Toro Greensmaster 3250-D 04383 Service Manual
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Toro Greensmaster 3250-D 04383 Service Manual

Toro Greensmaster 3250-D 04383 Service Manual

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Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing,
and repair of major systems and components on the
Greensmaster 3250--D (Model 04383).
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR'S MANUALS FOR OPERATING,
MAINTENANCE AND ADJUSTMENT INSTRUC-
TIONS. Space is provided in Chapter 2 of this book to
insert the Operator's Manuals and Parts Catalogs for
your machine. Additional copies of the Operator's
Manuals and Parts Catalog are available on the internet
at www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
E The Toro Company - - 2000, 2003, 2004, 2005, 2006, 2007, 2009, 2012
Greensmaster
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
Note: A Note will give general information about the
correct operation, maintenance, service, testing, or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
Part No. 00062SL (Rev. J)

Service Manual

(Model 04383)
R
3250- -D

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Summary of Contents for Toro Greensmaster 3250-D 04383

  • Page 1: Service Manual

    IMPORTANT: The IMPORTANT notice will give im- specifications or this publication without notice. portant instructions which must be followed to pre- vent damage to systems or components on the machine. E The Toro Company - - 2000, 2003, 2004, 2005, 2006, 2007, 2009, 2012...
  • Page 2 This page is intentionally blank. Greensmaster 3250−D...

  • Page 3: Table Of Contents

    Table Of Contents Chapter 1 - - Safety Chapter 6 - - Chassis Safety Instructions ......1 -- 2 Specifications .
  • Page 4 This page is intentionally blank. Greensmaster 3250−D...

  • Page 5: Safety Instructions 1

    Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS ..... . Before Operating ......While Operating .

  • Page 6: Safety Instructions

    Safety Instructions The GREENSMASTER 3250--D was tested and certi- The safety alert symbol means fied by Toro for compliance with national and interna- CAUTION, WARNING or DANGER — tional standards as specified in the Operator’s Manual. “personal safety instruction”. Read...

  • Page 7: While Operating

    While Operating 10. Do not run the engine in a confined area without ad- 16. The GREENSMASTER 3250−D may exceed noise equate ventilation. Exhaust fumes are hazardous and levels of 85 dB(A) at the operator position. Ear protec- could be deadly. tors are recommended, for prolonged exposure, to re- duce the potential of permanent hearing damage.

  • Page 8: Safety And Instruction Decals

    The Toro Company. lieved by stopping engine and lowering cutting units and 38. When changing attachments, tires, or performing attachments to the ground.

  • Page 9: Product Records

    Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......EQUIVALENTS AND CONVERSIONS ... Decimal and Millimeter Equivalents .

  • Page 10: Equivalents And Conversions

    Equivalents and Conversions 0.09375 Product Records and Maintenance Greensmaster 3250−D Page 2 − 2 Rev. H...

  • Page 11: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
  • Page 12 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Grade 1, 5, & SAE Grade 1 Bolts, Screws, Studs, & SAE Grade 5 Bolts, Screws, Studs, & SAE Grade 8 Bolts, Screws, Studs, & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
  • Page 13 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Class 10.9 Bolts, Screws, and Studs with Thread Size Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...

  • Page 14: Maintenance

    Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 -- 20 UNF 65 + 10 ft--lb 88 + 14 N--m Grade 5 1/4 -- 20 UNC 140 + 20 in--lb...

  • Page 15: Introduction 3

    Chapter 3 Engine Table of Contents INTRODUCTION ......Replace Fuel Filter .

  • Page 16: Introduction

    Stratton dealer or distributor. If no parts list is avail- Daihatsu Repair Manual for 3−Cylinder, Water−Cooled, able, be sure to provide your distributor with the Toro Diesel Engines. The use of some specialized test equip- model and serial number.

  • Page 17: Specifications

    Specifications Item Description Make / Designation Briggs and Stratton Vanguard/Daihatsu, Water−cooled, Diesel, Model 522447 Number of Cylinders Horsepower Governed to 14.5 + 0.5 HP @ 2600 RPM Torque kg−m (ft−lb) 4.76 (34.5) @ 2300 RPM Bore x Stroke mm (in.) 68 x 78 (2.68 x 3.07) Total Displacement cc (cu.

  • Page 18: General Information

    General Information DANGER Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while en- gine is running, hot, or when machine is in an en- closed area.

  • Page 19: Fill Fuel Tank

    Fill Fuel Tank The engine runs on No. 2 diesel fuel. Fuel tank capacity is approximately 6.0 gallons (22.7 L). 1. Clean area around fuel tank cap. 2. Remove fuel tank cap. 3. Fill tank to about one inch below the top of tank, (bot- tom of the filler neck).

  • Page 20: Drain Water From Fuel Filter/Water Separator

    Drain Water from Fuel Filter/Water Separator Any water accumulation should be drained from the fuel filter/water separator before each use or when warning light glows. 1. Position machine on a level surface and stop the en- gine. Note: Because the accumulated water will be mixed with diesel fuel, drain the fuel filter into a suitable con- tainer and dispose of properly.

  • Page 21: Adjustments

    Adjustments Adjust Alternator Belt Make sure belt is properly tensioned to assure the prop- er operation of the machine and prevent unnecessary wear. On new belts, check tension after 8 hours of op- eration. The engine belt should be tensioned so it deflects 0.20 inch (5 mm) with a 2 to 3 lbf (9 to 13 N) load applied mid- way between the crankshaft and alternator pulley.

  • Page 22: Service And Repairs

    Service and Repairs Service Air Cleaner Service air cleaner filter every 200 hours (more fre- quently in extreme dusty or dirty conditions). 1. Check air cleaner body and hoses for damage which could possibly cause an air leak. Replace air cleaner body if damaged.

  • Page 23: Change Engine Oil And Filter

    Change Engine Oil and Filter Change oil and filter initially after the first 50 hours of op- eration, thereafter change oil every 50 hours and filter every 100 hours. However, change oil more frequently when engine is operated in extremely dusty or dirty conditions.

  • Page 24: Muffler And Air Cleaner

    Muffler and Air Cleaner RIGHT FRONT Figure 12 1. Pipe plug 11. Exhaust plate 21. Vaculator valve 2. Air cleaner bracket 12. Exhaust pipe 22. Fuel hose (to injector pump) 3. Lock nut 13. R−clamp 23. Not used 4. Cap screw 14.
  • Page 25 Muffler Removal (Fig. 13) Air Cleaner Removal (Fig. 15) 1. Park machine on a level surface, lower the cutting 1. Park machine on a level surface, lower the cutting units, stop the engine, engage parking brake, and re- units, stop the engine, engage parking brake, and re- move the key from the ignition switch.

  • Page 26: Radiator

    Radiator Figure 17 1. Hose clamp 13. Lower cooler bracket 25. Expansion tank hose 14. Plug 26. Not used 2. Radiator hose (to water pump) 3. Barb hose fitting 15. Cap screw 27. Thermostat housing 4. Radiator 16. Lock spring washer 28.

  • Page 27: Chapter 4 - - Hydraulic System

    Radiator Removal (Fig. 17) Radiator Installation (Fig. 17) 1. Park machine on a level surface, lower the cutting 1. Secure fan shroud (19) to radiator (4) with four cap units, stop the engine, engage parking brake, and re- screws (22), lock nuts (28), and flat washers (31). move the key from the ignition switch.

  • Page 28: Fuel Tank

    Fuel Tank 30 to 60 in−lb (3.4 to 7.8 N−m) ANTISEIZE LUBRICANT RIGHT FRONT Figure 18 19. Clamp 1. Fuel cap 10. Hose clamp 2. Fuel tank 11. Fuel fitting 20. Double hose clamp 3. Grommet 12. Not used 21. Fuel hose (to fuel filter/water sep.) 4.
  • Page 29 Fuel Tank Removal (Fig. 18) Fuel Tank installation (Fig. 18) 1. Park machine on a level surface, lower cutting units, 1. Position fuel tank (2) to the mounting plate (13). Be stop the engine, engage parking brake, and remove the careful not to damage any fuel hoses.

  • Page 30: Engine

    Engine Figure 19 1. Daihatsu engine 17. Lower alternator bracket 33. Cap screw 2. Fan adapter 18. Rubber mount 34. Hydrostat support brace (LH) 3. Overflow tank 19. Cap screw 35. Hydrostat support brace (RH) 4. Engine fan 20. Flange lock nut 36.

  • Page 31: Engine Removal

    Engine Removal PUMP INLET HOSE 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Release lockup handle, and pivot steering arm and steering wheel all the way forward. Lift seat forward to gain access to the engine.
  • Page 32 10. Remove fuel tank and hydraulic reservoir as fol- lows: A. Remove three cap screws (6) and two flat wash- ers (14) securing tank mounting plate (13) to the support bracket (17) and frame (Fig. 18). B. Disconnect hydraulic hose to power steering from from the hydraulic reservoir.
  • Page 33 12. Separate relief valve from the pump plate by remov- ing both cap screws flat washers, and lock nuts (Fig. 26). 13. Separate hydrostat from the pump plate as follows: A. Loosen both set screws securing the hydrostat shaft to the hub (Fig. 27). CAUTION Use caution when removing the traction control mechanism.
  • Page 34 17. Remove three flange lock nuts (20), flat washers A. Attach a short section of chain between both en- (21), washers (45), and cap screws (19) securing the gine mounts front engine mount (13) and rear engine mount (11) to B.

  • Page 35: Engine Installation

    Engine Installation F. The white/red wire to the oil pressure switch. 1. If the pump plate, backing plate, or engine mounts G. Plug−in connector with white and green wires to were removed from the engine, install them to the en- the alternator.
  • Page 36 A. Position mounting plate and tanks onto the 14. Connect hydraulic oil cooler if installed (Fig. 21). frame. A. Connect tube and O−ring to hydraulic fitting on B. Connect fuel hose coming from the fuel filter/wa- the hydraulic reservoir. ter separator at the injector pump inlet (Fig. 24). B.

  • Page 37: Clean Radiator And Screen

    Clean Radiator and Screen To prevent the cooling system from overheating, the ra- diator screen and radiator must be kept clean. Check and clean screen and radiator daily. If necessary, clean any debris off these parts hourly. Clean these compo- nents more frequently in dusty and/or dirty conditions.
  • Page 38 This page is intentionally blank. Engine Greensmaster 3250−D Page 3 − 24...

  • Page 39: Hydraulic Schematics 4

    Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......SERVICE AND REPAIRS .
  • Page 40 This page is intentionally blank. Page 4 - - 2 Greensmaster 3250--D Hydraulic System (Rev. I)

  • Page 41: Specifications

    Specifications Item Description Hydrostatic Transmission (P3) Variable displacement piston pump Maximum Pump Displacement (per revolution) 1.24 in (20.3 cc) Charge Pressure 100 to 150 PSI (6.9 to 10.3 bar) Gear Pump 2 section, positive displacement gear type pump Front Section (P1) (cutting reels) Displacement (per revolution) 0.55 in (9.0 cc) Rear Section (P2) (steering/lift) Displacement (per revolution)

  • Page 42: General Information

    2/3 oz bottles. One bottle is sufficient for 4 to 6 gallons of hydraulic fluid. Order Part No. 44--2500 from your Authorized Toro Distributor. 1. Position machine on a level surface. Make sure ma- chine has cooled down so fluid is cold.
  • Page 43 Towing Traction Unit In case of emergency, the Greensmaster 3250--D can be towed for a short distance. However, Toro does not recommend this as a standard practice. 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.

