Notes Affected Description SC2, SC3, SC4 SC2, SC3, SC4 SC2, SC3, SC4 SC2, SC3, SC4 SC2, SC3, SC4 The maximum allowed current is being drawn by the indicated actuator.
Machine Faults (continued) Fault ID Fault Title C1932 Lift/Lower Motor Bus Voltage Low C1941 Lift/Lower Controller - Internal Software Failure C1942 Lift/Lower Motor Overload C1A01 Steering Motor - High Temp Shutdown C1A11 Steering Motor Controller - High Temp Shutdown Fault Controller(s) Condition/Circuit Additional Notes Affected Description SC2, SC3, SC4 SC2, SC3, SC4 SC2, SC3, SC4 SC7 SC7 Greensmaster® eTriFlex 3360 and 3370 The 48V bus voltage measures less than 32V in the indicated actuat
Machine Faults (continued) Fault ID Fault Title C1A20 Steering Motor Speed Sensor Out of Range C1A22 Steering Motor Stall C1A27 Steering Motor Position Error C1A32 Steering Motor Bus Voltage Low C1A41 Steering Controller Over Current Fault Controller(s) Condition/Circuit Additional Notes Affected Description SC7 SC7 SC7 SC7 SC7 A sensor inside the motor fails. Traction and steering is disabled.
Machine Faults (continued) Fault ID Fault Title C1A55 Steering Motor Phase U - Open Circuit C1A5C Steering Motor Phase V - Open Circuit C1A5D Steering Motor Phase W - Open Circuit C1A69 Steering Wheel Sensor Feedback Noisy C1A6C Steering Controller - Internal Hardware Failure Fault Controller(s) Condition/Circuit Additional Notes Affected Description SC7 SC7 SC7 SC7 SC7 Greensmaster® eTriFlex 3360 and 3370 The steering motor controller detects an open circuit on motor phase U.
Machine Faults (continued) Fault ID Fault Title C1A7D Steering Controller - Internal Software Failure C1A7E Steering Motor Software Hardware Incompatibility P0524 Oil Pressure Low - Kill Engine Fault Controller(s) Condition/Circuit Additional Notes Affected Description SC7 SC7 T1 An unexpected steering motor controller software error occurs. Traction and steering is disabled. The steering motor controller software is not compatible with the hardware. Traction and steering is disabled.
Machine Faults (continued) Fault ID Fault Title P06E9 Starter/Generator Timeout P0A1B Traction Controller Short P0A2A Traction Motor - Temperature Sensor Failure Fault Controller(s) Condition/Circuit Additional Notes Affected Description T1 SC5, SC6 SC5, SC6 Service Actions The starter function of the starter/generator was engaged for more than the maximum time permitted. Starter/Generator is disabled. 1. Cycle the key switch. 2. Test the key switch.
Machine Faults (continued) Fault ID Fault Title P0A3C Traction Motor Controller - High Temp Warning Fault Controller(s) Condition/Circuit Additional Notes Affected Description SC5, SC6, T5 The temperature is greater than 90°C (194° F) in the indicated traction motor controller. Traction motor current is limited on a linear basis until the temperature drops below 90°C (194° F) or exceeds 100° C (212° F). Service Actions 1. Reduce the ground speed. 2.
Machine Faults (continued) Fault ID Fault Title Fault Controller(s) Condition/Circuit Additional Notes Affected Description Service Actions T6 The starter/generator controller detects an internal overcurrent condition. PTO and starter/generator is disabled. Replace and program the starter/generator controller (contact an Authorized Toro Distributor for assistance). P0A80 Battery Internal Hardware Failure SC8 A Li-ion battery internal hardware component has failed.
Machine Faults (continued) Fault ID Fault Title P0AE5 Hybrid/EV Contactor Stuck Closed P0AE6 Precharge Failure P0AFA Battery - Low Voltage Fault Controller(s) Condition/Circuit Additional Notes Affected Description T6 T6 SC8 There is a problem with control of the 48V main contactor – the contactor is closed when it should be open. The minimum precharge voltage (38V) was not achieved in the appropriate time. PTO, starter/generator, and lift/lower is disabled.
Machine Faults (continued) Fault ID Fault Title P0C06 Traction Motor Phase Short Fault Controller(s) Condition/Circuit Additional Notes Affected Description SC5, SC6 Traction is disabled. Two traction motor phases are shorted together but not shorted to ground in the indicated traction motor controller or motor. Service Actions 1. Verify that the U, V, and W motor phase cables are in the correct order. 2. Check the motor power cables. 3.
Machine Faults (continued) Fault ID Fault Title P0E8E Traction Motor Bus Voltage Low Fault Controller(s) Condition/Circuit Additional Notes Affected Description SC5, SC6, T5 The traction motor measures the 48V bus voltage at less than: 38V (SC5, SC6) or 32V for T5 Traction is disabled. Note: If more than one Bus Voltage - Low fault is reported, go to fault U1512 and follow the listed service actions. Service Actions 1.
Machine Faults (continued) Fault ID Fault Title P1520 Traction Motor Speed Sensor Out of Range Fault Controller(s) Condition/Circuit Additional Notes Affected Description SC5, SC6, T5 The speed sensor reading is outside the normal operating range in the indicated traction motor. Traction is disabled. Service Actions 1. Inspect the wiring and connectors. 2. Test the supply voltage to the speed sensor. 3. Test the ground to the speed sensor. 4. Replace the traction motor.
Machine Faults (continued) Fault ID Fault Title P1531 Traction Motor Internal Regulator Voltage High P1532 Traction Motor Internal Regulator Voltage Low P1541 Traction Motor Phase - Voltage High Fault Controller(s) Condition/Circuit Additional Notes Affected Description T5 T5 SC5, SC6 The internal regulator voltage is greater than 15V. The internal regulator voltage is less than 10V. The motor phase voltage is out-of-range high in the indicated traction motor. 3WD Traction is disabled.
Machine Faults (continued) Fault ID Fault Title P1542 Traction Motor Phase - Voltage Low Fault Controller(s) Condition/Circuit Additional Notes Affected Description SC5, SC6 The motor phase voltage is out-of-range low in the indicated traction motor. Traction is disabled. Service Actions If the fault occurs at start up (contactor does not close): 1. Test the cables on the U, V, and W phases. 2. Inspect the motor power cables connections. 3.
Machine Faults (continued) Fault ID Fault Title P156C Traction Controller - Internal Hardware Failure Fault Controller(s) Condition/Circuit Additional Notes Affected Description SC5, SC6 An internal component of the controller fails in the indicated traction motor controller. Traction is disabled. Service Actions 1. Replace and program the traction motor controller (contact an Authorized Toro Distributor for assistance). 2. Cycle the key switch. 3.
Machine Faults (continued) Fault ID Fault Title P1A21 Battery Charging - Over Current Fault Controller(s) Condition/Circuit Additional Notes Affected Description SC8 A Li-ion battery cell charging current is greater than 12.52A when the battery temperature is between 5° (41° F) and 45° C (113° F), or greater than 6.25A when the battery temperature less than 5° C (41° F) or greater than 45° C (113° F). Battery contactor in Li-ion battery controller is opened. Service Actions 1.
Machine Faults (continued) Fault ID Fault Title P1B2C Starter/Generator Motor - Stall P1B31 Starter/Generator Motor Internal Regulator Voltage - High P1B41 Starter/Generator Bus Voltage High P1B42 Starter/Generator Bus Voltage Low P1B4C Starter/Generator Hardware Over Voltage Fault Controller(s) Condition/Circuit Additional Notes Affected Description T6 T6 T6 T6 T6 The starter/generator stalls for 3 seconds or more. The internal regulator voltage is greater than 18V.
Machine Faults (continued) Fault ID Fault Title Fault Controller(s) Condition/Circuit Additional Notes Affected Description P1B51 Starter/Generator Hardware Phase Over Current T6 P1B6C Starter/Generator Internal Hardware Failure T6 P210E Traction Pedal 1 Sensor/Switch Analog vs Analog conflict P2503 Alternator Charging Too Low SC5 T1 P2504 Alternator Charging Too High T1 P2530 Key Start/Run Correlation Fault T1 P2BE8 Traction Motor Contactor Open SC5 Greensmaster® eTriFlex 3360 and 3370 Th
Machine Faults (continued) Fault ID Fault Title P2BE9 Traction Motor Contactor Closed P2BEA Traction Motor Precharge Failure Fault Controller(s) Condition/Circuit Additional Notes Affected Description SC5 SC5, SC6 The wheel motor contactor is detected closed when it should be open Traction is disabled. Traction is disabled. There is a short on the 48V traction bus, too much resistance, or too much capacitance in the indicated traction motor controller. Service Actions 1.
Machine Faults (continued) Fault ID Fault Title Fault Controller(s) Condition/Circuit Additional Notes Affected Description U012A CAN Bus Communication Fault Precharge Controller T1 U0131 CAN Bus Communication Fault - Steering T1 U0156 CAN Bus Communication Fault InfoCenter U0292 CAN Bus Communication Fault - Traction Motor 2 U029B CAN Bus Communication Fault - Traction Motor 3 T1 T1 T1 The primary controller never establishes or loses communication with the precharge controller (T6).
Machine Faults (continued) Fault ID Fault Title U1012 Controller Logic Voltage - Low Fault Controller(s) Condition/Circuit Additional Notes Affected Description T1, T6 12V logic circuit voltage is below 8.8V (T1), or 48V logic circuit voltage is below 32V (T6). PTO is disabled. Service Actions 1. Check the power supply (fused) to the controller. 2. If the fault is generated by the T1: primary controller, test the 48 VDC/12 VDC converter.
Machine Faults (continued) Fault ID Fault Title U1123 CAN Bus Communication Fault - CU Motor 2 U1124 CAN Bus Communication Fault - CU Motor 3 U1128 CAN Bus Communication Fault Lift/Lower Motor 1 U1129 CAN Bus Communication Fault Lift/Lower Motor 2 U112A CAN Bus Communication Fault Lift/Lower Motor 3 U1140 CAN Bus Communication Fault - Battery Cell Module Fault Controller(s) Condition/Circuit Additional Notes Affected Description T1 T1 T1 T1 T1 SC8 Greensmaster® eTriFlex 3360 and 3370 The T1:
Machine Faults (continued) Fault ID Fault Title Fault Controller(s) Condition/Circuit Additional Notes Affected Description Service Actions U1301 Software Version Incompatibility CU Motor 1 T1 The cutting unit 1 (center) software is incompatible. Engine is disabled. Update machine software (contact your Authorized Toro Distributor for assistance) U1302 Software Version Incompatibility CU Motor 2 T1 The cutting unit 2 (left) software is incompatible. Engine is disabled.
Machine Faults (continued) Fault ID Fault Title U130E Software Version Incompatibility - Processor Mismatch Fault Controller(s) Condition/Circuit Additional Notes Affected Description Service Actions SC5, SC6, SC7 The software is incompatible in the component indicated. Traction is disabled. Update machine software (contact an Authorized Toro Distributor for assistance). U130F Software Version Incompatibility Unknown T1 The T1: Primary controller has detected an incompatible software version.
Machine Faults (continued) Fault ID Fault Title U1512 48V System Bus Voltage Low U1700 Board Internal Error - IPE U1701 Board Internal Error - IPE Fault Controller(s) Condition/Circuit Additional Notes Affected Description T1 T6 T1 Tthree or more components on the machine are reporting a Bus Voltage - Low fault. PTO and the generator function of the starter/generator is disabled. Inputs or outputs in the T6: precharge controller are not working correctly.
Using the InfoCenter Display for Troubleshooting The InfoCenter Splash Screen and Main Information Screen can be used to check the operation of various components. The neutral, parking brake, and seat icons represent the switch activity and can be used to verify the switch and its circuit wiring integrity. The battery icon can be used to check battery voltage and circuit wiring integrity.
TRACTION (example): (continued) • Depress the traction pedal in the forward direction slowly. Pedal Fwd should change from OFF to ON, Pedal Sig 1 voltage should increase, and Pedal Sig 2 voltage should decrease as the pedal is depressed forward. If not, the traction pedal or its circuit wiring is faulty and should be tested. • Depress the traction pedal in the reverse direction slowly.
Troubleshooting General Operation Problems 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. Model 04580 machines have a separate batteries for the 12 VDC system and the 48 VDC system.
Greensmaster 3360 (Model 04580) Many aspects of machine and component operation are visible using the InfoCenter; refer to Using the InfoCenter Display for Troubleshooting (page 3–39). Machine faults may also appear on the InfoCenter display to assist in troubleshooting. Problem Possible Cause Corrective Action Nothing happens when the key switch is set to the ON position A fuse or the circuit wiring is damaged. Test the 15A fuse located in fuse holder 1 under the right side cover. Test the 7.
Greensmaster 3370 (Model 04590) For eTriFlex 3370 (model 04590) machines, a series of events occur to power up the machine prior to operating the machine steering, traction, lift/lower, and cutting unit functions. The events are explained here to assist with troubleshooting a machine that does not power up correctly. Many aspects of machine operation are visible for troubleshooting using the InfoCenter; refer to Using the InfoCenter Display for Troubleshooting (page 3–39).
Greensmaster 3370 (Model 04590) (continued) Note: With the exception of 12V power to the T1: primary controller Logic input, 12V control system power is made available to the machine through the shutdown delay relay. • 12V should pass through the 2A fuse in 12V fuse holder 2 under the right side cover and be available at the telematics connector (connector P71 pin 2).
Greensmaster 3370 (Model 04590) (continued) Problem Nothing happens when the key switch is set to the ON position Possible Cause Corrective Action The 48V battery disconnect is not connected or is connected to the battery charger. Connect the 48V battery disconnect. The lithium-ion battery controller (BMS) is not communicating with all of the lithium-ion batteries via the battery interface harness.
Troubleshooting a Lithium-Ion Battery-Related Fault (Model 04590) While a battery-related fault is active, the SC8: lithium-Ion battery controller (BMS) keeps its internal battery contactor open, not allowing battery power to go to the machine. As a result, the machine will not respond (the InfoCenter will not display any information) when the key switch is set to the ON position.
Aftercut Appearance 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. Refer to the Cutting Unit Operator’s Manual detailed adjustment procedures.
Factors That Can Affect Quality of Cut (continued) Factor Possible Problem/Correction Cutting unit alignment and ground following Check cutting unit stabilizer springs and suspension ball joints for damage, binding condition, or wear. The ball joint base has a slip fit condition with reference to the suspension, and should be free to rotate. Repair if necessary. Roller type and condition A variety of cutting unit rollers are available.
Grooming Performance 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. IMPORTANT Improper or overaggressive use of the groomer (e.g., too deep or too frequent grooming) may cause unnecessary stress on the turf leading to severe turf damage. Use the groomer carefully.
Universal Groomer Problems (Optional) Problem The groomer reel does not rotate. The turf is damaged or has uneven grooming. Possible Cause Corrective Action 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 drive between the groomer and the reel has separated. Repair the groomer drive. The groomer is set too aggressively.
Battery Charger Error and Fault Codes (Model 04590) If a battery charger error or fault appears, additional information may be available by disconnecting the charger, connecting the batteries to the machine, and using the machine InfoCenter to check for any active machine faults. Problem Codes E-0-0-1, or E-0-4-7 Possible Cause Battery high voltage Corrective Action Ensure that the battery voltage is correct and the cable connections are secure. Ensure that the battery is in good condition.
