Toro Greensmaster 3250-D 04383 Service Manual Download Page 119

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Greensmaster 3250--D

Hydraulic System (Rev. I)

Page 4 -- 81

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Hydraulic System

Summary of Contents for Greensmaster 3250-D 04383

Page 1: ...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...

Page 2: ...Greensmaster 3250 D This page is intentionally blank...

Page 3: ...ME and MJ Series Service Procedure Service Manual 2704 003 Sauer Danfoss Steering Unit Type OSPM Service Manual Chapter 5 Electrical System Electrical Schematics 5 2 Special Tools 5 3 Troubleshooting...

Page 4: ...Greensmaster 3250 D This page is intentionally blank...

Page 5: ...Rev H Greensmaster 3250 D Page 1 1 Safety Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS 2 Before Operating 2 While Operating 3 Maintenance and Service 4 SAFETY AND INSTRUCTION DECALS 4 Safety...

Page 6: ...y Copies of the Operator s Manual are available on the internet at www Toro com 2 Never allow children to operate the machine Never allow adults to operate it without proper instructions 3 Become fami...

Page 7: ...at the operator position Ear protec tors are recommended for prolonged exposure to re duce the potential of permanent hearing damage 17 Raise the cutting units when driving from one work area to anoth...

Page 8: ...away from the cutting units at tachments and any moving parts Keep everyone away 34 Do not overspeed the engine by changing governor settings To assure safety and accuracy have an Autho rized Toro Di...

Page 9: ...asteners Inch Series 4 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners 5 Other Torque Specifications 6 Conversion Factors 6 MAINTENANCE 6 Product Records Insert a copy of the...

Page 10: ...0 09375 Rev H Greensmaster 3250 D Page 2 2 Product Records and Maintenance Equivalents and Conversions...

Page 11: ...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 Seri...

Page 12: ...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...

Page 13: ...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...

Page 14: ...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...

Page 15: ...Throttle Control 7 Adjust Idle Speed 7 SERVICE AND REPAIRS 8 Service Air Cleaner 8 Change Engine Oil and Filter 9 Replace Fuel Filter 9 Muffler and Air Cleaner 10 Muffler Removal and Installation 11 A...

Page 16: ...tratton Vanguard Daihatsu Repair Manual for 3 Cylinder Water Cooled Diesel Engines The use of some specialized test equip ment is explained However the cost of the test equip ment and the specialized...

Page 17: ...ion Ratio 24 5 1 Firing Order 1 2 3 Dry Weight approximate kg lb 72 159 Fuel No 2 Diesel per ASTM D975 Fuel Capacity liters gallons 22 7 6 0 Fuel Injection Pump VE Bosch type Governor All speed type L...

Page 18: ...the fuel tank 1 Checking Engine Oil IMPORTANT Check level of oil every 8 operating hours or daily Crankcase capacity is approximately 3 5 qts 3 3 L with filter 1 Position machine on a level surface 2...

Page 19: ...he engine 3 Start engine and continue to operate primer button until engine runs smooth Figure 4 1 Fuel filter 2 Priming pump 3 Drain Plug 2 1 3 Check Cooling System The cooling system is filled with...

Page 20: ...ted water will be mixed with diesel fuel drain the fuel filter into a suitable con tainer and dispose of properly 2 Place a drain pan under the fuel filter 3 Open the drain plug on the fuel filter wat...

Page 21: ...just belt to proper tension and tighten bolts Figure 7 1 Bolt 2 Belt 2 1 Adjust Throttle Control Proper throttle operation is dependent upon proper ad justment of throttle control Make sure throttle c...

Page 22: ...t ex ceed 40 psi to prevent damage to the filter element Rinse filter from the clean side to dirty to side C Dry filter element using warm flowing air that does not to exceed 160 F 71 C or allow eleme...

Page 23: ...es when replacement becomes necessary 1 Close fuel shut off valve DANGER Because diesel fuel is flammable use caution when storing or handling it Do not smoke while filling the fuel tank Do not fill f...

Page 24: ...late 12 Exhaust pipe 13 R clamp 14 Washer 15 Flat washer 16 Cap screw 17 Air cleaner hose 18 Lock nut 19 Hose clamp 20 Decal 21 Vaculator valve 22 Fuel hose to injector pump 23 Not used 24 Hose clamp...

Page 25: ...If the exhaust pipe 12 was removed install pipe to exhaust plate 11 with clamp 10 4 Carefully attach muffler 7 to the exhaust pipe 12 Secure muffler 7 to the pump plate 30 with two cap screws 4 5 Sec...

Page 26: ...er bracket 14 Plug 15 Cap screw 16 Lock spring washer 17 Radiator hose from water jacket 18 Cap screw 19 Fan shroud 20 Worm clamp 21 Pop rivet 22 Cap screw 23 Double hose clamp 24 Breather hose 25 Exp...

Page 27: ...sup port tab and double hose clamp 23 to the frame tab 7 Remove the radiator support 8 from the frame and onto a workbench 8 Remove four cap screws 18 and lock nuts 9 se curing the radiator 4 to the r...

Page 28: ...uel tank 3 Grommet 4 Flat washer 5 Not used 6 Washer head screw 7 Not used 8 Not used 9 Fuel shut off fitting 10 Hose clamp 11 Fuel fitting 12 Not used 13 Mounting plate 14 Flat washer 15 Not used 16...

Page 29: ...t and support the mounting plate up from the rear of the machine 4 Loosen hose clamp 26 and disconnect fuel hose 23 from fuel fitting 11 5 Loosen hose clamp 10 and disconnect fuel hose 18 from fuel ta...

Page 30: ...acket LH 25 Engine bracket RH 26 Cap screw 27 Pump plate 28 Upper spacer 29 Spacer 30 Cap screw 31 Thrust washer 32 Lock nut 33 Cap screw 34 Hydrostat support brace LH 35 Hydrostat support brace RH 36...

Page 31: ...n and pets 6 Drain radiator 4 as follows Fig 17 A Open drain petcock 32 on the back of the radia tor Drain radiator completely into a suitable contain er and close petcock B Disconnect expansion tank...

Page 32: ...19 E Disconnect fuel hose from the injector pump that goes to the fuel tank Fig 24 Loosen clamps 19 and 20 to allow removal of the hose Fig 18 F Disconnect fuel hose coming from the fuel filter water...

Page 33: ...ing 14 Disconnect electrical connections from the follow ing engine components A The black negative battery cable and black wire harness ground on the hydrostat end of the en gine block B The red batt...

Page 34: ...the other person guides the engine out of the frame 18 Remove engine from the frame A Attach a short section of chain between both en gine mounts B Connect hoist or chain fall to center of chain IMPO...

Page 35: ...arter terminals C The orange wire to the glow plug bus D The blue white wires and plug in connector to the ETR solenoid injection pump E The yellow red wire to the water temperature switch F The white...

Page 36: ...Secure mounting bracket to the air cleaner bracket B Connect air cleaner hose 17 to the engine air intake manifold 14 Connect hydraulic oil cooler if installed Fig 21 A Connect tube and O ring to hyd...

Page 37: ...port 2 Remove fan shroud to access radiator corners 3 If installed lift oil cooler from supports CAUTION Use eye protection such as goggles when using compressed air IMPORTANT Air pressure should not...

Page 38: ...Greensmaster 3250 D Page 3 24 Engine This page is intentionally blank...

Page 39: ...op Speed 53 Adjust Implement Relief Valve R5 Machines with Serial Number Under 220999999 54 Adjust Manifold Relief Valves R1 and R2 54 SERVICE AND REPAIRS 55 General Precautions for Removing and Insta...

Page 40: ...Greensmaster 3250 D Hydraulic System Rev I Page 4 2 This page is intentionally blank...

Page 41: ...r motor Steering Control Valve Distributor valve with rotary meter Implement Steering and Lift Relief Pressure R5 Machines with Serial Number Under 220999999 1000 PSI 69 0 bar over Charge Pressure Mac...

Page 42: ...e with others IMPORTANT Use only types of hydraulic fluids specified in the Operator s Manual Other fluids may cause system damage Checking Fluid Level Note A red dye additive for the hydraulic system...

Page 43: ...ice IMPORTANT Do not tow the machine faster than 2 to 3 mph because drive system may be damaged If machine must be moved a considerable distance transport it on a truck or trailer 1 Locate by pass val...