  • Page 44: Hydraulic Hoses

    Tube Installation in this section). If the hose has an el- bow at one end, tighten the swivel nut on that end before tightening the nut on the straight end of the hose. For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).
  • Page 45 Hydraulic Hose and Tube Installation (O- -Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ C. Use a second wrench to tighten the nut to the cor- tube and the fitting are free of burrs, nicks, scratches or rect Flats From Wrench Resistance (F.F.W.R.).
  • Page 46 Hydraulic Fitting Installation (SAE Straight Thread O- -Ring Fitting into Component Port) Non- -Adjustable Fitting (Fig. 6) 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate meth- 1.
  • Page 47 Adjustable Fitting (Fig. 8) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is rec- ommended that the O--ring be replaced any time the connection is opened.

  • Page 48: Hydraulic Schematics

    Hydraulic Schematics Page 4 - - 10 Greensmaster 3250--D Hydraulic System (Rev. I)
  • Page 49 Greensmaster 3250--D Page 4 - - 11 Hydraulic System (Rev. I)
  • Page 50 Page 4 - - 12 Greensmaster 3250--D Hydraulic System (Rev. I)
  • Page 51 Greensmaster 3250--D Page 4 - - 13 Hydraulic System (Rev. I)

  • Page 52: Hydraulic Flow Diagrams

    Hydraulic Flow Diagrams Page 4 - - 14 Greensmaster 3250--D Hydraulic System (Rev. I)
  • Page 53 Traction Forward and Reverse Forward Reverse The hydrostat (P3) is driven directly by the engine. The The traction circuit operates essentially the same in re- traction circuit of the hydraulic system acts essentially verse as it does in the forward direction. However, the as a closed loop.
  • Page 54 Page 4 - - 16 Greensmaster 3250--D Hydraulic System (Rev. I)
  • Page 55 Raise and Lower Cutting Units (Serial Number Under 260999999) The gear pump (P2) is directly coupled to the hydrostat Lower Cutting Units through gear pump (P1). It supplies hydraulic pressure Circuit operation for lowering the lift cylinders is similar for raising and lowering the cutting units, for the steering to raising them.
  • Page 56 Page 4 - - 18 Greensmaster 3250--D Hydraulic System (Rev. I)
  • Page 57 Raise and Lower Cutting Units (Serial Number Above 270000000) The gear pump (P2) is directly coupled to the hydrostat Lower Cutting Units through gear pump (P1). It supplies hydraulic pressure Circuit operation for lowering the lift cylinders is similar for raising and lowering the cutting units, for the steering to raising them.
  • Page 58 Page 4 - - 20 Greensmaster 3250--D Hydraulic System (Rev. I)

  • Page 59: Mow And Backlap (Serial Number Under 260999999)

    Mow and Backlap (Serial Number Under 260999999) The gear pump (P1) is directly coupled to the the hydros- On units with the optional backlap kit installed, flow tat which is driven directly by the engine. Taking its suc- through the manifold block is different. Oil flow from port tion directly from the hydraulic reservoir, the gear pump (P1) flows through the 11 position reel speed control (P1) supplies oil flow to the hydraulic manifold block and...
  • Page 60 Page 4 - - 22 Greensmaster 3250--D Hydraulic System (Rev. I)
  • Page 61 Mow and Backlap (Serial Number Above 270000000) The gear pump (P1) is directly coupled to the hydrostat Oil flow from manifold port (P1) flows through the reel which is driven directly by the engine. Taking its suction speed control valve (FC1). Flow across the speed con- directly from the hydraulic reservoir, the gear pump (P1) trol valve is pressure compensated by the logic cartridge supplies oil flow to the hydraulic manifold block and to...
  • Page 62 Page 4 - - 24 Greensmaster 3250--D Hydraulic System (Rev. I)

  • Page 63: Right And Left Turn

    Right and Left Turn The gear pump (P2) is directly coupled to the hydrostat direction for a right turn. The rotary meter ensures that through gear pump (P1). It supplies hydraulic pressure the oil flow to the cylinder is proportional to the amount to the steering control valve for turning the rear wheel, of the turning on the steering wheel.

  • Page 64: Special Tools

    Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit - - TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.
  • Page 65 Hydraulic Test Fitting Kit - - TOR4079 This kit includes a variety of O--ring face seal fittings to TORO TEST FITTING KIT (NO. TOR4079) enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings.

  • Page 66: Troubleshooting

    Troubleshooting The charts that follow contain information to assist in Refer to the Testing section of this Chapter for precau- troubleshooting. There may possibly be more than one tions and specific test procedures. cause for a machine malfunction. Problem Possible Cause Hydraulic oil leaks from system.
  • Page 67 Problem Possible Cause No traction exists in either direction. Parking brake is not released. Oil level in reservoir is low. Hydrostat by--pass valve is open. Charge pressure is low (see Charge Pressure Relief Valve (R4) Pressure Test). Traction pump (P3) or wheel motor(s) are worn or damaged (see Traction Drive Hydrostat (P3) Flow and Wheel Motor Efficiency Tests).
  • Page 68 Problem Possible Cause Cutting units will not lift or lift slowly. Engine speed is too low. Reservoir oil level is low. Lift cylinder linkage is binding or broken. Lift cylinder bushings bind. Charge circuit pressure is low (see Charge Relief Valve (R4) Pres- sure Test).
  • Page 69 Problem Possible Cause The steering wheel can be turned The steering cylinder is worn. without the rear wheel turning. The gear set in the steering control valve is worn. Steering response is too slow and Oil supply to the steering control valve is insufficient. heavy when trying to turn quickly.

  • Page 70: Testing

    Testing The most effective method for isolating problems in the 1. Clean machine thoroughly before disconnecting or hydraulic system is by using hydraulic test equipment disassembling any hydraulic components. Always keep such as pressure gauges and flow meters in the circuits in mind the need for cleanliness when working on hy- during various operational checks (see the Special draulic equipment.
  • Page 71 4. For problems with steering or lift/lower pressure, 5. For issues with the cutting system, consider per- consider performing the following hydraulic tests: forming the following hydraulic tests: Charge Pressure Relief Valve (R4) Pressure Test Mow Circuit Relief Valve (R1) Pressure Test Lower Cutting Units Relief Valve (R2) Pressure Test Reel Motor Case Drain Flow Test Implement Relief Valve (R5) Pressure Test...

  • Page 72: Traction Drive Hydrostat (P3) Flow Test (Using Tester With Flowmeter And Pressure

    Traction Drive Hydrostat (P3) Flow Test (Using Tester with Flowmeter and Pressure Gauge) HOSE FROM UPPER FITTING TRACTION WHEEL MOTORS OPTIONAL REAR WHEEL MOTOR TESTER DUMP VALVE FROM GEAR PUMP (P2) High Pressure Low Pressure HYDROSTAT Return or Suction TO HYDRAULIC RESERVOIR Flow Page 4 - - 34...
  • Page 73 Procedure for Traction Drive Hydrostat (P3) Flow 8. Start engine and move throttle to full speed (2750 + Test 50 RPM) position. This test measures hydrostat pump output (flow). Dur- CAUTION ing this test, pump load is created at the flowmeter using the adjustable load valve on the tester.

  • Page 74: Wheel Motor Efficiency Test

    Wheel Motor Efficiency Test (Using Tester with Flowmeter and Pressure Gauge) HOSE FROM UPPER FITTING TRACTION WHEEL MOTORS OPTIONAL REAR WHEEL (3WD) MOTOR TESTER DUMP VALVE FROM GEAR PUMP High Pressure HYDROSTAT Low Pressure TO HYDRAULIC RESERVOIR Return or Suction Flow Page 4 - - 36 Rev.
  • Page 75 Procedure for Wheel Motor Efficiency Test 12. Slowly push traction pedal in forward direction until 1000 PSI (69 bar) is displayed on the tester pressure Note: Over a period of time, a wheel motor can wear gauge. internally. A worn motor may by--pass oil to its case drain causing the motor to be less efficient.
  • Page 76 Charge Relief Valve (R4) Pressure Test (Using Pressure Gauge) TRACTION WHEEL MOTORS OPTIONAL REAR WHEEL MOTOR PUMP (P3) CHARGE PORT SCHEMATIC AND PICTURE ARE FROM A MACHINE WITH SERIAL NUMBER UNDER 220999999 DUMP VALVE FROM LIFT CIRCUIT TO REEL MOTOR CIRCUIT TO STEERING AND LIFT...
  • Page 77 Procedure for Charge Relief Valve (R4) Pressure 7. Shut off engine. Test 8. If specification is not met, remove hydrostat back 1. Make sure hydraulic oil is at normal operating tem- plate assembly that contains the charge relief valve (see perature by operating the machine for approximately ten Piston Pump Service in the Service and Repairs section (10) minutes.
  • Page 78 Gear Pump (P2) Flow and Implement Relief Valve (R5) Pressure Tests (Using Tester with Flowmeter and Pressure Gauge) RELIEF VALVE (R5) PUMP DISCHARGE FITTING PHOTO SHOWS RELIEF VALVE (R5) AS USED IN MACHINES WITH SERIAL NUMBER UNDER 220999999 TO REEL MOTOR FROM LIFT CIRCUIT TO STEERING AND...

  • Page 79: Charge Relief Valve (R4) Pressure Test

    5. Open control valve on tester and shut off engine. CAUTION Note: The implement relief valve (R5) is in series with charge relief valve (R4). (R4) pressure will affect (R5) Before continuing further, read and become fa- pressure. miliar with Precautions for Hydraulic Testing. 6.
  • Page 80 Lower Cutting Units Relief Valve (R2) Pressure Test (Using Pressure Gauge) SCHEMATIC FROM MACHINE WITH SERIAL NUMBER TO AND FROM UNDER 220999999 SHOWN REEL MOTORS OPTIONAL VALVES LIFT CYLINDERS LOWER RAISE FLOW MANIFOLD BLOCK CONTROL FILTER VALVE TO TRACTION CHARGE CIRCUIT COOLER ENGINE...

  • Page 81: Pressure Test

    Procedure for Lower Cutting Units Relief Valve (R2) B. For machines with serial number over Pressure Test 230000000, relief pressure should be 400 PSI (27.6 bar) higher than charge relief (R4) pressure (e.g. 1. Make sure hydraulic oil is at normal operating tem- if charge relief valve pressure is 100 PSI (6.9 bar), perature by operating the machine for approximately ten the lower relief valve (R2) pressure should be...

  • Page 82: Gear Pump (P1) Flow Test

    Gear Pump (P1) Flow Test (Using Tester with Flowmeter and Pressure Gauge) PUMP (P1) OUTLET TO HYDRAULIC MANIFOLD TO HYDRAULIC MANIFOLD SCHEMATIC FROM MACHINE WITH SERIAL NUMBER UNDER 220999999 SHOWN FROM LIFT TESTER CIRCUIT TO STEERING AND LIFT CIRCUITS TO TRACTION CHARGE CIRCUIT ENGINE GEAR PUMP...
  • Page 83 Procedure for Gear Pump (P1) Flow Test CAUTION 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately ten (10) minutes. Do not engage the cutting units when performing this test. 2. Park machine on a level surface with the cutting units lowered.

