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Toro Greensmaster eTriFlex 3360, Service Manual

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Toro Greensmaster eTriFlex 3360 Service Manual Download Page 227

Removing the Starter/Generator Assembly (continued)

15. Loosen the 4 cap screws (item 8) securing the starter/generator to the

engine frame, then rotate the starter/generator clockwise to loosen the
starter/generator drive belt.

16. Remove the fasteners and the starter/generator from the engine frame.

Greensmaster® eTriFlex 3360 and 3370

Page 5–123

Electrical System: Service and Repairs

19239SL Rev B

Summary of Contents for Greensmaster eTriFlex 3360

Page 1: ...239SL Rev B Greensmaster eTriFlex 3360 and 3370 Model 04580 and 04590 2019 The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 Original Instructions EN Contact us at www Toro com All Right...

Page 2: ...Revision History Revision Date Description A 06 2019 Initial Issue B 12 2019 Model 04590 information added Revision History Page 2 Greensmaster eTriFlex 3360 and 3370 19239SL Rev B...

Page 3: ...ncourage user feedback Please comment on the completeness accuracy organization usability and readability of this manual by an e mail to servicemanuals toro com or Mail to Technical Publication Manage...

Page 4: ...Reader Comments Page 4 Greensmaster eTriFlex 3360 and 3370 19239SL Rev B...

Page 5: ...fer to the Table of Contents for a list of the systems and the related topics covered in this manual Refer to the machine Operator s Manual for additional information about operating maintaining and a...

Page 6: ...icon is used to highlight an assembly torque requirement that is different than what is recommended in the Standard Torque Tables refer to Standard Torque for Dry Zinc Plated and Steel Fasteners Inch...

Page 7: ...4 Engine Model 04580 4 1 General Information 4 2 Service and Repairs 4 3 Chapter 5 Electrical System 5 1 General Information 5 3 Electrical System Operation 5 4 Electrical System Quick Checks 5 18 Ad...

Page 8: ...Wire Harness Diagram 3370 A 10 Wire Harness Diagram 3370 continued A 11 Additional Reference Materials Kawasaki FS481V Service Manual Preface Page 8 Greensmaster eTriFlex 3360 and 3370 19239SL Rev B...

Page 9: ...ter 1 Safety Table of Contents Safety Instructions 1 2 Think Safety First 1 3 Jacking Instructions 1 6 Safety and Instructional Decals 1 7 Greensmaster eTriFlex 3360 and 3370 Page 1 1 Safety 19239SL R...

Page 10: ...sult in serious injury CAUTION This safety symbol means caution When you see this symbol carefully read the instructions that follow Failure to obey the instructions can result in minor to moderate in...

Page 11: ...tart Avoid burns Do not touch the engine muffler or other components which may be hot during operation while the unit is running or shortly after it has been running Avoid fires and explosions Use ext...

Page 12: ...hand Using tools All tools should be in proper working order Do not use tools that are broken or in disrepair Use the proper tool for the proper application Using lifts hoists and jacks All lifts hoi...

Page 13: ...that involve electrical equipment such as appliances wiring circuit breakers and outlets Never use water to extinguish class C fires the risk of electrical shock is far too great Class C extinguisher...

Page 14: ...ck securely under the desired jacking point Foot step on the left side of the machine Jack bracket on the right side of the machine Caster fork at the rear of the machine g286954 Figure 1 1 Foot step...

Page 15: ...safety and instructional decals are affixed to the traction unit and the cutting units of the Greensmaster 3360 3370 If any decal becomes illegible or damaged replace it with a new decal Part numbers...

Page 16: ...Safety Safety and Instructional Decals Page 1 8 Greensmaster eTriFlex 3360 and 3370 19239SL Rev B...

Page 17: ...lating the Torque Values When Using a Drive Adapter Wrench 2 6 Identifying the Fastener 2 7 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 2 8 Standard Torque for Dry Zinc Plated...

Page 18: ...s Choke Manual Fuel Pump Pulse Type Fuel Refer to the Traction Unit Operator s Manual Fuel tank capacity 18 5 L 4 9 US gallons Operating RPM fixed 2 400 rpm 100 Engine oil Refer to the Traction Unit O...

Page 19: ...t range is 1 6 to 1 1 mm 0 062 to 0 438 inch depending on type of bedknife installed An optional high height of cut kit is available to obtain a cut range of 11 1 to 25 4 mm 0 438 to 1 0 inch Effectiv...

Page 20: ...g reel is located on the opposite side of the cutting unit from the cutting unit motor Groomer height setting Mowing 0 8 to 15 7 mm 0 030 to 0 620 inch HOC range 1 5 to 19 1 mm 0 060 to 0 750 inch Wid...

Page 21: ...ss of the surface underneath the head of the fastener or similar condition which affects the installation As noted in the following tables the torque values should be reduced by 25 for lubricated fast...

Page 22: ...en using a torque wrench with a drive adapter wrench the calculated torque will be lower than the listed torque recommendation Example The measured effective length of the torque wrench distance from...

Page 23: ...the fastener and pre applied dry thread locking compound Keep in mind a fastener with a locking feature usually means there will be friction during initial installation and during removal Toro recomm...

Page 24: ...70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 6 75 8 77 8 104 11 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 11 142 15 1 2 20 UNF 32 4 53 7 72 9 85 9 115 12 120 12 163 16 5 8 11 UNC 65 10 88 12 119 16 150 15...

Page 25: ...2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 N m Note Reduce the torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lu...

Page 26: ...4 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 Scre...

Page 27: ...tener installation Most thread locking compounds allow the fastener to be removed with standard tools once cured High strength thread locking compounds may require applying heat to the fastener and th...

Page 28: ...TV which form a flexible silicone rubber that bonds to a wide variety of smooth or porous materials when cured Standard silicone sealants are designed to perform in temperatures from 51 F to 232 C 60...

Page 29: ...392 Use this aerosol spray on the battery terminals ring terminals and fork terminals to reduce corrosion problems Apply the terminal protector to the connection after you secure the battery cable rin...

Page 30: ...ed shaft handle and four screws Lithium Ion Battery Shipping Kit Toro Part No 137 9650 Use the original packaging or the battery shipping kit and a certified carrier to ship one of the lithium ion bat...

Page 31: ...paper is used to test the cutting reel performance after adjusting the reel to bedknife clearance Reel Drive Shaft K Line Part No TOR4112 Use the drive shaft for rotating the reel during cutting unit...

Page 32: ...ng surface of the bedbar it is necessary to grind the bedknife after installing it to the bedbar 1 Place the angle indicator on the bottom side of the bedknife with the digital display facing you as s...

Page 33: ...reel and other spherical components Tape calibration is in fixed inch readings no adjustments Roller Rebuilding Tools The following combination of washers and spacers can be used to install bearings a...

Page 34: ...lable from an local authorized Toro Distributor Cutting Unit Motor Rotor Tool K Line Part No TOR6028 The cutting unit motor rotor tool is recommended to remove and install the rotor from the cutting u...

Page 35: ...2 ounce Toro Part No 137 0872 Aids in accurately filling the optional Universal Groomer gear box with oil Greensmaster eTriFlex 3360 and 3370 Page 2 19 Specifications and Maintenance Special Tools 19...

Page 36: ...Specifications and Maintenance Special Tools Page 2 20 Greensmaster eTriFlex 3360 and 3370 19239SL Rev B...

Page 37: ...3 41 General Operation Problems Model 04580 3 42 General Operation Problems Model 04590 3 43 Aftercut Appearance 3 46 Grooming Performance 3 48 Universal Groomer Problems Optional 3 49 Battery Charge...

Page 38: ...focus of the problem 3 Assess Performance Ensure you have all the necessary tools for testing Test all potential causes of the failure Reevaluate and create a new hypothesis if necessary 4 Repair Retu...

Page 39: ...e parking brake B2159 TRACTION DISABLED Out of seat Traction Denied Seat B215A TRACTION DISABLED Traction illegally engaged Traction Denied Return pedal to neutral B215B Model 04580 Only TRACTION DISA...

Page 40: ...ENIED Function switch not in NEUTRAL Backlap Denied Set function switch to NEUTRAL B2551 BACKLAP DENIED Parking brake not engaged Backlap Denied Engage parking brake B2553 BACKLAP DENIED Fault s Activ...

Page 41: ...ponent not ready 112 Inhibit calibration Fault active 113 Inhibit calibration Not in seat 114 Inhibit calibration Not in neutral 115 Inhibit calibration In neutral 116 Inhibit calibration Pbrake engag...

Page 42: ...e Cutting Unit installed Continue 1100 Traction diagnostic messages enabled 1101 Steering diagnostic messages enabled Troubleshooting Battery Charger Error and Fault Codes Model 04590 Page 3 6 Greensm...

Page 43: ...depending on which switch failed 1 Use the InfoCenter Diagnostics Lift Lower Inputs screen to observe joystick switch operation 2 Test the joystick switches 3 Check the circuit wiring and all the circ...

Page 44: ...detected on the engine run output Indicates a short to a high source The short could be to battery voltage or to another signal that is in a high state 1 Check the engine run output circuit wiring and...

Page 45: ...uit wiring to ground 3 Test the brake actuator relay and the brake actuator 4 Swap the T1 Primary controller with a known good unit contact an Authorized Toro Distributor for assistance C1025 Parking...

