Toro 04510 Greensmaster 3300 TriFlex Service Manual Download Page 3

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Greensmaster 3300/3400

Table Of Contents

Chapter 1 -- Safety

General Safety Instructions

1 -- 2

. . . . . . . . . . . . . . . . . .

Jacking Instructions

1 -- 5

. . . . . . . . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals

1 -- 6

. . . . . . . . . . . . . . . .

Chapter 2 -- Product Records and Maintenance

Product Records

2 -- 1

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance

2 -- 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equivalents and Conversions

2 -- 2

. . . . . . . . . . . . . . . .

Torque Specifications

2 -- 3

. . . . . . . . . . . . . . . . . . . . . . .

Chapter 3 -- Gasoline Engine

Specifications

3 -- 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information

3 -- 3

. . . . . . . . . . . . . . . . . . . . . . . .

Fuel Evaporative Control System

3 -- 4

. . . . . . . . . . . . .

Adjustments

3 -- 7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs

3 -- 8

. . . . . . . . . . . . . . . . . . . . . . . .

BRIGGS & STRATTON REPAIR MANUAL FOR

4-CYCLE

V-TWIN

CYLINDER

OHV

HEAD

ENGINES

Chapter 4 -- Diesel Engine

Specifications

4 -- 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information

4 -- 3

. . . . . . . . . . . . . . . . . . . . . . . .

Adjustments

4 -- 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs

4 -- 6

. . . . . . . . . . . . . . . . . . . . . . . .

KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,

02--E3B SERIES

Chapter 5 -- Hydraulic System

Specifications

5 -- 3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information

5 -- 4

. . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Schematic

5 -- 10

. . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Flow Diagrams

5 -- 12

. . . . . . . . . . . . . . . . . . .

Special Tools

5 -- 22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

5 -- 26

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing

5 -- 32

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments

5 -- 54

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs

5 -- 56

. . . . . . . . . . . . . . . . . . . . . . .

EATON, MEDIUM DUTY PISTON PUMP, REPAIR

INFORMATION,

MODEL

70160

VARIABLE

DISPLACEMENT PISTON PUMP

PARKER TORQMOTOR

SERVICE PROCEDURE

(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)

SAUER/DANFOSS STEERING UNIT TYPE OSPM

SERVICE MANUAL

Chapter 6 -- Electrical System

General Information

6 -- 3

. . . . . . . . . . . . . . . . . . . . . . . .

Turf Guardian Leak Detector

System Operation

6 -- 4

. . . . . . . . . . . . . . . . . . . . . . . .

Special Tools

6 -- 6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

6 -- 8

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical System Quick Checks

6 -- 23

. . . . . . . . . . . . .

Adjustments

6 -- 24

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Testing

6 -- 26

. . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs

6 -- 54

. . . . . . . . . . . . . . . . . . . . . . .

Chapter 7 -- Chassis

Specifications

7 -- 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information

7 -- 3

. . . . . . . . . . . . . . . . . . . . . . . .

Special Tools

7 -- 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments

7 -- 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs

7 -- 6

. . . . . . . . . . . . . . . . . . . . . . . .

Chapter 8 -- DPA Cutting Units

Specifications

8 -- 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information

8 -- 3

. . . . . . . . . . . . . . . . . . . . . . . .

Special Tools

8 -- 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Factors That Can Affect Cutting Performance

8 -- 6

. .

Set Up and Adjustments

8 -- 10

. . . . . . . . . . . . . . . . . . . .

Service and Repairs

8 -- 12

. . . . . . . . . . . . . . . . . . . . . . .

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Summary of Contents for 04510 Greensmaster 3300 TriFlex

Page 1: ...ual Additional copies of the Operator s Manuals and Parts Catalog are available on the internet at www Toro com The Toro Company reserves the right to change product specifications or this publication without notice This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions ma...

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Page 3: ...ecial Tools 5 22 Troubleshooting 5 26 Testing 5 32 Adjustments 5 54 Service and Repairs 5 56 EATON MEDIUM DUTY PISTON PUMP REPAIR INFORMATION MODEL 70160 VARIABLE DISPLACEMENT PISTON PUMP PARKER TORQMOTORTM SERVICE PROCEDURE TC TB TE TJ TF TG TH AND TL SERIES SAUER DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Chapter 6 Electrical System General Information 6 3 Turf Guardian Leak Detector System ...

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Page 5: ...Chapter 9 Groomer Specifications 9 2 General Information 9 3 Troubleshooting 9 4 Adjustments 9 6 Service and Repairs 9 7 Chapter 10 Foldout Drawings Hydraulic Schematic 10 3 Electrical Schematics 10 4 Wire Harness Drawings 10 8 Groomer Foldout Drawings ...

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Page 7: ...3300 3400 Page 1 1 Safety Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS 2 Before Operating 2 While Operating 3 Maintenance and Service 4 JACKING INSTRUCTIONS 5 SAFETY AND INSTRUCTION DECALS 6 Safety ...

Page 8: ...he contents of the Opera tor s Manuals and Operator s DVD before starting and operating the vehicle Become familiar with the controls and know how to stop the vehicle and engine quickly Additional copies ofthe Operator s Manual are available on the internet at www Toro com 2 Keep all shields safety devices and decals in place If a shield safety device or decal is defective illegible or damaged rep...

Page 9: ...run engine in a confined area without ade quate ventilation Exhaust fumes are hazardous and could possibly be deadly 4 Do not touch engine exhaust system components or radiator if equipped while engine is running or soon af ter it is stopped These areas could be hot enough to cause burns 5 Before getting off the seat A Make sure cutting units are disengaged B Verify that functional control lever i...

Page 10: ...ts Keep bystanders away 11 Do not overspeed the engine by changing governor setting To assure safety and accuracy check maximum engine speed 12 Shut engine off before checking or adding oil to the engine crankcase 13 Disconnect battery before servicing the machine Disconnect negative battery cable first and positive cable last If battery voltage is required for troubleshoot ing or test procedures ...

Page 11: ...oving 2 Position jack securely under the frame jacking point A The left side jacking point is the frame channel under the step behind the LH front wheel Fig 1 B The right side jacking point is the frame bracket behind the RH front wheel Fig 2 3 Jack front of machine off the ground 4 Position appropriate jack stands under the frame as close to the wheel as possible to support the machine Rear End J...

Page 12: ... decals are affixed to the traction unit and the cutting units of Greensmaster TriFlex 3300 and 3400 machines If any decal becomes illegible or damaged install a new decal Part numbers are listed in your Parts Catalog and Operator s Manual Order replacement decals from your Authorized Toro Distributor ...

Page 13: ...nd Cutting Unit Oper ator s Manuals and Parts Catalog for your Greensmas ter at the end of this chapter Additionally if any optional equipment or accessories have been installed to your machine insert the Installation Instructions Operator s Manuals and Parts Catalogs for those options at the end of this chapter Maintenance Maintenance procedures and recommended service in tervals for your Greensm...

Page 14: ...0 09375 Greensmaster 3300 3400 Page 2 2 Product Records and Maintenance Equivalents and Conversions ...

Page 15: ... nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Fastener Identification Figure 1 Grade 1 Grade 5 Grade 8 Inch Series Bolts and Screws Figure 2 Class 8 8 Class 10 9 Metric Bolts and Screws Using a Torque Wrench with an Offset Wrench Use of an offset wrench e g crowfoot wrench will affect torque wrench calibration...

Page 16: ... 16 2 22 3 30 3 41 4 43 4 58 5 3 8 24 UNF 17 2 18 2 24 3 35 3 47 4 50 4 68 5 7 16 14 UNC 27 3 27 3 37 4 50 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 5 75 7 77 7 104 9 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 10 142 14 1 2 20 UNF 32 3 53 7 72 9 85 8 115 11 120 10 163 14 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 20 285 27 5 8 18 UNF 75 10 95 15 129 20 170 15 230 20 240 20 325 27 3 4 10 U...

Page 17: ... lb 90 10 N m 92 9 ft lb 125 12 N m M16 X 2 0 166 15 ft lb 225 20 N m 229 22 ft lb 310 30 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 37 ft lb 610 50 N m NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite NOTE Torque values may have to be reduced ...

Page 18: ...in lb Wheel Bolts and Lug Nuts Thread Size Recommended Torque 7 16 20 UNF Grade 5 65 10 ft lb 88 14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5 Class 8 8 80 10 ft lb 108 14 N m For steel wheels and non lubricated fasteners Thread Cutting Screws Zinc Plated Steel Thread Size Threads per Inch Baseline Torque Size Type A Type B Baseline Torque N...

Page 19: ...CONTROL SYSTEM 4 ADJUSTMENTS 7 Choke Cable Adjustment 7 Throttle Cable Adjustment 7 SERVICE AND REPAIRS 8 Fuel Evaporative Control System Serial Number Below 312000000 8 Fuel Evaporative Control System Serial Number Above 312000000 10 Fuel Tank 12 Engine 14 Engine Removal 14 Engine Installation 16 BRIGGS STRATTON VANGUARD V TWIN OHV REPAIR MANUAL Gasoline Engine ...

Page 20: ...p Pulsating Crankcase Vacuum Fuel Unleaded regular grade gasoline Fuel Tank Capacity 6 0 U S gallons 22 7 liters Low Idle no load 1650 100 RPM High Idle no load 2920 50 RPM Lubrication System Pressure Lubrication Gear Driven Geroter Oil Pump Engine Oil See Operator s Manual Crankcase Oil Capacity 1 75 U S quarts 1 65 liters with new filter Ignition System Flywheel magneto twin electronic armatures...

Page 21: ...plained However the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility Service and repair parts for Briggs Stratton Vanguard V Twin OHV engines are supplied through your local lo cal Toro distributor If no parts list is available be sure to provide your distributor with the Toro model and serial number along with the...

Page 22: ...l System Figure 1 FRESH AIR FILTER CARBON CANNISTER FUEL TANK ENGINE CHECK VALVE CHECK VALVE CHECK VALVE FRESH AIR FILTER CARBON CANNISTER FUEL TANK ENGINE TO INTAKE MANIFOLD TO INTAKE MANIFOLD TO AIR CLEANER SERIAL NUMBER BELOW 312000000 SERIAL NUMBER ABOVE 312000000 ...

Page 23: ... 312000000 Figure 1 illustrates the components used in the evaporative control system Machines With Serial Number Below 312000000 On machines with serial number below 312000000 the carbon canister is mounted under the fuel tank mount plate One fitting at the engine intake manifold is used to connect the evaporative system to the engine These machines use an inline check valve between the carbon ca...

Page 24: ...Greensmaster 3300 Page 3 6 Gasoline Engine This page is intentionally blank ...

Page 25: ...ent move choke control several times to make sure that choke operation is correct 6 Assemble air cleaner Throttle Cable Adjustment 1 Park machine on a level surface disengage and low er cutting units move functional control lever to neutral N engage parking brake stop the engine and remove the key from the ignition switch Wait for all machine movement to stop 2 Adjust throttle control on console t...

Page 26: ...to engine intake manifold 4 Grommet 2 used 5 Fuel hose cannister to tank vent 6 Hose clamp 3 used 7 Carbon canister 8 Bracket 9 Flange nut 2 used 10 Fuel hose cannister to check valve 11 Fuel hose 12 Fresh air filter 13 R clamp 14 Washer head screw 15 Check valve 16 Cap screw 17 R clamp 18 Spacer screw attached to engine 19 Worm clamp 4 used 10 1 2 5 7 8 9 19 11 12 6 13 14 15 3 17 19 4 19 19 6 16 ...

Page 27: ...ulic reservoir fuel tank and tank mount plate to reach the cannister see Tank Mount Plate Assembly in the Service and Re pairs section of Chapter 7 Chassis 3 Inspect carbon cannister and attached for damage or obvious leaks A damaged or leaking cannister should be replaced 4 Remove components as needed using Figure 3 as a guide A If check valve item 15 is removed note direction of arrow on valve b...

Page 28: ...itting 34 Engine hose to air cleaner 35 Engine hose to intake manifold 29 28 33 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 1 3 6 14 14 20 25 18 14 14 18 29 29 29 30 31 32 34 35 The function of the fuel evaporative control system is to collect and store evaporative emissions from the fuel tank and engine On machines with serialnumberabove 312000000 a carbon canister mounte...

Page 29: ... or leakingcannis ter should be replaced 4 Remove components as needed using Figure 5 as a guide A If either purge hose assembly item 27 or tee hoseassembly item28 isto beremoved labelends of hose for assembly purposes Both of these as semblies include a check valve so direction of instal lation is important for correct operation of the evaporative control system The check valve is not available a...

Page 30: ...pply hose 14 Hose clamp 3 used 15 R clamp 16 Fuel filter 17 Fuel hose 18 Clamp 19 Washer head screw 20 Check valve 21 Fuel hose 22 Fuel tank 23 Fuel tank cap 24 Clip 2 used 25 Flat washer 2 used 26 Flange head screw 2 used 27 Fitting LH thread 28 O ring 29 Shut off valve 30 Nut LH thread 31 Fuel vent valve 32 Grommet 33 Flange bushing 4 used 34 Washer 4 used 35 Cap screw 4 used 5 1 2 3 5 7 8 9 10 ...

Page 31: ...e fuel shut off valve 3 Remove fuel hose item 5 from fuel vent valve item 31 4 Remove four 4 cap screws item 35 flat washers item 34 and flange bushings item 33 that secure the fuel tank to the tank mount plate item 2 Remove the fuel tank from the machine 5 If necessary remove fuel supply hose item 13 from fuel shut off valve 6 If necessary remove shut off valve and fitting as sembly from fuel tan...

Page 32: ...Lubricant 25 to 38 ft lb 34 to 51 N m 20 to 25 in lb 2 3 to 2 8 N m 170 to 200 in lb 19 3 to 22 6 N m Engine Removal Fig 9 1 Park machine on a level surface disengage and low er cutting units move functional control lever to neutral N engage parking brake stop the engine and remove the key from the ignition switch Wait for all machine movement to stop CAUTION The engine and exhaust system may be h...

Page 33: ...at rear muffler mount screw 8 Loosen the two 2 square head screws item 21 that secure the engine hub item20 to the engine crank shaft 9 Support the engine assembly to prevent it from shift ing or falling 10 Remove four 4 cap screws item 13 that secure engine assembly to pump mount item 12 IMPORTANT Make sure to not damage the engine fuel lines hydraulic hoses electrical harness con trol cables or ...

Page 34: ... to 38 ft lb 34 to 51 N m 6 Make sure that rubber coupling item 22 is not dis torted Secure engine hub to engine crankshaft with two 2 square head screws item 21 Torque screws from 90 to 110 in lb 10 2 to 12 4 N m 7 Secure wire harness ground connector to engine as sembly with cap screw item 5 flat washer item 26 lock washer item 25 and flange nut item 6 Fig 11 Make sure that lock washer is positi...

Page 35: ...ERAL INFORMATION 3 Operator s Manual 3 ADJUSTMENTS 5 Adjust Throttle Control 5 SERVICE AND REPAIRS 6 Air Cleaner Assembly 6 Exhaust System 8 Fuel Tank 10 Radiator 12 Engine 14 Engine Removal 14 Engine Installation 16 Engine Bell Housing 18 KUBOTA WORKSHOP MANUAL DIESEL ENGINE SM E3B SERIES Diesel Engine ...

Page 36: ...p to B20 Fuel with Low or Ultra Low Sulfur Content Fuel Injector Pump Bosch MD Type Mini Fuel Injection Nozzle Bosch Throttle Type Fuel Capacity 6 0 U S gallons 22 7 liters Governor Centrifugal Mechanical Low Idle no load 1500 150 100 RPM High Idle no load 2880 50 RPM Engine Oil API CH 4 CI 4 or higher Engine Oil Viscosity See Operator s Manual Oil Pump Gear Driven Trochoid Type Crankcase Oil Capa...

Page 37: ... specialized test equipment is explained However the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility Service and repair parts for Kubota engines are sup plied through your local local Toro distributor If no parts list is available be sure to provide your distributor with the Toro model and serial number Operator s...