  • Page 84: Mow Circuit Relief Valve (R1) Pressure Test (Using Tester With Flowmeter And

    Mow Circuit Relief Valve (R1) Pressure Test (Using Tester with Flowmeter and Pressure Gauge) TO LEFT REEL MOTOR TO AND FROM REEL MOTORS SCHEMATIC FROM MACHINE WITH SERIAL NUMBER UNDER 220999999 SHOWN OPTIONAL VALVES TO AND FROM LIFT CYLINDERS TO HYDRAULIC RESERVOIR MANIFOLD BLOCK FROM STEERING...
  • Page 85 Procedure for Mow Circuit Relief Valve (R1) Pres- 10. On machines with serial number above 270000000, sure Test system pressure should be from 2700 to 3300 PSI (186.3 to 227.7 bar). Record test results. 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately ten A.

  • Page 86: Reel Motor Case Drain Flow Test

    Reel Motor Case Drain Flow Test (Using Tester with Flowmeter and Pressure Gauge) RIGHT MOTOR CASE DRAIN REAR MOTOR CASE DRAIN LEFT MOTOR CASE DRAIN REAR MOTOR RETURN LEFT MOTOR RETURN RIGHT MOTOR RETURN RIGHT MOTOR MEASURING CONTAINER REAR MOTOR LEFT MOTOR High Pressure...
  • Page 87 1. Make sure hydraulic oil is at normal operating tem- duated in ounces or milliliters (e.g. Toro #TOR4077) and perature by operating the machine for approximately ten collect hydraulic fluid for 15 seconds. After 15 sec- (10) minutes.

  • Page 88: Steering Control Valve Test

    Steering Control Valve Test PLUG STEERING CYLINDER (CYLINDER ROD FULLY EXTENDED) POWER STEERING VALVE (LEFT TURN) SCHEMATIC FROM MACHINE WITH SERIAL NUMBER High Pressure UNDER 220999999 SHOWN Low Pressure Return or Suction Flow Page 4 - - 50 Greensmaster 3250--D Hydraulic System (Rev.
  • Page 89 Procedure for Steering Control Valve Test 1. Make sure the hydraulic tank is full. 2. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately ten (10) minutes. 3. Drive machine slowly in a figure eight on a flat level surface.

  • Page 90: Adjustments

    Adjustments Adjust Transmission for Neutral If the machine “creeps” when the traction control pedal E. From each side of the bulkhead, tighten locknuts is in the neutral position, the neutral return mechanism evenly, securing traction cable to the bulkhead. Do must be adjusted.

  • Page 91: Adjust Mowing Speed

    Adjust Mowing Speed The machine is adjusted at the factory, but speed may be varied if desired. 1. Loosen jam nut on trunnion cap screw located on the traction control assembly. 2. Loosen nut securing the lock and mow brackets on pedal pivot.

  • Page 92: Adjust Implement Relief Valve (R5) (Machines With Serial Number Under 220999999)

    Adjust Implement Relief Valve (R5) (Machine Serial Number Under 220999999) For machines with serial number under 220999999, the implement (lift/steering) relief valve (R5) (Figure 26) is adjustable. Note: The implement relief valve (R5) for machines with serial number over 230000000 is incor- porated into the steering control valve and is not adjust- able.

  • Page 93: Service And Repairs

    Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- 1. Check oil level in the hydraulic reservoir and add cor- tem, park machine on a level surface, engage parking rect oil if necessary.

  • Page 94: Gear Pump

    Gear Pump 27 to 31 ft- -lb (37 to 42 N- -m) Figure 28 Pump inlet hose O- -ring 11. O- -ring Gear pump Hose clamp 12. Hydrostat Hydraulic fitting O- -ring 13. Hex socket screw Hydraulic fitting O- -ring 14.
  • Page 95 Removal (Fig. 28) Installation (Fig. 28) 1. Make sure mounting and O--ring sealing surfaces on the gear pump and hydrostat are clean. CAUTION 2. Replace all O--rings with new ones. Apply clean hy- draulic oil to all O--rings. Before continuing further, read and become fa- miliar with General Precautions for Removing 3.

  • Page 96: Gear Pump Service

    Gear Pump Service Figure 29 Front plate Back- -up gasket 14. Key Back plate Wear plate 15. Not used Front body 10. Pressure seal 16. Back gear Back body 11. Cap screw 17. Washer Drive gear 12. O- -ring 18. Plug Front idler gear 13.

  • Page 97: Hydraulic System Start--Up

    Hydraulic System Start- -up Note: When initially starting the hydraulic system with CAUTION new or rebuilt components such as motors, pumps, or lift cylinders, it is important that this start--up procedure be used. This procedure reduces the chance of damag- ing the system or its components from not purging the Be careful when operating the cutting unit reels.

  • Page 98: Hydrostatic Transmission

    Hydrostatic Transmission ILLUSTRATION FOR MACHINE WITH SERIAL NUMBER UNDER 220999999 SHOWN Antiseize 90 to 110 in- -lb Loctite #242 Lubricant (10.2 to 12.4 N- -m) Figure 30 Hose clamp 17. Hydraulic fitting 33. Cap screw O- -ring 18. 90 hydraulic fitting 34.
  • Page 99 Removal (Fig. 30) 1. Before removing any parts from the hydraulic sys- tem, park machine on a level surface, engage parking brake, lower cutting units, and stop engine. CAUTION Use caution when removing the lock nut from the pin. The extension spring is under tension and may cause personal injury during removal.
  • Page 100 9. Pull gear pump (28) and connected hoses assem- blies (27 and 38) away from the hydrostat (45) and se- cure. 10. Remove hose assemblies (25, 26, and 29) and O-- rings (6 and 16) from the hydraulic fittings (3 and 17). Al- low hoses to drain into a suitable container.

  • Page 101: Piston Pump Service

    Piston Pump Service REAR OF TRACTION UNIT Parts not listed in partlist are not serviced separately. Figure 35 18. Check valve 34. Shaft seal Drive shaft 19. Dump valve 35. Retaining ring Bearing 20. O- -ring 36. Retaining ring Cap screw 21.

  • Page 102: Piston Pump Crush Ring Replacement

    Piston Pump Crush Ring Replacement 29 ft- -lb (39 N- -m) Figure 36 Crush ring Camplate (control shaft) O- -ring Shims Bearing cone Washers Cover plate Bearing cup 10. Cap screws Housing Note: The shims replace the crush ring in the cover 5.

  • Page 103: Change Hydraulic Oil And Filter

    Change Hydraulic Oil and Filter Change hydraulic filter initially after the first 50 operating hours, thereafter change hydraulic oil and filter after ev- ery 800 hours. Contaminated oil looks milky or black HOSE when compared to clean oil. If oil becomes contami- nated, flush hydraulic system (see Flush Hydraulic Sys- tem).

  • Page 104: Wheel Motors

    Wheel Motors 250 to 400 ft- -lb (339 to 542 N- -m) RH 15 LH 16 15 RH 16 LH 70 to 90 ft- -lb (95 to122 N- -m) RIGHT FRONT Figure 38 1. Lug nut 12. Brake shoe 23. Brake lever 2.
  • Page 105 Note: The brake assembly consists of return spring 3. Lubricate new O--rings (18) with clean hydraulic (11), brake cam (9), brake shoes (12), backing plate (8), fluid. Install O--rings and hose assemblies (15 or 16) to and retaining clip (10). the hydraulic fittings (17).
  • Page 106 70 to 90 ft- -lb (95 to122 N- -m) 80 to 100 in- -lb (9.0 to 11.3 N- -m) RIGHT 85 ft- -lb FRONT (115 N- -m) 30 ft- -lb (41 N- -m) Figure 39 1. Castor fork 10. Cap screw 18.
  • Page 107 5. Loosen both set screws (24) on bearing (5). Slide 5. Position hydraulic motor and hub assembly (2), flan- flangettes (6 and 8) and bearing (5) off the motor shaft. gettes (6 and 8) with bearing (5), and wheel (25) into the castor fork (1).

  • Page 108: Wheel Motor Service

    Wheel Motor Service 12 13 Parts not listed in partlist are not serviced separately. 19, 20, 21 15, 16, 23 1, 4, 5, 6, 7, 15 2, 3, 8, 9, 10 Figure 40 Dirt seal 11. Coupling shaft 20. Vane Bearing 12.

  • Page 109: Flush Hydraulic System

    Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time 10. Start engine and let it idle at low speed for a mini- there is a severe component failure or the system is mum of two (2) minutes. Increase engine speed to high contaminated (oil appears milky or black or con- idle for minimum of one (1) minute under no load.

  • Page 110: Implement Relief Valve

    Implement Relief Valve (Machines with Serial Number Under 220999999) RELIEF VALVE 20 ft- -lb (27 N- -m) LEFT REAR Figure 43 Hose assembly Lock nut 11. Relief valve cartridge Hose assembly Cap screw 12. O- -ring O- -ring Flat washer 13.
  • Page 111 Installation CAUTION 1. Lubricate new O--rings with clean hydraulic fluid. Install O--rings and hydraulic fittings to the valve body. Use eye protection such as goggles when using 2. Secure valve body to the mounting plate with cap compressed air. screws, flat washers, and lock nuts. 4.

  • Page 112: Reel Motors

    Reel Motors RIGHT FRONT FRONT REEL MOTORS Figure 44 Cap screw 12. Spacer 22. Hydraulic tube Flat washer 13. Reel motor 23. Hydraulic tube Tube clamp 14. Hose assembly 24. Rubber grommet Lock nut 15. Hose assembly 25. O- -ring Plug 16.
  • Page 113 RIGHT FRONT REAR REEL MOTOR Figure 45 Bulkhead lock nut 11. Grommet 20. Tube clamp Bulkhead lock nut 12. Hydraulic straight fitting 21. Cap screw Hex washer head screw 13. 90 Hydraulic fitting 22. Lock nut Hydraulic hose 14. Hose bracket 23.

  • Page 114: Reel Motor Service

    Reel Motor Service (Serial Number Under 220999999) 190 to 210 in- -lb (21.5 to 23.7 N- -m) Figure 46 Hex socket head screw Idler gear assembly 11. Spacer Washer Drive shaft assembly 12. Shaft seal Dowel pin Seal ring 13. Retaining ring Cover assembly Load plate assembly 14.
  • Page 115 Inspection (Fig. 46) Note: Make sure idler gear is installed into the gear pocket opposite the external drain port. 1. Remove all nicks and burrs from all parts with an emery cloth. 3. Dip idler gear and drive shaft assemblies into clean hydraulic oil.
  • Page 116 Reel Motor Service (Serial Number Over 230000000) 215 to 280 in- -lb (24 to 32 N- -m) Figure 47 1. Rear cover 5. Pressure seal 9. Idler gear 2. Drive gear 6. Back- -up ring 10. Cap screw 3. Seal 7.
  • Page 117 IMPORTANT: Mark the relative positions of the gear teeth and the bearing blocks so they can be re- assembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. 7. Place the motor on its side and push on the rear bear- ing block to remove the bearing block and gear set (Fig.
  • Page 118 Reassembly 8. Install dowel pins in body. NOTE: When reassembling the motor, check the identi- IMPORTANT: Do not dislodge O- -rings, pressure fication marks made during disassembly to make sure seals, or back- -up rings during final assembly. the parts are properly aligned during reassembly. 9.
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  • Page 120: Oil Cooler (If Equipped)

    Oil Cooler (If Equipped) OIL FLOW Figure 52 Oil cooler Tube assembly 11. O- -ring Lower formed hose Tube assembly 12. Radiator screen Upper formed hose Hydraulic fitting 13. Upper cooler bracket Grommet Hydraulic fitting 14. Lower cooler bracket Hose clamp 10.
  • Page 121 7. Plug ends of the oil cooler. Clean exterior of the 3. Clean radiator screen and reinstall. cooler. 4. Remove clamps that where used to prevent drain- 8. The oil cooler should be free of corrosion and exces- age from the formed hoses. sive pitting of tubes.