Troubleshooting: Battery Charger Error and Fault Codes Page 3–52 Greensmaster® eTriFlex 3360 and 3370 (Model 04590) 19239SL Rev C
Chapter 4 Engine (Model 04580) Table of Contents General Information .............................................................................................................................. 4–2 Traction Unit Operator’s Manual ........................................................................................................ 4–2 Kawasaki Owner’s Manual................................................................................................................. 4–2 Kawasaki Service Manual .....
General Information This chapter provides information about the gasoline engine used in the Greensmaster eTriFlex machine. The general maintenance procedures are described in the engine Operator’s Manual. Detailed information on engine troubleshooting, testing, disassembly, and assembly is identified in the Kawasaki FS481V Service Manual. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Kawasaki FS481V Service Manual.
Service and Repairs Fuel Tank g286303 Figure 11 1. Clamp (4 each) 6. Stand pipe 11. Carriage bolt (4 each) 2. Flange nut (4 each) 7. Cap screw 12. Foam pad (4 each) 3. Fuel tank 8. Fuel cap 13. Carbon canister assembly 4. Bushing (2 each) 9. Fuel supply hose 14. Fuel vent hose 5. Vent fitting Hose clamp (2 each) 15. Push nut (4 each) Greensmaster® eTriFlex 3360 and 3370 19239SL Rev C 10.
DANGER Gasoline is highly flammable and explosive. A fire or an explosion from the fuel can burn you, burn other people, and damage property. • Use caution whenever you store or handle gasoline. • Do not smoke while handling gasoline. • Do not fill the fuel tank while the engine is running, while the engine is hot, or when the machine is in an enclosed area. • Always fill the fuel tank outside and wipe up any spilled gasoline before starting the engine.
Installing the Fuel Tank (continued) 5. Check the fuel tank position and adjust if necessary: A. Install and lower the hood. B. The fuel tank should be aligned (square) with the front edge of the hood. C. Loosen the fuel tank clamps and adjust the tank position if necessary. D. Ensure the engine does not contact the back of the fuel tank and tighten the fuel tank clamp fasteners. 6. Fill the fuel tank with fuel and open the fuel shut-off valve. 7. Connect the 48V battery disconnect. 8.
Evaporative Control System g286481 Figure 13 1. Hose clamp (2 each) 6. Vent hose (valve to intake manifold) 11. Hose clamp (2 each) 2. Hose clamp 7. Vent hose (valve to intake tube) 12. Vent hose (fresh air filter) 3. Vent hose (tank to canister) 8. Cap screw 13. Carbon canister 4. Vent hose (canister to valve) 9. Clamp 14. Canister bracket 5. Vacuum valve 10.
Evaporative Control System (continued) 4. Test the operation of the vacuum control valve. The valve should open (allow flow between ports A and B) when 21 to 29 mm Hg (0.8 to 1.1 inch Hg) vacuum is applied to port C. 5. Repair or replace evaporative system components as necessary.
Cooling System g286401 Figure 14 1. Screen guard 4. Air ducts (in hood) 2. Rotating screen (under screen guard) 5. Air duct screen (in hood) 3. Blower housing IMPORTANT The engine that powers the eTriFlex model 04580 machine is aircooled. Operating the engine with dirty or plugged cooling fins, a blocked screen guard or rotating screen, a plugged or dirty blower housing, or plugged intake screens or ducts in the hood may result in the engine overheating and cause engine damage.
Cooling System (continued) CAUTION The engine and exhaust system may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the engine. IMPORTANT Never clean engine with pressurized water. Water could enter and contaminate the fuel system. 2. Carefully clean the area around the cooling fins on both cylinder heads. 3. Clean the screen guard and blower housing of dirt and debris 4.
Exhaust System g286389 Figure 15 1. Exhaust gasket (2 each) 7. Shoulder screw (2 each) 2. Lock washer (4 each) 8. Conical washer (2 each) 3. Hex nut (4 each) 4. Exhaust pipe – LH 10. 9. Muffler Flange nut (2 each) 5. Exhaust pipe – RH 11. Heat shield 6. Muffler clamp (2 each) Removing the Exhaust System CAUTION The engine and exhaust system may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the engine. 1.
Removing the Exhaust System (continued) 2. Remove the hood and rear wheel assembly for additional clearance if desired; refer to Removing and Installing the Hood Assembly (page 6–43) and Removing and Installing the Wheels (page 6–9). 3. Remove the fasteners securing the muffler to the engine frame. 4. Remove the fasteners securing the exhaust pipes to the cylinder heads, and remove the muffler assembly from the machine. Retrieve the two conical washers from the muffler brackets.
Engine g286719 Figure 17 1. Engine assembly 5. Cap screw (4 each) 2. Choke cable 6. Pulley cover 3. Flange nut (2 each) 7. Cap screw (2 each) 4. Cap screw (2 each) 8. Wire harness ground wire (at engine block) 9. 10. Wire harness connector Cap screw (ground) Removing the Engine Refer to Figure 17 for this procedure. 1. Park the machine on a level surface, lower the cutting units, shut off the engine, remove the key from the key switch and unplug the 48V battery disconnect. 2.
Removing the Engine (continued) 6. Disconnect the electrical system wiring from the engine: • The engine wire harness connector at the main wire harness (left side of engine). Check the engine and the harness connector for damage or corrosion and clean or repair as necessary. • The wire harness ground at the engine (near front left engine mount). 7. Disconnect the choke cable from the engine. 8. Remove the clamp securing the engine oil drain hose to the right side battery tray. 9.
Removing the Engine (continued) g286730 Figure 18 1. Engine frame assembly 6. Cap screw 11. Isolating mount – front (2 each) 2. Cap screw 7. Clamp 12. Cap screw (4 each) 3. Cap screw ( 2 each) 8. Lock nut 13. Flat washer (3 each) 4. Isolating mount – rear 9. Flange nut (4 each) 14. Cap screw (2 each) 5. Lock nut (3 each) 10. Wire harness connector A. Disconnect the starter/generator from the machine wire harness.
Removing the Engine (continued) CAUTION The engine frame assembly weighs approximately 68 kg (150 lb). Use an appropriate lift to remove the engine frame assembly. C. Remove the engine frame assembly from the machine. 10. Remove the fasteners securing the drip pan to the engine frame (item 3 and 4 in Figure 17). 11. Remove the starter/generator drive belt: A. Tilt the Operator seat forward and remove the pulley cover (item 6 in Figure 17). B.
Removing the Engine (continued) g308239 Figure 20 1. Cap screw 2. Front engine lift lug CAUTION The engine assembly weighs approximately 42 kg (92 lb). Use an appropriate lift to remove the engine assembly. 13. Remove the 4 fasteners securing the engine to the engine frame and lift the engine from the machine. 14. Continue to disassemble the engine as necessary. Installing the Engine Refer to Figure 17 for this procedure.
Installing the Engine (continued) g286602 Figure 21 1. Engine 3. Set screw (2 each) 2. Engine pulley 4. Square key CAUTION The engine assembly weighs approximately 42 kg (92 lb). Use an appropriate lift to install the engine assembly. IMPORTANT Make sure to not damage the engine, fuel or vent hoses, oil drain hose, electrical harnesses, control cables or other parts while installing the engine. 2. Secure the engine to the engine frame with the 4 cap screws previously removed. 3.
Installing the Engine (continued) 6. If the engine was removed from the machine separately, proceed to step 8 of this procedure. If the entire engine frame assembly (including the starter/generator) was removed: A. Secure the 3 engine frame assembly isolation mounts to the machine with the fasteners previously removed. B. Connect the machine wire harness to the starter/generator. 7. Install the clamp securing the engine oil drain hose to the right side battery tray. 8.
Chapter 5 Electrical System Table of Contents General Information .............................................................................................................................. 5–3 Traction Unit Operator’s Manual and Accessory Installation Instructions............................................ 5–3 Kawasaki Engine Electrical Components........................................................................................... 5–3 Electrical Drawings .........................................
Cutting Unit Lift/Lower Switches....................................................................................................... 5–79 Lift/Lower Actuators ........................................................................................................................ 5–81 Engine Oil Pressure Switch (Model 04580) ...................................................................................... 5–84 Traction Pedal Position Sensor ............................................................
General Information The Traction Unit Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Traction Unit Operator’s Manual for additional information when servicing the machine.
Electrical System Operation The eTriFlex machines have 4 different functional subsystems. Each subsystem has components that operate on 12 VDC, and components that operate on 48 VDC. Many of the machine control functions operate on a typical 12 VDC system. The electric traction motors, electric steering motor, electric cutting unit lift/lower actuators, and the electric cutting unit motors operate on an 48 VDC electrical system.
Steering Subsystem The steering subsystem components work together to coordinate the position of the steering wheel with the position of the rear caster fork. The Radius Dependant Speed System (RDS) uses steering position information from the steering subsystem to control the traction and cutting unit drive subsystems. The steering subsystem and traction subsystem work together to steer the machine.
Lift/Lower Subsystem The T1: Primary controller receives an input signal from the lift/lower switches and sends a CAN message to the lift/lower actuator controllers to lift or lower the cutting unit lift arms. The lift/lower subsystem consists of the following components: • Cutting Unit Lift and Lower Switches “Joystick”: The two identical lift/lower switches are mounted below the joystick and act as inputs to the T1: Primary controller.
48 VDC System Components The eTriFlex 48 VDC system includes a 48 VDC battery pack, an engine driven starter/generator (model 04580), two front traction motors, a steering input device and a steering motor, three cutting unit lift/lower actuators, three cutting unit motors, a main contactor and a traction motor contactor. An optional rear wheel traction motor and an LED light kit that runs on 48 VDC are also available.
48 VDC System Components (continued) Control for the components in the 48 VDC system is handled by the front traction motor controllers (SC5: Traction 1 and SC6: Traction 2), a controller in the optional rear traction motor (T5: Traction 3), a controller in the steering motor (SC7: Steering), a controller in each lift/lower actuator (SC1: Lift/Lower 1, SC2: Lift/Lower 2, SC3: Lift/Lower 3), a controller in each cutting unit motor (T2: Cutting Unit 1, T2: Cutting Unit 2, T3: Cutting Unit 3), along with direc
48V Battery Disconnect CAUTION Before installing, removing or servicing components in the 48 VDC system (e.g. cutting unit motors, starter/generator), separate the 48V battery disconnect. This will prevent unexpected operation of 48V system components. The 48V battery disconnect is attached to a bracket behind the left side cover. Unplug the disconnect to make sure that 48 VDC components do not operate unexpectedly.
InfoCenter g288424 Figure 23 1. Operator’s console 2. InfoCenter The InfoCenter Display is a three button LCD device located on the operator’s console. The InfoCenter provides information to the machine operator during machine operation, provides electrical system diagnostic assistance for technicians, and allows access to adjustable machine and attachment settings. Power for the InfoCenter is available when the key switch is in the ON or START position. A 7.
InfoCenter (continued) g288412 Figure 24 InfoCenter Screens – Greensmaster 3360/3370 eTriFlex Greensmaster® eTriFlex 3360 and 3370 19239SL Rev C Page 5–11 Electrical System: Electrical System Operation
CAN bus Communications The machine controllers communicate with each other on a Controller Area Network (CAN) bus system. Using this network allows full integration of all the different electrical components of the machine, allowing them to operate together as one. The integration of the controllers allows the InfoCenter display to access machine settings, calibrate various machine components, and assist with electrical system diagnostics.
CAN bus Communications (continued) g287505 Figure 26 1. CAN bus isolation module 13. T6: Pre–charge controller (model 04590 only) 2. CAN A – 12V side 14. SC2: Lift/Lower 1 actuator controller (center) 3. CAN B– 48V side 15. SC2: Lift/Lower 2 actuator controller (left) 4. CAN bus terminator resistor (4 each) 16. SC2: Lift/Lower 3 actuator controller (right) 5. T1: Primary controller 17. SC5: Traction 1 motor controller (right) 6. SC1: InfoCenter 18.
T1: Primary Controller g288348 Figure 27 (right side cover removed) 1. 2. Primary controller (T1) Machine harness connector The eTriFlex machines use a primary controller (T1) to manage machine electrical functions. The primary controller is a TEC 5004 series microcontroller that monitors the condition of various machine switches and sensors (inputs) and directs electrical power to control appropriate machine functions (outputs) based on the state of the inputs.
SC8: Lithium-Ion Battery Controller (Model 04590) g311711 Figure 28 (shown with hood removed) 1. SC8: Lithium–ion battery controller The eTriFlex 3370 uses a Lithium–ion battery controller or Battery Management System (BMS) to manage the lithium-ion batteries. Each of the eight lithium-ion batteries communicates with the BMS through a sub-net via the battery interface harness. The battery interface harness includes a 4-pin connector at each of the batteries and a 9-pin connector at the BMS.
SC8: Lithium-Ion Battery Controller (Model 04590) (continued) Note: When the key switch is set to the Off position, the BMS delays disconnecting the batteries from the machine for approximately 3 seconds to allow time for all of the other machine controllers to shut down. • Communicates battery information to the machine during operation via the CAN bus. • Communicates battery information to the battery charger via the CAN bus. • Supplies battery pack signal voltage to the key switch.
T6: Precharge Controller (Model 04590) g311532 Figure 29 (shown with hood removed) 1. T6: Precharge controller The eTriFlex 3370 uses a TEC 2400 series microcontroller as a precharge controller (T6) to manage the precharge function. Precharge is a preliminary mode which limits the inrush of current during the power up procedure. This current, if not limited, can cause considerable stress or damage to the 48 VDC system components.
Electrical System Quick Checks Testing the 12V Charging System (Model 04580) Battery Voltage Table At least 0.50 VDC over the initial battery voltage. Initial battery voltage = 12.30 VDC Battery voltage after 3 minutes charge = 12.85 VDC Difference = +0.55 VDC This is a simple test that determines if the 12V charging system is functioning. It tells you if the 12V charging system has an output, but not its capacity. Tool required: Digital multimeter to set the DC volts. 1.
Testing the 12V Charging System (Model 04580) (continued) Note: Depending upon the condition of the battery, its current charge and the battery temperature, the battery voltage increases at different rates as the battery charges. Refer to the Battery Voltage Table (page 5–18) for an example of a charging system that is functioning. Checking the Interlock System Operation CAUTION The interlock system is for the operator’s protection; do not bypass any of the interlock system components.
Adjustments Adjusting the Starter/Generator Drive Belt Tension (Model 04580) For additional starter/generator service information; refer to Generator Assembly (Model 04580) (page 5–120). 1. Remove the fuel tank; refer to Removing the Fuel Tank (page 4–4). 2. Tilt the operator seat forward and remove the starter/generator pulley cover. 3.
Adjusting the Steering Position Sensor g290691 Figure 32 1. Steering position sensor 4. Slot in magnet bolt 2. Magnetic bolt 5. Flat on caster fork shaft 3. Jam nut The steering position sensor is a two–piece assembly located on top of the rear wheel caster fork shaft. The sensor portion includes 2 analog hall effect sensors. The second piece of the assembly is a bolt with a magnetic head threaded into the caster fork shaft. The steering position sensor follows the rear caster fork movement.
Adjusting the Manual Parking Brake Switch g290133 Figure 33 1. Manual parking brake switch 3. Latch 2. Jam nut (2 each) 4. Brake pedal support The manual parking brake switch is located directly under the brake pedal assembly. The manual parking brake switch is an input to the T1: primary controller. The switch is a normally open proximity switch that closes when the foot actuated parking brake is disengaged (the parking brake latch is in close proximity to the switch).
Testing the Electrical Components The Greensmaster eTriFlex 3360 and 3370 machines have isolated electrical systems; they do not use the machine frame as ground. Use an unpainted surface of the engine block or an unpainted engine fastener as a ground for testing 12V components unless instructed otherwise. Use the B- terminal of the front traction motor controllers (SC5 or SC6) as a ground for testing 48V components unless instructed otherwise.