Page 44: ...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...

Page 45: ...h in 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 m...

Page 46: ...t Records 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...

Page 47: ...ion with 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...

Page 48: ...L R PB T P MA MB REEL MOTORS MOW BACKLAP M1 M2 M3 14 8 5 1 3 7 22 4 20 3 13 9 BARS 7 100 9 5 1 24 DISPLACEMENT PRESSURE COMPONENT P1 P2 P3 M1 M2 M3 M4 M5 V1 R1 R2 R4 5 9 55 8 168 8 10 3 10 3 12 0 168...

Page 49: ...3250 D Hydraulic System Rev I Page 4 11 Hydraulic Schematic Greensmaster 3250 D All solenoids are shown as de energized Serial Number From 230000000 To 230001500 OPTIONAL 3WD TRACTION WHEEL MOTOR Hydr...

Page 50: ...ydraulic Schematic Greensmaster 3250 D All solenoids are shown as de energized Serial Number From 230001501 To 260999999 OPTIONAL 3WD TRACTION WHEEL MOTOR BACKLAP AND REEL SPEED CONTROL VALVES ARE INC...

Page 51: ...master 3250 D Hydraulic System Rev I Page 4 13 Hydraulic Schematic Greensmaster 3250 D All solenoids are shown as de energized Serial Number Over 270000000 OPTIONAL 3WD TRACTION WHEEL MOTOR Hydraulic...

Page 52: ...HYDROSTAT OIL COOLER OIL FILTER P1 P2 ENGINE RPM GEAR PUMP MANIFOLD BLOCK STEERING CONTROL VALVE L R PB T P MA MB REEL MOTORS M1 M2 M3 R5 V1 OPTIONAL KIT Traction Forward High Pressure Low Pressure Ch...

Page 53: ...ge Charge circuit pressure is maintained by the charge relief valve R4 that is attached to the hydrostat back plate Reverse The traction circuit operates essentially the same in re verse as it does in...

Page 54: ...RPM GEAR PUMP MANIFOLD BLOCK STEERING CONTROL VALVE L R PB T P MA MB REEL MOTORS M1 M2 M3 R5 V1 OPTIONAL KIT All other solenoids are shown as de energized Solenoids S2 and S3 are shown in the energiz...

Page 55: ...nt The lift cylinder position is locked in place since there is no complete circuit of flow to and from the lift cylinders Note On traction units with serial numbers from 230000601 to 260999999 soleno...

Page 56: ...S1R1 ENERGIZED ENERGIZED NOT ENERGIZED All other solenoids are shown as de energized Solenoids S2 and S3 are shown in the energized position Raise Cutting Units High Pressure Low Pressure Charge Retur...

Page 57: ...line for the center cut ting unit allows a slight delay in raising that cutting unit When solenoid valves S2 and S3 de energize spring action returns the valves to their original position and by passe...

Page 58: ...P1 P2 ENGINE RPM GEAR PUMP MANIFOLD BLOCK STEERING CONTROL VALVE L R PB T P MA MB REEL MOTORS M1 M2 M3 R5 V1 OPTIONAL KIT All other solenoids are shown as de energized Solenoid S1 is shown in the ene...

Page 59: ...lve S6 is ener gized when the cutting units are raised This forces the return flow from the reel motors through the 125 orifice putting back pressure on the reel circuit and stopping the reels from ro...

Page 60: ...TION WHEEL MOTOR ENERGIZED S1R1 All other solenoids are shown as de energized Solenoid S1R1 is shown in the energized position Mow High Pressure Low Pressure Charge Return or Suction Flow Greensmaster...

Page 61: ...R1 is energized In the energized position this valve directs oil flow to the reel motors and also func tions as the mow circuit relief valve Oil flow from manifold port P1 flows through the reel speed...

Page 62: ...2 ENGINE RPM GEAR PUMP MANIFOLD BLOCK STEERING CONTROL VALVE L R PB T P MA MB REEL MOTORS M1 M2 M3 R5 V1 OPTIONAL KIT All solenoids are shown as de energized Spool valve is positioned for a right turn...

Page 63: ...sed out port PB back through solenoid valve S2 to the hydrostat Second the remainder of the flow is drawn through rotary meter V1 and out port R Pressure moves the piston in the direction for a right...

Page 64: ...pter fit tings for use on this machine Use hydraulic tester as recommended in Testing section of this chapter 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic te...

Page 65: ...FITTING KIT NO TOR4079 Measuring Container TOR4077 Use this container for doing hydraulic motor efficiency testing motors with case drain lines only Measure effi ciency of a hydraulic motor by restri...

Page 66: ...er if installed is damaged or plugged By pass relief is stuck open or air flow is obstructed Working load of machine e g use of verticutter may require use of oil cooler Charge pressure is low see Cha...

Page 67: ...or drive pump is noisy ca vitation Reservoir oil level is low Hydraulic pump suction line is restricted Hydraulic pump suction line has an air leak Reels will not turn Solenoid valve S1 is stuck open...

Page 68: ...insufficient oil flow Emergency steering ball in steering control valve is missing or damaged Regular adjustments to steering wheel are necessary because of dif ficulty of driving in a straight line L...

Page 69: ...e is worn Steering response is too slow and heavy when trying to turn quickly Oil supply to the steering control valve is insufficient Turning steering wheel turns ma chine in the opposite direction H...

Page 70: ...of injury Gangrene may result from such an injury 1 Clean machine thoroughly before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on...

Page 71: ...elief Valve R4 Pressure Test Lower Cutting Units Relief Valve R2 Pressure Test Implement Relief Valve R5 Pressure Test Gear Pump P2 Flow Test Steering Control Valve Test 5 For issues with the cutting...

Page 72: ...ostat P3 Flow Test Using Tester with Flowmeter and Pressure Gauge TRACTION WHEEL MOTORS M4 M5 DUMP VALVE R4 P3 HYDROSTAT FROM GEAR PUMP P2 TO HYDRAULIC RESERVOIR TESTER High Pressure Low Pressure Retu...

Page 73: ...and flow meter in series with the pump and the disconnected hose Make sure flow control valve on the tester is fully open 7 Make sure functional lever is in the transport posi tion 8 Start engine and...

Page 74: ...ciency Test Using Tester with Flowmeter and Pressure Gauge TRACTION WHEEL MOTORS M4 M5 DUMP VALVE R4 P3 HYDROSTAT FROM GEAR PUMP TO HYDRAULIC RESERVOIR TESTER High Pressure Low Pressure Return or Suct...

Page 75: ...flow meter in series with the pump and the disconnected hose same tester connections as Traction Drive Hydrostat P3 Flow Test Make sure the tester flow control valve is fully open CAUTION Use extreme...

Page 76: ...N WHEEL MOTORS M4 M5 DUMP VALVE R4 P3 HYDROSTAT P1 P2 ENGINE RPM GEAR PUMP R5 CIRCUIT TO REEL MOTOR CIRCUITS AND LIFT CIRCUIT FROM LIFT High Pressure Low Pressure Return or Suction Flow 3WD OPTIONAL R...

Page 77: ...10 3 bar Record test results 7 Shut off engine 8 If specification is not met remove hydrostat back plate assembly that contains the charge relief valve see Piston Pump Service in the Service and Repa...

Page 78: ...SCHARGE FITTING CIRCUIT FROM LIFT RELIEF VALVE R5 FROM HYDROSTAT SCHEMATIC FROM MACHINE WITH SERIAL NUMBER UNDER 220999999 SHOWN PHOTO SHOWS RELIEF VALVE R5 AS USED IN MACHINES WITH SERIAL NUMBER UNDE...

Page 79: ...ressure will affect R5 pressure 6 Implement relief valve R5 pressure should be A For machines with serial number under 220999999 relief valve R5 pressure should be 900 to 1100 PSI 62 to 76 bar higher...

Page 80: ...T CYLINDERS S1 T S2 S3 S4 R1 R2 FC1 LC1 RD1 O1 P1 ST PT P2 OIL COOLER OIL FILTER P1 P2 ENGINE RPM GEAR PUMP MANIFOLD BLOCK STEERING CONTROL VALVE L R PB T P MA MB R5 V1 OPTIONAL KIT FLOW CONTROL VALVE...

Page 81: ...est if relief pressure cannot be determined within the LOWER func tion six 6 second timeframe repeat this test proce dure Note The lower cutting units relief valve R2 is in se ries with charge relief...