  • Page 122: Lift Cylinders

    Lift Cylinders HYDRAULIC CYLINDER Figure 53 Hose assembly Lift arm 11. Frame Hose assembly Hydraulic cylinder 12. 90 Hydraulic fitting O- -ring Cap screw 13. O- -ring Cotter pin Ram pivot pin 14. Washer Clevis pin 10. Spacer Front Cylinder Removal (Fig. 53) 5.
  • Page 123 HYDRAULIC CYLINDER Figure 54 Hose assembly Clevis pin 13. O- -ring Hose assembly Lift arm 14. Flow control valve (if equipped) O- -ring Hydraulic cylinder 15. O- -ring hydraulic fitting 10. Retaining ring 16. O- -ring Orificed hydraulic fitting 11. Cylinder pin 17.

  • Page 124: Lift Cylinder Service

    Lift Cylinder Service REAR HYDRAULIC CYLINDER 24 to 30 ft- -lb (33 to 41 N- -m) Figure 55 Barrel Uni- -ring O- -ring Shaft O- -ring 10. Back- -up ring Rod seal 11. Dust seal Piston Head 12. Internal collar FRONT HYDRAULIC CYLINDER 24 to 30 ft- -lb (33 to 41 N- -m)
  • Page 125 Disassembly IMPORTANT: Do not clamp vise jaws against the shaft surface. Protect shaft surface before mount- 1. Remove oil from lift cylinder into a drain pan by slowly ing in a vice. pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder.

  • Page 126: Hydraulic Manifold

    Hydraulic Manifold ILLUSTRATION FOR MACHINE WITH SERIAL NUMBER UNDER 260999999 SHOWN Figure 57 Hydraulic manifold assembly 12. Cap screw 23. O- -ring Hydraulic straight fitting 13. Hydraulic hose 24. O- -ring Hydraulic fitting 14. Hydraulic hose 25. O- -ring O- -ring 15.
  • Page 127 Removal (Fig. 57) IMPORTANT: Before disconnecting any hydraulic fittings from the hydraulic manifold block, make 1. Before removing any parts from the hydraulic sys- sure the position of each fitting is observed and tem, park machine on a level surface, engage parking matchmarked to ensure it is oriented properly on brake, lower cutting units, and stop the engine.

  • Page 128: Hydraulic Manifold Service Serial Number Under 260999999

    Hydraulic Manifold Service (Serial Number Under 260999999) 15 in- -lb PLUG TORQUE (1.7 N- -m) 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 (58 to 62 N- -m) 35 ft- -lb SAE #10: 60 to 62 ft- -lb (81 to 84 N- -m) (47 N- -m)
  • Page 129 Solenoid Operated Cartridge Valves (Fig. 58) C. Torque cartridge valve using a deep socket to 35 ft- -lb (47 N- -m). 1. Make sure the manifold is clean before removing the valve(s). D. Make sure a new O--ring is at each end of the so- lenoid coil.
  • Page 130 Hydraulic Manifold Service (Serial Number Over 270000000) 20 ft- -lb 60 in- -lb (27 N- -m) 25 ft- -lb (6.7 N- -m) (34 N- -m) 20 ft- -lb (27 N- -m) 25 ft- -lb (34 N- -m) 60 in- -lb (6.7 N- -m) 20 ft- -lb (27 N- -m)
  • Page 131 NOTE: The ports on the hydraulic manifold are marked 5. Cleaning cartridge valves: for easy identification of components. Example: FC1 is A. For non--solenoid operated valves: the flow control valve and P1 is the gear pump connec- Submerge valve in clean mineral spirits to flush out tion port (See Hydraulic Schematics to identify the func- contamination.
  • Page 132 Rotary Cartridge Valves IMPORTANT: Use care when installing the rotary cartridge valve. Slight bending or distortion of 1. Remove rotary handle from valve (Fig. 60): the stem tube can cause binding and malfunc- tion. Make sure that deep well socket fully en- A.
  • Page 133 Mow/Backlap Spool (Fig. 61) 1. Remove mow/backlap spool from manifold: A. Remove backlap switch from manifold before re- Loctite 603 moving mow/backlap spool. Remove dowel pin and ball from manifold port after switch is removed. Re- move and discard O--ring from switch. B.

  • Page 134: Flow Control And Backlap Valves

    Flow Control and Backlap Valves (If Equipped on Serial Number Under 260999999) 35 ft- -lb (47 N- -m) 35 ft- -lb (47 N- -m) 35 ft- -lb (47 N- -m) Figure 62 Backlap bracket 10. Logic cartridge (Port LC1) 19. Indicator plate N.O.
  • Page 135 Flow Control and Two Position Directional Valves 6. Reinstall the cartridge valve (7 or 13): (Fig. 62) A. Lubricate new O--ring and backup ring of seal kit (8 or 11) with clean hydraulic oil and install. The O-- ring and backup ring of seal kit must be arranged CAUTION properly on the cartridge valve (7 or 13) for proper operation and sealing.
  • Page 136 Logic Cartridge Valves (Fig. 62) CAUTION CAUTION Use eye protection such as goggles when using compressed air. Before continuing further, read and become fa- miliar with General Precautions for Removing 4. Clean logic cartridge valve (10) using clean mineral and Installing Hydraulic System Components. spirits.

  • Page 137: Rear Lift Cylinder Flow Control Valve

    Rear Lift Cylinder Flow Control Valve HYDRAULIC CYLINDER FLOW CONTROL VALVE Figure 63 Hose assembly O- -ring Hydraulic fitting O- -ring Flow control valve Hydraulic cylinder Hydraulic fitting O- -ring Removal 1. Before removing any parts from the hydraulic sys- tem, park machine on a level surface, engage parking brake, lower cutting units, and stop the engine.

  • Page 138: Steering Control Valve

    Steering Control Valve ILLUSTRATION FOR MACHINE WITH SERIAL NUMBER UNDER 220999999 35 ft- -lb (47 N- -m) Antiseize Lubricant Figure 65 Knob 14. Steering arm cover 26. Warning decal Lockup handle 15. Steering column assembly 27. Steering wheel cap Lockup spacer 16.
  • Page 139 Removal (Fig. 65) ILLUSTRATION FOR MACHINE 1. Before removing any parts from the hydraulic sys- WITH SERIAL NUMBER FROM 230000001 TO tem, park the machine on a level surface, engage the 270999999 parking brake, lower the cutting units, and stop the en- gine.
  • Page 140 Installation (Fig. 65) 5. Connect remaining hoses to fittings in steering con- trol valve. 1. Install removed hose assemblies and O--rings to the steering control valve. Install removed hydraulic fittings 6. Install cable tie to the hose assemblies. and O--rings to the control valve. 7.
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  • Page 142: Steering Control Valve Service

    Steering Control Valve Service (Serial Number Under 220999999) BOTTOM INNER RACE OUTER RACE GEAR WHEEL 18 to 27 ft- -lb (24 to 37 N- -m) 18 to 27 ft- -lb (24 to 37 N- -m) Figure 68 Dust seal Cross pin 16.
  • Page 143 Note: The cross pin can be seen through the open end of the spool. 7. Make sure cross pin is kept horizontal in the spool and sleeve. Remove sleeve, ring, and bearing from the housing by pressing the spool out the housing bottom (Fig.
  • Page 144 4. Install ring over the sleeve. Make sure ring is able OUTER RACE to rotate free of the springs. NEEDLE BEARING 5. Insert cross pin into the spool and sleeve (Fig. 69). INNER RACE 6. Install bearing assembly onto the spool and sleeve (Fig.
  • Page 145 16. Secure special screw with new washer 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). SPECIAL 18.
  • Page 146 Steering Control Valve Service (Serial Number From 230000000 to 270999999) 150 in- -lb (17 N- -m) 140 to 160 in- -lb (16 to 18 N- -m) Figure 78 1. Steering valve housing 11. O- -ring 21. Plug 2. Dust seal 12.
  • Page 147 8. Put the thrust bearing and races into the housing. CAUTION The thrust bearing goes between the two races (Fig. 79). IMPORTANT: Do not damage the dust or quad seals The centering springs are under tension. Re- when installing the spool and sleeve assembly. move the retaining ring carefully.
  • Page 148 Steering Control Valve Service (Serial Number Over 280000000) 20 to 24 ft- -lb (27 to 33 N- -m) Figure 80 Plug 11. Thrust washer 21. Inner gearwheel Plug 12. Bearing 22. End cover Spring 13. Cross pin 23. O- -ring (5 used) Relief valve 14.
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  • Page 150: Steering Cylinder

    Steering Cylinder CYLINDER ASSEMBLY 65 to 85 ft- -lb (88 to 115 N- -m) 65 to 85 ft- -lb (88 to 115 N- -m) ASSEMBLY RIGHT FRONT WHEEL ASSEMBLY Figure 81 1. Slotted hex nut 14. Valve stem 27. Bearing cone 2.
  • Page 151 Removal (Fig. 81) CAUTION 1. Before removing any parts from the hydraulic sys- tem, park machine on a level surface, set brake, lower cutting units, and stop engine. Support rear wheel to prevent dropping and causing personal injury while removing hex nut. Use two people to remove steering cylinder.

  • Page 152: Steering Cylinder Service

    Steering Cylinder Service SERIAL NUMBER BELOW 260999999 Figure 82 Seal kit Wear ring 11. Head Rod wiper Piston ring 12. Piston U- -cup O- -ring 13. Barrel Back- -up ring Set screw 14. Rod O- -ring 10. Threaded cap SERIAL NUMBER ABOVE 270000000 Figure 83 Seal kit Wear ring...
  • Page 153 Disassembly (Figs. 82 and 83) Assembly (Figs. 82 and 83) IMPORTANT: To prevent damage when clamping NOTE: Due to steering cylinder design for serial num- cylinder barrel in a vise, clamp only on pivot end. Do bers above 270000000, the seal kit may include several not clamp the vise jaws against the shaft surface.

  • Page 154: Hydraulic Reservoir

    Hydraulic Reservoir 30 to 60 in- -lb (3.4 to 6.8 N- -m) Figure 84 Hydraulic barb fitting 11. O- -ring 21. Return hose Hydraulic straight fitting 12. Flat washer 22. Tube assembly Fuel tank clamp 13. Grommet 23. Hose clamp Hex washer head screw 14.
  • Page 155 5. Remove cap screw and flat washer securing the console shroud to the hydraulic tank. Remove both cap screws and flat washers securing the console shroud to the lower panel (Fig. 87). 6. Remove three hex head screws and flat washers securing the mounting plate (29) to the frame.

  • Page 156: Leak Detector

    Leak Detector 17 to 21 ft- -lb (23 to 28 N- -m) 17 to 21 ft- -lb 100 to 125 in- -lb (23 to 28 N- -m) (11.3 to 14.1 N- -m) 30 to 60 in- -lb (3.4 to 6.8 N- -m) Figure 88 Clamp 14.
  • Page 157 Removal (Fig. 88) 1. Before removing any parts from the hydraulic sys- tem, park machine on a level surface, set brake, lower cutting units, and stop engine. CAUTION Before continuing further, read and become fa- miliar with General Precautions for Removing and Installing Hydraulic System Components.
  • Page 158 IMPORTANT: Do not over tighten cap screw. 2. Secure sight gauge (34) and new O--ring (28) to the Threads in tank may become damaged. leak detection tank (11). Torque gauge from 100 to 125 in- -lb (11.3 to 14.1 N- -m). 6.