Identifying the 12 VDC System Fuses and their Functions A group of fuses used to protect the 12 VDC system are located in 2 covered fuse holders under the right side cover. These are mini blade style fuses. g287311 Figure 35 (right side cover removed) 1. 10A fuse – brake actuator relay 5. Open 9. 7.5A fuse – spare 2. 7.5A fuse – T1: Primary outputs 6. 15A fuse – main (model 04580) 10. 12V fuse holder 1 3. 2A fuse – telematics connector 7. 2A fuse – T1: Primary logic 11.
Identifying the 48 VDC System Fuses and their Functions A group of fuses used to protect the 48 VDC system are located in an open fuse block under the operator’s seat. These are standard blade ATO style fuses. g287256 Figure 36 (seat raised) 1. 10A 80V fuse – SC2:Lift/Lower Actuator 1 (center) power bus 5. 5A 80V fuse – 48V controller logic 2. 10A 80V fuse – SC3:Lift/Lower Actuator 2 (left) power bus 6. 30A 80V fuse – SC7:Steering Motor power bus 3.
Identifying the 48 VDC System Fuses and their Functions (continued) g291449 Figure 37 (model 04590 only) 3. 1. Cap 2.
Identifying the 48 VDC System Fuses and their Functions (continued) Three fuses are used to protect the 48 VDC cutting unit motors. An additional fuse is used to protect the optional 48 VDC 3WD (rear) traction motor. These are Maxi blade fuses located in a covered fuse block under the left side cover. g287313 Figure 38 (left side cover removed) 1. 35A 58V fuse – T2:Cutting Unit 1 (center) power bus 2. 35A 58V fuse – T3:Cutting Unit 2 (left) power bus 3.
Identifying the 48 VDC System Fuses and their Functions (continued) Two fuses are used to protect the 48 VDC standard (front) traction motors. These are MIDI style fuses located in separate covered holders. The fuse holder for SC5:Traction 1 (right) is located under the operator seat. The fuse holder for SC6:Traction 2 (left) is located under the left side cover. On machines with an engine/generator (model 04580), a single fuse is used to protect the starter/generator.
Identifying the 48 VDC System Fuses and their Functions (continued) If a Mega style fuse is removed, tighten the hex nuts that secure the fuse from 12 to 17 N·m (9 to 13 ft-lb), then coat the terminals with battery terminal protector Toro Part No. 107-0392 to reduce corrosion. g287325 Figure 40 1. 150A 70V fuse (model 04580) or 175A 70V fuse (model 04590) Testing a Fuse 1. Turn the key switch to the RUN position (do not start the engine). 2.
CAN bus The machine controllers communicate with each other on a Controller Area Network (CAN) bus system; refer to CAN bus Communications (page 5–12) for CAN bus operation notes. Controllers that operate on 12 VDC connect to the 12V side of the CAN bus (CAN A), while controllers that operate on 48 VDC connect to the 48V side of the CAN bus (CAN B). A 120 ohm CAN termination resistor is located at each end of CAN A, and at each end of CAN B (4 total); refer to CAN bus Terminator Resistors (page 5–101).
Testing the CAN bus (continued) 3. Locate the CAN bus isolation module and disconnect it from the machine wire harness. Check the module and the harness connector for damage or corrosion and clean or repair as necessary. g287575 Figure 42 (right side cover removed) 1. CAN bus isolation module 2. Machine wire harness connector 4. Set the key switch to the ON position. 5. Use a multimeter (DC voltage setting) to check for 12 VDC across terminals A and B of the machine wire harness connector.
Testing the CAN bus (continued) • A reading of more than 500k ohms indicates damage to the wiring of the CAN side being tested; refer to Appendix A (page A–1). 8. Connect the CAN bus isolation module to the machine wire harness after testing.
CAN bus Isolation Module The CAN bus isolation module is part of the CAN bus. The isolation module brings both sides of the CAN (CAN A – 12 VDC and CAN B – 48 VDC) together so they can communicate as one network. Power for the isolation module is available when the key switch is in the ON or START position. A 7.5 Amp fuse protects all of the key switched circuits, including the CAN bus isolation module power circuit. The module plugs into the machine wire harness under the right side cover.
T1: Primary Controller g288348 Figure 44 (right side cover removed) 1. T1: Primary controller 3. 2. Machine harness connector Harness connector screw The eTriFlex machines use a primary controller (T1) to manage machine electrical functions; refer to T1: Primary Controller (page 5–14) for T1: primary controller operation notes. The primary controller is attached to the machine under the right side cover. The logic and memory circuit is protected by a 2 Amp fuse.
T1: Primary Controller (continued) T1: Primary Controller Inputs INPUT NUMBER DESCRIPTION INPUT NUMBER DESCRIPTION IN 1 Not Used IN 11 Not Used IN 2 Cutting Unit Raise Switch IN 12 Not Used IN 3 Cutting Unit Lower Switch IN 13 Not Used IN 4 Manual Parking Brake Switch IN 14 Not Used IN 5 Seat Switch AIN1 Not Used IN 6 Engine Oil Pressure Switch (Model 04580) AIN2 Not Used IN 7 Function Control Switch – Neutral position AIN3 Not Used IN 8 Function Control Switch – Mow positio
T1: Primary Controller (continued) IMPORTANT When testing for wire harness continuity at the connector for the controller, take care to not damage the connector pins with multimeter test leads. If connector pins are enlarged or damaged during testing, connector repair may be necessary for proper machine operation. g289676 Figure 45 1. Machine wire harness connector P01 2. Tab 3. T1: Primary controller A 50 pin platform wire harness connector is attached to the controller.
Starter/Generator (Model 04580) The starter/generator is a 48 VDC, air cooled, brushless, permanent magnet device. To operate, the starter/generator requires 48V logic power (supplied by the logic relay). The starter/generator supplies power to all of the 48V components via the 48V power bus when the main contactor and traction motor contactor are energized. Since the 48V batteries are connected to the 48V power bus, the starter/generator also charges the 48V batteries.
Testing the Starter/Generator (continued) 4. Access the InfoCenter Diagnostics > Generator > Inputs screen. g292336 Figure 47 48V system voltage should be present at the starter/generator logic circuit Gen Logic V and at the starter/generator power bus circuit Gen Bus V. • If – – – appears, the controller is not communicating on the CAN bus. Voltage must be present at the controller logic circuit before communication can occur on the CAN bus.
Testing the Starter/Generator (continued) g292337 Figure 48 A. Gen Current should read 0A while the engine is not running. B. Start the engine. Gen Current: should read from 3A to 10A (depending on battery condition) while the engine is running at 2,400 rpm. 7. If the InfoCenter diagnostics inputs report normally and the starter/generator output is out of range, repair or replace the starter/generator or starter/generator controller; refer to Generator Assembly (Model 04580) (page 5–120).
SC8: Lithium-Ion Battery Controller (Model 04590) g311711 Figure 49 (shown with hood removed) 1. SC8: Lithium–ion battery controller The eTriFlex 3370 uses a Lithium-ion battery controller or Battery Management System (BMS) to manage the lithium-ion batteries; refer to SC8: Lithium-Ion Battery Controller (Model 04590) (page 5–15) for SC8: lithium-ion battery controller operation notes. The BMS is located under the hood attached to the back of the center mounted batteries.
Testing the SC8: Lithium-Ion Battery Controller (Model 04590) (continued) g312559 Figure 50 1. Lithium-Ion battery controller (BMS) 4. M-S terminal (battery interface harness) 7. COM terminal (machine wire harness) 2. Positive (+) terminal (power supply positive (+) cable) 5. –B terminal (negative (-) battery cable) 8. Controller wire harness connector 3. +B terminal (positive (+) battery cable) 6.
Removing and Installing the SC8: Lithium-Ion Battery Controller (Model 04590) (continued) g312564 Figure 51 1. Battery cable terminal (typical) 2. 1/2 inch ID rubber hose IMPORTANT Do not open the lithium-Ion battery controller. There are no serviceable parts on or in the controller. If you open the controller, you will void the warranty. The controller is protected by tamper-alerting devices. 1.
Removing and Installing the SC8: Lithium-Ion Battery Controller (Model 04590) (continued) g312581 Figure 52 1. Power supply positive (+) cable 7. SC8: lithium-ion battery controller (BMS) 13. Negative (-) battery cable 2. Machine wire harness positive (+) cable 8. Controller bracket and T6: precharge controller assembly 14. Power supply negative (-) cable 3. Positive (+) battery cable 9. Flange nut (2 each) 15. Controller wire harness connector 4. Carriage bolt (2 each) 10.
Removing and Installing the SC8: Lithium-Ion Battery Controller (Model 04590) (continued) IMPORTANT Pay close attention to the lithium-ion battery controller orientation during installation. Install the controller with the positive (+) terminals upward; refer to Figure 52. 10. Install the lithium-ion battery controller in reverse order. 11. Tighten the power supply and battery cable fasteners from 8.5 to 9.5 N·m (75 to 85 in-lb), then apply battery terminal protector Toro Part No.
T6: Precharge Controller (Model 04590) g311004 Figure 53 (shown with hood removed) 1. T6: Precharge controller 2. Machine wire harness connector P03 (black) 3. Machine wire harness connector P02 (gray) The eTriFlex 3370 uses a TEC 2400 series microcontroller as a precharge controller (T6) to manage the precharge function; refer to T6: Precharge Controller (Model 04590) (page 5–17) for T6: precharge controller operation notes.
Testing the T6: Precharge Controller (Model 04590) (continued) 4. Access the InfoCenter Diagnostics > Precharge > Inputs screen. g311218 Figure 54 Logic V • If 48V system voltage is present, the T1: primary controller has energized the logic relay and power is being supplied to the precharge controller precharge input (connector P02 pin 6). • If – – – appears, the controller is not communicating on the CAN bus.
Testing the T6: Precharge Controller (Model 04590) (continued) T6: Precharge Controller Inputs (continued) INPUT NUMBER DESCRIPTION INPUT NUMBER DESCRIPTION Precharge Logic Relay Switch On IN 5 Not Used IN 1 Not Used IN 6 Not Used IN 2 Not Used IN 7 Not Used IN 3 Not Used IN 8 Not Used IN 4 Not Used AIN1 Not Used T6: Precharge Controller Outputs OUTPUT NUMBER DESCRIPTION OUTPUT NUMBER DESCRIPTION OUT 1 Not Used Precharge Precharge Voltage to Reel Motors, Lift Actuators, 3WD Tr
Testing the T6: Precharge Controller (Model 04590) (continued) g311294 Figure 55 1. Machine wire harness connector P02 (gray) 2. Machine wire harness connector P03 (black) 3. T6: Precharge controller Two 12 pin wire harness connectors are attached to the controller. The connection terminal function for the controller and the wire harness connector pins are shown above. The connectors are keyed the same.
48 VDC/12 VDC Converter (Model 04590) g307998 Figure 56 1. 48 VDC/12 VDC Converter 2. T1: Primary Controller The 48V battery pack and the 48 VDC/12 VDC converter are used to supply the 12 VDC electrical system with power. The 48 VDC/12 VDC converter is located under the right side cover below the T1: primary controller.
Testing the 48 VDC/12 VDC Converter (continued) Location Harness 1 Main 2 Main Connector Pin Wire Color 1 Black P07 P07 2 Red Expected Reading Connector Graphic 12 VDC (nominal) 5. If testing determines the converter is faulty, replace the converter. 6. If the converter tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1).
Front Traction Motor Controllers The traction motor controllers are separate from the motors and control each motor individually. The right side controller (SC5: Traction 1) is located under the right side cover and controls the right side traction motor. The left side controller (SC6: Traction 2) is located under the left side cover and controls the left side traction motor.
Testing the Front Traction Motor Controllers The InfoCenter Display can also be used to monitor the current draw for the traction motors during machine operation. During operation, some variance in the traction motor current draw is expected even when driving straight. 1. Park the machine on a level surface, lower the cutting units and set the key switch to the OFF position. 2. Set the function control switch to the NEUTRAL position. 3. Sit in the operator seat and set the key switch on the ON position. 4.
Testing the Front Traction Motor Controllers (continued) IMPORTANT Allow the traction motor controller to fully discharge before disconnecting the wire harness or any of the controller cables. Use a digital multimeter to measure the voltage across the controller –B and +B terminals. If the output voltage is greater than 1 VDC, wait 15 minutes and measure the output voltage again. Continue measuring the output voltage until it is less than 1 VDC. 6.
Testing the Front Traction Motor Controllers (continued) IMPORTANT Allow the traction motor controller to fully discharge before disconnecting the wire harness or any of the controller cables. Use a digital multimeter to measure the voltage across the controller –B and +B terminals. If the output voltage is greater than 1 VDC, wait 15 minutes and measure the output voltage again. Continue measuring the output voltage until it is less than 1 VDC. B.
Front Traction Motor The two front traction motors are brushless permanent magnet motors located directly behind the front wheels. Each motor is attached to an oil filled gear box with an internal disc brake. Each motor includes a rotary encoder to recognize the motor speed. The motor controllers are separate from the motors and control each motor individually.
Testing the Front Traction Motors (continued) 1. Park the machine on a level surface, lower the cutting units and set the key switch to the OFF position. 2. Set the function control switch to the NEUTRAL position. 3. Check the machine wire harness at the traction motor connector: A. Locate and disconnect the multi-pin machine wire harness connector from the traction motor. Check the motor and the harness connector for damage or corrosion and clean or repair as necessary. B.
Rear Wheel Traction Motor (Optional 3WD) The rear wheel traction motor is a 48 VDC, brushless, permanent magnet motor. The rear wheel traction motor has its own on-board controller (T5). If a problem exists with the rear wheel traction motor, a fault may have occurred that would be indicated by a fault code on the InfoCenter Display.
Testing the Rear Wheel Traction Motor (continued) If logic voltage is present at the controller, and CAN bus communication is suspect, the CAN bus circuit is damaged. The CAN bus wiring should be checked for corrosion or damage and cleaned or repaired as necessary. The rear wheel traction motor controller CAN bus transceiver can also be tested if necessary; refer to Testing Devices (Nodes) on the CAN bus (page 5–32). • If 00.
Steering Input Device g293846 Figure 63 1. Button head screw (6 each) 2. Screw 3. 4. 9. Roll pin 10. Flange head screw (4 each) Cap 11. Steering mount Hex nut 12. Steering input device 5. Washer 13. Lock nut (4 each) 6. Steering wheel 14. Cover 7. Set screw (2 each) 15. Device wire harness connector 8. Shaft adapter The steering input device is mounted to the steering arm behind the steering wheel.
Testing the Steering Input Device (continued) 3. Sit in the operator seat and set the key switch to the ON position. 4. Access the InfoCenter Diagnostics > Steering > Inputs screen. g293809 Figure 64 5. The steering input device sensor signal voltage characteristics are: • St Wheel Sig 1 and St Wheel Sig 2 voltages should decrease as you turn the steering wheel to the right (clockwise).
Testing the Steering Input Device (continued) 7. St Wheel Feel is the amount of current being sent by the T1: Primary controller to the steering input device brake coil, and not necessarily what is being received by the coil. The steering input device brake coil amperage characteristics are: • St Wheel Feel should be approximately 220 mA when the steering wheel is at rest or turned slowly in either direction.
Steering Motor g293930 Figure 66 1. Steering motor 6. Gasket 2. Flange head screw (4 each) 7. Pinion gear 3. Cap screw 8. Retaining ring 4. Washer 9. Steering gear box housing 5. Bracket – harness The steering motor is mounted to the steering gear box housing over the rear wheel caster fork. The steering motor has its own on-board controller (SC7).