Page 38: ...Greensmaster 3400 Page 4 4 Diesel Engine This page is intentionally blank ...

Page 39: ...ever on fuel injection pump Fig 1 The speed control lever should be contacting the high speed screw when the throttle control lever is in the FAST position 3 If necessary throttle control can be adjusted by loos ening cable jam nuts and repositioning control cable un til speed control lever contacts high speed screw when the throttle control lever is in the FAST position Fig 2 Tighten cable jam nu...

Page 40: ...vice and Repairs Air Cleaner Assembly Figure 3 1 Air inlet hood 2 Flat washer 2 used 3 Cap screw 2 used 4 Mounting bracket 5 Air cleaner assembly 6 Hose clamp 2 used 7 Flange nut 2 used 8 Air intake hose 9 R clamp FRONT RIGHT 1 4 5 3 2 7 6 8 9 6 ...

Page 41: ...Installation Fig 3 IMPORTANT Any leaks in the air cleaner system will allow dirt into engine and will cause serious en gine damage Make sure that all air cleaner compo nents are in good condition and are properly secured during assembly 1 Assemble air cleaner system using Figures 3 and 4 as guides A If plug was removed from air cleaner housing ap ply sealant to threads of plug before assembly B Ma...

Page 42: ...4 Exhaust pipe 5 Flange head screw 6 Flange nut 4 used 7 Lock washer 3 used 8 Exhaust plate 9 Exhaust gasket 10 Flange nut 11 Flange nut 12 Brace 13 Flat washer 8 used 14 Cap screw 4 used 15 Brace 16 Spring 4 used 17 Muffler shield 18 Flange head screw FRONT RIGHT 18 16 16 10 17 1 2 3 6 8 9 11 13 5 7 12 14 15 4 3 6 13 13 ...

Page 43: ...on Fig 5 1 Make sure the engine is off IMPORTANT If exhaust studs were removed from engine cylinder head thoroughly clean threads in head and apply Loctite 277 or equivalent to stud threads before installing studs into head NOTE Make sure exhaust plate and engine exhaust manifold sealing surfaces are free of debris or damage that may prevent a tight seal 2 If exhaust gasket item 9 was removed plac...

Page 44: ...e 16 Hose clamp 17 Fuel supply hose 17 1 2 12 13 14 7 6 8 9 4 16 5 15 11 11 10 30 to 50 in lb 3 4 to 5 6 N m Antiseize Lubricant 3 3 Fuel Tank Removal Fig 6 1 Park machine on a level surface disengage and low er cutting units move functional control lever to neutral N engage parking brake stop the engine and remove the key from the ignition switch Wait for all machine movement to stop CAUTION The ...

Page 45: ...rom elbow fitting on front of tank 7 Remove the fuel tank from the machine 8 If necessary remove fuel supply hose from shut off valve 9 If necessary remove shut off valve and fitting as sembly from fuel tank Fig 7 The nut and fitting have left hand threads Fuel Tank Installation Fig 6 1 Install fitting assembly and shut off valve into fuel tank if they were removed from tank Fig 7 The nut and fitt...

Page 46: ... Receptacle 2 used 12 Cap screw 4 used 13 Flat washer 4 used 14 R clamp 15 Screen 16 Flange head screw 12 used 17 Lock nut 4 used 18 Flange head screw 4 used 19 Front shroud 20 Flange nut 12 used 21 Lower radiator hose 22 Upper radiator hose 23 Breather hose to thermostat 24 Overflow hose to overflow tank 25 Fuel pump assembly 15 2 1 16 3 17 4 18 20 20 16 16 16 16 20 20 6 8 9 10 11 13 7 12 14 19 5...

Page 47: ...both r clamps item 7 on front shroud item 19 9 Remove flange head screw and flange nut that se cure fuel pump assembly to front shroud Position fuel pump assembly away from radiator assembly 10 Disconnect fan wire connector from machine wire harness 11 Support radiator assembly to prevent it from falling 12 Remove four 4 flange nuts that secure front shroud to machine Remove radiator assembly from...

Page 48: ...tor assembly 20 V belt 21 Fuel water separator 22 Cap screw 2 used 23 Engine support 24 Cap screw 4 used 25 Lock washer 4 used 26 Lock washer ground connection 27 Rear engine mount 28 R clamp air intake hose 19 20 21 22 22 23 24 26 25 27 28 18 Engine Removal Fig 9 1 Park machine on a level surface disengage and low er cutting units move functional control lever to neutral N engage parking brake st...

Page 49: ...OTE Before disconnecting wire harness connectors label all electrical leads for assembly purposes A Negative battery cable and wire harness ground from lower engine mount fastener Fig 11 B Fuel stop solenoid Fig 12 C Glow plug bus Fig 12 D Temperature sender Fig 12 E Alternator connector and stud Fig 13 F Starter motor solenoid and fusible link harness Fig 13 G Oil pressure switch near oil filter ...

Page 50: ...allow the pump coupling to slide out of the engine coupling flange Fig 16 Once the engine has cleared the pump coupling carefully re move the engine from the machine 14 If necessary remove engine support item 23 from engine Engine Installation Fig 9 1 Make sure that all removed engine components are correctly installed to the engine 2 If engine support item 23 was removed from en gine secure suppo...

Page 51: ...le see Adjust Throttle Control in the Adjustments section of this chap ter 10 Installexhaustsystemtomachine seeExhaustSys tem Installation in this section 11 Install radiator to machine see Radiator Installation in this section 12 Install air cleaner to machine see Air Cleaner Instal lation in this section Make sure that all hose clamps are properly tightened 13 Insert fuel supply hose and fuel re...

Page 52: ... of Chapter 4 Hydraulic System 2 As necessary remove bell housing and coupling flange from engine using Figure 17 as a guide Installation Fig 17 1 If coupling flange was removed from engine fly wheel position flange to flywheel and align mounting holes Secure flange to flywheel with five 5 flange head screws Tighten screws in a star pattern 2 If bell housing was removed from engine make sure that ...

Page 53: ...4 Adjust Traction Control Assembly 55 SERVICE AND REPAIRS 56 General Precautions for Removing and Installing Hydraulic System Components 56 Flush Hydraulic System 57 Filtering Closed Loop Traction Circuit 58 Hydraulic System Start up 59 Gear Pump 60 Gear Pump Service 62 Piston Traction Pump Neutral System 64 Piston Traction Pump 66 Piston Traction Pump Service 70 Piston Pump Crush Ring Replacement...

Page 54: ...Greensmaster 3300 3400 Hydraulic System Page 5 2 This page is intentionally blank ...

Page 55: ...rotor motor Parker TF Series Displacement per revolution 10 3 in3 169 cc Rear Wheel Motor Optional 3WD Kit Orbital rotor motor Parker TG Series Displacement per revolution 20 6 in3 337 cc Mow Circuit Relief Pressure 2700 to 3300 PSI 186 to 227 bar Cutting Reel Motor Gear motor Casappa Maximum Pump Displacement per revolution 0 73 in3 12 cc Power Steering Valve Hydrostatic Steering Unit Sauer Danfo...

Page 56: ...hydraulic oil recommendations 1 Hydraulic reservoir 2 Fuel tank Figure 1 2 1 Pushing Traction Unit In case of emergency your Greensmaster can be pushed for a very short distance However Toro does not recommend this as a standard procedure 1 Make sure that engine is not running 2 Locate by pass valve on piston traction pump Fig 2 Rotate by pass valve so slot is vertical IMPORTANT Do not push the ma...

Page 57: ...ion can damage other components in the circuit so it must be removed to prevent additional component fail ure The recommended method of removing traction circuit contamination would be to temporarily install the Toro high flow hydraulic filter see Special Tools in this chap ter into the circuit This filter should be used when con necting hydraulic test gauges in order to test traction circuit comp...

Page 58: ...on the hose Use two wrenches hold the hose straight with one wrench and tighten the hose swivel nut onto the fit ting with the other wrench see Hydraulic Hose and Tube Installation in this section If the hose has an el bow at one end tighten the swivel nut on that end before tightening the nut on the straight end of the hose For additional hydraulic hose information refer to Toro Service Training ...

Page 59: ...the Torque Specifica tions section of Chapter 2 Product Records and Main tenance 5 If a torque wrench is not available or if space at the swivel nut prevents use of a torque wrench an alternate method of assembly is the Flats From Wrench Resist ance F F W R method Fig 2 A Using a wrench tighten the swivel nut onto the fit ting until light wrench resistance is reached approxi mately 30 in lb B Mark...

Page 60: ...ords and Maintenance to determine necessary con version information 5 If a torque wrench is not available or if space at the port prevents use of a torque wrench an alternate meth od of assembly is the Flats From Finger Tight F F F T method A Install the fitting into the port and tighten it down full length until finger tight B If port material is steel tighten the fitting to the listed F F F T If...

Page 61: ...ith a wrench and use a torque wrench to tighten the fitting to the rec ommended installation torque shown in Figure 7 This tightening process will require the use of an offset wrench e g crowfoot wrench Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offset wrench will be lowe...

Page 62: ...EL 3 CENTER REEL 1 G1 G1 G2 BREATHER A B OR1 037 B A LEAK DETECTOR VOLUME EXPANSION TANK LEAK DETECTOR KIT OUT IN TOP PORT BOTTOM PORT BACK PORT C1 S4 S1 FORWARD JOINT END STEERING CYLINDER 1160 VALVE PSI POWER STEERING HYDROSTAT 4 5 BYPASS VALVE 1 9 GPM 70 to MOW 6 7 GPM AT 3 8 MPH TRANSPORT 17 5 GPM AT 10 MPH PSI OPTIONAL 3WD FRONT PORT 10 3 20 6 3000 PSI PUMP 25 PSI 028 FRONT PORT 73 73 FRONT P...

Page 63: ...Greensmaster 3300 3400 Hydraulic System Page 5 11 This page is intentionally blank Hydraulic System ...

Page 64: ...3 58 1 44 110 150 PSI L R OR2 OR3 028 LEFT FRONT REEL 2 RIGHT FRONT REEL 3 CENTER REEL 1 G1 G1 G2 BREATHER A B OR1 037 B A LEAK DETECTOR VOLUME EXPANSION TANK LEAK DETECTOR KIT OUT IN TOP PORT BOTTOM PORT BACK PORT C1 S4 S1 FORWARD JOINT END STEERING CYLINDER 1160 VALVE PSI POWER STEERING HYDROSTAT 4 5 BYPASS VALVE 1 9 GPM 70 to MOW 6 7 GPM AT 3 8 MPH TRANSPORT 17 5 GPM AT 10 MPH PSI OPTIONAL 3WD ...

Page 65: ...raction pedal so complete pump swash rotation is possible Forward The piston traction pump is driven directly by the en gine The hydraulic traction circuit acts essentially as a closed loop Taking its suction directly from the return side of the wheel motors of the traction circuit the piston pump supplies oil flow to the wheel motors through the supply side of the traction circuit With the engine...

Page 66: ... LEAK DETECTOR VOLUME EXPANSION TANK LEAK DETECTOR KIT OUT IN S4 S1 JOINT END STEERING CYLINDER 1160 VALVE PSI POWER STEERING 4 5 25 PSI 028 FRONT PORT 73 73 FRONT PORT M1 M2 MV PORV OR1 OR2 FC LC G P T PRV LIFT CONTROL MANIFOLD MOW CONTROL MANIFOLD RIGHT FRONT 3 LEFT FRONT 2 Extend to Lower Extend to Raise CENTER 1 Extend to Lower ENGINE GEAR C 3000 PSI 4 0 GPM 7 0 GPM 10 3 RIGHT A B A B 33 58 1 ...

Page 67: ...Cutting Units When the joystick is moved to the lower position the Toro Electronic Controller TEC energizes all of the lift control manifold solenoid valves for approximately three 3 seconds This time frame ensures that the cutting units will be fully lowered to allow them to float during op eration The controller also provides a short delay in en ergizing solenoid valve S4 which delays the loweri...

Page 68: ...E EXPANSION TANK LEAK DETECTOR KIT OUT IN S4 S1 JOINT END STEERING CYLINDER 1160 VALVE PSI POWER STEERING 4 5 25 PSI 028 FRONT PORT 73 73 FRONT PORT M1 M2 MV PORV OR1 OR2 FC LC G P T PRV LIFT CONTROL MANIFOLD MOW CONTROL MANIFOLD RIGHT FRONT 3 LEFT FRONT 2 Extend to Lower Extend to Raise CENTER 1 Extend to Lower ENGINE GEAR C 3000 PSI 4 0 GPM 7 0 GPM 10 3 RIGHT A B A B 33 58 1 44 110 150 PSI G1 G2...

Page 69: ...ection is directed through the pow er steering valve de energized solenoid valve S1 in the lift control manifold oil filter and to the traction charge circuit Flow in excess of charge circuit needs then re turns to the gear pump input Raise Cutting Units When the joystick is moved tothe raiseposition theToro Electronic Controller TEC energizes lift control man ifold solenoid valves S1 S3 and S4 fo...

Page 70: ...28 LEFT FRONT REEL 2 RIGHT FRONT REEL 3 CENTER REEL 1 G1 G1 G2 BREATHER A B OR1 037 B A LEAK DETECTOR VOLUME EXPANSION TANK LEAK DETECTOR KIT OUT IN TOP PORT BOTTOM PORT BACK PORT C1 S4 S1 FORWARD JOINT END STEERING CYLINDER 1160 VALVE PSI POWER STEERING HYDROSTAT 4 5 BYPASS VALVE 1 9 GPM 70 to MOW 6 7 GPM AT 3 8 MPH TRANSPORT 17 5 GPM AT 10 MPH PSI OPTIONAL 3WD FRONT PORT 10 3 20 6 3000 PSI PUMP ...

Page 71: ...lso functions as the mow circuit relief valve Oil flow from manifold port P flows through the flow con trol valve FC used to adjust reel speed Flow across the flow control valve is pressure compensated by the logic cartridge valve LC The logic cartridge valve maintains a pressure differential of 75 PSI 5 2 bar across the speed control valve Any excess flow above the speed control valve setting is ...

Page 72: ...R2 OR3 028 LEFT FRONT REEL 2 RIGHT FRONT REEL 3 CENTER REEL 1 G1 G1 G2 BREATHER A B OR1 037 B A LEAK DETECTOR VOLUME EXPANSION TANK LEAK DETECTOR KIT OUT IN TOP PORT BOTTOM PORT BACK PORT C1 S4 S1 FORWARD JOINT END STEERING CYLINDER 1160 VALVE PSI POWER STEERING HYDROSTAT 4 5 BYPASS VALVE 1 9 GPM 70 to MOW 6 7 GPM AT 3 8 MPH TRANSPORT 17 5 GPM AT 10 MPH PSI OPTIONAL 3WD FRONT PORT 10 3 20 6 3000 P...

Page 73: ... is proportional to the amount of the turning on the steering wheel Fluid leaving the cylinder flows back through the spool valve out steering valve port T and then to the traction charge circuit The power steering valve returns to the neutral position when turning is complete Left Turn When a left turn is made with the engine running the turning of the steering wheel positions the power steer ing...

Page 74: ...Number TOR47009 Figure 11 Hydraulic Tester Pressure and Flow This tester requires O ring Face Seal ORFS adapter fittings for use on this machine see Hydraulic Test Fit ting Kit TOR4079 in this section 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 ...

Page 75: ...low in the operating circuit with a gauge rated from 4 to 40 GPM 20 to 150 LPM Toro Part Number AT40002 NOTE This tester does not include hydraulic hoses see Hydraulic Hose Kit TOR6007 below Figure 13 Hydraulic Hose Kit This kit includes hydraulic fittings and hoses needed to connect 40 GPM hydraulic tester AT40002 or high flow hydraulic filter kit TOR6011 to machine hydraulic trac tion system com...

Page 76: ...cing a failed traction circuit component e g piston traction pump or wheel motor the high flow hy draulic filter can be installed in the traction circuit The filter will ensure that contaminates are removed from the closed loop and thus do not cause additional compo nent damage Toro Part Number TOR6011 NOTE This kit does not include hydraulic hoses see Hydraulic Hose Kit TOR6007 above NOTE Replace...