  • Page 159: Electrical Schematics 5

    Chapter 5 Electrical System Table of Contents ELECTRICAL SCHEMATICS ....Functional Control Lever Reed Switches SPECIAL TOOLS ......and Actuator .

  • Page 160: Electrical Schematics

    Electrical Schematics The electrical schematic and other electrical drawings for the Greensmaster 3250−D are located in Chapter 8 − Electrical Diagrams. Electrical System (Rev. C) Greensmaster 3250−D Page 5 − 2...

  • Page 161: Special Tools

    Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: Toro recommends the use of a DIGITAL Volt-- Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.

  • Page 162: Troubleshooting

    Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and CAUTION components used on this machine (see Wiring Sche- matics section of this chapter). Remove all jewelry, especially rings and If the machine has any interlock switches by−passed, watches, before doing any electrical trouble- shooting or testing.
  • Page 163 Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Wiring to start circuits (see Wiring Schematics) is loose, corroded, or damaged. Diode D5 circuit is open. Run relay or high temperature relay is faulty. High temperature switch is shorted. ETR solenoid is faulty.

  • Page 164: General Run And Transport Problems

    General Run and Transport Problems Problem Possible Causes Engine kills when the Functional Control Lever is in the Operator is sitting too far forward on the seat (seat MOW or TRANSPORT position with the operator in the switch not depressed). seat.

  • Page 165: Cutting Unit Operating Problems

    Cutting Unit Operating Problems Problem Possible Causes Cutting units run (but should not) when raised. Joy stick relay R7 is faulty or shorted. Solenoid valve S1 is faulty. Mow relay is faulty or shorted. Mow sensor is shorted. Cutting units do not run when lowered with the Wiring to run/mow/backlap circuits (see Wiring Functional Control Lever in the MOW or NEUTRAL Schematics) components is loose, corroded, or...

  • Page 166: Electrical System Quick Checks

    Electrical System Quick Checks Battery Test Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals. 12.68 V (or higher) Fully charged (100%) Set the multimeter to the DC volts setting. The battery 12.45 V 75% charged should be at a temperature of 60 to 100...

  • Page 167: Component Testing

    Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION circuit (e.g. unplug the ignition switch connector before doing a continuity check). When testing electrical components for continu- Note: See the Briggs and Stratton Vanguard/Dai- ity with a multimeter (ohms setting), make sure hatsu Repair Manual for 3 Cylinder Water−Cooled that power to the circuit has been disconnected.

  • Page 168: Safety Relays

    Safety Relays Two styles of safety relays have been used on Green- smaster 3250−D machines. Later production machines (after serial number 250000000) have a different relay terminal arrangement than relays on earlier machines (Fig. 4). Relay operation is identical regardless of termi- nal layout.

  • Page 169: Seat Switch

    Seat Switch The seat switch is normally open and closes when the operator is on the seat. If the neutral switch or traction interlock switch is open when the operator raises out of the seat, the engine will stop. The switch and its electri- cal connector are located directly under the seat.

  • Page 170: Functional Control Lever Reed Switches And Actuator

    Functional Control Lever Reed Switches and Actuator Both reed switches are normally open. They close when the actuator comes in close proximity to the switch. These switches are used to sense the Functional Con- trol Lever in either the NEUTRAL or MOW position. 1.

  • Page 171: Leak Detector (Optional)

    Leak Detector (Optional) Operation The leak detector system is designed to assist in the ear- FILLER CAP ly detection of hydraulic oil system leaks. If the oil level FLUID LEVEL in the main tank is lowered by 4 to 5 ounces, the level COLD switch in the leak detection tank will close.
  • Page 172 Test Operation CLEAN ROD SCREWDRIVER 1. Place ignition switch in the ON position. DO NOT VALVE ASSEMBLY START ENGINE. Move leak detector switch downward PLUG REMOVED and hold. After the one second time delay elapses, the alarm should sound. WARNING SOLENOID BUZZER RETURN...
  • Page 173 CONNECTOR RED/WHT VALVE SOLENOID TEST SWITCH − − 1 SEC. BLACK BLACK DELAY CONNECTOR TIMER CONNECTOR LEVEL SWITCH AUDIO ALARM − BLK/WHT LEAK DETECTOR CIRCUIT 270 OHM RESISTOR BLACK Figure 16 Components can be tested by isolating them from the rest of the circuit and individually testing the suspected component.

  • Page 174: Warning Light Cluster

    Warning Light Cluster Two styles of warning light clusters have been used on the Greensmaster 3250--D. On machines with serial WATER Serial Number Below (RED) (RED) number below 250000000, the four warning lights are 250000000 included in one component (Fig. 18). On machines with serial number above 250000000, the four warning lights are included in two components (Fig.

  • Page 175: High Temperature Shutdown Switch

    High Temperature Shutdown Switch The high temperature shutdown switch is located on the water pump, which is located on the rear end of the en- gine block. The high temperature shutdown switch has a yellow/red wire connected to it (Fig. 20). CAUTION Make sure engine is cool before removing the temperature switch.

  • Page 176: Oil Pressure Switch

    Oil Pressure Switch The switch is located on the front cylinder head above the injection pump and governor assembly. It is a nor- mally closed switch and opens with pressure. Testing with the engine off 1. Turn the ignition switch to ON. The oil pressure lamp should be on.

  • Page 177: Lower Reels Time Delay

    Lower Reels Time Delay This is a solid state timer. Upon the application of power, the load is energized and the time delay is started. After 6 seconds the load is de−energized. 1. Connect voltmeter across test load and test load to timer.

  • Page 178: Diode Circuit Boards

    Diode Circuit Boards Each circuit board contains four diodes. The diodes are used for circuit protection from inductive voltage spikes and for safety circuit logic. Diode D8 is not used. Diode D1 This diode prevents current flow to solenoid S3 when so- lenoids S2 and S4 are energized through lower relay R6.

  • Page 179: Solenoid Valve Coils

    Solenoid Valve Coils Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The me- ter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal re- sistance of the meter and test leads.

  • Page 180: Glow Relay

    Glow Relay When energized, the glow relay allows electrical current to the engine glow plugs. Two styles of glow relays have been used on the Greensmaster 3250--D. On machines with serial num- ber below 250000000, two of the four relay connections GLOW are secured with screws (Fig.

  • Page 181: Service And Repairs

    Service and Repairs Note: See the Briggs and Stratton Vanguard/Dai- hatsu Repair Manual for 3 Cylinder Water−Cooled Diesel Engines for more component repair information. Verify Interlock System Operation 1. Sit on the seat, engage parking brake, and move Functional Control Lever to NEUTRAL. Try to depress CAUTION traction pedal.

  • Page 182: Specifications 6

    Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes.
  • Page 183 B. Temperature correct each cell reading. For each H. Using the table below, determine the minimum voltage for the cell temperature reading. 10_F (5.5_C) above 80_F (26.7_C) add 0.004 to the specific gravity reading. For each 10_F (5.5_C) be- low 80_F (26.7_C) subtract 0.004 from the specific Minimum Battery Electrolyte gravity reading.
  • Page 184 Charging CAUTION To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging meth- Do not charge a frozen battery because it can ex- od is presented here. This charging method can be ac- plode and cause injury.

  • Page 185: Special Tools 6

    Chapter 6 Chassis Table of Contents SPECIFICATIONS ......SPECIAL TOOLS ......ADJUSTMENTS .

  • Page 186: Specifications

    Specifications Item Description Front tire pressure, 19 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 −...

  • Page 187: Adjustments

    Adjustments Brake Adjustment CAUTION Before and after adjusting the brakes, always check the brakes in a wide open area that is flat and free of other persons and obstructions. Note: The brake adjustment rods are located on each side of the machine. Adjust each brake equally. 1.

  • Page 188: Service And Repairs

    Service and Repairs Rear Wheel (2WD) 70 to 90 ft−lb (95 to122 N−m) ASSEMBLY RIGHT FRONT WHEEL ASSEMBLY Figure 3 1. Slotted hex nut 14. Valve stem 27. Bearing cone 2. Cotter pin 15. Lug nut 28. Bearing cup 16. Lock nut 3.
  • Page 189 Removal (Fig. 3) 1. Park machine on a level surface. Make sure engine is off. Set brake and block front wheels. 2. Jack up and secure the rear wheel off the ground. Note: The wheel assembly consists of the tire (12), rim (13), and valve stem (14) with cap.
  • Page 190 D. Place second bearing cone on the castor fork 3. Install wheel and hub assemblies into the castor fork shaft with the wide edge up. Place remaining steer- (4). Insert bolt (5) into motor adapter plate (34) mounting ing washer on top of the bearing cone. hole.

  • Page 191: Rear Wheel (3Wd)

    Rear Wheel (3WD) 80 to 100 in−lb (9.0 to 11.3 N−m) RIGHT 85 ft−lb FRONT (115 N−m) 30 ft−lb (41 N−m) Figure 5 1. Castor fork 10. Cap screw 18. Lock nut 2. Hub and motor assembly 11. Lock nut 19.
  • Page 192 Figure 6 1. Hydraulic motor 5. Hub 9. Thrust washer 2. 45_ Hydraulic fitting 6. Clutch roller bearing 10. Washer 7. Drive stud 11. Snap ring 3. O−ring 4. O−ring 8. Grease fitting 12. Grease seal Disassembly (Fig. 6) OUTER BEARING EDGE MUST BE FLUSH WITH EDGE 1.
  • Page 193 Installation (Fig. 5) 5. Secure hydraulic motor and hub assembly (2) loosely to the left inside of the castor fork (1) with both 1. Secure wheel (25) to the four drive studs of the hy- socket head screws (12) lock nuts (13). draulic motor and hub assembly (2) with four lug nuts (23).

  • Page 194: Front Wheels And Brakes

    Front Wheel and Brake 250 to 400 ft−lb (339 to 542 N−m) RH 15 LH 16 15 RH 16 LH 70 to 90 ft−lb (95 to122 N−m) RIGHT FRONT Figure 8 1. Lug nut 12. Brake shoe 23. Brake lever 2.
  • Page 195 Removal (Fig. 8) 1. Park machine on a level surface. Make sure engine is off. Make sure brake is in the OFF position. 2. Block front and rear of wheels not being jacked up. Lift front wheel off the ground using a jack, and place blocks beneath the frame under the hydraulic wheel mo- tor (20).

  • Page 196: Front Lift Arms

    Front Lift Arms 67 to 83 ft−lb (91 to 112 N−m) Figure 10 1. Front lift frame 11. Cap screw 21. Spacer tube 2. Bushing 12. Jam nut 22. Lock nut 3. Grease fitting 13. Carrier spacer 23. Pull frame spacer 24.
  • Page 197 Disassembly (Fig. 10) 67 to 83 ft−lb (91 to 112 N−m) 1. Park machine on a level surface. Make sure engine is off and brake is set. 2. Remove cutting unit from front lift arm (see Opera- tor’s Manual). 3. Disassemble front lift arm as needed using Figures 10 and 11 as guides.

  • Page 198: Center Lift Arm

    Center Lift Arm 100 to 150 ft−lb (136 to 203 N−m) 67 to 83 ft−lb (91 to 112 N−m) Figure 12 1. Center lift arm 14. Lock nut 26. Phillips screw (3 used) 2. Bushing 15. Lock nut 27. Wear pad 3.
  • Page 199 Disassembly (Fig. 12) 67 to 83 ft−lb (91 to 112 N−m) 1. Park machine on a level surface. Make sure engine is off and brake is set. 2. Remove center cutting unit from lift arm (see Opera- tor’s Manual). 3. Disassemble center lift arm as needed using Fig- ures 12 and 13 as guides.
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  • Page 201: Introduction 7

    Chapter 7 SPA and 4−Bolt Cutting Units Table of Contents Backlapping (Units with Backlap/Variable Reel INTRODUCTION ......SPECIFICATIONS .