Testing the Steering Motor (continued) g293903 Figure 67 5. 48V system voltage should be present at the steering motor controller logic circuit Logic Voltage. • If – – – appears, the controller is not communicating on the CAN bus. Voltage must be present at the controller logic circuit before communication can occur on the CAN bus. If voltage is not present at the logic circuit, the logic circuit is damaged.
Testing the Steering Motor (continued) • Turning the steering wheel in both directions. The current required to move the rear caster wheel should appear next to Mtr Current while the steering motor is moving. • The amount of current required to turn the rear caster wheel should not exceed 6A. 8. Locate the steering motor and disconnect it from the machine wire harness. Check the motor connector and the harness connector for damage or corrosion and clean or repair as necessary.
Location ID Module The location ID module is part of the 48 VDC electrical circuit, and is used to identify the 3 cutting unit motors and the optional rear wheel traction motor individually. The ID module enables machine operation features such as starting and stopping the center cutting unit slightly later than the front cutting units. The location ID module plugs into the main wire harness under the right side cover. g287899 Figure 69 (right side cover removed) 1. 2.
Testing the Location ID Module (continued) 7. If the ID module tests correctly and a circuit problem still exists, check the wire harness: A. Use a multimeter (ohms setting) to measure and record the resistance across the disconnected machine wire harness connector terminals. g287900 Figure 70 1. Machine wire harness connector B. The resistance across connector terminal F (black/white wire) and each of the terminals C, D, and E should be 18k to 20k ohms.
Cutting Unit Motors The three cutting unit motors are identical 48 VDC, brushless, permanent magnet motors. Each motor has its own on-board controller (T1: center cutting unit, T2: left cutting unit, T3: right cutting unit). If a problem exists with any cutting unit motor, a fault may have occurred that would be indicated by a fault code on the InfoCenter Display.
Testing the Cutting Unit Motors (continued) • If – – – appears, the controller is not communicating on the CAN bus. Voltage must be present at the controller logic circuit before communication can occur on the CAN bus. If voltage is not present at the logic circuit, the logic circuit is damaged. The circuit wiring should be checked for corrosion or damage and cleaned or repaired as necessary. If logic voltage is present at the controller, and CAN bus communication is suspect, the CAN bus circuit is damaged.
Key Switch (Model 04580) POSITION CLOSED CIRCUITS OFF 1 + 6, 4 + 5 RUN 1+3+4+5+6 START 1+2+4+5+6 The key switch on the console has three (3) positions − OFF, RUN and START. The key switch is an input used by the T1: Primary controller to manage various machine functions. Testing the Key Switch The key switch and its circuit wiring can be tested using the InfoCenter Display; refer to Using the InfoCenter Display for Troubleshooting (page 3–39) Diagnostics > Engine > Inputs.
Key Switch (Model 04590) POSITION CLOSED CIRCUITS OFF NONE RUN B + C + F, D + E START A+B+C The key switch on the console has three (3) positions − OFF, RUN and START . The START position is not used on this machine. The key switch is used to energize the T6: Precharge controller and the SC8: 48V Battery Controller. Testing the Key Switch 1. Park the machine on a level surface, lower the cutting units and set the key switch to the OFF position. 2.
Function Control Switch POSITION CLOSED CIRCUITS NEUTRAL 1 + 2, 4 + 5 MOW 2 + 3, 4 + 5 TRANSPORT 2 + 3, 5 + 6 The function control switch is located on the operator console. The function control switch allows the operator to select between NEUTRAL (also used for backlapping), MOW (low speed range), and TRANSPORT (high speed range).
Light Switch (Optional) POSITION CLOSED CIRCUITS FRONT AND REAR FACING LIGHTS ON 1 + 2, 4 + 5 OFF NONE REAR FACING LIGHT ON 2 + 3, 5 + 6 The light switch is located on the operator console. Pushing down on the right side of the switch energizes the front and rear facing lights. Pushing down on the left side of the switch energizes the rear facing light. Testing the Light Switch 1.
Seat Switch g289941 Figure 73 1. Seat assembly 2. Seat switch wire harness 3. Seat switch The seat switch is a normally open switch that closes when the operator is on the seat. The seat switch and its electrical connector are located directly under the seat. The seat switch is part of the safety interlock system; refer to Checking the Interlock System Operation (page 5–19) for a better understanding of how the switch is used.
Testing the Seat Switch (continued) B. Access the top of the switch by slipping between the seat frame and the seat base foam. C. Release the switch from underneath and remove the switch. D. Install the seat switch in the reverse order. 6. If the seat switch and seat switch harness tests correctly and a circuit problem still exists, check the main wire harness; refer to Appendix A (page A–1). 7. Connect the wire harnesses to the switch before returning the machine to service.
Brake Actuator The eTriFlex machines use a single mechanical brake assembly that can be used as a service brake, a manual parking brake, and an automatic parking brake. The service brake and manual parking brake are controlled by a cable connected to pedals at the operator’s left foot, while the automatic parking brake is controlled by an 12 VDC electric brake actuator. When the brake actuator is de-energized, an extension spring extends the actuator and engages the brakes.
Testing the Brake Actuator (continued) 4. Disconnect the brake actuator from the machine harness. Check the actuator and the harness connector for damage or corrosion and clean or repair as necessary. 5. Remove the actuator from the machine. 6. Use the cylinder pin to clamp the body of the actuator securely in a vise, and manually extend and retract the actuator rod. The actuator rod should travel approximately 32 mm (1.25 inch) in each direction smoothly. 7.
Manual Parking Brake Switch g290079 Figure 75 (view from under foot panel) 1. Manual parking brake switch 2. Latch The switch is located directly under the brake pedal assembly. The manual parking brake switch is an input to the T1: primary controller. The switch is a normally open proximity switch that closes when the foot actuated parking brake is disengaged (the parking brake latch is in close proximity to the switch).
Testing the Manual Parking Brake Switch (continued) B. Disconnect the machine wire harness from the parking brake switch. Check the switch and the harness connector for damage or corrosion and clean or repair as necessary. C. Set the key switch to the ON position (do not start the engine) and use a multimeter (DC voltage setting) to verify that the machine wire harness pink wire has system voltage (12 VDC) present. Set the key switch to the OFF position. D.
Cutting Unit Lift/Lower Switches g290159 Figure 76 1. 2. 3. Console Knob Jam nut (2 each) 6. 7. 8. Lower switch Lift switch Cap screw (2 each) 4. Stem 9. Hex nut (2 each) 5. Joystick assembly Raise/Lower Switch Testing Reference JOYSTICK POSITION RAISE SWITCH CIRCUIT LOWER SWITCH CIRCUIT LIFT 1 + 2 1 + 3 CENTER 1 + 3 1 + 3 LOWER 1 + 3 1 + 2 The 2 cutting unit lift/lower switches are located on the joystick bracket attached to the operator console.
Testing the Cutting Unit Lift/Lower Switches (continued) 2. Disconnect the battery negative (-) cable at the 12V system battery (model 04580); refer to Removing and Installing the 12V System Battery (Model 04580) (page 5–105), or unplug the 48V battery disconnect (model 04590); refer to 48V Battery Disconnect (page 5–9). 3. Remove the console cover; refer to Removing and Installing the Control Console (page 6–38). 4. Disconnect the wire harness from the switch.
Lift/Lower Actuators Three electric linear actuators are used on eTriFlex machines to lift and lower the cutting units. Each lift/lower actuator is unique and cannot be interchanged with each other. The lift/lower actuators may be referred to by number: #1 = center (rear), #2 = left, #3 = right. The front lift/lower actuators retract to lift the cutting units, while the center (rear) lift/lower actuator extends to lift the cutting unit. Each lift/lower actuator has its own on-board controller.
Testing the Lift/Lower Actuators 1. Park the machine on a level surface, lower the cutting units and set the key switch to the OFF position. 2. Engage the manual parking brake and set the function control switch to the NEUTRAL position. 3. Sit in the operator seat and set the key switch to the ON position. 4. Access the InfoCenter Diagnostics > Lift/Lower > Inputs screen. g292214 Figure 78 (joystick in the Lower position) A. Move the joystick to the LOWER position.
Testing the Lift/Lower Actuators (continued) g292215 Figure 79 (left cutting unit lowering) • Act # Mode should read Off while the actuator is stationary. • Act # Current should read 0A while the actuator is stationary. • Move the joystick to the LOWER position. Lower should appear next to Act # Mode while the actuator is moving. The current required to move the actuator should appear next to Act # Current while the actuator is moving. • Move the joystick to the RAISE position.
Engine Oil Pressure Switch (Model 04580) g289630 Figure 80 1. 2. Oil filter Engine oil pressure switch The engine oil pressure switch is located on the right side of the engine near the oil filter. The oil pressure switch is a normally open switch that closes under engine oil pressure. The condition of the engine oil pressure switch is monitored by the T1: Primary controller.
Testing the Engine Oil Pressure Switch (continued) 4. Replace the switch as necessary. 5. If the switch tests correctly and a circuit problem still exists, check the machine wire harness; refer to Appendix A (page A–1). 6. After testing, connect the engine wire harness to the switch before returning the machine to service.
Traction Pedal Position Sensor g290223 Figure 81 1. Traction pedal position sensor 3. Shield 2. Wire harness connector 4. Screw (2 each) The traction pedal position sensor is a separate component in the traction pedal assembly. The sensor includes 2 analog hall effect sensors. The traction pedal sensor follows the traction pedal movement. The sensor operates on 5VDC supplied by the SC5: Traction 1 motor controller (right side).
Testing the Traction Pedal Position Sensor (continued) 2. Ensure the traction pedal assembly is able to move from full forward stop to full rearward stop. 3. Use the InfoCenter to view the sensor signal voltage: A. Sit in the operator seat and set the key switch to the ON position. B. Set the function control switch to the NEUTRAL position. C. From the InfoCenter Main Menu, select Diagnostics > Traction > Inputs. g290532 Figure 82 (shown with traction pedal fully forward) D.
Testing the Traction Pedal Position Sensor (continued) 5. Replace the traction pedal position sensor if necessary. Ensure the sensor drive is aligned with the tab on the pedal shaft before tightening the mounting fasteners. 6. If the traction pedal position sensor tests correctly and a circuit problem still exists, check the machine wire harness; refer to Appendix A (page A–1). 7.
Steering Position Sensor g290696 Figure 83 1. Steering position sensor 3. Caster fork shaft 2. Magnetic bolt 4. Sensor harness connector The steering position sensor is a two–piece assembly located on top of the rear wheel caster fork shaft. The sensor portion includes 2 analog hall effect sensors. The second piece of the assembly is a bolt with a magnetic head threaded into the caster fork shaft. The steering position sensor follows the rear caster fork movement.
Testing the Steering Position Sensor (continued) 1. Park the machine on a level surface, lower the cutting units, set the key switch to the OFF position and remove the key. 2. Raise and support the rear of the machine; refer to Jacking Instructions (page 1–6). 3. Ensure the rear wheel assembly is able to move from full right stop to full left stop (approximately 50° in either direction). 4.
Testing the Steering Position Sensor (continued) C. Turn the caster fork by hand until it is square with the machine (straight). Using a multimeter (DC voltage setting), 2.0 – 3.0 VDC should be present at both sensor connector pins 3 and 6. D. Turn the rear caster fork by hand fully to the left (counterclockwise). Using a multimeter (DC voltage setting), 3.7 – 3.9 VDC should be present at sensor connector pin 3 and 1.1 – 1.3 VDC should be present at sensor connector pin 6. E.
Relays Greensmaster eTriFlex machines use a number of electrical relays. Some of the relays have four (4) terminals and some have five (5) terminals. The number of terminals the relay has determines how the relay should be tested. A tag near the wire harness relay connector can be used to identify each relay. g291275 Figure 85 eTriFlex 3360 Model 04580 1. Logic relay 2. Brake actuator relay Electrical System: Testing the Electrical Components 3.
g291276 Figure 86 eTriFlex 3370 Model 04590 1. Logic relay 2. Brake actuator relay 3. Shutdown delay relay (model 04590) The relays are located under the right side cover: • • • • The logic relay is a 4 terminal relay with a 12V coil. The brake actuator relay is a 5 terminal relay with a 12V coil. The engine relay (model 04580) is a 5 terminal relay with a 12V coil. The shutdown delay relay (model 04590) is a 4 terminal relay with a 48V coil.
Identifying the Relays and their Functions (continued) Shutdown Delay Relay (Model 04590) The shutdown delay relay is energized when the key switch is set to the RUN position. When energized, the shutdown delay relay supplies power to the 12V control circuits (manual parking brake switch, T1: primary controller outputs, InfoCenter display, CAN bus isolation module, brake actuator relay switch terminal).
Testing Relays with 4 Terminals (continued) relay should make and break continuity between terminals 30 and 87 as +voltage is applied and removed from terminal 85. 8. Replace the relay as necessary. 9. If the relay tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 10. Install the relay and connect the wire harness. 11.
Testing Relays with 5 Terminals (continued) 7. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as +voltage is applied and removed from terminal 85. 8. Connect multimeter (ohms setting) leads to relay terminals 30 and 87A. Apply +12 VDC to terminal 85.
Contactors Two contactors are used on eTriFlex machines. Both contactors are located under the left side cover. The main contactor connects the 48V batteries to the 48V power bus for the lift/lower actuators, cutting unit motors, the optional 3WD traction motor, and the starter/generator (model 04580). The steering motor is connected to the 48V power bus at all times and is not controlled by the main contactor. The main contactor is energized be the logic relay.
Testing the Contactors (continued) Note: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from the measured value for the tested component. 5. Apply 48 VDC directly across the contactor coil terminals. The contactor should should produce an audible “click”.
Diode Assemblies Multimeter Red (+) Lead Multimeter Black (-) Lead Resistance DIODE TERMINAL A DIODE TERMINAL B VERY LOW DIODE TERMINAL B DIODE TERMINAL A VERY HIGH Two different diodes are used on the eTriFlex machines. The maximum current allowed through any of the diodes is 6 amps. The diodes can be identified by their black color and diode symbol on the end of the diode body. g288593 Figure 90 1. Main contactor diode 2. Traction motor contactor diode 3.
Testing the Diode Assemblies (continued) 4. If the diode tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1).
CAN bus Terminator Resistors The machine controllers communicate with each other on a Controller Area Network (CAN) bus system. Controllers that operate on 12 VDC connect to the 12V side of the CAN bus (CAN A), while controllers that operate on 48 VDC connect to the 48V side of the CAN bus (CAN B). The two sides of the CAN bus communicate as one network through the use of a CAN bus Isolation Module. The entire CAN bus is made up of two specially designed twisted wires.
IMPORTANT All 4 terminator resistors are required for proper CAN bus operation. Testing the CAN bus Terminator Resistors 1. Park the machine on a level surface, lower the cutting units, set the key switch to the OFF position and remove the key. 2. Unplug the 48V battery disconnect; refer to 48V Battery Disconnect (page 5–9). On model 04580 machines, disconnect the battery negative (-) cable at the 12V system battery; refer to Removing and Installing the 12V System Battery (Model 04580) (page 5–105). 3.
Batteries (Model 04580) Caring for the Batteries (Model 04580) WARNING The battery gases are explosive; also, they can cause nausea. • Wear safety goggles and rubber gloves when working with electrolyte. Charge the battery in a well ventilated place so that the gasses produced while charging can dissipate. • Keep open flames and electrical sparks away from the battery; do not smoke.
