Briggs & Stratton 3250 SERIES Service manual

Briggs & Stratton 3250 SERIES Service manual
Part No. 00062SL (Rev. J)
Service Manual
(Model 04383)
GreensmasterR 3250--D
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 INSTRUCTIONS. 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.
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUCTION. 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 repair of the machine.
IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the
machine.
E The Toro Company - 2000, 2003, 2004, 2005, 2006, 2007, 2009, 2012
This page is intentionally blank.
Greensmaster 3250−D
1
2
3
6
Chapter 3 -- Engine
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 4
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 7
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 8
Briggs and Stratton, Vanguard/Daihatsu Repair Manual
for 3--Cylinder, Water--Cooled, Diesel Engines
Chapter 4 -- Hydraulic System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 4
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . 4 -- 10
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . 4 -- 14
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 26
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 28
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 32
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 52
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 -- 55
Eaton Gear Pumps, Repair Information, Series 26,
Model 26000, Multiple Gear Pumps
Eaton Medium Duty Piston Pump, Repair Information,
Model 70160 Variable Displacement Piston Pump
Ross Torqmotor TM MG, MF, MP, MB, ME, and MJ
Series Service Procedure (Service Manual
2704--003)
Sauer/Danfoss Steering Unit Type OSPM Service
Manual
Chapter 5 -- Electrical System
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 4
Electrical System Quick Checks . . . . . . . . . . . . . . 5 -- 8
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 9
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 -- 23
Greensmaster 3250--D
Rev. I
Chapter 7 -- SPA and 4 Bolt Cutting Units
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 7
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 9
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 7 -- 17
Chapter 7.1 -- DPA Cutting Units
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup and Adjustments . . . . . . . . . . . . . . . . . . .
Service and Repairs . . . . . . . . . . . . . . . . . . . . . .
7.1 -7.1 -7.1 -7.1 -7.1 --
2
3
5
7
8
7.2 -7.2 -7.2 -7.2 -7.2 --
2
3
4
6
7
Chapter 7.2 -- Groomer (DPA Cutting Unit)
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs . . . . . . . . . . . . . . . . . . . . . .
Chapter 8 -- Electrical Diagrams
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . 8 -- 3
Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 9
Electrical Harness Drawings . . . . . . . . . . . . . . . . 8 -- 16
Chassis
2 -2 -2 -2 --
Cutting
Units
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions . . . . . . . . . . . . . . . .
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
3
4
Electrical
Diagrams
Chapter 2 -- Product Records and Maintenance
6 -6 -6 -6 --
Product Records
and Maintenance
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . .
Engine
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 2
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 4
Hydraulic
System
Chapter 6 -- Chassis
Electrical
System
Chapter 1 -- Safety
Safety
Table Of Contents
This page is intentionally blank.
Greensmaster 3250−D
Chapter 1
Safety
Safety
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . .
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Service . . . . . . . . . . . . . . . . . . . .
SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
Greensmaster 3250−D
2
2
3
4
4
Page 1 − 1
Rev. H
Safety
Safety Instructions
The GREENSMASTER 3250--D was tested and certified by Toro for compliance with national and international standards as specified in the Operator’s Manual.
Although hazard control and accident prevention partially are dependent upon the design and configuration
of the machine, these factors are also dependent upon
the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine. Improper use or
maintenance of the machine can result in injury or
death.
The safety alert symbol means
CAUTION, WARNING or DANGER —
“personal safety instruction”. Read
and under stand the instruction because it has to
do with safety. Failure to comply with the instruction may result in personal injury.
WARNING
To reduce the potential for injury or death, comply
with the following safety instructions.
Before Operating
1. Read and understand the contents of this Operator’s Manual before starting and operating the machine.
Become familiar with all controls and know how to stop
quickly. Copies of the Operator’s Manual are available
on the internet at www.Toro.com.
2. Never allow children to operate the machine. Never
allow adults to operate it without proper instructions.
3. Become familiar with the controls, and know how to
stop the engine quickly.
4. Keep all shields, safety devices, and decals in
place. If a shield, safety device, or decal is defective, illegible, or damaged: repair or replace it before operating
the machine.
6. Wearing safety glasses, safety shoes, long pants
and a helmet is advisable and required by some local
safety and insurance regulations.
7. Make sure work area is clear of objects which might
be picked up and thrown by the reels.
8. Do not carry passengers on the machine. Keep everyone, especially children and pets, away from the
areas of operation.
9. Diesel fuel is flammable; handle it carefully.
5. Always wear substantial shoes. Do not operate machine while wearing sandals, tennis shoes or sneakers.
Do not wear loose fitting clothing which could get caught
in moving parts and cause personal injury.
A. Use an approved diesel container.
B. Do not remove cap from fuel tank when engine is
hot or running.
C. Do not smoke while handling diesel fuel.
D. Fill fuel tank outdoors and no higher than to the
bottom of filler neck. Do not overfill.
E. Wipe up any spilled fuel.
Safety
Page 1 -- 2
Rev. I
Greensmaster 3250--D
While Operating
11. Sit on the seat when starting and operating the machine.
12. Check the operation of the interlock switches daily
for proper operation (see Verify Interlock System Operation in Chapter 5 − Electrical System). Replace any malfunctioning switches before operating the machine.
13. To start the engine:
A. Sit on the seat, make sure cutting units are disengaged.
B. Verify that functional control lever is in neutral.
16. The GREENSMASTER 3250−D may exceed noise
levels of 85 dB(A) at the operator position. Ear protectors are recommended, for prolonged exposure, to reduce the potential of permanent hearing damage.
17. Raise the cutting units when driving from one work
area to another.
18. Do not touch engine, muffler or exhaust pipe while
engine is running or soon after it is stopped because
these areas could be hot enough to cause burns.
19. If a cutting unit strikes a solid object or vibrates abnormally, stop immediately, turn engine off, wait for all
motion to stop and inspect for damage. A damaged reel
or bedknife must be repaired or replaced before operation is continued.
20. Before getting off the seat:
C. Verify that parking brake is set.
A. Make sure cutting units are disengaged.
D. Proceed to start engine.
B. Verify that functional control system is in neutral.
14. Using the machine demands attention, and to prevent loss of control:
C. Set the parking brake.
A. Mow only in daylight or when there is good artificial light.
B. Watch for holes or other hidden hazards.
C. Do not drive close to sand traps, ditches, creeks
or other hazards.
D. Reduce speed when making sharp turns. Avoid
sudden stops and starts.
E. Before backing up, look to the rear to be sure no
one is behind the machine.
F. Watch out for traffic when near or crossing
roads. Always yield the right−of−way.
G. Apply the service brakes when going downhill to
keep forward speed slow and to maintain control of
the machine.
15. Keep hands, feet and clothing away from moving
parts and the reel discharge area. The grass baskets
must be in place during operation of the reels or thatchers for maximum safety. Shut the engine off before emptying the baskets.
Greensmaster 3250−D
D. Stop the engine and remove key from ignition
switch.
21. Traverse slopes carefully. Do not start or stop suddenly when traveling uphill or downhill.
22. Operator must be skilled and trained in how to drive
on hillsides. Avoid wet slopes. Failure to use caution on
slopes or hills may cause loss of control and vehicle to
tip or roll possibly resulting in personal injury or death.
23. If engine stalls or loses headway and cannot make
it to the top of a slope, do not turn machine around. Always back slowly straight down the slope.
24. DON’T TAKE AN INJURY RISK! When a person or
pet appears unexpectedly in or near the mowing area,
STOP MOWING. Careless operation, combined with
terrain angles, ricochets, or improperly positioned
guards can lead to thrown object injuries. Do not resume
mowing until area is cleared.
25. Whenever machine is left unattended, make sure
cutting units are fully raised and reels are not spinning,
key is removed from ignition switch and parking brake
is set.
Page 1 − 3
Rev. G
Safety
Safety
10. Do not run the engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and
could be deadly.
Maintenance and Service
26. Before servicing or making adjustments to the machine, stop the engine, remove key from switch to prevent accidental starting of the engine.
27. Be sure entire machine is in good operating condition. Keep all nuts, bolts, screws and hydraulic fittings
tight.
28. Make sure all hydraulic line connectors are tight,and
all hydraulic hoses and lines are in good condition before applying pressure to the system.
29. Keep body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pressure.
Use paper or cardboard, not hands, to search for leaks.
Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and do serious damage. If
fluid is ejected into the skin it must be surgically removed
within a few hours by a doctor familiar with this form of
injury or gangrene may result.
30. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be relieved by stopping engine and lowering cutting units and
attachments to the ground.
31. To reduce potential fire hazard, keep the engine
area free of excessive grease, grass, leaves and accumulation of dirt. Never wash a warm engine or electrical
connections with water.
32. Check all fuel lines for tightness and wear on a regular basis, and tighten or repair as needed.
33. If the engine must be running to perform a maintenance adjustment, keep hands, feet, clothing and any
other parts of the body away from the cutting units, attachments and any moving parts. Keep everyone away.
34. Do not overspeed the engine by changing governor
settings. To assure safety and accuracy, have an Authorized Toro Distributor check maximum engine speed
with a tachometer. Maximum governed engine speed
should be 2750 + 50 RPM.
35. Engine must be shut off before checking oil or adding oil to the crankcase.
36. If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.
37. At the time of manufacture, the GREENSMASTER
3250−D conformed to safety standards in effect for riding mowers. To make sure of optimum performance and
continued safety certification of the machine, use genuine TORO replacement parts and accessories. Replacement parts and accessories made by other
manufacturers could be dangerous, and such use could
void the product warranty of The Toro Company.
38. When changing attachments, tires, or performing
other service, use correct blocks, hoists, and jacks.
Make sure machine is parked on a solid level floor such
as a concrete floor. Prior to raising the machine, remove
any attachments that may interfere with the safe and
proper raising of the machine. Always chock or block
wheels. Used jack stands or solid wood blocks to support the raised machine. If the machine is not properly
supported by blocks or jack stands, the machine may
move or fall, which may result in personal injury.
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
the traction unit. If any decal becomes illegible or damaged, install a new decal. Part numbers are listed in your
Parts Catalog. Order replacement decals from your Authorized Toro Distributor.
Safety
Page 1 − 4
Rev. H
Greensmaster 3250−D
Chapter 2
Product Records and Maintenance
Table of Contents
1
2
2
2
3
3
Product Records
and Maintenance
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . .
Decimal and Millimeter Equivalents . . . . . . . . . . . .
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated, and
Steel Fasteners (Inch Series). . . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated, and
Steel Fasteners (Metric Fasteners). . . . . . . . . . .
Other Torque Specifications . . . . . . . . . . . . . . . . . .
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
5
6
6
6
Product Records
Insert a copy of the Operator’s Manual and Parts Catalog for your Greensmaster 3250--D at the end of this
chapter. Additionally, if any optional equipment or accessories have been installed to your machine, insert
the Installation Instructions, Operator’s Manuals and
Parts Catalogs for those options at the end of this chapter.
Greensmaster 3250--D
Page 2 -- 1 Rev. I
Product Records and Maintenance
Equivalents and Conversions
0.09375
Product Records and Maintenance
Page 2 − 2
Rev. H
Greensmaster 3250−D
Torque Specifications
These Torque Specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in this Service Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (Loctite), degree of lubrication on the
fastener, presence of a prevailing torque feature, hardness of the surface underneath the fastener’s head, or
similar condition which affects the installation.
As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread engagement, etc.
The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Fastener Identification
Grade 1
Grade 5
Grade 8
Class 8.8
Inch Series Bolts and Screws
Class 10.9
Metric Bolts and Screws
Figure 1
Figure 2
Using a Torque Wrench with an Offset Wrench
Use of an offset wrench (e.g. crowfoot wrench) will affect
torque wrench calibration due to the effective change of
torque wrench length. When using a torque wrench with
an offset wrench, multiply the listed torque recommendation by the calculated torque conversion factor (Fig.
3) to determine proper tightening torque. Tightening
torque when using a torque wrench with an offset
wrench will be lower than the listed torque recommendation.
If the listed torque recommendation for a fastener is
from 76 to 94 ft--lb, the proper torque when using this
torque wrench with an offset wrench would be from 72
to 89 ft--lb.
Offset wrench
Example: The measured effective length of the torque
wrench (distance from the center of the handle to the
center of the square drive) is 18”.
The measured effective length of the torque wrench with
the offset wrench installed (distance from the center of
the handle to the center of the offset wrench) is 19”.
Torque wrench
B
(effective length of torque
wrench + offset wrench)
TORQUE CONVERSION FACTOR = A / B
The calculated torque conversion factor for this torque
wrench with this offset wrench would be 18 / 19 = 0.947.
Greensmaster 3250--D
(effective length of
torque wrench)
A
Page 2 -- 3 Rev. I
Figure 3
Product Records and Maintenance
Product Records
and Maintenance
Recommended fastener torque values are listed in the
following tables. For critical applications, as determined
by Toro, either the recommended torque or a torque that
is unique to the application is clearly identified and specified in this Service Manual.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Thread Size
Grade 1, 5, &
8 with Thin
Height Nuts
SAE Grade 1 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
in−lb
in−lb
N−cm
10 + 2
13 + 2
147 + 23
# 6 − 32 UNC
# 6 − 40 UNF
# 8 − 32 UNC
13 + 2
25 + 5
# 10 − 24 UNC
30 + 5
SAE Grade 8 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
in−lb
N−cm
in−lb
N−cm
15 + 2
170 + 20
23 + 2
260 + 20
17 + 2
190 + 20
25 + 2
280 + 20
29 + 3
330 + 30
41 + 4
460 + 45
31 + 3
350 + 30
43 + 4
485 + 45
42 + 4
475 + 45
60 + 6
675 + 70
48 + 4
540 + 45
68 + 6
765 + 70
282 + 30
# 8 − 36 UNF
18 + 2
SAE Grade 5 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
339 + 56
# 10 − 32 UNF
1/4 − 20 UNC
48 + 7
53 + 7
599 + 79
100 + 10
1125 + 100
140 + 15
1580 + 170
1/4 − 28 UNF
53 + 7
65 + 10
734 + 113
115 + 10
1300 + 100
160 + 15
1800 + 170
5/16 − 18 UNC
115 + 15
105 + 17
1186 + 169
200 + 25
2250 + 280
300 + 30
3390 + 340
5/16 − 24 UNF
138 + 17
128 + 17
1446 + 192
225 + 25
2540 + 280
325 + 30
3670 + 340
ft−lb
ft−lb
N−m
ft−lb
N−m
ft−lb
N−m
3/8 − 16 UNC
16 + 2
16 + 2
22 + 3
30 + 3
41 + 4
43 + 4
58 + 5
3/8 − 24 UNF
17 + 2
18 + 2
24 + 3
35 + 3
47 + 4
50 + 4
68 + 5
7/16 − 14 UNC
27 + 3
27 + 3
37 + 4
50 + 5
68 + 7
70 + 7
95 + 9
7/16 − 20 UNF
29 + 3
29 + 3
39 + 4
55 + 5
75 + 7
77 + 7
104 + 9
1/2 − 13 UNC
30 + 3
48 + 7
65 + 9
75 + 8
102 + 11
105 + 10
142 + 14
1/2 − 20 UNF
32 + 3
53 + 7
72 + 9
85 + 8
115 + 11
120 + 10
163 + 14
5/8 − 11 UNC
65 + 10
88 + 12
119 + 16
150 + 15
203 + 20
210 + 20
285 + 27
5/8 − 18 UNF
75 + 10
95 + 15
129 + 20
170 + 15
230 + 20
240 + 20
325 + 27
3/4 − 10 UNC
93 + 12
140 + 20
190 + 27
265 + 25
359 + 34
375 + 35
508 + 47
3/4 − 16 UNF
115 + 15
165 + 25
224 + 34
300 + 25
407 + 34
420 + 35
569 + 47
7/8 − 9 UNC
140 + 20
225 + 25
305 + 34
430 + 45
583 + 61
600 + 60
813 + 81
7/8 − 14 UNF
155 + 25
260 + 30
353 + 41
475 + 45
644 + 61
660 + 60
895 + 81
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
Product Records and Maintenance
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Note: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.
Page 2 − 4
Greensmaster 3250−D
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws, and Studs with
Regular Height Nuts
(Class 8 or Stronger Nuts)
Class 10.9 Bolts, Screws, and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)
M5 X 0.8
57 + 5 in−lb
640 + 60 N−cm
78 + 7 in−lb
885 + 80 N−cm
M6 X 1.0
96 + 9 in−lb
1018 + 100 N−cm
133 + 13 in−lb
1500 + 150 N−cm
M8 X 1.25
19 + 2 ft−lb
26 + 3 N−m
27 + 2 ft−lb
36 + 3 N−m
M10 X 1.5
38 + 4 ft−lb
52 + 5 N−m
53 + 5 ft−lb
72 + 7 N−m
M12 X 1.75
66 + 7 ft−lb
90 + 10 N−m
92 + 9 ft−lb
125 + 12 N−m
M16 X 2.0
166 + 15 ft−lb
225 + 20 N−m
229 + 22 ft−lb
310 + 30 N−m
M20 X 2.5
325 + 33 ft−lb
440 + 45 N−m
450 + 37 ft−lb
610 + 50 N−m
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
Greensmaster 3250−D
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Note: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately + 10% of the
nominal torque value.
Page 2 − 5
Product Records and Maintenance
Product Records
and Maintenance
Thread Size
Other Torque Specifications
SAE Grade 8 Steel Set Screws
Wheel Bolts and Lug Nuts
Recommended Torque
Thread Size
Thread Size
Square Head
Hex Socket
1/4 -- 20 UNC
140 + 20 in--lb
73 + 12 in--lb
5/16 -- 18 UNC
215 + 35 in--lb
145 + 20 in--lb
3/8 -- 16 UNC
35 + 10 ft--lb
18 + 3 ft--lb
1/2 -- 13 UNC
75 + 15 ft--lb
50 + 10 ft--lb
Recommended Torque**
7/16 -- 20 UNF
Grade 5
65 + 10 ft--lb
88 + 14 N--m
1/2 -- 20 UNF
Grade 5
80 + 10 ft--lb
108 + 14 N--m
M12 X 1.25
Class 8.8
80 + 10 ft--lb
108 + 14 N--m
M12 X 1.5
Class 8.8
80 + 10 ft--lb
108 + 14 N--m
** For steel wheels and non--lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23, or Type F
Thread Size
Baseline Torque*
No. 6 -- 32 UNC
20 + 5 in--lb
No. 8 -- 32 UNC
Thread
Size
Threads per Inch
Baseline Torque*
Type A
Type B
No. 6
18
20
20 + 5 in--lb
30 + 5 in--lb
No. 8
15
18
30 + 5 in--lb
No. 10 -- 24 UNC
38 + 7 in--lb
No. 10
12
16
38 + 7 in--lb
1/4 -- 20 UNC
85 + 15 in--lb
No. 12
11
14
85 + 15 in--lb
5/16 -- 18 UNC
110 + 20 in--lb
3/8 -- 16 UNC
200 + 100 in--lb
* Hole size, material strength, material thickness & finish
must be considered when determining specific torque
values. All torque values are based on non--lubricated
fasteners.
Conversion Factors
in--lb X 11.2985 = N--cm
ft--lb X 1.3558 = N--m
N--cm X 0.08851 = in--lb
N--m X 0.7376 = ft--lb
Maintenance
Maintenance procedures and recommended service intervals for the Greensmaster 3250--D are covered in the
Operator’s Manual. Refer to this publication when performing regular equipment maintenance.
Product Records and Maintenance
Page 2 -- 6
Rev. I
Greensmaster 3250--D
Chapter 3
Engine
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . .
Fuel Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fill Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleed Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Cooling System . . . . . . . . . . . . . . . . . . . . . . .
Drain Water from Fuel Filter/Water Separator . . .
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Throttle Control . . . . . . . . . . . . . . . . . . . . . . .
Adjust Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Service Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . .
Change Engine Oil and Filter . . . . . . . . . . . . . . . . .
Greensmaster 3250−D
2
3
4
4
4
5
5
6
6
7
7
7
7
8
8
9
Replace Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Muffler and Air Cleaner . . . . . . . . . . . . . . . . . . . . . 10
Muffler Removal and Installation . . . . . . . . . . . . . . 11
Air Cleaner Removal and Installation . . . . . . . . . . 11
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Radiator Removal and Installation . . . . . . . . . . . . 13
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuel Tank Removal and Installation . . . . . . . . . . . 15
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . 21
Clean Radiator and Screen . . . . . . . . . . . . . . . . . . 23
BRIGGS & STRATTON, VANGUARD/DAIHATSU REPAIR MANUAL FOR 3−CYLINDER, WATER−
COOLED, DIESEL ENGINES
Page 3 − 1
Engine
Engine
Table of Contents
Introduction
This Chapter gives information about specifications,
maintenance, troubleshooting, testing, and repair of the
diesel engine used in the Greensmaster 3250.
ment is explained. However, the cost of the test equipment and the specialized nature of some repairs may
dictate that the work be done at an engine repair facility.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
tools are described in the Briggs & Stratton, Vanguard/
Daihatsu Repair Manual for 3−Cylinder, Water−Cooled,
Diesel Engines. The use of some specialized test equip-
Service and repair parts for Briggs & Stratton, Vanguard/
Daihatsu engines are supplied through your local Briggs
and Stratton dealer or distributor. If no parts list is available, be sure to provide your distributor with the Toro
model and serial number.
Engine
Page 3 − 2
Greensmaster 3250−D
Specifications
Item
Briggs and Stratton Vanguard/Daihatsu, Water−cooled, Diesel,
Model 522447
Number of Cylinders
3
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. in.)
850 (51.8)
Compression Ratio
24.5:1
Firing Order
1− 2−3
Dry Weight (approximate) kg (lb.)
72 (159)
Fuel
No. 2 Diesel per ASTM D975
Fuel Capacity liters (gallons)
22.7 (6.0)
Fuel Injection Pump
VE (Bosch) type
Governor
All speed type
Low Idle (no load)
1500 + 50 RPM
High Idle (no load)
2750 + 50 RPM
Engine Oil
SAE 10W−30 CD, CE, CF, CF−4, or CG−4
Oil Pump
Gear Driven Trochoid Type
Crankcase Oil Capacity liters (U.S. qt.)
3.3 (3.5) with filter
Water Pump
Belt Driven Centrifugal Type
Cooling System Capacity liters (U.S. qt.)
3.1 (3.3)
Starter
12 VDC 1.2 KW
Alternator/Regulator
12 VDC 40 AMP
Greensmaster 3250−D
Page 3 − 3
Engine
Engine
Make / Designation
Description
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 engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and
wipe up any spilled diesel fuel before starting the
engine. Store fuel in a clean, safety−approved
container and keep cap in place. Use diesel fuel
for the engine only; not for any other purpose.
Fuel Shutoff Valve
This valve should be shut when removing the engine or
placing the unit in long term storage.
1
Figure 1
1. Fuel shut off (under the fuel tank)
Checking Engine Oil
IMPORTANT: Check level of oil every 8 operating
hours or daily.
1
Crankcase capacity is approximately 3.5 qts. (3.3 L)
with filter.
1. Position machine on a level surface.
2
2. Remove dipstick and wipe it with a clean rag. Push
dipstick into the tube and make sure it is seated fully. Remove dipstick from tube and check level of oil. If oil level
is low, remove filler cap from valve cover and add
enough oil to raise level to FULL mark on dipstick. Add
the oil slowly and check the level often during this process. DO NOT OVERFILL.
3. The engine uses any high-quality detergent oil having the American Petroleum Institute -API- “service classification” CD, CE, CF or CF−4 or CG−4 or higher.
Recommended viscosity (weight) is SAE 10W30.
Engine
Figure 2
1. Fill cap
2. dipstick
4. Install the filler cap and dipstick firmly in place.
Page 3 − 4
Greensmaster 3250−D
Fill Fuel Tank
The engine runs on No. 2 diesel fuel. Fuel tank capacity
is approximately 6.0 gallons (22.7 L).
1
1. Clean area around fuel tank cap.
2. Remove fuel tank cap.
3. Fill tank to about one inch below the top of tank, (bottom of the filler neck). Do not overfill. Install cap.
4. Wipe up any fuel that may have spilled to prevent a
fire hazard.
Figure 3
1. Fuel cap
Bleed Fuel System
1. Position machine on a level surface. Make sure fuel
tank is at least half full.
2
Engine
1
2. Press primer button on top of fuel filter until resistance is felt.
Note: It may be necessary to operate the primer button up to 30 times or more after starting the engine.
3. Start engine and continue to operate primer button
until engine runs smooth.
3
Figure 4
1. Fuel filter
2. Priming pump
3. Drain Plug
Check Cooling System
The cooling system is filled with a 50/50 solution of water
and ethylene glycol antifreeze. Check level of the coolant at the beginning of each day before starting the engine. Capacity of cooling system is approximately 3.6
qts. (3.4 L).