Page 46: ...output Indicates short to ground 1 Check the logic relay output circuit wiring and connectors P01 P47 2 Test the logic relay output circuit wiring to ground 3 Test the logic relay 4 Swap the T1 Primar...

Page 47: ...an Authorized Toro Distributor for assistance C181C Cutting Unit Motor Controller High Temp Warning T2 T3 T4 The motor controller temperature is greater than 90 C 194 F in the indicated cutting unit...

Page 48: ...lace and program the motor if the fault moves to the new position contact an Authorized Toro Distributor for assistance C1841 Cutting Unit Motor Logic Voltage High T2 T3 T4 The 48V logic voltage measu...

Page 49: ...condition is detected in the indicated cutting unit PTO is disabled 1 Cycle the key switch 2 Replace and program the motor contact an Authorized Toro Distributor for assistance C1901 Lift Lower Motor...

Page 50: ...go to fault U1501 and follow the listed service actions 1 Check the logic power connection to the actuator 2 Replace and program the actuator contact an Authorized Toro Distributor for assistance 3 Cy...

Page 51: ...disabled for 30 seconds 1 Let the actuator rest for 30 seconds 2 Use the InfoCenter to re calibrate the actuator 3 Replace and program the actuator contact an Authorized Toro Distributor for assistan...

Page 52: ...ment 2 Check for binding or restriction of the rear caster wheel assembly 3 Verify proper wiring of the steering position sensor connector P69 4 Test the steering position sensor 5 Replace and program...

Page 53: ...controller detects an open circuit on motor phase W Traction and steering is disabled 1 Test the steering motor 48V bus standard blade fuse under seat and the power connection to the 48V battery 2 Rep...

Page 54: ...i ion battery cell temperature was measured to be 70 C 158 F or higher Battery contactor in Li ion battery controller is opened Allow the machine to cool before operating P058F Battery Low Temp Shutdo...

Page 55: ...ter to calibrate the traction motors P0A2F Traction Motor High Temp Warning SC5 SC6 T5 The traction motor temperature is greater than 150 C 302 F for SC5 SC6 or 120 C 248 F for T5 Traction performance...

Page 56: ...air through the air intake by feeling with your hand or by testing with a piece of paper 2 Let the machine cool 3 Reduce the cutting loads by reducing the reel speed or reducing mow speed 4 Replace an...

Page 57: ...y contactor in Li ion battery controller is opened The Li ion battery controller SC8 is likely damaged Forward a copy of the battery output file BDS to Toro Service contact an Authorized Toro Distribu...

Page 58: ...mponent P0AFA Battery Low Voltage SC8 A Li ion battery cell voltage was measured to be low but is still recoverable Battery contactor in Li ion battery controller is opened 1 Charge the batteries The...

Page 59: ...s fault occurred P0D2F Traction Motor Logic Voltage Low SC5 SC6 T5 The traction motor measures the 48V logic voltage at less than 38V SC5 SC6 or 32V for T5 Traction is disabled Note If more than one L...

Page 60: ...e at the motor connector to determine whether the voltage is high or the controller is measuring high 2 Check the battery voltage 3 Inspect the wiring to the motor 4 Replace the traction motor For SC5...

Page 61: ...id SC5 SC6 The speed sensor reading is invalid in the indicated traction motor Traction is disabled 1 Inspect the wiring and connectors 2 Test the supply voltage to the speed sensor 3 Test the ground...

Page 62: ...of range high in the indicated traction motor Traction is disabled If the fault occurs at start up contactor does not close 1 Test the cables on the U V and W phases 2 Inspect the motor power cables c...

Page 63: ...e InfoCenter to calibrate the traction motor controller For SC5 calibrate the traction pedal first then the traction motors For SC6 calibrate the traction motors P1554 Traction Motor Contactor Coil Sh...

Page 64: ...dware in the indicated traction motor controller Traction is disabled 1 Replace and program the traction motor controller contact an Authorized Toro Distributor for assistance 2 Cycle the key switch 3...

Page 65: ...eed or reducing mow speed 4 Replace the starter generator motor P1B11 Starter Generator Controller High Temp Shutdown T6 The starter generator controller temperature is greater than 100 C 212 F PTO an...

Page 66: ...d go to fault U1511 and follow the listed service actions 1 Test the 48V batteries 2 Verify that all starter generator motor to controller connections are good 3 Replace and program the starter genera...

Page 67: ...s less than 8 8V PTO is disabled 1 Test the 15A mini blade style fuse in the 12V fuse holder under the right side cover 2 Test the circuit wiring and connector P70 3 Test the alternator refer to the K...

Page 68: ...otors U0110 CAN Bus Communication Fault Traction Motor 1 T1 The primary controller never establishes or loses communication with the right side traction motor controller SC5 Traction is disabled 1 Tes...

Page 69: ...3 Replace and program the InfoCenter contact an Authorized Toro Distributor for assistance U0292 CAN Bus Communication Fault Traction Motor 2 T1 The primary controller never establishes or loses commu...

Page 70: ...t often this fault is caused by installing a controller that was programmed while it was installed in another machine Update machine software contact an Authorized Toro Distributor for assistance U111...

Page 71: ...contact an Authorized Toro Distributor 4 Cycle the key switch 5 Use the InfoCenter to calibrate the lift lower actuator U1129 CAN Bus Communication Fault Lift Lower Motor 2 T1 The T1 Primary controlle...

Page 72: ...e Engine is disabled Update machine software contact your Authorized Toro Distributor for assistance U1307 Software Version Incompatibility Starter Generator T1 The starter generator software is incom...

Page 73: ...tor motor to controller connections are good 3 Test the starter generator test procedure pending 4 Replace and program the starter generator contact an Authorized Toro Distributor for assistance U1502...

Page 74: ...ter generator contact an Authorized Toro Distributor for assistance U1700 Board Internal Error IPE T6 Inputs or outputs in the T6 precharge controller are not working correctly Machine is disabled 1 T...

Page 75: ...gnostics Input or Output Screen for the desired machine function 3 Manually operate the input component The component state on the InfoCenter display should alternate ON and OFF or the signal voltage...

Page 76: ...ed with optional 3WD should display 0 0 mph kph When the vehicle is traveling in a straight line the traction speeds displayed should be approximately the same If not the traction motors may require r...

Page 77: ...the 48 VDC system For effective troubleshooting and repairs you must have a good understanding of the electrical circuits and components that are used on this machine refer to the Electrical Schematic...

Page 78: ...Clean repair or replace the cables as necessary Nothing happens when the key switch is set to the ON position The 12V AGM battery is discharged or damaged Charge the battery and replace if necessary...

Page 79: ...echarge controller Logic input connector P03 pin 6 to wake up the precharge controller C 48V should pass through the 5A fuse in the 48V fuse block under the operator s seat and be available at termina...

Page 80: ...ogic power should be available at the SC7 steering motor controller connector P46 pin 15 48V logic power should be available at the SC5 traction 1 right motor controller connector P35 pin 10 and SC6 t...

Page 81: ...12 VDC converter fuse or circuit wiring is damaged Test the 10A fuse in the 48V fuse block under the operator s seat Check for 48 VDC at the 48 VDC 12 VDC converter connector P07 pin 4 The 12V shutdo...

Page 82: ...reel adjustment Check the bedknife to reel contact daily The bedknife must have light contact across the entire reel No contact will dull the cutting edges Excessive contact accelerates wear of both e...

Page 83: ...ing Unit Parts Manual for a listing of available accessories or contact your local Authorized Toro Distributor for additional information Ensure that the rollers rotate freely Repair the roller bearin...

Page 84: ...hat affect quality of cut also affect grooming performance Variables that Affect the Use and Performance of the Groomer 1 The growing season and weather conditions 2 General turf conditions 3 The freq...

Page 85: ...mer Installation Instructions for groomer set up information The groomer reel blades are bent damaged or missing Repair or replace the blades if necessary The groomer reel shaft is bent or damaged Rep...

Page 86: ...the cable connections are clean and secure Code E 0 2 3 High AC voltage error greater than 270 VAC Connect the charger to an AC power source that provides stable AC power between 85 270 VAC at 45 65...

Page 87: ...saki Owner s Manual 4 2 Kawasaki Service Manual 4 2 Service and Repairs 4 3 Fuel Tank 4 3 Evaporative Control System 4 6 Cooling System 4 8 Exhaust System 4 10 Engine 4 12 Additional Reference Materia...

Page 88: ...e be sure to provide your distributor with the Toro model and serial number along with the engine model and serial number Traction Unit Operator s Manual The Operator s Manual provides information reg...

Page 89: ...nge nut 4 each 7 Cap screw 12 Foam pad 4 each 3 Fuel tank 8 Fuel cap 13 Carbon canister assembly 4 Bushing 2 each 9 Fuel supply hose 14 Fuel vent hose 5 Vent fitting 10 Hose clamp 2 each 15 Push nut 4...

Page 90: ...Open or remove the hood refer to Removing and Installing the Hood Assembly page 6 43 3 Close the fuel shut off valve 4 Allow the engine to completely cool 5 Use a siphon or pump to empty the fuel tank...