Storing the Batteries (Model 04580) If you store the machine for more than 30 days: 1. Ensure that the key switch is in the OFF position. 2. Unplug the 48V battery disconnect; refer to 48V Battery Disconnect (page 5–9). 3. Disconnect the ground (-) cable from the 12V battery; refer to Removing and Installing the 12V System Battery (Model 04580) (page 5–105). 4. Charge the batteries fully before storage; refer to Charging the Batteries (Model 04580) (page 5–110). 5.
Servicing the Batteries (Model 04580) Battery Specifications 12V system battery Type: absorbed glass mat (AGM), valve regulated lead acid (VRLA) Nominal voltage: 12 AH rating: 16.5 Length: 15.0 cm (5.9 inches) Width: 6.6 cm (2.6 inches) Height including terminal posts: 10.7 cm (4.2 inches) 48V system batteries – 4 each Type: absorbed glass mat (AGM), valve regulated lead acid (VRLA) Nominal voltage: 12 AH rating: 9.0 Length: 19.6 cm (7.7 inches) Width: 13.2 cm (5.
Removing and Installing the 12V System Battery (Model 04580) (continued) IMPORTANT Be careful when removing the battery cables and ensure that you do not damage the terminal posts or cable connectors. 1. Remove the right side cover. 2. Remove the battery cover. 3. Disconnect the ground (-) cable from the battery terminal, then disconnect the positive (+) cable from the battery terminal. 4. Remove the lock nuts, carriage bolts, and the battery clamp. 5. Install the battery in reverse order. 6.
Removing and Installing the 48V System Batteries (Model 04580) g291925 Figure 94 1. Battery (4 each) 2. 3. 15. Retaining ring 8. Push nut (2 each) Battery cover – RH 9. Battery hold down (2 each) 16. Clamp (10 each) Battery cover – LH 10. Lock nut (2 each) 17. Flat washer 4. Flat washer (4 each) 11. Jumper cable (2 each) 18. Flange nut 5. Flange head screw (4 each) 12. Lock washer (8 each) 19. Battery cable assembly 6. Flange nut (4 each) 13. Cap screw (8 each) 20.
Removing and Installing the 48V System Batteries (Model 04580) (continued) WARNING The battery terminals, metal tools and metal vehicle parts could short together and cause sparks during battery removal and installation. Damaged cables could short against metal vehicle parts and cause sparks. Sparks can cause battery gasses to explode. When removing or installing the batteries, do not allow the battery terminals to short against metal parts of the vehicle.
Removing and Installing the 48V System Batteries (Model 04580) (continued) 14. Carefully install the battery jumper cables(item 11)-. Do not allow tools or vehicle components to complete the battery circuit during cable installation. Tighten the battery terminal cap screws from 5.2 to 4.5 N·m (46 to 54 in-lb). 15. After you make the connections, apply battery terminal protector Toro Part No.
Inspecting, Maintaining, and Testing the Batteries (Model 04580) (continued) IMPORTANT Many locally available battery load testers do not, have any adjustment on the load that is put on the battery. Results received from using load testers should follow the recommendations of the load tester manufacturer. Charging the Batteries (Model 04580) The batteries may be individually charged with a 12V charger rated for operation with absorbed glass mat (AGM), valve regulated lead acid (VRLA) batteries.
Batteries (Model 04590) The Greensmaster 3370 is powered by eight maintenance free lithium-ion batteries. Two batteries are located under a cover on the right side of the machine, two batteries are located under a cover on the left side of the machine, and Four batteries are located in the center of the machine under the hood. Each battery consists of numerous cells.
Caring for the Lithium-Ion Batteries (Model 04590) (continued) Keep the battery covers clean. A dirty battery cover will increase the heat in the battery and will reduce the energy capacity and life of the battery. Storing the Lithium-Ion Batteries (Model 04590) Do not store the machine in a location where the temperature will drop below -25°C (-13°F) or rise above 45°C (113°F).
Charging the Lithium-Ion Batteries (Model 04590) Refer to the Traction Unit Operator’s Manual for battery charging and battery charger operation information. Refer to Battery Charger Error and Fault Codes in this manual for battery charger troubleshooting information. Note: A record of battery charger operation data can be downloaded by inserting a flash drive into the USB port on the battery charger.
Removing and Installing the Lithium-Ion Batteries (Model 04590) (continued) g309819 Figure 96 1. Positive (+) battery cable – center 3. Hex nut 2. Washer 4. Positive (+) battery cable – left side Electrical System: Batteries (Model 04590) 5.
Removing and Installing the Lithium-Ion Batteries (Model 04590) (continued) g310213 Figure 97 1. Right side mounted battery assembly 4. Washer 7. 2. Left side mounted battery assembly 5. Battery interface harness 3. Hex nut Battery clamp nut (8 each) 6. Carriage bolt (8 each) 5. To remove the side mounted batteries: A. Label and disconnect the negative (-) battery cable, positive (+) battery cable, and battery interface harness from both lithium-ion batteries. B.
Removing and Installing the Lithium-Ion Batteries (Model 04590) (continued) g310864 Figure 98 1. Center battery cover 5. Lock nut (2 each) 2. Battery cover clamp (4 each) 6. Center mounted battery assembly 10. 9. Washer (4 each) 3. Battery interface harness 7. Flange head screw (2 each) Negative (–) wire harness terminal 4. Flange head screw (2 each) 8. Hex nut (4 each) 11. Positive (+) wire harness terminal 6. To remove one or more of the center mounted batteries: A.
Removing and Installing the Lithium-Ion Batteries (Model 04590) (continued) F. Label and disconnect the machine wire harness connectors from the T6: precharge controller. G. Remove the 4 fasteners securing the center mounted battery try to the machine. CAUTION The center mounted battery assembly weighs approximately 67 kg (148 lbs). Use an appropriate lift and the lift points provided to remove the center mounted battery assembly. H. Raise the center mounted battery assembly approximately 7.5 cm (3 inch).
Removing and Installing the Lithium-Ion Batteries (Model 04590) (continued) g310850 Figure 99 1. Lock nut (6 each) 9. Carriage bolt (4 each) 17. Battery support (2 each) 2. Battery clamp rod (2 each) 10. Controller bracket 18. Negative (-) battery cable (3 each) 3. Flat washer (2 each) 11. Lock nut (3 each) 19. Carriage bolt (3 each) 4. Jam nut (4 each) 12. T6: Precharge controller 20. Battery retainer 5. Battery (4 each) 13. Hex nut (10 each) 21. Battery tray 22.
Removing and Installing the Lithium-Ion Batteries (Model 04590) (continued) 7. Install the batteries in reverse order. 8. Tighten the battery clamp nuts from 2.8 to 3.9 N·m (25 to 35 in-lb). 9. Connect the positive (+) battery cable at the center mounted batteries, and at each set of side mounted batteries; refer to Figure 96. 10. Tighten the battery cable fasteners from 8.5 to 9.5 N·m (75 to 85 in-lb), then apply battery terminal protector Toro Part No.
Service and Repairs Generator Assembly (Model 04580) Note: If the starter/generator controller is replaced for any reason, the machine software must be updated; contact an Authorized Toro Distributor for assistance. Replacing the Starter/Generator Drive Belt 1. Remove the fuel tank; refer to Removing the Fuel Tank (page 4–4). 2. Tilt the operator seat forward and remove the starter/generator pulley cover. 3. Loosen the hex nuts and extend the adjustment pin as far as possible to relax the extension spring.
Removing the Starter/Generator Assembly g286730 Figure 101 1. Engine frame assembly 6. Cap screw 2. Cap screw 7. Clamp 12. Cap screw (4 each) 3. Cap screw ( 2 each) 8. Lock nut 13. Flat washer (3 each) Flange nut (4 each) 14. Cap screw (2 each) 4. Isolating mount – rear 5. Lock nut (3 each) 9. 10. 11. Isolating mount – front (2 each) Wire harness connector Refer to Figure 101 for this procedure 1.
Removing the Starter/Generator Assembly (continued) 5. Remove the fuel tank; refer to Removing the Fuel Tank (page 4–4). 6. Remove the evaporative control system carbon canister from the machine. 7. Disconnect the electrical system wiring from the engine: • The engine wire harness connector at the main wire harness (left side of engine). Check the engine and wire harness connector for damage or corrosion and clean or repair as necessary.
Removing the Starter/Generator Assembly (continued) 15. Loosen the 4 cap screws (item 8) securing the starter/generator to the engine frame, then rotate the starter/generator clockwise to loosen the starter/generator drive belt. 16. Remove the fasteners and the starter/generator from the engine frame.
Disassembling the Starter/Generator g288750 Figure 103 1. Generator assembly 2. Plug (2 each) 3. Cap screw (2 each) 10. Washer head screw (2 each) 19. Woodruff key 11. Flange head screw (3 each) 20. O−ring 12. Collar 21. Square key 4. Flat washer (2 each) 13. Flange head screw 22. Generator pulley 5. Washer head screw (6 each) 14. Generator cover 23. Washer 6. Controller assembly 15. Torx screw (4 each) 24. Cap screw 7. Flange nut (2 each) 16.
Disassembling the Starter/Generator (continued) 3. Remove the access cover (item 9) and the cover gasket from the controller. Discard the cover gasket. 4. Record the position of the connectors and the wire harnesses for assembly purposes. Carefully remove the starter/generator and controller harness connectors from the controller opening and unplug the connectors. 5. Remove the three flange head screws (item 11) that secure the starter/generator stator conductors to the controller connectors. 6.
Disassembling the Starter/Generator (continued) 9. Remove the spring bracket from the starter/generator housing. Note: If the starter/generator housing/stator requires replacement, the starter/generator assembly must be replaced. The starter/generator housing/stator is not available separately. 10. Continue to disassemble the starter/generator if necessary: g288751 Figure 105 1. Housing/stator assembly 8. O−ring 2. O−ring 9. Cover 3. Bearing 10. Flange screw (6 each) 4. Rotor assembly 11.
Disassembling the Starter/Generator (continued) A. Remove the six flange head screws that secure the cover to the housing/stator assembly. Do not remove the cover at this time. B. Secure the base plate of the starter/generator rotor tool (part number TOR6029) to the drive side of the starter/generator housing/stator with three 3/8–16 X 3 inch cap screws. g289007 Figure 106 1. Generator housing/stator assembly (drive side) 2. Generator rotor tool base plate 3. Generator rotor tool shaft C.
Assembling the Starter/Generator Refer to Figure 103 for this procedure. 1. Make sure that all the starter/generator components are clean before assembly. 2. Assembly the starter/generator internal components: A. If the bearings were removed from the rotor assembly, install new bearings onto the rotor shaft. Make sure the new bearings are fully pressed onto rotor shaft. B. If the isolator was removed, lubricate a new gasket with dielectric lubricant and install it to the isolator.
Assembling the Starter/Generator (continued) A. Make sure that tapered surfaces of the rotor shaft and the fan are thoroughly clean. B. Position the woodruff key into the rotor shaft and install the starter/generator fan. C. Install the collar and flange head screw (item 13). Tighten the screw from 19 to 21 N·m (170 to 190 in−lb). 6. Lubricate a new O-ring (item 20) with dielectric lubricant and install it into the groove on the isolator. 7. Install the controller: A.
Installing the Starter/Generator Assembly (continued) 7. Install the clamp securing the engine oil drain hose to the right side battery tray. 8. Connect the choke control cable to the engine: A. Set the choke control at the operator control panel to the full choke position. B. Connect the choke control cable to the choke lever at the carburetor. C. Set the choke lever at the carburetor to the full closed position and secure the cable housing to the engine with the clamp and cap screw previously removed. 9.
Front Traction Motor The front traction motors can be replaced separate from the front traction gear box. The front traction gear box can be removed or installed before or after the motor is removed from the machine; refer to Front Traction Gear Box (page 6–11). If the front traction motor is replaced for any reason, the traction motors must be calibrated; refer to Calibrating the Front Traction Motors (page 5–56). For front traction motor testing information; refer to Front Traction Motor (page 5–55).
Removing and Installing the Front Traction Motor (continued) 4. Remove the cotter pin and clevis pin securing the brake linkage to the brake lever. Discard the cotter pin. 5. Remove the extension spring from the brake lever. 6. Remove the brake lever from the taction motor assembly. 7. Remove the fasteners securing the arm (item 3) to the frame and the traction motor and remove the arm. 8. Remove the support link. 9.
Rear Traction Motor (Optional) The optional rear traction motor is attached to the rear wheel gear box cover. The rear wheel gear box must be removed and disassembled to access the motor mounting fasteners. If the rear traction motor is replaced for any reason, the machine software must be updated; contact an Authorized Toro Distributor for assistance. g293227 Figure 108 1. 3WD traction motor 6. 2. O-ring 7. Set screw 3. Gasket 8. Spur gear 4. Gear box cover 9. Socket head cap screw 5.
Disassembling the Rear Traction Motor g293229 Figure 109 1. Cap screw (6 each) 7. Bearing 2. Motor cover 8. O-ring 3. O-ring 9. Housing assembly 4. Wave washer 10. Lip seal 5. Bearing 11. O-ring 6. Rotor Note: If the motor housing, stator, controller or cable is damaged, 3WD traction motor replacement is necessary as these components are not available separately.
Disassembling the Rear Traction Motor (continued) g295018 Figure 110 1. 3WD traction motor housing 2. Motor rotor tool base plate 3. Motor rotor tool shaft 5. Install the rotor tool shaft into the base plate and turn it in against the rotor shaft. CAUTION The rotor magnets are very powerful and can cause the rotor to shift position very rapidly during removal. Be cautious during rotor removal to prevent component damage or personal injury. 6.
Assembling the Rear Traction Motor (continued) 4. Lubricate new O-rings with dielectric lubricant and install the O-rings into the grooves in the motor cover. Place the wave washer in the cover bearing bore and fit the rotor assembly into the cover. 5. Secure the base plate of the motor rotor tool to the housing with four M6 – 1.0 X 50 cap screws. 6. Install the rotor tool shaft into the base plate and turn it in so the end of the shaft prevents the rotor body from entering the housing assembly.
Cutting Unit Motor If a cutting unit motor is replaced for any reason, the machine software must be updated; contact an Authorized Toro Distributor for assistance. Removing the Cutting Unit Motor 1. Park the machine on a level surface, lower the cutting units, set the key switch to the OFF position and remove key from the key switch. 2. Unplug the 48V battery disconnect; refer to 48V Battery Disconnect (page 5–9). IMPORTANT When removing the cutting unit motor, take care to not damage the cable.
Disassembling the Cutting Unit Motor g289205 Figure 111 1. Cap screw (12 each) 6. Rotor 2. Motor cover 7. Bearing (2 each) 12. Gear box cover 3. O-ring 8. O-ring (2 each) 13. Lip seal 4. Wave washer (2 each) 9. Housing assembly 14. O-ring 5. Bearing (2 each) 10. 11. Output gear O-ring Note: If the motor housing, stator, controller or cable is damaged, cutting reel motor replacement is necessary as these components are not available separately.
Disassembling the Cutting Unit Motor (continued) 1. Inspect the cutting unit motor cable for wear or damage. replace cable components or complete cutting unit motor assembly if necessary. g289220 Figure 112 1. O-ring 2. Barb fitting 3. 4. 9. Ferrule nut 10. Connector – 2 pin Hose 11. Wedge – 2 pin Convoluted tubing – 0.88 inch 12. Convoluted tubing – 0.63 inch 5. Bulkhead fitting 13. Cable tie (4 each) 6. Bulkhead nut (2 each) 14. Connector – 4 pin 7. Bulkhead fitting 15.