1
CAUTION
If engine has been running, pressurized hot coolant can escape when the radiator cap is removed
and may cause burns.
Figure 5
1. Reserve tank
1. Park machine on a level surface.
2. Check coolant level. Coolant should be between
lines on the reserve tank when engine is cold.
4. If the coolant level is low, remove reserve tank cap
and add a 50/50 mixture of water and permanent ethylene glycol antifreeze. Do not overfill.
3. Install reserve tank cap.
Greensmaster 3250−D
Page 3 − 5
Engine
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.
2
1
1. Position machine on a level surface and stop the engine.
Note: Because the accumulated water will be mixed
with diesel fuel, drain the fuel filter into a suitable container and dispose of properly.
3
2. Place a drain pan under the fuel filter.
3. Open the drain plug on the fuel filter/water separator
approximately one turn and drain any accumulated water. If necessary, operate the priming pump to drain water. Tighten the plug after draining.
Figure 6
1. Fuel filter
2. Priming pump
3. Drain Plug
4. Start the engine and make sure the warning light
goes out. Check for leaks.
Engine
Page 3 − 6
Greensmaster 3250−D
Adjustments
Adjust Alternator Belt
Make sure belt is properly tensioned to assure the proper operation of the machine and prevent unnecessary
wear. On new belts, check tension after 8 hours of operation.
2
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 midway between the crankshaft and alternator pulley.
1
1. Loosen bolts securing the alternator to the engine
and adjusting bracket.
2. Adjust belt to proper tension and tighten bolts.
Figure 7
1. Bolt
2. Belt
Engine
Adjust Throttle Control
Proper throttle operation is dependent upon proper adjustment of throttle control. Make sure throttle control is
operating properly.
3
4
1. Move remote throttle control lever to SLOW position.
2. Loosen cable clamp screw securing cable to engine.
3. Move cable until speed control lever contacts idle
speed screw
2
1
Figure 8
1. Throttle cable
2. Cable clamp
3. Speed control lever
4. Idle speed screw
Adjust Idle Speed (Fig. 8)
1. Move remote throttle control lever to SLOW position.
3. Adjust idle speed screw to obtain 1500 RPM.
4. Tighten lock nut.
2. Loosen lock nut on idle speed screw.
Greensmaster 3250−D
Page 3 − 7
Engine
Service and Repairs
Service Air Cleaner
Service air cleaner filter every 200 hours (more frequently in extreme dusty or dirty conditions).
2
1. Check air cleaner body and hoses for damage
which could possibly cause an air leak. Replace air
cleaner body if damaged.
2. Release latches securing the air cleaner cover to
the air cleaner body. Separate cover from the body.
Clean inside of air cleaner cover.
1
3. Gently slide filter out of the air cleaner body to reduce the amount of dust dislodged. Avoid knocking filter
against the air cleaner body.
4. Inspect filter. Discard filter if damaged. Do not wash
or reuse a damaged filter.
3
Figure 9
1. Air cleaner latches
2. Dust cup
3. Filter
Washing Method
A. Prepare a solution of filter cleaner and water.
Soak filter element for about 15 minutes. Refer to
directions on the filter cleaner carton for complete
information.
B. After soaking the filter for 15 minutes, rinse it with
clear water. Maximum water pressure must not exceed 40 psi to prevent damage to the filter element.
Rinse filter from the clean side to dirty to side.
5. Inspect new filter for shipping damage. Check sealing end of the filter. Do not install a damaged filter.
6. Insert new filter properly into the air cleaner body.
Make sure filter is sealed properly by applying pressure
to the outer rim of the filter when installing. Do not press
on the flexible center of the filter.
7. Reinstall cover and secure latches.
C. Dry filter element using warm, flowing air that
does not to exceed 160F (71C), or allow element
to air−dry. Do not use a light bulb to dry the filter element because damage could result.
Compressed Air Method
CAUTION
Use eye protection such as goggles when using
compressed air.
A. Blow compressed air from the inside to the outside of the dry filter element. Do not exceed 100 psi
to prevent damage to the element.
B. Keep air hose nozzle at least 2 inches (5 cm)
from the filter. Move nozzle up and down while rotating the filter element. Inspect for holes and tears by
looking through the filter toward a bright light.
Engine
Page 3 − 8
Greensmaster 3250−D
Change Engine Oil and Filter
Change oil and filter initially after the first 50 hours of operation, 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.
1. Remove drain plug letting the oil flow into the drain
pan. When the oil stops flowing, install drain plug.
2
2. Remove oil filter. Apply a light coat of clean oil to the
new filter gasket.
1
3. Screw filter on by hand until the gasket contacts the
filter adapter. Tighten filter from 1/2 to 3/4 of a turn further. Do not overtighten.
Figure 10
4. Add oil to crankcase (see Check Engine Oil).
1. Drain plug
2. Oil filter
Engine
5. Dispose of oil properly.
Replace Fuel Filter
Change filter every 800 hours. Use the following procedures when replacement becomes necessary:
2
1. Close fuel shut−off valve.
1
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 engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and
wipe up any spilled diesel fuel before starting the
engine. Store fuel in a clean, safety−approved
container and keep cap in place. Use diesel fuel
for the engine only; not for any other purpose.
3
Figure 11
1. Fuel filter
2. Priming pump
3. Drain Plug
2. Clean area where filter canister mounts.
3. Disconnect sensor wire and remove drain plug.
7. Install drain plug with new o-ring. Connect sensor
wire.
4. Remove filter canister and clean mounting surface.
8. Push primer button until resistance is felt.
5. Lubricate gasket on filter canister with clean oil.
9. Start engine and check for leaks.
6. Install filter canister by hand until gasket contacts
mounting surface, then rotate an additional 1/3 turn.
Greensmaster 3250−D
Page 3 − 9
Engine
Muffler and Air Cleaner
15
26
18
9
6
19
1
5
19
RIGHT
21
17
FRONT
2
16
15
3
20
7
12
13
4
10
28
11
10
27
4
8
15
24
14
22
30
4
24
25
29
Figure 12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Pipe plug
Air cleaner bracket
Lock nut
Cap screw
Mounting bracket
Air cleaner body
Muffler
Muffler shield
Air inlet hood
Clamp
Engine
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Exhaust plate
Exhaust pipe
R−clamp
Washer
Flat washer
Cap screw
Air cleaner hose
Lock nut
Hose clamp
Decal
Page 3 − 10
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Vaculator valve
Fuel hose (to injector pump)
Not used
Hose clamp
Fuel hose (from fuel tank)
Cap screw
Exhaust gasket
Metric hex nut
Fuel filter/water separator
Pump plate
Greensmaster 3250−D
Muffler Removal (Fig. 13)
Air Cleaner Removal (Fig. 15)
1. Park machine on a level surface, lower the cutting
units, stop the engine, engage parking brake, and remove the key from the ignition switch.
1. Park machine on a level surface, lower the cutting
units, stop the engine, engage parking brake, and remove the key from the ignition switch.
2. Loosen hose clamp (19), and disconnect air cleaner
hose (17) from the air cleaner body (6).
CAUTION
3. Remove lock nut (18) from cap screw (16).
4. Remove air cleaner body (6) from the mounting
bracket (5).
5. Further disassemble air cleaner as necessary.
2. Remove muffler shield (8) from from the muffler (7)
by removing the four cap screws (4) securing the shield
to the muffler.
Air Cleaner Installation (Fig. 16)
3. Remove clamp (10) securing the exhaust pipe (12)
to the muffler (7).
2. If the air cleaner bracket (2) was removed, secure
bracket to the frame with two cap screws (26), flat washers (15), flat washers (15), and lock nuts (3).
4. Remove two cap screws (4) securing the muffler (7)
to the rear of the pump plate (30). Carefully separate
muffler from the pump plate and exhaust pipe (12).
5. Further disassemble muffler as necessary.
1. Make sure the engine is off.
3. If the mounting bracket (5) was removed, secure
bracket to the air cleaner bracket (2) with two cap screws
(16) and lock nuts (18).
4. Carefully place air cleaner body (6) into the mounting bracket (5).
Muffler Installation (Fig. 14)
1. Make sure the engine is off.
Note: Mount all fasteners before securing tightly to
ensure a proper fit.
5. Reconnect air cleaner hose (17) to the air cleaner
(6) and secure with hose clamp (19).
2. If the exhaust plate (11) was removed, install plate
to exhaust manifold with a new gasket. Secure plate to
the manifold with metric hex nuts (28).
3. If the exhaust pipe (12) was removed, install pipe to
exhaust plate (11) with clamp (10).
4. Carefully attach muffler (7) to the exhaust pipe (12).
Secure muffler (7) to the pump plate (30) with two cap
screws (4).
5. Secure exhaust pipe (12) to the muffler (7) with
clamp (10).
6. Secure muffler shield (8) to the muffler (7) with four
cap screws (4).
Greensmaster 3250−D
Page 3 − 11
Engine
Engine
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the engine and exhaust system to cool before working on the muffler.
Radiator
3
24
25
34
12
1
15
2
20
20
18
35
1
27
16
1
17
19
20
24
18
3
22
24
4
5
9
7
31
23
9
9
18
35
1
30
6
28
10
8
11
14
32
7
13
21
Figure 17
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Hose clamp
Radiator hose (to water pump)
Barb hose fitting
Radiator
Upper cooler bracket
Fan warning decal
Washer head screw
Radiator support assembly
Lock nut
Screen
Swell latch
Radiator cap decal
Engine
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Lower cooler bracket
Plug
Cap screw
Lock spring washer
Radiator hose (from water jacket)
Cap screw
Fan shroud
Worm clamp
Pop rivet
Cap screw
Double hose clamp
Breather hose
Page 3 − 12
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Expansion tank hose
Not used
Thermostat housing
Lock nut
Not used
Alternator guard
Flat washer
Drain petcock
Not used
Radiator cap
Flat washer
Greensmaster 3250−D
Radiator Removal (Fig. 17)
Radiator Installation (Fig. 17)
1. Park machine on a level surface, lower the cutting
units, stop the engine, engage parking brake, and remove the key from the ignition switch.
1. Secure fan shroud (19) to radiator (4) with four cap
screws (22), lock nuts (28), and flat washers (31).
2. Slide radiator (4) into the radiator support (8). Secure radiator to support with four cap screws (18) and
lock nuts (9). Also, install alternator guard (30) with
washer (30) to the radiator support.
CAUTION
DO NOT open radiator cap or drain coolant if the
engine or radiator is hot. Pressurized hot coolant
can escape and cause burns.
3. Position radiator support (8) to the frame.
A. Secure rear radiator support tab and double
hose clamp (23) to the frame with cap screw (18),
flat washer (35), and lock nut (9). Secure upper radiator support tab to frame with cap screw (7).
Ethylene−gycol antifreeze is poisonous. Dispose of it properly or store it in a properly labeled
container away from children and pets.
B. Secure lower portion of the radiator support to
the frame with cap screw (7). Secure alternator
guard (30) to the frame tab with cap screw (18) and
lock nut (9).
2. Place a suitable container under the front end of the
radiator. Open drain petcock (32) on the back of the radiator. Drain radiator completely and close petcock.
A. Radiator hoses (2 and 17) with hose clamps (1).
4. If the hydraulic oil cooler is installed, drain hydraulic
reservoir and remove oil cooler (see Engine Removal).
5. Remove the following hoses from the radiator:
B. Breather hose (24) with hose clamp (20).
A. Loosen hose clamp (20) and disconnect breather hose (24).
5. If the hydraulic oil cooler was installed, install oil
cooler to the radiator (see Engine Removal). Fill the hydraulic reservoir (see Check Hydraulic System Fluid in
Chapter 5 − Hydraulic System).
B. Loosen hose clamps (1) and disconnect radiator
hoses (2 and 17).
6. Install screen (10) to radiator support (8).
6. Remove the following fasteners to remove the radiator support (8) from the frame:
7. Fill radiator (4) with coolant (see Check Cooling
System).
A. Lock nut (9) and cap screw (18) securing the alternator guard (29) to the frame tab. Cap screw (7)
securing the lower radiator support to the frame.
B. Cap screw (7) securing the upper radiator support tab to the frame. Lock nut (9), cap screw (18),
and flat washer (30) securing the rear radiator support tab and double hose clamp (23) to the frame
tab.
7. Remove the radiator support (8) from the frame and
onto a workbench.
8. Remove four cap screws (18) and lock nuts (9) securing the radiator (4) to the radiator support (8). Slide
radiator out of the support.
9. Remove four cap screws (22), lock nuts (28), and
flat washers (31) securing the fan shroud (19) to the radiator (4). Separate the shroud from the radiator.
Greensmaster 3250−D
Page 3 − 13
Engine
Engine
4. Connect the following hoses to the radiator:
3. Remove screen (10) from radiator support (8).
Fuel Tank
1
13
17
2
6
10
24
10
11
6
26
14
13
30 to 60 in−lb
(3.4 to 7.8 N−m)
25
3
ANTISEIZE
LUBRICANT
4
10
16
18
23
21
10
9
RIGHT
22
FRONT
19
27
6
20
23
6
Figure 18
1.
2.
3.
4.
5.
6.
7.
8.
9.
Fuel cap
Fuel tank
Grommet
Flat washer
Not used
Washer head screw
Not used
Not used
Fuel shut−off fitting
Engine
10.
11.
12.
13.
14.
15.
16.
17.
18.
Hose clamp
Fuel fitting
Not used
Mounting plate
Flat washer
Not used
Cap screw
Support Bracket
Fuel hose
Page 3 − 14
19.
20.
21.
22.
23.
24.
25.
26.
27.
Clamp
Double hose clamp
Fuel hose (to fuel filter/water sep.)
Hose clamp
Fuel hose (from injector pump)
Fuel hose
Grommet
Worm clamp
Hose clamp
Greensmaster 3250−D
Fuel Tank Removal (Fig. 18)
Fuel Tank installation (Fig. 18)
1. Park machine on a level surface, lower cutting units,
stop the engine, engage parking brake, and remove the
key from the ignition switch.
1. Position fuel tank (2) to the mounting plate (13). Be
careful not to damage any fuel hoses.
A. Apply antiseize lubricant to the threads of the
three cap screws (16).
DANGER
B. Secure fuel tank to the plate with three flat washers (4) and cap screws.
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 engine is running or in an enclosed area. Always fill fuel tank
outside and wipe up any spilled diesel fuel before
starting the engine. Store fuel in a clean, safety−
approved container, and keep the cap in place.
Use diesel fuel for the engine only; not for any
other purpose.
C. Torque cap screws from 30 to 60 in−lb (3.4 to 7.8
N−cm).
2. Connect fuel hose (18) to the fuel tank with hose
clamp (10).
3. Connect fuel hose (23) to fuel fitting (11) with hose
clamp (26).
A. Position mounting plate to the frame. Make sure
to align plate holes with frame holes and support
bracket (28).
A. Close fuel shut−off valve (9) below the fuel tank.
B. Disconnect fuel hose (21) from the fuel shut−off
valve (9). Place hose into a suitable container for
draining the tank
B. Secure mounting plate to the frame and support
bracket with two flat washers (14) and three cap
screws (6).
C. Drain fuel tank completely by opening the fuel
shut off valve.
5. Connect fuel hose (21) to the fuel shut−off valve (9).
3. Gain access to the fasteners securing the fuel tank
(2) to the mounting plate (13) as follows:
A. Remove three cap screws (6) and two flat washers (14) securing mounting plate to the frame and
support bracket (17).
6. Open fuel shut−off valve (9) below the fuel tank.
7. Fill fuel tank with fuel (see Fill Fuel Tank). Check fuel
lines and tank for leaks.
B. Lift and support the mounting plate up from the
rear of the machine.
4. Loosen hose clamp (26) and disconnect fuel hose
(23) from fuel fitting (11).
5. Loosen hose clamp (10) and disconnect fuel hose
(18) from fuel tank (2).
6. Remove three cap screws (16) and flat washers (4)
securing the fuel tank (2) to the mounting plate (13). Remove the tank from the mounting plate being careful not
to damage any fuel hoses.
Greensmaster 3250−D
Page 3 − 15
Engine
Engine
4. Install mounting plate (13) to the frame as follows:
2. Drain fuel tank (2) as follows:
Engine
31
39
31
34 30
31
10
9
19
8
28
3 11
43
15
30
19
18 31
24
32
15
30
15
31
6
44
1
37
35
15
36
27
15
18
28
1
5
22
12
33
17
42
15
15 47
29
31
16
46
7
38
45
15
25
21
32
23
15
20
15
12
2
26
14 16
38
21
15
20
45
4
13
41
16
19
38
15
40
45
15
18
16
20
21
Figure 19
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Daihatsu engine
Fan adapter
Overflow tank
Engine fan
Upper alternator bracket
Lock washer
Nut
Overflow tank hose
Overflow tank cap
Worm clamp
Rear engine mount
Double hose clamp
Front engine mount
Support bracket
Cap screw
Lock nut
Engine
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Lower alternator bracket
Rubber mount
Cap screw
Flange lock nut
Flat washer
Alternator
V−belt
Engine bracket (LH)
Engine bracket (RH)
Cap screw
Pump plate
Upper spacer
Spacer
Cap screw
Thrust washer
Lock nut
Page 3 − 16
33. Cap screw
34. Hydrostat support brace (LH)
35. Hydrostat support brace (RH)
36. Lock nut
37. Cap screw
38. Mount spacer
39. Cap screw
40. Washer head screw
41. Fan deflector
42. Flat washer
43. Cable tie
44. Flat washer
45. Washer
46. Hose clamp
47. Cap screw
48. Fuel hose (to fuel filter/water sep.)
Greensmaster 3250−D
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.
3. Remove console shroud from the control panel.
4. Drain fuel tank (see Fuel Tank Removal):
Figure 20
CAUTION
4
The hydraulic fluid may be hot. To avoid possible
burns, allow hydraulic system to cool before disconnecting any hoses.
9
5
3
8
1
Engine
2
5. Drain hydraulic reservoir as follows (Fig 20):
7
A. Clamp pump inlet hose to prevent hydraulic tank
from inadvertently draining.
6
B. Loosen hose clamp, and remove pump inlet
hose from the gear pump.
C. Drain hydraulic tank completely into a suitable
container by releasing the clamp from the hose.
Plug hose and pump to prevent contamination.
CAUTION
Figure 21
1.
2.
3.
4.
5.
6.
7.
8.
9.
Tube
O−ring
Hydraulic fitting
Oil filter
8. Remove air cleaner as follows (Fig. 12):
A. Disconnect air cleaner hose (17) at the engine
air intake manifold.
DO NOT open radiator cap or drain coolant if the
engine or radiator is hot. Pressurized hot coolant
can escape and cause burns. Ethylene−gycol antifreeze is poisonous. Dispose of it properly or
store it in a properly labeled container away from
children and pets.
B. Disconnect mounting bracket (5) from the air
cleaner bracket (2). Remove air cleaner and mounting bracket from the air cleaner bracket.
6. Drain radiator (4) as follows (Fig. 17):
A. Open drain petcock (32) on the back of the radiator. Drain radiator completely into a suitable container and close petcock.
B. Disconnect expansion tank hose (25) and and
radiator hose (17) at the thermostat housing (27).
Disconnect radiator hose (2) at the water pump.
CAUTION
The muffler and muffler tube may be hot. Avoid
possible burns, allow exhaust system to cool before working on the muffler.
9. Remove muffler as follows (Fig. 12):
7. Disconnect hydraulic oil cooler if installed (Fig. 21).
A. Disconnect tube and O−ring from hydraulic fitting on the hydraulic reservoir.
B. Disconnect tube and O−ring from hydraulic fitting on the oil filter.
Greensmaster 3250−D
Hydraulic oil cooler
Tube
O−ring
Hydraulic fitting
Hydraulic reservoir
Page 3 − 17
A. Disconnect exhaust plate (11) from the exhaust
manifold by removing four metric hex nuts (28).
B. Remove two cap screws (4) securing the muffler
(7) to the pump plate (30). Remove muffler with muffler shield (8) attached.
Engine
10. Remove fuel tank and hydraulic reservoir as follows:
1
A. Remove three cap screws (6) and two flat washers (14) securing tank mounting plate (13) to the
support bracket (17) and frame (Fig. 18).
2
B. Disconnect hydraulic hose to power steering
from from the hydraulic reservoir. Make sure hose to
gear pump is disconnected at the pump (Fig. 22).
C. If the oil cooler is not installed, disconnect hydraulic hose from the hydraulic oil filter (Fig. 23).
D. Disconnect fuel hose (21) going to the fuel filter/
water separator at the fuel shut−off fitting (9) (Fig.
18). Disconnect double hose clamp (12) from fuel
hose (48) and rear engine mount (11) near the over
flow tank (Fig. 19).
Figure 23
1. Hydraulic hose
E. Disconnect fuel hose from the injector pump that
goes to the fuel tank (Fig. 24). Loosen clamps (19
and 20) to allow removal of the hose (Fig. 18).
2. Hydraulic oil filter
2
3
F. Disconnect fuel hose coming from the fuel filter/
water separator at the injector pump inlet (Fig. 24).
1
G. Make sure cable ties and hose clamps securing
hoses to the frame and supports are removed.
H. Lift mounting plate and tanks from the machine.
11. Loosen socket head screw securing the throttle
cable to cable clamp. Disconnect cable from the cable
clamp and speed control lever (Fig. 25).
Figure 24
1. Hose (to fuel tank)
2. Injector pump
3. Hose (from fuel filter/water separator
5
4
2
1
3
1
Figure 22
1. Hose (to gear pump)
2. Hose clamp
3. Hose (to power steering)
4. O−ring
5. Hydraulic reservoir
2
Figure 25
1. Socket head screw
2. Cable clamp
Engine
4
3
Page 3 − 18
3. Throttle clamp
4. Speed control lever
Greensmaster 3250−D
12. Separate relief valve from the pump plate by removing both cap screws flat washers, and lock nuts (Fig. 26).
1
13. Separate hydrostat from the pump plate as follows:
A. Loosen both set screws securing the hydrostat
shaft to the hub (Fig. 27).
2
CAUTION
Use caution when removing the traction control
mechanism. The extension spring is under tension and may cause personal injury during removal.
Figure 26
1. Relief valve
2. Cap screw
B. Remove cap screw and flat washer securing
pump lever and plate to the trunnion shaft (Fig. 28).
8
D. Disconnect extension spring from the spring
bracket. Remove traction control mechanism from
the pump as a complete unit (Fig. 28).
5
6
1
2
E. Remove both locknuts, cap screws, and flat
washers securing the hydrostat to the pump plate.
Be careful not to lose the key (Fig. 27).
7
4
3
F. Swing hydrostat out from the machine and secure to prevent dropping.
14. Disconnect electrical connections from the following engine components:
Figure 27
1.
2.
3.
4.
A. The black (negative) battery cable and black
wire harness ground on the hydrostat end of the engine block.
5.
6.
7.
8.
Set screw
Hydrostat
Hub
Lock nut
Cap screw
Flat washer
Pump plate
Key
6
7
1
B. The red battery cable and red wire with plug on
the starter solenoid. Both gray and one black wire
from starter terminals.
C. The orange wire on the glow plug bus.
D. The blue/white wires and plug−in connector to
the ETR solenoid (injection pump).
4
2
3
5
E. The yellow/red wire on the water temperature
switch.
Figure 28
F. The white/red wire on the oil pressure switch.
G. Plug−in connector with white and green wires to
the alternator. Also, grey wire with rubber cap.
15. Remove both hex washer head screws (40) securing the fan deflector (41) to the front engine mount (13)
(Fig. 19).
Greensmaster 3250−D
1.
2.
3.
4.
Cap screw & flat washer
Cap screw
Spacer
Cable support bracket
5. Pump
6. Extension spring
7. Spring bracket
16. Separate fan adapter (2) and fan (4) from engine
crank shaft pulley for better clearance (Fig. 19).
Page 3 − 19
Engine
Engine
C. Remove cap screws and spacers securing the
cable support bracket to the pump (Fig. 28).
A. Attach a short section of chain between both engine mounts
17. Remove three flange lock nuts (20), flat washers
(21), washers (45), and cap screws (19) securing the
front engine mount (13) and rear engine mount (11) to
the rubber mounts (18) (Fig. 19).
B. Connect hoist or chain fall to center of chain.
IMPORTANT: Make sure not to damage the engine,
fuel and hydraulic lines, electrical harness, or other
parts while removing the engine.
CAUTION
C. Slowly remove engine and mounts from the machine.
One person should operate the chain fall or hoist
while the other person guides the engine out of
the frame.