Page 77: ...e effi ciency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system Toro Part Number TOR4077 Figure 18 Wheel Hub Puller The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors Toro Part Number TOR4097 Figure 19 Hydraulic System ...

Page 78: ...oams Oil level in reservoir is low Hydraulic system has wrong type of oil The pump suction line has an air leak Hydraulic system operates hot Oil level in reservoir is low or inlet filter is loose or clogged Oil is contaminated or too light Parking brake is applied or incorrectly adjusted Piston pump by pass valve is open or defective Working load of machine may require use of oil cooler Oil coole...

Page 79: ...pter No traction exists in either direction Parking brake is applied or incorrectly adjusted Oil level in reservoir is low other hydraulic systems also affected Piston pump by pass valve is open Charge pressure is low Relief valve s in piston traction pump are leaking or damaged Wheel motor s are worn or damaged see Wheel Motor Efficiency Test in the Testing section of this chapter Piston pump is ...

Page 80: ... mow control manifold is not shifting Logic cartridge valve LC in mow control manifold is stuck open Front gear pump section for mow circuit is damaged see Mow Cir cuit Gear Pump Flow Test in the Testing section of this chapter Reel speed is erratic A cutting unit problem exists see Cutting Unit chapter Mow control manifold cartridge valve is leaking or damaged Mow control manifold orifice is plug...

Page 81: ... of this chapter Rear gear pump section is worn or damaged steering and charge circuits affected as well see Steering Lift Circuit Gear Pump Flow Test in the Testing section of this chapter Front cutting units 2 and 3 raise but will not stay up NOTE Lift cylinders and control manifold check valves cannot pro vide an absolutely perfect seal The cutting units will eventually lower if left in the rai...

Page 82: ...acklash results when turning steer ing wheel Cardan shaft fork in power steering valve is worn or broken Leaf springs in power steering valve are worn or broken Splines on the steering column are worn Rear wheel shimmies when the steering wheel is turned Air is in the steering cylinder Mechanical connections to the wheel or wheel bearing are worn The steering wheel can be turned without the rear w...

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Page 84: ...onents Always keep in mind the need for cleanliness when working on hy draulic equipment Contamination will cause excessive wear of components 2 To prevent hydraulic system contamination put met al caps or plugs on any hydraulic lines left open or ex posed during testing or removal of components 3 The engine must be in good operating condition En gine speed will affect test accuracy Check pump spe...

Page 85: ...ely that traction pressure will reach relief valve settings If however a piston pump relief valve is leak ing or otherwise faulty traction performance would be affected 4 For problems with the steering and lift lower circuit consider performing one or more of the following tests A Steering Lift Relief Valve Pressure B Lower Cutting Units Relief Valve RV Pressure C Steering Lift Circuit Gear Pump F...

Page 86: ... operatingthe machinefor approximatelyten 10 minutes 2 Park machine on a level surface with the cutting units lowered Make sure engine is off and the parking brake is engaged Make sure the hydraulic tank is full CAUTION Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section 3 Thoroughly clean junction o...

Page 87: ...on system load D The charge pressure should drop no more than 20 from no load charge pressure measured in step 8 above e g if charge pressure in step 8 is 125 PSI 8 6 bar charge pressure in forward or reverse under load should be more than 100 PSI 6 9 bar E If charge pressure is good under no load but drops below specification when under traction load the piston traction pump and or wheel motors s...

Page 88: ...M PORT BACK PORT C1 HYDROSTAT BYPASS VALVE 1 9 GPM 70 to MOW 6 7 GPM AT 3 8 MPH TRANSPORT 17 5 GPM AT 10 MPH PSI OPTIONAL 3WD FRONT PORT 10 3 20 6 3000 PSI PUMP 100 MOTOR LEFT MOTOR HYDRAULIC RESERVOIR FROM POWER STEERING AND LIFT CONTROL VALVES FROM STEERING VALVE TO POWER CONTROL VALVE TO MOW TESTER UPPER PUMP PISTON FITTING UPPER PUMP PISTON FITTING FRONT FRONT PUMP FROM GREENSMASTER 3300 PUMP ...

Page 89: ...ic hose kit see Special Tools in this chapter to connecttester to machine Make sure thatfit ting and hose connections are properly tightened Also make sure the flow control valve on tester is fully open 7 After installing tester start engine and run at low idle speed Check for hydraulic leakage and correct before proceeding with test 8 Move functional lever to the transport position CAUTION Wheels...

Page 90: ...ITTING FRONT FRONT WHEEL MOTOR EFFICIENCY TEST FOR RIGHT FRONT WHEEL MOTOR SHOWN NOTE Over a period of time a wheel motor can wear internally A worn motor may by pass oil to its case drain causing the motor to be less efficient Eventually enough oil loss will cause the wheel motor to stall under heavy load conditions Continued operation with a worn inefficient motor can generate excessive heat cau...

Page 91: ...ma chine 12 Move throttle so engine is running at high idle speed 13 Slowly push traction pedal in forward direction until 1000 PSI 69 bar is displayed on the tester pressure gauge Make sure that wheel motor being tested is not rotating 14 Wheel motor internal leakage will be shown on flow meter in GPM Flow should be less than 1 5 GPM for the tested wheel motor 15 Release traction pedal to the neu...

Page 92: ...B OR1 037 B A TOP PORT BOTTOM PORT BACK PORT C1 S4 FORWARD JOINT END STEERING CYLINDER 1160 VALVE PSI POWER STEERING HYDROSTAT 4 5 BYPASS VALVE 1 9 GPM 70 to MOW 6 7 GPM AT 3 8 MPH TRANSPORT 17 5 GPM AT 10 MPH PSI OPTIONAL 3WD FRONT PORT 10 3 20 6 3000 PSI PUMP 25 PSI 028 RIGHT FRONT 3 LEFT FRONT 2 Extend to Lower Extend to Raise CENTER 1 Extend to Lower LIFT CONTROL MANIFOLD 100 MOTOR LEFT MOTOR ...

Page 93: ...ow idle speed Check for hy draulic leakage and correct before proceeding with test 8 Move throttle so engine is running at high idle speed CAUTION While measuring steering lift relief valve pres sure do not allow circuit pressure to exceed 1400 PSI 82 8 bar 9 Watch the pressure gauge and move the joystick to the raise position Momentarily hold the joystick with the cutting units fully raised causi...

Page 94: ...G2 A B OR1 037 B A TOP PORT BOTTOM PORT BACK PORT C1 S4 FORWARD JOINT END STEERING CYLINDER 1160 VALVE PSI POWER STEERING HYDROSTAT 4 5 BYPASS VALVE 1 9 GPM 70 to MOW 6 7 GPM AT 3 8 MPH TRANSPORT 17 5 GPM AT 10 MPH PSI OPTIONAL 3WD FRONT PORT 10 3 20 6 3000 PSI PUMP 25 PSI 028 RIGHT FRONT 3 LEFT FRONT 2 Extend to Lower Extend to Raise CENTER 1 Extend to Lower LIFT CONTROL MANIFOLD 100 MOTOR LEFT M...

Page 95: ...eding with test 7 Move throttle so engine is running at high idle speed NOTE The lower cutting units function is electrically timed and automatically turns off after approximately three 3 seconds 8 Watch pressure gauge carefully while moving the joystick to LOWER and note pressure that relief valve opens Release joystick shut off engine and record test results NOTE While performing this hydraulic ...

Page 96: ...R OR2 OR3 028 G1 G1 G2 A B OR1 037 B A TOP PORT BOTTOM PORT BACK PORT C1 S4 FORWARD JOINT END STEERING CYLINDER 1160 VALVE PSI POWER STEERING HYDROSTAT 4 5 BYPASS VALVE 1 9 GPM 70 to MOW 6 7 GPM AT 3 8 MPH TRANSPORT 17 5 GPM AT 10 MPH PSI OPTIONAL 3WD FRONT PORT 10 3 20 6 3000 PSI PUMP 25 PSI 028 RIGHT FRONT 3 LEFT FRONT 2 Extend to Lower Extend to Raise CENTER 1 Extend to Lower LIFT CONTROL MANIF...

Page 97: ...the disconnected hose Also make sure flow control valve on the tester is fully open 5 Make sure that traction pedal and joystick are in neu tral and the parking brake is engaged 6 Start engine and run at low idle speed Check for hy draulic leakage and correct before proceeding with test 7 Move throttle so engine is running at high idle speed IMPORTANT Do not fully restrict oil flow through tester ...

Page 98: ...3300 3400 Hydraulic System Page 5 46 Power Steering Valve Test P T E BALL JOINT L R END PORT 1160 VALVE PSI POWER STEERING 4 5 STEERING CYLINDER PLUG CYLINDER ROD FULLY EXTENDED ROTATED FOR LEFT TURN STEERING WHEEL ...

Page 99: ...steering wheel must be able to turn with no more than 45 in lb 5 1 N m of torque 6 If either of these performance tests indicate a steer ing problem determine if the steering cylinder is faulty using the following procedure A Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged B Turn the steering wheel all the way to the l...

Page 100: ...ure Gauge SUCTION STRAINER OPTIONAL OIL SW COOLER 73 FRONT PORT GEAR 33 58 LEFT FRONT REEL 2 RIGHT FRONT REEL 3 CENTER REEL 1 BREATHER LEAK DETECTOR VOLUME EXPANSION TANK LEAK DETECTOR KIT OUT IN S1 PUMP FRONT PORT 73 73 FRONT PORT M1 M2 MV PORV OR1 OR2 FC LC G P T PRV MOW CONTROL MANIFOLD TESTER VALVE TO POWER STEERING ...

Page 101: ...sition and reel speed knob FC is set to highest speed setting fully open CAUTION Do not engage the cutting units when performing this test 6 After hydraulic tester has been connected start en gine and run at low idle speed Check for hydraulic leak age and correct before proceeding with test 7 Move throttle so engine is running at high idle speed IMPORTANT Do not fully restrict oil flow through tes...

Page 102: ... TO LEFT REEL MOTOR SUCTION STRAINER OPTIONAL OIL SW COOLER 73 FRONT PORT GEAR 33 58 LEFT FRONT REEL 2 RIGHT FRONT REEL 3 CENTER REEL 1 BREATHER LEAK DETECTOR VOLUME EXPANSION TANK LEAK DETECTOR KIT OUT IN S1 PUMP FRONT PORT 73 73 FRONT PORT M1 M2 MV PORV OR1 OR2 FC LC G P T PRV MOW CONTROL MANIFOLD TESTER VALVE TO POWER STEERING ...

Page 103: ...Make sure backlap lever on the mow control man ifold is in the mow position and reel speed knob FC is set to highest speed setting fully open CAUTION Keep away from reels during test to prevent per sonal injury from the rotating reel blades 7 After hydraulic tester has been connected start en gine and run at low idle speed Check for hydraulic leak age and correct before proceeding with test 8 Move...

Page 104: ...RT LEFT FRONT REEL 2 RIGHT FRONT REEL 3 CENTER REEL 1 FRONT PORT 73 73 FRONT PORT TESTER FROM MOW PORT M1 TO MOW PORT M2 MEASURING CONTAINER MANIFOLD MANIFOLD CAP 1 Left motor case drain hose 2 Left motor return hose 3 Right motor case drain hose 4 Right motor return hose 5 Center motor return hose 6 Center motor case drain hose 6 5 3 4 2 1 ...

Page 105: ...n end of disconnected hose into a drain pan 7 One person should sit on the seat and operate the machine while another person reads the tester and measures case drain leakage Make sure functional control lever is in NEUTRAL Start engine and move the throttle to full speed CAUTION Keep away from reels during test to prevent per sonal injury from the rotating reel blades 8 Engage reels by positioning...

Page 106: ...al injury may result Always install and tighten the cap be fore pressurizing the system 1 Locate relief valve on control manifold 2 Remove cap on relief valve with an allen wrench 3 To increase pressure setting turn the adjustment socket on the valve in a clockwise direction A 1 8 turn on the socket will make a measurable change in relief pressure 4 To decrease pressure setting turn the adjustment...

Page 107: ... traction pedal locked in place the pedal should be at a right angle 90o to platform Fig 34 If neces sary adjust location of ball joint on neutral lock cable to allow correct angle of pedal In the neutral position there should be no tension on the traction cable If cable is adjusted too tight machine could creep when in the neutral position Adjust jam nuts on traction cable to reduce tension on ca...

Page 108: ...nstallation after repairs are completed 5 Note the position of hydraulic fittings especially el bow fittings on hydraulic components before removal Mark parts if necessary to make sure they will be aligned properly when reinstalling hydraulic hoses and tubes After Repair or Replacement of Components 1 Check oil level in the hydraulic reservoir and add cor rect oil if necessary Drain and refill hyd...

Page 109: ...draulic fluids including biodegrad able fluid specified in the Traction Unit Operator s Manual Other fluids could cause system damage 6 Connect all hydraulic hoses and lines that were dis connected prior to system draining see Hydraulic Hose and Tube Installation in the General Information section of this chapter 7 Fill hydraulic reservoir with new hydraulic oil 8 Disconnect appropriate electrical...

Page 110: ...eding CAUTION All wheels will be off the ground and rotating dur ing this procedure Make sure machine is well supported so it will not move and accidentally fall to prevent injuring anyone around machine IMPORTANT While engaging the traction circuit monitor the indicator on the high flow hydraulic fil ter If the indicator should show red either reduce pressure on the traction pedal or reduce engin...

Page 111: ...fuel stop solenoid 7 Turn ignition key switch and engage starter for ten 10 seconds to prime pumps Return ignition switch to off and wait one 1 minute to allow starter to cool Re peat step a second time 8 Reconnect engine electrical component s that were disabled in step 6 above 9 With the functional control lever in the neutral N position start engine and run at low idle speed The charge pump sho...

Page 112: ...Precautions for Removing and Installing Hydraulic System Components in this section 1 Park machine on a level surface engage the parking brake lower the cutting units and stop the engine Re move key from the ignition switch 2 Thoroughly clean hydraulic hose ends and fittings on gear pump to prevent hydraulic system contamination 3 Label all hose connections on gear pump for as sembly purposes 4 Cl...

Page 113: ...cessive pressure in the piston pump and damage seals IMPORTANT Position gear pump to the piston traction pump so that the gear pump inlet suction port is facing up 3 Position gear pump to the piston traction pump so that the pump inlet is facing up 4 Secure gear pump to the piston pump with two 2 socket head screws and flat washers Torque screws from 27 to 31 ft lb 37 to 42 N m 5 Lubricate and pla...

Page 114: ...nd seal replacement only Individual gears hous ings and thrust plates are not available separately If internal components are worn or damaged the gear pump must be replaced as a complete assembly IMPORTANT Keep gears and thrust plates for each pump section together do not mix parts between pump sections 1 Plug pump ports and thoroughly clean exterior of pump with cleaning solvent Make sure work ar...

Page 115: ...stalled in the same position during assembly Keep the parts for each pump section together do not mix parts between sections 8 Clean all parts Check all components for burrs scoring nicks and other damage 9 Replace the entire pump assembly if any pump com ponents are excessively worn or scored Gear Pump Assembly Fig 40 1 Apply clean hydraulic oil to all parts before assem bling NOTE Pressure and b...

Page 116: ... end ball joint 21 Cap screw 22 Washer 23 Flange nut 24 Flange nut 25 Cap screw 26 Traction control cable 27 Cap screw 2 used diesel 28 Muffler bracket diesel 29 Piston traction pump 30 Key Figure 42 200 to 250 in lb 23 to 28 N m Antiseize Lubricant 5 16 3 6 22 17 23 2 1 18 10 14 11 7 19 15 12 21 9 27 25 20 4 8 26 17 17 13 28 27 24 29 Antiseize Lubricant FRONT RIGHT PUMP ASSEMBLY FROM GREENSMASTER...