Disassembling the Cutting Unit Motor (continued) g289233 Figure 113 1. Cutting unit motor housing (gear box side) 3. 2. Motor rotor tool base plate Motor rotor tool shaft 9. Install the rotor tool shaft into the base plate and turn it in against the rotor shaft. CAUTION The rotor magnets are very powerful and can cause the rotor to shift position very rapidly during removal. Be cautious during rotor removal to prevent component damage or personal injury. 10.
Assembling the Cutting Unit Motor (continued) 5. Secure the base plate of the cutting unit motor rotor tool to the gear box side of the housing with four M6 – 1.0 X 16 cap screws. 6. Install the rotor tool shaft into the base plate and turn it in so the end of the shaft prevents the rotor body from entering the housing assembly. IMPORTANT The rotor magnets are very powerful and can cause the rotor to shift position very rapidly during installation.
Assembling the Cutting Unit Motor (continued) g289245 Figure 114 1. Output gear 2. Gear box cover 3. Lip seal 14. Lubricate new O-rings with dielectric lubricant and install the O-rings into the grooves in the gear box cover. IMPORTANT The output shaft splines can be sharp; be careful not to damage the lip seal when installing the gear box cover. 15. Carefully install the gear box cover and secure it with the six cap screws previously removed. Tighten the screws from 8 to 9 N·m (70 to 80 in- lb).
Chapter 6 Chassis Table of Contents General Information .............................................................................................................................. 6–2 Adjustments .......................................................................................................................................... 6–3 Adjusting the Brakes ..........................................................................................................................
General Information The traction unit Operator’s Manual and optional accessory Installation Instructions provide information regarding the operation, general maintenance procedures, and maintenance intervals for your machine. Refer to the traction unit Operator’s Manual and optional accessory Installation Instructions for additional information when servicing the machine.
Adjustments Adjusting the Brakes The eTriFlex machines use a single mechanical brake assembly that can be used as a service brake, a manual parking brake, and an automatic parking brake. The service brake and manual parking brake are controlled by a cable connected to pedals at the operator’s left foot, while the automatic parking brake is controlled by an 12 VDC electric brake actuator. The brake system engages 2 brake calipers (located between each front traction motor and front traction gear box).
Checking the Brake Adjustment (continued) parking brake. If the gaps do not increase when the manual parking brake is engaged, adjust the brake cable: refer to Adjusting the Brake Cable (page 6–6). Adjusting the Brake Linkage 1. Park the machine on a level surface, set the key switch to the OFF position and remove the key. 2. Loosen the hex nuts and adjust the eye bolt as far as possible to relax the extension spring. Remove the spring. g283623 Figure 116 1. Front traction motor – RH 4.
Adjusting the Brake Linkage (continued) g283626 Figure 117 1. 2. Brake rod Brake rod spring 5. 6. Clevis nut Washer 3. Jam nut (2 each) 7. Lower brake rod clevis 4. Upper brake rod clevis 8. Clevis pin D. Use new cotter pins and install the brake rod assembly to the upper brake arms only. 5. Remove the cotter pin and clevis pin from the lower brake rod clevis. Discard the cotter pin. IMPORTANT Adjust each brake rod individually. 6.
Adjusting the Brake Linkage (continued) 7. Ensure the flat side of the lower brake rod clevis is toward the traction motor and install the clevis pin with a new cotter pin. 8. Adjust the brake cable; refer to Adjusting the Brake Cable (page 6–6). Adjusting the Brake Cable 1. Park the machine on a level surface, set the key switch to the OFF position and remove the key. 2. Loosen the hex nuts and adjust the eye bolt as far as possible to relax the extension spring. Remove the spring. g283623 Figure 119 1.
Adjusting the Brake Cable (continued) 5. Use the 3/8 inch square drive hole in the right side upper brake arm to fully extend the brake actuator. 6. The gap between the brake actuator rod nut and the actuator clevis nut should be 3.3 to 3.8 mm (0.13 to 0.15 inch) and the clevis pin holes should be parallel to the ground. Loosen the clevis nut and adjust the clevis if necessary. g283646 Figure 120 1. Brake actuator 2. 3. 4. Clevis 7. Rod nut 5. Extension spring Clevis nut 6.
Aligning the Rear Wheel Caster Fork g291172 Figure 121 1. Rear caster fork 3. Straight edge 2. Wheel Hub 4. Center (rear) cutting unit suspension mount plate 1. Remove the rear wheel; refer to Removing and Installing the Wheels (page 6–9). 2. Clamp a straight edge to the rear wheel hub flange. 3. Rotate the caster fork by hand until the straight edge aligns with the lower mounting bolt on the center (rear) cutting unit suspension mount plate. 4.
Service and Repairs Wheels and Tires g282533 Figure 122 1. Front wheel assembly (2 each) 2. Rear wheel assembly 3. Lug nut (4 each wheel) Removing and Installing the Wheels 1. Raise the machine off the ground; refer to Jacking Instructions (page 1–6). 2. Remove and install the wheel and tire assemblies as necessary. 3. Tighten the wheel lug nuts in a crossing pattern from 95 to 122 N·m (70 to 90 ft-lb).
Front Wheel Hubs Removing and Installing the Front Wheel Hubs g282531 Figure 123 1. Lock nut 4. Drive stud (4 each hub) 2. Hardened washer 5. Woodruff key 3. Hub 1. Loosen but do not remove the front hub nut. 2. Raise the machine and remove the front wheel; refer to Jacking Instructions (page 1–6). IMPORTANT DO NOT hit the front wheel hub or gear box assembly with a hammer during front hub removal. Hammering the assembly may damage to the gear box. 3.
Front Traction Gear Box g282714 Figure 124 1. Front traction gear box assembly 2. Front traction motor assembly 3. 4. 9. Gasket 10. Countershaft assembly Plug 11. Brake caliper O-ring 12. Drain plug 5. Cap screw 13. Barb fitting 6. 7. Washer Cap screw (10 each) 14. 15. Hose Vent 8. Dowel pin (2 each) Removing the Front Traction Gear Box Refer to Figure 124 for this procedure. 1. Remove the front wheel; refer to Removing and Installing the Wheels (page 6–9). 2.
Removing the Front Traction Gear Box (continued) 7. Locate and retrieve the 2 dowel pins. 8. Use a new O-ring and install the drain plug. Installing the Front Traction Gear Box Refer to Figure 124 for this procedure. 1. Remove any residual gasket material from the gear box and wheel motor gasket surfaces. 2. Fit the dowel pins and a new gasket in position and install the gear box. 3.
Front Traction Gear Box Service g282826 Figure 125 1. Gear box housing 6. Jam nut (2 each) 11. Countershaft assembly 2. Nose cover 7. Tab washer (2 each) 12. O-ring 3. Cap screw (4 each) 8. Bearing cone (2 each) 13. Output shaft assembly 4. Lip seal 9. Bearing cup (2 each) 14. Wheel hub lock nut 5. O-ring 10. Roller bearing (2 each) Servicing the Front Traction Gear Box 1.
Servicing the Front Traction Gear Box (continued) 10. Press a new inner bearing cone onto the output shaft. Ensure the bearing cone is flush against the output gear. 11. Press a new roller bearing onto the countershaft assembly behind the countershaft gear. Ensure the bearing is flush against the countershaft gear. 12. Install the output shaft assembly. A. Position the output shaft assembly in the gear box housing and install the outer bearing cone. B.
Rear Wheel Hub (Standard) g282532 Figure 126 1. Dust cap 6. Bearing cone (2 each hub) 2. Cotter pin 7. Bearing cup (2 each hub) 3. Nut retainer 8. Hub assembly 9. Drive stud (4 each hub) 4. Nut 5. Spindle washer 10. Lip seal Disassembling the Rear Wheel Hub and Bearings (Standard) Refer to Figure 126 for the following procedure. 1. Raise the machine and remove the rear wheel; refer to Jacking Instructions (page 1–6). 2. Carefully remove the dust cap from the wheel hub. 3.
Disassembling the Rear Wheel Hub and Bearings (Standard) (continued) 6. Clean and inspect the axle spindle for wear or damage. Replace the spindle if necessary. Assembling the Rear Wheel Hub and Bearings (Standard) Refer toFigure 126 for the following procedure. 1. Assemble the wheel hub as follows: A. If the bearing cups were removed from the wheel hub, press the inner and outer cups into the wheel hub until they seat against the wheel hub shoulder.
Rear Wheel Hub (Optional 3WD) g293602 Figure 127 1. Dust plug 5. Thrust bearing (2 each) 2. O-ring 6. Roller clutch (3 each) 10. Wave washer 3. Retaining ring 7. Hub 11. Lip seal 4. Thrust washer (4 each) 8. Grease fitting 9. Drive stud (4 each) Removing and Installing the Rear Wheel Hub 1. Remove the rear wheel; refer to Removing and Installing the Wheels (page 6–9). 2. Remove the dust plug from the hub assembly. Inspect the dust plug O-ring and replace as necessary. 3.
Servicing the Rear Wheel Hub (continued) g293603 Figure 128 1. Dust cap (outside of hub) 3. Lip seal (inside of hub) 2. Grease fitting and passage 4. Roller clutch – white roller cage A. Press the old roller clutches from the hub. B. Press one new roller clutch from the inside of the hub. The white roller cage of the roller clutch must be toward the inside (lip seal) of the hub. The roller clutch should rest just below the inner shoulder of the hub and not block the grease passage. C.
Rear Wheel Gear Box (Optional 3WD) g293226 Figure 129 1. Rear wheel gear box and motor assembly 7. Flange nut (2 each) 2. Rear wheel hub assembly 8. Spacer (2 each) 3. 4. Vent hose Vent fitting 9. 10. Harness bracket Flat washer (2 each) 5. O-ring 11. Cap screw (2 each) 6. Flange head screw (4 each) Removing and Installing the Rear Wheel Gear Box Refer to Figure 129 for this procedure. 1. Remove the rear wheel; refer to Removing and Installing the Wheels (page 6–9). 2.
Servicing the Rear Wheel Gear Box g293710 Figure 130 1. Rear traction motor 11. Key 21. Axle shaft 2. Gasket 12. Spur gear 22. Key 3. Plug – drain 13. Wave washer 23. Gear 133 T 4. Plug – level 14. Dowel pin (2 each) 24. Washer 5. O-ring 15. Gear box housing 25. Set screw 6. Socket head screw (17 each) 16. Plug – fill 26. Dowel pin 7. Gear box cover 17. Bearing (2 each) 27. Socket head screw 8. Gasket 18. Retaining ring 28. Gear 23 T 9.
Servicing the Rear Wheel Gear Box (continued) 7. Remove the rear traction motor if necessary; refer to Rear Traction Motor (Optional) (page 5–133). 8. Inspect and replace all of the gear box components as necessary. Ensure all bearings are pressed fully against their respective shoulders. 9. Assemble the gear box in reverse order. Use a new axle shaft seal and housing gasket. Tighten the gear box cover fasteners in a crossing pattern to 15 N·m (11 ft-lb).
Traction Pedal Assembly g283959 Figure 131 1. Flange nut (2 each) 10. Flange head screw (2 each) 19. Flange head screw (2 each) 2. Washer (4 each) 11. Motion control bracket 20. Pedal shaft 3. Connecting link 12. Screw (2 each) 21. Flange nut (2 each) 4. Bearing spacer (4 each) 13. Sensor shield 22. Traction pedal 5. Bearing (2 each) 14. Traction position sensor 23. Flange head screw 6. Roll pin 15. Retaining ring 24. Extension spring 7. Pedal – forward 16.
Brake Assembly The eTriFlex machines use a single mechanical brake assembly that can be used as a service brake, a manual parking brake, and an automatic parking brake. The service brake and manual parking brake are controlled by a cable connected to pedals at the operator’s left foot, while the automatic parking brake is controlled by a 12 VDC electric brake actuator. The brake system engages 2 brake calipers (located between each front traction motor and front traction gear box).
Replacing the Brake Cable (continued) 4. Loosen the 2 adjuster jam nuts at the brake adjuster and remove the cable from the adjuster bracket. 5. Disconnect the brake cable from the left side brake arm. 6. Install the new cable in the reverse order. 7. Adjust the brake cable; refer to Adjusting the Brake Cable (page 6–6). Removing and Installing the Brake Linkage g283329 Figure 133 1. Hex nut (2 each) 11. Cotter pin (5 each) 21. Clevis pin 2. Eye bolt 12. Clevis – actuator 22.
Removing and Installing the Brake Linkage (continued) 1. Park the machine on a level surface, set the key switch to the OFF position and remove the key. 2. Loosen the hex nuts and adjust the eye bolt as far as possible to relax the extension spring. Remove the spring. 3. Use the 3/8 inch square drive hole in the right side upper brake arm (item 8) to fully retract the brake actuator. 4. Disconnect the actuator clevis (item 12) from the link and brake shaft assembly. Discard the cotter pin. 5.
Removing and Installing the Brake Pedals g283330 Figure 134 1. Cap screw (3 each) 15. Adjuster jam nut (2 each) 2. Clevis pin 16. Manual parking brake switch 3. Brake pawl 17. Cotter pin (2 each) 4. Pedal support 18. Rod – pawl 5. Cap screw (2 each) 19. Flange nut 6. Flange nut (3 each) 20. Nylon bushing (2 each) 7. Retaining ring 21. Torsion spring 8. Cap screw 22. Cap screw 9. Pivot 23. Brake pedal 10. Brake cable 24. Washer (2 each) 11. Retaining ring 25.
Removing and Installing the Brake Pedals (continued) 2. Disconnect the brake cable from the brake pedal and pedal support (remove 2 retaining rings). Note: Record the location of any cable ties securing the wire harness to the machine, and replace them during assembly. 3. Disconnect the manual parking brake switch from the machine wire harness. Check the switch and the harness connector for damage or corrosion and clean or repair as necessary. 4.
Servicing the Brake Caliper g282974 Figure 135 1. Support link 6. Brake lever and shaft 11. Brake rotor 2. Washer (2 each) 7. Clevis pin 12. Brake caliper 3. Cap screw (2 each) 8. Shoulder bolt 13. Brake pad (2 each) 4. Return spring 9. Clevis 14. Brake block 5. Cotter pin 10. Lip seal 1. Remove the front traction gear box; refer to Removing the Front Traction Gear Box (page 6–11). 2. Loosen the hex nuts and adjust the eye bolt as far as possible to relax the extension spring.
Servicing the Brake Caliper (continued) • The minimum brake rotor thickness is 4.6 mm (0.180 inch). 11. Inspect the lever shaft seal (item 10) and replace it if necessary. Apply a coating of grease to the seal lip. 12. Assemble and install the brake caliper and rotor into the motor housing as an assembly. 13. Install the brake lever and shaft, then secure the assembly in position with the shoulder bolt. 14. Fit the brake linkage clevis over the brake lever.
Rear Wheel Caster Fork g282282 Figure 136 1. Cap screw (2 each) 12. Upper steering housing 2. Steering position sensor and bracket 13. Sector gear 3. Magnetic carrier bolt 14. Gasket 4. Jam nut 15. Dowel pin (2 each) 5. Castle nut 16. Lower steering housing 6. Tang washer 17. Lip seal 7. 8. Washer Bearing cone (2 each) 18. 19. Caster fork Flange head screw 9. Bearing cup (2 each) 20. Rear wheel spindle 10. Plug 21. Hex hut (4 each) 11.