18. Remove engine from the frame.
Engine
19. Remove engine mounts, backing plate, and pump
plate as necessary to repair the engine (Fig. 19).
Page 3 − 20
Greensmaster 3250−D
Engine Installation
F. The white/red wire to the oil pressure switch.
1. If the pump plate, backing plate, or engine mounts
were removed from the engine, install them to the engine using Figure 19 as a guide.
G. Plug−in connector with white and green wires to
the alternator. Also, grey wire with rubber cap.
7. Install hydrostat to the pump plate as follows:
CAUTION
CAUTION
One person should operate the chain fall or hoist
while the other person guides the engine into the
frame.
Use caution when installing the extension
spring. The spring is under tension and may
cause personal injury during installation.
A. Attach a short section of chain between both engine mounts.
A. Apply antiseize lubricant to the key and install
into hydrostat shaft. Slide shaft and key into hub
(Fig. 27).
B. Connect a hoist or chain fall at the center of the
short section of chain.
B. Secure hydrostat to the pump plate with both flat
washers, cap screws, and locknuts. (Fig. 27).
IMPORTANT: Make sure not to damage engine, fuel
and hydraulic lines, electrical harness, or other
parts while installing the engine. Make sure fan
adapter and fan are in position for installation before lowering the engine.
C. Connect extension spring to the spring bracket
while installing traction control mechanism from the
pump as a complete unit (Fig. 28).
D. Secure cable support bracket to the pump with
cap screws and spacers (Fig. 28).
C. Lower engine and mounts into the machine.
3. Secure front engine mount (13) and rear engine
mount (11) to the rubber mounts (18) with three cap
screws (19), flat washers (21), washers (45), and flange
lock nuts (20). Align mounts and tighten fasteners before releasing the engine from the chain fall (Fig. 19).
4. Install fan adapter (2) and fan (4) to the engine crank
shaft pulley (Fig. 19).
5. Secure fan deflector (4) to the front engine mount
(13) with both hex washer head screws (40) (Fig. 19).
6. Connect electrical connections to the following engine components:
E. Secure pump lever and plate to the trunnion
shaft with cap screw and flat washer (Fig. 28).
F. Secure hydrostat shaft to the hub by tightening
both set screws(Fig. 27).
8. Secure relief valve to the pump plate with both cap
screws, flat washers, and lock nuts (Fig. 26).
9. Connect cable to the cable clamp and speed control
lever. Loosen socket head screw securing the throttle
cable to cable clamp. (Fig. 25).
10. Install air cleaner as follows (Fig. 22):
A. Secure air cleaner and bracket to the pump
plate.
A. The black (negative) battery cable and black
wire harness ground on the hydrostat end of the engine block.
B. Connect hose leading to the radiator to the
cleaner.
B. The red battery cable and red wire with plug to
the starter solenoid. Both gray and one black wire to
starter terminals.
C. The orange wire to the glow plug bus.
C. Route and connect hose, leading from the cleaner to the engine valve cover, to the valve cover and
cleaner.
11. Install fuel tank and hydraulic reservoir as follows:
D. The blue/white wires and plug−in connector to
the ETR solenoid (injection pump).
E. The yellow/red wire to the water temperature
switch.
Greensmaster 3250−D
Page 3 − 21
Engine
Engine
2. Install engine to the frame.
A. Position mounting plate and tanks onto the
frame.
14. Connect hydraulic oil cooler if installed (Fig. 21).
A. Connect tube and O−ring to hydraulic fitting on
the hydraulic reservoir.
B. Connect fuel hose coming from the fuel filter/water separator at the injector pump inlet (Fig. 24).
C. Connect fuel hose to the injector pump that goes
to the fuel tank (Fig. 24). Secure hoses to frame with
clamps (19 and 20) (Fig. 18).
B. Connect tube and O−ring to hydraulic fitting on
the oil filter.
15. Connect hoses to radiator (4) as follows (Fig. 17):
A. Connect radiator hose (2) to the water pump.
D. Connect double hose clamp (12) to fuel hose
(48) and rear engine mount (11) near the over flow
tank (Fig. 19). Connect fuel hose (21) going to the
fuel filter/water separator at the fuel shut−off fitting
(9) (Fig. 18).
E. If the oil cooler is not installed, Connect hydraulic hose to the hydraulic oil filter (Fig. 23).
F. Connect hydraulic hose to power steering at the
hydraulic reservoir (Fig. 22).
B. Make sure drain petcock (32) on the back of the
radiator is shut.
C. Connect expansion tank hose (25) and radiator
hose (17) to the thermostat housing (27).
16. Connect remaining hydraulic reservoir as follows
(Fig 20):
A. Remove plug from pump inlet hose.
G. Make sure hoses are secured to the frame and
supports with cable ties and hose clamps.
B. Secure pump inlet hose to the gear pump with
hose clamp.
H. Secure tank mounting plate (13) to the support
bracket (17) and frame with three cap screws (6)
and two flat washers (14) (Fig. 18).
12. Install muffler as follows (Fig. 12):
A. Position muffler to machine with muffler shield
(8) attached.
B. Secure muffler (7) to the pump plate (30) with
two cap screws (4).
C. Secure exhaust plate (11) to the exhaust manifold with four metric hex nuts (28).
13. Install air cleaner as follows (Fig. 12):
A. Install air cleaner and mounting bracket (5) to the
air cleaner bracket (2). Secure mounting bracket to
the air cleaner bracket.
B. Connect air cleaner hose (17) to the engine air
intake manifold.
C. Remove clamp from pump inlet hose that was
used to prevent hydraulic tank from inadvertently
draining.
17. Make sure all fuel hoses are connected properly
(see Fuel Tank Installation).
18. Install console shroud to the control panel.
19. Make sure fuel shutoff valve is open. Fill fuel tank
with fuel (see Fill Fuel Tank). Check tank and hoses for
leaks.
20. Fill cooling system with coolant (see Check Cooling
System). Check radiator and hoses for leaks.
21. Adjust alternator belt (see Adjust Alternator Belt).
22. Fill hydraulic reservoir with hydraulic oil (see Check
Hydraulic System Fluid in Chapter 5 − Hydraulic System). Check reservoir and hoses for leaks.
23. Bleed fuel system (see Bleed Fuel System).
24. Adjust throttle control lever and cable (see Adjust
Throttle Control).
Engine
Page 3 − 22
Greensmaster 3250−D
Clean Radiator and Screen
To prevent the cooling system from overheating, the radiator 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 components more frequently in dusty and/or dirty conditions.
2
1. Release latches and remove radiator screen from
the radiator support.
2. Remove fan shroud to access radiator corners.
3. If installed, lift oil cooler from supports.
1
CAUTION
Figure 29
1. Screen
2. Latches
Engine
Use eye protection such as goggles when using
compressed air.
IMPORTANT: Air pressure should not exceed 40 psi
(2.8 bar) because damage to the radiator fins may
result.
4. Working from the fan side of the radiator, blow out
radiator with compressed air. If installed, blow out oil
cooler.
5. If installed, mount oil cooler to supports.
6. Clean screen. Reinstall fan shroud and screen to
the radiator support. Secure latches.
1
2
Figure 30
1. Radiator
Greensmaster 3250−D
Page 3 − 23
2. Radiator support
Engine
This page is intentionally blank.
Engine
Page 3 − 24
Greensmaster 3250−D
Chapter 4
Hydraulic System
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Check Hydraulic System Fluid . . . . . . . . . . . . . . . . . 4
Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Hose and Tube Installation . . . . . . . . . . . 7
Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 8
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . 10
Serial Number Under 220999999 . . . . . . . . . . . . . 10
Serial Number From 230000000 To 230001500 . 11
Serial Number From 230001501 To 260999999 . 12
Serial Number Above 270000000 . . . . . . . . . . . . . 13
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . 14
Traction Forward and Reverse . . . . . . . . . . . . . . . . 14
Raise and Lower Cutting Units
(Serial Number Under 260999999) . . . . . . . . . . 16
(Serial Number Above 270000000) . . . . . . . . . . 18
Mow and Backlap
(Serial Number Under 260999999) . . . . . . . . . . 20
(Serial Number Above 270000000) . . . . . . . . . . 22
Right and Left Turn . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 28
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Precautions for Hydraulic Testing . . . . . . . . . . . . . 32
Traction Drive Hydrostat (P3) Flow Test . . . . . . . . 34
Wheel Motor Efficiency Test . . . . . . . . . . . . . . . . . . 36
Charge Relief Valve (R4) Pressure Test . . . . . . . . 38
Gear Pump (P2) Flow and Implement Relief
Valve (R5) Pressure Test . . . . . . . . . . . . . . . . . . . 40
Lower Cutting Units Relief Valve (R2)
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Gear Pump (P1) Flow Test . . . . . . . . . . . . . . . . . . . 44
Mow Circuit Relief Valve (R1) Pressure Test . . . . 46
Reel Motor Case Drain Flow Test . . . . . . . . . . . . . 48
Steering Control Valve Test . . . . . . . . . . . . . . . . . . . 50
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Adjust Transmission for Neutral . . . . . . . . . . . . . . . 52
Adjust Transport Speed . . . . . . . . . . . . . . . . . . . . . . 52
Adjust Mowing Speed . . . . . . . . . . . . . . . . . . . . . . . 53
Adjust Cutting Unit Drop Speed . . . . . . . . . . . . . . . 53
Adjust Implement Relief Valve (R5) (Machines
with Serial Number Under 220999999) . . . . . . . 54
Adjust Manifold Relief Valves (R1 and R2) . . . . . . 54
Greensmaster 3250--D
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 55
General Precautions for Removing and
Installing Hydraulic System Components . . . . . 55
Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Gear Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . 58
Hydraulic System Start--up . . . . . . . . . . . . . . . . . . . 59
Hydrostatic Transmission . . . . . . . . . . . . . . . . . . . . 60
Piston Pump Service . . . . . . . . . . . . . . . . . . . . . . . . 63
Piston Pump Crush Ring Replacement . . . . . . . . . 64
Change Hydraulic Oil and Filter . . . . . . . . . . . . . . . 65
Wheel Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Wheel Motor Service . . . . . . . . . . . . . . . . . . . . . . . . 70
Flush Hydraulic System . . . . . . . . . . . . . . . . . . . . . . 71
Implement Relief Valve . . . . . . . . . . . . . . . . . . . . . . 72
Reel Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Reel Motor Service
Serial Number Under 220999999 . . . . . . . . . . . . 76
Serial Number Over 230000000 . . . . . . . . . . . . . 78
Oil Cooler (If Equipped) . . . . . . . . . . . . . . . . . . . . . . 82
Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Lift Cylinder Service . . . . . . . . . . . . . . . . . . . . . . . . . 86
Hydraulic Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Hydraulic Manifold Service
Serial Number Under 260999999 . . . . . . . . . . . . 90
Serial Number Above 270000000 . . . . . . . . . . . 92
Flow Control and Backlap Valves (If Equipped on
Serial Number Under 260999999) . . . . . . . . . . . 96
Rear Lift Cylinder Flow Control Valve . . . . . . . . . . 99
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . 100
Steering Control Valve Service
Serial Number Under 220999999 . . . . . . . . . . . 102
Serial Number From 230000000 to 270999999106
Serial Number Above 280000000 . . . . . . . . . . 110
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Steering Cylinder Service . . . . . . . . . . . . . . . . . . . 114
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . 116
Leak Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
EATON GEAR PUMPS, REPAIR INFORMATION, SERIES 26, MODEL 26000, MULTIPLE GEAR PUMPS
EATON, MEDIUM DUTY PISTON PUMP, REPAIR
INFORMATION, MODEL 70160 VARIABLE DISPLACEMENT PISTON PUMP
ROSS TORQMOTOR TM MG, MF, MP, MB, ME, AND
MJ SERIES SERVICE PROCEDURE (SERVICE
MANUAL 2704--003)
SAUER/DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
Page 4 -- 1 Rev. J
Hydraulic System (Rev. I)
Hydraulic
System
Table of Contents
This page is intentionally blank.
Hydraulic System (Rev. I)
Page 4 -- 2
Greensmaster 3250--D
Specifications
Item
Description
Hydrostatic Transmission (P3)
Maximum Pump Displacement (per revolution)
Charge Pressure
Variable displacement piston pump
1.24 in3 (20.3 cc)
100 to 150 PSI (6.9 to 10.3 bar)
Gear Pump
Front Section (P1) (cutting reels) Displacement (per revolution)
Rear Section (P2) (steering/lift) Displacement (per revolution)
2 section, positive displacement gear type pump
0.55 in3 (9.0 cc)
0.31 in3 (5.1 cc)
Wheel Motors (Front)
Orbital rotor motor
Wheel Motor (Optional Rear)
Orbital rotor motor
Reel Motor
Gear motor
Steering Control Valve
Distributor valve with rotary meter
Implement (Steering and Lift) Relief Pressure (R5)
Machines with Serial Number Under 220999999
Machines with Serial Number Over 230000000
1000 PSI (69.0 bar) over Charge Pressure
1150 PSI (79.3 bar) over Charge Pressure
Hydraulic Manifold Relief Valves
Mow Circuit (R1)
Cutting Unit Lower (R2) (Serial Number Under 220999999)
Cutting Unit Lower (R2) (Serial Number Over 230000000)
Hydraulic Filter
5 Micron spin--on cartridge type
Hydraulic Oil
Hydraulic Reservoir
Greensmaster 3250--D
See Operator’s Manual
Reservoir (without leak detector) capacity 5.5 gal. U.S. (20.8 L)
Reservoir (with leak detector) capacity 8.1 gal. U.S. (30.7 L)
Page 4 -- 3
Rev. J
Hydraulic System (Rev. I)
Hydraulic
System
2400 PSI (166 bar)
150 PSI (10.3 bar) over Charge Pressure
400 PSI (27.6 bar) over Charge Pressure
General Information
Operator’s Manual
The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for your Greensmaster 3250--D. Refer to that
publication for additional information when servicing the
machine.
Check Hydraulic System Fluid
The hydraulic system on the Greensmaster 3250--D is
designed to operate on high quality hydraulic fluid. Refer
to the Operator’s Manual for hydraulic fluid recommendations.
1
2
IMPORTANT: Check level of hydraulic fluid before
engine is first started and daily thereafter.
Note: If changing from one type of hydraulic fluid to
another, be certain to remove all the old fluid from the
system, as some fluids are incompatible with others.
IMPORTANT: Use only types of hydraulic fluids
specified in the Operator’s Manual. Other fluids may
cause system damage.
Figure 1
1.
Hydraulic oil cap
2.
Filler screen
Checking Fluid Level
Note: A red dye additive for the hydraulic system fluid
is available in 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 machine has cooled down so fluid is cold.
2. Remove cap from reservoir and check level of fluid.
The fluid should be up to bottom of screen in filler neck.
IMPORTANT: To prevent system contamination,
clean top of hydraulic fluid containers before puncturing. Make sure pour spout and funnel are clean.
3. If fluid level is low, slowly fill reservoir with appropriate hydraulic fluid until level reaches bottom of screen.
DO NOT OVERFILL.
4. Install reservoir cap. Wipe up any fluid that may
have spilled.
Hydraulic System (Rev. I)
Page 4 -- 4
Greensmaster 3250--D
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.
1. Locate by--pass valve on the hydrostat. Rotate
valve 90o.
1
2
Figure 2
1.
By--pass valve
2.
Hydrostat
Hydraulic
System
2. Before starting engine, close by--pass valve by rotating it back 90o. Do not start engine when the valve is
open.
Greensmaster 3250--D
Page 4 -- 5
Hydraulic System (Rev. I)
Hydraulic Hoses
Hydraulic hoses are subject to extreme conditions such
as pressure differentials during operation and exposure
to weather, sun, chemicals, very warm storage conditions or mishandling during operation and maintenance.
These conditions can cause hose damage and deterioration. Some hoses are more susceptible to these
conditions than others. Inspect all machine hydraulic
hoses frequently for signs of deterioration or damage:
Hard, cracked, cut, abraded, charred, leaking or
otherwise damaged hose.
Kinked, crushed, flattened or twisted hose.
Blistered, soft, degraded or loose hose cover.
Cracked, damaged or badly corroded hose fittings.
When replacing a hydraulic hose, be sure that the hose
is straight (not twisted) before tightening the fittings.
This can be done by observing the imprint (layline) on
the hose. Use two wrenches; hold the hose straight with
one wrench and tighten the hose swivel nut onto the fitting with the other wrench (See Hydraulic Hose and
Tube Installation in this section). If the hose has an elbow at one end, tighten the swivel nut on that end before
tightening the nut on the straight end of the hose.
WARNING
Before disconnecting or performing any work on
hydraulic system, relieve all pressure in system
(see Relieving Hydraulic System Pressure in this
section).
Keep body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands, to
search for leaks. Hydraulic fluid escaping under
pressure can have sufficient force to penetrate
the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar
with this type of injury. Gangrene may result from
such an injury.
For additional hydraulic hose information, refer to Toro
Service Training Book, Hydraulic Hose Servicing (Part
Number 94813SL).
Hydraulic System (Rev. I)
Page 4 -- 6
Greensmaster 3250--D
Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting)
1. Make sure threads and sealing surfaces of the hose/
tube and the fitting are free of burrs, nicks, scratches or
any foreign material.
C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The
markings on the nut and fitting body will verify that the
connection has been properly tightened.
2. As a preventative measure against leakage, it is recommended that the face seal O--ring be replaced any
time the connection is opened. Make sure the O--ring is
installed and properly seated in the fitting groove. Lightly
lubricate the O--ring with clean hydraulic oil.
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
3. Place the hose/tube against the fitting body so that
the flat face of the hose/tube sleeve fully contacts the O-ring in the fitting.
Swivel Nut
4. Thread the swivel nut onto the fitting by hand. While
holding the hose/tube with a wrench, use a torque
wrench to tighten the swivel nut to the recommended
installation torque shown in Figure 5. This tightening
process will require the use of an offset wrench (e.g.
crowfoot wrench). Use of an offset wrench will affect
torque wrench calibration due to the effective length
change of the torque wrench. Tightening torque when
using a torque wrench with an offset wrench will be lower
than the listed installation torque (see Using a Torque
Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 -- Product Records and Maintenance).
1/2 to 3/4
1/2 to 3/4
1/2 to 3/4
1/2 to 3/4
1/3 to 1/2
1/3 to 1/2
Fitting Body
O--ring
Tube or Hose
Hydraulic
System
Figure 3
5. If a torque wrench is not available or if space at the
swivel nut prevents use of a torque wrench, an alternate
method of assembly is the Flats From Wrench Resistance (F.F.W.R.) method (Fig. 2).
Mark Nut
and Fitting
Body
A. Using a wrench, tighten the swivel nut onto the fitting until light wrench resistance is reached (approximately 30 in--lb).
B. Mark the swivel nut and fitting body. Hold the
hose/tube with a wrench to prevent it from turning.
F.F.W.R.
Final
Position
Initial
Position
Extend Line
AFTER TIGHTENING
AT WRENCH RESISTANCE
Figure 4
Fitting Dash Size
Hose/Tube Side Thread Size
Installation Torque
4
9/16 -- 18
18 to 22 ft--lb (25 to 29 N--m)
6
11/16 -- 16
27 to 33 ft--lb (37 to 44 N--m)
8
13/16 -- 16
37 to 47 ft--lb (51 to 63 N--m)
10
1 -- 14
60 to 74 ft--lb (82 to 100 N--m)
12
1 3/16 -- 12
85 to 105 ft--lb (116 to 142 N--m)
16
1 7/16 -- 12
110 to 136 ft--lb (150 to 184 N--m)
20
1 11/16 -- 12
140 to 172 ft--lb (190 to 233 N--m)
Figure 5
Greensmaster 3250--D
Page 4 -- 7
Hydraulic System (Rev. I)
Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port)
Non--Adjustable Fitting (Fig. 6)
1. Make sure all threads and sealing surfaces of fitting
and component port are free of burrs, nicks, scratches
or any foreign material.
5. If a torque wrench is not available, or if space at the
port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.)
method.
2. As a preventative measure against leakage, it is recommended that the O--ring be replaced any time the
connection is opened.
3. Lightly lubricate the O--ring with clean hydraulic oil.
Fitting threads should be clean with no lubricant applied.
A. Install the fitting into the port and tighten it down
full length until finger tight.
B. If port material is steel, tighten the fitting to the
listed F.F.F.T. If port material is aluminum, tighten fitting to 60% of listed F.F.F.T.
Size
IMPORTANT: Before installing fitting into port, determine port material. If fitting is to be installed into
an aluminum port, installation torque is reduced.
4. Install the fitting into the port. Then, use a torque
wrench and socket to tighten the fitting to the recommended installation torque shown in Figure 7.
F.F.F.T.
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
NOTE: Use of an offset wrench (e.g. crowfoot wrench)
will affect torque wrench calibration due to the effective
length change of the torque wrench. Tightening torque
when using a torque wrench with an offset wrench will
be less than the recommended installation torque. See
Using a Torque Wrench with an Offset Wrench in the
Torque Specifications section of Chapter 2 -- Product
Records and Maintenance to determine necessary conversion information.
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
Fitting
O--ring
Figure 6
Fitting
Dash Size
Fitting Port Side
Thread Size
Installation Torque Into
Steel Port
Installation Torque Into
Aluminum Port
4
7/16 -- 20
15 to 19 ft--lb (21 to 25 N--m)
9 to 11 ft--lb (13 to 15 N--m)
5
1/2 -- 20
18 to 22 ft--lb (25 to 29 N--m)
11 to 15 ft--lb (15 to 20 N--m)
6
9/16 -- 18
34 to 42 ft--lb (47 to 56 N--m)
20 to 26 ft--lb (28 to 35 N--m)
8
3/4 -- 16
58 to 72 ft--lb (79 to 97 N--m)
35 to 43 ft--lb (48 to 58 N--m)
10
7/8 -- 14
99 to 121 ft--lb (135 to 164 N--m)
60 to 74 ft--lb (82 to 100 N--m)
12
1 1/16 -- 12
134 to 164 ft--lb (182 to 222 N--m)
81 to 99 ft--lb (110 to 134 N--m)
14
1 3/16 -- 12
160 to 196 ft--lb (217 to 265 N--m)
96 to 118 ft--lb (131 to 160 N--m)
16
1 5/16 -- 12
202 to 248 ft--lb (274 to 336 N--m)
121 to 149 ft--lb (165 to 202 N--m)
20
1 5/8 -- 12
247 to 303 ft--lb (335 to 410 N--m)
149 to 183 ft--lb (202 to 248 N--m)
Figure 7
Hydraulic System (Rev. I)
Page 4 -- 8
Greensmaster 3250--D
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 recommended that the O--ring be replaced any time the
connection is opened.
Lock Nut
3. Lightly lubricate the O--ring with clean hydraulic oil.
Fitting threads should be clean with no lubricant applied.
Back--up Washer
4. Turn back the lock nut as far as possible. Make sure
the back up washer is not loose and is pushed up as far
as possible (Step 1 in Figure 9).
O--ring
5. Install the fitting into the port and tighten finger tight
until the washer contacts the face of the port (Step 2).
6. To put the fitting in the desired position, unscrew it by
the required amount, but no more than one full turn
(Step 3).
7. Hold the fitting in the desired position with a wrench
and use a torque wrench to tighten the fitting to the recommended installation torque shown in Figure 7. This
tightening process will require the use of an offset
wrench (e.g. crowfoot wrench). Use of an offset wrench
will affect torque wrench calibration due to the effective
length change of the torque wrench. Tightening torque
when using a torque wrench with an offset wrench will
be lower than the listed installation torque (see Using a
Torque Wrench with an Offset Wrench in the Torque
Specifications section of Chapter 2 -- Product Records
and Maintenance).
Step 1
Step 3
Step 2
Step 4
Figure 9
8. If a torque wrench is not available, or if space at the
port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.)
method. Hold the fitting in the desired position with a
wrench and, if port material is steel, tighten the lock nut
with a second wrench to the listed F.F.F.T (Step 4). If port
material is aluminum, tighten fitting to 60% of listed
F.F.F.T.
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
Greensmaster 3250--D
F.F.F.T.
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
Page 4 -- 9
Hydraulic System (Rev. I)
Hydraulic
System
Figure 8
IMPORTANT: Before installing fitting into port, determine port material. If fitting is to be installed into
an aluminum port, installation torque is reduced.