  • Page 202: Introduction

    Introduction There are two different types of cutting units covered in Maintenance procedures for both cutting units are the this chapter: the Single Point Adjust and 4−Bolt Adjust. same, except where noted. If a chapter subheading Both units are similar in design and construction. How- does not specify a particular type of cutting unit, the pro- ever, each unit has different bedbars with different meth- cedure can be used for both types of units.

  • Page 203: Specifications

    Specifications 4−BOLT SINGLE POINT ADJUST UNIT ADJUST UNIT Figure 14 Height−of−Cut (HOC): Cutting height is adjusted on placeable roller that may be moved to change transport the rear roller by two vertical screws and held by two height. locking capscrews. Bench HOC range is 3/32 inch Bedknife: Replaceable, 13−screw, single edged, high (2.4mm) to 1−1/32 inches (26mm).

  • Page 204: General Information

    General Information Lift Roller Position The cutting unit comes with its lift roller installed in the top position. The position of the roller may be changed as follows: 1. Remove hex head screw and lock nut from the lift roller and frame. 2.

  • Page 205: Special Tools

    Special Tools Order special tools from your Toro Distributor. Some tools may have been supplied with your mower or available as TORO parts. Some tools may also be avail- able from a local supplier. Gauge Bar Assembly Used to verify height--of--cut. Toro Part No. 13--8199.
  • Page 206 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 the housing. Toro Part No. 2410−30. Figure 20 Page 7 − 6 Greensmaster 3250−D...

  • Page 207: Troubleshooting

    “sponginess” or attempting to cut off too much grass shooting, see Aftercut Appearance Troubleshooting Aid height may not always be overcome by adjusting the (Toro part no. 00076SL). cutting unit. It is important to remember that the lower the height−of−cut, the more critical these factors are.
  • Page 208 Factor Possible Problem/Correction Bedknife attitude Set attitude (angle) as recommended. See Leveling Front Roller to Reel and Attitude Adjustments. Rear roller adjustment Check and adjust as necessary. The rear roller must be leveled so it is parallel with the reel for proper height−of−cut setting.

  • Page 209: Adjustments

    Adjustments Daily Adjustments (Single Point Adjust Cutting Units) Prior to each day’s mowing, or as required, each cutting unit must be checked to verify proper bedknife−to−reel contact. This must be performed even though quali- ty of cut is acceptable. 1. Lower cutting units onto a hard surface, shut off en- gine, and remove the key from the ignition switch.

  • Page 210: Adjust Bedknife Parallel To Reel (Single Point Adjust Cutting Units)

    (see Cutting Unit Removal and Installation). unit to achieve the sharp edges needed for preci- sion cutting. Refer to the Toro General Service 2. Position cutting unit on a level surface. Training Book, Reel Mower Basics (part no.

  • Page 211: Adjust Bedknife Parallel To Reel

    C. Should the reel be unable to cut the paper, it will be necessary to either backlap or regrind the cutting unit to achieve the sharp edges needed for preci- sion cutting. Refer to the Toro General Service Training Book, Reel Mower Basics (part no. 09168SL) for additional information.

  • Page 212: Adjust And Level Front Roller To Reel

    Adjust and Level Front Roller to Reel 1. If the cutting unit is not removed from the machine, remove reel motor from the cutting unit and cutting unit from lift arm (see Cutting Unit Removal and Installation). Note: Make sure leveling plate covers the full length of reel blades.

  • Page 213: Adjust Attitude

    Adjust Attitude There are four positions for the front roller brackets. Position 1: The least aggressive position is used for very soft and tender turf, or the highest height− É É É É É É É É É of−cut (Fig. 27). É...

  • Page 214: Adjust Top Shield Height

    4. Position both front brackets as follows: Note: The top side plate hole and top bracket hole should yield Position 2 (standard setting). A. Insert eccentric bolt (shoulder bolt) through one of the two positions in the figure 8 hole in the frame and one of the top holes of the front bracket (Fig.

  • Page 215: Adjust Height−Of−Cut

    Adjust Height−of−Cut Note: Cutting units will deliver differing effective height−of−cuts depending on their configuration. In fact, effective cutting height may be influenced by any of the following factors: turf conditions, roller profiles, cutting unit attitude, cutting unit accessories, weight of cutting units, and bedknife profile.

  • Page 216: Adjust Front Roller Brush/Scraper

    Adjust Front Roller Brush/Scraper 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Loosen socket head screws securing the clamp blocks to the roller shaft. Note: Secure one end of the brush assembly at a time to simplify the following steps.

  • Page 217: Service And Repairs

    Service and Repairs Cutting Unit Removal and Installation IMPORTANT: When sharpening, setting height-of- cut, or performing other maintenance procedures on the cutting units, store the cutting unit reel mo- tors in support tubes on the frame to prevent dam- age to the hoses. Do not raise suspension to transport position when the reel motors are in the holders in the traction unit frame.
  • Page 218 5. Slide sleeve back on each ball joint receiver and hook onto cutting unit ball studs (Fig. 37). Note: On units without plastic spacers (Toro P/N 104−2067), spacers can be installed to help direct 6. Mount basket onto carrier frame.

  • Page 219: Backlapping

    3. Attach backlap motor or drive to the socket exten- sion. 4. Follow instructions and procedures for backlapping in the Toro General Service Training Book, Reel Mower Basics (part no. 09168SL). 5. If the splined coupling was moved from the left side of the cutting unit for backlapping, replace the coupling to the left side.
  • Page 220 7. Rotate flow control valve knob to position 1. Note: Additional instructions and procedures on 8. Apply lapping compound with a long handled brush backlapping are available in the Toro General Service (see Special Tools). Training Book, Reel Mower Basics (part no. 09168SL).

  • Page 221: Rollers And Bedbar Assembly

    Rollers and Bedbar Assembly (Single Point Adjust Cutting Units) ‘ Figure 42 1. Front roller assembly 21. Height−of−cut adjustment bracket 40. Eccentric bolt Bedbar and bushing 22. Roller assembly 41. Carriage screw Bedbar 23. Compression spring 42. Wiehle roller Bedknife 24.

  • Page 222: Rear Roller And Height−Of−Cut Adjuster Removal And Installation

    Rear Roller and Height−of−Cut Adjuster Removal and Installation Note: Figure 42 shows the Rollers and Bedbar Installation (Fig. 42) Assembly for a Single Point Adjust (SPA) cutting units. 1. Place cutting unit on a level working surface. Both the SPA and 4−Bolt cutting units a similar in construction.

  • Page 223: Front Roller Removal And Installation

    Front Roller Removal and Installation Removal 1. Position machine on a clean and level surface, low- er cutting units, stop engine, engage parking brake, and remove key from the ignition switch. Note: The front roller can be removed with the cutting unit either attached to the lift arm or removed from the lift arm.

  • Page 224: Bearing Replacement For Standard Rear Roller

    Bearing Replacement for Standard Rear Roller 1.495 to 1.525 inch (3.797 to 3.874 cm) Figure 45 1. Roller tube 3. Shield washer 5. Grease fitting 2. Shaft 4. Retaining Ring 6. Bearing Removal B. Make sure dimension of 1.495 to 1.525 inch (3.797 to 3.874 cm) between washer and the end of 1.
  • Page 225 3. Shaft 5. Grease fitting 2. Bearing 4. Retaining Ring Removal Roller Type TORO BEARING RECESS 1. Clean inside of roller tube around the shaft and bearing. Both ends of the roller tube should be free of dirt Standard Front 99−4211...

  • Page 226: Bearing Replacement For Wiehle Rear Roller

    3. Grease fitting Note: This procedure is for the Wiehle Rear Roller Kit Install New Bearings (Model 04488) only. The Toro part number for the roller 1. Make sure bearing cavity of Wiehle roller is clean is 94−8150. and free of dirt. Apply No. 2 multipurpose lithium based Remove Bearings grease to the outside diameter of the machine bearing.

  • Page 227: Bedbar Removal And Installation

    Bedbar Removal and Installation (Single Point Adjust Cutting Units) Removal 1. Remove rear roller (see Rear Roller Removal and Installation). 2. Loosen both flange lock nuts securing the hex head flange screw to the frame tab (Fig. 48). 3. Remove hex head flange screw (39), flat washer (38), and quad ring (37) from the bedbar (3) on the right side of the unit (Fig.

  • Page 228: Bedknife Adjuster Service

    Bedknife Adjuster Service (Single Point Adjust Cutting Unit) Removal (Fig. 42) 1. Position machine on a clean and level surface, low- er cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove both pivot screws (30) from the pivot hous- ing (28).

  • Page 229: Rollers And Bedbar Assembly

    Rollers and Bedbar Assembly (4−Bolt Adjust Cutting Units) RIGHT FRONT Figure 51 1. Front roller assembly 13. Cap screw 25. Wiehle roller Not used 14. Cap screw 26. Roller shaft Special screw (13 used) 15. Height−of −cut collar 27. Bearing Bedknife 16.

  • Page 230: Bedbar Removal And Installation

    Bedbar Removal and Installation (4−Bolt Adjust Cutting Units) Removal 1. Position cutting unit on a clean level surface to allow access to the bedbar and rear roller. 2. Remove rear roller (see Rear Roller Removal and Installation). Note: The top hex head screws should remain in the adjustment brackets.

  • Page 231: Bedknife Replacement And Grinding

    Front Angle bedknife. Remove small amounts of material with each pass of the grinder. Figure 42 2. Refer to Toro General Service Training Book, Reel Mower Basics (part no. 09168SL) for additional bed- knife grinding information. Standard Bedknife Bedknife Grinding Specifications (Fig. 42) Standard bedknife relief angle (see Fig.

  • Page 232: Preparing A Reel For Grinding

    Relief Angle Range to 40 Blade Land Width 0.040 in (1.0 mm) 3. Refer to Toro General Service Training Book, Reel Land Width Range 0.030 to 0.060 in (0.7 to 1.5 mm) Mower Basics (part no. 09168SL) for additional reel Max.

  • Page 233: Reel Assembly

    Reel Assembly RIGHT FRONT Figure 58 1. Reel 12. Bearing 23. Cap screw Shield rod 13. Grease seal 24. Roll pin Reel frame 14. Tapered screw 25. Pad Flat washer 15. Hex washer head screw 26. Not used Cap screw 16.

  • Page 234: Reel And Bearing Removal And Installation

    Reel and Bearing Removal and Installation Removal (Fig. 58) 1. Remove reel motor from the cutting unit and the cut- ting unit from lift arm (see Cutting Unit Removal and Installation). 2. Place cutting unit on a level working surface. 3.
  • Page 235 Installation (Fig. 58) Note: If bearings (12) where removed, grease seals (13) should be replaced. Both bearings should be re- Press bearing to here. placed as a set. 1. If bearings (12) and grease seals (13) were re- moved from the reel shaft (1), install seals and bearings to the shaft as follows: A.

  • Page 236: Rear Roller Scraper Removal And Installation

    Rear Roller Scraper Removal and Installation RIGHT FRONT Figure 61 1. Flange head nut 5. Torsion spring (LH) 8. Torsion spring (RH) 2. Hex head screw 6. Scraper 9. Lock nut 3. Bracket (LH) 7. Bracket (RH) 10. Height−of−cut tab 4.