Page 91: ...V battery disconnect 8 Start the engine and check the fuel system for leaks Repair any leaks as necessary before returning the machine to service Checking the Fuel Lines and Connections g286482 Figure...

Page 92: ...the air intake tube is used to control evaporative emission flow through the system The carbon canister is connected to both the fuel tank vent and the vacuum control valve When the engine is running...

Page 93: ...e The valve should open allow flow between ports A and B when 21 to 29 mm Hg 0 8 to 1 1 inch Hg vacuum is applied to port C 5 Repair or replace evaporative system components as necessary Greensmaster...

Page 94: ...in the hood may result in the engine overheating and cause engine damage To ensure proper engine cooling make sure the screen guard rotating screen cooling fins and other external surfaces of the eng...

Page 95: ...nd debris 4 If necessary remove the screen guard from the blower housing and clean the rotating screen that is attached to the flywheel 5 If necessary remove the blower housing from the engine for com...

Page 96: ...mp 2 each Removing the Exhaust System CAUTION The engine and exhaust system may be hot To avoid possible burns allow the engine and exhaust system to cool before working on the engine 1 Park the machi...

Page 97: ...and heat shield 2 Use new exhaust gaskets and fit the muffler assembly to the machine 3 Install all the fasteners used to secure the muffler assembly loosely Ensure the conical washer is installed be...

Page 98: ...its shut off the engine remove the key from the key switch and unplug the 48V battery disconnect 2 Disconnect the negative battery cable at the 12V system battery refer to Removing and Installing the...

Page 99: ...ire harness ground at the engine near front left engine mount 7 Disconnect the choke cable from the engine 8 Remove the clamp securing the engine oil drain hose to the right side battery tray 9 If the...

Page 100: ...ge nut 4 each 14 Cap screw 2 each 5 Lock nut 3 each 10 Wire harness connector A Disconnect the starter generator from the machine wire harness Check the starter generator and the harness connector for...

Page 101: ...xtension spring g286883 Figure 17 1 Generator drive belt 5 Hex nut 2 each 2 Generator pulley 6 Adjustment pin 3 Engine pulley 7 Extension spring 4 Engine frame 8 Cap screw 4 each C Loosen the 4 cap sc...

Page 102: ...gure 15 for this procedure IMPORTANT Ensure that all parts removed from the engine during maintenance are installed 1 If the engine pulley was removed A Apply anti seize lubricant to the engine shaft...

Page 103: ...while installing the engine 2 Secure the engine to the engine frame with the 4 cap screws previously removed 3 Remove the front engine lift lug and reinstall the fastener used to secure the lift lug...

Page 104: ...p and cap screw previously removed 9 Connect the electrical system wiring to the engine The wire harness ground at the engine near front left engine mount The engine wire harness connector at the main...

Page 105: ...5 20 Adjusting the Starter Generator Drive Belt Tension Model 04580 5 20 Adjusting the Steering Position Sensor 5 21 Adjusting the Manual Parking Brake Switch 5 22 Testing the Electrical Components 5...

Page 106: ...tteries Model 04580 5 105 Batteries Model 04590 5 111 Caring for the Lithium Ion Batteries Model 04590 5 111 Storing the Lithium Ion Batteries Model 04590 5 112 Shipping and Transporting the Lithium I...

Page 107: ...tenance intervals for the machine and its accessories Refer to the traction unit Operator s Manual and accessory Installation Instructions for additional information Kawasaki Engine Electrical Compone...

Page 108: ...Pedal Position Sensor A dual hall effect sensor attached to the traction pedal that sends reciprocal signals to the SC5 Traction 1 controller for direction and speed The two signals are part of a redu...

Page 109: ...teering wheel This feature of the steering input device produces a more natural power steering feel for the operator SC7 Steering Motor The SC7 Steering motor is attached to a reduction gear box and i...

Page 110: ...it on the machine Individual cutting unit motor location information is necessary for RDS operation for cutting unit timing starting and stopping the center cutting unit slightly later than the front...

Page 111: ...and managed by a lithium ion battery controller SC8 IMPORTANT When connecting the individual batteries in the 48 VDC system make sure that battery polarity is correct System damage can occur if the in...

Page 112: ...tting unit slightly later than the front cutting units The two front traction motors are brushless permanent magnet motors The motor controllers are separate from the motors and control each motor ind...

Page 113: ...ect is attached to a bracket behind the left side cover Unplug the disconnect to make sure that 48 VDC components do not operate unexpectedly Apply dielectric grease to the contact surfaces of the bat...

Page 114: ...available when the key switch is in the ON or START position A 7 5 Amp fuse protects all of the key switched circuits including the InfoCenter power circuit The InfoCenter communicates with the other...

Page 115: ...InfoCenter continued g288412 Figure 22 InfoCenter Screens Greensmaster 3360 eTriFlex Greensmaster eTriFlex 3360 and 3370 Page 5 11 Electrical System Electrical System Operation 19239SL Rev B...

Page 116: ...ough the use of a CAN bus Isolation Module IMPORTANT Logic voltage must be present at the controller before communication with that controller can occur on the CAN bus The entire CAN bus is made up of...

Page 117: ...20 SC8 Lithium ion Battery controller model 03590 only 9 T3 Cutting Unit 2 motor controller left 21 CAN B diagnostic port 10 T4 Cutting Unit 3 motor controller right 22 Lithium ion battery interface m...

Page 118: ...ng input device and the fuel solenoid and engine relay on Greensmaster 3360 machines The status of inputs to the controller as well as outputs from the controller can be monitored with the InfoCenter...

Page 119: ...to the machine The BMS is also connected to the CAN bus which allows it to forward battery information to the rest of the machine The BMS is located under the hood attached to the back of the center...

Page 120: ...uit with voltage when the key switch is in the OFF position is the low amperage signal voltage Pack Sig from the BMS to the key switch Refer to SC8 Lithium Ion Battery Controller Model 04590 page 5 40...

Page 121: ...the precharge controller precharge input The precharge controller then supplies a controlled precharge voltage to the reel motors lift actuators and optional 3WD traction motor via the precharge outpu...

Page 122: ...meter lead to the negative battery post of the 12V system battery and record the battery voltage g286601 Figure 28 1 Shoulder screw 4 12V system battery 2 Front right side cover 5 Negative terminal 3...

Page 123: ...disengage the manual parking brake move the function control switch to the MOW or TRANSPORT position and engage the traction pedal The machine should not move if you are not in the seat 2 Sit in the s...

Page 124: ...ckwise to tension the drive belt g289346 Figure 29 1 Generator pulley 4 Extension spring 2 Cap screw 4 each 5 Hex nut 2 each 3 Generator drive belt 6 Adjustment pin 4 Measure the extension spring leng...

Page 125: ...alignment while adjusting the steering position sensor 2 Loosen the jam nut under the magnet bolt 3 Adjust the magnetic bolt so the slot in the bolt aligns with the flat on the castor fork shaft strai...

Page 126: ...standing of how the switch is used For manual parking brake switch testing information refer to Manual Parking Brake Switch page 5 77 1 Park the machine on a level surface lower the cutting units and...

Page 127: ...unplug the key switch connector before doing a continuity check of the switch Always check the item being tested and the harness connector for damage or corrosion and clean or repair as necessary IMP...

Page 128: ...er removed 1 10A fuse brake actuator relay 5 Open 9 7 5A fuse spare 2 7 5A fuse T1 Primary outputs 6 15A fuse main model 04580 10 12V fuse holder 1 3 2A fuse telematics connector 7 2A fuse T1 Primary...

Page 129: ...80V fuse SC7 Steering Motor power bus 3 10A 80V fuse SC4 Lift Lower Actuator 3 right power bus 7 10A 80V fuse Optional work lights model 04580 or 48 VDC 12 VDC converter model 04590 4 Open 8 10A 80V...

Page 130: ...heir Functions continued g291449 Figure 35 model 04590 only 1 Cap 3 Fuse holder 2 3A 80V fuse T6 Precharge controller model 04590 Electrical System Testing the Electrical Components Page 5 26 Greensma...

Page 131: ...i blade fuses located in a covered fuse block under the left side cover g287313 Figure 36 left side cover removed 1 35A 58V fuse T2 Cutting Unit 1 center power bus 2 35A 58V fuse T3 Cutting Unit 2 lef...

Page 132: ...o 25 in lb 2 Coat the terminals with battery terminal protector Toro Part No 107 0392 to reduce corrosion 3 Install the fuse holder cover and secure it with a new cable tie g287324 Figure 37 seat rais...

Page 133: ...the fuse holder block use a multimeter to check that 12 VDC exists at both of the terminal test points on the fuse If 12 VDC exists at 1 of the fuse test points but not at the other the fuse is damag...

Page 134: ...wer 2 actuator controller left 4 CAN bus terminator resistor 4 each 16 SC2 Lift Lower 3 actuator controller right 5 T1 Primary controller 17 SC5 Traction 1 motor controller right 6 SC1 InfoCenter 18 S...

Page 135: ...6 Set the key switch to the OFF position 7 Use a multimeter ohms setting to measure and record the resistance of CAN A across the machine wire harness connector terminals C and D and CAN B across ter...

Page 136: ...ss the CAN HI and CAN LOW terminals of the device Use to the appropriate electrical schematic or wire harness diagram for your machine in to determine the specific device terminals for testing refer t...