Hydraulic System (Rev. I)
Page 4 -- 10
P3
HYDROSTAT
1500 RPM LOW IDLE
2750 RPM HIGH IDLE
R4
BY--PASS
VALVE
OPTIONAL 3WD
TRACTION
WHEEL MOTOR
FORWARD
M4
M5
TRACTION WHEEL MOTORS
R5
OIL
COOLER
(OPTIONAL KIT)
ENGINE
RPM
OIL
FILTER
T
S1
P1
P1
R1
LC1
O1
RD1
M1
S2
P2
S3
OPTIONAL
VALVES
PT ST
MB
BACKLAP
REEL MOTORS
GEAR PUMP
P2
FC1
MA
MOW
M2
M3
PB
T
P
V1
MANIFOLD BLOCK
R2
S4
L2A
L2B
L1B
L3A
L3B
L
R
All solenoids are shown as
de--energized
Greensmaster 3250--D
Hydraulic Schematic
Serial Number Under 220999999
FLOW
CONTROL
VALVE
RAISE
LOWER
#1 LIFT CYLINDERS
STEERING
CONTROL
VALVE
#2
#3
FLOW RATE CALCULATED AT 2800 RPM AND 98% EFFICIENCY
DISPLACEMENT, FLOW RATE, AND PRESSURE CHART
DISPLACEMENT
PRESSURE
FLOW RATE
lbs/in 2 BARS
COMPONENT in 3/rev cm 3/rev
GPM
LPM
9.5
P1
.58
--5.9
22.4
P2
5.1
3.7
13.9
.31
--P3
1.24
20.3
14.8
55.8
--M1
--.73
12.0
--M2
.73
12.0
----M3
.73
12.0
----M4
10.3
168.8
----M5
10.3
168.8
----3WD
20.6
337.6
----V1
4.88
80
----R1
--2400
166
------R2
150
10
-R4
--100
7
-R5
--1000
69
---
Hydraulic Schematics
Greensmaster 3250--D
Greensmaster 3250--D
Page 4 -- 11
Hydraulic System (Rev. I)
OPTIONAL 3WD
TRACTION
WHEEL MOTOR
Hydraulic
System
All solenoids are shown as
de--energized
Greensmaster 3250--D
Hydraulic Schematic
Serial Number From 230000000
To 230001500
Hydraulic System (Rev. I)
Page 4 -- 12
Greensmaster 3250--D
OPTIONAL 3WD
TRACTION
WHEEL MOTOR
NOTE: MANIFOLD
BACKLAP AND REEL
SPEED CONTROL VALVES
ARE INCLUDED ON
SERIAL NUBMERS
ABOVE 240000000
All solenoids are shown as
de--energized
Greensmaster 3250--D
Hydraulic Schematic
Serial Number From 230001501
To 260999999
Greensmaster 3250--D
Page 4 -- 13
Hydraulic System (Rev. I)
Hydraulic
System
All solenoids are shown as
de--energized
Greensmaster 3250--D
Hydraulic Schematic
Serial Number Over 270000000
OPTIONAL 3WD
TRACTION
WHEEL MOTOR
Hydraulic System (Rev. I)
Page 4 -- 14
P3
HYDROSTAT
1500 RPM LOW IDLE
2750 RPM HIGH IDLE
R4
BY--PASS
VALVE
OPTIONAL 3WD
TRACTION
WHEEL MOTOR
M4
M5
TRACTION WHEEL MOTORS
R5
OIL
COOLER
(OPTIONAL KIT)
ENGINE
RPM
OIL
FILTER
T
S1
P1
P1
R1
LC1
O1
RD1
M1
S2
P2
S3
OPTIONAL
VALVES
PT ST
MB
GEAR PUMP
P2
FC1
MA
M2
M3
REEL MOTORS
PB
T
P
V1
MANIFOLD BLOCK
R2
S4
L2A
L2B
L1B
L3A
L3B
L
R
High Pressure
Low Pressure (Charge)
Return or Suction
Flow
Greensmaster 3250--D
Traction Forward
FLOW
CONTROL
VALVE
RAISE
LOWER
#1 LIFT CYLINDERS
STEERING
CONTROL
VALVE
#2
#3
Schematic For Machine With
Serial Number Under 220999999
Shown.
All solenoids are shown as
de--energized.
Hydraulic Flow Diagrams
Greensmaster 3250--D
Traction Forward and Reverse
Forward
Reverse
The hydrostat (P3) is driven directly by the engine. The
traction circuit of the hydraulic system acts essentially
as a closed loop. Taking its suction directly from the return side of the wheel motors of the traction circuit, the
hydrostat supplies oil flow to the wheel motors through
the supply side of the traction circuit.
The traction circuit operates essentially the same in reverse as it does in the forward direction. However, the
flow through the circuit is reversed.
Oil flowing out of the wheel motors returns to the top port
of the hydrostat and is continuously pumped out the bottom port.
Hydraulic oil is supplied to the traction circuit from the
gear pump (P2) though the steering control valve and
back through the charge circuit check valves. This oil replaces oil losses from flow through the internal case
drain, internal bleed valve, and small amounts of leakage. Charge circuit pressure is maintained by the
charge relief valve (R4) that is attached to the hydrostat
back plate.
Oil flowing out of the wheel motors returns to the bottom
port of the hydrostat and is continuously pumped out the
bottom port.
The charge circuit functions the same in reverse as it did
in the forward direction.
Traction Circuit Cooling
The traction circuit is cooled by a bleed off circuit in the
hydrostat. The bleed off circuit includes an internal bleed
valve which allows about 1 GPM of hydraulic oil to pass
from the reverse side of the hydrostat while operating
the traction unit in the forward direction. The internal
bleed valve closes when operating the traction in the reverse direction.
Note: The bleed valve threads into the hydrostat back
plate. Access to the bleed valve requires removal of the
back plate from the hydrostat.
Greensmaster 3250--D
Page 4 -- 15
Hydraulic System (Rev. I)
Hydraulic
System
With the engine running and traction pedal in the neutral
position, the hydrostat supplies no flow to the wheel motors. When the traction pedal is pressed to the forward
position, the linkage from the pedal positions the swash
plate in the hydrostat so oil flows out the bottom port of
the pump. Oil flow out of the bottom port goes to the
wheel motors and turns them in the forward direction.
With the engine running and traction pedal in the neutral
position, the hydrostat supplies no flow to the wheel motors. When the traction pedal is pressed to the reverse
position, the linkage from the pedal positions the swash
plate in the hydrostat so oil flows out the top port of the
pump. Oil flow out of the top port goes to the wheel motors and turns them in the reverse direction.
Hydraulic System (Rev. I)
Page 4 -- 16
Greensmaster 3250--D
P3
HYDROSTAT
1500 RPM LOW IDLE
2750 RPM HIGH IDLE
R4
BY--PASS
VALVE
OPTIONAL 3WD
TRACTION
WHEEL MOTOR
M4
M5
TRACTION WHEEL MOTORS
R5
OIL
COOLER
(OPTIONAL KIT)
ENGINE
RPM
OIL
FILTER
T
S1
P1
P1
R1
LC1
O1
RD1
M1
S2
P2
S3
OPTIONAL
VALVES
PT ST
MB
REEL MOTORS
GEAR PUMP
P2
FC1
MA
M2
M3
PB
T
P
V1
MANIFOLD BLOCK
R2
S4
L2A
L2B
L1B
L3A
L3B
L
R
High Pressure
Low Pressure (Charge)
Return or Suction
Flow
Greensmaster 3250--D
Raise Cutting Units
FLOW
CONTROL
VALVE
RAISE
LOWER
#1 LIFT CYLINDERS
STEERING
CONTROL
VALVE
#2
#3
Schematic For Machine With Serial Number
Under 220999999 Shown.
Solenoids S2 and S3 are shown in the energized position.
All other solenoids are shown as de--energized.
Raise and Lower Cutting Units (Serial Number Under 260999999)
The gear pump (P2) is directly coupled to the hydrostat
through gear pump (P1). It supplies hydraulic pressure
for raising and lowering the cutting units, for the steering
circuit, and for maintaining 100 to 150 PSI (6.9 to 10.3
bar) to the low pressure side of the traction circuit
(charge pressure). The gear pump (P2) takes its suction
from the hydraulic reservoir. Maximum circuit pressure
is limited by relief valve (R5).
Lower Cutting Units
During conditions of not lifting or lowering cutting units,
flow from the gear pump is by--passed through the steering control valve and solenoid valve (S2) directly to the
hydrostat and the charge relief valve (R4). Flow then returns to the hydraulic reservoir.
When the cutting units are to be lowered, solenoid valve
(S2) is energized and blocks flow directly to the hydrostat. Flow is directed to de--energized solenoid valve
(S3), which directs flow to energized solenoid valve (S4)
and the lift cylinders. Hydraulic pressure against the cylinder pistons moves their shafts causing the cutting
units to lower. At the same time, the pistons push the hydraulic fluid out of the lift cylinders and back through solenoid valves (S4 and S3) to the hydrostat. Flow into the
flow control valve is slowed by the variable orifice to allow the rear cutting unit to lower after the front units.
When the cutting units are to be raised, solenoid valve
(S2) is energized and blocks flow directly to the hydrostat. Flow is directed to energized solenoid valve (S3),
which directs flow to de--energized solenoid valve (S4)
and the lift cylinders. Hydraulic pressure against the cylinder pistons moves their shafts causing the cutting
units to raise. At the same time, the pistons push the hydraulic fluid out of the lift cylinders and back through solenoid valves (S4 and S3) to the hydrostat.
When the solenoid valves de--energize, spring action
returns the valves to their original position and by-passes flow back to the hydrostat stopping lift cylinder
movement. The lift cylinder position is locked in place
since there is no complete circuit of flow to and from the
lift cylinders.
To control pressure while lowering cutting units, system
is equipped with adjustable relief valve (R2) in the hydraulic manifold.
When the solenoid valves de--energize, spring action
returns the valves to their original position and by-passes flow back to the hydrostat stopping lift cylinder
movement.
Note: On traction units with serial numbers from
230000601 to 260999999, solenoid valve (S6) is energized when the cutting units are raised. This forces the
return flow from the reel motors through the .125” orifice,
putting back pressure on the reel circuit, and stopping
the reels from rotating.
Greensmaster 3250--D
Page 4 -- 17
Hydraulic System (Rev. I)
Hydraulic
System
Raise Cutting Units
Circuit operation for lowering the lift cylinders is similar
to raising them. However, the solenoid valve (S3) remains de--energized and in the down position and solenoid valve (S4) is energized and shifts down. Flow is
reversed to and from the lift cylinders, thus moving the
cutting units down.
Hydraulic System (Rev. I)
Page 4 -- 18
Greensmaster 3250--D
S1R1
(NOT ENERGIZED)
(ENERGIZED)
(ENERGIZED)
(NOT ENERGIZED)
High Pressure
Low Pressure (Charge)
Return or Suction
Flow
Greensmaster 3250--D
Raise Cutting Units
OPTIONAL 3WD
TRACTION
WHEEL MOTOR
Schematic For Machine With Serial Number
Above 270000000 Shown.
Solenoids S2 and S3 are shown in the energized position.
All other solenoids are shown as de--energized.
Raise and Lower Cutting Units (Serial Number Above 270000000)
During cutting unit hold (not raising or lowering) conditions, flow from the gear pump (P2) is by--passed
through the steering control valve and de--energized solenoid valve (S2) directly to the hydrostat and the charge
relief valve (R4). Flow then returns to the hydraulic reservoir.
Raise Cutting Units
When the cutting units are to be raised, solenoid valve
(S2) is energized and blocks flow directly to the hydrostat. Flow is directed to energized solenoid valve (S3),
which directs flow to de--energized solenoid valve (S4)
and the lift cylinders. Hydraulic pressure against the cylinder pistons moves their shafts causing the cutting
units to raise. At the same time, the pistons push the hydraulic fluid out of the lift cylinders and back through energized solenoid valve (S3) to the hydrostat. Raise
speed for the front cutting units is controlled by a .055
orifice. A .055 orifice in the return line for the center cutting unit allows a slight delay in raising that cutting unit.
Lower Cutting Units
Circuit operation for lowering the lift cylinders is similar
to raising them. However, the solenoid valve (S3) remains de--energized and solenoid valve (S4) is energized. Flow is reversed to and from the lift cylinders,
lowering the cutting units.
When the cutting units are to be lowered, solenoid valve
(S2) is energized and blocks flow directly to the hydrostat. Flow is directed to de--energized solenoid valve
(S3), which directs flow to the lift cylinders. Hydraulic
pressure against the cylinder pistons moves their shafts
causing the cutting units to lower. At the same time, the
pistons push the hydraulic fluid out of the lift cylinders to
energized solenoid valve (S4). Flow continues back
through solenoid valves (S3) to the hydrostat. Lower
speed for the front cutting units is controlled by the .055
orifice. A .055 orifice and adjustable flow control valve
for the center cutting unit allows a slight delay in lowering
that cutting unit.
To control pressure while lowering the cutting units, the
system is equipped with adjustable relief valve (R2) in
the hydraulic manifold.
When solenoid valves (S2) and (S4) de--energize,
spring action returns the valves to their original position
and by--passes flow back to the hydrostat stopping lift
cylinder movement.
When solenoid valves (S2) and (S3) de--energize,
spring action returns the valves to their original position
and by--passes flow back to the hydrostat stopping lift
cylinder movement. The lift cylinder position is locked in
place since there is no complete circuit of flow to and
from the lift cylinders.
Greensmaster 3250--D
Page 4 -- 19
Hydraulic System (Rev. I)
Hydraulic
System
The gear pump (P2) is directly coupled to the hydrostat
through gear pump (P1). It supplies hydraulic pressure
for raising and lowering the cutting units, for the steering
circuit and for maintaining 100 to 150 PSI (6.9 to 10.0
bar) to the low pressure side of the traction circuit
(charge pressure). The gear pump (P2) takes its suction
from the hydraulic reservoir. Maximum circuit pressure
is limited by relief valve (R5) which is located in the
steering control valve.
Hydraulic System (Rev. I)
Page 4 -- 20
Greensmaster 3250--D
P3
HYDROSTAT
1500 RPM LOW IDLE
2750 RPM HIGH IDLE
R4
BY--PASS
VALVE
OPTIONAL 3WD
TRACTION
WHEEL MOTOR
M4
M5
TRACTION WHEEL MOTORS
R5
OIL
COOLER
(OPTIONAL KIT)
ENGINE
RPM
OIL
FILTER
T
S1
P1
P1
R1
LC1
O1
RD1
M1
S2
P2
S3
OPTIONAL
VALVES
PT ST
MB
GEAR PUMP
P2
FC1
MA
M2
M3
REEL MOTORS
PB
T
P
V1
MANIFOLD BLOCK
R2
S4
L2A
L2B
L1B
L3A
L3B
L
High Pressure
Low Pressure (Charge)
Return or Suction
Flow
Greensmaster 3250--D
Mow
FLOW
CONTROL
VALVE
RAISE
LOWER
#1 LIFT CYLINDERS
R
STEERING
CONTROL
VALVE
#2
#3
Schematic For Machine With Serial Number
Under 220999999 Shown.
Solenoid S1 is shown in the energized postion.
All other solenoids are shown as de--energized.
Mow and Backlap (Serial Number Under 260999999)
With the engine running and the Functional Control and
Raise/Lower/Mow levers positioned so the reels will
not turn (see Operator’s Manual), solenoid valve (S1) is
de--energized. S1 by--passes flow from the gear pump
(P1) directly to the hydraulic reservoir.
Mow
With the engine running and the Functional Control and
Raise/Lower/Mow levers positioned so the reels will
turn (see Operator’s Manual), solenoid valve (S1) is energized. Flow is diverted to the reel motors. Gear pump
(P1) flow is routed out manifold port (MA), and to the reel
motors that are connected in series. Oil flows through
the left (M2), right (M3), and then rear reel motor (M1)
as it turns the motors in the mow direction. The oil then
returns through the manifold block, oil filter and then to
the reservoir.
Note: On traction units with serial numbers from
230000601 to 260999999, solenoid valve (S6) is energized when the cutting units are raised. This forces the
return flow from the reel motors through the .125” orifice,
putting back pressure on the reel circuit, and stopping
the reels from rotating.
Greensmaster 3250--D
On units with the optional backlap kit installed, flow
through the manifold block is different. Oil flow from port
(P1) flows through the 11 position reel speed control
valve (FC1). Flow across the speed control valve is
pressure compensated by the logic cartridge valve
(LC1). The logic cartridge valve maintains a pressure
differential of 75 PSI (5.2 bar) across the speed control
valve. Any excess flow above what the speed control
valve is set for is by--passed to the reservoir through the
logic cartridge valve. With the backlap valve (RD1) in the
mow position, oil flows through the valve, out port (MA),
and to the reel motors that are connected in series.
Oil flows through the left (M2), right (M3), and then rear
reel motor (M1) as it turns the motors in the mow direction. The oil then returns through the manifold block and
oil filter and then to the reservoir.
Backlap
On machines with backlap capabilities, backlapping operation is the same as mowing operation, except for the
position of the backlap valve (RD1). When the backlap
valve is in the backlap position, oil flows through the
rear (M1), right (M3), and then left (M2) reel motor as it
turns the motors in the backlap direction.
Page 4 -- 21
Hydraulic System (Rev. I)
Hydraulic
System
The gear pump (P1) is directly coupled to the the hydrostat which is driven directly by the engine. Taking its suction directly from the hydraulic reservoir, the gear pump
(P1) supplies oil flow to the hydraulic manifold block and
to the cutting reel motors.
Hydraulic System (Rev. I)
Page 4 -- 22
Greensmaster 3250--D
S1R1
(ENERGIZED)
High Pressure
Low Pressure (Charge)
Return or Suction
Flow
Greensmaster 3250--D
Mow
OPTIONAL 3WD
TRACTION
WHEEL MOTOR
Schematic For Machine With Serial Number
Above 270000000 Shown.
Solenoid S1R1 is shown in the energized position.
All other solenoids are shown as de--energized.
Mow and Backlap (Serial Number Above 270000000)
With the engine running and the Functional Control and
Raise/Lower/Mow levers positioned so the reels will
not turn (see Operator’s Manual), solenoid relief valve
(S1R1) in the hydraulic manifold is de--energized. The
de--energized (S1R1) by--passes flow from the gear
pump (P1) to the oil filter and hydraulic reservoir. Additionally, manifold pressure reducing valve (PRV) will remain seated to prevent the reel motors (and reels) from
rotating.
Oil flow from manifold port (P1) flows through the reel
speed control valve (FC1). Flow across the speed control valve is pressure compensated by the logic cartridge
valve (EP). The logic cartridge valve maintains a pressure differential of 75 PSI (5.2 bar) across the speed
control valve. Any excess flow above the speed control
valve setting is by--passed to the reservoir through the
logic cartridge valve. With the backlap valve (MR) in the
mow position, oil flows through the backlap valve, out
manifold port (MA), and to the reel motors that are connected in series. Oil flows through the left (M2), right
(M3), and then rear reel motor (M1) as it turns the motors
in the mow direction.
When in the mow position, manifold pressure reducing
valve (PRV) will shift allowing oil to return to the reservoir
through the manifold block and oil filter.
Mow
Backlap
With the engine running and the Functional Control and
Raise/Lower/Mow levers positioned so the reels will
turn (see Operator’s Manual), solenoid relief valve
(S1R1) is energized. In the energized position, this
valve directs oil flow to the reel motors and also functions as the mow circuit relief valve.
Backlapping operation is the same as mowing operation, except for the position of the backlap valve (MR).
When the backlap valve (MR) is in the backlap position,
oil flows through the rear (M1), right (M3), and then left
(M2) reel motor as it turns the motors in the backlap
direction.
Greensmaster 3250--D
Page 4 -- 23
Hydraulic System (Rev. I)
Hydraulic
System
The gear pump (P1) is directly coupled to the hydrostat
which is driven directly by the engine. Taking its suction
directly from the hydraulic reservoir, the gear pump (P1)
supplies oil flow to the hydraulic manifold block and to
the cutting reel motors. Maximum circuit pressure is limited by solenoid relief valve (S1R1) which is located in
the hydraulic manifold.
Hydraulic System (Rev. I)
Page 4 -- 24
Greensmaster 3250--D
P3
HYDROSTAT
1500 RPM LOW IDLE
2750 RPM HIGH IDLE
R4
BY--PASS
VALVE
OPTIONAL 3WD
TRACTION
WHEEL MOTOR
M4
M5
TRACTION WHEEL MOTORS
R5
OIL
COOLER
(OPTIONAL KIT)
ENGINE
RPM
OIL
FILTER
T
S1
P1
P1
R1
LC1
O1
RD1
M1
S2
P2
S3
OPTIONAL
VALVES
PT ST
MB
GEAR PUMP
P2
FC1
MA
M2
M3
REEL MOTORS
PB
T
P
V1
MANIFOLD BLOCK
R2
S4
#2
#3
STEERING
CONTROL
VALVE
SPOOL VALVE
L2A
L2B
L1B
L3A
L3B
L
R
High Pressure
Low Pressure (Charge)
Return or Suction
Flow
Greensmaster 3250--D
Right Turn
FLOW
CONTROL
VALVE
RAISE
LOWER
#1 LIFT CYLINDERS
Schematic For Machine With Serial Number
Under 220999999 Shown.
All solenoids are shown as de--energized.
Spool valve is positioned for a right turn.
Right and Left Turn
With the steering wheel in the neutral position (rear
wheel positioned straight ahead) and the engine running, the spool valve is in the center position. Flow enters the steering control valve at Port (P) and goes
through the spool valve, by--passing the steering cylinder. Flow leaves the control valve out port (PB) and continues through solenoid valve (S2) to the hydrostat.
Right Turn
When a right turn is made with the engine running, the
turning of the steering wheel positions the spool valve so
that flow goes through the top of the spool. Flow entering
the steering control valve at Port (P) goes through the
spool and is routed to two places. First, most of the flow
through the valve is by--passed out port (PB) back
through solenoid valve (S2) to the hydrostat. Second,
the remainder of the flow is drawn through rotary meter
(V1) and out port (R). Pressure moves the piston in the
Greensmaster 3250--D
direction for a right turn. The rotary meter ensures that
the oil flow to the cylinder is proportional to the amount
of the turning on the steering wheel. Fluid leaving the
cylinder flows back through the spool valve then out port
(T) and to the hydrostat.
The steering wheel and steering control valve return to
the neutral position when turning is complete.
Left Turn
When a left turn is made with the engine running, the
turning of the steering wheel positions the spool valve so
that flow goes through the bottom of the spool. Flow entering the steering control valve at Port (P) goes through
the spool and is routed to two places. First, most of the
flow through the valve is by--passed out port (PB) back
through solenoid valve (S2) to the hydrostat. Second,
the remainder of the flow is drawn through rotary meter
(V1) and out port (L). Pressure moves the piston in the
direction for a left turn. The rotary meter ensures that the
oil flow to the cylinder is proportional to the amount of the
turning on the steering wheel. Fluid leaving the cylinder
flows back through the spool valve then out port (T) and
to the hydrostat.
The steering wheel and steering control valve return to
the neutral position when turning is complete.
Page 4 -- 25
Hydraulic System (Rev. I)
Hydraulic
System
The gear pump (P2) is directly coupled to the hydrostat
through gear pump (P1). It supplies hydraulic pressure
to the steering control valve for turning the rear wheel,
for raising and lowering the cutting units, and for maintaining 100 to 150 PSI (6.9 to 10.3 Bar) to the low pressure side of the traction circuit (charge pressure). The
gear pump (P2) takes its suction from the hydraulic reservoir. Maximum circuit pressure is limited by relief valve
(R5).
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.
Contains one each: 1000 PSI (70 Bar), 5000 PSI (350
Bar) and 10000 PSI (700 Bar) gauges. Use gauges as
recommended in Testing section of this chapter.
Figure 10
Hydraulic Tester (Pressure and Flow) -- TOR214678
This tester requires O--ring face seal (ORFS) adapter fittings for use on this machine. Use hydraulic tester as
recommended in Testing section of this chapter.
1. INLET HOSE: Hose connected from the system circuit to the inlet side of the hydraulic tester.
2. LOAD VALVE: A simulated working load is created
in the circuit by turning the valve to restrict flow.
3. PRESSURE GAUGE: 0 to 5000 PSI gauge to provide operating circuit pressure.
4. FLOW METER: This meter measures actual oil flow
in the operating circuit with a gauge rated at 15 GPM.
Figure 11
5. OUTLET HOSE: A hose from the outlet side of the
hydraulic tester connects to the hydraulic system circuit.
O--ring Kit -- 16--3799
The kit includes O--rings in a variety of sizes for face seal
and port seal hydraulic connections. It is recommended
that O--rings be replaced whenever a hydraulic connection is loosened.
Figure 12
Hydraulic System (Rev. I)
Page 4 -- 26
Greensmaster 3250--D
Hydraulic Test Fitting Kit -- TOR4079
This kit includes a variety of O--ring face seal fittings to
enable you to connect test gauges into the system.
TORO TEST FITTING KIT (NO. TOR4079)
The kit includes: tee’s, unions, reducers, plugs, caps,
and male test fittings.