Page 117: ...emoved frompump apply Loctite 242 or equivalent to threads of screws that secure support to pump B If plate item 2 was removed from pump trunnion shaft make sure that both trunnion shaft and plate bore are thoroughly cleaned before installing plate to shaft Secure plate to trunnion shaft with flat washer item 3 and cap screw item 4 Torque cap screw from 200 to 250 in lb 23 to 28 N m C If damper le...

Page 118: ... screw 2 used 24 Flat washer 2 used 25 O ring 26 Traction control cable 27 90o hydraulic fitting 2 used 28 O ring 29 Hydraulic hose traction forward 30 Hydraulic hose traction reverse 21 20 26 22 23 27 28 24 25 29 17 14 13 15 18 19 27 30 FRONT RIGHT PUMP ASSEMBLY FROM GREENSMASTER 3300 SHOWN 27 to 31 ft lb 37 to 42 N m NOTE The piston traction and gear pump assembly can be removed from the machine...

Page 119: ...ION Support the gear and piston pump assembly when removing its supporting fasteners to pre vent it from falling and causing damage or per sonal injury 9 Support pump assembly to prevent it from falling 10 Remove two 2 cap screws item 23 and flat wash ers item 24 that secure pump assembly to pump mount Separate pump assembly from the pump mount and remove pump from machine 11 If necessary remove p...

Page 120: ... aged or worn fittings or connectors 6 Lubricate and place new O rings onto all removed hydraulic fittings Install fittings into pump openings making sure that fitting orientation is as noted during re moval Tighten fittings see Hydraulic Fitting Installation in the General Information section of this chapter 7 Position pump assembly to pump mount and secure with two 2 cap screws item 23 and flat ...

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Page 122: ...it 12 Gasket 13 Valve plate 14 Bearing 15 Dowel pin 16 Back plate 17 O ring 18 Forward relief valve 19 Bypass valve 20 O ring 21 Cap screw 2 used 22 Cap screw 2 used 23 Coupler 24 Roll pin 25 Cover plate 26 Swash plate insert 27 Shaft seal 28 Washer 3 used per plate 29 Housing 30 Retaining ring 31 Bearing race 32 Thrust bearing 33 Washer 34 Shaft seal 35 Retaining ring 36 Retaining ring 37 Plug 38...

Page 123: ...ely that traction pressure will reach relief valve settings If however a pump relief valve is leaking or otherwise faulty tractionperformance would be affected IMPORTANT The shim kit item 7 is used to replace the original crush ring not shown in the cover plate item 25 If the camplate item 10 cover plate item 25 or housing item 29 is replaced during servic ing the old crush ring must be replaced S...

Page 124: ...he cover plate in the same location that the crush ring was removed from 4 Assemble housing sub assembly consisting of the housing camplate bearing cone bearing cup and cov er plate see Eaton Medium Duty Piston Pump Repair Information Model70160Variable DisplacementPiston Pump at the end of this chapter 5 Install washers and cap screws to the cover plate and housing Torque cap screws to 29 ft lbs ...

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Page 126: ...e Re move key from the ignition switch CAUTION Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components in this section 2 Loosen but do not remove lug nuts item 9 and lock nut item 7 Loosen lock nut at least two 2 turns 3 Chock front and rear of wheels not being lifted to pre vent the machine from moving Lift front wheel o...

Page 127: ...from wheel motor ports Lubricate and place new O rings onto fittings Install fittings into motor openings making sure that fitting orientation is as noted during removal Tighten fittings see Hydraulic Fit ting Installation in the General Information section of this chapter 3 Remove caps from disconnected hydraulic lines 4 Lubricate and position new O rings to fittings on wheel motor Use labels pla...

Page 128: ...lic fitting 2 used 10 Hydraulic tube 11 Hydraulic tube 12 Tube clamp 2 used 13 Cover plate 14 Cap screw 15 Hydraulic hose 16 Hydraulic hose 17 Hose guide 18 Rear fork 19 O ring 20 Cap screw 2 used 21 O ring 22 Wheel stud 4 used 23 Woodruff key Figure 53 FRONT RIGHT 75 ft lb 101 N m 21 4 13 1 10 11 3 17 2 6 14 20 9 12 8 5 7 15 16 18 19 19 19 22 75 ft lb 101 N m 250 to 400 ft lb 339 to 540 N m 65 to...

Page 129: ...tor and motor plate item 2 from machine 12 If fitting removal from wheel motor is necessary mark fitting orientation to allow correct assembly Re move hydraulic fittings and O rings from motor Discard removed O rings Rear Wheel Motor Optional 3WD Installation Fig 53 1 If fittings were removed from rear wheel motor lubri cate and place new O rings onto motor fittings Install fittings into motor ope...

Page 130: ...the stator The right wheel motor s has a reverse timed manifold NOTE If machine is equipped with optional 3WD kit the rear wheelmotor has the same basic construction as the front wheel motors IMPORTANT DO NOT interchange wheel motors on machine i e do not put RH motor on left side of ma chine If necessary use parts catalogand part num ber on wheel motor to identify RH and LH motors NOTE For wheel ...

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Page 132: ... for Removing and Installing Hydraulic System Components in this section 2 Thoroughly clean hydraulic hose ends and fittings on reel motor to prevent hydraulic system contamination 3 Label hydraulic hoses for assembly purposes 4 Disconnect hydraulic hoses from fittings on the reel motor Allow hoses to drain into a suitable container Cap or plug hoses and motor fittings to prevent contami nation 5 ...

Page 133: ... motor shaft with clean grease B Align reel motor shaft splines with splines in cut ting reel Slide reel motor into cutting unit side plate Fig 57 C Pull motor clamp toward the motor until clamp ful ly engages slots on both sides of the motor mount Fig 58 There should be an audible click as clamp engages mount 4 Remove caps and plugs from disconnected hydrau lic hoses and motor fittings 5 Using la...

Page 134: ...2 14 15 16 17 18 19 4 Disassembly Fig 59 1 Plug motor ports and clean the outside of the motor thoroughly After cleaning remove plugs and drain any oil out of the motor 2 Use a marker to make a diagonal line across the front cover and body for assembly purposes Fig 60 IMPORTANT Prevent damage when clamping the motor into a vise clamp on the front flange only Also use a vise with soft jaws 3 Clamp ...

Page 135: ... up washer and shaft seal from the front cover Fig 61 Dis card removed seals Inspection 1 Remove any nicks and burrs from all parts with emery cloth CAUTION Use eye protection such as goggles when using compressed air 2 Clean all parts with solvent Dry all parts with com pressed air 3 Inspect drive gears and idler gears for the following Fig 62 A Gear shafts should be free of rough surfaces and ex...

Page 136: ...he pressure seal side down and the open side of the pressure seal pointing to the inlet side of the mo tor Carefully install shaft into front cover 7 Lubricate the idler gear shaft with clean hydraulic oil Install idler gear shaft into the remaining position in the front thrust plate Apply a light coating of clean hydraulic oil to gear faces 8 Installrearthrustplate withpressure sealside upand ope...

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Page 138: ...Hydraulic hose 7 Flange head screw 2 used Figure 63 FRONT RIGHT 2 3 6 1 5 7 4 2 2 NOTE The ports on the mow control manifold are marked for easy identification of components Example PRV is the proportional relief valve and T is the return port see Hydraulic Schematic to identify the function of the hydraulic lines and cartridge valves at each port location ...

Page 139: ...ne IMPORTANT Before removing any hydraulic fit tings from the hydraulic manifold make sure the position of each fitting is observed and recorded to ensure proper fitting installation 8 If hydraulic fittings are to be removed from manifold mark fitting orientation to allow correct assembly Re move hydraulic fittings and O rings from manifold Fig 64 Discard removed O rings Installation Fig 63 1 If f...

Page 140: ...PORV 13 Spring pin 2 used 14 Flow control cartridge port FC 15 Rotary handle assembly 16 Pressure compensator port LC 17 Zero leak plug 2 used 18 Orifice 0 013 port OR1 19 Orifice 0 060 port OR2 20 Backlap switch port SW 21 O ring 22 Shim 23 Ball FRONT VIEW FROM BELOW Figure 65 60 in lb 6 7 N m 25 ft lb 34 N m 20 ft lb 27 N m 40 ft lb 54 N m 2 3 6 8 9 10 11 13 1 5 7 12 14 15 4 7 6 8 7 2 2 16 17 18...

Page 141: ...ervice in this section Refer to Figure 65 for mow manifold cartridge valve and plug installation torque Rotary Handle Assembly Fig 66 1 To remove rotary handle from valve A Loosen two 2 set screws that secure handle cap B Remove screw and then lift handle cap from valve C Locate and retrieve detent pin compression spring bushing and lip seal The sleeve bearing should stay in the cap D Loosen two 2...

Page 142: ...mow backlap spool into manifold A Install O rings and back up ring to upper grooves on spool Apply a light coating of grease to O rings B Carefully push spool down into manifold port until lower O ring and back up ring groove is exposed on bottom of manifold Install lower O ring and back up ring to spool Apply a light coating of grease to O ring C Install lower retaining ring to spool D Carefully ...

Page 143: ...em CAUTION Use eye protection such as goggles when using compressed air 6 Clean cartridge valve using clean mineral spirits Submerge valve in clean mineral spirits to flush out con tamination Particles as fine as talcumpowder can affect the operation of high pressure hydraulic valves If car tridge design allows use a wood or plastic probe to push the internal spool in and out 20 to 30 times to flu...

Page 144: ...ose 8 Flange nut 9 Clevis pin 3 used 10 Pivot pin 11 Hydraulic hose 12 Hydraulic hose 13 Flange head screw 14 O ring 15 90o hydraulic fitting 2 used 16 O ring 17 Washer 3 used 18 Rue ring 3 used 19 Hydraulic hose 20 Hydraulic hose 21 Straight hydraulic fitting 3 used 22 45o hydraulic fitting 23 Cutting unit suspension Figure 68 11 12 17 18 2 6 8 9 10 13 1 5 7 14 15 16 19 20 4 2 4 3 6 21 22 15 21 1...

Page 145: ...bly Remove hydraulic fittings and O rings from cylinder Discard removed O rings 9 Inspect threads and sealing surfaces of fittings and lift cylinder ports Replace components if damage is found Lift Cylinder Installation Fig 68 1 If fittings were removed from lift cylinder lubricate and place new O rings onto fittings Install fittings into cylinder ports making sure that fitting orientation is as n...

Page 146: ...0 Head seal 11 Dust seal 12 Head 13 Shaft Figure 69 FRONT LIFT CYLINDER SHOWN 40 ft lb 54 N m 2 3 6 8 9 10 11 1 5 7 12 4 2 3 6 8 9 10 11 13 1 5 7 12 4 13 NOTE The center lift cylinder 1 cutting unit has less stroke than the front lift cylinders 2 and 3 cutting units which are identical Service procedures for all lift cylinders used on Greensmaster TriFlex machines are the same ...

Page 147: ... Lint in a hydraulic system will cause damage 8 Carefully inspect internal surface of barrel for dam age deep scratches out of round etc Inspect shaft head and piston for evidence of excessive scoring pit ting or wear Replace entire cylinder if internal compo nents are found to be worn or damaged Assembly Fig 69 1 Make sure all lift cylinder parts are clean before as sembly 2 Coat new seal kit com...

Page 148: ... 90o hydraulic fitting 10 O ring 11 Hydraulic hose 12 Hydraulic hose 13 Tee fitting 14 45o hydraulic fitting 15 Hydraulic hose 16 Flange head screw 2 used 17 Hydraulic tube 18 Hydraulic tube 19 Hydraulic hose 20 Hydraulic hose 21 Hydraulic hose 22 Hydraulic hose 23 90o hydraulic fitting 24 O ring Figure 70 FRONT RIGHT 11 12 17 18 2 3 6 8 9 10 13 1 5 7 14 15 16 19 20 4 2 2 4 3 6 6 6 6 21 22 23 24 ...

Page 149: ...Remove manifold assembly from the machine IMPORTANT Before removing any hydraulic fitting from the hydraulic manifold make sure the position of fitting is observed and recorded to ensure proper fitting installation IMPORTANT A flow control orifice is placed be neath hydraulic fittings in lift control manifold ports C4 and C6 If either of these fittings is removed from the lift junction manifold ma...

Page 150: ...port S3 15 Check valve port CV 16 45o fitting 17 Orifice 0 037 port C2 25 ft lb 34 N m 60 in lb 6 7 N m 20 ft lb 27 N m UP VIEW FROM BELOW Figure 71 2 6 8 9 10 11 13 1 5 7 12 14 15 16 4 2 2 3 8 9 9 10 17 3 20 ft lb 27 N m 20 ft lb 27 N m 60 in lb 6 7 N m 20 ft lb 27 N m 20 ft lb 27 N m NOTE The ports on the lift control manifold are marked for easy identification of components Example S1 is the so...

Page 151: ...several zero leak plugs These plugs have a tapered sealing surface on the plug head that is designed to re sist vibration induced plug loosening The zero leak plugs also have an O ring to provide a secondary seal If zero leak plug removal is necessary lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug the impact will allow plug removal with less chan...

Page 152: ...eering wheel 7 Button head screw 6 used 8 Tinnerman nut 6 used 9 Flange head screw 4 used 10 Power steering valve 11 Steering arm 12 Steering valve cover 13 Straight hydraulic fitting 3 used 14 Straight hydraulic fitting 2 used 15 Steering mount Figure 72 FRONT RIGHT 20 to 26 ft lb 28 to 35 N m 6 7 8 9 10 5 1 2 3 4 11 12 13 14 13 14 15 Antiseize Lubricant ...

Page 153: ...ntamination 9 Remove steering valve from machine 10 If necessary remove hydraulic fittings and O rings from power steering valve Discard removed O rings Installation Fig 72 1 If fittings were removed from power steering valve lubricate and place new O rings onto fittings Install fit tings into steering valve openings Tighten fittings see Hydraulic Fitting Installation in the General Information se...

Page 154: ...17 Cardan shaft 18 O ring 19 Distribution plate 20 Outer gearwheel 21 Inner gearwheel 22 End cover 23 O ring 5 used 24 Cap screw 5 used 25 Spring set 26 Ball stop 27 Ball 28 P port 29 L port Figure 74 v 10 16 11 12 13 14 15 17 18 2 1 3 4 8 5 9 6 19 7 20 18 18 21 22 23 24 20 to 24 ft lb 27 to 33 N m 11 26 27 25 29 28 NOTE For service of the power steering valve see the Sauer Danfoss Steering Unit T...

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Page 156: ...and stop the engine Re move key from the ignition switch CAUTION Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components in this section 2 Operate all hydraulic controls to relieve hydraulic system pressure 3 To allow easier access to steering cylinder raise and support tank mount plate assembly hydraulic reservoir fuel t...

Page 157: ...ints and cylinder attachment bores on ma chine 4 Place cylinder spacer item 10 onto cylinder barrel ball joint 5 Insert ball joints of cylinder into attachment points on frame and rear fork assembly 6 Secure both steering cylinder ball joints to machine with two 2 jam nuts item 4 Install first jam nut and torque from 60 to 80 ft lb 82 to 108 N m Then while holding first jam nut with wrench tighten...

Page 158: ...ering Cylinder Service 1 Shaft 2 Collar 3 Head ball joint end 4 Dust seal 5 Shaft seal 6 O ring and backup ring 7 Wear ring 8 Piston seal 9 Dowel pin 10 Piston 11 O ring 12 Barrel 13 Head non ball joint end Figure 77 2 3 6 8 9 10 11 13 1 5 7 12 4 2 4 5 6 7 ...

Page 159: ...ulic system will cause damage 11 Carefully inspect internal surface of barrel for dam age deep scratches out of round etc Inspect shaft both heads and piston for evidence of excessive scor ing pitting or wear Replace entire steering cylinder if in ternal components are damaged Assembly Fig 77 1 Put a coating of clean hydraulic oil on all new seals back up rings wear rings and O rings 2 Install new...