Removing the Rear Wheel Caster Fork Refer to Figure 136 for this procedure. 1. Park the machine on a level surface, set the key switch to the OFF position and remove the key. 2. Remove the rear wheel; refer to Removing and Installing the Wheels (page 6–9). 3. Remove the 4 fasteners securing the rear wheel spindle or the rear wheel gear box to the castor fork; refer to Removing and Installing the Rear Wheel Gear Box (page 6–19) for 3WD machines. 4.
Installing the Rear Wheel Caster Fork (continued) 9. Install the upper bearing cone, washer, a new tang washer, and the castle nut on the caster shaft. 10. Remove the caster support and while rotating the caster fork by hand, torque the castle nut to 8.5 to 20.3 N∙m (75 to 180 in-lb) to seat the bearings. Support the caster fork and loosen the nut until it is away from the washer and the caster shaft has end-play.
Steering Housing g282340 Figure 137 1. Steering motor 12. Sector gear 2. Flange head screw (13 each) 13. Gasket 3. Cap screw 14. Dowel pin (2 each) 4. Washer 15. Lower steering housing 5. Bracket – harness 16. Lip seal 6. Upper steering housing 17. Lock nut 7. Flange head screw (8 each) 18. Engine mount 8. 9. Gasket Plug 19. 20. Washer Cap screw 10. Pinion gear 21. Flange head screw (2 each) 11.
Removing and Installing the Steering Gear Box (continued) 3. Remove the lock nut, cap screw (item 20) and washer from the center of the rear engine frame mount. 4. Support the rear of the engine frame and remove the upper steering housing from the machine frame. 5. Remove additional items from the upper steering housing as needed. 6. Install the upper steering housing in reverse order. Tighten the fasteners securing the upper steering housing to the machine frame from 102 to 115 N·m (75 to 85 ft-lb). 7.
Steering Arm Assembly g284711 Figure 138 1. Flange nut 12. Hex nut 23. Gas cylinder 2. Spacer 13. Screw 24. Jam nut 3. Cap screw 14. Cap 25. Retaining ring 4. Flat washer 15. Washer 26. Bushing 5. Speed nut (6 each) 16. Steering wheel 27. Retaining ring 6. Steering mount 17. Set screw (2 each) 28. Flange head screw (3 each) 7. Steering arm 18. Flange head screw (4 each) 29. Platform support – RH 8. Flange head screw (2 each) 19. Steering input device 30.
Removing the Steering Arm (continued) 1. Park the machine on a level surface, set the key switch to the OFF position and remove the key. 2. Remove the cover (item 21) and disconnect the steering input device from the machine wire harness. Check the steering input device and the harness connector for damage or corrosion and clean or repair as necessary. Note: The steering wheel, steering input device, and steering mount may be removed from the steering arm as an assembly if desired.
Installing the Steering Arm (continued) CAUTION The gas cylinder is under high pressure at all times. Avoid pressing the gas cylinder release pin while either end of the cylinder is not secured to the machine. Do not open the gas cylinder. 3. Install the gas cylinder: A. If previously removed, fully thread the end of the gas cylinder into the pivot lever. B. Install the pivot lever and gas cylinder as an assembly then install the retaining ring (item 27). C.
Control Console g283981 Figure 139 Key switch 17. Panel nut 10. Jam nut 18. Arm rest Lock nut (2 each) 11. Button head screw (10 each) 19. Console Jam nut (2 each) 12. Collar 20. Flange nut (2 each) 5. Joystick stem 13. InfoCenter display 21. Flange nut (2 each) 6. Flange head screw (4 each) 14. Boot 22. Flange head screw (2 each) 7. Speed nut (2 each) 15. Knob 8. Choke control 16. Function control switch 1. Console cover 2. Joystick assembly 3. 4. 9.
Removing and Installing the Control Console (continued) Check the InfoCenter, switches, and the harness connectors for damage or corrosion and clean or repair as necessary. 4. Record the location of any cable ties and disconnect the choke control cable at the engine. Remove the choke control knob before removing the choke control. 5. Remove the 2 fasteners securing the console to the support and remove the console. 6. Install the console and console components in reverse order.
Platform Assembly g283802 Figure 140 1. Platform – RH 7. Flange head screw (3 each) 13. Thrust washer 2. Spacer 8. Flange head screw (3 each) 14. Flange bushing (2 each) 3. Pedal stop screw 4. Flange head screw (3 each) Platform – LH 15. Washer 10. Cap screw 16. Cap screw 5. 6. Rubber bumper (2 each) 11. Flange nut (4 each) Platform support – RH 12. Platform support – LH 9. 1. Align the platforms with each other before tightening the fasteners. 2.
Operator’s Seat g308438 Figure 141 A standard seat (model 04508) and a premium seat (model 04729) is available for the Greensmaster 3360/3370 machines. Refer to the specific seat Installation Instructions and Parts Catalog available at www.Toro.com for additional information.
Frame Assembly g308072 Figure 142 1. Side casting – RH 5. Step 2. Jack bracket 6. Step bracket 3. Bushing (2 each) 7. Side casting – LH 4. Cap screw (8 each) 8. Bushing (2 each) If the side castings were removed from the machine, tighten the cap screws (Item 4) from 102 to 115 N·m (75 to 85 ft-lb).
Hood Assembly g281771 Figure 143 1. Hood 2. Screen (2 each) 9. 10. Shoulder screw (2 each) Hood bracket (2 each) 3. Panel fastener (8 each) 11. Shoulder bolt (2 each) 4. Foam strip 12. Lock nut (2 each) 5. Flange nut (6 each) 13. Hinge bracket (2 each) 6. Lock nut (2 each) 14. Flange head screw (4 each) 7. Hinge bracket 15. Flange head screw (4 each) 8. Flange head screw (6 each) 16.
Removing and Installing the Hood Assembly (continued) C. Open the hood and align the brackets with the markings made during removal, or, adjust the hood brackets as needed to allow the hood to rest squarely along the top and sides of the fuel tank. D. Tighten the bracket fasteners.
Cutting Unit Suspension Assembly g281457 Figure 144 1. Suspension assembly (3 each) 7. Motor cable bulkhead (3 each) 13. Flange head screw (6 each) 2. Flange screw (3 each suspension) 8. Spring retainer – left (3 each) 14. Spring retainer – right (3 each) 3. Cotter pin (3 each) 9. Stabilizer spring – left (3 each) 15. Stabilizer spring – right (3 each) 4. Washer (3 each) 10. Spacer (6 each) 16. Socket head screw (6 each) 5. Lift/Lower actuator 11. Cap screw (6 each) 17.
Removing the Cutting Unit Suspension Assembly (continued) 4. If a front suspension assembly will be removed from the machine, remove the front wheel; refer to Wheels and Tires (page 6–9). 5. Loosen the bulkhead nut that secures the cutting unit motor cable to the bracket on the suspension assembly, and separate the cable from the bracket. 6. Remove the fasteners securing the lift/lower actuator to the cutting unit suspension. 7. Support the cutting unit motor away from the suspension assembly.
Servicing the Cutting Unit Suspension Assembly g281479 Figure 145 1. Pivot mount Ball joint clamp (6 each) 17. Steering head 10. Flange head screw (8 each) 18. Grommet Ball joint (6 each) 11. Upper A−arm 19. Counterbalance bracket 4. Retaining ring (6 each) 12. Lift plate 20. Counterbalance spring (3 each) 5. Striker plate 13. Flange head screw (2 each) 21. Cotter pin 22. Clevis pin 2. 3. 9. Lower A−arm 6. Pop rivet (2 each) 14. Cap screw (4 each) 7. Steering stop 15.
Servicing the Cutting Unit Suspension Assembly (continued) CAUTION Be careful when disassembling the counterbalance mechanism. The counterbalance springs are under heavy load and may cause personal injury. 4. Remove tension from the counterbalance mechanism: A. Use 3/8 inch drive breaker bar in the square hole of the counterbalance tensioner to hold tensioner in place. B.
Servicing the Cutting Unit Suspension Assembly (continued) g286889 Figure 146 1. 2. Lower A arm Counterbalance bracket 3. 4. Counterbalance tensioner Clevis pin 7. Install the cutting unit; refer to the traction unit Operators Manual. 8. Install the grass basket. Installing the Cutting Unit Suspension Assembly Refer to Figure 144 for this procedure. 1. Ensure all suspension components are correctly assembled. 2.
Installing the Cutting Unit Suspension Assembly (continued) g281602 Figure 147 1. Stabilizer spring 2. Spring bracket 3. Rear of pivot mount Note: To reduce the chance of turf damage when the cutting unit is lowered, properly adjusted stabilizer springs should square the cutting unit with the machine as the cutting unit is raised. Adjust the stabilizer springs if necessary. 5. Move the cutting unit motor to its storage location at the front of the suspension assembly. 6.
Cutting Unit Suspension Crossarm Assembly g281280 Figure 148 1. Crossarm 6. RH crossarm mount 11. Socket head screw (8 each) 2. Flange bushing (8 each) 7. Pivot pin (2 each) 12. Basket horn (2 each) 3. Link (4 each) 8. Lever (2 each) 13. Flange head screw (4 each) 4. Lock nut (4 each) 9. Spring (2 each) 14. Suspension steering head 5. LH crossarm mount 10. Pivot pin (2 each) Three (3) identical cutting unit suspension assemblies are used on Greensmaster eTriFlex machines.
Chassis: Service and Repairs Page 6–52 Greensmaster® eTriFlex 3360 and 3370 19239SL Rev C
Chapter 7 DPA Cutting Units Table of Contents General Information .............................................................................................................................. 7–2 Cutting Unit Operator's Manual .......................................................................................................... 7–2 Supporting the Cutting Unit when Servicing ....................................................................................... 7–2 Adjustments .........................
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 cutting units on your machine. Additionally, if optional kits have been installed on the cutting units (e.g. groomer or rear roller brush), the Installation Instructions for the kit includes set-up, operation and maintenance information.
Adjustments DPA Cutting Unit Characteristics CAUTION Never install or work on or near a cutting unit or cutting unit suspension with the engine running. Always set the key switch to the OFF position and remove the key before working on or near a cutting unit. The dual point adjust (DBA) bedknife-to-reel adjustment system incorporated in this cutting unit simplifies the adjustment procedure needed to deliver optimum mowing performance.
Leveling the 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 a limited amount of side plate adjustment is possible to make sure that the rear roller and cutting reel remain parallel. Note: Use a pie tape to measure the reel diameter taper; service limit 0.25 mm (0.01 inch).
Leveling the Rear Roller (continued) g284061 Figure 151 1. Side plate 2. Shoulder bolt (2 each) 3. Rear roller 5. Adjust the position of the side plate so the rear roller contacts the bench plate at both ends, making the rear roller parallel to the reel. Tighten the shoulder bolts from 24 to 27 N∙m (210 to 240 in-lb). 6. Recheck the clearance between the rear roller and the bench plate.
Service and Repairs Bedbar Assembly g285020 Figure 152 1. Bedbar assembly 5. Plastic washer (4 each) 2. Washer (2 each) 6. Bedbar pivot bolt (2 each) 3. Compression spring (2 each) 7. Lock nut (2 each) 4. Lock nut (2 each) 8. Metal washer (2 each) 9. 10. Nylon bushing (2 each) Rubber bushing (2 each) Removing the Bedbar Refer to Figure 152 for this procedure. 1. Remove the cutting unit from the machine and place the cutting unit on a flat work surface. 2.
Removing the Bedbar (continued) 3. Tip the cutting unit to expose the bedknife and support the rear of the cutting unit; refer to Supporting the Cutting Unit when Servicing (page 7–2). 4. Loosen the lock nuts (item 7) on each bedbar pivot bolt. 5. Remove the two bedbar pivot bolts, two metal washers and four plastic washers from the cutting unit side plates. CAUTION Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when handling the bedbar. 6.
Installing the Bedbar (continued) CAUTION Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when handling the bedbar. Note: If a new bedknife is attached to the bedbar, there may be interference between the bedknife and the reel when installing the bedbar. Turn the bedbar adjusting screws counterclockwise to increase bedknife clearance if necessary. 4. Position the bedbar into the cutting unit.
Removing the Bedbar Adjuster g285044 Figure 154 1. 2. Lock nut Compression spring 6. 7. Wave washer Flange bushing (2 each) 3. Washer 8. Bedbar adjuster shaft 4. Bedbar adjuster screw 5. Retaining ring 9. 10. Detent Cap screw 1. Remove bedbar; refer to Removing the Bedbar (page 7–6). 2. Remove the lock nut, compression spring and washer from the bedbar adjuster screw. Note: The bedbar adjuster shaft has left-hand threads. 3. Unscrew the bedbar adjuster shaft from the bedbar adjuster screw.
Installing the Bedbar Adjuster (continued) 5. Install the washer, spring and lock nut onto the adjuster screw. 6. Install the bedbar; refer to Installing the Bedbar (page 7–7).
Bedknife Removing the Bedknife g227001 Figure 155 1. Bedknife screw (13 used) 2. Bedbar 3. Bedknife 1. Remove the bedbar from the cutting unit; refer to Removing the Bedbar (page 7–6). 2. Remove screws from bedbar using a socket wrench and bedknife screw tool; refer to Bedknife Screw Tool (page 2–18). Discard the screws. Remove bedknife from the bedbar. 3. Refer to Grinding the Bedknife (page 7–12) for additional information. Installing the Bedknife 1.
Installing the Bedknife (continued) g226894 Figure 156 6. Working from the center of the bedknife toward each end, tighten screws from 23 to 28 N-m (200 to 250 in-lb). 7. After installing the bedknife to bedbar, grind the bedknife. Grinding the Bedknife Bedknife Grinding Specifications Standard Bedknife Relief Angle 3° minimum Fairway Bedknife Relief Angle 3° minimum Extended Bedknife Relief Angle 7° minimum Front Angle Range 13° to 17° g207289 Figure 157 1. Top angle 4. Front surface 2.
Grinding the Bedknife (continued) IMPORTANT Do Not grind the bedknife below it's service limit. Operating the cutting unit with the bedknife below the service limit may result in poor after-cut appearance and reduce the structural integrity of the bedknife. The bedknife service limit occurs when the reel contacts the back of the bedknife scallop during operation; refer to Figure 158. Check for reel contact marks at the back of the bedknife scallop prior to grinding.
Reel Assembly g285181 Figure 159 1. Crossmember 8. Cap screw (2 each) 15. Crosslink 2. Side plate – LH 9. Side plate – RH 16. Electric motor adapter 3. Flange head screw (2 each) 10. Counterweight 17. Socket head screw (2 each) 4. Shoulder bolt (4 each) 11. Hex nut (4 each) 18. Motor clamp 5. Flange nut (4 each) 12. O-ring (2 each) 19. Cap screw (2 each) 6. Reel assembly 13. Grass shield 20. Counterweight 7. Pitch arm (2 each) 14.
Removing the Reel Assembly (continued) 2. If the cutting unit is equipped with an optional groomer or rear roller brush, remove the drive components for those options from cutting unit. Refer to Removing the Gear Box Assembly (page 8–4), and/or Rear Roller Brush (Optional) (page 7–30) for additional information. 3. Remove the fasteners that secure the counterweights to the left side plate, and remove the counterweights. Remove and discard the O-ring.
Removing the Reel Assembly (continued) B. Insert a long-handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move. IMPORTANT To avoid grinding the reel, do not contact the cutting edge of any blade with the pry bar as this may damage the cutting edge and/or cause a high blade. C.
Inspecting the Reel Assembly g227240 Figure 161 1. Cutting reel 6. Reel nut (black – left hand thread) 2. Flocked seal (2 each) 7. Groove indication left hand threads 3. Bearing (2 each) 8. Left-most reel spider 4. Plug (2 each) 9. Bearing shoulder 5. reel nut (right hand thread) 1. Remove the reel nuts from the cutting reel. Check the splines in the reel nuts for excessive wear or distortion and replace them if necessary.