Figure 13
Measuring Container -- TOR4077
Hydraulic
System
Use this container for doing hydraulic motor efficiency
testing (motors with case drain lines only). Measure efficiency of a hydraulic motor by restricting the outlet flow
from the motor and measuring leakage from the case
drain line while the motor is pressurized by the hydraulic
system.
Figure 14
Wheel Hub Puller -- TOR4097
The wheel hub puller allows safe removal of the wheel
hub from the shaft of wheel motors.
Figure 15
Greensmaster 3250--D
Page 4 -- 27
Hydraulic System (Rev. I)
Troubleshooting
The charts that follow contain information to assist in
troubleshooting. There may possibly be more than one
cause for a machine malfunction.
Refer to the Testing section of this Chapter for precautions and specific test procedures.
Problem
Possible Cause
Hydraulic oil leaks from system.
Fitting(s), hose(s), or tube(s) are loose or damaged.
O--ring(s) or seal(s) are missing or damaged.
Hydraulic fluid foams.
Oil level in reservoir is low.
Hydraulic system has wrong type of oil.
One of the pump suction lines has an air leak.
Hydraulic system operates hot.
Oil level in reservoir is low, or inlet filter is loose or clogged.
Oil is contaminated or too light.
Parking brake is applied or brakes are incorrectly adjusted.
Hydrostat by--pass valve is open or defective.
Oil cooler (if installed) is damaged or plugged. By--pass relief is
stuck open or air flow is obstructed.
Working load of machine (e.g. use of verticutter) may require use of
oil cooler.
Charge pressure is low (see Charge Pressure Relief Valve (R4)
Pressure Test).
Wheel motor(s) or reel motor(s) are worn or damaged (see Wheel
Motor Efficiency and Reel Motor Case Drain Flow Tests).
Traction pump (P3) is worn or damaged (see Traction Drive Hydrostat (P3) Flow Test).
Neutral is difficult to find, or unit operates in one direction only.
External traction control linkage is misadjusted, disconnected, binding, or damaged.
Traction pump (P3) is worn or damaged (see Traction Drive Hydrostat (P3) Flow Test).
Traction response is sluggish.
Hydraulic oil is very cold.
Parking brake is applied or brakes are incorrectly adjusted.
Hydrostat by--pass valve is open or defective.
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).
Hydraulic System (Rev. I)
Page 4 -- 28
Greensmaster 3250--D
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).
Wheel motor will not turn.
Brakes are binding.
Key on wheel motor shaft is sheared or missing.
Wheel motor is damaged.
Wheel motor will not hold load in
neutral.
Make up fluid from charge pump is not available.
Reel motor drive pump is noisy (cavitation).
Reservoir oil level is low.
Hydrostat ball check valves are damaged.
Hydraulic pump suction line is restricted.
Reels will not turn.
Solenoid valve S1 is stuck open.
An electrical problem exists (see Chapter 5 -- Electrical System).
Relief valve R1 is stuck open (see Mow Circuit Relief Valve (R1)
Pressure Test).
LC1 logic valve (when Backlap Kit is installed) is stuck open.
Gear pump P1 is damaged (see Gear Pump (P1) Flow Test).
Reel speed is erratic.
Cutting Unit problem exists (see Cutting Unit Chapter).
Hydraulic manifold reel circuit cartridge is leaking or damaged.
Hydraulic manifold orifice is plugged.
Reel speed is low.
Cutting Unit problem exists (see Cutting Unit Chapter).
Hydraulic manifold reel circuit cartridge is leaking or damaged.
Excessive internal wear in reel motor exists (see Reel Motor Case
Drain Flow Test).
Greensmaster 3250--D
Page 4 -- 29
Hydraulic System (Rev. I)
Hydraulic
System
Hydraulic pump suction line has an air leak.
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) Pressure Test).
Implement relief valve (R5) is leaking or damaged (see Implement
Relief Valve (R5) Pressure Test).
Solenoid valve (S2) in hydraulic manifold is leaking or damaged.
Relief valve (R2) is stuck leaking or damaged (see Lower Cutting
Units Relief Valve (R2) Pressure Test).
Lift cylinders leak internally.
Spool in steering control valve is hung up (see Steering Control
Valve Test).
Gear pump (P2) is damaged (see Gear Pump (P2) Flow Test).
Cutting units raise, but will not stay
up.
Hydraulic manifold solenoid valve (S4) leaks.
Steering wheel is hard to turn.
Steering control valve has insufficient oil flow.
Lift cylinders leak internally.
Emergency steering ball in steering control valve is missing or
damaged.
Regular adjustments to steering
wheel are necessary because of difficulty of driving in a straight line.
Leaf springs in steering control valve are worn or broken.
Gear wheel set in steering control valve is worn.
Steering cylinder is seized or its piston seals are worn (see Steering Control Valve Test).
Steering wheel will not return to the
neutral position.
Spool and sleeve are sticking to steering control housing assembly
(see Steering Control Valve Test).
Steering wheel can turn on its own.
Leaf springs in steering control valve are broken or stuck.
Spool and sleeve are sticking to steering control housing assembly
(see Steering Control Valve Test).
Backlash results when turning steering wheel.
Cardan shaft fork in steering control valve is worn or broken.
Leaf springs in steering control valve are worn or broken.
Splines on the steering column are worn.
Rear wheel shimmies when the
steering wheel is turned.
Hydraulic System (Rev. I)
Air is in the steering cylinder.
Mechanical connections to the wheel or wheel bearing are worn.
Page 4 -- 30
Greensmaster 3250--D
Problem
Possible Cause
The steering wheel can be turned
without the rear wheel turning.
The steering cylinder is worn.
Steering response is too slow and
heavy when trying to turn quickly.
Oil supply to the steering control valve is insufficient.
Turning steering wheel turns machine in the opposite direction.
Hoses to the steering cylinder are reversed.
Steering force (possibly to one side
only) is insufficient.
Hydraulic flow to steering control valve is low.
The gear set in the steering control valve is worn.
Hydraulic
System
Steering relief valve (R5) is leaking or damaged.
Greensmaster 3250--D
Page 4 -- 31
Hydraulic System (Rev. I)
Testing
The most effective method for isolating problems in the
hydraulic system is by using hydraulic test equipment
such as pressure gauges and flow meters in the circuits
during various operational checks (see the Special
Tools section in this Chapter).
1. Clean machine thoroughly before disconnecting or
disassembling any hydraulic components. Always keep
in mind the need for cleanliness when working on hydraulic equipment. Contamination will cause excessive
wear of components.
Before Performing Hydraulic Tests
2. Put metal caps or plugs on any hydraulic lines left
open or exposed during testing or removal of components.
IMPORTANT: All obvious areas such as oil supply,
filter, binding linkages, loose fasteners, improper
adjustments, solenoid valve operation, or electrical
connections/circuits must be checked before assuming that a hydraulic component is the source of
the problem.
Precautions for Hydraulic Testing
CAUTION
Failure to use gauges with recommended pressure (psi) rating as listed in test procedures
could result in damage to the gauge and possible
personal injury from leaking hot oil.
All testing should be performed by two (2)
people. One person should be in the seat to operate the machine, and the other should read and
record test results.
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the
ignition switch in OFF. Remove key from the ignition switch.
3. The engine must be in good operating condition.
Engine speed will affect test accuracy. Check pump
speed with a phototac when performing hydraulic tests.
4. The inlet and the outlet hoses must be properly connected and not reversed (tester with pressure and flow
capabilities) to prevent damage to the hydraulic tester or
components.
5. When using tester with pressure and flow capabilities, open load valve completely in the hydraulic tester
to minimize the possibility of damaging components.
6. Install fittings finger tight and far enough to make
sure that they are not cross--threaded before tightening
them with a wrench.
7. Position tester hoses to prevent rotating machine
parts from contacting and damaging the hoses or tester.
8. Check oil level in the hydraulic reservoir. After connecting test equipment, make sure tank is full.
9. Check control linkages for improper adjustment,
binding,or broken parts.
10. All hydraulic tests should be made with the hydraulic
oil at normal operating temperature.
WARNING
11. Record the results of all performed hydraulic tests.
Before disconnecting or performing any work on
the hydraulic system, all pressure in the system
must be relieved and all rotating machine parts
must be stopped. Stop engine; lower or support
attachments.
Hydraulic Testing
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Do not use hands to search for leaks;
use paper or cardboard. Hydraulic fluid escaping under pressure can have sufficient force to
penetrate the skin and cause serious injury. If
fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result
from such an injury.
2. Hydraulic system problems (e.g. low hydraulic oil
level, contaminated oil, incorrect engine speed) will affect the entire hydraulic system.
Hydraulic System (Rev. I)
1. Use the Hydraulic Schematic, Hydraulic Flow Diagrams, and the Troubleshooting section found in this
Chapter to assist in problem identification and solution.
3. For traction related problems (e.g. machine will not
go up an incline), consider performing the following hydraulic tests:
Charge Pressure Relief Valve (R4) Pressure Test
Wheel Motor Efficiency Test
Traction Drive Hydrostat (P3) Flow Test
Page 4 -- 32
Greensmaster 3250--D
5. For issues with the cutting system, consider performing the following hydraulic tests:
Mow Circuit Relief Valve (R1) Pressure Test
Reel Motor Case Drain Flow Test
Gear Pump (P1) Flow Test
Hydraulic
System
4. For problems with steering or lift/lower pressure,
consider performing the following hydraulic tests:
Charge Pressure Relief Valve (R4) Pressure Test
Lower Cutting Units Relief Valve (R2) Pressure Test
Implement Relief Valve (R5) Pressure Test
Gear Pump (P2) Flow Test
Steering Control Valve Test
Greensmaster 3250--D
Page 4 -- 33
Hydraulic System (Rev. I)
Traction Drive Hydrostat (P3) Flow Test (Using Tester with Flowmeter and Pressure
Gauge)
HOSE FROM
UPPER FITTING
M5
TRACTION WHEEL MOTORS
M4
OPTIONAL
REAR WHEEL
MOTOR
TESTER
3WD
DUMP
VALVE
R4
FROM GEAR PUMP (P2)
P3
High Pressure
TO HYDRAULIC
RESERVOIR
Hydraulic System (Rev. I)
HYDROSTAT
Low Pressure
Return or Suction
Flow
Page 4 -- 34
Greensmaster 3250--D
Procedure for Traction Drive Hydrostat (P3) Flow
Test
8. Start engine and move throttle to full speed (2750 +
50 RPM) position.
This test measures hydrostat pump output (flow). During this test, pump load is created at the flowmeter using
the adjustable load valve on the tester.
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten
(10) minutes.
2. Park machine on a level surface with the cutting
units lowered and off. Make sure engine is off. Make
sure the hydraulic tank is full.
The drive wheels will be off the ground and rotating during this test. Make sure machine is well
supported so it will not move and accidentally
fall to prevent injuring anyone near the machine.
9. Slowly push traction pedal into fully forward position.
10. Slowly close flow control valve until pressure gauge
reads 1000 PSI (69 bar).
Before continuing further, read and become familiar with Precautions for Hydraulic Testing.
3. Make sure that traction pedal is adjusted to the neutral position (see Traction Pedal in the Adjustments Section). Also, ensure that pump is at full stroke when
traction pedal is pushed into fully forward position.
4. Block up front wheels off the ground (also rear
wheel if machine is equipped with 3WD) to allow flow
through the traction circuit.
5. Disconnect hose from the upper hydraulic fitting on
the side of the hydrostat.
6. Install tester with pressure gauge and flow meter in
series with the pump and the disconnected hose. Make
sure flow control valve on the tester is fully open.
7. Make sure functional lever is in the transport position.
11. Observe flow gauge. TESTER READING should be
a minimum flow of 12.5 GPM. Record test results.
12. Release traction pedal, open control valve on tester,
and turn off machine.
13. If specifications are not met consider the following:
A. The traction pedal and/or traction speed may
need adjustment (see Traction Pedal in the Adjustments Section).
B. The hydrostat needs to be repaired or replaced
as necessary.
C. Make necessary repairs before performing additional tests.
14. If specifications are met, check wheel motor efficiency (see Wheel Motor Efficiency Test in this section).
15. If testing is complete, disconnect tester from pump
fitting and hose. Reconnect hose to pump fitting.
Page 4 -- 35 Rev. J
Hydraulic System (Rev. I)
Hydraulic
System
CAUTION
Greensmaster 3250--D
CAUTION
Wheel Motor Efficiency Test (Using Tester with Flowmeter and Pressure Gauge)
HOSE FROM
UPPER FITTING
M5
TRACTION WHEEL MOTORS
M4
CAP
CAP
OPTIONAL
REAR WHEEL (3WD)
MOTOR
TESTER
3WD
DUMP
VALVE
R4
FROM GEAR PUMP
P3
High Pressure
TO HYDRAULIC
RESERVOIR
HYDROSTAT
Low Pressure
Return or Suction
Flow
Hydraulic System (Rev. I)
Page 4 -- 36
Rev. J
Greensmaster 3250--D
Note: Over a period of time, a wheel motor can wear
internally. A worn motor may by--pass oil to its case drain
causing the motor to be less efficient. Eventually,
enough oil loss will cause the wheel motor to stall under
heavy load conditions. Continued operation with a worn,
inefficient motor can generate excessive heat, cause
damage to seals and other components in the hydraulic
system, and affect overall machine performance.
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten
(10) minutes. Make sure the hydraulic tank is full.
2. Park machine on a level surface with the cutting
units lowered and off. Make sure engine is off and the
parking brake is engaged.
3. Read Precautions for Hydraulic Testing.
4. Make sure that traction pedal is adjusted to the neutral position (see Adjust Traction Drive for Neutral in the
Adjustments Section).
5. Attach a heavy chain to the rear of the machine
frame and an immovable object to prevent the machine
from moving during testing.
12. Slowly push traction pedal in forward direction until
1000 PSI (69 bar) is displayed on the tester pressure
gauge.
13. Wheel motor internal leakage will be shown on flow
meter in GPM. Flow should be less than 1.5 GPM for
the tested wheel motor.
14. Release traction pedal, rotate wheel being tested,
and retest. Testing of wheel motor leakage in three different wheel positions will provide most accurate test results.
15. Release traction pedal and shut engine off. Record
results of flow test.
16. If specification is not met, the tested wheel motor
needs to be repaired or replaced as necessary.
17. Test second front wheel motor. Reconnect hydraulic
lines to untested front wheel motor. Disconnect and cap
hydraulic lines to tested front wheel motor. Complete
steps 11 to 16 for the second front wheel motor.
18. If machine has 3 wheel drive, test rear wheel motor:
A. Both front wheel motors should have hydraulic
lines connected. Block up both front wheels off the
ground. Release parking brake so front wheels can
turn freely.
6. If machine has 3 wheel drive, block up the rear
wheel off the ground to allow flow through the rear wheel
motor.
B. Attach a heavy chain to the rear of the machine
frame and an immovable object to prevent the machine from moving during testing.
7. Chock front wheel being tested to prevent rotation
of the wheel. Make sure parking brake is on.
C. Position rear wheel on the ground and chock
rear wheel to prevent it from turning.
8. Disconnect hydraulic lines from front wheel motor
that is not being tested. Cap the disconnected hydraulic
lines and plug ports in wheel motor (see Special Tools).
9. Disconnect hose from the upper hydraulic fitting on
the side of the hydrostat.
10. Install tester with pressure gauge and flow meter in
series with the pump and the disconnected hose (same
tester connections as Traction Drive Hydrostat (P3)
Flow Test). Make sure the tester flow control valve is
fully open.
CAUTION
Use extreme caution when performing test. The
rear wheel will be trying to move the machine.
D. Complete steps 11 to 16.
19. Disconnect tester from hydraulic fitting and hose.
Reconnect hose to pump connection.
CAUTION
Use extreme caution when performing test. The
wheel being tested will be trying to move the machine.
11. Start engine and move throttle to full speed (2750 +
50 RPM).
Greensmaster 3250--D
Page 4 -- 37
Hydraulic System (Rev. I)
Hydraulic
System
Procedure for Wheel Motor Efficiency Test
Charge Relief Valve (R4) Pressure Test (Using Pressure Gauge)
M5
TRACTION WHEEL MOTORS
M4
OPTIONAL
REAR WHEEL
MOTOR
3WD
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
R4
TO STEERING
AND LIFT
CIRCUITS
R5
P3
ENGINE
RPM
P1
P2
HYDROSTAT
GEAR PUMP
High Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System (Rev. I)
Page 4 -- 38
Rev. J
Greensmaster 3250--D
Procedure for Charge Relief Valve (R4) Pressure
Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten
(10) minutes.
2. Park machine on a level surface with the cutting
units lowered. Make sure engine is off and the parking
brake is engaged. Make sure the hydraulic tank is full.
7. Shut off engine.
8. If specification is not met, remove hydrostat back
plate assembly that contains the charge relief valve (see
Piston Pump Service in the Service and Repairs section
of this chapter). Repair or replace relief valve components as necessary.
9. A dynamic charge pressure test can be performed
as follows:
A. With tester still connected, sit in the operator
seat, start the engine and release the parking brake.
CAUTION
B. Press the traction pedal to forward.
3. Disconnect hydraulic hose from the fitting in the
charge port of piston pump P3 (traction pump section).
Connect T--fitting and pressure gauge to the fitting and
hose connection.
4. Make sure that traction pedal and lift control are in
neutral and the parking brake is engaged.
5. Start engine and operate at full speed (2750 + 50
RPM).
6. Pressure gauge should read approximately 100 to
150 PSI (6.9 to 10.3 bar). Record test results.
Greensmaster 3250--D
C. While machine is moving, monitor the charge
pressure reading on the pressure gauge.
D. The charge pressure should drop no more than
15% from initial test reading (Step 7 above). A pressure drop of more than 15% indicates a traction circuit leak (e.g. a worn or damaged hydrostat and/or
wheel motor). Further testing of the traction circuit
should be completed (see Traction Drive Hydrostat
(P3) Flow and Wheel Motor Efficiency Tests in this
section).
10. When testing is complete, disconnect pressure
gauge and T--fitting from the pump fitting and hose. Reconnect hose to the pump fitting.
Page 4 -- 39 Rev. J
Hydraulic System (Rev. I)
Hydraulic
System
Before continuing further, read and become familiar with Precautions for Hydraulic Testing.
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
CIRCUIT
Hydraulic
System
TO STEERING AND
LIFT CIRCUITS
TESTER
FROM LIFT
CIRCUIT
TO TRACTION
CHARGE CIRCUIT
R5
P1
P2
ENGINE
RPM
SCHEMATIC FROM MACHINE
WITH SERIAL NUMBER
UNDER 220999999 SHOWN
GEAR PUMP
FROM HYDROSTAT
High Pressure
Low Pressure
Return or Suction
Flow
Procedure for Gear Pump (P2) Flow Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten
(10) minutes.
Hydraulic System (Rev. I)
2. Park machine on a level surface with the cutting
units lowered. Make sure engine is off and the parking
brake is engaged. Make sure the hydraulic tank is full.
Page 4 -- 40 Rev. J
Greensmaster 3250--D
5. Open control valve on tester and shut off engine.
CAUTION
Before continuing further, read and become familiar with Precautions for Hydraulic Testing.
Note: The implement relief valve (R5) is in series with
charge relief valve (R4). (R4) pressure will affect (R5)
pressure.
6. Implement relief valve (R5) pressure should be:
3. On gear pump (P2) (rear pump section), disconnect
the hydraulic hose from the discharge fitting on the bottom of the pump.
4. Install tester with pressure gauge and flow meter in
series with gear pump (P2) and the disconnected hose.
Make sure the flow control valve on the tester is fully
open.
5. Make sure that traction pedal and lift control are in
neutral and the parking brake is engaged.
6. Operate engine at full speed (2750 + 50 RPM).
7. Watch flow and pressure gauge carefully while
slowly closing the flow control valve on the tester until
the pressure gauge reads 800 PSI (55.2 bar).
8. Minimum flow gauge reading should be 3.1 GPM.
Record test results.
9. Open control valve on tester and shut off engine.
10. If specification is not met, check for restriction in the
pump intake line. If no restriction is found, repair or replace gear pump (P2).
Procedure for Implement Relief Valve (R5) Pressure
Test
CAUTION
Do not allow pressure to exceed 1400 PSI (82.8
bar).
1. Measure and record charge relief valve (R4) pressure (see Charge Relief Valve (R4) Pressure Test in this
section).
2. Use same tester connections as described in Gear
Pump (P2) Flow Test (see above). Fully open control
valve on the tester.
3. Start and run engine at full speed (2750 + 50 RPM).
4. Watch the pressure gauge on the tester and move
the lift lever to the raise position. Momentarily hold the
lift lever with the cutting units fully raised causing the relief valve (R5) to open. Record pressure at which the relief valve (R5) opens.
Greensmaster 3250--D
A. For machines with serial number under
220999999, relief valve (R5) pressure should be
900 to 1100 PSI (62 to 76 bar) higher than the
charge relief valve (R4) pressure (e.g. if the
charge relief valve pressure is 100 PSI (6.9 bar), the
implement relief valve (R5) pressure should be
1000 to 1200 PSI (69 to 83 bar)).
B. For machines with serial number over
230000000, relief valve (R5) pressure should be
1050 to 1250 PSI (73 to 86 bar) higher than the
charge relief valve (R4) pressure (e.g. if the
charge relief valve pressure is 100 PSI (6.9 bar), the
implement relief valve (R5) pressure should be
1150 to 1350 PSI (80 to 93 bar)).
7. If relief valve (R5) pressure is incorrect:
A. For machines with serial number under
220999999, adjust implement relief valve (see Adjust Implement Relief Valve (R5) in the Adjustments
section of this Chapter). Retest relief valve pressure
if adjustment is performed.
B. For machines with serial number over
230000000, inspect relief valve (R5) located in the
steering control valve (see Steering Control Valve
Service in the Service and Repairs section of this
Chapter). Clean relief valve or service steering control valve as needed.
IMPORTANT: Hold steering wheel at full lock only
long enough to get a system pressure reading.
8. Relief Valve (R5) is also activated by the steering
system. With tester still connected to gear pump P2,
start engine and watch the pressure gauge. Turn the
steering wheel completely in one direction and hold. Relief valve (R5) should open just after rear wheel gets to
the full lock position. Relief pressure measured with the
steering system should be similar to results in step 5.
Note: Lower Cutting Units Relief Valve (R2) Pressure
can be measured with tester positioned as described in
this check (see Lower Cutting Units Relief Valve (R2)
Pressure Test in this section).
9. After testing is complete, disconnect tester from the
pump and hose. Reconnect hose to the pump.
Page 4 -- 41 Rev. J
Hydraulic System (Rev. I)
Lower Cutting Units Relief Valve (R2) Pressure Test (Using Pressure Gauge)
SCHEMATIC FROM MACHINE
WITH SERIAL NUMBER
UNDER 220999999 SHOWN
TO AND FROM
REEL MOTORS
MA
MB
OPTIONAL
RD1
VALVES
S4
O1
FC1
R2
LC1
S3
L3B
#3
L3A
S2
#1
L1B
R1
S1
LIFT CYLINDERS
LOWER
RAISE
L2B
T
#2
L2A
OIL
FILTER
FLOW
CONTROL
VALVE
MANIFOLD BLOCK
P1
PT ST
P2
P
V1
R5
T
OIL
COOLER
(OPTIONAL KIT)
R
TESTER
TO TRACTION
CHARGE
CIRCUIT
L
ENGINE
RPM
P1
PB
P2
STEERING
CONTROL
VALVE
GEAR PUMP
FROM HYDROSTAT
High Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System (Rev. I)
Page 4 -- 42
Rev. J
Greensmaster 3250--D
Procedure for Lower Cutting Units Relief Valve (R2)
Pressure Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten
(10) minutes.
2. Park machine on a level surface with the cutting
units lowered. Make sure engine is off and the parking
brake is engaged. Make sure the hydraulic tank is full.
CAUTION
Before continuing further, read and become familiar with Precautions for Hydraulic Testing.
3. Measure and record charge relief valve (R4) pressure (see Charge Relief Valve (R4) Pressure Test in this
section).
B. For machines with serial number over
230000000, relief pressure should be 400 PSI (27.6
bar) higher than charge relief (R4) pressure (e.g.
if charge relief valve pressure is 100 PSI (6.9 bar),
the lower relief valve (R2) pressure should be
approximately 500 PSI (34.5 bar)).
8. If relief valve (R2) pressure is incorrect, adjust relief
valve (R2) (see Adjust Manifold Relief Valves in the Adjustments section of this Chapter). Retest relief valve
pressure if adjustment is performed.
9. After testing is complete, disconnect tester from
gear pump and hose. Reconnect hose to hydraulic fitting on pump.