Page 160: ... Hydraulic hose 33 O ring 34 Hydraulic hose 35 O ring 36 O ring 37 Hose clamp 38 Suction hose 39 O ring 40 Tank mount plate 41 O ring Figure 78 v 17 to 21 ft lb 23 to 28 N m Antiseize Lubricant 31 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 3 19 19 19 21 1 29 30 28 27 110 to 140 in lb 12 5 to 15 8 N m 70 to 80 ft lb 95 to 108 N m 30 to 38 ft lb 41 to 51 N m 30 to 50 in lb 3 4 to 5...

Page 161: ... rings from removed fittings 13 Remove oil level sensor item 11 from hydraulic res ervoir Discard O ring from sensor 14 Clean hydraulic reservoir and reservoir components with clean solvent Inspect reservoir for leaks cracks or other damage Installing Hydraulic Reservoir Fig 78 1 Lubricate and place new O rings onto all removed fittings Install fittings into reservoir openings Use marks made durin...

Page 162: ... 20 Spacer 4 used 21 O ring 22 O ring 23 Hydraulic hose 24 Hydraulic hose 25 Hose clamp 26 Suction hose Figure 80 v 2 3 4 5 6 7 8 9 10 11 16 17 18 15 30 to 50 in lb 3 4 to 5 6 N m 6 19 20 21 22 23 24 25 26 27 1 12 13 14 17 to 21 ft lb 23 to 28 N m 70 to 80 ft lb 95 to 108 N m 30 to 38 ft lb 41 to 51 N m 30 to 38 ft lb 41 to 51 N m Antiseize Lubricant 30 to 50 in lb 3 4 to 5 6 N m Antiseize Lubrica...

Page 163: ...voir as needed Discard O rings from removed fittings and plugs 13 Clean hydraulic reservoir and reservoir components with clean solvent Inspect reservoir for leaks cracks or other damage Installing Hydraulic Reservoir Fig 80 IMPORTANT When installing reservoir cover and reservoir to machine do not over tighten cap screws Threads in reservoir may become dam aged 1 Lubricate and place new O rings on...

Page 164: ...rew 2 used 24 Lock washer 2 used 25 Oil level sensor 26 O ring Figure 81 17 to 21 ft lb 23 to 28 N m 15 2 3 4 5 6 7 8 9 10 18 19 20 21 16 17 22 23 3 19 19 19 21 24 1 12 13 14 11 11 11 11 25 30 to 60 in lb 3 4 to 6 7 N m 110 to 140 in lb 12 5 to 15 8 N m 40 to 50 ft lb 55 to 67 N m 40 to 50 ft lb 55 to 67 N m 26 Antiseize Lubricant 30 to 50 in lb 3 4 to 5 6 N m Antiseize Lubricant Illustration from...

Page 165: ...is attached to the leak detector tank Fig 83 See Fuel System Carbon Canister Serial Number Above 312000000 in the Service and Repairs section ofChap ter 3 Gasoline for information on disconnecting the canister 8 Remove leak detector tank assembly from machine 9 If necessary remove valve hose item 20 hydraulic fitting item 18 and breather assembly from leak detec tor tank Discard all removed O ring...

Page 166: ...aulic reservoir Threads in reservoir may become damaged 6 Secure leak detector tank to hydraulic reservoir with four spacers item 9 neoprene washers item 8 flat washers item 7 and cap screws item 6 Torque cap screws from 30 to 50 in lb 3 4 to 5 6 N m NOTE Monitor hydraulic fluid level in leak detector tankwindow Asairisremoved fromthe hydrauliccircuit additional oil may have to be added to reservo...

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Page 168: ...apter 14 Hydraulic fitting 15 O ring 16 Solenoid valve assembly 17 Cover 18 Straight barb fitting 19 Hose clamp 4 used 20 Valve hose 21 90o barb fitting 2 used 22 Tank hose 23 Cap screw 2 used 24 Lock washer 2 used 25 Oil level sensor Figure 84 17 to 21 ft lb 23 to 28 N m 30 to 50 in lb 3 4 to 5 6 N m 15 2 3 4 5 6 7 8 9 10 18 19 20 21 16 17 22 23 3 19 19 19 21 24 1 12 13 14 11 11 11 11 25 30 to 60...

Page 169: ...ocedures see Control Manifold Cartridge Valve Service in this section A When installing cartridge valve torque valve 35 ft lb 47 N m B When installing solenoid coil apply a drop of Loc tite 242 or equivalent to threads of valve and torque nut 10 in lb 1 1 N m Installation Fig 84 1 If fittings were removed from solenoid valve man ifold lubricate and place new O rings onto fittings Install fittings ...

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Page 171: ...00 28 Indicator Lights Greensmaster 3400 29 Hour Meter 30 Fuse Block Greensmaster 3300 31 Fuse Block Greensmaster 3400 with Serial Number Below 312000000 32 Fuse Block Greensmaster 3400 with Serial Number Above 312000000 33 Fusible Links 34 Seat Switch 35 Neutral and Mow Switches 36 Parking Brake Switch 37 Joystick Raise and Lower Switches 38 Backlap Switch 39 Hydraulic Solenoid Valve Coils 40 Mai...

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Page 173: ...ng on the machine disconnect the battery cables from the battery disconnect the wire harness connector from the Toro Electronic Controller s and discon nect the terminal connector from the alternator These steps will prevent damage to the machine electrical system Figure 1 1 2 1 TEC controller 2 Harness connector CAN bus Communications The TEC controller communicates with other electrical componen...

Page 174: ...Before Start Up Cold Oil With ignition switch OFF solenoid valve is open Before start up hydraulic fluid is at levelmark ofsight gauge oil cold Oil level sensor float is in raised position keeping alarm circuit open Figure 2 TANK SIGHT GAUGE SOLENOID VALVE open ALARM off OIL LEVEL SENSOR raised open MAIN HYDRAULIC TANK LEAK DETECTOR Normal Operation Warm Oil When ignition switch is turned ON solen...

Page 175: ...larm will sound and the console indicator light will illuminate after a one 1 second time delay NOTE During normal operation with cutting units low ered approximately 5 oz 148 ml of hydraulic fluid will leak before the oil level sensor float closes the alarm cir cuit and activates the alarm Figure 4 MAIN HYDRAULIC TANK LEAK DETECTOR TANK SIGHT GAUGE SOLENOID VALVE closed ALARM on lowered closed OI...

Page 176: ... connector located under the operator seat to verify correct electrical functions of the Toro Electronic Controller TEC TEC inputs and outputs can be checked using the Diagnostic Display Toro Part Number for Diagnostic Display 85 4750 Toro PartNumber for Greensmaster 3300 3400 Overlay English 115 8227 NOTE Diagnostic Display overlays are available in several languages for your Greensmaster Refer t...

Page 177: ...terminal Toro Part Number 107 0392 Figure 9 Dielectric Gel Dielectric gel should be used to prevent corrosion of connection terminals To ensure completecoating ofter minals liberally apply gel to both component and wire harness connector plug connector to component un plug connector reapply gel to both surfaces and recon nect harness connector to component Connectors should be thoroughly packed wi...

Page 178: ... turn off The light should remain off during normal machine operation If the machine TEC controller detects an electrical sys tem malfunction fault during machine operation the diagnostic light will flash rapidly The light will stop flash ing and will automatically reset when the ignition switch is turned to the OFF position The fault however will be retained in controller memory and can be retrie...

Page 179: ...faults that have occurred within the last forty 40 hours of operation the diagnostic light will flash continuously after performing the above fault re trieval switch sequence If a fault code is not retrieved from the controller memory within forty 40 hours of machine operating time the fault cannot be retrieved from controller memory using this procedure If necessary contact your Toro distribu tor...

Page 180: ...e 1 Place machine switches in fault retrieval see above The diagnostic light should be displaying the fault codes 2 Operator seat should remain UNOCCUPIED 3 Move backlap valve on mow control manifold to the BACKLAP position 4 Move joystick to the RAISE position 5 Monitor the diagnostic light for continuous flashing indicating that all faults have been cleared from the con troller memory ...

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Page 182: ...installed on the harness Store the Diagnos tic Display in a dry secure indoor location not on machine CAUTION The interlock switches are for the protection of the operator and bystanders and to ensure cor rect operation of the machine Do not bypass or disconnect interlock switches Check the opera tion of the interlock switches daily for proper op eration Replace any malfunctioning switches before ...

Page 183: ...h see Com ponent Testing in this chapter Replace all defective switches and repair any damaged wiring NOTE The LEAK DETECTOR controller input is only used on Greensmaster 3300 machines The COOLANT TEMPand ALTFAULTcontroller inputs are only used on Greensmaster3400machines TheHYD TEMPcontrol ler input is only used on Greensmaster 3400 machines equipped with the optional hydraulic oil cooler The ELE...

Page 184: ...raise rear position LED ON Joystick NOT moved to raise rear position LED OFF ALT FAULT DSL Greensmaster 3400 machines only Engine not running OR alternator faulty LED ON Alternator OK LED OFF LOW ENGINE OIL PRESSURE Engine not running OR low engine oil pressure LED ON Engine oil pressure OK LED OFF NEUTRAL SWITCH Functional control lever in neutral position LED ON Functional control lever in mow o...

Page 185: ...t press and hold toggle button 6 Sit on seat start engine and attempt to operate the desired function of the machine The appropriate output LED s should illuminate on the Diagnostic Display to in dicate that the TEC controller is turning on that function see Diagnostic Display Outputs and LED Operation chart on next page The outputs can be checked with the ignition switch in the RUN position and t...

Page 186: ...n LED OFF PRV REEL ENGAGE TEC output exists to energize mow manifold solenoid coil PRV LED ON No TEC output to energize mow manifold solenoid coil PRV LED OFF S1 LIFT LOWER ENABLE TEC output exists to energize lift manifold solenoid coil S1 LED ON No TEC output to lift manifold solenoid coil S1 LED OFF S2 LOWER TEC output exists to energize lift manifold solenoid coil S2 LED ON No TEC output to li...

Page 187: ...empt is made Functional control lever is not in the NEUTRAL position The parking brake is disengaged and the operator seat is unoccupied Battery cables are loose or corroded Battery ground to frame is loose or corroded Battery is discharged or faulty Fuse s is are faulty The fusible link harness at the engine starter motor is faulty Wiring to the start circuit components is loose corroded or damag...

Page 188: ...ll coil is faulty Greensmaster 3400 Fuel solenoid or circuit wiring is faulty Fuel pump or circuit wiring is faulty Greensmaster 3400 The engine glow plug circuit does not operate properly Greensmaster 3400 see below The engine glow plug circuit does not operate properly Greensmaster 3400 Wiring in the engine glow circuit is loose corroded or damaged see electrical schematic in Chapter 10 Foldout ...

Page 189: ...ded or damaged see electrical schematic in Chapter 10 Foldout Drawings The engine alternator belt is loose or damaged Greensmaster 3400 Voltage regulator is loose or not grounded to engine Greensmaster 3300 Charge circuit relay or circuit wiring is faulty Greensmaster 3300 Alternator fusible link in the fusible link harness is faulty Battery is faulty Alternator voltage regulator is faulty Engine ...

Page 190: ...y A hydraulic problem exists see Chapter 5 Hydraulic System The TEC Controller is faulty Cutting units will not raise Wiring to raise circuit components is loose corroded or damaged see electrical schematic in Chapter 10 Foldout Drawings Fuse or fuse block is faulty Raise switch in joystick assembly is faulty Lift manifold solenoid valve coil s S1 S3 and or S4 or circuit wiring is faulty A hydraul...

Page 191: ...orward Mow Transport Lever in Mow Backlap OUTPUTS S1 Energized Lift Lower Enable S2 Energized Directional S3 Energized C U 2 3 Hold Lower S4 Energized C U 1 Hold Lower Engine Run Engine Start X P Component Input Position Not Relevent for Function Component Output Energized KEY TO CHART PRV Energized Diag Lamp Leak Detector Momentarily Closed Open O M Cutting Unit Tap Off X X X X X X X X X X X X X ...

Page 192: ...lap OUTPUTS S1 Energized Lift Lower Enable S2 Energized Directional S3 Energized C U 2 3 Hold Lower S4 Energized C U 1 Hold Lower Engine Run Engine Start Engine Glow Plugs Energized Fan on Engine Coolant Temperature PRV Energized Coolant Over Temp Fan Energize Diag Lamp Leak Detector X P Component Input Position Not Relevent for Function Component Output Energized KEY TO CHART Momentarily Closed O...

Page 193: ...tery charge and battery temperature the battery voltage will increase at different rates as the battery charges Start the engine and run at high idle Allow the battery to charge for at least three 3 minutes Record the bat tery voltage After running the engine for at least three 3 minutes battery voltage should be at least 0 50 volt higher than initial battery voltage An example of a charging syste...

Page 194: ... be tween the parking brake switch and the tab on the park ing brake lever should be 0 125 3 2 mm Fig 17 2 If gap is incorrect loosen jam nuts that secure switch to frame bracket Position switch with jam nuts to allow correct gap between switch and brake lever tab Tighten jam nuts to secure adjustment Jam nuts should be torqued from 162 to 198 in lb 18 4 to 22 3 N m After jam nuts are tightened ma...

Page 195: ...switches see Control Console Disas sembly in the Service and Repairs section of Chapter 7 Chassis 2 When the functional control lever is placed in the neutral or mow position the gap between the appropri ate switch head and the tab on the functional lever should be from 0 090 to 0 120 2 3 to 3 0 mm Fig 20 3 If gap is incorrect loosen jam nuts that secure switch to console bracket Position switch w...

Page 196: ...e Diagnostic Display in the Troubleshooting section of this chapter If input testing verifies that the ignition switch and circuit wiring are functioning correctly no further ignition switch testing is necessary If however input testing determines that the ignition switch and circuit wiring are not functioning correctly proceed with the fol lowing ignition switch testing procedure 3 Remove console...

Page 197: ...g ignition switch testing procedure 3 Remove console cover from console assembly to gain access to ignition switch see Control Console Dis assembly in the Service and Repairs section of Chapter 7 Chassis 4 Make sure ignition switch is in the OFF position Dis connect wire harness connector from ignition switch 5 The ignition switch terminals are identified in Figure 24 and the circuitry of the swit...

Page 198: ...ilpressure dropsto anunsafe level IMPORTANT If the oil pressure indicator light is il luminated with the engine running shut off the en gine immediately To testthe oilpressure lightand circuitwiring groundthe wire attached to oil pressure switch located on the en gine near the oil filter Turn ignition switch to the RUN position the engine oil pressure light should come on in dicating correct opera...

Page 199: ...mate the high temperature warning light will come on To test the high temperature warning lightand circuitwir ing turn ignition switch to the RUN position and ground the wire attached to high temperature warning switch lo cated on the engine water pump housing see High Temperature Warning Switch in this section The high temperature warning light should illuminate when the wire is grounded Glow Plu...

Page 200: ... the hour meter 4 Connect the positive terminal of a 12 VDC source to the positive terminal of the hour meter 5 Connect the negative terminal of the voltage source to the other terminal of the hour meter 6 The hour meter should move 1 10 of an hour in six 6 minutes 7 Disconnect the voltage source from the hour meter 8 Replace the hour meter if necessary 9 Connect harness electrical connector to th...

Page 201: ...ydraulic oil cooling fan relay Right Fuse 4 7 5 Amp Protects TEC output power supply for lift solenoids S3 front cutting units and S4 center cutting unit Left Fuse 1 10 Amp Protects power supply for hour meter low engine oil pressure indicator light and proximity switches parking brake neutral and mow Left Fuse 2 15 Amp Protects power supply for Turf DefenderTM Leak Detector solenoid and option al...

Page 202: ...c light Right Fuse 3 7 5 Amp Protects TEC output power supply for fan relay cutting reels engage solenoid lift enable solenoid S1 and lift lower solenoid S2 Right Fuse 4 7 5 Amp Protects TEC output power supply for lift solenoids S3 front cutting units S4 center cutting unit and over temperature indicator light Left Fuse 1 10 Amp Protects power supply for hour meter low engine oil pressure indicat...