Page 82: ...ssure Gauge P1 P2 ENGINE RPM GEAR PUMP R5 TO TRACTION CHARGE CIRCUIT FROM HYDROSTAT TO HYDRAULIC MANIFOLD FROM LIFT TESTER TO HYDRAULIC MANIFOLD PUMP P1 OUTLET TO STEERING AND LIFT CIRCUITS High Press...

Page 83: ...is fully open 5 If a backlap kit is installed on the machine make sure backlap knob on the manifold block is in the mow position and reel speed is set to maximum 6 Make sure tester load valve is full...

Page 84: ...L2B L2A L3B L3A OPTIONAL VALVES S1 T S2 S3 S4 R1 R2 FC1 LC1 RD1 O1 P1 ST PT P2 TO HYDRAULIC RESERVOIR MANIFOLD BLOCK MA MB FROM GEAR PUMP P1 FROM STEERING TO AND FROM LIFT CYLINDERS TO LEFT REEL MOTOR...

Page 85: ...e slowly clos ing the flow control valve on the tester to fully closed 9 On machines with serial number under 260999999 system pressure should be from 2160 to 2640 PSI 149 to 182 2 bar Note If a detha...

Page 86: ...and Pressure Gauge MEASURING M1 M2 M3 CONTAINER FROM MANIFOLD PORT MA TO MANIFOLD PORT MB TO HYDRAULIC RESERVOIR RIGHT MOTOR RETURN LEFT MOTOR RETURN LEFT MOTOR CASE DRAIN RIGHT MOTOR CASE DRAIN REAR...

Page 87: ...into a drain pan 7 One person should sit on the seat and operate the machine while a second person measures case drain leakage Make sure functional control lever is in NEU TRAL Start engine and move t...

Page 88: ...ge 4 50 Steering Control Valve Test POWER L R PB T P V1 STEERING VALVE LEFT TURN STEERING CYLINDER PLUG High Pressure Low Pressure Return or Suction Flow SCHEMATIC FROM MACHINE WITH SERIAL NUMBER UNDE...

Page 89: ...R5 Pressure and Gear Pump P2 Flow tests to make sure that relief valve and gear pump are functioning correctly 6 If either of these performance tests indicate a steer ing problem determine if the stee...

Page 90: ...ine D Rotate eccentric until creep does not occur in ei ther direction When the wheel stops rotating tight en nut locking eccentric and adjustment Verify adjustment with throttle in SLOW and FAST posi...

Page 91: ...r cutting unit lower circuit has a flow control valve which is preset at the factory to about 3 turns open An adjustment may be required to compen sate for differences in hydraulic oil temperatures mo...

Page 92: ...a turn counterclockwise 4 Install and tighten cap to valve After adjustment re test pressure setting see TESTING Figure 26 CAP ADJUSTMENT HEX SOCKET Adjust Manifold Relief Valves R1 and R2 These reli...

Page 93: ...t labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed 5 Note the position of hydraulic fittings especially el bow fittings on hydraulic components befo...

Page 94: ...hose 2 Gear pump 3 Hydraulic fitting 4 Hydraulic fitting 5 O ring 6 O ring 7 Hose clamp 8 O ring 9 O ring 10 Hydraulic hose 11 O ring 12 Hydrostat 13 Hex socket screw 14 Flat washer 15 Hydraulic hose...

Page 95: ...O rings from the gear pump 7 Support gear pump Separate gear pump from the hydrostatbyremoving bothhex sockethead screwsand flat washers Remove O ring from between the gear pump and hydrostat Install...

Page 96: ...r 8 Back up gasket 9 Wear plate 10 Pressure seal 11 Cap screw 12 O ring 13 Adapter plate 14 Key 15 Not used 16 Back gear 17 Washer 18 Plug 19 Suction fitting Figure 29 11 17 1 18 8 10 9 5 6 3 12 16 14...

Page 97: ...engage starter for ten 10 seconds to the prime pump Allow the starter to cool and repeat this step again 7 Reconnect electrical connector to the fuel stop sole noid 8 Make sure traction pedal is in ne...

Page 98: ...c T fitting 31 Hose assembly 32 Hex socket head screw 33 Cap screw 34 Flat washer 35 Relief valve base 36 90o hydraulic fitting 37 Lock nut 38 Hose assembly 39 Hydraulic T fitting 40 Flat washer 41 Re...

Page 99: ...cable sup port of the neutral system assembly to the hydrostat Lift and secure neutral system assembly away from the hy drostat Fig 33 CAUTION Before continuing further read and become fa miliar with...

Page 100: ...h cap screws 15 flat washers 19 and lock nuts 14 4 Apply Loctite 242 or equivalent to threads of both square head screws 5 Install screws 5 in pump hub 4 to secure hub to pump shaft Torque screws from...

Page 101: ...ining ring 31 Bearing race 32 Thrust bearing 33 Washer 34 Shaft seal 35 Retaining ring 36 Retaining ring 37 O ring 38 O ring 39 Seal kit 40 O ring 41 Charge relief housing 42 Charge relief poppet R4 4...

Page 102: ...into the 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 Me...

Page 103: ...Place drain pan under filter and remove filter Allow hydraulic oil to drain completely 2 Fill replacement filter with hydraulic fluid see Check Hydraulic System Fluid lubricate the sealing gasket and...

Page 104: ...gage the parking brake lower the cutting units and stop the en gine CAUTION Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Co...

Page 105: ...Install O rings and hydraulic fittings 17 to the mo tor and tighten 3 Lubricate new O rings 18 with clean hydraulic fluid Install O rings and hose assemblies 15 or 16 to the hydraulic fittings 17 Tigh...

Page 106: ...the cutting units and stop the en gine CAUTION Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components 2 Chock both front w...

Page 107: ...to 122 N m 3 Reinstall grease fitting 22 onto hydraulic motor and hub assembly 2 so it points away from the wheel 25 4 Install flangette 8 bearing 5 and relube flangette 6 onto the motor shaft 5 Posi...

Page 108: ...ff key 18 Wear plate 19 Rotor 20 Vane 21 Stator 22 Manifold 23 Commutator ring 24 End cover 25 Rotor set 26 Commutator assembly 27 Seal kit 28 Housing assembly Figure 40 1 2 3 4 5 6 7 8 9 10 16 17 18...

Page 109: ...il to gasket on the new filter Screw filter on until gasket contacts mounting plate then tighten filter half a turn Note Use only hydraulic fluids including biodegrad able specified in Checking Hydrau...

Page 110: ...Before removing any parts from the hydraulic sys tem park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine CAUTION Before continuing further read an...

Page 111: ...ed in small valve orifices or seal areas causing malfunc tion B If sealing surfaces appear pitted or damaged the hydraulic system may be over heating or there may be water in the system CAUTION Use ey...

Page 112: ...9 24 10 11 11 7 17 6 13 8 14 15 1 3 2 3 25 26 27 28 28 27 30 29 30 29 FRONT RIGHT 31 FRONT REEL MOTORS Removal Fig 44 and 45 1 Before removing any parts from the hydraulic sys tem park machine on a le...

Page 113: ...oil to drain from hoses into a suitable container Put caps or plugs on ends of hoses to prevent contamination 5 Remove hydraulic fittings and O rings from the reel motor Put caps or plugs in motor ope...

Page 114: ...g ring with retaining ring pliers B Plug both motor ports 3 4 16 UNF 2B with threaded plugs Attach hydraulic hand pump to the external drain port 7 16 20 UNF 2B CAUTION Point shaft seal away from face...

Page 115: ...ear and drive shaft assemblies into clean hydraulic oil Install both assemblies into the cover as sembly gear pockets Make sure that both gears mesh 4 Coat new load plate assembly lightly with petrole...

Page 116: ...the motor thoroughly After cleaning remove plugs and drain any oil out of the motor 2 Use a marker or scribe to make a diagonal mark across the front flange body and rear cover for reas sembly purpose...

Page 117: ...ION Use eye protection such as goggles when using compressed air 2 Clean all motor components with solvent Dry all parts with compressed air 3 Inspect drive gear idler gear and bearing blocks Fig 51 f...

Page 118: ...ty using identification marks made during disassembly 7 Remove any excess lubrication from mating sur faces of body rear cover and front flange Make sure that these surfaces are clean and dry 8 Instal...