Page 137: ...module 2 Wire harness connector Testing the CAN bus Isolation Module There is not a test procedure specifically for the CAN bus isolation module Test the CAN bus before replacing the isolation module...

Page 138: ...ne under the right side cover The logic and memory circuit is protected by a 2 Amp fuse Power for the primary controller outputs is available when the key switch is in the ON or START position A 7 5 A...

Page 139: ...IN 10 Not Used AIN6 Not Used T1 Primary Controller Outputs OUTPUT NUMBER DESCRIPTION OUTPUT NUMBER DESCRIPTION OUT 1 Logic Relay OUT 10 Not Used OUT 2 Engine Control Model 04580 OUT 11 Not Used OUT 3...

Page 140: ...ached to the controller The connection terminal function for the controller and the wire harness connector pins are shown above If the wire harness connector is removed from the T1 primary controller...

Page 141: ...tion refer to InfoCenter page 5 10 The starter generator is not serviceable and is best tested by using the information provided on the InfoCenter display as described in the following test procedure...

Page 142: ...repaired as necessary If logic voltage is present at the controller and CAN bus communication is suspect the CAN bus circuit is damaged The CAN bus wiring should be checked for corrosion or damage an...

Page 143: ...If the InfoCenter diagnostics inputs report normally and the starter generator output is out of range repair or replace the starter generator or starter generator controller refer to Generator Assembl...

Page 144: ...he hood attached to the back of the center mounted batteries Note If the SC8 Lithium Ion Battery Controller is replaced for any reason the machine software must be updated contact an Authorized Toro D...

Page 145: ...he contactor inside the BMS has closed and battery power should be available to the machine Once the BMS internal contactor has closed battery pack voltage can be tested across the BMS positive and ne...

Page 146: ...oid the warranty The controller is protected by tamper alerting devices 1 Park the machine on a level surface lower the cutting units set the key switch to the OFF position and remove the key 2 Unplug...

Page 147: ...oller wire harness connector P02 gray 4 Label and disconnect the battery interface harness and the machine wire harness connector from the lithium ion battery controller 5 Label and disconnect the mac...

Page 148: ...rd refer to Figure 50 10 Install the lithium ion battery controller in reverse order 11 Tighten the power supply and battery cable fasteners from 8 5 to 9 5 N m 75 to 85 in lb then apply battery termi...

Page 149: ...for the precharge controller outputs is available when the logic relay is energized Note If the precharge controller T6 is replaced for any reason the machine software must be updated contact an Auth...

Page 150: ...ecessary The precharge controller CAN bus transceiver can also be tested if necessary refer to Testing Devices Nodes on the CAN bus page 5 32 If 00 0V is present the logic relay or logic circuit wirin...

Page 151: ...Contactor Coil ground 5 VDC OUT Not Used N C 1 Not Used 12 VDC OUT Not Used N C 2 Not Used The machine electrical schematic and wire harness drawings in Appendix A page A 1 can be used to identify po...

Page 152: ...ched to the controller The connection terminal function for the controller and the wire harness connector pins are shown above The connectors are keyed the same Pay close attention to the wire harness...

Page 153: ...following test procedure 1 Park the machine on a level surface lower the cutting units set the key switch to the OFF position and remove the key from the switch 2 Remove the right side cover 3 Discon...

Page 154: ...k 2 Main P07 2 Red 12 VDC nominal 5 If testing determines the converter is faulty replace the converter 6 If the converter tests correctly and a circuit problem still exists check the wire harnesses r...

Page 155: ...traction motors themselves are not directly on the CAN bus The traction motor controller is not serviceable and is best tested by using the information provided on the InfoCenter display as described...

Page 156: ...for corrosion or damage and cleaned or repaired as necessary If logic voltage is present at the controller and CAN bus communication is suspect the CAN bus circuit is damaged The CAN bus wiring should...

Page 157: ...eration is an issue test the traction motor refer to Front Traction Motor page 5 55 9 If replacing the traction motor controller is necessary A Disconnect the 48V battery disconnect refer to 48V Batte...

Page 158: ...ctor G Lift the rubber boots from the cable terminals and coat the terminals with battery terminal protector Toro Part No 107 0392 to reduce corrosion Fit the rubber boots securely over the terminals...

Page 159: ...t be calibrated g292897 Figure 58 right side traction motor shown 1 Traction Motor 4 Motor terminal W red 2 Wire harness connector 5 Motor terminal V orange 3 Motor terminal U black Testing the Front...

Page 160: ...age A 1 4 Disconnect the 48V battery disconnect refer to 48V Battery Disconnect page 5 9 5 Label and disconnect the 3 traction motor power cables at the traction motor 6 Use a multimeter ohms setting...

Page 161: ...s replaced for any reason the machine software must be updated contact an Authorized Toro Distributor for assistance Testing the Rear Wheel Traction Motor The InfoCenter Display can also be used to mo...

Page 162: ...cable electrical connections at the machine wire harness Check the motor and the harness connector for damage or corrosion and clean or repair as necessary 8 Use a multimeter ohms setting measure the...

Page 163: ...drag feedback for a more natural feel when turning the steering wheel The brake coil is controlled by a pulse width modulated PWM signal from the T1 Primary controller The steering input device is not...

Page 164: ...to the left counterclockwise The signal voltage range should be from 0 2V to 4 7V When the signal voltage reaches either end of the voltage range the voltage will reset and continue to increase or dec...

Page 165: ...ne wire harness Check both connectors for corrosion or damage and clean or repair as necessary 10 Use a multimeter ohms setting to measure the resistance of the brake coil across the steering input de...

Page 166: ...the following test procedure Refer to Appendix A page A 1 for circuit wiring information Note If the steering motor SC7 is replaced for any reason the machine software must be updated contact an Auth...

Page 167: ...logic voltage is present at the controller and CAN bus communication is suspect the CAN bus circuit is damaged The CAN bus wiring should be checked for corrosion or damage and cleaned or repaired as...

Page 168: ...ntation of the steering motor prior to removal B Remove the fasteners securing the steering motor to the upper steering housing and remove the steering motor Locate and discard the steering motor gask...

Page 169: ...utting units set the key switch to the OFF position and remove the key from the key switch 2 Remove the right side cover 3 Unplug the 48V battery disconnect refer to 48V Battery Disconnect page 5 9 4...

Page 170: ...ls C D and E should be 18k to 20k ohms If the machine is equipped with an optional rear wheel traction motor resistance across connector terminal F and B should also be 18k to 20k ohms C An incorrect...

Page 171: ...logic power supplied by the logic relay and a connection to the 48V power bus supplied by the main contactor when energized The cutting unit motor controller is not serviceable and is best tested by...

Page 172: ...sconnect refer to 48V Battery Disconnect page 5 9 7 Locate and disconnect the cutting unit motor cable electrical connections at the machine wire harness for the motor being tested Check the motor and...

Page 173: ...y Model 04580 page 5 105 3 Remove the console cover 4 Disconnect the wire harness connector from the switch Check the switch and the harness connector for damage or corrosion and clean or repair as ne...

Page 174: ...connector from the switch Check the switch and the harness connector for damage or corrosion and clean or repair as necessary Remove the switch from the console if necessary 5 Use a multimeter ohms se...

Page 175: ...system battery model 04580 refer to Removing and Installing the 12V System Battery Model 04580 page 5 105 or unplug the 48V battery disconnect model 04590 refer to 48V Battery Disconnect page 5 9 3 Re...

Page 176: ...console cover 4 Disconnect the wire harness connector from the switch Check the switch and the harness connector for damage or corrosion and clean or repair as necessary Remove the switch from the con...

Page 177: ...position and remove the key from the key switch 2 Raise the seat and disconnect the wire harness connector from the seat switch harness Check the harness connectors for damage or corrosion and clean o...

Page 178: ...all the seat switch in the reverse order 6 If the seat switch and seat switch harness tests correctly and a circuit problem still exists check the main wire harness refer to Appendix A page A 1 7 Conn...

Page 179: ...835 Figure 72 1 Brake actuator 4 Extension spring 7 link plate 2 each 2 Cylinder pin 5 Eye bolt 8 Clevis pin 3 Hair pin 2 each 6 Cotter pin 9 Brake actuator connector Testing the Brake Actuator The br...

Page 180: ...und The actuator should retract 8 Connect the brake actuator A terminal black wire to a 12 VDC power supply and connect the B terminal green wire to ground The actuator should extend 9 Replace the act...

Page 181: ...main information screen of the InfoCenter Display refer to InfoCenter Display page 5 33 P icon If testing determines that the switch and circuit wiring are not functioning correctly proceed with the f...

Page 182: ...ohms setting and verify that the machine wire harness black wire is closed to ground has continuity E Use a multimeter ohms setting and verify that the machine wire harness blue wire has continuity at...

Page 183: ...inal and a normally closed terminal The cutting unit lift lower switches are part of the safety interlock system refer to Checking the Interlock System Operation page 5 19 for a better understanding o...

Page 184: ...n or repair as necessary 5 Use a multimeter ohms setting to determine whether continuity exists between the various terminals for each switch position refer to the Raise Lower Switch Testing Reference...