Page 203: ... 5 Amp Protects TEC output power supply for fan relay cutting reels engage solenoid lift enable solenoid S1 and lift lower solenoid S2 Right Fuse 4 7 5 Amp Protects TEC output power supply for lift solenoids S3 front cutting units S4 center cutting unit and over temperature indicator light Left Fuse 1 10 Amp Protects power supply for start relay and solenoid Left Fuse 2 10 Amp Protects power suppl...

Page 204: ...links should fail current to the protected circuit will cease Refer to the electrical schematic and wire harness drawings in Chapter 10 Foldout Draw ings for additional circuit information Testing Make sure that ignition switch is OFF Disconnect nega tive battery cable from battery terminal and then dis connect positive cable from battery see Battery Service in the Service and Repairs section of t...

Page 205: ... 3 Make sure ignition switch is in the OFF position 4 Disconnect seat switch wire harness connector from machine wire harness at rear of operator seat Fig 41 5 Check the continuity of the switch by connecting a multimeter ohms setting across the seat switch wire harness connector terminals 6 With no pressure on the seat there should be no continuity open between the harness terminals 7 Press direc...

Page 206: ... to gain access to neutral and mow switches see Control Console Disassembly in the Service and Repairs sec tion of Chapter 7 Chassis Locate switch that is to be tested Fig 42 4 Turn ignition switch to the RUN position do not start engine and check LED on cable end of switch A The neutral switch LED should be illuminated only when the functional control lever is in the neu tral position The neutral...

Page 207: ... RUN position do not start engine and check LED on cable end of parking brake switch The switch LED should be illuminated when the parking brake is not applied 5 With the ignition switch still in the RUN position do not start engine apply parking brake and check LED on cable end of parking brake switch The switch LED should not be illuminated when the parking brake is applied 6 If the brake switch...

Page 208: ...om console assembly to gain access to joystick switches see Control Console Disassembly in the Service and Repairs section of Chapter 7 Chassis 4 Make sure ignition switch is in the OFF position Dis connect wire harness connectors from joystick switches 5 Check the continuity of the raise switch by connect ing a multimeter ohms setting across the switch con nector terminals as follows A With the j...

Page 209: ...cklap switch and circuit wiring are not functioning correctly proceed with the following backlap switch testing procedure 3 Make sure ignition switch is in the OFF position 4 Remove left side cover next to operator seat to allow access to hydraulic mow control manifold Locate the backlap switch on the bottom of the manifold Discon nect the harness electrical connector from the backlap switch 5 Che...

Page 210: ...isplay verifies that the TEC outputs are not func tioning correctly consider that a problem with controller inputs controller fuses or the TEC controller may exist 1 Park machine on level surface lower cutting units stop engine apply parking brake and remove key from ignition switch 2 Determine solenoid coil s that are to be tested and locate coil on correct hydraulic manifold A Remove right side ...

Page 211: ...stance is incorrect replace sole noid refer to appropriate control manifold service pro cedures in the Service and Repairs section of Chapter 5 Hydraulic System NOTE To assist in troubleshooting identical solenoid valve coils can be exchanged If the problem follows the exchanged coil an electrical problem likely exists with the coil If the problem remains unchanged something other than the solenoi...

Page 212: ...ler out put with the Diagnostic Display before disconnecting and testing the relay see Diagnostic Displayin theTrou bleshooting section of this chapter Testing 1 Park machine on a level surface lower cutting units stop engine apply parking brake and remove key from ignition switch Remove right side cover next to operator seat to allow access to relays 2 Make sure ignition switch is in the OFF posi...

Page 213: ...tance 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 val ue from the measured value of the relay being testing 3 Using a multimeter ohms setting measure coil re sistance between terminals 85 and 86 Fig 55 Resist...

Page 214: ...epicts the connection termi nal functions of the TEC controller A fifty 50 pin wire harness connector attaches to the controller The con nector pins are listed in the diagram Note that electrical power for controller outputs is providedthrough three 3 connectors each protected with a 7 5 amp fuse The handheld Diagnostic Display see Special Tools in this chapter with the correct Display overlay sho...

Page 215: ...rmination resistors The resistors plug into the wire harness near the hydrau lic lift control manifold under the right side cover next to the operator seat NOTE Refer to the Electrical Schematics and Wire Harness Drawings in Chapter 10 Foldout Drawings for additional information on termination resistor locations and wire connections Resistor Test The termination resistors Fig 58 can be individuall...

Page 216: ...hat the oil level sensor and circuit wiring are not functioning correctly proceed with the following sensor testing procedure 1 If the oil level sensor is connected to the main wire harness remove hydraulic tank cap from filler neck of hydraulic reservoir Start the engine Insert a clean rod or screw driver into filler neck and gently push down on sensor float Fig 60 Alarm should sound and console ...

Page 217: ...emove key from ignition switch 2 Remove console cover from console assembly to gainaccess toalarm seeControl ConsoleDisassembly in the Service and Repairs section of Chapter 7 Chas sis IMPORTANT Make sure to observe polarity on the alarm terminals when testing Damage to the alarm may result from an improper connection 3 Disconnect wire harness connector from alarm Cor rectly connect 12VDC source t...

Page 218: ...sconnect positive red cable see Battery Ser vice in the Service and Repairs section of this chapter 3 Note wire locations on starter solenoid for assembly purposes Disconnect cables and wire harness connec tors from solenoid 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 o...

Page 219: ...hose from the fuel pump outlet Fig 65 4 Make sure fuel hose attached to the fuel pump inlet is free of obstructions Also make sure that fuel shut off valve on fuel tank is open 5 For fuel pump testing place section of fuel hose on fuel pump outlet and secure in place with hose clamp Place other end of fuel hose into a large graduated cyl inder sufficient enough to collect 1 quart 0 95 liter IMPORT...

Page 220: ...id pull coil is energized and the solenoid plunger retracts Once the plunger is retracted the hold coil will keep it retracted for continued engine operation When the solenoid is de energized the plunger extends to shut off fuel supply to the engine causing the engine to stop running NOTE A fusible link in the machine wire harness pro tects the fuel solenoid pull coil circuit If this link should f...

Page 221: ...le the hot oil with extreme care to prevent personal injury or fire NOTE Prior to taking resistance readings with a digital multi meter short the meter test leads together The me ter will display a small resistance value usually 0 5 ohms or less due to the internal resistance of the meter and test leads Subtract this value from from the mea sured value of the component you are testing 5 Check resi...

Page 222: ... energized The diode plugs into the wiring harness in the engine area see Greensmaster 3400 Wire Harness Drawing in Chapter 10 Foldout Drawings Diode Test The diode Fig 69 can be tested usinga digitalmultime ter diode test or ohms setting and the table to the right Figure 69 1 Diode 2 Male terminal 3 Female terminal 2 1 3 Multimeter Red Lead on Terminal Multimeter Black Lead on Terminal Continuity...

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Page 224: ...Correct problem if not operating properly 2 With the engine not running sit on the seat engage parking brake keep traction pedal in neutral and place functional control lever in MOW or TRANSPORT Try to start the engine If the engine does not crank the inter lock system is operating correctly Correct problem if not operating properly 3 Sit on the seat and set the parking brake Start the engine and ...

Page 225: ...ases are explosive keep open flames and electrical sparks away from the battery do not smoke Nausea may result if the gases are inhaled Un plug charger from electrical outlet before con necting or disconnecting charger leads to or from battery posts 2 Keep top of battery clean by washing periodically with a brush dipped in baking soda sodium bicarbon ate solution Flush top surface with water after...

Page 226: ...C Electrolyte Specific Gravity fully charged from 1 250 to 1 280 Electrolyte Specific Gravity discharged 1 240 Battery Removal Fig 70 or 71 IMPORTANT Be careful to not damage terminal posts or cable connectors when removing the bat tery cables 1 Disconnect the negative cable from the battery first to prevent short circuiting the battery other compo nents or the operators hands Then disconnect the ...

Page 227: ... bottom of the cap tubes Charge at 15 to 25 amps for fifteen 15 minutes to allow sufficient mixing of the electrolyte Battery Installation Fig 70 or 71 IMPORTANT To prevent possible electrical prob lems install only a fully charged battery 1 Make sure the ignition switch and all accessories are off 2 Make sure the battery compartment is clean and re painted if necessary 3 Make sure that battery ca...

Page 228: ... is one ofthe mostreliable means oftesting a battery as itsimulates the cold cranking test A commercialbat tery load tester is required to perform this test CAUTION Follow the battery load tester manufacturer s instructions when using a load tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 0 VDC recharge the battery B If the batter...

Page 229: ...s 5 amps 171 to 250 5 8 hrs 6 amps 11 5 hrs 6 amps 17 3 hrs 6 amps 23 hrs 6 amps above 250 6 hrs 10 amps 12 hrs 10 amps 18 hrs 10 amps 24 hrs 10 amps CAUTION Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60oF 16oC before connecting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are e...

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Page 231: ...S 4 ADJUSTMENTS 5 Parking Brake Adjustment 5 SERVICE AND REPAIRS 6 Wheels 6 Brake Service 8 Brake Cables 10 Rear Wheel Spindle Assembly 12 Rear Steering Fork 14 Control Console 16 Tank Mount Plate Assembly 18 Cutting Unit Suspension Crossarm Assembly 20 Cutting Unit Suspension Assembly 22 Cutting Unit Suspension Service 24 Frame Assembly 26 Chassis ...

Page 232: ...scription Front tire pressure 19 x 10 50 x 8 4 ply 12 to 16 PSI 83 to 110 kPa Rear tire pressure 19 x 10 50 x 8 4 ply 12 to 16 PSI 83 to 110 kPa Wheel lug nut torque 65 to 85 ft lb 89 to 115 N m Wheel motor wheel hub lock nut torque 250 to 400 ft lb 339 to 542 N m ...

Page 233: ...he Traction Unit and Cutting Unit Operator s Manuals provide information regarding the operation general maintenance procedures and maintenance intervals for your Greensmaster TriFlex machine Refer to these publications for additional information when servicing the machine Chassis ...

Page 234: ...moval of the wheel hub from the shaft of the hydraulic wheel motors used on Greensmaster TriFlex machines Toro Part Number TOR4097 Figure 1 Grease Fitting This grease fitting can be used to allow the frame tube to be filled with grease after service of the rear steering fork Toro Part Number 302 5 Figure 2 ...

Page 235: ...distance should be from 6 120 to 6 240 156 to 158 mm Fig 3 3 If necessary adjust location of brake cable jam nuts at brake cable bracket so that distance between pins is correct 4 After adjusting parking brake cables check that brake actuator levers are fully released when parking brake is not applied Also when parking brake is not ap plied front wheels should rotate freely 1 Brake lever engaged 2...

Page 236: ...Greensmaster 3300 3400 Page 7 6 Chassis Service and Repairs Wheels 1 Front wheel 2 Lug nut 4 used per wheel 3 Rear wheel Figure 5 65 to 85 ft lb 89 to 115 N m 2 3 1 1 2 FRONT RIGHT ...

Page 237: ...the machine Always chock or block wheels Use jack stands or other appropriate load holding de vices to support the raised machine If the ma chine is not properly supported the machine may move or fall which may result in personal injury CAUTION 4 Using a jack raise machine so wheel is off ground see Jacking Instructions in Chapter 1 Safety Sup port machine with appropriate jack stands 5 Remove lug...

Page 238: ... Chock wheels to prevent machine from shifting 3 Loosen but do not remove lock nut item 7 from wheel motor shaft 4 Remove front wheel assembly see Wheel Removal in this section Make sure to support machine with jack stands 5 Make sure parking brake is disengaged 6 Remove e ring and clevis pin that secure brake cable to brake actuator lever Position brake cable end away from lever Fig 7 IMPORTANT D...

Page 239: ...oes are properly positioned to pivot and actuator points 6 If brake drum was separated from wheel hub align holes in drum and hub Secure hub to drum by pressing wheel studs into assembly Make sure that stud shoul ders are fully pressed against drum surface IMPORTANT Before brake drum assembly is installed thoroughly clean tapers of wheel hub and wheel motor shaft Make sure that tapers are free of ...

Page 240: ...g 9 Screw 10 Pin 11 Equalizer bracket 12 Retaining ring 3 used 13 Proximity sensor 14 Flange nut 2 used 15 Cotter pin 16 RH brake cable bracket 17 RH brake cable 18 Flat washer 19 LH brake cable bracket 20 LH brake cable 21 Yoke pin 22 Washer head screw 4 used 23 E ring 2 used 24 RH cover 25 Flange head screw 3 used Figure 9 1 2 4 6 8 10 11 12 14 16 17 20 21 18 7 9 15 5 19 3 22 23 13 22 24 25 FRON...

Page 241: ...e bracket 6 Note location of cable ties and routing of brake cable for assembly purposes Remove brake cable from ma chine Brake Cable Installation Fig 9 1 Using notes taken during brake cable removal route brakecableontomachine Makesurethatparkingbrake is not applied 2 Connect brake cable to equalizer bracket at brake le ver A Route brake cable end through hole in frame bracket B Connect cable end...

Page 242: ...used 5 Wheel hub 6 Bearing cup 2 used 7 Wheel stud 4 used 8 Tab washer 9 Jam nut 10 Retainer 11 Dust cap 12 Cotter pin 13 Cap screw 2 used 14 Cap screw 2 used 15 Rear wheel assembly 16 Flange nut 2 used Figure 10 See text for tightening procedure 5 16 15 2 3 6 8 4 10 11 12 1 7 13 14 4 65 to 85 ft lb 89 to 115 N m FRONT RIGHT 9 ...

Page 243: ...ud shoulders are fully pressed against hub surface 4 Apply a light coating of grease to wheel spindle 5 Pack both bearing cones with grease Install one bearing into the bearing cup on inboard side of the wheel hub IMPORTANT The lip of the seal must be toward the bearing The seal should be pressed in so it is flush with the end of the wheel hub 6 Lubricate the inside of a new seal and press it into...

Page 244: ...20 Flange nut 2 used 21 Rear steering fork 22 Ball joint 2 used 23 Retaining ring 2 used 24 Steering cylinder 25 Bearing cone 2 used 26 Bearing cup 2 used 27 Steering washer 28 Slotted hex nut 29 Cotter pin 30 Plug 31 Cylinder spacer 65 to 85 ft lb 89 to 115 N m 60 to 80 ft lb 82 to 108 N m 180 to 216 in lb 21 to 24 N m 20 22 23 25 30 31 Removal Fig 11 1 Park machine on a level surface engage the ...

Page 245: ...be until they seat against the shoulder of the frame 2 Apply a light coating of grease to steering fork spindle 3 Pack both bearing cones with grease Install one bearing onto the steering spindle 4 Install steering fork assembly into frame A Insert steering fork spindle up through frame tube B Hold the steering fork in place Install the steering washer and upper bearing cone onto the spindle C Sec...

Page 246: ...ck rod 8 Jam nut 9 Washer head screw 2 per control 10 Joystick assembly 11 Lock nut 2 per control 12 Screw 7 used 13 Flange nut 4 used 14 Carriage screw 2 used 15 Alarm if equipped 16 Alarm nut if equipped 17 Nut 18 Washer 19 Ignition switch 20 Knob 21 Throttle control 22 Console support standard seat 1 7 8 5 6 4 13 9 11 2 12 14 3 10 15 16 17 18 19 20 21 22 ...

Page 247: ...gure 14 as a guide Iffinger spring wash ers item 7 in Fig 14 were removed position washers so that fingers on washer point towards pivot hub 3 Install all removed components to control console using Figure 12 as a guide 4 Position console cover item 2 to console and se cure with screws item 12 1 Console 2 Pivot tube 3 Functional lever 4 Split bushing 5 Cap screw 6 Flat washer 7 Lock nut 8 Roller p...

Page 248: ...300 GREENSMASTER 3400 NOTE For access to fasteners that secure hydraulic reservoir and fuel tank and also to access machine com ponents at rear of machine e g steering cylinder rear steering fork the tank mount plate assembly hydraulic reservoir fuel tank and tank mount plate can be raised and supported If necessary the complete tank mount plate assembly can be removed from the machine CAUTION Bef...