Page 119: ...Greensmaster 3250 D Hydraulic System Rev I Page 4 81 This page is intentionally blank Hydraulic System...

Page 120: ...al Precautions for Removing and Installing Hydraulic System Components CAUTION The radiator and oil cooler may be hot To avoid possible burns allow the engine and cooling systems to cool before workin...

Page 121: ...il cooler onto cooler brackets while attaching the formed hoses to the cooler Secure hoses by tighten ing the hose clamps 3 Clean radiator screen and reinstall 4 Remove clamps that where used to preve...

Page 122: ...hydraulic connections for reassembly 3 Disconnect hose assemblies and O rings from the hydraulic fittings Allow hoses to drain into a suitable container 4 Remove cotter pin from the clevis pin Pull c...

Page 123: ...ic System Components 2 Label all hydraulic connections for reassembly 3 Disconnect hose assemblies and O ring from the hydraulic fittings Allow hoses to drain into a suitable container 4 Remove cotter...

Page 124: ...10 Back up ring 11 Dust seal 12 Internal collar Figure 55 REAR HYDRAULIC CYLINDER 1 6 7 11 2 3 4 5 8 9 10 12 24 to 30 ft lb 33 to 41 N m 1 Barrel 2 Shaft 3 Nut 4 Piston 5 Uni ring 6 O ring 7 Rod seal...

Page 125: ...draulic oil A Install Uni ring and O ring to the piston B Install dust seal O ring back up ring and dust seal to the head IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surfa...

Page 126: ...17 O ring 18 O ring 19 O ring 20 O ring 21 O ring 22 O ring 23 O ring 24 O ring 25 O ring 26 O ring 27 O ring 28 O ring 29 O ring 30 O ring 31 O ring 32 O ring 2 16 11 2 5 10 7 13 6 14 1 9 16 12 8 3...

Page 127: ...fittings Allow hoses to drain into a suitable container 5 Remove both cap screws 12 from the hydraulic manifold Remove manifold assembly from the ma chine IMPORTANT Before disconnecting any hydraulic...

Page 128: ...5 ft lb 47 N m 35 ft lb 47 N m 15 in lb 1 7 N m 35 ft lb 47 N m Loctite 242 Loctite 242 Loctite 242 PLUG TORQUE SAE 4 9 to 11 ft lb 12 to 14 N m SAE 6 16 to 18 ft lb 22 to 24 N m SAE 8 43 to 46 ft lb...

Page 129: ...in easily without binding Note Use care when handling the cartridge valve Slight bending or distortion of the stem tube can cause binding and malfunction C Torque cartridge valve using a deep socket...

Page 130: ...e R2 19 Logic control cartridge valve OR1 20 Ball 21 Solenoid coil 22 Dowel pin 23 Ball switch N O 24 O ring 25 Flow control cartridge valve FC2 26 Nut 27 Flow control orifice 025 28 Hydraulic fitting...

Page 131: ...amination can become lodged in smallvalve orifices or seal areas causing valve malfunction B If valve sealing surfaces appear pitted or dam aged the hydraulic system may be overheating or there may be...

Page 132: ...nd dry with compressed air 5 Reinstall rotary cartridge valve into manifold port A Lubricate new O rings and backup rings of seal kit with clean hydraulic oil and install The O rings and backup rings...

Page 133: ...w 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...

Page 134: ...r wire 15 Harness 16 Relay 17 Knob 18 Jam nut 19 Indicator plate 20 Spring 21 Spring 22 Detent plate 23 Set screw 24 Ball 25 Locating plate 26 Locating plate 27 Manifold Figure 62 2 1 3 4 6 5 9 10 12...

Page 135: ...cartridge valve 7 or 13 for proper operation and sealing B Thread valve carefully into the applicable port RD1 or FC1 The valve should go in easily without binding Torque valve to 35 ft lb 47 N m 7 Re...

Page 136: ...If sealing surfaces appear pitted or damaged the hydraulic system may be overheating or there may be water in the system CAUTION Use eye protection such as goggles when using compressed air 4 Clean l...

Page 137: ...raulic fitting Allow hose to drain into a suitable container 3 Remove hydraulic fitting and O ring from flow con trol valve Remove valve and O ring from hydraulic fit ting Put caps or plug on hydrauli...

Page 138: ...raulic fitting 2 used 18 Cap screw 19 Steering arm 20 Decal 21 Socket head screw 3 used 22 Square head screw 23 Steering control valve 24 Thrust washer 25 Speed nut 6 used 26 Warning decal 27 Steering...

Page 139: ...teering column Fig 67 Use appropriate illustration as a guide when removing steering control valve 6 For hydraulic hoses that attach to fittings in steering control valve disconnect hoses from fitting...

Page 140: ...steering arm cover with cap screws 4 Forhydraulichose s thatthreaddirectlyintocontrol valve correctly connect opposite end of hose to fitting on hydraulic manifold or steering cylinder 5 Connect rema...

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Page 142: ...b 24 to 37 N m 18 to 27 ft lb 24 to 37 N m Disassembly Fig 68 1 Make sure caps or plugs are in motor openings to prevent contamination Clean motor with solvent IMPORTANT Use caution when using a vise...

Page 143: ...carefully out of the sleeve 10 Press springs out of their slots in the spool 11 Remove dust seal and O ring kin ring from the housing Discard all seals O rings and washers 12 Remove all nicks and bur...

Page 144: ...the largest threaded hole Secure ball into hole by threading in the bushing Make sure the top of the bushing lies just bellow the surface of the housing Fig 74 10 Coat new O ring lightly with petroleu...

Page 145: ...asher into the hole shown Fig 76 and 77 17 Secure remaining screws with washers into control valve Torque all screws in a criss cross pattern from 18 to 27 ft lb 24 to 37 N m 18 Install dust seal care...

Page 146: ...s is extremely important when repairing hydraulic components Work in a clean area Before disassembly drain the oil then plug the ports and thoroughly clean the exterior During repairs always protect m...

Page 147: ...springs 5 Apply a light coating of clean hydraulic fluid to the spool and slide it into the sleeve Be sure the centering springs fit into the notches in the sleeve 6 Install the pin 7 Apply a light co...

Page 148: ...Spool 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 Fig...

Page 149: ...Greensmaster 3250 D Hydraulic System Rev I Page 4 111 This page is intentionally blank Hydraulic System...

Page 150: ...lic hose 22 90o Hydraulic fitting 23 O ring 24 O ring 25 Hydraulic hose 26 Jam nut 27 Bearing cone 28 Bearing cup 29 Rear spindle spacer 30 Grease fitting 31 Decal 32 Hose clamp 33 Hex washer head scr...

Page 151: ...ings and O rings from the cylinder CAUTION Support rear wheel to prevent dropping and causing personal injury while removing hex nut Use two people to remove steering cylinder 8 If the rear ball joint...

Page 152: ...ing ring 13 Piston 14 Rod 15 Barrel 16 Head ball joint end 8 7 2 3 4 5 12 13 10 9 11 14 6 1 2 3 16 5 6 7 15 12 NOTE On machines with serial number above 270000000 Fig 83 the steering cylinder design d...

Page 153: ...clean solvent Dry parts with com pressed air Do not wipe parts dry with paper towels or cloth Lint in a hydraulic system will cause damage 7 Carefully inspect internal surface of barrel for dam age d...

Page 154: ...29 30 to 60 in lb 3 4 to 6 8 N m Removing Hydraulic Reservoir Fig 84 1 Before removing any parts from the hydraulic sys tem park machine on a level surface set brake lower cutting units and stop engin...

Page 155: ...re all bracket fasteners are tight Installing Hydraulic Reservoir Fig 84 1 Place antiseize lubricant into all four inserts at the bottom of the hydraulic tank 6 Position tank onto the mounting plate 2...

Page 156: ...arness 22 R clamp 23 Oil level sensor 24 O ring 25 Cartridge valve with O ring 26 Formed inlet hose 27 Hydraulic barb fitting 28 O ring 29 Plug 30 Cap screw 31 Flat washer 32 Grommet 33 Hydraulic oil...

Page 157: ...and black wires on the main tractor har ness Pull leak detector harness out of the access hole on the hydraulic tank 7 Loosen four cap screws securing the valve assem bly to the fill neck on the hydra...