FRONT
S1
MANIFOLD FROM MACHINE
WITH SERIAL NUMBER
UNDER 270000000 SHOWN
S3
4. Use same tester connections as described in Gear
Pump (P2) Flow Test. Fully open control valve on the
tester.
Note: The LOWER function is electrically timed and
automatically turns off after approximately six (6) seconds.
6. Watch pressure gauge carefully while moving the
Raise/Lower -- Mow Control lever to LOWER and note
pressure that relief valve opens. Shut off engine and record test results.
S4
S2
Hydraulic
System
5. Start engine and move throttle to full speed (2750 +
50 RPM). Make sure that cutting units are fully lowered
and engage the cutting units.
RELIEF
VALVE (R2)
Figure 16
S2
S3
FRONT
Note: While performing this hydraulic test, if relief
pressure cannot be determined within the LOWER function six (6) second timeframe, repeat this test procedure.
Note: The lower cutting units relief valve (R2) is in series with charge relief valve (R4). (R4) pressure will affect (R2) pressure.
S4
S1R1
7. The lower cutting units relief pressure (R4) should
be:
A. For machines with serial number under
220999999, relief pressure should be 150 PSI (10.3
bar) higher than charge relief (R4) pressure (e.g.
if charge relief valve pressure is 100 PSI (6.9 bar),
the lower relief valve (R2) pressure should be
approximately 250 PSI (17.2 bar)).
Greensmaster 3250--D
MANIFOLD FROM MACHINE
WITH SERIAL NUMBER
OVER 270000000 SHOWN
Page 4 -- 43 Rev. J
RELIEF
VALVE (R2)
Figure 17
Hydraulic System (Rev. I)
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
CIRCUIT
TESTER
TO STEERING AND
LIFT CIRCUITS
TO TRACTION
CHARGE CIRCUIT
R5
P1
P2
ENGINE
RPM
GEAR PUMP
High Pressure
FROM HYDROSTAT
Low Pressure
Return or Suction
Flow
Hydraulic System (Rev. I)
Page 4 -- 44
Greensmaster 3250--D
Procedure for Gear Pump (P1) Flow Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten
(10) minutes.
2. Park machine on a level surface with the cutting
units lowered. Make sure engine is off and the parking
brake is engaged. Make sure the hydraulic tank is full.
CAUTION
Do not engage the cutting units when performing
this test.
7. Start engine and move throttle to full speed (2750 +
50 RPM).
8. Watch pressure gauge carefully while slowly closing the flow control valve on the tester until 2000 PSI
(138 bar) is obtained.
CAUTION
Before continuing further, read and become familiar with Precautions for Hydraulic Testing.
3. On gear pump (P1) (reel drive), disconnect the hose
that leads to port P1 on the hydraulic manifold.
4. Install tester with pressure gauge and flow meter in
series with gear pump (P1) and the disconnected hose.
Make sure the flow control valve on the tester is fully
open.
5. If a backlap kit is installed on the machine, make
sure backlap knob on the manifold block is in the mow
position and reel speed is set to maximum.
9. Flow indication should be 5.4 GPM minimum. Record test results.
10. Open control valve on tester and shut off engine.
11. If flow was less than 5.4 GPM or a pressure of 2000
PSI (138 bar) cannot be obtained, check for restriction
in the pump intake line. If line is not restricted, remove
pump and repair or replace as necessary.
12. If testing is complete, disconnect tester from gear
pump and hose. Reconnect hose to the pump.
Greensmaster 3250--D
Page 4 -- 45 Rev. J
Hydraulic
System
6. Make sure tester load valve is fully open before
starting the engine.
Hydraulic System (Rev. I)
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
MA
MB
S4
RD1
OPTIONAL
VALVES
O1
R2
L3B
S3
FC1
LC1
L3A
S2
R1
L1B
S1
TO HYDRAULIC
RESERVOIR
TO AND FROM
LIFT CYLINDERS
L2B
T
L2A
P1
PT
ST
P2
MANIFOLD BLOCK
FROM STEERING
CIRCUIT
High Pressure
Low Pressure
FROM GEAR PUMP (P1)
Return or Suction
Flow
Hydraulic System (Rev. I)
Page 4 -- 46
Greensmaster 3250--D
Procedure for Mow Circuit Relief Valve (R1) Pressure Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten
(10) minutes.
10. On machines with serial number above 270000000,
system pressure should be from 2700 to 3300 PSI
(186.3 to 227.7 bar). Record test results.
A. If this specification is met, go to step 11.
B. If specification is not met, open control valve on
tester, shut off engine and remove solenoid relief
valve (S1R1) on manifold (Fig. 19). Clean or replace
valve (see Hydraulic Manifold Service (Serial Number Above 270000000) in the Service and Repairs
section of this chapter). Retest relief valve (R1)
pressure.
2. Park machine on a level surface with the cutting
units lowered. Make sure engine is off and the parking
brake is engaged. Make sure the hydraulic tank is full.
CAUTION
Before continuing further, read and become familiar with Precautions for Hydraulic Testing.
3. Disconnect hose connection on the bulkhead that
leads to the left reel motor.
4. Install tester with pressure gauge and flow meter in
series with the disconnected hose and bulkhead connection. Make sure the flow control valve on the tester is fully open.
11. Disengage cutting units. Open control valve on tester and shut off engine.
12. Disconnect tester from manifold and hose. Reconnect hose to the bulkhead connection.
13. Correctly readjust bedknife.
MANIFOLD FROM MACHINE
WITH SERIAL NUMBER
UNDER 260999999 SHOWN
FRONT
Hydraulic
System
5. To prevent reel damage, temporarily adjust bedknife to allow clearance between bedknife and reel (no
contact).
6. If a backlap kit is installed, make sure backlap knob
on the hydraulic manifold is in the mow position. Make
sure reel speed knob (FC1) is set to highest speed setting (fully open).
RELIEF
VALVE (R1)
CAUTION
Figure 18
Keep away from reels during test to prevent personal injury from the rotating reel blades.
S2
S3
FRONT
7. Start engine and move throttle to full speed (2750 +
50 RPM. Engage the cutting units.
S4
8. Watch pressure gauge carefully while slowly closing the flow control valve on the tester to fully closed.
9. On machines with serial number under 260999999,
system pressure should be from 2160 to 2640 PSI (149
to 182.2 bar). Note: If a dethatching kit is installed, system pressure should be from 2700 to 3300 PSI (186.3
to 227.7 bar). Record test results.
A. If this specification is met, go to step 11.
S1R1
MANIFOLD FROM MACHINE
WITH SERIAL NUMBER
OVER 270000000 SHOWN
B. If specification is not met, shut off engine and
adjust relief valve (R1) (Fig. 18) (see Adjust Manifold Relief Valves in the Adjustments section of this
Chapter). After adjustment, retest relief valve (R1)
pressure.
Greensmaster 3250--D
Page 4 -- 47
R2
Figure 19
Hydraulic System (Rev. I)
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
M3
RIGHT
MOTOR
MEASURING
CONTAINER
M1
REAR
MOTOR
M2
LEFT
MOTOR
High Pressure
Low Pressure
TO HYDRAULIC
RESERVOIR
Hydraulic System (Rev. I)
FROM MANIFOLD
PORT MA
Return or Suction
TO MANIFOLD
PORT MB
Page 4 -- 48
Flow
Rev. J
Greensmaster 3250--D
Procedure for Reel Motor Case Drain Flow Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten
(10) minutes. Make sure the hydraulic tank is full.
9. After achieving 1000 PSI (69 bar), place disconnected motor case drain hose into a container graduated in ounces or milliliters (e.g. Toro #TOR4077) and
collect hydraulic fluid for 15 seconds. After 15 seconds, remove hose end from container.
2. Park machine on a level surface with the cutting
units lowered. Make sure engine is off and the parking
brake is engaged.
10. Disengage cutting units by positioning functional
control lever to NEUTRAL position. Open control valve
on tester and stop the engine.
11. Identify amount of oil collected in the container. Record test results.
CAUTION
Before continuing further, read and become familiar with Precautions for Hydraulic Testing.
3. For the suspected bad reel motor, disconnect return
hose from motor. The return hose is connected to the
rear fitting on the reel motor.
4. Install tester with pressure gauge and flow meter in
series with the reel motor and the disconnected return
hose. Make sure the flow control valve on the tester
is fully open.
12. If flow was greater than 16.0 ounces (473 milliliters) (.5 GPM/1.9 LPM), repair or replace the reel motor
as necessary.
13. Disconnect tester from motor and return hose. Reconnect hose to the motor.
14. Remove plug from bulkhead fitting. Reconnect case
drain hose to the bulkhead fitting.
15. Test other reel motors as needed.
Hydraulic
System
5. If a back lap kit is installed, make sure backlap knob
on the hydraulic manifold is in the mow position and reel
speed is set to maximum.
6. Disconnect hose from case drain of the motor to be
tested at the bulkhead fitting.
A. Plug the bulkhead port.
B. Leave the case drain hose from the motor open
and place open end of disconnected hose into a
drain pan.
7. One person should sit on the seat and operate the
machine while a second person measures case drain
leakage. Make sure functional control lever is in NEUTRAL. Start engine and move the throttle to full speed
(2750 + 50 RPM).
Figure 20
CAUTION
Keep away from reels during test to prevent personal injury from the rotating reel blades.
8. Engage reels by positioning the functional control
lever to MOW position. While watching pressure gauge,
slowly close flow control valve on the tester until a pressure of 1000 PSI (69 bar) is obtained.
Greensmaster 3250--D
Page 4 -- 49 Rev. J
Hydraulic System (Rev. I)
Steering Control Valve Test
P
PLUG
R
V1
STEERING CYLINDER
(CYLINDER ROD
FULLY EXTENDED)
T
L
POWER
STEERING
VALVE (LEFT TURN)
PB
SCHEMATIC FROM MACHINE
WITH SERIAL NUMBER
UNDER 220999999 SHOWN
High Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System (Rev. I)
Page 4 -- 50
Greensmaster 3250--D
Procedure for Steering Control Valve Test
1. Make sure the hydraulic tank is full.
2. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten
(10) minutes.
3. Drive machine slowly in a figure eight on a flat level
surface.
REMOVE
THIS HOSE
A. There should be no shaking or vibration in the
steering wheel or rear wheel.
B. Steering wheel movements should be followed
immediately by a corresponding rear wheel movement without the steering wheel continuing to turn.
Figure 21
4. Stop the unit with the engine running. Turn steering
wheel with small quick movements in both directions.
Let go of the steering wheel after each movement.
B. The steering wheel should not continue to turn.
Note: The steering wheel must be able to turn with no
more than 45 in--lb (5.1 N--m) of torque.
Note: This steering test procedure will be affected by
incorrect rear tire pressure, binding in the hydraulic
steering cylinder, extra weight on the vehicle, and/or
binding of the steering fork assembly. Make sure that
these items are checked before proceeding with any hydraulic testing procedure.
5. Perform the Implement Relief Valve (R5) Pressure
and Gear Pump (P2) Flow tests to make sure that relief
valve and gear pump are functioning correctly.
6. If either of these performance tests indicate a steering problem, determine if the steering cylinder is faulty
using the following procedure.
A. Park machine on a level surface with the cutting
units lowered and off. Make sure engine is off and the
parking brake is engaged.
Before continuing further, read and become familiar with Precautions for Hydraulic Testing.
D. Read Precautions for Hydraulic Testing.
E. Remove hydraulic hose from the 90o fitting on the
rod end of the steering cylinder. Plug the end of the
hose.
F. With the engine off, continue turning the steering
wheel to the left (counterclockwise) with the steering
cylinder fully extended. Observe the open fitting on
the steering cylinder as the steering wheel is turned.
If oil comes out of the fitting while turning the steering
wheel to the left, the steering cylinder has internal
leakage and must be repaired or replaced.
G. Remove plug from the hydraulic hose. Reconnect hose to the steering cylinder fitting.
7. If steering problem exists and steering cylinder
tested acceptably, steering control valve requires service (see Steering Control Valve and Steering Control
Valve Service).
B. Turn the steering wheel all the way to the left
(counterclockwise) so the steering cylinder rod is fully extended.
C. Turn engine off.
Greensmaster 3250--D
Page 4 -- 51
Hydraulic System (Rev. I)
Hydraulic
System
A. The steering wheel must go back immediately to
the neutral position.
CAUTION
Adjustments
Adjust Transmission for Neutral
If the machine “creeps” when the traction control pedal
is in the neutral position, the neutral return mechanism
must be adjusted.
E. From each side of the bulkhead, tighten locknuts
evenly, securing traction cable to the bulkhead. Do
not twist cable.
1. Block up under the frame so one of the front wheels
is off the floor. If machine is equipped with 3 wheel drive
kit, raise and support rear wheel off the floor as well.
Chock wheels not being lifted to prevent the machine
from moving.
Note: If cable tension exists when in neutral, machine
may creep when the functional control lever is moved to
the Mow or Transport position.
5
3
2. Start engine, move throttle to SLOW and check
wheel that is off shop floor; wheel must not be rotating.
3. If the raised wheel is rotating, stop engine and proceed as follows:
A. Loosen both jam nuts securing traction control
cable to bulkhead on hydrostat. Make sure jam nuts
are loosened equally and sufficiently to allow adjustment.
1
B. Loosen nut securing eccentric to the top of the
hydrostat.
C. Move functional control lever to neutral and
throttle to slow. Start engine.
2
4
Figure 22
1.
2.
3.
Traction control cable
Bulkhead
Jam nuts
4.
5.
Eccentric
Lock nut
D. Rotate eccentric until creep does not occur in either direction. When the wheel stops rotating, tighten nut locking eccentric and adjustment. Verify
adjustment with throttle in SLOW and FAST positions.
Adjust Transport Speed
The traction pedal is adjusted for maximum transport
speed at the factory, but an adjustment may be required
if pedal reaches full stroke before it contacts pedal stop,
or if a decrease in transport speed is desired.
1
2
1. Press down on traction pedal and see if pedal contacts stop before tension is felt on cable. If an adjustment
is required:
A. Loosen flange head locknuts securing pedal
stop to floor plate.
B. Adjust pedal stop so it contacts pedal rod before
minimum tension is felt on the cable. Tighten nuts.
Figure 23
1.
Hydraulic System (Rev. I)
Page 4 -- 52
Pedal stop
2.
Floor plate
Greensmaster 3250--D
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
2. Loosen nut securing the lock and mow brackets on
pedal pivot.
1
3. Rotate trunnion cap screw clockwise to reduce
mowing speed or counterclockwise to increase mowing speed.
4. Tighten jam nut on the trunnion cap screw and nut
on the lock and mow brackets to lock adjustment. Check
adjustment and re--adjust as required.
3
Figure 24
1.
2.
Jam nut
Nut
3.
Trunnion cap screw
Adjust Cutting Unit Drop Speed
Note: Allow hydraulic oil to reach full operating temperature before adjusting flow control valve.
Hydraulic
System
The machine’s rear cutting unit lower circuit has a flow
control valve which is preset at the factory to about 3
turns open. An adjustment may be required to compensate for differences in hydraulic oil temperatures, mowing speeds, etc. If an adjustment is required, proceed as
follows:
2
1
1. Raise seat and locate flow control valve mounted to
the hydraulic cylinder for the center pull frame.
2. Loosen set screw on the adjusting knob of the flow
control valve.
Figure 25
1.
Flow control valve
2.
Rear hydraulic cylinder
3. If the center cutting unit is dropping too late, rotate
knob 1/4 turn counterclockwise.
4. If the center cutting unit is dropping too early, rotate
knob 1/4 turn clockwise.
5. After desired setting has been achieved, tighten set
screw.
Greensmaster 3250--D
Page 4 -- 53
Hydraulic System (Rev. I)
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 incorporated into the steering control valve and is not adjustable.
WARNING
CAP
Never adjust the relief valve with the hydraulic
system pressurized. Hydraulic oil will spray out
of the valve with the cap off. Personal injury may
result. Always install the cap and tighten before
pressurizing the system.
1. Locate relief valve and remove cap from valve.
2. To increase pressure setting, turn the adjustment
socket inside the valve 1/8 of a turn clockwise.
3. To decrease pressure setting, turn the adjustment
socket inside the valve 1/8 of a turn counterclockwise.
ADJUSTMENT
HEX SOCKET
4. Install and tighten cap to valve. After adjustment, retest pressure setting (see TESTING).
Figure 26
Adjust Manifold Relief Valves (R1 and R2)
These relief valves are installed on the hydraulic manifold. Relief valve (R1) is in the mow circuit and relief
valve (R2) is the lower cutting units relief.
WARNING
CAP
Never adjust the relief valve with the hydraulic
system pressurized. Hydraulic oil may spray out
of the valve with the cap off. Personal injury may
result. Always install the cap and tighten before
pressurizing the system.
1. Locate relief valve and remove cap from valve.
ADJUSTMENT
HEX SOCKET
Note: An 1/8--turn of the adjustment socket is about
50 psi (3.5 bar), or 1 turn is about 400 psi (27.6 bar).
2. To increase pressure setting, turn the adjustment
socket inside the valve 1/8 of a turn clockwise.
3. To decrease pressure setting, turn the adjustment
socket inside the valve 1/8 of a turn counterclockwise.
Figure 27
4. Install and tighten cap to valve. After adjustment, retest pressure setting (see TESTING).
Hydraulic System (Rev. I)
Page 4 -- 54
Greensmaster 3250--D
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 system, park machine on a level surface, engage parking
brake, lower cutting units or attachments, and stop engine. Remove key from the ignition switch
1. Check oil level in the hydraulic reservoir and add correct oil if necessary. Drain and refill hydraulic system
reservoir, and change oil filter if component failure was
severe or system is contaminated (see Flush Hydraulic
System).
CAUTION
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the
ignition switch in RUN and the engine OFF. Make
sure all electrically operated control valves are
actuated. Return ignition switch to OFF when
pressure has been relieved. Remove key from
the ignition switch.
3. Put caps or plugs on any hydraulic lines, hydraulic fittings, and components left open or exposed to prevent
contamination.
2. Lubricate O--rings and seals with clean hydraulic oil
before installing hydraulic components.
3. Make sure caps or plugs are removed from the hydraulic tubes, hydraulic fittings, and components before
reconnecting.
4. Use proper tightening methods when installing hydraulic hoses and fittings (see Hydraulic Fitting Installation).
5. After repairs, check control linkages or cables for
proper adjustment, binding, or broken parts.
6. After disconnecting or replacing any hydraulic components, operate machine functions slowly until air is
out of system (see Charge Hydraulic System).
7. Check for hydraulic oil leaks. Shut off engine and correct leaks if necessary. Check oil level in hydraulic reservoir and add correct oil if necessary.
4. Put labels on disconnected hydraulic lines and
hoses for proper installation after repairs are completed.
5. Note the position of hydraulic fittings (especially elbow fittings) on hydraulic components before removal.
Mark parts if necessary to make sure they will be aligned
properly when reinstalling hydraulic hoses and tubes.
Greensmaster 3250--D
Page 4 -- 55
Hydraulic System (Rev. I)
Hydraulic
System
2. Clean machine before disconnecting, removing, or
disassembling any hydraulic components. Make sure
hydraulic components, hoses connections, and fittings
are cleaned thoroughly. Always keep in mind the need
for cleanliness when working on hydraulic equipment.
Gear Pump
1
27 to 31 ft--lb
(37 to 42 N--m)
13
7
14
2
11
12
5
3
8
6
4
15
9
10
1.
2.
3.
4.
5.
Pump inlet hose
Gear pump
Hydraulic fitting
Hydraulic fitting
O--ring
Hydraulic System (Rev. I)
6.
7.
8.
9.
10.
Figure 28
O--ring
Hose clamp
O--ring
O--ring
Hydraulic hose
Page 4 -- 56
11.
12.
13.
14.
15.
O--ring
Hydrostat
Hex socket screw
Flat washer
Hydraulic hose
Greensmaster 3250--D
Removal (Fig. 28)
Installation (Fig. 28)
1. Make sure mounting and O--ring sealing surfaces
on the gear pump and hydrostat are clean.
CAUTION
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components.
1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking
brake, lower cutting units, and stop engine.
2. Clamp pump inlet hose to prevent draining the hydraulic tank.
2. Replace all O--rings with new ones. Apply clean hydraulic oil to all O--rings.
3. Place O--ring on the gear pump.
4. Position gear pump to the hydrostat so that the
pump inlet is facing up.
5. Secure gear pump to the hydrostat with both hex
socket head screws and flat washers. Torque screws
from 27 to 31 ft--lb (37 to 42 N--m).
3. Label all hose connections for reassembly purposes.
6. Inspect threads and sealing surfaces of hydraulic fittings and hydraulic hose connectors. Replace any damaged or worn fittings or connectors.
4. Loosen hose clamp, and remove pump inlet hose
from the gear pump. Allow hydraulic oil to drain from
hose into a suitable container.
7. Install O--rings into gear pump. Install fittings and
tighten to positions noted during removal.
IMPORTANT: Note position hydraulic fittings for
reassembly purposes.
8. Secure pump inlet hose and hose clamp to the gear
pump. Tighten hose clamp.
9. Remove clamp from pump inlet hose to allow hydraulic oil flow to the gear pump.
Hydraulic
System
5. Remove hydraulic hoses and O--rings from hydraulic fittings. Allow hydraulic oil to drain from hoses into a
suitable container.
6. Remove hydraulic fittings and O--rings from the
gear pump.
7. Support gear pump. Separate gear pump from the
hydrostat by removing both hex socket head screws and
flat washers. Remove O--ring from between the gear
pump and hydrostat.
Greensmaster 3250--D
Page 4 -- 57
Hydraulic System (Rev. I)
Gear Pump Service
1
8
12 18
11
10
17
9
5
3
12
6
14
16
12
10
8
13
19
9
7
2
12
4
Figure 29
1.
2.
3.
4.
5.
6.
7.
Front plate
Back plate
Front body
Back body
Drive gear
Front idler gear
Back idler gear
8.
9.
10.
11.
12.
13.
Back--up gasket
Wear plate
Pressure seal
Cap screw
O--ring
Adapter plate
14.
15.
16.
17.
18.
19.
Key
Not used
Back gear
Washer
Plug
Suction fitting
Note: For repair of the gear pump, see Eaton Gear
Pumps, Repair Information, Series 26, Model 26000,
Multiple Gear Pumps at the end of this chapter.
Hydraulic System (Rev. I)
Page 4 -- 58
Greensmaster 3250--D
Hydraulic System Start--up
CAUTION
Be careful when operating the cutting unit reels.
Contact with the reel or other moving parts can
result in personal injury.
1. After the hydraulic system components have been
properly installed and if the traction pump was rebuilt or
replaced, make sure traction pump housing is at least
half full of clean hydraulic oil.
9. After the hydraulic system starts to show signs of fill,
accomplish the following:
2. Make sure all hydraulic connections and lines are
secured tightly.
A. If a reel motor was replaced or rebuilt, run the
cutting units at the minimum speed setting (under
no load) for ten (10) minutes in both directions.
3. Make sure hydraulic reservoir is full. Add correct oil
if necessary (see Check Hydraulic System Fluid). Drain,
flush, and refill hydraulic system reservoir and change
oil filter if component failure was severe or system is
contaminated.
B. If a reel motor drive pump was replaced or rebuilt, run the cutting units at the minimum speed setting (under no load) for ten (10) minutes.
C. If a traction pump or a wheel motor was replaced
or rebuilt, run the traction unit so the wheels slowly
turn for ten (10) minutes.
4. Check control linkage for proper adjustment, binding, or broken parts.
5. Disconnect electrical connector to the fuel stop solenoid to prevent the engine from starting.
10. Operate the traction unit and cutting unit by gradually increasing their work load to full over a ten (10) minute
period.
6. Make sure traction pedal is in neutral and the cutting unit switch is off. Turn ignition key switch; engage
starter for ten (10) seconds to the prime pump. Allow the
starter to cool and repeat this step again.
11. Stop the machine. Check reservoir and fill if necessary. Check hydraulic components for leaks and tighten
any loose connections.
7. Reconnect electrical connector to the fuel stop solenoid.
8. Make sure traction pedal is in neutral and the cutting unit switch is off. Start engine and run it at low idle.
The charge pump should pick up oil and fill the hydraulic
system. If there is no indication of fill in 30 seconds, stop
the engine and determine the cause.
Greensmaster 3250--D
Page 4 -- 59
Hydraulic System (Rev. I)
Hydraulic
System
Note: When initially starting the hydraulic system with
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 damaging the system or its components from not purging the
system of air.