Page 249: ... gear pump suction hose into a suitable con tainer 3 Disconnecthydraulichosesfromfittingsonhydraulic tank Put clean caps or plugs on hoses and fittings 4 Close fuel shut off valve on fuel tank 5 Disconnect additional fuel system hoses A On Greensmaster 3300 machines disconnect hoses from fuelfilter and check valve that are located next to rear cylinder head Fig 16 Also remove cable tie that secure...

Page 250: ...ring 2 used 10 Pivot pin 2 used 11 Socket head screw 8 used 12 Basket horn 2 used 13 Flange head screw 4 used 14 Suspension steering head Figure 17 8 9 10 7 12 1 6 4 2 2 3 3 11 4 4 4 5 13 11 14 FRONT RIGHT NOTE Three 3 identical cutting unit suspension as semblies are used on Greensmaster TriFlex machines The cutting unit attaches to the crossarm assembly which is attached to the front of the cutt...

Page 251: ...sembly see Traction Unit Operator s Manual 4 Disassembly crossarm assembly as required using Figure 17 as a guide NOTE The flange head screws item 13 used to se cure the basket horn item 12 to the crossarm assembly have a patch lock to prevent loosening of the screws If screws are removed replace screws Assembly Fig 17 1 Assemble crossarm assembly using Figure 17 as a guide 2 Install cutting unit ...

Page 252: ...ange nut 6 used 14 Flange head screw 6 used 15 RH spring retainer 3 used Figure 18 FRONT RIGHT 55 to 60 ft lb 75 to 81 N m 6 4 1 3 2 5 9 10 13 14 7 11 12 15 8 NOTE Three 3 identical cutting unit suspension as semblies are used on Greensmaster TriFlex machines The cutting unit attaches to the crossarm assembly which is attached to the front of the cutting unit suspen sion assembly The crossarm asse...

Page 253: ... suspension assembly from machine Installation Fig 18 1 Make sure that all suspension components are cor rectly assembled 2 Position suspension assembly to frame Align mounting holes and secure suspension with three 3 flange head screws item 2 Torques screws from 55 to 60 ft lb 75 to 81 N m 3 Position reel motor and attached hydraulic hoses to suspension assembly Insert reel motor shaft into stor ...

Page 254: ... 9 10 11 12 13 20 23 17 16 18 21 3 9 3 4 4 4 8 8 9 14 14 19 24 21 6 15 15 15 15 22 67 to 83 ft lb 91 to 112 N m FRONT RIGHT 25 26 NOTE Three 3 identical cutting unit suspension as semblies are used on Greensmaster TriFlex machines The cutting unit attaches to the crossarm assembly which is attached to the front of the cutting unit suspen sion assembly See Cutting Unit Suspension Crossarm Assembly ...

Page 255: ...2 was removed from A arm se cure lift plate with two 2 flange head screws item 13 Torque screws from 67 to 83 ft lb 91 to 112 N m CAUTION Be careful when assembling the suspension counterbalance system The counterbalance spring is under heavy load and may cause per sonal injury D Install clevis pin item 26 into upper holes in counterbalance mount item 23 and hole in tension er arm item 16 Tensione...

Page 256: ... Step plate 9 Washer head screw 9 used 10 Frame assembly 11 R clamp 2 used 12 Manual tube 13 Cap 14 Plug 100 to 110 ft lb 136 to 149 N m 1 3 4 5 6 7 8 9 5 14 13 12 11 9 2 9 9 10 55 to 60 ft lb 75 to 81 N m The Greensmaster TriFlex frame assembly is illustrated in Figure 25 If the fasteners used to secure the front castings or ROPS assembly are loosened or removed refer to Figure 25 for fastener ti...

Page 257: ...NCE 6 SET UP AND ADJUSTMENTS 10 Characteristics 10 Leveling Rear Roller 11 SERVICE AND REPAIRS 12 Backlapping 12 Bedbar Assembly 14 Bedbar Adjuster Service 16 Bedknife Replacement and Grinding 18 Reel Assembly Removal and Installation 20 Reel Assembly Removal 21 Reel Assembly Installation 21 Reel Assembly Service 24 Preparing Reel for Grinding 26 Reel Motor Adapter 27 Front Roller 28 Rear Roller 2...

Page 258: ... the front roller by two 2 vertical screws Effective HOC may vary depending on turf conditions type of bedknife roller type and installed attachments Bedknife Replaceable single edged high carbon steel bedknife is fastened to a machined cast iron bed bar with thirteen 13 screws Optional bedknives are available Bedknife Adjustment Dual screw adjustment to the reel detents corresponding to 0 0007 in...

Page 259: ...lled on the cutting units e g rear roller brush the installation instructions for the kit in cludes set up and operation information Refer to those publications for additional information when servicing the cutting units Supporting Cutting Unit when Servicing Whenever the cutting unit has to be tipped to expose the bedknife or cutting reel support the rear of the cutting unit to make sure the lock...

Page 260: ...tment Bedknife Screw Tool This screwdriver type bit is made to fit Toro bedknife at taching screws Use this bit with a torque wrench to se cure the bedknife to the bedbar IMPORTANT To prevent damage to the bedbar DO NOT use an air or manual impact wrench with this tool Toro Part Number TOR510880 Figure 4 Handle Assembly For applying lapping compound to cutting units while keeping hands a safe dist...

Page 261: ...Circumference Measuring Tape 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 Toro Part Number TOR6023 Figure 8 Turf Evaluator Tool Many turf discrepancies are subtle and require closer examination In these instances the Turf Evaluator grass viewing to...

Page 262: ...ary See the Traction Unit Operator s manual Governed engine speed For best cutting performance and appearance engine should be run at maximum governed speed during machine operation Check maximum governed engine speed Adjust engine to specifications if necessary See Chapter 3 Gasoline Engine or Chapter 4 Diesel Engine Reel speed All cutting reels must rotate at the same speed within 100 rpm see Tr...

Page 263: ...tting edges may be corrected by backlapping see Backlapping in the Service and Repairs section of this chapter Rear roller adjustment Adjust the rear roller brackets to correct position depending on the height of cut range desired See Rear Roller Adjustment in the Cutting Unit Operator s Manual Height of cut Effective or actual height of cut depends on the cutting unit weight and turf conditions E...

Page 264: ...pair roller bearings as necessary See Roller Service in the Service and Repairs section of this chapter Refer to Cutting Unit Operator s Manual for roller options Cutting unit accessories A variety of cutting unit accessories are available that can be used to enhance aftercut appearance Refer to Operator s Manual for a listing of available accessories ...

Page 265: ...Greensmaster 3300 3400 DPA Cutting Units Page 8 9 This page is intentionally blank DPA Cutting Units ...

Page 266: ...ual self sharpening action This feature maintains sharp cutting edges assures good quality of cut and greatly reduces the need for routine backlapping In addition the rear roller positioning system allows for various height of cut ranges and aggressiveness of cut selections If a cutting unit is determined to be out of adjustment complete the following procedures in the specified order to adjust th...

Page 267: ... to cutting reel by using a 0 005 0 13 mm shim at each end of rear roller If the shim will pass under the roller at one end but not the other a frame adjustment should be made 4 Loosen but do not remove the two 2 shoulder bolts that secure the side plate to the frame opposite the side that is not level Fig 10 5 Adjust the position of the side plate to parallel the rear roller and cutting reel Then...

Page 268: ...he cutting units stop the engine and engage the parking brake 2 Remove the console cover to expose controls 3 Locate the reel speed control and backlap lever on the hydraulic mow manifold Figs 11 and 12 Rotate the reel speed control to position 1 and the backlap lever to the R backlap position 4 Make initial reel to bedknife adjustments appropriate for backlapping on all cutting units which are to...

Page 269: ...vement to stop After adjustments have been completed repeat steps 5 through 8 10 When the backlapping operation is completed stop the engine and remove the key from the ignition switch Run a file across the front face of the bedknife This will remove any burrs or rough edges that may have built up on the cutting edge 11 Repeat procedure for all cutting units to be backlap ped 12 When backlap opera...

Page 270: ...2 3 5 190 to 240 in lb 22 to 27 N m Bedbar Removal Fig 15 1 Position machine on a clean and level surface lower cutting units stop engine engage parking brake and re move key from the ignition switch 2 Remove the cutting unit from the machine and place cutting unit on a flat work area 3 Tip the cutting unit to expose the bedknife Support the rear of the cutting unit see Supporting Cutting Unit whe...

Page 271: ... Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when handling the bedbar 5 Position bedbar into cutting unit Make sure that the top of each bedbar arm is between washer item 11 and adjuster screw flange item 4 6 Position one 1 metal washer item 17 and one 1 plastic washer item 16 between bedbar and each cut ting unit side plate Fig 16 7 In...

Page 272: ...djuster Service Figure 17 1 Bedbar assembly 2 Compression spring 3 Lock nut 4 Bedbar adjuster shaft 5 Flange bushing 6 Cap screw 7 Detent 8 Wave washer 9 Retaining ring 10 Bedbar adjuster screw 11 Washer FRONT RIGHT Antiseize Lubricant 2 3 6 8 9 10 11 1 5 7 4 5 ...

Page 273: ...ent item 7 was removed secure detent to cut ting unit side plate with cap screw 2 If flange bushings item 5 were removed align key on bushing to slot in frame and install bushings 3 Slide adjuster shaft item 4 into flange bushings in cutting unit side plate Secure adjuster shaft with wave washer item 8 and retaining ring item 9 NOTE Adjuster shaft item 4 has left hand threads 4 Apply antiseize lub...

Page 274: ...rust scale and corrosion from bedbar surface Lightly oil bedbar surface before installing bedknife 2 Make sure that screw threads in bedbar 5 16 18UNC 2A are clean If necessary use tap to clean threads 3 Apply antiseize lubricant to the threads of new screws Take care to keep antiseize lubricant from taper on screw heads IMPORTANT Do not use an impact wrench to tight en screws into the bedbar 4 Us...

Page 275: ...so clean anddress grinding stone often during the grinding process 1 Use Toro General Service Training Book Reel Mow er Basics part no 09168SL and grinder manufactur er s instructions for bedknife grinding information 2 After bedknife grinding is complete install bedbar to cutting unit see Bedbar Installation in this section Figure 19 1 2 4 6 8 3 5 7 9 10 12 11 13 TOR510880 Figure 20 Relief Angle ...

Page 276: ...NT RIGHT Grease OD 210 to 240 in lb 24 to 27 N m 4 2 9 5 13 1 4 5 5 5 7 15 3 7 11 3 8 210 to 240 in lb 24 to 27 N m 10 12 surface Grease OD surface 6 14 16 18 11 17 NOTE This section provides the procedure for remov ing and installing the cutting reel assembly cutting reel flocked seals reel bearings bearing lock screw and reel nut from the cutting unit Refer to Reel Assembly Ser vice later in thi...

Page 277: ... item4 and flange nuts item 5 that secure the LH side plate to the cutting unit cross member Remove the LH side plate from the reel shaft rollers bedbar and cutting unit crossmember Locate and remove flat wire spring item 14 Remove pitch arm item 7 from side plate 11 Carefully slide the cutting reel assembly with flocked seals reel bearings bearing lock screw and reel nut from the RH side plate 1 ...

Page 278: ...positioned 11 Secure front and rear rollers to LH side plate see Front Roller Installation and Rear Roller Installation in this section 12 Adjust cutting unit see Cutting Unit Operator s Manual NOTE The parallel position of the rear roller to the cut ting reel is controlled by the precision machined cross member and side plates of the cutting unit If necessary the cutting unit side plates can be l...

Page 279: ...Greensmaster 3300 3400 DPA Cutting Units Page 8 23 This page is intentionally blank DPA Cutting Units ...

Page 280: ...mbly Service 1 Cutting reel 2 Flocked seal 2 used 3 Bearing 2 used 4 Plug 5 Bearing lock screw RH thread 6 Reel nut LH thread Figure 24 90 to 110 ft lb 123 to 149 N m FRONT RIGHT Right Hand Threads Left Hand Threads 1 2 3 4 5 3 2 90 to 110 ft lb 123 to 149 N m 6 ...

Page 281: ...r exces sive wear or distortion Replace reel nut if damage is evi dent Assembly of Cutting Reel Fig 24 1 If bearings and or flocked seals were removed from reel shaft discard removed components and replace IMPORTANT The flocked seal should be installed so the flocked side of the seal is toward the bearing location 2 Slide flocked seals flocked side orientated toward bearing location and bearings f...

Page 282: ...ind ing Specifications chart to the right Additional reel grinding information can be found in the Toro General Service Training Book Reel Mower Basics part no 09168SL 2 After completing the reel grinding process adjust cutting unit see Cutting Unit Operator s Manual Reel Grinding Specifications Reel Diameter New 5 06 in 128 5 mm Service Limit Reel Diameter 4 50 in 114 3 mm Reel Shaft Diameter OD ...

Page 283: ...ate using Fig 27 as a guide 4 Remove O rings as necessary from motor adapter Fig 28 Installation 1 If large O ring was removed from flange of motor adapter lubricate O ring with grease Small O rings should be installed into motor adapter without lubrica tion Make sure that O rings are correctly positioned in grooves in adapter 2 Install reel motor adapter to cutting unit side plate us ing Fig 27 a...

Page 284: ... condition of HOC screws item 5 in both HOC arms If necessary apply antiseize lubricant to threads of new HOC screw Thread new HOC screw into HOC arm NOTE When assembling HOC arms to side plates make sure that ring on HOC screw fits into the notch on the side plate 3 If both HOC arms were removed from cutting unit side plate position one of the arms to side plate Secure arm to side plate with plow...

Page 285: ...the remaining rear roller retainer assembly on the cutting unit 6 If necessary remove the second rear roller retainer assembly from the cutting unit Installation Fig 31 1 Place cutting unit on a level working surface NOTE Refer to Cutting Unit Operator s Manual for number of roller shims required for various height of cut settings 2 If both rear roller retainer assemblies were removed from cutting...

Page 286: ...ds of bearing lock nuts Replace lock nut if any damage is found 4 Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until seal and bearing areremovedfromrollercavity Removesecondsealand bearing from roller cavity by tapping on shaft 5 Clean bearing cavity in roller and remove any rust with crocus cloth Assembly 1 Place roller shaft into roller NOTE If bearing loc...

Page 287: ...t Tighten nuts untilthey bottomagainstbearings Fig 36 Remove nuts from roller shaft 8 Position an assembly spacer and yellow assembly washer see Special Tools on each end of roller shaft Fig 37 Thread nut onto each end of shaft 9 Tighten each nut until the yellow assembly washers bottom out against the roller housing Remove nuts as sembly washers and assembly spacers from roller shaft 10 Lubricate...

Page 288: ...20 Bearing spacer 21 Spacer 22 Cap screw 23 Bearing spacer 24 Hex nut 2 used 25 Weight 26 Cap screw 2 used Figure 38 FRONT RIGHT FRONT RIGHT 100 ft lb 136 N m 70 to 80 in lb 8 to 9 N m 130 to 140 in lb 15 to 16 N m 26 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 23 8 12 12 24 25 Antiseize Lubricant NOTE Drive components for the rear roller brush are located on the right side of the cut...

Page 289: ...e brush Fig 39 Torque lock nuts from 20 to 25 in lb 2 3 to 2 8 N m 1 Roller brush shaft 2 J bolt 3 Roller brush 4 Lock nut Figure 39 20 to 25 in lb 2 3 to 2 8 N m 1 2 3 4 2 Assemble roller brush components using Figure 38 as a guide and the following assembly notes A The screws item 12 that are used to secure the cover item 1 driven pulley item 10 and drive plate item 9 have a threadlock feature t...

Page 290: ...en and idler pulleys C After belt installation make sure that belt and pulleygroovesarealigned andthatbeltis centeredin pulleys 6 To tension the drive belt A Pushdown onthe idlerpulley andsecure withcap screw item 22 and flange nut item 8 Make sure that cover plate item 7 is covering the slot in the drive plate to prevent debris from entering the brush drive area B After idler pulley is secured ch...