Page 158: ...g 88 1 Coat all O rings with clean hydraulic oil 2 Secure sight gauge 34 and new O ring 28 to the leak detection tank 11 Torque gauge from 100 to 125 in lb 11 3 to 14 1 N m 3 Secure both hydraulic bar...

Page 159: ...t Open Circuit 8 COMPONENT TESTING 9 Ignition Switch 9 Safety Relays 10 Seat Switch 11 Hour Meter 11 Fuse Block 11 Functional Control Lever Reed Switches and Actuator 12 Backlap Switch If Equipped 12...

Page 160: ...reensmaster 3250 D Page 5 2 Electrical System Rev C Electrical Schematics The electrical schematic and other electrical drawings for the Greensmaster 3250 D are located in Chapter 8 Electrical Diagram...

Page 161: ...he use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internalresistance ofa digitalme ter in the voltage mode will make sure that excess cur rent is not allo...

Page 162: ...s are loose or corroded Battery ground to frame is loose or corroded Wiring at starter is faulty Starter solenoid is faulty Starter mounting bolts are loose or not supplying a sufficient ground for so...

Page 163: ...de D5 circuit is open Run relay or high temperature relay is faulty High temperature switch is shorted ETR solenoid is faulty Glow plugs are faulty Engine or fuel system is malfunctioning see Chapter...

Page 164: ...t switch from closing Seat switch is faulty or out of adjustment Seat switch wiring is loose corroded or damaged Battery does not charge Wiring to the charging circuit see Wiring Schematics components...

Page 165: ...faulty Mow sensor and or mow relay is faulty or grounded Raise switch and or joystick relay R7 is faulty or grounded Cutting units will not raise Wiring to run mow backlap circuits see Wiring Schemat...

Page 166: ...s is a simple test used to determine if a charging sys tem is functioning It will tell you if a charging system has an output but not its capacity Use a multimeter set to the DC volts setting Connectt...

Page 167: ...ting electrical components for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected Ignition Switch The ignition key switch has three positions OFF RUN...

Page 168: ...7 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is ap plied and removed from terminal 85 3 Disconnect voltage from...

Page 169: ...itch through the seat cushion There should be continuity as the seat cushion approaches the bottom of its travel 6 Connect switch electrical connector Reinstall seat 1 Seat bolts 2 Electrical connecto...

Page 170: ...itch just closes and then rotate actuator two complete turns closer to switch 6 When adjusting switches or actuator tighten jam nuts 30o past finger tight 7 After switch or actuator adjustment check c...

Page 171: ...he hydraulic oil during machine operation will cause oil to transfer into the leak detection tank The oil is allowed to return to the main tank when the ignition switch is turned off see Fig 12 13 and...

Page 172: ...crew driver into valve assembly and gently push down on switch float Fig 15 Alarm should sound after one second delay 5 Release float alarm should stop sounding 6 If alarm fails to stop sounding turn...

Page 173: ...er is removed the timer is reset 1 Isolate timer from the circuit Connect 12VDC source in series with voltmeter to connector of timer Make sure to observe polarity 2 The voltmeter should jump from 0 t...

Page 174: ...4 Turn the ignition switch to OFF Connect white red wire to the oil pressure switch High Temperature Water Shutdown Light When the coolant temperature is above 238oF 114oC the temperature light comes...

Page 175: ...e engine and remove the temperature switch 2 Put switch in a container of oil with a thermometer and slowly heat the oil Fig 21 CAUTION Handle the hot oil with extreme care to prevent personal injury...

Page 176: ...agrams Testing with the engine on 1 If the lamp is on with the engine running shut off the engine immediately 2 Disconnect the white red wire from the switch 3 Turn the ignition switch to ON The oil p...

Page 177: ...s started After 6 seconds the load is de energized 1 Connect voltmeter across test load and test load to timer Connect 12VDC source to timer and load Make sure to observe polarity After 6 seconds ther...

Page 178: ...start only with the Functional Con trol Lever in NEUTRAL neutral sensor closed Also it allows the engine to continue to run with either the Func tional Control Lever in NEUTRAL Neutral Sensor closed...

Page 179: ...d to switch on Remove voltage source from solenoid 3 Measure resistance between the two solenoid coil connector terminals The coil resistance for machines with serial numbers under 260999999 is identi...

Page 180: ...at are con nected to the wire harness with a four wire connector Fig 34 1 Verify coil resistance between terminals 86 and 85 with a multimeter ohms setting Resistance should be from 41 to 51 ohms 2 Co...

Page 181: ...is moved to NEUTRAL or TRANSPORT 1 Sit on the seat engage parking brake and move Functional Control Lever to NEUTRAL Try to depress traction pedal If the pedal does not depress the inter lock system i...

Page 182: ...ctions and maintenance A Check for cracks caused by overly tight or loose hold down clamp Replace battery if cracked and leaking B Check battery terminal posts for corrosion Use a terminal brush or st...

Page 183: ...timeter to the battery terminals F Apply a test load of one half the Cranking Perfor mance see Battery Specifications rating of the bat tery for 15 seconds G Take a voltage reading at 15 seconds then...

Page 184: ...s 22 hrs 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 beca...

Page 185: ...Rev D Chapter 6 Chassis Table of Contents SPECIFICATIONS 2 SPECIAL TOOLS 2 ADJUSTMENTS 3 Brake Adjustment 3 SERVICE AND REPAIRS 4 Rear Wheel 2WD 4 Rear Wheel 3WD 7 Front Wheels and Brakes 10 Front Lif...

Page 186: ...x 10 50 x 2 ply 8 to 12 PSI 0 55 to 0 83 bar Rear tire pressure 19 x 10 50 x 2 ply 8 to 15 PSI 0 55 to 1 04 bar Wheel lug nut torque 70 to 90 ft lb 95 to 122 N m Special Tools Wheel Hub Puller TOR4097...

Page 187: ...or proper amount of free travel A Loosen clevis by exposing more threads on the brake rod to decrease free travel of the brake pedal B Tighten clevis by exposing fewer threads on the brake rod to incr...

Page 188: ...Steering cylinder 21 Hydraulic hose 22 90_ Hydraulic fitting 23 O ring 24 O ring 25 Hydraulic hose 26 Jam nut 27 Bearing cone 28 Bearing cup 29 Rear spindle spacer 30 Grease fitting 31 Decal 32 Hose c...

Page 189: ...ame and make sure ball joint 17 releases from the shaft ring of the steering cylinder 20 E Inspect bearing cones 27 and bearing cups 28 for damage and replace if necessary F Remove bearing cones 27 an...

Page 190: ...front corners of the tank The third screw goes through support from under the plate 3 Install wheel and hub assemblies into the castor fork 4 Insert bolt 5 into motor adapter plate 34 mounting hole I...

Page 191: ...front wheels 2 Jack up and secure the rear wheel off the ground CAUTION Support wheel 25 and motor and hub assembly 2 to prevent dropping them and causing per sonal injury while removing hex head scr...

Page 192: ...rings 6 must point to the long side of the end of the hub 5 A Press two bearings into each end of the hub B The outer edge of the outer bearings must be flush with the recessed edge within the hub C C...

Page 193: ...6 and 8 with bearing 5 and wheel 25 into the castor fork 1 Make sure hose fittings on the motor face to the rear 5 Secure hydraulic motor and hub assembly 2 loosely to the left inside of the castor f...

Page 194: ...bracket 15 Hydraulic hose 16 Hydraulic hose 17 45_ Hydraulic fitting 18 O ring 19 O ring 20 Hydraulic motor 21 Flat washer 22 Brake rod 23 Brake lever 24 Lock nut 25 Jam nut 26 Cap screw 27 Cap screw...

Page 195: ...e four cap screws 26 lock nuts 29 and backing plate 8 from the brake bracket 14 8 Parts should be clean and free of rust Inspect brake shoe 12 and brake drum 5 contact surfaces for ex cessive wear Rep...

Page 196: ...r spacer 14 Flange bushing 15 Torsion spring 16 Cap screw 17 Washer head screw 18 Pin 19 Link bracket 20 Flat washer 21 Spacer tube 22 Lock nut 23 Pull frame spacer 24 Phillips head screw 3 used 25 We...

Page 197: ...as removed from front lift frame torque cap screw from 67 to 83 ft lb 91 to 112 N m B If pull frame item 1 in Fig 11 was removed from clevis on lift frame torque cap screw from 67 to 83 ft lb 91 to 11...