Page 185: ...ssages The lift lower actuators are not serviceable and are best tested by using the information provided on the InfoCenter display as described in the following test procedure Refer to Appendix A pag...

Page 186: ...ears the actuator is not communicating on the CAN bus Voltage must be present at the controller logic circuit before communication can occur on the CAN bus If voltage is not present at the logic circu...

Page 187: ...nostics inputs and outputs report normally and the actuator does not function properly replace the actuator and update the machine software contact an Authorized Toro Distributor 8 Calibrate the lift...

Page 188: ...Display refer to Using the InfoCenter Display for Troubleshooting page 3 39 If testing determines that the switch and circuit wiring are not functioning correctly proceed with the following test proc...

Page 189: ...ly and a circuit problem still exists check the machine wire harness refer to Appendix A page A 1 6 After testing connect the engine wire harness to the switch before returning the machine to service...

Page 190: ...or controller via the CAB bus The sensor signals are constantly monitored for traction fault detection If a traction pedal position sensor fault occurs while the machine is moving the machine will slo...

Page 191: ...Sig 1 and Pedal Sig 2 should be 2 55 3 20 V I Set the key switch to the OFF position 4 If any of the sensor readings are out of range test the traction position sensor A Disconnect the machine wire ha...

Page 192: ...edal position sensor refer to Calibrating the Traction Pedal Position Sensor page 5 88 Calibrating the Traction Pedal Position Sensor 1 Sit in the operator seat and set the key switch on the ON positi...

Page 193: ...the machine is moving the machine will slowly come to a stop The brake pedal can be used to stop the machine sooner if necessary A steering sensor fault will disable the traction system until the ign...

Page 194: ...om the InfoCenter Main Menu select Diagnostics Steering Inputs g290697 Figure 82 shown with caster fork turned to the left D Turn the caster fork by hand until it is square with the machine straight R...

Page 195: ...1 10 After testing connect the machine wire harness and calibrate the steering system Calibrate the steering system center first then calibrate the steering system range refer to Calibrating the Stee...

Page 196: ...minals the relay has determines how the relay should be tested A tag near the wire harness relay connector can be used to identify each relay g291275 Figure 83 eTriFlex 3360 Model 04580 1 Logic relay...

Page 197: ...ergized by the T1 primary controller the logic relay provides 48V power to the logic circuits of all of the 48 volt controllers T2 T6 and SC2 SC8 T1 and SC1 operate on 12V logic power Brake Actuator R...

Page 198: ...over 4 Disconnect the wire harness connector from the relay being tested Check the relay and the harness connector for damage or corrosion and clean or repair as necessary Remove the relay from the mo...

Page 199: ...y Model 04580 page 5 105 or unplug the 48V battery disconnect model 04590 refer to 48V Battery Disconnect page 5 9 3 Remove the right side cover 4 Disconnect the wire harness connector from the relay...

Page 200: ...hould make and break continuity between terminals 30 and 87A as 12 VDC is applied and removed from terminal 85 9 Replace the relay as necessary 10 If the relay tests correctly and a circuit problem st...

Page 201: ...the logic relay g291504 Figure 87 1 Main contactor 3 Left side battery box 5 Main terminals 2 Traction motor contactor 4 Coil terminals Testing the Contactors 1 Park the machine on a level surface low...

Page 202: ...ance across the contactor coil terminals Resistance of the coil should be approximately 195 ohms 8 If testing determines that the contactor is faulty replace the contactor 9 If the contactor tests cor...

Page 203: ...e assembly is used for circuit protection from voltage spikes that occur when the traction motor contactor is de energized The diode plugs into the machine wire harness near the wire harness connector...

Page 204: ...ed 4 If the diode tests correctly and a circuit problem still exists check the wire harnesses refer to Appendix A page A 1 Electrical System Testing the Electrical Components Page 5 100 Greensmaster e...

Page 205: ...nector P58 2 CAN A termination resistor at connector P66 4 CAN A termination resistor at connector P65 The CAN bus and the termination resistors are part of the machine wire harness One of the CAN A t...

Page 206: ...nnector for damage or corrosion and clean or repair as necessary 4 Use a digital multimeter ohms setting and measure the resistance across the pins of the CAN bus termination resistor There should be...

Page 207: ...of soda solution Flush the top surface with water after cleaning 2 If corrosion occurs at the battery terminals disconnect the battery cables Always disconnect the negative cable first Clean the cabl...

Page 208: ...ies fully before storage refer to Charging the Batteries Model 04580 page 5 110 5 Store the battery in the appropriate environment Recommended storage temperatures should be between 10 C to 25 C 50 F...

Page 209: ...H rating 9 0 Length 19 6 cm 7 7 inches Width 13 2 cm 5 1 inches Height including terminal posts 18 3 cm 6 6 inches The battery is the heart of the electrical system With the regular and correct servic...

Page 210: ...terminal then disconnect the positive cable from the battery terminal 4 Remove the lock nuts carriage bolts and the battery clamp 5 Install the battery in reverse order 6 Tighten the battery terminal...

Page 211: ...each 3 Battery cover LH 10 Lock nut 2 each 17 Flat washer 4 Flat washer 4 each 11 Jumper cable 2 each 18 Flange nut 5 Flange head screw 4 each 12 Lock washer 8 each 19 Battery cable assembly 6 Flange...

Page 212: ...o the battery trays 7 Carefully remove the batteries from the machine 8 If battery cable removal is needed record the routing of the cables for installation purposes before removing the cables from th...

Page 213: ...tor to reduce corrosion refer to Battery Terminal Protector page 2 13 4 If the 48V system battery voltage drops below 50 VDC battery inspection and or charging may be necessary 5 Use a digital multime...

Page 214: ...charged with a 12V charger rated for operation with absorbed glass mat AGM valve regulated lead acid VRLA batteries The voltage of this battery type is slightly lower than flooded lead acid batteries...

Page 215: ...y must be disposed of or recycled in accordance with local and federal regulations For information on how to properly dispose of lithium ion batteries contact your local municipality or recycling faci...

Page 216: ...es Model 04590 The US Department of Transportation and international transportation authorities require that lithium ion batteries be shipped using special packaging and only be handled by carriers ce...

Page 217: ...ngth of 1 2 inch internal diameter rubber hose immediately after disconnecting the cable g310876 Figure 93 1 Battery cable terminal typical 2 1 2 inch ID rubber hose IMPORTANT Do not open the lithium...

Page 218: ...04590 continued g309819 Figure 94 1 Positive battery cable center 3 Hex nut 5 Positive battery cable right side 2 Washer 4 Positive battery cable left side Electrical System Batteries Model 04590 Page...

Page 219: ...battery cable and battery interface harness from both lithium ion batteries B Remove the 4 nuts washers and bolts that secure the batteries to the battery tray CAUTION Each battery weighs approximatel...

Page 220: ...age 6 43 B Remove the center battery cover C Label and disconnect the negative battery cable and negative wire harness terminal and the positive battery cable and the positive wire harness terminal fr...

Page 221: ...ints provided to remove the center mounted battery assembly H Raise the center mounted battery assembly approximately 7 5 cm 3 inch Label and disconnect the negative battery cable from the bottom of t...

Page 222: ...tery cable 3 each 14 Foam strip 2 each 22 Foam strip 2 each 7 Positive battery cable 15 Washer 10 each 8 SC8 Lithium Ion battery controller BMS 16 Negative battery cable IMPORTANT Pay close attention...

Page 223: ...atteries and at each set of side mounted batteries refer to Figure 94 10 Tighten the battery cable fasteners from 8 5 to 9 5 N m 75 to 85 in lb then apply battery terminal protector Toro Part No 107 0...

Page 224: ...rator spring bracket if necessary g286883 Figure 98 1 Generator drive belt 5 Hex nut 2 each 2 Generator pulley 6 Adjustment pin 3 Engine pulley 7 Extension spring 4 Engine frame 8 Cap screw 4 each 4 L...

Page 225: ...is procedure 1 Park the machine on a level surface lower the cutting units set the key switch to the OFF position and remove the key from the key switch 2 Unplug the 48V battery disconnect refer to 48...

Page 226: ...eck the starter generator and the harness connector for damage or corrosion and clean or repair as necessary 11 Tilt the operator seat forward and remove the starter generator pulley cover 12 Remove t...

Page 227: ...starter generator to the engine frame then rotate the starter generator clockwise to loosen the starter generator drive belt 16 Remove the fasteners and the starter generator from the engine frame Gr...

Page 228: ...cover 23 Washer 6 Controller assembly 15 Torx screw 4 each 24 Cap screw 7 Flange nut 2 each 16 Flat washer 4 each 25 Square head set screw 2 each 8 Cover gasket 17 Rotating screen 26 Spring bracket 9...

Page 229: ...ler is replaced the machine software must be updated contact an Authorized Toro Distributor for assistance 7 Remove the starter generator fan A Remove the flange head screw and the collar from the sta...

Page 230: ...assembly 11 Lip seal 5 Bearing 12 Screw 2 each 6 Wave washer 13 Isolator 7 O ring 14 Gasket Use of the starter generator rotor tool part number TOR6029 is recommended for this procedure refer to Gene...

Page 231: ...ry rapidly during removal Be cautious during rotor removal to prevent component damage or personal injury D Turn the rotor tool shaft to push the rotor and cover assembly from the housing stator assem...