Page 291: ... of Groomer Adjustment 6 SERVICE AND REPAIRS 7 Groomer Belt Replacement Forward Rotating Groomer Drive 7 Groomer Cover Counter Rotating Groomer Drive 8 Grooming Reel Forward Rotating Groomer Drive 10 Grooming Reel Counter Rotating Groomer Drive 14 Grooming Reel Service 17 Grooming Reel Bearing Replacement 18 Idler Assembly Forward Rotating Groomer Drive 20 Idler Assembly Counter Rotating Groomer D...

Page 292: ...talled in place of grooming reel GROOMER HEIGHT SETTING From 0 030 to 0 620 inch 0 8 to 15 7 mm at mowing HOC range of 0 060 to 0 750 inch 1 5 to 19 1 mm WIDTH OF GROOMER 19 380 inches 49 2 cm HEIGHT ADJUSTMENT KNOB Allows a 0 003 inch 0 08 mm increment of height adjustment for each click of the adjuster UP DOWN FEATURE Allows grooming reel to be raised above the height depth adjustment for no gro...

Page 293: ...lation Instructions for the groomer provide in formation regarding the operation general mainte nance procedures and maintenance intervals for the groomer assembly on your Greensmaster TriFlex ma chine Refer to this publication for additional information when servicing the groomer assembly Groomer ...

Page 294: ...r carefully READ AND UNDERSTAND THE INSTAL LATION INSTRUCTIONS BEFORE OPERATING OR TESTING GROOMER PERFORMANCE Variables That Affect the Use and Performance of Grooming Reels 1 The growing season and weather conditions 2 General turf conditions 3 The frequency of grooming cutting number of cut tings per week and how many passes per cutting 4 The blade spacing on the grooming reel 5 The height of c...

Page 295: ...grooming reel counter rotating groomer drive Handle on groomer cover is rotated rearward so that groomer drive is disengaged Seized grooming reel or idler bear ing s in groomer side plate s Broken or damaged drive idler spring Groomer drive gears are worn or damaged Handle needs to be rotated toward the front of the machine to engage the groomer drive Identify and replace faulty bear ing s Replace...

Page 296: ...et to the desired height of cut see Cutting Unit Operator s Manual for cutting unit adjustment procedures 3 Position the grooming reel to the lowered grooming position Fig 1 NOTE Improper or over aggressive use of the groom ing reel i e too deep or too frequent grooming may cause unnecessary stress on the turf leading to severe greens damage Use the groomer cautiously 4 On one end of the grooming ...

Page 297: ...h on pulley nut and rotating idler bracket to relax belt tension Slip groomer drive belt off pulleys Fig 3 Carefully re lease idler bracket IMPORTANT Make sure that the drive belt is cen tered on the pulleys and correctly aligned with pulley grooves after installation 5 Install new drive belt to drive pulley idler pulley and driven pulley observing correct belt routing Fig 3 6 Secure belt cover to...

Page 298: ...n gaged 4 Remove groomer cover assembly from machine Fig 4 A Remove five 5 flange head screws that secure groomer cover assembly to RH drive plate B Remove groomer cover assembly and gasket from machine Discard gasket 5 If necessary remove shaft from groomer cover Fig 5 A Loosen set screw item 9 on top of shaft and slide handle from shaft B Remove retaining ring item 8 and thrust washer item 5 fro...

Page 299: ...hat it extends toward the front of the cover F Apply Loctite 242 or equivalent to threads of set screw Install set screw into end of shaft to secure handle in place 2 Install groomer cover assembly to RH drive plate as sembly Fig 4 A Make sure that handle on groomer cover is ro tated toward the front of the machine B Fill groomer cover with approximately five 5 ounces 142 grams of Mobil XHP221 gre...

Page 300: ...eize Lubricant 100 ft lb 135 N m 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 20 21 22 23 24 11 12 13 25 26 27 17 to 21 ft lb 24 to 28 N m Remove the grooming reel to replace individual blades to replace worn groomer components to reverse the blades on the shaft if not equipped with carbide blades or to replace the grooming shaft Removal Fig 7 1 Park machine on a clean and level surface lower...

Page 301: ... for wear or damage Also inspect pulleys and idler components for wear or damage Replace components as needed Installation Fig 7 1 Apply a light coating of grease to ends of grooming shaft and also to seal lips in RH drive and LH support plates Make sure that all bearings bushings and seals are properly installed 2 Make sure that O ring item 27 is installed on grooming shaft Apply light coating of...

Page 302: ... unit with plow bolt item 22 special wash er item 16 and lock nut item 21 14 Secure RH groomer arm assembly to drive plate with spring washer item 12 and lock nut item 13 15 Center front roller to cutting unit and tighten cap screws item 10 to secure roller 16 Install groomer drive belt item 3 and groomer drive cover item 2 to drive plate see Groomer Belt Replace ment in this section 17 If equippe...

Page 303: ...Greensmaster 3300 3400 Groomer Page 9 13 This page is intentionally blank Groomer ...

Page 304: ...1 19 125 ft lb 170 N m 120 in lb 13 5 N m 120 in lb 13 5 N m 17 to 21 ft lb 23 to 28 N m Antiseize Lubricant 31 Remove the grooming reel to replace individual blades to replace worn groomer components to reverse the blades on the shaft if not equipped with carbide blades or to replace the grooming shaft Removal Fig 10 1 Park machine on a clean level surface Lower cut ting units completely to the g...

Page 305: ...bly from grooming shaft and cutting unit 14 Carefully pull the grooming reel assembly from the LH support plate 15 Inspect seals bushings and bearings in RH drive plate LH support plate and groomer arms for wear or damage Also inspect gears and idler components for wear or damage Replace components as needed Installation Fig 10 1 Apply a light coating of grease to ends of grooming reel shaft and a...

Page 306: ...cure gears with flange nuts and torque flange nuts 120 in lb 13 5 N m 9 Install extension spring to RH drive plate assembly Fig 11 10 Insert front roller into LH groomer arm assembly 11 Make sure that bushing item 3 is installed in RH drive plate assembly 12 Apply antiseize lubricant to threads of RH groomer arm lift rod 13 Position RH groomer arm assembly to front roller RH drive plate and cuttin...

Page 307: ...gainst the lock nut installed on one end of groomer shaft Then place first blade against installed spacer Fig 14 IMPORTANT If groomer is equipped with blades with carbide tips make sure that blades are installed with the tips in the same direction 2 For 1 2 inch 1 3 cm blade spacing make sure there are two 2 blade spacers between blades Fig 14 3 When all blades have been installed place second thi...

Page 308: ...blies Figs 20 21 and 22 Discard all removed seals and bearings Bearing Installation 1 Install new grooming reel bearings and seals into RH drive plate and LH support plate assemblies Fig 23 IMPORTANT Bearings should be installed with ex tended inner races toward center of housing Also apply pressure equally to inner and outer bearing races when installing bearings A Press new outer bearing fully t...

Page 309: ...utting unit see Grooming Reel Forward Rotating or Counter Rotating in this section 4 Check and adjust grooming reel height and mower height of cut settings 5 Install cutting unit to the machine 6 Lubricate groomer bearings NOTE After greasing groomer bearings operate groomer for 30 seconds stop machine and wipe any ex cess grease from groomer shaft and seals 1 RH drive plate assy 2 Bearing 2 used ...

Page 310: ...r Assembly Forward Rotating Groomer Drive Figure 24 1 Pivot hub 2 Spacer 3 Idler bracket 4 Spacer 5 RH drive plate 6 O ring 7 Retaining ring 8 Grease fitting 9 Bearing 2 used 10 Retaining ring 11 Idler pulley 12 Lock nut 9 10 12 11 5 3 4 2 1 7 8 6 ...

Page 311: ...move groomer belt cover drive belt and drive pulley from right side of cutting unit see Grooming Reel Forward Rotating Groomer Drive Removal in this sec tion 4 Using Figures 24 and 25 as guides remove idler bracket idler pulley and or idler bearings as needed Installation 1 Assemble removed components using Figures 24 and 25 as guides NOTE When properly installed the idler pulley should move freel...

Page 312: ...re that handle on groomer cover is rotated toward front of machine so that groomer drive is en gaged 4 Remove groomer cover assembly and gasket from groomer drive on right side of cutting unit see Groomer Cover Counter Rotating Groomer Drive in this sec tion 5 Remove RH drive plate assembly from right side of cutting unit see Grooming Reel Counter Rotating Groomer Drive in this section 6 Using Fig...

Page 313: ...ange nuts that secure idler gears 120 in lb 13 5 N m 5 Install extension spring to idler bracket and adjust ment cam 6 Fill groomer cover with approximately five 5 ounces 142 grams of Mobil XHP221 grease or equivalent Install new gasket and then groomer cover assembly to RH drive plate see Groomer Cover Counter Rotating Groomer Drive in this section 7 Check and adjust grooming reel height and mowe...

Page 314: ... 5 Groomer lift rod 6 Lock screw 7 Bushing 8 Lift arm assembly LH shown 9 Detent spring 10 Spring washer 11 Cap screw 12 Bushing 13 Wave washer 14 Groomer adjuster 15 Side plate LH shown 16 Lock nut 17 Spring washer 18 Bushing 13 3 5 14 2 6 4 7 12 9 10 8 11 7 1 Antiseize Lubricant Antiseize Lubricant Antiseize Lubricant 17 16 18 15 ...

Page 315: ... arm using Figure 30 as a guide NOTE Right and left side HOC groomer arms item 1 and lift arm assemblies item 8 are different other com ponents shown in Figure 30 are the same on both sides of cutting unit NOTE Grooved pin item 3 is used to retain lock screw item 6 to lift arm assembly Assembly Fig 30 1 Assemble lift arm using Figure 30 as a guide 2 Apply antiseize lubricant to threads of groomer ...

Page 316: ... brush uses the same procedure as removal and installation of the grooming reel see Grooming Reel in this section To remove the groomer brush from the shaft remove the lock nut and J bolt from both ends of the brush and slide the brush from the shaft When assembling the brush to the shaft secure the assembly with J bolts and lock nuts Make sure that the J bolts are installed with the threaded port...

Page 317: ...Greensmaster 3300 Serial Number Above 312000000 5 Greensmaster 3400 Serial Number Below 312000000 6 Greensmaster 3400 Serial Number Above 312000000 7 WIRE HARNESS DRAWINGS Greensmaster 3300 Serial Number Below 312000000 8 Greensmaster 3300 Serial Number Above 312000000 10 Greensmaster 3400 Serial Number Below 312000000 12 Greensmaster 3400 Serial Number Above 312000000 14 Foldout Drawings ...

Page 318: ...Greensmaster 3300 3400 Page 10 2 Foldout Drawings This page is intentionally blank ...

Page 319: ...DETECTOR VOLUME EXPANSION TANK LEAK DETECTOR KIT OPTIONAL OUT IN TOP PORT BOTTOM PORT BACK PORT C1 S4 S1 FORWARD OIL FILTER JOINT END STEERING CYLINDER 1160 1 5 Bore 3 4 Rod 6 19 Stroke VALVE PSI POWER STEERING HYDROSTAT 4 5 BYPASS VALVE 1 9 GPM 70 100 MOW 6 7 GPM AT 3 8 MPH TRANSPORT 17 5 GPM AT 10 MPH PSI OPTIONAL 3WD FRONT PORT 10 3 20 6 3000 PSI PUMP 25 PSI 028 FRONT PORT 73 73 FRONT PORT M1 M...

Page 320: ...Page 10 4 Electrical Schematic Greensmaster 3300 NOT USED ON GR3300 NOT USED ON GR3300 NOT USED ON GR3300 NOT USED ON GR3300 Serial Number Below 312000000 DISPLAY CAN TRAK ...

Page 321: ...Page 10 5 Electrical Schematic Greensmaster 3300 Serial Number Above 312000000 NOT USED ON GR3300 NOT USED ON GR3300 NOT USED ON GR3300 NOT USED ON GR3300 DISPLAY CAN TRAK ...

Page 322: ...Page 10 6 Electrical Schematic Greensmaster 3400 NOT USED ON GR3400 NOT USED ON GR3400 NOT USED ON GR 3400 NOT USED ON GR3400 Serial Number Below 312000000 DISPLAY CAN TRAK ...

Page 323: ...Page 10 7 Electrical Schematic Greensmaster 3400 Serial Number Above 312000000 NOT USED ON GR3400 NOT USED ON GR3400 NOT USED ON GR 3400 NOT USED ON GR3400 DISPLAY CAN TRAK ...

Page 324: ...Page 10 8 Wire Harness Drawing Greensmaster 3300 NOT USED ON GR3300 NOT USED ON GR3300 Serial Number Below 312000000 NOT USED ON GR3300 NOT USED ON GR3300 ...

Page 325: ... WHITE BLACK WHITE BLACK BLUE PINK BLUE BLACK VIOLET BLACK BLACK WHITE RED BLACK BLACK YELLOW RED BLACK RED BLACK YELLOW BLACK RED BLACK BLACK PINK BLACK VIOLET GREEN YELLOW BLACK BLACK PINK RED PINK WHITE ORANGE RED GREEN ORANGE BROWN WHITE BLACK PINK BROWN PINK BLACK BLACK GRAY BLACK YELLOW BROWN VIOLET TAN BLACK PINK BLUE RED BLACK BLUE GRAY GREEN BLACK ORANGE BLACK BLACK BLUE BLACK BLACK TAN B...

Page 326: ...Page 10 10 Wire Harness Drawing Greensmaster 3300 Serial Number Above 312000000 NOT USED ON GR3300 NOT USED ON GR3300 NOT USED ON GR3300 NOT USED ON GR3300 ...

Page 327: ... RED WHITE GRAY BLACK WHITE RED WHITE BLACK WHITE RED WHITE BLACK WHITE RED WHITE BLACK WHITE RED WHITE RED WHITE BLK WHITE BLK WHITE BLK WHITE BLACK WHITE RED WHITE BLACK PINK PINK BLUE BLUE BLACK BLACK BLACK BLACK RED BLACK YELLOW RED BLACK BLACK RED BLACK WHITE BLACK BLACK VIOLET YELLOW BLACK RED PINK BLACK PINK BROWN WHITE ORANGE GREEN RED BLACK RED ORANGE PINK WHITE VIOLET BLACK BLACK PINK VI...

Page 328: ...Page 10 12 Wire Harness Drawing Greensmaster 3400 NOT USED ON GR3400 NOT USED ON GR3400 Serial Number Below 312000000 NOT USED ON GR3400 NOT USED ON GR3400 ...

Page 329: ...RANGE GRAY PINK BLACK BLACK BLUE RED GREEN ORANGE ORANGE PINK VIOLET WHITE BLACK BLACK RED WHITE RED WHITE RED WHITE BLACK WHITE RED WHITE BLACK WHITE GRAY RED WHITE BLACK WHITE RED WHITE BLACK WHITE BLACK WHITE BLACK WHITE BLACK WHITE RED WHITE BLUE PINK BLUE BLACK BLACK PINK BLACK BLACK WHITE RED WHITE RED BLACK RED YELLOW YELLOW BLACK RED BLUE BLACK BLACK GREEN YELLOW BLACK PINK BLACK VIOLET BL...

Page 330: ...Page 10 14 Wire Harness Drawing Greensmaster 3400 Serial Number Above 312000000 NOT USED ON GR3400 NOT USED ON GR3400 NOT USED ON GR3400 NOT USED ON GR3400 ...

Page 331: ...BLUE BLACK PINK RED WHITE BLACK WHITE RED WHITE BLACK WHITE RED WHITE BLACK WHITE RED WHITE RED WHITE RED WHITE BLK WHITE BLK WHITE BLK WHITE RED WHITE BLACK WHITE RED WHITE BLACK WHITE RED WHITE BLACK WHITE PINK RED GREEN GREEN BLUE GREEN VIOLET WHITE BROWN BLUE GRAY TAN BLACK BLACK BLACK ORANGE YELLOW BLACK YELLOW GRAY BLACK GRAY WHITE GREEN BLACK BLACK BLUE BLACK WHITE GRAY BLACK YELLOW BLUE BR...

Page 332: ...Page 10 16 This page is intentionally blank ...

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