Page 198: ...er 19 Spacer 20 Cap screw 2 used 21 Flat washer 22 Eccentric bushing 23 Pull frame spacer 24 Bushing 25 Lift frame 26 Phillips screw 3 used 27 Wear pad 28 Transport plate 29 Lock nut 3 used 30 Cap scr...

Page 199: ...red between the front wheel mounts when the lift frame is in the raised position 2 Assemble center lift arm using Figures 12 and 13 as guides A If clevis item 31 was removed from center lift frame tor...

Page 200: ...Greensmaster 3250 D Page 6 16 Chassis Rev D This page is intentionally blank...

Page 201: ...Backlapping Units without Backlap Variable Reel Speed Kit 19 Backlapping Units with Backlap Variable Reel Speed Kit 20 Rollers and Bedbar Assembly Single Point Adjust Cutting Units 21 Rear Roller and...

Page 202: ...on How ever each unit has different bedbars with different meth ods of bedknife adjustment see Specifications Maintenance procedures for both cutting units are the same except where noted If a chapter...

Page 203: ...ight end and held in place by a snap ring The floating coupler may be moved to the other end when the cutting unit is used on the tractor front right position Frame Construction Single top tube is wel...

Page 204: ...d as follows 1 Remove hex head screw and lock nut from the lift roller and frame 2 Position lift roller to the proper hole on the frame In sert hex head screw through the frame and roller Lower Hole f...

Page 205: ...oro Part No 13 8199 Figure 3 Backlapping Brush Assembly TOR299100 Used to apply lapping compound to cutting units while keeping the operator s hands at a safe distance from the rotating reel Figure 4...

Page 206: ...oller kit Model 04488 rollers only A driv ing tube is used to install bearings into the roller A drill bushing is used to drill into bearing shafts without a re moval hole Figure 19 Plastic Plug This...

Page 207: ...ions if necessary See Adjustments section in Chapter 3 Engine Reel bearing condition Check bearings for wear and replace if necessary Make sure bearing housings are secured properly Keep bearings well...

Page 208: ...t number of blades for clip frequency and optimum height of cut range Cutting unit alignment and pull frame ground following Check pull frames and lift arms for damage binding or bushing wear Repair i...

Page 209: ...r as if it was cut with a dull reel grass will appear torn or ripped After extended running a ridge will eventually develop at both ends of the bedknife These ridges must be rounded off or filed flush...

Page 210: ...osen both flange lock nuts securing the pivot hub to the frame Fig 10 6 Rotate flange lock nuts on the top and bottom of the frame tab clockwise orcounterclockwise toraise orlow er the end of the bedb...

Page 211: ...until the paper is pinched lightly all the way across the reel A slight drag should result when the paper is pulled This drag should be the same for the entire length of the bedknife 4 After adjustin...

Page 212: ...tated acts as an eccentric cam to raise or lower the roller On the bolt head there is an identification dot which denotes the offset of the bolt The dot indicates in which direction the right end of r...

Page 213: ...Fig 30 HOC Range 3 32 to 3 4 inch 2 4 to 19mm Note A more aggressive setting will increase grass removal and provide a cleaner cut but may cause in creased scalping and marking Note A more aggressive...

Page 214: ...top shield can be raised for extremely wet conditions 1 Loosen cap screws and nuts securing top shield to each side plate 2 Adjust top shield to desired position and secure fas teners 3 Repeat above...

Page 215: ...t is from bar face to underside of screw head 1 Gauge bar 2 Cap screw 3 Rear roller bracket 4 Height of cut adjuster Figure 33 1 2 4 3 5 Place bar across the front and rear rollers Adjust rear roller...

Page 216: ...justing gauge bar gives you an aggressive setting B Adjusting the brush assembly so it is midway be tween the adjusting gauge bar and the cutting edge of the bedknife will provide a medium setting C A...

Page 217: ...cial Tools into the hole in the bearing housing from which the hydraulic motor was removed 5 Slide sleeve back on each ball joint receiver Re move receiver from each unit s ball studs Fig 37 6 For the...

Page 218: ...es not read with extension brackets Groomer Extension Kit part no 99 4255 is required 4 On the rear cutting unit rotate and latch unit into into the service position Fig 38 A Lower the suspension syst...

Page 219: ...right end of cutting unit If coupling is in the left end of cutting unit move coupling the right end for backlapping 3 Attach backlap motor or drive to the socket exten sion 4 Follow instructions and...

Page 220: ...the reels 7 Rotate flow control valve knob to position 1 8 Apply lapping compound with a long handled brush see Special Tools CAUTION Be careful when backlapping the reel because contact with the ree...

Page 221: ...26 Cap screw 27 Spring arm 28 Pivot housing 29 Single point adjuster 30 Pivot screw 31 Plastic bushing 32 Flat washer 33 Lock nut 34 Lock nut 35 Height of cut adjuster 36 Pivot hub RH 37 Quad ring 38...

Page 222: ...4 from the H O C ad juster Slide adjuster from the frame tab Installation Fig 42 1 Place cutting unit on a level working surface 2 If the H O C adjusters 35 or H O C adjustment brackets 21 were remove...

Page 223: ...haft Fig 43 6 If the front roller position is to be changed the re maining front bracket may be removed from the frame using step 4 Installation 1 Place cutting unit on a level working surface 2 Deter...

Page 224: ...ring recess Both ends inside the roller tube should be free of dirt and debris 2 Press bearing into the roller tube with the seal side facing out A Install shield washer onto the shaft B Make sure dim...

Page 225: ...ube should be free of dirt and debris 2 Press bearing into the roller tube with the seal side facing outward Make sure bearing is recessed from the end of the roller tube as described in the follow in...

Page 226: ...bearing replacement kit to drill a hole through the bearing shaft 2 Remove machine bearing with bearing puller 3 Clean roller bearing cavity of Wiehle roller and re move any rust with a crocus cloth...

Page 227: ...hey are worn or damaged Fig 42 Installation 1 Apply antiseize lubricant to both bedbar pins Tap pivot hub 13 to the bedbar pin on the left side of the bedbar 3 with a soft hammer Tap pivot hub 36 to t...

Page 228: ...42 or equivalent to the threads of both hex head screws Se cure spring arm to the pivot housing with both hex head screws 2 Place thrust washer new nylon thrust washer and second thrust washer onto th...

Page 229: ...rew 15 Height of cut collar 16 Lock nut 17 Height of cut adj bracket rear 18 Rear roller assembly 19 Carriage screw 20 Lock nut 21 Height of cut adjuster 22 Flat washer 23 Lock nut 24 Eccentric bolt 2...

Page 230: ...4 Remove both wheel bolts 10 from each end of the bedbar 5 and frame Fig 51 5 Remove bedbar 5 from the cutting unit Fig 51 Installation 1 Apply antiseize lubricant to the threads of both wheel bolts...

Page 231: ...g surface of the bedbar a new bedknife will not be perfectly flat after it is installed Because of this it is necessary to backlap or grind a new bedknife after installing it to the bedbar Follow the...

Page 232: ...Remove small amounts of material with each pass of the grinder 3 Refer to Toro General Service Training Book Reel Mower Basics part no 09168SL for additional reel grinding information 4 After completi...

Page 233: ...30 Plastic cap 31 Retaining ring 32 Splined coupler Figure 58 FRONT RIGHT 25 18 12 11 13 27 13 32 9 10 14 7 15 8 16 4 2 30 23 21 22 19 20 17 12 29 6 4 5 3 1 10 31 28 24 27 Note Figure 58 shows the ree...

Page 234: ...revent damage to bearings by pulling on the in ner bearing race B Use bearing puller to remove bearings and seals Inspection 1 Inspect splined coupler 32 as follows Fig 58 A Remove retaining ring 31 a...

Page 235: ...2 or equivalent to the threads of the two tapered screws 14 C Insert both tapered screws 14 through the side plate and bearing housing 10 Start tapered nuts 8 onto screws D Place bearing spacer 29 int...

Page 236: ...nd hex head screw from the H O C adjustment bracket and collar B Insert carriage screws M8 1 25 x 20 through both H O C adjustment brackets and collars to se cure the rear roller to the brackets Secur...