Page 232: ...the base plate and turn it in so the end of the shaft prevents the rotor body from entering the housing stator assembly IMPORTANT The rotor magnets are very powerful and can cause the rotor to shift p...

Page 233: ...the controller 8 Lubricate a new cover gasket item 8 with dielectric lubricant and install the gasket into the groove in the access cover Secure the cover to the controller and tighten the screws fro...

Page 234: ...of engine 10 Connect the evaporative control system carbon canister to the engine vent hose 11 Install the fuel tank refer to Installing the Fuel Tank page 4 4 12 Install the exhaust system refer to...

Page 235: ...box assembly 6 Shoulder bolt 11 Thrust washer 6 each 2 Button head cap screw 2 each 7 Button head screw 12 Support link 3 Arm LH 8 Washer 13 Clevis pin 4 Button head cap screw 2 each 9 Extension sprin...

Page 236: ...ers securing the arm item 3 to the frame and the traction motor and remove the arm 8 Remove the support link 9 Remove the 4 fasteners securing the traction motor to the frame and remove the traction m...

Page 237: ...uare key 2 O ring 7 Set screw 3 Gasket 8 Spur gear 4 Gear box cover 9 Socket head cap screw 5 Socket head screw 6 each Removing the Rear Traction Motor Refer to Figure 106 for this procedure 1 Remove...

Page 238: ...includes very powerful magnets that can cause the rotor to move unexpectedly if working on a metal surface Also any metallic debris that gets attracted to the rotor can damage the motor after assembl...

Page 239: ...e washer from the rotor assembly 8 Remove and discard the O rings from the motor cover 9 Remove and discard the O ring from the motor housing 10 If necessary remove and discard the bearings from the r...

Page 240: ...the cover to the housing with the six cap screws and tighten the screws from 8 to 9 N m 70 to 80 in lb 9 Make sure that rotor rotates without binding before installing the motor assembly Installing t...

Page 241: ...e and discard the O ring from the cutting unit motor flange 5 Inspect the cutting unit threaded insert splines for wear Replace the inserts if necessary refer to Reel Assembly page 7 14 6 Locate the c...

Page 242: ...separately Use of the cutting unit motor rotor tool part number TOR6028 is recommended for this procedure refer to Cutting Unit Motor Rotor Tool page 2 18 IMPORTANT When servicing the cutting unit mo...

Page 243: ...re the gear box cover to the front of the motor housing 3 Carefully slide the gear box cover from the front of the motor 4 Remove and discard the O rings from the gear box cover 5 Carefully remove and...

Page 244: ...ring from the motor housing 14 If necessary remove and discard the bearings from the output gear and rotor 15 Inspect the cutting unit motor components for wear or damage Replace components or complet...

Page 245: ...embly is fully seated in the housing remove the rotor tool base plate 8 Secure the cover to the housing with the six cap screws and tighten the screws from 8 to 9 N m 70 to 80 in lb 9 Make sure that r...

Page 246: ...Motor 1 Install a new O ring to the flange of the cutting unit motor 2 Coat the splines of the cutting unit motor shaft with No 2 multipurpose lithium base grease 3 Install the cutting unit motor to t...

Page 247: ...Wheel Hub Standard 6 15 Rear Wheel Hub Optional 3WD 6 17 Rear Wheel Gear Box Optional 3WD 6 19 Traction Pedal Assembly 6 22 Brake Assembly 6 23 Rear Wheel Caster Fork 6 30 Steering Housing 6 33 Steer...

Page 248: ...rding the operation general maintenance procedures and maintenance intervals for your machine Refer to the traction unit Operator s Manual and optional accessory Installation Instructions for addition...

Page 249: ...e approximately 3 3 mm 0 13 inch If no gap exists at one or both brake rod assemblies adjust the brake linkage refer to Adjusting the Brake Linkage page 6 4 g312800 Figure 113 1 Brake rod 3 Brake leve...

Page 250: ...e spring g283623 Figure 114 1 Front traction motor RH 4 Extension spring 2 Hex nut 2 each 5 Upper brake arm RH 3 Eye bolt 6 Brake rod assembly 3 Use the 3 8 inch square drive hole in the right side up...

Page 251: ...ve the cotter pin and clevis pin from the lower brake rod clevis Discard the cotter pin IMPORTANT Adjust each brake rod individually 6 Loosen the hex nut at the upper brake rod clevis and adjust the b...

Page 252: ...ssible to relax the extension spring Remove the spring g283623 Figure 117 1 Front traction motor RH 4 Extension spring 2 Hex nut 2 each 5 Upper brake arm RH 3 Eye bolt 6 Brake rod assembly 3 Use the 3...

Page 253: ...ground Loosen the clevis nut and adjust the clevis if necessary g283646 Figure 118 1 Brake actuator 4 Clevis 7 Hex nuts 2 each 2 Rod nut 5 Extension spring 3 Clevis nut 6 Eye bolt 7 Install the exten...

Page 254: ...alling the Wheels page 6 9 2 Clamp a straight edge to the rear wheel hub flange 3 Rotate the caster fork by hand until the straight edge aligns with the lower mounting bolt on the center rear cutting...

Page 255: ...g and Installing the Wheels 1 Raise the machine off the ground refer to Jacking Instructions page 1 6 2 Remove and install the wheel and tire assemblies as necessary 3 Tighten the wheel lug nuts in a...

Page 256: ...he front hub lock nut is loosened at least two revolutions Use a 3 jaw puller to loosen the front hub assembly from the gear box shaft 4 Remove the wheel hub lock nut hardened washer and the wheel hub...

Page 257: ...the front wheel refer to Removing and Installing the Wheels page 6 9 2 Remove the front wheel hub refer to Removing and Installing the Front Wheel Hubs page 6 10 3 Remove the drain plug item 12 and al...

Page 258: ...p screws in a clockwise pattern from 18 to 22 N m 160 to 200 in lb 4 Apply a medium strength thread locking compound Loctite 243 or equivalent to the cap screw item 5 Install the washer and cap screw...

Page 259: ...iscard the lip seal and O ring 4 Loosen and remove the jam nuts and tab washers from the output shaft assembly 5 Remove the output shaft from the gear box housing and retrieve the outer bearing cone 6...

Page 260: ...to the shaft threads and install the second tab washer and the outer jam nut E Hold the inner jam nut and tighten the outer jam nut from 190 to 217 N m 140 to 160 ft lb F Ensure the torque required to...

Page 261: ...t and spindle washer that secure the wheel hub to the spindle Slide the wheel hub with the bearings from the spindle 5 Disassemble the wheel hub as follows Note Ensure that you do not damage the hub b...

Page 262: ...d in so that it is flush with the end of the wheel hub The lip of the oil seal must be toward the inner bearing D Lubricate the inside of new oil seal and press it into the wheel hub Note Ensure that...

Page 263: ...wise forward direction and engage with the rear wheel gear box shaft when rotated in the clockwise reverse direction 6 Grease the hub fitting with high temperature grease Mobil XHP 222 or equivalent b...

Page 264: ...hub The white roller cage of each roller clutch must be toward the inside lip seal of the hub The roller clutches should rest just below the inner shoulder of the hub and not block the grease passage...

Page 265: ...the 3WD traction motor connections to the machine wire harness and disconnect the 2 connectors Check the motor and the harness connector for damage or corrosion and clean or repair as necessary 5 Remo...

Page 266: ...emoving or disassembling the gear box 1 Remove the rear wheel gear box from the machine refer to Removing and Installing the Rear Wheel Gear Box page 6 19 2 Remove the fasteners and separate the gear...

Page 267: ...of the gear box components as necessary Ensure all bearings are pressed fully against their respective shoulders 9 Assemble the gear box in reverse order Use a new axle shaft seal and housing gasket T...

Page 268: ...er 2 each 25 Spacer 2 each 8 Pad forward 17 Bushing 2 each 26 Flange head screw 2 each 9 Pad reverse 18 Platform support RH Remove repair or replace the traction pedal components as necessary IMPORTAN...

Page 269: ...t in the operator seat a large extension spring keeps the brakes engaged When the key switch is in the RUN or START position and the operator is in the operator seat the electric brake actuator pulls...

Page 270: ...Cotter pin 5 each 21 Clevis pin 2 Eye bolt 12 Clevis actuator 22 Retaining ring 3 Hair pin 2 each 13 Clevis pin 2 each rod 23 Brake cable 4 Flange nut 4 each 14 Upper clevis brake rod 24 Pin actuator...

Page 271: ...chine Discard the cotter pins 6 Disconnect the brake cable from the left side brake arm 7 Remove the fasteners securing the brake shaft bearings item 5 to the machine and remove the bearings and shaft...

Page 272: ...e nut 3 each 20 Nylon bushing 2 each 7 Retaining ring 21 Torsion spring 8 Cap screw 22 Cap screw 9 Pivot 23 Brake pedal 10 Brake cable 24 Washer 2 each 11 Retaining ring 25 Detent 12 Park pedal 26 Fla...

Page 273: ...ort to the left platform and remove the assembly from the machine 5 Repair or replace the brake pedal components as necessary 6 Ensure the park pedal item 12 moves freely with the torsion spring 7 Che...