Inspecting the Reel Assembly (continued) IMPORTANT The seal must be installed with the flocked side of the seal toward the bearing. 4. Slide the new flocked seals and press the bearings onto the reel shaft until they contact the shoulder of the reel shaft. Note: The reel nut on the left end of the cutting reel has a black finish and has left-hand threads. The left end of the cutting reel shaft is identified with a groove cut just inside of the left-most reel spider.
Installing the Reel Assembly (continued) IMPORTANT To avoid grinding the reel, do not contact the cutting edge of any blade with the pry bar as this may damage the cutting edge and/or cause a high blade. g285246 Figure 162 1. Reel nut (right end shown) 3. Weld side of reel support plate 2. Reel shaft 4. Pry bar B. Move the pry bar against the weld side of the reel support plate closest to the reel nut being tightened.
Installing the Reel Assembly (continued) 13. If the cutting unit is equipped with an optional groomer or optional rear roller brush, install the components for those options. Refer to Installing the Gear Box Assembly (page 8–10), and Rear Roller Brush (Optional) (page 7–30) for additional information. Preparing the Reel for Grinding Reel Grinding Specifications Reel Diameter New (D) 128.5 mm (5.06 inch) Reel Diameter Service Limit 114.3 mm (4.50 inch) Reel Diameter Taper Limit (D1 – D2) 0.25 mm (0.
Preparing the Reel for Grinding (continued) Basics (part no. 09168SL) found on the Service Reference Set available from your Authorized Toro Distributor. Relief grind the reel blades to the minimum blade land width if the reel blade land width exceeds the service limit. Spin grind the reel to establish the specified blade land width or to restore the reel’s cylindrical shape. Note: Always adjust the cutting unit after grinding the reel and/or bedknife; refer to the Cutting Unit Operator’s Manual.
Electric Cutting Unit Motor Adapter g285260 Figure 164 1. Hex nut (2 each) 4. Motor clamp 2. Motor adapter 5. O-ring 3. Socket head screw (2 each) 6. O-ring (2 each) Removing and Installing the Cutting Unit Motor Adapter Refer to Figure 164 for this procedure. 1. Remove the electric motor from the cutting unit and move it to the storage location at the front of the cutting unit suspension. 2. Remove the motor adapter from the cutting unit side plate.
Roller Assemblies Removing the Front Roller g285300 Figure 165 1. Front roller assembly 4. Height-of-cut arm (2 each) 2. Height-of-cut screw (2 each) 5. Pinch bolt (2 each) 3. Lock nut (2 each) 6. Plow bolt (2 each) Refer to Figure 165 for this procedure. 1. Remove the cutting unit from the machine and place it on a level work surface. Use an appropriate support to raise the front roller off of the work surface. 2.
Installing the Front Roller (continued) 3. Secure one of the height-of-cut arms to the side plate with a plow bolt, height-of-cut washer and lock nut. The tab on the height-of-cut washer should be oriented downward and fit into the slot of the height-of-cut arm. 4. Slide the front roller shaft into the height-of-cut arm attached to the cutting unit. 5. Slide the remaining height-of-cut arm onto the other end of roller shaft.
Removing the Rear Roller (continued) 2. Loosen the flange nuts that secure the rear roller retainer assemblies (flange nuts, socket head screws, shaft retainer, spacer and shims) to the cutting unit. Note: On cutting units equipped with the optional High Height-of-Cut Kit, there will be additional roller shims installed between the rear roller and the cutting unit side plate. 3. Remove one of the rear roller retainer assemblies. 4. Slide the rear roller assembly from the remaining retainer assembly. 5.
Disassembling the Roller g206889 Figure 167 1. Bearing lock nut 5. Wiehle roller 2. V-ring 6. Smooth roller 3. 4. Seal Ball bearing 7. Roller shaft 1. To hold the roller shaft stationary while removing the bearing lock nut, install a 3/8-24 UNF 2B screw with a jam nut into the threaded end of the roller shaft and tighten the jam nut against the roller shaft. Remove the bearing lock nuts. 2. Carefully inspect the seating surface and threads of the bearing lock nuts and replace them if damaged.
Assembling the Roller g206890 Figure 168 1. Roller 4. V-ring 2. Ball bearing 5. Bearing lock nut 3. Seal 6. Roller shaft Note: Special tools are required to assemble the rollers; refer to Roller Rebuilding Tools (page 2–19). The following procedure describes the assembling the rollers using the set of assembly washers and spacers. 1. Place the roller shaft into the roller.
Assembling the Roller (continued) IMPORTANT Failure to grease bearing lock nut before seal installation may result in seal damage. 5. Fill the seal 75 to 90% full with #2 grease and apply a coating of grease to the underside of the bearing lock nut to prevent damaging the seal damage during installation. Carefully fit a seal onto each bearing lock nut. g206892 Figure 170 1. 2. Seal Bearing lock nut 6. Install a bearing lock nut with seal onto each end of the roller shaft.
Assembling the Roller (continued) g206894 Figure 172 1. Seal 3. Yellow assembly washer 2. Assembly spacer 4. Bearing lock nut 8. Tighten the bearing lock nuts until the yellow assembly washers bottom out against the roller housing. Remove the bearing lock nuts, assembly washers, and assembly spacers. Note: The V-rings should be installed without any lubrication. 9. Carefully fit a dry V-ring onto each bearing lock nut. g227754 Figure 173 1. Bearing lock nut 2. V-ring 10.
Rear Roller Brush (Optional) g285302 Figure 174 (shown with Universal Groomer installed) 1. Rear roller brush assembly Note: The Installation Instructions for the rear roller brush kit has detailed information regarding assembly and adjustment. Use the Installation Instructions along with this Service Manual when servicing the rear roller brush.
g285393 Figure 175 (shown without Universal Groomer installed) 1. Lock nut (2 each) 16. Bearing bracket LH 31. Drive pulley 2. Brush shaft 17. Drive housing 32. Retaining ring 3. J-bolt (2 each) 18. Spacer (as required) 33. Flange nut (4 each) 4. Brush element 19. Driven pulley 34. Flange head screw (4 each) 5. O-ring (2 each) 20. Lock nut 35. Flange head screw 6. Lock nut (2 each) 21. Torsion spring 36. Adapter housing (used without groomer) 7. Cover 22.
CAUTION Contact with the reel or other cutting unit parts can result in personal injury. Use heavy gloves when handling the cutting reel. Replacing the Roller Brush Element Refer to Figure 175 for this procedure. 1. Remove the cutting unit from the machine and place it on a level work surface. 2. Remove the RH bearing bracket assembly. 3. Remove the brush element from the shaft. 4. Slide the new brush element onto the shaft while rotating the brush. 5.
Drive and Support Components (continued) g285506 Figure 176 1. Drive shaft assembly 3. Weld side of reel support plate 2. Reel shaft 4. Pry bar B. Insert a long-handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move.
Drive and Support Components (continued) G. Assemble the drive shaft and drive adapter (machines without a universal groomer) with a medium strength thread locking compound (Loctite 243 or equivalent) and tighten from 150 to 163 N∙m (110 to 120 ft-lb). H. Insert a long-handled pry bar through the front of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move. g285505 Figure 177 1. Drive shaft assembly 3.
Drive and Support Components (continued) IMPORTANT The brush drive belt may fail prematurely if the pulleys are not properly aligned. 10. Using a straight edge, determine the number of spacers necessary under the driven pulley to align the pulleys. Tighten the lock nut securing the driven pulley from 20 to 26 N∙m (15 to 19 ft-lb). g285394 Figure 178 (shown with Universal Groomer installed) 1. Straight edge 11. Install and adjust the drive belt and install the cover.
DPA Cutting Units: Service and Repairs Page 7–36 Greensmaster® eTriFlex 3360 and 3370 19239SL Rev C
Chapter 8 Universal Groomer (Optional) Table of Contents General Information .............................................................................................................................. 8–2 Installation Instructions ...................................................................................................................... 8–2 Service and Repairs .............................................................................................................................
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.
Service and Repairs g285612 Figure 179 1. Gear box assembly 3. Groomer reel 5. Counterweight assembly 2. Idler assembly 4. Height adjuster assembly (2 each) 6. Flat head screw (2 each) CAUTION Never work on the groomer with the key switch in the RUN or START position. Always set the key switch to the OFF position, remove the key from the switch and wait for all machine movement to stop before working on the groomer.
The Gear Box Assembly g285625 Figure 180 1. Gear box assembly 4. Clevis pin 2. Drive shield 5. Input shaft 3. Cotter pin The groomer gear box assembly is located on the opposite side of the cutting unit from the cutting unit motor. The groomer gear boxes for eTriFlex machines are installed on the right side of the cutting unit. Removing the Gear Box Assembly Refer to Figure 180 for this procedure. 1. Remove the cutting unit from the machine and place it on a level work surface. 2.
Removing the Gear Box Assembly (continued) g285819 Figure 181 1. 5/16–18 X 5/8 inch square head set screw 4. Reel shaft 2. Input shaft assembly 5. Weld side of reel support plate 3. Groomer gear box assembly 6. Pry bar 7. Insert a long-handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move.
Removing the Gear Box Assembly (continued) 9. Rest the handle of the pry bar against the front roller and turn the drive shaft counterclockwise to loosen it from the reel. Continue to unscrew the drive shaft and remove the gear box from the cutting unit. 10. If the hex head on the end of the drive shaft is damaged during removal: A. Remove the drain/fill plug and drain the oil from the gear box. g285845 Figure 182 1. Socket head screw (4 each) 8. Sun gear 2. Gear box cover assembly 9.
Removing the Gear Box Assembly (continued) g285909 Figure 183 1. Damaged input shaft assembly 4. Weld side of reel support plate 2. Drive shaft removal tool 5. Pry bar 3. Reel shaft H. Insert a long-handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move.
Servicing the Gear Box g285711 Figure 184 1. Drive adapter – silver 21. Detent ball 2. Input shaft 22. Detent spring 3. O-ring (3 each) 23. Oil seal 4. V-ring 24. Socket-head screw (4 each) 5. 6. Oil seal Groomer housing 25. 26. Groomer cover Cover gasket 7. Ball bearing (2 each) 27. Thrust washer 8. Retaining ring 28. Ball bearing 9. Driven gear 29. Ring gear 10. Actuator shaft 30. Flange bushing 11. Pin 31. Sun gear 12. O-ring 32. Bearing 13. Knob 33.
Servicing the Gear Box (continued) 1. Remove the drain/fill plug and drain the oil from the gear box. 2. Remove the 4 socket-head screws and separate the gear box cover and housing. Remove and discard the cover gasket. 3. Slide the sun gear, ring gear, and planet gears from the pins on the gear box housing. 4. Continue to disassemble the gear box as necessary. 5.
Installing the Gear Box Assembly Refer to Figure 180 for this procedure. 1. Apply medium strength thread locking compound (Loctite 243 or equivalent) to the threads in the reel and allow the thread locking compound to cure for 15 minutes before continuing this procedure. 2. Insert a long-handled pry bar through the front of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move. g285822 Figure 185 1.
Installing the Gear Box Assembly (continued) 8. Apply a retaining compound (Loctite 609 or equivalent) to the lip of the drive housing and install the drive shield, or, if the cutting unit is equipped with an optional powered rear roller brush, install the rear roller brush drive assembly; refer to Rear Roller Brush (Optional) (page 7–30). 9. Install the groomer reel assembly; refer to Installing the Groomer Reel (page 8–16).
The Idler Assembly g285713 Figure 186 1. Socket-head screw (2 each) 2. 9. Stub shaft 10. 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. Remove the cutting unit from the machine and place it on a level work surface. 2.
Installing the Idler Assembly (continued) 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. Use the through hole in the shaft to prevent the shaft from rotating and tighten the flange nut from 37 to 45 N∙m (27 to 33 ft-lb). E.
The Groomer Reel g285715 Figure 187 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, set the key switch to the OFF position and remove the key from the key switch.
Servicing the Groomer Reel (continued) blades to put the sharpest blade edge forward. The blades that are rounded to the midpoint of the blade tip must be reversed or replaced for best groomer performance. g285716 Figure 188 1. Groomer reel shaft 5. Rounded edge 2. Groomer blade (40 each) 6. Midpoint 3. Spacer (39 each) 7. Centered on shaft 4. Locknut (2 each) 1.
Servicing the Groomer Reel (continued) tightening the lock nut, spacers should not be free to rotate and the groomer blades should be centered on the shaft. 7. Install the groomer reel back onto the cutting unit; refer to Installing the Groomer Reel (page 8–16). Installing the Groomer Reel 1. Position the cutting unit on a level surface. If the cutting unit is attached to the traction unit, lower the cutting unit, set the key switch to the OFF position and remove the key from the key switch. 2.
The Height Adjuster Assembly g285728 Figure 189 1. Clevis pin 8. Flange nut 15. Quick up cover 2. Cotter pin 9. Washer (2 each) 16. Detent spring 3. Tabbed washer 10. Compression spring 17. Button-head screw 4. Lock nut 11. Pinch bolt 18. Height adjuster knob 5. Bumper 12. Height-of-cut bracket 19. Height adjustment bolt 6. Plow bolt 13. Quick up lever 7. Height adjustment rod 14.
Assembling the Height Adjuster (continued) 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. Tighten the lock nut finger tight. 3. Position front roller between the height adjuster assemblies and secure the remaining height adjuster assembly to the cutting unit side plate with a plow bolt, tabbed washer and lock nut. Tighten the lock nut finger tight. 4.
The Grooming Brush (Optional) g285731 Figure 191 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 8–14). The grooming brush element or shaft can be serviced separately.
Universal Groomer (Optional): Service and Repairs Page 8–20 Greensmaster® eTriFlex 3360 and 3370 19239SL Rev C
Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations.........................................................................................................A–2 Electrical Schematic – 3360...............................................................................................................A–3 Electrical Schematic – 3370...............................................................................................................A–4 Electrical Schematic – 3370 (continued) .
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.
Electrical Schematic – 3360 g291901 Model 04580, Drawing 122-0142 Rev C, Sheet 1 of 1 19239SL Rev C Page A–3
Electrical Schematic – 3370 g309035 Page A–4 19239SL Rev C Model 04590, Drawing 122-1618 Rev B, Sheet 1 of 2
Electrical Schematic – 3370 (continued) g309036 Model 04590, Drawing 122-1618 Rev B, Sheet 2 of 2 19239SL Rev C Page A–5
Wire Harness Drawing – 3360 g287361 Page A–6 19239SL Rev C Model 04580, Drawing 122-1619 Rev D, Sheet 1 of 1
Wire Harness Diagram – 3360 g293957 Model 04580, Drawing 122-1619 Rev D, Sheet 1 of 2 19239SL Rev C Page A–7
Wire Harness Diagram – 3360 (continued) g293958 Page A–8 19239SL Rev C Model 04580, Drawing 122-1619 Rev D, Sheet 2 of 2
Wire Harness Drawing – 3370 g309034 Model 04580, Drawing 122-1620 Rev D, Sheet 1 of 1 19239SL Rev C Page A–9
Wire Harness Diagram – 3370 g309032 Page A–10 19239SL Rev C Model 04590, Drawing 122-1620 Rev D, Sheet 1 of 2
Wire Harness Diagram – 3370 (continued) g309033 Model 04590, Drawing 122-1620 Rev D, Sheet 2 of 2 19239SL Rev C Page A–11