Page 237: ...nd remove key from the ignition switch 2 Loosen caps crews securing each end of the roller shaft to the front roller brackets 3 Remove cap screws and locknuts securing the left front roller bracket to...

Page 238: ...Greensmaster 3250 D SPA and 4 Bolt Cutting Units Rev A Page 7 38 This page is intentionally blank...

Page 239: ...pping Units without Optional Backlap Variable Reel Speed Kit 8 Backlapping Units with Optional Backlap Variable Reel Speed Kit 9 Bedbar Assembly 10 Bedbar Removal and Installation 11 Bedbar Adjuster S...

Page 240: ...aceable floating coupler with an inter nal eight tooth spline is factory installed on the right end and held in place by a snap ring Frame Construction Precision machined die cast alu minum cross memb...

Page 241: ...l Number TOR299100 Figure 3 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 IMPORTA...

Page 242: ...utting unit side plate Toro Part Number 104 0532 Figure 7 Plastic Plug This cap is used for placement into the bearing housing when the reel motor is removed It prevents dirt and de bris from entering...

Page 243: ...ee Chapter 6 Wheels and Brakes Governed engine speed Check maximum governed engine speed Adjust engine to specifications if necessary See Maintenance section in the Traction Unit Operator s Manual and...

Page 244: ...cut depends on the cutting unit weight and turf conditions Effective height of cut will be different from the bench set height of cut See Height of Cut Adjustment in the Cutting Unit Operator s Manua...

Page 245: ...inual 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...

Page 246: ...he flange head screws for the reel drive mo tor into the motor adapter plate and leave approximately 1 2 inch 12 7 mm of threads exposed on each screw 3 Install motor by rotating the motor clockwise s...

Page 247: ...d to start the reels 7 Rotate flow control valve knob to position 1 8 Apply lapping compound with a long handled brush see Special Tools CAUTION Be careful when backlapping the reel because contact wi...

Page 248: ...nge bushing 4 Washer plastic 5 Washer metal 6 Bedbar 7 Bedbar pivot bolt 8 Flange nut 9 Flange nut 10 Shim 11 Spacer 12 Retainer 13 Cap screw 14 Rear roller assembly 15 Lock nut 16 Bedknife 17 Bedknif...

Page 249: ...e bushing should be installed flush with the inside of the side plate Fig 13 2 Install the flange bushings 3 with flange facing out ward 3 Thread the flange nuts 8 all the way up to the head of each b...

Page 250: ...f necessa ry 6 If the detent 7 is damaged remove it from the cut ting unit frame by removing the cap screw 9 and lock washer 8 Installation Fig 14 1 If the detent 7 was removed install the cap screw 9...

Page 251: ...ee Bedbar Installation Grinding Since there can be variations in the mounting surface of the bedbar a new bedknife will not be perfectly flat after it is installed Because of this it is necessary to b...

Page 252: ...seal 10 Right side plate assembly 11 O ring 12 Bearing 13 Inner grease seal 14 Retaining ring 15 Wave washer 16 Seal strip 17 Frame assembly 18 Flange nut 19 Cap screw 20 Lift hook 21 Cap screw 22 Gr...

Page 253: ...arms Fig 20 Do not remove the set screws 6 Loosen the saddle strap screws and flange nuts se curing the rear roller to the the side plates Fig 20 Do not remove the screws and nuts 7 Remove the capscr...

Page 254: ...ecessary Fig 22 11 Fill remaining voids behind inner grease seal 13 and outer grease seal 9 lips with Mobil High Tempera ture HP or equivalent grease Right Side Plate Service Fig 18 1 Remove the inner...

Page 255: ...he drive adapter inside of the reel shaft Fig 21 The adapter should be free of bending and distortion Check the splines for excessive cracks or distortion Replace the reel if necessary D Check the ser...

Page 256: ...this chapter 9 Install the rear roller as follows Fig 23 A On one of the saddle clamps remove one of the screws and nuts securing it to the side plate B Install rear roller into saddle clamps and loo...

Page 257: ...unts of material with each pass of the grinder 3 Refer to Toro General Service Training Book Reel Mower Basics part no 09168SL for reel grinding infor mation 4 After completing the grinding process A...

Page 258: ...Greensmaster 3250 D Dual Point Adjust Cutting Units Rev D Page 7 1 20 This page is intentionally blank...

Page 259: ...haft from the cutting unit Remove the remaining front roller bracket if necessary Installation Fig 25 1 Place cutting unit on a level working surface 2 If both front roller brackets were removed A Ins...

Page 260: ...read two No 8 x 3 4 in long 164 in diameter self tapping screws through the seal removal tool and into the drilled holes in the seal 5 Thread two 1 4 20 x 1 in long cap screws into the seal removal to...

Page 261: ...any rust or corrosion with an abrasive cloth 6 Inspect bearings roller shaft spiral retaining rings and roller body for wear or damage Replace compo nents as necessary Bearing Installation 1 Pressing...

Page 262: ...ock 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 are removed from roller cavity Remove sec...

Page 263: ...t with seal onto each end of the roller shaft Tighten nuts until they bottom against bearings Fig 33 Remove nuts from roller shaft 8 Position an assembly spacer and yellow assembly washer see Special...

Page 264: ...Greensmaster 3250 D Dual Point Adjust Cutting Units Rev D Page 7 1 26 This page is intentionally blank...

Page 265: ...Transport Mode 3 TROUBLESHOOTING 4 Factors Affecting Grooming 4 Groomer Reel Mechanical Problems 5 ADJUSTMENTS 6 Height Depth of Groomer Adjustment 6 SERVICE AND REPAIRS 7 Groomer Belt Replacement 7...

Page 266: ...mer GROOMER PENETRATION From 410 inch 10 4 mm above ground level to 0 125 inch 3 2 mm below ground level at mowing HOC range of 062 to 296 inch 1 6 to 7 5 mm WIDTH OF GROOMER 19 inches 48 3 cm HEIGHT...

Page 267: ...position remove the lock screw and rotate the lift arm to raise the groomer reel Install the lock screw to retain the groomer reel in the non grooming position Fig 1 To place the groomer reel in the...

Page 268: ...age Use the groomer carefully READ AND UNDERSTAND THE OPERA TION INSTRUCTIONS BEFORE OPERATING OR TESTING GROOMER PERFORMANCE Variables That Affect the Use and Performance of Grooming Reels 1 The grow...

Page 269: ...nd replace faulty bear ing s Replace spring If the belt slips it probably is worn and must be replaced Repair or replace belt if necessary A broken or worn belt could be the result of improper belt ro...

Page 270: ...lean and cutting reel is set to the desired height of cut See Cutting Unit Operator s Manual for cutting unit adjustment procedures 3 Position the groomer reel to the lowered grooming position Fig 3 N...

Page 271: ...r Fig 4 4 Pivot idler pulley by placing a 12mm wrench on pulley nut and rotating idler bracket to relax belt tension Slip groomer drive belt off pulleys Fig 5 Carefully re lease idler bracket 5 Instal...

Page 272: ...27 28 29 30 31 20 27 34 35 33 17 37 25 24 23 36 60 to 80 ft lbs 81 to 108 N m Antiseize Lubricant 32 100 to 120 in lbs 11 3 to 13 5 N m Remove the groomer reel to reverse the shaft replace individual...

Page 273: ...groomer drive side plate item 10 to the cutting unit frame Remove the groomer drive side plate assembly 12 Remove the cap plug item 21 from non drive side plate Fig 8 13 Remove the flange nut that sec...

Page 274: ...torque cap plug from 60 to 80 ft lbs 81 to 108 N m Fig 8 11 Insert front roller into non drive side groomer arm 12 Position drive side groomer arm to front roller groomer drive side plate and cutting...

Page 275: ...tion When installing groomer blades on ear lier hex shaped shafts rotate location mark on each installed blade one flat of the shaft either in a clockwise or counterclockwise direction The direction o...

Page 276: ...te and groomer reel from cutting unit see Groomer Reel Removal in this section 2 Remove non drive groomer side plate from cutting unit A Remove hydraulic reel motor from cutting unit see Hydraulic Ree...

Page 277: ...cant to threads of lift arm as sembly stud Place spring washer and lock nut on lift rod threads Fig 15 Tighten lock nut C Position motor mount to groomer side plate Fig 14 Secure motor mount and groom...