  • Page 237: Front Roller Brush/Scraper Removal And Installation

    Front Roller Brush/Scraper Removal and Installation Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Loosen and remove cap screws securing each end of the roller shaft to the front roller brackets. 3.
  • Page 238 This page is intentionally blank. Page 7 − 38 Greensmaster 3250−D SPA and 4−Bolt Cutting Units (Rev. A)
  • Page 239 Chapter 7.1 Dual Point Adjust Cutting Units Table of Contents SPECIFICATIONS ......Bedbar Assembly .

  • Page 240: Specifications

    Specifications DUAL POINT ADJUST UNIT Figure 1 Bedknife: Replaceable single edged, high carbon steel Height−of−Cut (HOC): Cutting height is adjusted on the front roller by two vertical screws and held by two bedknife is fastened to a machined cast iron bedbar with locking capscrews.

  • Page 241: Special Tools

    Special Tools Order special tools from your Toro Distributor. Some tools may have been supplied with your mower or available as TORO parts. Some tools may also be avail- able from a local supplier. Gauge Bar Assembly Used to verify height--of--cut.
  • Page 242 This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the TurfEvaluator (Toro part no. 97931SL)

  • Page 243: Troubleshooting

    Aftercut Appearance Troubleshooting Aid cutting unit. It is important to remember that the lower (Toro part no. 00076SL). the height−of−cut, the more critical these factors are. See Adjustments in the Cutting Unit Operator’s Manual...
  • Page 244 Factor Possible Problem/Correction Bedknife to reel adjustment Check 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 edges. Quality of cut is adversely affected by both conditions (see Bedknife to Reel Adjustment in the Cutting Unit Operator’s Manual).

  • Page 245: Set Up And Adjustments

    Set Up and Adjustments Characteristics If a cutting unit is determined to be out of adjustment, complete the following procedures in the specified order CAUTION to adjust the cutting unit properly. 1. Adjust the bedknife parallel to the reel. Never install or work on the cutting units or lift arms with the engine running.

  • Page 246: Service And Repairs

    3. Attach backlap motor or drive to the socket exten- sion. 4. Follow instructions and procedures for backlapping in the Toro General Service Training Book, Reel Mower Basics (part no. 09168SL). Rev. I Page 7.1 - - 8 Greensmaster 3250--D Dual Point Adjust Cutting Units (Rev.

  • Page 247: Backlapping (Units With Optional Backlap/Variable Reel Speed Kit)

    7. Rotate flow control valve knob to position 1. Note: Additional instructions and procedures on 8. Apply lapping compound with a long handled brush backlapping are available in the Toro General Service (see Special Tools). Training Book, Reel Mower Basics (part no. 09168SL).

  • Page 248: Bedbar Assembly

    Bedbar Assembly 190 to 240 in−lbs (21 to 27 Nm) Antiseize Lubricant Figure 12 Side plate Bedbar pivot bolt 13. Cap screw Rubber bushing Flange nut 14. Rear roller assembly Flange bushing Flange nut 15. Lock nut Washer (plastic) 10. Shim 16.

  • Page 249: Bedbar Removal And Installation

    Bedbar Removal and Installation Removal (Fig. 12) 1. Position machine on a clean and level surface, low- Â Â Â Â Ç Ç Ç Ç er cutting units, stop engine, engage parking brake, and Â Â Â Â Ç Ç Ç Ç remove key from the ignition switch.

  • Page 250: Bedbar Adjuster Service

    Bedbar Adjuster Service 15 to 20 ft−lbs (20 to 27 Nm) Figure 14 Adjuster shaft Jam nut Cap screw Flange bushing Adjuster screw 10. Washer Cutting unit frame Detent 11. Spring Wave washer Lock washer 12. Lock nut Removal (Fig. 14) Installation (Fig.

  • Page 251: Bedknife Replacement And Grinding

    Front Angle bedknife. Remove small amounts of material with each pass of the grinder. Figure 17 2. Refer to Toro General Service Training Book, Reel Mower Basics (part no. 09168SL) for bedknife grinding information. Bedknife Grinding Specifications (see Fig. 17)

  • Page 252: Reel Assembly

    Reel Assembly 17 to 20 ft−lbs (23 to 27 Nm) General Purpose Grease RIGHT FRONT General Purpose Grease Figure 18 18. Flange nut Reel 10. Right side plate assembly Speedi sleeve 11. O−ring 19. Cap screw V−ring 12. Bearing 20. Lift hook Drive coupler 13.

  • Page 253: Reel Removal

    Reel Removal (Fig. 18) 1. Remove reel motor from the cutting unit (see Hy- draulic Reel Motor Removal in this chapter). 2. Remove the 2 capscrews securing the counter weight to the side plate (Fig. 19). Remove the counter weight. 3.

  • Page 254: Left Side Plate Service

    4. Remove all grease from the side plate bore. 5. Insert the wave washer (15) into the side plate. Note: Replacement Seal Kit (Toro Part No. 106-6937) is available for side plate service of dual point adjust cut- Note: Replacement Seal Kit (Toro Part No. 106-6937) ting units.

  • Page 255: Reel Service

    2. Remove the V−ring (3) from the reel shaft. 3. Using a flat blade screw driver or similar tool, re- move the speedi sleeve (2) from the reel shaft. Figure 21 Note: Replacement Seal Kit (Toro Part No. 106-6937) 1. Reel shaft 3. Adapter spline 2. Drive adapter is available for reel service of dual point adjust cutting units.

  • Page 256: Reel Installation

    Note: For severely tapered reels, a .010 in. (.254 mm) shim (Toro Part No. 106-6923) is available for the rear 10. Install the front roller (see Front Roller Installation in roller mount.

  • Page 257: Preparing A Reel For Grinding

    Blade Relief Angle each pass of the grinder. Relief Angle Range to 40 3. Refer to Toro General Service Training Book, Reel Blade Land Width 0.040 in. (1.0 mm) Mower Basics (part no. 09168SL) for reel grinding infor- Land Width Range 0.030 to 0.060 in.
  • Page 258 This page is intentionally blank. Page 7.1 − 20 Greensmaster 3250−D Dual Point Adjust Cutting Units (Rev. D)

  • Page 259: Front Roller Removal And Installation

    Front Roller Removal and Installation Removal (Fig. 25) 1. Position machine on a clean and level surface, low- er cutting units, stop engine, engage parking brake, and remove key from the ignition switch. Note: The front roller can be removed with the cutting unit either attached to the lift arm or removed from the lift arm.

  • Page 260: Roller Service (Roller Shaft With Circlip)

    Roller Service (Roller Shaft with Circlip) Figure 26 Roller seal Roller bearing Roller shaft Spiral retaining ring Rear roller body Front roller body Seal Removal .188 in. dia (2) 1. Make a seal removal tool from a 1/4 x 3 x 3 in. (.63 .625 in.
  • Page 261 Bearing Removal Note: Replace both roller bearings as a set after a bearing failure. 1. Remove the roller seals (see Roller Seal Removal in this chapter of this manual). 2. Remove both spiral retaining rings from the roller shaft. Note: Roller bearings have a press fit into the roller body and a slip fit on the roller shaft.

  • Page 262: Roller Service (Threaded Roller Shaft)

    Roller Service (Threaded Roller Shaft) Figure 29 Wiehle roller Ball bearing V−ring Smooth roller Seal Bearing lock nut Roller shaft Disassembly 1. To hold roller shaft for bearing lock nut removal, install a 3/8−24 UNF 2B screw into threaded end of roller shaft and secure in place with jam nut.
  • Page 263 Note: Special tool TOR4105 (see Special Tools) can be used instead of washers and spacer when installing bearings and seals in roller. 2. Position a new bearing, black assembly washer (see Special Tools) and original lock nut onto each end of the roller shaft (Fig.
  • Page 264 This page is intentionally blank. Page 7.1 − 26 Greensmaster 3250−D Dual Point Adjust Cutting Units (Rev. D)
  • Page 265 Chapter 7.2 Groomer (DPA Cutting Unit) Table of Contents SPECIFICATIONS ......SERVICE AND REPAIRS .

  • Page 266: Specifications

    Specifications MOUNTING: The groomer is mounted to the Dual Point WIDTH−OF−GROOMER: 19 inches (48.3 cm). Adjust (DPA) cutting reel bearing housings and frame. HEIGHT ADJUSTMENT KNOB: Allows a 0.003 inch (0.08 mm) increment of height adjustment for each click REEL CONSTRUCTION: 2.375 inch (6 cm) diameter, 41 steel blades with 1/2 inch blade spacing.

  • Page 267: General Information

    General Information Groomer Position IMPORTANT: Before changing groomer position, make certain that the reel drive is in the disengaged position and that the cutting reel is not rotating. To place the groomer reel in the raised, non−grooming position, remove the lock screw and rotate the lift arm to raise the groomer reel.

  • Page 268: Troubleshooting

    Troubleshooting Factors Affecting Grooming There are a number of factors that can affect the perfor- IMPORTANT: Improper or overaggressive use of mance of grooming. These factors vary for different golf the groomer reel, such as too deep or frequent courses and from green to green. It is important to in- grooming, may cause unnecessary stress on the spect the turf frequently and vary the grooming practice turf leading to severe turf damage.

  • Page 269: Groomer Reel Mechanical Problems

    Groomer Reel Mechanical Problems Problem Possible Causes Correction The groomer reel rotates when it is The groomer reel should rotate Normal operation. in the raised, transport position. whenever the cutting reel is en- gaged. No rotation of the groomer reel. Seized groomer reel or idler bear- Identify and replace faulty bear- ing(s) in groomer side plate(s).

  • Page 270: Adjustments

    Adjustments CAUTION Never work on the cutting unit with the engine running. Always stop the engine and remove the key from the ignition switch before working on the mower. Note: See Cutting Unit Operator’s Manual for adjust- ment procedures for the cutting units on the Green- smaster 3250−D.

  • Page 271: Service And Repairs

    Service and Repairs Groomer Belt Replacement 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, en- gage parking brake and remove key from the ignition switch. 2. If equipped, remove rotating rear roller brush from cutting unit.

  • Page 272: Groomer Reel

    Groomer Reel 100 to 120 in−lbs (11.3 to 13.5 N−m) Antiseize Lubricant 100 in−lbs Loctite #242 (11.3 N−m) 60 to 80 ft−lbs (81 to 108 N−m) RIGHT FRONT 34 35 100 to 120 in−lbs (11.3 to 13.5 N−m) Figure 6 1.
  • Page 273 6. Remove lock nut (item 25) and spring washer (item 24) that secure drive side groomer arm lift rod to drive side plate (Fig. 7). 7. Remove lock nut (item 35), tab washer (item 34) and plow bolt (item 27) that secure drive side groomer arm assembly to drive side plate.
  • Page 274 5. Carefully place drive side plate onto groomer shaft 13.Apply antiseize lubricant to threads of lift arm assem- taking care not to damage seals in side plate. Position bly stud on groomer arm. Install spring washer (item 24) side plate to the cutting unit frame and secure with two and lock nut (item 25) to secure drive side groomer arm shoulder nuts (item 8).

  • Page 275: Groomer Reel Service

    Groomer Reel Service Disassembly (Fig. 10) 200 to 250 in−lbs Inspect groomer reel blades frequently for damage and (22.6 to 28.3 N−m) wear. Straighten bent blades with a pliers. Either replace worn blades or reverse worn blades on the groomer shaft to put the sharpest blade edge forward (Fig.