Page 274: ...ive hole in the right side upper brake arm item 8 to fully retract the brake actuator 4 Remove the support link item 1 5 Remove the brake return spring 6 Remove the cotter pin and the clevis pin from...

Page 275: ...t then secure the assembly in position with the shoulder bolt 14 Fit the brake linkage clevis over the brake lever Use a new cotter pin and install the clevis pin and cotter pin to secure the brake li...

Page 276: ...Castle nut 16 Lower steering housing 6 Tang washer 17 Lip seal 7 Washer 18 Caster fork 8 Bearing cone 2 each 19 Flange head screw 9 Bearing cup 2 each 20 Rear wheel spindle 10 Plug 21 Hex hut 4 each 1...

Page 277: ...ng Remove and discard the seal in the lower steering housing 13 Inspect the upper and lower bearing cups in the frame for wear or damage and replace them if necessary Installing the Rear Wheel Caster...

Page 278: ...rease fitting Toro part 302 5 or equivalent Lubricate the steering housing until grease is seen at the upper bearing Wipe up any excess grease 13 Install the magnetic carrier bolt and jam nut all the...

Page 279: ...w 10 Pinion gear 21 Flange head screw 2 each 11 Retaining ring Removing and Installing the Steering Gear Box Refer to Figure 135 for this procedure 1 Remove the caster fork refer to Rear Wheel Caster...

Page 280: ...ame 5 Remove additional items from the upper steering housing as needed 6 Install the upper steering housing in reverse order Tighten the fasteners securing the upper steering housing to the machine f...

Page 281: ...each 19 Steering input device 30 Pivot lever 9 Button head screw 6 each 20 Lock nut 4 each 31 Flange bushing 10 Roll pin 21 Cover 32 Pivot pedal 11 Shaft adapter 22 Carriage bolt 33 Pedal pad If the...

Page 282: ...with a roll pin and 2 set screws Discard the roll pin 4 Record the position of the steering mount item 6 for assembly and remove if necessary CAUTION The gas cylinder is under high pressure at all tim...

Page 283: ...the steering input device by pressing a new roll pin and installing 2 set screws Tighten each set screw from 8 to 10 N m 70 to 90 in lb IMPORTANT The lower right mounting hole of the steering mount is...

Page 284: ...ntrol switch For console switch testing information refer to Testing the Electrical Components page 5 23 Removing and Installing the Control Console Refer to Figure 137 for this procedure 1 Park the m...

Page 285: ...ontrol cable at the engine Remove the choke control knob before removing the choke control 5 Remove the 2 fasteners securing the console to the support and remove the console 6 Install the console and...

Page 286: ...ch 11 Flange nut 4 each 6 Platform support RH 12 Platform support LH 1 Align the platforms with each other before tightening the fasteners 2 If the right side platform support item 6 was removed from...

Page 287: ...at model 04729 is available for the Greensmaster 3360 3370 machines Refer to the specific seat Installation Instructions and Parts Catalog available at www Toro com for additional information Greensma...

Page 288: ...racket 3 Bushing 2 each 7 Side casting LH 4 Cap screw 8 each 8 Bushing 2 each If the side castings were removed from the machine tighten the cap screws Item 4 from 102 to 115 N m 75 to 85 ft lb Chassi...

Page 289: ...od brackets as needed to allow the hood to rest squarely on the fuel tank Removing and Installing the Hood Assembly Refer to Figure 141 for this procedure 1 Park the machine on a level surface set the...

Page 290: ...brackets with the markings made during removal or adjust the hood brackets as needed to allow the hood to rest squarely along the top and sides of the fuel tank D Tighten the bracket fasteners Chassi...

Page 291: ...r eTriFlex machines The cutting unit attaches to the crossarm assembly which is attached to the front of the cutting unit suspension assembly The crossarm assembly can be serviced with the suspension...

Page 292: ...e fasteners securing the lift lower actuator to the cutting unit suspension 7 Support the cutting unit motor away from the suspension assembly CAUTION Support the suspension assembly when removing it...

Page 293: ...each 21 Cotter pin 6 Pop rivet 2 each 14 Cap screw 4 each 22 Clevis pin 7 Steering stop 15 Counterbalance tensioner 8 Flange head screw 5 each 16 Flange nut 4 each The cutting unit suspension assembl...

Page 294: ...and allow to dry Apply a medium strength retaining compound to the ball joint housing before installation B If a ball joint clamp item 9 is removed ensure the raised boss in the clamp bore fits in the...

Page 295: ...ly removed Tighten the screws from 102 to 115 N m 75 to 85 ft lb 3 Install the front wheel if previously removed refer to Removing and Installing the Wheels page 6 9 4 If the stabilizer springs are re...

Page 296: ...e machine as the cutting unit is raised Adjust the stabilizer springs if necessary 5 Move the cutting unit motor to its storage location at the front of the suspension assembly 6 Fit the cutting unit...

Page 297: ...Suspension steering head 5 LH crossarm mount 10 Pivot pin 2 each Three 3 identical cutting unit suspension assemblies are used on Greensmaster eTriFlex machines The cutting unit attaches to the crossa...

Page 298: ...Chassis Service and Repairs Page 6 52 Greensmaster eTriFlex 3360 and 3370 19239SL Rev B...

Page 299: ...icing 7 2 Adjustments 7 3 DPA Cutting Unit Characteristics 7 3 Leveling the Rear Roller 7 4 Service and Repairs 7 6 Bedbar Assembly 7 6 Bedknife 7 11 Reel Assembly 7 14 Electric Cutting Unit Motor Ada...

Page 300: ...peration and maintenance information Refer to the Cutting Unit Operator s Manual and the kit Installation Instructions for additional information when servicing the cutting units Supporting the Cuttin...

Page 301: ...tioning 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 o...

Page 302: ...g to fit a 0 13 mm 0 005 in shim between the rear roller and the bench plate at each end of rear roller Rotate the roller and recheck the clearance at each end a few times to account for any roller ru...

Page 303: ...el to the reel Tighten the shoulder bolts from 24 to 27 N m 210 to 240 in lb 6 Recheck the clearance between the rear roller and the bench plate If necessary loosen and adjust second side plate on the...

Page 304: ...h 7 Lock nut 2 each 4 Lock nut 2 each 8 Metal washer 2 each Removing the Bedbar Refer to Figure 150 for this procedure 1 Remove the cutting unit from the machine and place the cutting unit on a flat w...

Page 305: ...ushings and rubber bushings in the side plates for wear or damage Replace the bushings if necessary Installing the Bedbar g226763 Figure 151 1 Side plate 5 Metal washer 2 Rubber bushing 6 Bedbar 3 Nyl...

Page 306: ...vot bolt 6 Position one plastic washer between the bedbar and the inside of each side plate 7 Install the bedbar pivot bolt assemblies Make sure the washers are not caught on the threads of the pivot...

Page 307: ...Inspect the flange bushings in the cutting unit side plate and replace them if necessary 6 Inspect the detent and replace it if necessary Installing the Bedbar Adjuster 1 If previously removed secure...

Page 308: ...ontinued 5 Install the washer spring and lock nut onto the adjuster screw 6 Install the bedbar refer to Installing the Bedbar page 7 7 DPA Cutting Units Service and Repairs Page 7 10 Greensmaster eTri...

Page 309: ...ust scale and corrosion from the bedbar surface under the bedknife Lightly oil the bedbar surface before installing the bedknife 2 Make sure that screw threads in bedbar 5 16 18UNC 2A are clean 3 Use...

Page 310: ...dknife Relief Angle 7 minimum Front Angle Range 13 to 17 g207289 Figure 155 1 Top angle 4 Front surface 2 Top surface 5 Front angle 3 Remove burr Since there can be variations in the mounting surface...

Page 311: ...iamond grinding wheel is recommended to prevent overheating or damaging the bedknife edge while grinding Because the top grind angle on bedknives is critical for edge retention and therefore after cut...

Page 312: ...mbly 13 Grass shield 20 Counterweight 7 Pitch arm 2 each 14 Flat wire spring Removal of the cutting reel requires removal of the left or right side plate from the cutting unit frame The opposite side...

Page 313: ...he O ring CAUTION Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when removing the cutting reel IMPORTANT If the reel bearings or seals are b...

Page 314: ...reel nut F Tip the cutting unit back onto its rollers 5 Remove the bedbar refer to Removing the Bedbar page 7 6 6 Remove the front roller refer to Removing the Front Roller page 7 23 7 Remove the rea...

Page 315: ...additional information 2 Press the bearings and slide the seals from the reel shaft Discard the seals and inspect the reel bearings to insure that they spin freely and have a minimal amount of axial...

Page 316: ...thin coat of grease to the outside of the cutting reel bearings and carefully slide the cutting reel assembly into the right side plate Make sure that the reel bearing is fully seated in the side plat...

Page 317: ...reel has a silver finish and has right hand threads C Rest the handle of the pry bar against the front roller and tighten the reel nut closest to the pry bar Tighten the reel nut from 123 to 149 N m...

Page 318: ...m 1 375 inch g227307 Figure 161 R Direction of Rotation Before grinding a cutting reel make sure that all the cutting unit components are in good condition Depending on the type of grinder used faulty...

Page 319: ...blade land width or to restore the reel s cylindrical shape Note Always adjust the cutting unit after grinding the reel and or bedknife refer to the Cutting Unit Operator s Manual To extend the cutti...