Hydrostatic Transmission
32
28
1
40
24
1
3
6
25
2
15
19
ILLUSTRATION FOR MACHINE
WITH SERIAL NUMBER
UNDER 220999999 SHOWN
47
Antiseize
Lubricant
20
29
16
90 to 110 in--lb
(10.2 to 12.4 N--m)
Loctite #242
17
45
6
38
2
3
17
41
38
22
18
4
5
13
11
33
7
8
9
39
34
44
10
35
26
42
23
21
46
36
27
43
25
37
14
7
30
12
11
31
Figure 30
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Hose clamp
O--ring
90o hydraulic fitting
Pump hub
Square head screw
O--ring
Flat washer
Drive coupling
Coupling spacer
Pump Adapter
Cap screw
Cap screw
Lock nut
Lock nut
Cap screw
O--ring
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Hydraulic fitting
90o hydraulic fitting
Flat washer
O--ring
O--ring
O--ring
Hose assembly
Pump inlet hose
Hose assembly
Hose assembly
Hose assembly
Gear pump
Hose assembly
Hydraulic T--fitting
Hose assembly
Hex socket head screw
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
Cap screw
Flat washer
Relief valve base
90o hydraulic fitting
Lock nut
Hose assembly
Hydraulic T--fitting
Flat washer
Relief valve cartridge (R5)
O--ring
O--ring
O--ring
Hydrostat
Pump plate
Key
Note: On machines with serial number over
230000000, the relief valve cartridge (R5) (item 41) is incorporated into the steering control valve.
Hydraulic System (Rev. I)
Page 4 -- 60
Greensmaster 3250--D
Removal (Fig. 30)
6
2
1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking
brake, lower cutting units, and stop engine.
4
1
3
CAUTION
Use caution when removing the lock nut from the
pin. The extension spring is under tension and
may cause personal injury during removal.
Note: The neutral system assembly can be removed
from the hydrostat without complete disassembly.
2. Remove extension spring from the spring bracket
(Fig. 31).
5
Figure 31
1.
2.
3.
Lock nut
Cap screw
Extension spring
4.
5.
6.
4
Dampener hose
Jam nut
Spring bracket
3
3. Disconnect extension spring from the neutral arm.
Remove cap screw and pivot washer from camplate
shaft of hydrostat (Fig. 32).
1
4. Remove both cap screws securing the cable support of the neutral system assembly to the hydrostat. Lift
and secure neutral system assembly away from the hydrostat (Fig. 33).
Hydraulic
System
2
6
CAUTION
5
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components.
Figure 32
1.
2.
3.
Extension spring
Neutral arm
Cap screw
5. Label all hose connections for reassembly purposes.
4.
5.
6.
Pivot washer
Hydrostat
Cable support
1
6. Clamp pump inlet hose (24) to prevent draining the
hydraulic reservoir.
1
2
7. Separate gear pump from the hydrostat (see Hydraulic Gear Pump Removal).
3
8. Plug suction port at the end of the gear pump to prevent possible leakage of hydraulic fluid (Fig. 34).
Figure 33
1.
2.
Greensmaster 3250--D
Page 4 -- 61
Cap screw
Cable support
3.
Hydrostat
Hydraulic System (Rev. I)
9. Pull gear pump (28) and connected hoses assemblies (27 and 38) away from the hydrostat (45) and secure.
10. Remove hose assemblies (25, 26, and 29) and O-rings (6 and 16) from the hydraulic fittings (3 and 17). Allow hoses to drain into a suitable container.
11. Remove hydraulic fittings (3 and 17) and O--rings (2
and 20) from the hydrostat (45).
12. Loosen both set screws (5) on the pump hub (4)
enough to allow the hydrostat (45) shaft to be removed.
CAUTION
SUCTION PORT
Support the hydrostat when removing its supporting fasteners to prevent it from falling and
causing personal injury.
13. Remove both lock nuts (14), cap screws (15), and
flat washers (19) from the hydrostat (45) flange and
pump plate (46).
14. Separate hydrostat (45) from the pump plate (46)
and pump hub (4). Remove key (47) from the hydrostat
shaft.
Installation (Fig. 30)
1. Make sure the inside of the pump hub (4) is clean.
Apply antiseize lubricant to both the hydrostat (45) shaft
and the inside of the pump hub.
Figure 34
8. Install O--rings (6 and 16) and hose assemblies (25,
26, and 29) to the hydrostat (45) and hydraulic fittings (3
and 17).
IMPORTANT: Failure to remove the plug will cause
excessive pressure in the hydrostat and damage
seals.
9. Remove plug from the suction port on the gear
pump (Fig. 34).
10. Install gear pump to the hydrostat (see Hydraulic
Gear Pump Installation).
11. Remove clamp from pump inlet hose (24).
2. Coat key (47) with petroleum jelly and insert it into
the hydrostat (45) shaft. Position hydrostat to the pump
plate (46) and pump hub (4). Slide the shaft into the hub
with the key.
12. Position neutral system assembly to the hydrostat
(45). Secure assembly to the hydrostat by securing the
cable support to the hydrostat with both cap screws (Fig.
33).
3. Secure the hydrostat (45) to the pump plate (46)
with both cap screws (15), flat washers (19), and lock
nuts (14).
13. Fasten and tighten cap screw and pivot washer to
the camplate shaft of the hydrostat. Connect extension
spring to the neutral arm (Fig. 32).
4. Apply Loctite #242 (or equivalent) to threads of both
square head screws (5). Install screws (5) in pump hub
(4) to secure hub to pump shaft. Torque screws from 90
to 110 in--lb (10.2 to 12.4 N--m).
14. Connect extension spring with dampener to the
spring bracket (Fig. 31).
5. Lubricate all new O--rings with clean hydraulic fluid.
15. Check neutral position of the traction pedal. If adjustment is required, see Adjust Transmission for Neutral.
6. Install new O--rings (2 and 20) and hydraulic fittings
(3 and 17) to the hydrostat.
7. Inspect threads and sealing surfaces of hydraulic fittings and hydraulic hose connectors. Replace any damaged or worn fittings or connectors.
Hydraulic System (Rev. I)
Page 4 -- 62
Greensmaster 3250--D
Piston Pump Service
36
19
17
44
43
42
41
37
20
23
18
40
21
14
45
REAR
OF TRACTION UNIT
22
16
15
15
4
24
8
27
9
49
48
46
47
13
26
28
12
11
5
Parts not listed in
partlist are not
serviced separately.
7
6
8
29
3
1
4
2
35
16
14
24
39
6
34
33
30
32
31
19
30
31
7
25
28
20
36
37
6
12
17
20
27
30
34
35
36
37
4
Figure 35
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Key
Drive shaft
Bearing
Cap screw
Cover plate
O--ring
Shim kit (for crush ring replacement)
Bearing cone
Key
Camplate
Rotating kit
Gasket
Valve plate
Bearing
Dowel pin
Back plate
O--ring
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Check valve
Dump valve
O--ring
Cap screw
Cap screw
Coupler
Roll pin
Cover plate
Camplate insert
Shaft seal
Washer
Housing
Retaining ring
Bearing race
Thrust bearing
Washer
Note: For repair of the piston pump, see Eaton, Medium Duty Piston Pump, Repair Information, Model
70160 Variable Displacement Piston Pump at the end of
this chapter.
Greensmaster 3250--D
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
Shaft seal
Retaining ring
Retaining ring
O--ring
O--ring
Seal kit
O--ring
Charge relief housing
Charge relief poppet (R4)
Charge relief spring
Washer
Retaining ring
Bleed--off valve poppet
Bleed--off spring
O--ring
Cartridge
IMPORTANT: The shims (7) are used to replace a
crush ring in the cover plate (25). If the camplate
(10), cover plate (25), or housing (29) is replaced
during servicing, the old crush ring must be replaced using the procedure (Piston Pump Crush
Ring Replacement) on the following page in conjunction with the pump service manual.
Page 4 -- 63
Hydraulic System (Rev. I)
Hydraulic
System
10
Piston Pump Crush Ring Replacement
4
5
8
7
29 ft--lb
(39 N--m)
2
3
9
10
v
6
1
Figure 36
1.
2.
3.
4.
Crush ring
Shims
Cover plate
Housing
5.
6.
7.
Camplate (control shaft)
Bearing cone
Bearing cup
Note: The shims replace the crush ring in the cover
plate. If the camplate, cover plate, or housing is replaced
during servicing of the pump, the old crush ring can not
be used to make sure of proper preload.
1. Remove crush ring from the cover plate. Measure
thickness of crush ring.
5. Install washers and cap screws to the cover plate
and housing. Torque cap screws to 29 ft--lbs (39 N--m).
6. Check torque required to rotate control shaft.
Torque should be 5 to 15 in--lbs (0.6 to 1.7 N--m).
A. If torque is too low, add additional shims and repeat steps 3 through 6 until the specified torque is
achieved.
2. Stack shims to the thickness of the crush ring.
3. Insert shims into the cover plate in the same location
that the crush ring was removed from.
4. Assemble housing sub assembly consisting of the
housing, camplate, bearing cone, bearing cup, and cover plate (see Eaton, Medium Duty Piston Pump, Repair
Information, Model 70160 Variable Displacement Piston
Pump at the end of this chapter).
Hydraulic System (Rev. I)
8. O--ring
9. Washers
10. Cap screws
B. If torque is too high, remove shims and repeat
steps 3 through 6 until the specified torque is
achieved.
7. Complete assembly of the pump (see pump service
manual at the end of this chapter).
Page 4 -- 64
Greensmaster 3250--D
Change Hydraulic Oil and Filter
Change hydraulic filter initially after the first 50 operating
hours, thereafter change hydraulic oil and filter after every 800 hours. Contaminated oil looks milky or black
when compared to clean oil. If oil becomes contaminated, flush hydraulic system (see Flush Hydraulic System).
HOSE
Note: If oil is not going to be drained, disconnect and
plug hydraulic line going to filter.
1. Clean area around filter mounting area. Place drain
pan under filter and remove filter. Allow hydraulic oil to
drain completely.
2. Fill replacement filter with hydraulic fluid (see Check
Hydraulic System Fluid), lubricate the sealing gasket
and hand turn until gasket contacts filter head. Then
tighten 3/4 turn further. Filter should now be sealed.
FILTER
Figure 37
3. Fill hydraulic reservoir with approximately 5.5 gallons (8.1 gallons if machine is equipped with leak detector) of hydraulic oil (see Check Hydraulic System Fluid).
Hydraulic
System
4. Start engine and run it at idle for 3 to 5 minutes to
circulate the fluid and remove any air trapped in the system. Stop engine and recheck fluid level.
5. Dispose of hydraulic fluid properly.
Greensmaster 3250--D
Page 4 -- 65
Hydraulic System (Rev. I)
Wheel Motors
4
250 to 400 ft--lb
(339 to 542 N--m)
3
24
6
5
7
12
11
30
1
RH 15
LH 16
8
9
32
15 RH
16 LH
14
18
2
13
17
12
19
70 to 90 ft--lb
(95 to122 N--m)
20
26
29
10
RIGHT
23
FRONT
22
28
21
25
31
27
Figure 38
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Lug nut
Tire
Rim
Valve stem
Brake drum
Wheel hub
Drive stud
Backing plate
Brake cam
Retaining clip
Return spring
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Brake shoe
Bearing plate
Brake bracket
Hydraulic hose
Hydraulic hose
45o Hydraulic fitting
O--ring
O--ring
Hydraulic motor
Flat washer
Brake rod
Front Wheel Motor Removal (Fig. 38)
1. Before removing any parts from the hydraulic system, park the machine on a level surface, engage the
parking brake, lower the cutting units, and stop the engine.
CAUTION
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Brake lever
Lock nut
Jam nut
Cap screw
Cap screw
Lock nut
Lock nut
Cap screw
Swivel clevis
Woodruff key
3. Remove lug nuts (1), tire (2) and rim (3), and bearing
plate (13) from drive studs (7). Loosen but do not remove lock nut (24) from hydraulic wheel motor (20)
shaft.
IMPORTANT: DO NOT hit wheel hub (6) with a hammer during removal or installation. Hammering may
cause damage to the hydraulic wheel motor (20).
Note: The brake drum assembly consists of the wheel
hub (6), brake drum (3), and drive stud (7).
4. Use wheel hub puller (see Special Tools) to free
wheel hub assembly from motor shaft. Do not disassemble hub assembly. Remove lock nut (24) and key
(32) from the hydraulic wheel motor (20) shaft.
2. Chock front and rear of wheels not being lifted to
prevent the machine from moving. Lift front wheel off the
5. Remove retaining clip (10) from the brake cam (9)
ground using a jack, and place blocks beneath the
and brake lever (23). Separate lever from cam.
frame.
Page 4 -- 66
Greensmaster 3250--D
Hydraulic System (Rev. I)
Note: The brake assembly consists of return spring
(11), brake cam (9), brake shoes (12), backing plate (8),
and retaining clip (10).
3. Lubricate new O--rings (18) with clean hydraulic
fluid. Install O--rings and hose assemblies (15 or 16) to
the hydraulic fittings (17). Tighten hose connections.
6. Remove brake assembly from the brake bracket
(14) by removing four cap screws (26) and lock nuts (29)
from the backing plate (8) and brake bracket. Do not disassemble.
Note: The brake assembly consists of return spring
(11), brake cam (9), brake shoes (12), backing plate (8),
and retaining clip (10).
8. Disconnect both hose assemblies (15 or 16) and O-rings (18) from the both hydraulic fittings (17). Allow
hoses to drain into a suitable container.
9. Remove hydraulic fittings (17) and O--rings (19)
from the hydraulic wheel motor (20).
10. Remove four cap screws (30) from brake bracket
(14) and hydraulic wheel motor (20). Remove motor
from the frame.
Front Wheel Motor Installation (Fig. 38)
1. Position hydraulic wheel motor (20) to the frame.
Make sure ports of motor face the rear of the machine.
Secure motor and brake bracket (14) to the frame with
four cap screws (30).
2. Remove caps or plugs from the hydraulic wheel motor (20). Lubricate new O--rings (19) with clean hydraulic
fluid. Install O--rings and hydraulic fittings (17) to the motor and tighten.
Greensmaster 3250--D
4. Install brake assembly to the brake bracket (14) by
securing the backing plate (8) to the brake bracket with
four cap screws (26) and lock nuts (29).
5. Secure brake lever (23) to the brake cam (9) with the
retaining clip (10).
IMPORTANT: DO NOT hit wheel hub (6) with a hammer during removal or installation. Hammering may
cause damage to the hydraulic wheel motor (20).
Note: The brake drum assembly consists of the wheel
hub (6), brake drum (3), and drive stud (7).
6. Make sure that wheel hub bore and wheel motor
shaft are thoroughly cleaned. Install key (32) to the hydraulic wheel motor (20) shaft. Slide brake drum assembly onto the motor shaft.
7. Secure lock nut (24) to the hydraulic wheel motor
(20) shaft. Torque nut from 250 to 400 ft--lb (339 to 542
N--m).
8. Install bearing plate (13) and the tire (2) and rim (3)
to the brake drum assembly. Secure rim with lug nuts
(1). Torque nuts from 70 to 90 ft--lb (95 to 122 N--m).
Page 4 -- 67
Hydraulic System (Rev. I)
Hydraulic
System
7. Label all connections for reassembly purposes.
18
16
20
3
4
15
17
19
14
70 to 90 ft--lb
(95 to122 N--m)
9
1
11
80 to 100 in--lb
(9.0 to 11.3 N--m)
23
21
6
24
7
RIGHT
FRONT
22
5
8
13
10
3
4
12
30 ft--lb
(41 N--m)
2
85 ft--lb
(115 N--m)
25
Figure 39
1.
2.
3.
4.
5.
6.
7.
8.
9.
Castor fork
Hub and motor assembly
Hydraulic hose
Hydraulic hose
Bearing
Relube flangette
Grease fitting
Standard flangette
Bearing tab
10.
11.
12.
13.
14.
15.
16.
17.
Cap screw
Lock nut
Hex socket head screw
Lock nut
Cable tie
Tube clamp
Cover plate
Cap screw
Rear Wheel (3WD) Removal (Fig. 39)
1. Before removing any parts from the hydraulic system, park the machine on a level surface, engage the
parking brake, lower the cutting units, and stop the engine.
CAUTION
18.
19.
20.
21.
22.
23.
24.
25.
Lock nut
Clamp bracket
Hex washer head screw
Bearing adapter plate
Grease fitting
Lug nut
Set screw
Wheel
CAUTION
Support wheel and motor and hub assembly during removal to prevent dropping and causing
personal injury.
4. Remove wheel (25) and hydraulic motor and hub
assembly (2) from the castor fork (1) as follows:
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components.
2. Chock both front wheels to prevent the machine
from moving. Lift rear wheel off the ground using a jack,
and place blocks beneath the frame. Secure the rear
wheel off the ground.
A. Remove cap screws (10) and lock nuts (11) securing flangettes (6 and 8) and bearing tab (8).
B. Remove both socket head screws (12) and lock
nuts (13) from castor fork and motor.
C. Lower wheel and hydraulic motor and hub assembly from the castor fork.
3. Label hoses for reassembly. Remove hose assemblies (3 and 4) and O--rings from the hydraulic fittings on
the hydraulic motor and hub assembly (2). Allow hoses
to drain into a suitable container.
Hydraulic System (Rev. I)
Page 4 -- 68
Greensmaster 3250--D
5. Loosen both set screws (24) on bearing (5). Slide
flangettes (6 and 8) and bearing (5) off the motor shaft.
6. Remove grease fitting (22) from the hydraulic motor
and hub assembly (2). Remove four lug nuts (23) and
wheel (25) from the hub drive studs.
Note: For disassembly of the hub from the rear wheel
motor, see Rear Wheel (3WD) Disassembly instructions
in Chapter 6 -- Wheels and Brakes.
Rear Wheel (3WD) Installation (Fig. 39)
5. Position hydraulic motor and hub assembly (2), flangettes (6 and 8) with bearing (5), and wheel (25) into the
castor fork (1). Make sure hose fittings on the motor face
the rear.
6. Secure hydraulic motor and hub assembly (2)
loosely to the left inside of the castor fork (1) with both
socket head screws (12) lock nuts (13).
7. Secure flangettes (6 and 8) with bearing (5) loosely
to the right inside of the castor fork (1).
A. Position grease fitting (7) facing downward.
Note: For assembly of the hub to the rear wheel motor,
see Rear Wheel (3WD) Assembly instructions in Chapter 6 -- Wheels and Brakes.
B. Torque socket head screws (12) to 85 ft--lb (115
N--m).
1. Make sure grease fitting (22) is removed from the
hydraulic motor and hub assembly (2).
C. Install cap screws (10) and lock nuts (11) to flangettes. Torque cap screws (10) to 30 ft--lb (41
N--m).
2. Secure wheel (25) to the four drive studs of the hydraulic motor and hub assembly (2) with four lug nuts
(23). Torque nuts from 70 to 90 ft--lb (95 to 122 N--m).
8. Apply loctite to both set screws (24). Torque both
screws from 80 to 100 in--lb (9.0 to 11.3 N--cm).
3. Reinstall grease fitting (22) onto hydraulic motor
and hub assembly (2) so it points away from the wheel
(25).
9. Install hose assemblies (3 and 4) and O--rings to the
hydraulic fittings on the hydraulic motor and hub assembly (2).
Greensmaster 3250--D
Page 4 -- 69
Hydraulic
System
4. Install flangette (8), bearing (5), and relube flangette
(6) onto the motor shaft.
Hydraulic System (Rev. I)
Wheel Motor Service
12 13
11
10
3
1
4
5
6
7
8
9
8
14
2
15
16
17
24
5
23
Parts not listed in
partlist are not
serviced separately.
25
19, 20, 21
26
15, 16, 23
27
28
5
22
5
21
1, 4, 5, 6, 7, 15
19
20
5
2, 3, 8, 9, 10
18
Figure 40
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Dirt seal
Bearing
Housing
Back--up washer
Seal rings
Back--up washer
Inner seal
Thrust washer
Thrust bearing
Bearing
11.
12.
13.
14.
15.
16.
17.
18.
19.
Coupling shaft
Thrust bearing
Drive link
Cap screw
Commutator seal
Commutator
Woodruff key
Wear plate
Rotor
20.
21.
22.
23.
24.
25.
26.
27.
28.
Vane
Stator
Manifold
Commutator ring
End cover
Rotor set
Commutator assembly
Seal kit
Housing assembly
Note: For repair of the wheel motors, see the Ross
Torqmotor TM MG, MF, MP, MB, ME, and MJ Series Service Procedure (Service Manual 2704--003) at the end
of this chapter.
Hydraulic System (Rev. I)
Page 4 -- 70
Greensmaster 3250--D
Flush Hydraulic System
IMPORTANT: Flush the hydraulic system any time
there is a severe component failure or the system is
contaminated (oil appears milky or black or contains metal particles).
IMPORTANT: Flush hydraulic system when changIng from petroleum base hydraulic fluid. Operate
machine under normal operating conditions for at
least four (4) hours before draining.
1. Park machine on a level surface. Lower cutting
units, stop engine, and engage parking.
10. Start engine and let it idle at low speed for a minimum of two (2) minutes. Increase engine speed to high
idle for minimum of one (1) minute under no load.
11. Raise and lower cutting units several times.
12. Shut off engine and check for hydraulic oil leaks.
Check oil level in hydraulic reservoir and add correct oil
if necessary.
13. Operate the machine for two (2) hours under normal
operating conditions.
14. Check condition of hydraulic oil. If the flushing fluid
shows any signs of contamination, or if you are changing
to biodegradable fluid, repeat steps 1 through 14 again.
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components.
15. Assume normal operation and follow recommended maintenance intervals.
2. Clean area around hydrostat and pump inlet hose.
Clamp pump inlet hose. Remove hose from hydrostat,
release clamp, and drain reservoir into a suitable container. Drain hydraulic system while making sure lift cylinders, hoses, tube lines, and all other components are
drained from low points while the system is warm. Discard filter (Fig. 41).
PUMP INLET HOSE
3. Clean oil filter mounting area. Remove filter and
drain into a suitable container. Discard filter (Fig. 42).
4. Inspect and clean reservoir (see Inspecting Reservoir Parts).
5. Make sure filter mounting surface is clean. Apply hydraulic oil to gasket on the new filter. Screw filter on until
gasket contacts mounting plate, then tighten filter half a
turn.
Figure 41
Note: Use only hydraulic fluids (including biodegradable) specified in Checking Hydraulic System Fluid in
General section. Other fluids could cause system damage.
6. Reconnect all hydraulic hoses and lines that were
disconnected prior to draining. Fill hydraulic reservoir.
7. Disconnect electrical connector to the fuel stop solenoid to prevent engine from starting on diesel engine.
8. Turn ignition key switch; engage starter for ten (10)
seconds to the prime pump. Allow the starter to cool and
repeat this step again.
HYDRAULIC OIL FILTER
Figure 42
9. Connect electrical connector to the fuel stop solenoid on diesel engine.
Greensmaster 3250--D
Page 4 -- 71
Hydraulic System (Rev. I)
Hydraulic
System
CAUTION
Implement Relief Valve (Machines with Serial Number Under 220999999)
RELIEF VALVE
20 ft--lb
(27 N--m)
11
13
12
14
10
7
9
8
4
15
6
3
1
3
LEFT
5
REAR
3
2
Figure 43
1.
2.
3.
4.
5.
Hose assembly
Hose assembly
O--ring
90o hydraulic fitting
Tee hydraulic fitting
6.
7.
8.
9.
10.
Lock nut
Cap screw
Flat washer
Mounting plate
Relief valve body
11.
12.
13.
14.
15.
Relief valve cartridge
O--ring
O--ring
Back--up ring
O--ring
Removal
2. Label all hydraulic connections for reassembly.
1. Before removing any parts from the hydraulic system, park the machine on a level surface, engage the
parking brake, lower the cutting units, and stop the engine.
3. Disconnect hose assemblies and O--rings from the
both hydraulic fittings. Allow hoses to drain into a suitable container.
CAUTION
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components.
Hydraulic System (Rev. I)
4. Unscrew lock nuts from cap screws. Remove
screws and flat washers from the relief valve body and
mounting plate.
5. Remove tee fitting, 90o fitting, and O--rings from the
relief valve body.
Page 4 -- 72
Greensmaster 3250--D
Installation
CAUTION
1. Lubricate new O--rings with clean hydraulic fluid.
Install O--rings and hydraulic fittings to the valve body.
2. Secure valve body to the mounting plate with cap
screws, flat washers, and lock nuts.
3. Install O--rings and hose assemblies to hydraulic fittings. Tighten hose connections.
Disassembly
1. Unscrew relief valve cartridge from the relief valve
body. Remove O--rings and back--up ring.
2. Inspect ports of the relief valve body for damaged
sealing surfaces and threads and contamination.
3. Inspect relief valve cartridge for damaged sealing
surfaces and contamination.