  • Page 276: Groomer Reel Bearing Replacement

    Groomer Reel Bearing Replacement Seal lip Seal lip (toward center of (toward center of cutting unit) cutting unit) Seal lip (toward center of cutting unit) Figure 13 1. Drive side plate (LH shown) 4. Grease fitting 6. Side plate bushing 2.
  • Page 277 Bearing Installation 1. Install new bearings in both side plate assemblies (Fig. 13): A. Slide new bearings into non−drive side plates. Position extended inner race of bearings toward cen- ter of side plate housing. B. Press new bearings into drive side plates apply- ing pressure to outer bearing race only.

  • Page 278: Idler Assembly

    Idler Assembly Seal lip (toward center of Seal lip cutting unit) (toward center of cutting unit) Figure 16 1. Lock nut 6. Seal 11. Side plate bushing 2. Flat washer 7. Bearing 12. Idler bracket 3. Retaining ring 8. Grease fitting 13.

  • Page 279: Lift Arm Assembly

    Lift Arm Assembly Antiseize Lubricant Antiseize Lubricant Antiseize Lubricant Figure 18 1. HOC groomer arm (LH shown) 7. Bushing 13. Wave washer 2. Flange nut 8. Lift arm assembly (LH shown) 14. Groomer adjuster 3. Grooved pin 9. Detent spring 15.

  • Page 280: Groomer Brush

    Groomer Brush 20 to 25 in−lbs (2.3 to 2.8 N−m) 20 to 25 in−lbs (2.3 to 2.8 N−m) Figure 19 1. Groomer brush shaft 3. J−bolt 4. Groomer brush 2. Lock nut The groomer brush attaches to the groomer drive in place of the groomer reel.

  • Page 281: Electrical Schematics 8

    Chapter 8 Electrical Diagrams Table of Contents ELECTRICAL SCHEMATICS ....Serial Number Below 210000000 ... . . Serial Number Between 210000000 and 230000600 .
  • Page 282 This page is intentionally blank. Electrical Diagrams Greensmaster 3250−D Page 8 − 2...

  • Page 283: Serial Number Below 210000000

    HIGH TEMP SOLENOID OVERRIDE (PART OF INJECTION PUMP) SWITCH DAIHATSU GLOW PLUG BU/W CONTROLLER BATTERY GLOW RELAY HIGH TEMP RELAY (R2) (−) GLOW PLUGS GY/W HIGH TEMP SWITCH OPTIONAL BACKLAP RELAY (R9) FUSELINK 3 RUN RELAY (R1) GN/BK FUSELINK 2 MOW RELAY (R3) FUSELINK 1 IGNITION...

  • Page 284: Serial Number Between 210000000 And 230000600

    BLACK BLUE Greensmaster 3250−D BROWN VIOLET (Serial Number Between 210000000 and 230000600) GRAY WHITE Electrical Schematic GREEN YELLOW ORANGE SPLICE All relays and solenoids PINK FUSIBLE LINK are shown as de−energized. Page 8 − 4 Rev. H...

  • Page 285: Serial Number Between 230000600 And 240999999

    BLACK BLUE BROWN VIOLET GRAY WHITE GREEN YELLOW ORANGE SPLICE PINK FUSIBLE LINK Greensmaster 3250−D (Serial Number Between 230000600 and 240999999) Electrical Schematic All relays and solenoids are shown as de−energized. Page 8 − 5 Rev. H...

  • Page 286: Serial Number Between 250000000 And 250999999

    BLACK BLUE BROWN VIOLET GRAY WHITE GREEN YELLOW ORANGE SPLICE PINK FUSIBLE LINK Greensmaster 3250−D (Serial Number Between 250000000 and 250999999) Electrical Schematic All relays and solenoids are shown as de−energized. Page 8 − 6 Rev. H...

  • Page 287: Serial Number Between 260000000 And 260999999

    BLACK BLUE BROWN VIOLET GRAY WHITE GREEN YELLOW ORANGE SPLICE PINK FUSIBLE LINK Greensmaster 3250−D (Serial Number Between 260000000 and 260999999) Electrical Schematic All relays and solenoids are shown as de−energized. Page 8 − 7 Rev. H...

  • Page 288: Serial Number Above 270000000

    BLACK BLUE BROWN VIOLET GRAY WHITE GREEN YELLOW ORANGE SPLICE PINK FUSIBLE LINK Greensmaster 3250−D (Serial Number Above 270000000) Electrical Schematic All relays and solenoids are shown as de−energized. Page 8 − 8 Rev. H...

  • Page 289: Crank

    HIGH TEMP SOLENOID OVERRIDE (PART OF INJECTION PUMP) SWITCH DAIHATSU GLOW PLUG BU/W CONTROLLER GLOW BATTERY RELAY HIGH TEMP RELAY (R2) (−) GLOW PLUGS GY/W HIGH TEMP SWITCH OPTIONAL BACKLAP RELAY (R9) FUSELINK 3 RUN RELAY (R1) GN/BK FUSELINK 2 MOW RELAY (R3) IGNITION FUSELINK 1...

  • Page 290: Run

    HIGH TEMP SOLENOID OVERRIDE (PART OF INJECTION PUMP) SWITCH DAIHATSU GLOW PLUG BU/W CONTROLLER GLOW BATTERY RELAY HIGH TEMP RELAY (R2) (−) GLOW PLUGS GY/W HIGH TEMP SWITCH OPTIONAL BACKLAP RELAY (R9) FUSELINK 3 RUN RELAY (R1) GN/BK FUSELINK 2 MOW RELAY (R3) IGNITION FUSELINK 1...

  • Page 291: Raise Reels

    HIGH TEMP SOLENOID OVERRIDE (PART OF INJECTION PUMP) SWITCH DAIHATSU GLOW PLUG BU/W CONTROLLER GLOW BATTERY RELAY HIGH TEMP RELAY (R2) (−) GLOW PLUGS GY/W HIGH TEMP SWITCH OPTIONAL BACKLAP RELAY (R9) FUSELINK 3 RUN RELAY (R1) GN/BK FUSELINK 2 MOW RELAY (R3) FUSELINK 1 IGNITION...

  • Page 292: Lower Reels

    HIGH TEMP SOLENOID OVERRIDE (PART OF INJECTION PUMP) SWITCH DAIHATSU GLOW PLUG BU/W CONTROLLER GLOW BATTERY RELAY HIGH TEMP RELAY (R2) (−) GLOW PLUGS GY/W HIGH TEMP SWITCH OPTIONAL BACKLAP RELAY (R9) FUSELINK 3 RUN RELAY (R1) GN/BK FUSELINK 2 MOW RELAY (R3) IGNITION FUSELINK 1...
  • Page 293 HIGH TEMP SOLENOID OVERRIDE (PART OF INJECTION PUMP) SWITCH DAIHATSU GLOW PLUG BU/W CONTROLLER GLOW BATTERY RELAY HIGH TEMP RELAY (R2) (−) GLOW PLUGS GY/W HIGH TEMP SWITCH OPTIONAL BACKLAP RELAY (R9) FUSELINK 3 RUN RELAY (R1) GN/BK FUSELINK 2 MOW RELAY (R3) FUSELINK 1 IGNITION...
  • Page 294 HIGH TEMP SOLENOID OVERRIDE (PART OF INJECTION PUMP) SWITCH DAIHATSU GLOW PLUG BU/W CONTROLLER GLOW BATTERY RELAY HIGH TEMP RELAY (R2) (−) GLOW PLUGS GY/W HIGH TEMP SWITCH OPTIONAL BACKLAP RELAY (R9) FUSELINK 3 RUN RELAY (R1) GN/BK FUSELINK 2 MOW RELAY (R3) FUSELINK 1 IGNITION...
  • Page 295 This page is intentionally blank. Page 8 − 15 Rev. H...
  • Page 296 RELAY #4 SEAT SWITCH RELAY #3 LOWER TIMER OPTIONAL LIGHTS RELAY #2 HIGH TEMP OVERIDE DIODE CONNECTOR 2 ALTERNATOR RELAY #1 HYD SOLENOID #2 WATER IN NEUTRAL FUEL LIGHT SENSOR SENSOR HYD SOLENOID #3 HYD SOLENOID #1 HYD SOLENOID #4 BACKLAP KIT J5 WARNING LIGHT...
  • Page 297 BACKLAP SEAT HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC BACKLAP KIT RELAY #1 RELAY #2 SWITCH STARTER ALTERNATOR SWITCH SOLENOID #4 SOLENOID #2 SOLENOID #3 SOLENOID #1 DIODE CONNECTOR #2 PRESSURE 3 87A RELAY #3 WATER TEMP SWITCH SP9 W57 RELAY #4 GLOW PLUG SP11 NEUTRAL SENSOR...
  • Page 298 RELAY #4 RELAY #3 RELAY #2 RELAY #1 HYD SOL #2 STARTER B+ ALTERNATOR HYD SOL #1 HYD SOL #3 HYD SOL #4 RELAY #8 RELAY #7 GLOW PLUG CONTROLLER RELAY #6 GLOW PLUGS RELAY #5 Greensmaster 3250−D (Serial Number Between 210000000 and 230000600) Electrical Harness Drawing Page 8 −...
  • Page 299 GLOW PLUG CONTROLLER Greensmaster 3250−D (Serial Number Between 210000000 and 230000600) Wiring Diagram Page 8 − 19 Rev. H...
  • Page 300 START RELAY RELAY HIGH TEMP RELAY HYD SOL #6 RUN SAFETY RELAY HYD SOL #2 STARTER B+ ALTERNATOR HYD SOL #4 HYD SOL #3 HYD SOL #1 START SAFETY RELAY JOYSTICK RELAY LOWER GLOW PLUG RELAY CONTROLLER GLOW PLUGS RAISE RELAY Greensmaster 3250−D (Serial Number Between 230000600 and 240999999)
  • Page 301 GLOW PLUG CONTROLLER Greensmaster 3250−D (Serial Number Between 230000600 and 240999999) Wiring Diagram Page 8 − 21 Rev. H...
  • Page 302 START RELAY MOW RELAY HIGH TEMP RELAY HYD SOL S6 HIGH TEMP OVERRIDE RUN SAFETY RELAY HYD SOL S2 STARTER B+ WATER IN FUEL LIGHT ALTERNATOR HYD SOL S4 HYD SOL S3 HYD SOL S1 STARTER B+ OIL PRESSURE ALT ”L” BACKLAP SWITCH OVERTEMP...
  • Page 303 GLOW PLUG CONTROLLER Greensmaster 3250−D (Serial Number Between 250000000 and 250999999) Wiring Diagram Page 8 − 23 Rev. H...
  • Page 304 START RELAY MOW RELAY HIGH TEMP RELAY HYD SOL S6 HIGH TEMP OVERRIDE RUN SAFETY RELAY HYD SOL S2 STARTER B+ WATER IN FUEL ALTERNATOR LIGHT HYD SOL S4 HYD SOL S3 HYD SOL S1 STARTER B+ OIL PRESSURE ALT ”L” BACKLAP SWITCH OVERTEMP...
  • Page 305 GLOW PLUG CONTROLLER Greensmaster 3250−D (Serial Number Between 260000001 and 260999999) Wiring Diagram Page 8 − 25 Rev. H...

  • Page 306: Above 270000000)

    Greensmaster 3250−D (Serial Number Above 270000000) Electrical Harness Drawing Page 8 − 26 Rev. H...

  • Page 307: Wiring Diagram

    Greensmaster 3250−D (Serial Number Above 270000000) Wiring Diagram Page 8 − 27 Rev. H...
  • Page 308 This page is intentionally blank. Page 8 − 28 Rev. H...

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