Page 278: ...te side of the cutting unit from the cutting reel hydraulic motor Figure 16 shows the groomer reel drive from the left side of the cutting unit Removal 1 Remove groomer belt cover drive belt and drive...

Page 279: ...arm to side plate Loosen lock screw item 6 completely 2 Remove lift arm from cutting unit 3 Disassemble lift arm using Figure 18 as a guide Note Right and left side HOC groomer arms item 1 and lift a...

Page 280: ...roomer brush uses the same procedure as removal and installation of the groomer reel see Groomer Reel in this section To remove the groomer brush from the shaft remove the lock nut and J bolt from bot...

Page 281: ...er Below 210000000 16 Wiring Diagram Serial Number Below 210000000 17 Electrical Harness Drawing Serial Number Between 210000000 and 230000600 18 Wiring Diagram Serial Number Between 210000000 and 230...

Page 282: ...Greensmaster 3250 D Page 8 2 Electrical Diagrams This page is intentionally blank...

Page 283: ...TCH HIGH TEMP RELAY R2 30 85 87 86 87a JOYSTICK JOYSTICK RELAY R7 30 85 87 86 87a RUN RELAY R1 R W Y BK Y R Y BK BU BK HIGH TEMP OVERRIDE SWITCH BU W ETR GN R MOW RELAY R3 HIGH TEMP SWITCH 30 85 87 86...

Page 284: ...rial Number Between 210000000 and 230000600 All relays and solenoids are shown as de energized Greensmaster 3250 D BLACK BK BLUE BU BROWN BN FUSIBLE LINK GRAY GY GN GREEN OR ORANGE PK PINK R RED VIO T...

Page 285: ...rial Number Between 230000600 and 240999999 All relays and solenoids are shown as de energized Greensmaster 3250 D BLACK BK BLUE BU BROWN BN FUSIBLE LINK GRAY GY GN GREEN OR ORANGE PK PINK R RED VIO T...

Page 286: ...rial Number Between 250000000 and 250999999 All relays and solenoids are shown as de energized Greensmaster 3250 D BLACK BK BLUE BU BROWN BN FUSIBLE LINK GRAY GY GN GREEN OR ORANGE PK PINK R RED VIO T...

Page 287: ...rial Number Between 260000000 and 260999999 All relays and solenoids are shown as de energized Greensmaster 3250 D BLACK BK BLUE BU BROWN BN FUSIBLE LINK GRAY GY GN GREEN OR ORANGE PK PINK R RED VIO T...

Page 288: ...matic Serial Number Above 270000000 All relays and solenoids are shown as de energized Greensmaster 3250 D BLACK BK BLUE BU BROWN BN FUSIBLE LINK GRAY GY GN GREEN OR ORANGE PK PINK R RED VIO T TAN WHI...

Page 289: ...CC J5 OR BK RED RED 30 85 87 86 87a BACKLAP RELAY R9 MOW OPTIONAL BACKLAP SWITCH HIGH TEMP RELAY R2 30 85 87 86 87a JOYSTICK JOYSTICK RELAY R7 30 85 87 86 87a RUN RELAY R1 R W Y BK Y R Y BK BU BK HIGH...

Page 290: ...PK ACC J5 OR BK RED RED 30 85 87 86 87a BACKLAP RELAY R9 MOW OPTIONAL BACKLAP SWITCH HIGH TEMP RELAY R2 30 85 87 86 87a JOYSTICK JOYSTICK RELAY R7 30 85 87 86 87a RUN RELAY R1 R W Y BK Y R Y BK BU BK...

Page 291: ...CC J5 OR BK RED RED 30 85 87 86 87a BACKLAP RELAY R9 MOW OPTIONAL BACKLAP SWITCH HIGH TEMP RELAY R2 30 85 87 86 87a JOYSTICK JOYSTICK RELAY R7 30 85 87 86 87a RUN RELAY R1 R W Y BK Y R Y BK BU BK HIGH...

Page 292: ...CC J5 OR BK RED RED 30 85 87 86 87a BACKLAP RELAY R9 MOW OPTIONAL BACKLAP SWITCH HIGH TEMP RELAY R2 30 85 87 86 87a JOYSTICK JOYSTICK RELAY R7 30 85 87 86 87a RUN RELAY R1 R W Y BK Y R Y BK BU BK HIGH...

Page 293: ...J5 OR BK RED RED 30 85 87 86 87a BACKLAP RELAY R9 MOW OPTIONAL BACKLAP SWITCH HIGH TEMP RELAY R2 30 85 87 86 87a JOYSTICK JOYSTICK RELAY R7 30 85 87 86 87a RUN RELAY R1 R W Y BK Y R Y BK BU BK HIGH T...

Page 294: ...5 OR BK RED RED 30 85 87 86 87a BACKLAP RELAY R9 MOW OPTIONAL BACKLAP SWITCH HIGH TEMP RELAY R2 30 85 87 86 87a JOYSTICK JOYSTICK RELAY R7 30 85 87 86 87a RUN RELAY R1 R W Y BK Y R Y BK BU BK HIGH TEM...

Page 295: ...Rev H Page 8 15 This page is intentionally blank...

Page 296: ...SWITCH P10 P28 P27 P26 P25 4 2 3 5 J11 J12 P29 GLOW RELAY 1 P9 P8 P7 P3 P5 P4 WATER TEMP SWITCH J15 J14 ENGINE GROUND J13 P31 B A P33 P32 ETR P1 J3 J2 J1 J4 P2 P30 FUSEBLOCK 7 5 3 1 8 6 4 2 3 1 2 4 5...

Page 297: ...4 W33 W32 W29 W31 P7 P8 P9 D E F DIODE CONNECTOR 2 SOLENOID 1 G H C A B B A B SP8 SP7 W94 W35 W36 W45 W37 W46 W38 W48 W47 SP6 SP11 W97 W88 W23 W31 W33 W27 W89 W90 W17 W93 W16 W13 W12 W23 W24 W27 W21 W...

Page 298: ...s Drawing Serial Number Between 210000000 and 230000600 Greensmaster 3250 D RELAY 1 RELAY 2 RELAY 3 RELAY 4 RELAY 5 RELAY 6 RELAY 7 HYD SOL 1 HYD SOL 2 HYD SOL 3 HYD SOL 4 RELAY 8 ALTERNATOR STARTER B...

Page 299: ...Rev H Page 8 19 Wiring Diagram Serial Number Between 210000000 and 230000600 Greensmaster 3250 D GLOW PLUG CONTROLLER...

Page 300: ...en 230000600 and 240999999 Greensmaster 3250 D HYD SOL 2 HYD SOL 4 ALTERNATOR STARTER B RELAY RELAY RELAY RELAY RELAY RELAY RELAY RELAY HYD SOL 6 HYD SOL 3 HYD SOL 1 START SAFETY JOYSTICK LOWER RAISE...

Page 301: ...Rev H Page 8 21 Wiring Diagram Serial Number Between 230000600 and 240999999 Greensmaster 3250 D GLOW PLUG CONTROLLER...

Page 302: ...YD SOL S6 HYD SOL S2 HYD SOL S4 HYD SOL S3 HYD SOL S1 FUSEBLOCK BACKLAP RELAY RELAY GLOW LOWER JOYSTICK SAFETY RELAY START RELAY RELAY RAISE RELAY OVERTEMP BACKLAP SWITCH HIGH TEMP OVERRIDE GLOW WATER...

Page 303: ...Rev H Page 8 23 Wiring Diagram Serial Number Between 250000000 and 250999999 Greensmaster 3250 D GLOW PLUG CONTROLLER...

Page 304: ...AFETY HIGH TEMP STARTER ALTERNATOR MOW RELAY HYD SOL S6 STARTER B HYD SOL S2 HYD SOL S4 HYD SOL S3 HYD SOL S1 RELAY RELAY BACKLAP SWITCH RELAY START HIGH TEMP OVERRIDE GLOW WATER IN FUEL LIGHT OIL PRE...

Page 305: ...Rev H Page 8 25 Wiring Diagram Serial Number Between 260000001 and 260999999 Greensmaster 3250 D GLOW PLUG CONTROLLER...

Page 306: ...Rev H Page 8 26 Electrical Harness Drawing Serial Number Above 270000000 Greensmaster 3250 D...

Page 307: ...Rev H Page 8 27 Wiring Diagram Serial Number Above 270000000 Greensmaster 3250 D...

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