Page 320: ...cutting unit side plate Note The lock nuts are captured in the back side of the side plate 3 Remove the large O ring and the 2 small O rings from the motor adapter Discard the large O ring 4 Lubricat...

Page 321: ...ting unit side plate and remove the height of cut arm 4 Slide the front roller assembly from the remaining height of cut arm 5 Remove the remaining height of cut arm from the cutting unit if necessary...

Page 322: ...eight of cut washer and lock nut 6 Center the front roller in the cutting unit and tighten the pinch bolts that secure the front roller shaft to the height of cut arms 7 Adjust the cutting unit height...

Page 323: ...a level work surface Place blocks under the bedbar to raise the rear of the cutting unit off of the work surface Note Refer to the Cutting Unit Operator s Manual to determine the number of shims requ...

Page 324: ...am nut against the roller shaft Remove the bearing lock nuts 2 Carefully inspect the seating surface and threads of the bearing lock nuts and replace them if damaged 3 Remove and discard the V rings 4...

Page 325: ...use the original lock nuts for installing the bearings and seals if possible to preserve the patch lock feature of the new lock nuts Use the new nuts only after the bearings and seals have been instal...

Page 326: ...it a seal onto each bearing lock nut g206892 Figure 168 1 Seal 2 Bearing lock nut 6 Install a bearing lock nut with seal onto each end of the roller shaft Tighten the bearing lock nuts until they bott...

Page 327: ...9 Carefully fit a dry V ring onto each bearing lock nut g227754 Figure 171 1 Bearing lock nut 2 V ring 10 Lubricate the lips of the installed seals with 2 general purpose grease Note If an original be...

Page 328: ...on regarding assembly and adjustment Use the Installation Instructions along with this Service Manual when servicing the rear roller brush For eTriFlex machines the drive components for the rear rolle...

Page 329: ...Cover 22 Idler bushing 37 O ring 8 Bearing bracket RH 23 Socket head screw 38 Cap screw 2 each 9 Socket head screw 4 each 24 Socket head screw 3 each 39 Counterweight assembly 10 Flocked seal 3 each...

Page 330: ...e brush shaft and install the RH bearing bracket IMPORTANT If brush to roller contact is incorrect brush operation will be adversely affected 7 Check that the roller brush is parallel to the rear roll...

Page 331: ...lade with the pry bar as this may damage the cutting edge and or cause a high blade C Move the pry bar against the weld side of the reel support plate closest to the rear roller brush drive shaft D Re...

Page 332: ...rge hex 1 375 inch and tighten the drive shaft from 135 to 150 N m 100 to 110 ft lb 4 Apply a light coating of grease to a new O ring and install the adapter housing machines without a universal groom...

Page 333: ...26 N m 15 to 19 ft lb g285394 Figure 176 shown with Universal Groomer installed 1 Straight edge 11 Install and adjust the drive belt and install the cover IMPORTANT If brush to roller contact is incor...

Page 334: ...DPA Cutting Units Service and Repairs Page 7 36 Greensmaster eTriFlex 3360 and 3370 19239SL Rev B...

Page 335: ...Installation Instructions 8 2 Service and Repairs 8 3 The Gear Box Assembly 8 4 The Idler Assembly 8 12 The Groomer Reel 8 14 The Height Adjuster Assembly 8 17 The Grooming Brush Optional 8 19 Greensm...

Page 336: ...up operation general maintenance procedures and maintenance intervals for the groomer assembly on your Greensmaster machine Refer to the Installation Instructions for additional information when servi...

Page 337: ...head screw 2 each CAUTION Never work on the groomer with the key switch in the RUN or START position Always set the key switch to the OFF position remove the key from the switch and wait for all mach...

Page 338: ...Groomer Reel page 8 14 3 Remove the drive shield or if the cutting unit is equipped with an optional powered rear roller brush remove the rear roller brush drive assembly to service the groomer drive...

Page 339: ...e IMPORTANT To avoid grinding the reel do not contact the cutting edge of any blade with the pry bar as this may damage the cutting edge and or cause a high blade 8 Move the pry bar against the weld s...

Page 340: ...each 4 Driven gear 11 Retaining ring 5 Thrust washer 12 Gear box housing assembly 6 Ring gear 13 Damaged drive shaft 7 Flange bushing B Remove the 4 socket head screws and remove the gear box cover as...

Page 341: ...utting edge and or cause a high blade I Move the pry bar against the weld side of the reel support plate closest to the drive shaft assembly J Use the drive shaft removal tool on the large flats of th...

Page 342: ...g 28 Ball bearing 9 Driven gear 29 Ring gear 10 Actuator shaft 30 Flange bushing 11 Pin 31 Sun gear 12 O ring 32 Bearing 13 Knob 33 Planet gear 3 each 14 Retaining ring 34 Flange bushing 3 each 15 Thr...

Page 343: ...and cover 8 Inspect the V ring seals bearings gears and bushings in the gear box assembly Replace the damaged or worn components as necessary 9 If the sun gear ring gear or the gear box housing beari...

Page 344: ...pport plate closest to the gear box assembly and rest the handle of the pry bar against the front roller 4 Position the gear box assembly against the cutting unit and turn the drive shaft assembly clo...

Page 345: ...or if the cutting unit is equipped with an optional powered rear roller brush install the rear roller brush drive assembly refer to Rear Roller Brush Optional page 7 30 9 Install the groomer reel asse...

Page 346: ...l page 8 14 3 Remove the cotter pin and clevis pin from the height adjustment rod at the front of the idler arm Discard the cotter pin 4 Remove the two socket head screws that secure the motor adapter...

Page 347: ...from 37 to 45 N m 27 to 33 ft lb E If the collar was removed from the idler arm install the collar and tighten from 33 to 41 N m 24 to 30 ft lb 2 Fit a new O ring to the motor adapter 3 Apply anti sei...

Page 348: ...onal injury Use heavy gloves when handling the groomer reel 2 Carefully remove the 4 jam nuts 4 bolts and 4 shaft clamps that secure the groomer reel to the output and stub shafts 3 Lift the groomer r...

Page 349: ...the shaft 5 Inspect and replace worn or damaged components 6 Assemble the groomer reel as follows Note New lock nuts have an adhesive patch to prevent the lock nut from loosening If a used lock nut i...

Page 350: ...it is attached to the traction unit lower the cutting unit set the key switch to the OFF position and remove the key from the key switch 2 Position the groomer reel between the groomer driven and stub...

Page 351: ...Height Adjuster 1 Remove the cutting unit from the machine 2 Remove the cotter pins and clevis pins that secure the height adjustment rods to the groomer gear box and idler arm Discard the cotter pins...

Page 352: ...ghten the lock nut finger tight 4 Center the front roller between the height of cut brackets and tighten the front roller pinch bolts 5 Install new cotter pins and clevis pins and secure the height ad...

Page 353: ...er Reel page 8 14 The grooming brush element or shaft can be serviced separately To remove the spiral grooming brush from the shaft remove the lock nut and J bolt from both ends of the brush assembly...

Page 354: ...Universal Groomer Optional Service and Repairs Page 8 20 Greensmaster eTriFlex 3360 and 3370 19239SL Rev B...

Page 355: ...ic 3370 A 4 Electrical Schematic 3370 continued A 5 Wire Harness Drawing 3360 A 6 Wire Harness Diagram 3360 A 7 Wire Harness Diagram 3360 continued A 8 Wire Harness Drawing 3370 A 9 Wire Harness Diagr...

Page 356: ...e a line with an alternate color These wires are identified with the wire color and line color with either a or _ separating the color abbreviations listed above e g R BK is a red wire with a black li...

Page 357: ...Model 04580 Drawing 122 0142 Rev A Sheet 1 of 1 19239SL Rev B Page A 3 Electrical Schematic 3360 g291901...

Page 358: ...Page A 4 19239SL Rev B Model 04590 Drawing 122 1618 Rev A Sheet 1 of 2 Electrical Schematic 3370 g309035...

Page 359: ...Model 04590 Drawing 122 1618 Rev A Sheet 2 of 2 19239SL Rev B Page A 5 Electrical Schematic 3370 continued g309036...

Page 360: ...Page A 6 19239SL Rev B Model 04580 Drawing 122 1619 Rev D Sheet 1 of 1 Wire Harness Drawing 3360 g287361...

Page 361: ...Model 04580 Drawing 122 1619 Rev D Sheet 1 of 2 19239SL Rev B Page A 7 Wire Harness Diagram 3360 g293957...

Page 362: ...Page A 8 19239SL Rev B Model 04580 Drawing 122 1619 Rev D Sheet 2 of 2 Wire Harness Diagram 3360 continued g293958...

Page 363: ...Model 04580 Drawing 122 1620 Rev D Sheet 1 of 1 19239SL Rev B Page A 9 Wire Harness Drawing 3370 g309034...

Page 364: ...Page A 10 19239SL Rev B Model 04590 Drawing 122 1620 Rev D Sheet 1 of 2 Wire Harness Diagram 3370 g309032...

Page 365: ...Model 04590 Drawing 122 1620 Rev D Sheet 2 of 2 19239SL Rev B Page A 11 Wire Harness Diagram 3370 continued g309033...

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