A. Contamination may cause valves to stick or
hang up. Contamination can become lodged in
small valve orifices or seal areas causing malfunction.
4. Clean relief valve cartridge using clean mineral spirits to flush out any contamination. Submerge cartridge
in clean mineral spirits to flush out contamination. Particles as fine as talcum powder can affect the operation
of high pressure hydraulic valves. Use compressed air
for cleaning.
Reassembly
1. Lubricate new O--rings and back--up ring with clean
hydraulic fluid. Install O--rings and back--up ring to the
relief valve cartridge.
2. Screw relief valve cartridge into the relief valve
body. Torque cartridge to 20 ft--lb (27 N--m).
3. Lubricate new O--rings with clean hydraulic fluid.
Connect hydraulic fittings and O--rings to the relief valve
body.
Hydraulic
System
B. If sealing surfaces appear pitted or damaged,
the hydraulic system may be over heating or there
may be water in the system.
Use eye protection such as goggles when using
compressed air.
Greensmaster 3250--D
Page 4 -- 73
Hydraulic System (Rev. I)
Reel Motors
1
2
3
3
20
31
18
4
23
5
16
15
22
14
21
29
7
29
7
30
25
19
30
17
6
8
10
11
12
24
7
11
17
27
13
15
26
6
14
28
RIGHT
FRONT
13
27
28
8
FRONT REEL MOTORS
Figure 44
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Cap screw
Flat washer
Tube clamp
Lock nut
Plug
90o Hydraulic fitting
Hydraulic fitting
Hydraulic fitting
Not used
Bulkhead nut
Washer
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Spacer
Reel motor
Hose assembly
Hose assembly
Hydraulic fitting
Hose assembly
T--block
Cap screw
Hydraulic tube
Hydraulic tube
Removal (Fig. 44 and 45)
1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking
brake, lower cutting units, and stop engine.
CAUTION
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components.
Hydraulic System (Rev. I)
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Hydraulic tube
Hydraulic tube
Rubber grommet
O--ring
O--ring
O--ring
O--ring
O--ring
O--ring
O--ring
2. Remove reel motor from the cutting unit (see Cutting Unit Removal and Installation in Chapter 7-- Cutting
Units).
Note: The position of hydraulic fittings on the reel motor is critical to properly reconnecting hydraulic hoses.
3. Label all hose connections for reassembly purposes. Matchmark reel motor and all hydraulic fittings
for reassembly purposes.
Page 4 -- 74
Greensmaster 3250--D
1
9
10
11
3
25
27
17
5
9
23
4
18
14
8
12
2
21
6
4
3
15
20
3
22
24
26
3
19
13
28
13
RIGHT
FRONT
1
9
10
16
11
9
REAR REEL MOTOR
7
Bulkhead lock nut
Bulkhead lock nut
Hex washer head screw
Hydraulic hose
Reel motor
Bulkhead bracket
Hydraulic tube
Hydraulic hose
Washer
Spacer
11.
12.
13.
14.
15.
16.
17.
18.
19.
Grommet
Hydraulic straight fitting
90o Hydraulic fitting
Hose bracket
Clamp
Hydraulic hose
O--ring
O--ring
O--ring
20.
21.
22.
23.
24.
25.
26.
27.
28.
Tube clamp
Cap screw
Lock nut
Hydraulic T--fitting
Hose retainer
Lock nut
Hose retainer
Cable tie
O--ring
4. Remove hose connections from the hydraulic fittings on the reel motor. Allow hydraulic oil to drain from
hoses into a suitable container. Put caps or plugs on
ends of hoses to prevent contamination.
3. Place O--ring on the face seal of a hydraulic fitting.
Secure fitting to the reel motor. Make sure that the match
marks are aligned. Repeat this step for the remaining fittings.
5. Remove hydraulic fittings and O--rings from the reel
motor. Put caps or plugs in motor openings to prevent
contamination.
4. Inspect threads and sealing surfaces of connections. Replace any worn or damaged connections.
Installation (Fig. 44 and 45)
1. Inspect threads and sealing surfaces of fittings. Replace any worn or damaged fittings.
2. Apply clean hydraulic oil to all O--rings.
Greensmaster 3250--D
5. Install reel motor to the cutting unit (see Cutting Unit
Removal and Installation in Chapter 7-- Cutting Units).
6. Secure hose connection to the proper hydraulic fitting on the reel motor. Repeat this step for the remaining
hose connections.
Page 4 -- 75
Hydraulic System (Rev. I)
Hydraulic
System
Figure 45
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Reel Motor Service (Serial Number Under 220999999)
3
4
5
6
1
7
2
8
9
190 to 210 in--lb
(21.5 to 23.7 N--m)
5
14
10
11
12
13
5
Figure 46
1.
2.
3.
4.
5.
Hex socket head screw
Washer
Dowel pin
Cover assembly
Needle bearing
6.
7.
8.
9.
10.
Idler gear assembly
Drive shaft assembly
Seal ring
Load plate assembly
Body assembly
Disassembly (Fig. 46)
1. Make sure caps or plugs are in motor openings to
prevent contamination. Clean motor with solvent.
Spacer
Shaft seal
Retaining ring
Dowel pin
IMPORTANT: Do not chisel or pry the shaft seal out
of its cavity. This could cause damage to the seal
bore or shaft and/or mounting hub area.
C. Apply pressure gradually into the motor. The
seal should “pop” easily out of the cavity.
IMPORTANT: Use extreme caution when using a
vise to hold the motor. Do not over tighten. Parts
may be distorted.
2. Remove shaft seal as follows:
11.
12.
13.
14.
D. Remove shaft seal and spacer from body assembly.
A. Remove retaining ring with retaining ring pliers.
3. Remove hex socket head screws and washers from
the cover assembly and body assembly.
B. Plug both motor ports (3/4--16 UNF--2B) with
threaded plugs. Attach hydraulic hand pump to the
external drain port (7/16--20 UNF--2B).
4. Separate cover assembly from body assembly by
tapping lightly on the drive shaft with a plastic hammer;
do not pry apart.
5. Remove load plate assembly from the drive shaft
and idler gear assemblies. Discard load plate assembly.
CAUTION
Point shaft seal away from face and body to prevent possible injury.
Hydraulic System (Rev. I)
6. Remove seal ring from the body assembly. Discard
seal ring.
Page 4 -- 76
Greensmaster 3250--D
1. Remove all nicks and burrs from all parts with an
emery cloth.
CAUTION
Use eye protection such as goggles when using
compressed air.
2. Clean all parts with solvent. Dry all parts with compressed air.
3. Inspect drive shaft and idler gear assemblies.
A. Bushing points and seal areas should be free of
excessive excessive wear and rough surfaces.
B. Gear faces should be free of excessive scoring
and wear.
Note: Make sure idler gear is installed into the gear
pocket opposite the external drain port.
3. Dip idler gear and drive shaft assemblies into clean
hydraulic oil. Install both assemblies into the cover assembly gear pockets. Make sure that both gears mesh.
4. Coat new load plate assembly lightly with petroleum
jelly. Install load plate assembly onto idler gear and drive
shaft assemblies. Make sure seal of assembly faces
away from the gear face.
5. Slide body assembly over the idler gear and drive
shaft assemblies onto the cover assembly. Make sure
that none of the parts become displaced. Install hex
socket head screws and washers. Hand tighten screws.
6. Rotate drive shaft to make sure gears mesh properly. Torque hex socket head screws from 190 to 210 in--lb
(21.5 to 23.7 N--m).
7. Install new spacer onto the drive shaft and into the
body assembly.
C. Gears should be free of excessive wear, nicks,
and, missing or broken teeth. Break sharp edges
with emery cloth.
IMPORTANT: Use extreme care when installing the
shaft seal to prevent damage to the seal.
D. Replace if either shaft is visibly bent.
8. Install new shaft seal as follows:
A. Make sure that the bore of the body assembly is
clean and free of burrs and nicks which could damage the seal.
4. Inspect cover and body assemblies.
A. Bearing needles should remain in cage and
move freely. If needle bearing(s) need replacement,
the entire assembly must be replaced.
B. Lubricate lips of the seal generously with clean
No. 2 multipurpose lithium base grease. Apply Loctite gasket eliminator 515 or equivalent to the outer
edge of the metal case of the seal.
B. Sealing faces and gear pockets should be free of
excessive scoring.
C. Make sure metal case of shaft seal faces away
from the motor. Use seal installer to press shaft seal
squarely into the bore.
Assembly (Fig. 46)
1. Coat new seal ring lightly with petroleum jelly. Install
seal ring into matching groove on the body assembly.
2. Apply a thin coat of petroleum jelly to both gear
pockets of the cover assembly. Install dowel pins into
body assembly.
Greensmaster 3250--D
9. Install retaining ring into bore of the body assembly.
10. Lubricate motor generously with clean hydraulic oil.
Page 4 -- 77
Hydraulic System (Rev. I)
Hydraulic
System
Inspection (Fig. 46)
Reel Motor Service (Serial Number Over 230000000)
6
5
7
9
8
7
10
5
11
6
1
215 to 280 in--lb
(24 to 32 N--m)
3
12
4
2
Figure 47
1.
2.
3.
4.
Rear cover
Drive gear
Seal
Tab washer
5.
6.
7.
8.
Pressure seal
Back--up ring
O--ring
Body
Disassembly
1. Plug motor ports and clean the outside of the motor
thoroughly. After cleaning, remove plugs and drain any
oil out of the motor.
9.
10.
11.
12.
Idler gear
Cap screw
Front flange
Washer (if equipped)
DIAGONAL MARK
2. Use a marker or scribe to make a diagonal mark
across the front flange, body, and rear cover for reassembly purposes (Fig. 48).
IMPORTANT: Avoid using excessive clamping
pressure on the motor flange to prevent distorting
the casting.
3. Clamp mounting flange of motor in a vise with the
shaft end down.
Figure 48
4. Loosen cap screws on the rear cover.
5. Take motor from the vise and remove cap screws.
6. Remove front flange from the body, then remove rear
cover. Locate and remove dowel pins from body.
Hydraulic System (Rev. I)
Page 4 -- 78
Greensmaster 3250--D
IMPORTANT: Mark the relative positions of the gear
teeth and the bearing blocks so they can be reassembled in the same position. Do not touch the
gear surfaces as residue on hands may be corrosive
to gear finish.
1
7. Place the motor on its side and push on the rear bearing block to remove the bearing block and gear set (Fig.
49).
8. Carefully remove and discard O--rings, pressure
seals, and back--up rings (Fig. 50) from motor. Do not
cause any damage to the machined grooves during the
removal process.
IMPORTANT: Make sure not to damage the counter
bore when removing the shaft seal from the front
plate.
2
Figure 49
1. Motor body
2. Bearing block & gear set
9. Position front flange with seal side up. Remove shaft
seal.
Inspection
1. Remove any nicks and burrs from all motor components with emery cloth.
Hydraulic
System
CAUTION
Use eye protection such as goggles when using
compressed air.
Figure 50
2. Clean all motor components with solvent. Dry all
parts with compressed air.
3. Inspect drive gear, idler gear and bearing blocks
(Fig. 51) for the following:
1
A. Gear shafts should be free of rough surfaces and
excessive wear at bushing points and sealing areas.
Scoring, rough surfaces, or wear on gear shafts indicates need for replacement.
2
B. Gear teeth should be free of excessive scoring
and wear. Any broken or nicked gear teeth must be
replaced.
3
C. Inspect gear face edge for sharpness. Sharp
edges of gears will mill into bearing blocks and, thus,
must be replaced.
D. Bearing areas of bearing blocks should not have
excessive wear or scoring.
E. Face of bearing blocks that are in contact with
gears should be free of wear, roughness or scoring.
4. Inspect front flange and rear cover for damage or
wear.
Greensmaster 3250--D
3
Figure 51
1. Drive gear
2. Idler gear
Page 4 -- 79
3. Bearing block
Hydraulic System (Rev. I)
Reassembly
8. Install dowel pins in body.
NOTE: When reassembling the motor, check the identification marks made during disassembly to make sure
the parts are properly aligned during reassembly.
IMPORTANT: Do not dislodge O--rings, pressure
seals, or back--up rings during final assembly.
1. Lubricate O--rings, pressure seals, back--up gaskets, and seal grooves with a thin coat of petroleum jelly.
Lubricate all other internal parts freely with clean hydraulic oil.
2. Install new shaft seal into front flange.
3. Install lubricated pressure seals into the grooves in
the front flange and rear cover. Follow by carefully placing the back--up rings into the grooves.
4. Install new O--rings to the body.
5. Lubricate gear faces and bearing surfaces of drive
gear, idler gear, and bearing blocks. Carefully assemble
bearing blocks and gears noting identification marks
made during disassembly.
6. Position the motor body on its side. Carefully slide
bearing block and gear assembly into the body cavity
using identification marks made during disassembly.
7. Remove any excess lubrication from mating surfaces of body, rear cover, and front flange. Make sure
that these surfaces are clean and dry.
Hydraulic System (Rev. I)
9. Gently slide the rear cover onto the assembly using
marker or scribe mark for proper location. Firm hand
pressure should be sufficient to engage the dowel pins.
10.Position the motor with rear cover downwards. Carefully slide the front flange onto the assembly using marker or scribe mark for proper location.
11. Install the four cap screws and hand tighten.
IMPORTANT: Avoid using excessive clamping
pressure on the motor housing to prevent distorting
the housing.
12.Place motor front flange in a vise and alternately
torque the cap screws from 215 to 280 in--lb (24 to 32
N--m).
13.Put a small amount of hydraulic oil in port on motor
and rotate driveshaft one revolution. Protect the shaft if
using a pliers. If drive shaft binds, disassemble motor
and repeat assembly process.
14.Remove motor from vise.
Page 4 -- 80
Greensmaster 3250--D
Hydraulic
System
This page is intentionally blank.
Greensmaster 3250--D
Page 4 -- 81
Hydraulic System (Rev. I)
Oil Cooler (If Equipped)
11
10
8
9
10
7
3
OIL FLOW
12
13
11
1
6
14
4
5
2
Figure 52
1.
2.
3.
4.
5.
Oil cooler
Lower formed hose
Upper formed hose
Grommet
Hose clamp
6.
7.
8.
9.
10.
Tube assembly
Tube assembly
Hydraulic fitting
Hydraulic fitting
O--ring
Removal (Fig. 52)
1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking
brake, lower cutting units, and stop engine.
O--ring
Radiator screen
Upper cooler bracket
Lower cooler bracket
2. Clamp upper and lower formed hoses to prevent
draining of the hydraulic system and tank.
3. Remove loosen hose clamps securing the formed
hoses to the oil cooler.
4. Lift oil cooler up from the cooler brackets. Remove
oil cooler from the formed hoses. Allow hoses and cooler
to drain into a suitable container.
CAUTION
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components.
5. To clean the oil cooler, back flush with cleaning solvent. After the cooler is clean, make sure all solvent is
drained from the cooler.
CAUTION
CAUTION
The radiator and oil cooler may be hot. To avoid
possible burns, allow the engine and cooling
systems to cool before working on the oil cooler.
Hydraulic System (Rev. I)
11.
12.
13.
14.
Use eye protection such as goggles when using
compressed air.
6. Use compressed air in a direction opposite the oil
flow to dry the cooler.
Page 4 -- 82
Greensmaster 3250--D
7. Plug ends of the oil cooler. Clean exterior of the
cooler.
8. The oil cooler should be free of corrosion and excessive pitting of tubes.
Installation (Fig. 52)
1. Make sure formed hoses and openings of the oil
cooler are clean.
4. Remove clamps that where used to prevent drainage from the formed hoses.
5. Fill hydraulic tank (see Check Hydraulic System
Fluid).
6. Start machine. Run machine at idle for 3 to 5 minutes to circulate hydraulic fluid and remove any air
trapped in the system. Stop machine and recheck hydraulic tank level.
Hydraulic
System
2. Hang oil cooler onto cooler brackets while attaching
the formed hoses to the cooler. Secure hoses by tightening the hose clamps.
3. Clean radiator screen and reinstall.
Greensmaster 3250--D
Page 4 -- 83
Hydraulic System (Rev. I)
Lift Cylinders
4
10 12 3
7
2
1
11
13
8
13
14
12
3
9
14
5
6
HYDRAULIC CYLINDER
Figure 53
1.
2.
3.
4.
5.
Hose assembly
Hose assembly
O--ring
Cotter pin
Clevis pin
6.
7.
8.
9.
10.
Lift arm
Hydraulic cylinder
Cap screw
Ram pivot pin
Spacer
Front Cylinder Removal (Fig. 53)
1. Before removing any parts from the hydraulic system, park the machine on a level surface, engage the
parking brake, lower the cutting units, and stop the engine.
Frame
90o Hydraulic fitting
O--ring
Washer
5. Support hydraulic cylinder to prevent it from dropping.
A. Remove cap screw from the ram pivot pin.
B. Pull ram pivot pin from the frame, spacer, and hydraulic cylinder.
C. Remove hydraulic cylinder from the frame.
CAUTION
Front Cylinder Installation
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components.
2. Label all hydraulic connections for reassembly.
3. Disconnect hose assemblies and O--rings from the
hydraulic fittings. Allow hoses to drain into a suitable
container.
4. Remove cotter pin from the clevis pin. Pull clevis pin
with washers from the hydraulic cylinder and lift arm.
Hydraulic System (Rev. I)
11.
12.
13.
14.
1. Position hydraulic cylinder to the frame. Insert ram
pivot pin with through the frame bracket, spacer, and cylinder. Secure pin with cap screw.
2. Position clevis of the hydraulic cylinder to the lift
arm. Insert clevis pin with washers through the cylinder
clevis and secure with cotter pin.
3. Connect hose assemblies and O--rings to the hydraulic fittings. Tighten hose connections.
Page 4 -- 84
Greensmaster 3250--D
12
11
10
10
HYDRAULIC CYLINDER
2 15
5
16
17
9
6
7
18
14
18
13
4
1
8
3
Figure 54
Hose assembly
Hose assembly
O--ring
90o hydraulic fitting
Orificed hydraulic fitting
Cotter pin
7.
8.
9.
10.
11.
12.
Clevis pin
Lift arm
Hydraulic cylinder
Retaining ring
Cylinder pin
Frame
Rear Cylinder Removal (Fig. 54)
1. Before removing any parts from the hydraulic system, park the machine on a level surface, engage the
parking brake, lower the cutting units, and stop the engine.
O--ring
Flow control valve (if equipped)
O--ring
O--ring
90o hydraulic fitting
Washer
5. Support hydraulic cylinder to prevent it from dropping.
A. Remove a retaining ring from the cylinder pin.
B. Pull cylinder pin from the hydraulic cylinder and
frame.
C. Remove hydraulic cylinder from the frame.
CAUTION
Rear Cylinder Installation
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components.
2. Label all hydraulic connections for reassembly.
3. Disconnect hose assemblies and O--ring from the
hydraulic fittings. Allow hoses to drain into a suitable
container.
4. Remove cotter pin from the clevis pin. Pull clevis pin
with washers from the hydraulic cylinder and lift arm.
Greensmaster 3250--D
13.
14.
15.
16.
17.
18.
1. Position hydraulic cylinder tho the frame. Insert cylinder pin with retaining ring through the frame bracket
and cylinder. Secure pin with retaining ring.
2. Position clevis of the hydraulic cylinder to the lift
arm. Insert clevis pin with washers through the cylinder
clevis and secure with cotter pin.
3. Connect hose assemblies and O--rings to the hydraulic fittings. Tighten hose connections.
Page 4 -- 85
Hydraulic System (Rev. I)
Hydraulic
System
1.
2.
3.
4.
5.
6.
Lift Cylinder Service
REAR HYDRAULIC CYLINDER
1
6
7
11
2
24 to 30 ft--lb
(33 to 41 N--m)
3
1.
2.
3.
4.
4
5
Barrel
Shaft
Nut
Piston
5.
6.
7.
8.
8
Uni--ring
O--ring
Rod seal
Head
9
10
12
Figure 55
9.
10.
11.
12.
O--ring
Back--up ring
Dust seal
Internal collar
FRONT HYDRAULIC CYLINDER
1
6
7
11
2
24 to 30 ft--lb
(33 to 41 N--m)
3
4
5
8
9
10
12
Figure 56
1.
2.
3.
4.
Barrel
Shaft
Nut
Piston
Hydraulic System (Rev. I)
5.
6.
7.
8.
Uni--ring
O--ring
Rod seal
Head
Page 4 -- 86
9.
10.
11.
12.
O--ring
Back--up ring
Dust seal
Internal collar
Greensmaster 3250--D
1. Remove oil from lift cylinder into a drain pan by slowly
pumping the cylinder shaft. Plug both ports and clean
the outside of the cylinder.
IMPORTANT: Prevent damage when clamping the
hydraulic cylinder into a vise; clamp on the clevis
only. Do not close vise enough to distort the barrel.
2. Mount lift cylinder in a vice. Remove internal collar
with a spanner wrench.
3. Extract shaft, head, and piston by carefully twisting
and pulling on the shaft.
IMPORTANT: Do not clamp vise jaws against the
shaft surface. Protect shaft surface before mounting in a vice.
4. Mount shaft securely in a vise by clamping on the clevis of the shaft. Remove lock nut and piston from the
shaft. Slide head off the shaft.
5. Remove Uni--ring and O--ring from the piston. Remove O--ring, back--up ring, rod seal, and dust seal from
the head.
Reassembly
1. Make sure all parts are clean before reassembly.
2. Coat new O--rings, Uni--rings, rod seal, back--up
ring, and dust seal with with clean hydraulic oil.
IMPORTANT: Do not clamp vise jaws against the
shaft surface. Protect shaft surface before mounting in a vice.
3. Mount shaft securely in a vise by clamping on the clevis of the shaft.
A. Coat shaft with with clean hydraulic oil.
B. Slide head onto the onto the shaft. Install rod seal
onto shaft and into head.
C. Install piston and nut onto the shaft. Torque nut
from 24 to 30 ft--lb (33 to 41 N--m).
D. Remove shaft from the vise.
IMPORTANT: Prevent damage when clamping the
hydraulic cylinder into a vise; clamp on the clevis
only. Do not close vise enough to distort the barrel.
4. Mount barrel in a vice.
5. Coat all internal parts with a light coat of clean hydraulic oil. Slide piston, shaft, and head assembly into
the barrel being careful not to damage the seals.
6. Clean threads of internal collar and threads in cylinder barrel. Apply medium strength thread locking compound (e.g. Loctite #242) to threads of internal collar.
Secure head in the barrel with internal collar using a
spanner wrench. Tighten collar until snug and the outer
end of the collar is flush with end of the barrel.
A. Install Uni--ring and O--ring to the piston.
B. Install dust seal, O--ring, back--up ring, and dust
seal to the head.
Greensmaster 3250--D
Page 4 -- 87
Hydraulic System (Rev. I)
Hydraulic
System
Disassembly
Hydraulic Manifold
4
1
2
14
7
13
21 6
10
24
15
30
22
28
5
29
9
16
19
23
25
20
8
27
26
32
16
31
17
15
11
31
2
4
18
3
ILLUSTRATION FOR MACHINE
WITH SERIAL NUMBER
UNDER 260999999 SHOWN
12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Hydraulic manifold assembly
Hydraulic straight fitting
Hydraulic fitting
O--ring
90o Hydraulic fitting
90o Hydraulic fitting
90o Hydraulic fitting
Hydraulic straight fitting
Hydraulic straight fitting
45o Hydraulic fitting
Hydraulic T--fitting
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Figure 57
Cap screw
Hydraulic hose
Hydraulic hose
O--ring
Orifice fitting
O--ring
O--ring
O--ring
O--ring
O--ring
O--ring
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
O--ring
O--ring
O--ring
O--ring
O--ring
O--ring
O--ring
O--ring
O--ring
O--ring
Note: The ports on the manifold are marked for easy identification of components. Example: R1 is the reel circuit
relief valve and P1 is the gear pump connection port. (see Hydraulic Schematic to identify the function of the hydraulic
lines and cartridge valves at each port location).
Hydraulic System (Rev. I)
Page 4 -- 88
Greensmaster 3250--D
Removal (Fig. 57)
1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking
brake, lower cutting units, and stop the engine.
IMPORTANT: Before disconnecting any hydraulic
fittings from the hydraulic manifold block, make
sure the position of each fitting is observed and
matchmarked to ensure it is oriented properly on
the manifold.
6. Disconnect hydraulic fittings and O--rings from the
manifold.
CAUTION
Installation (Fig. 57)
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components.
Note: Fitting orientation is determined by viewing the
manifold assembly from the side with its solenoids facing up.
2. Disconnect solenoid valve electrical connectors. If
a backlap kit is installed, disconnect electrical connector
to the ball switch.
1. Install hydraulic fittings and their respective O--rings
to the manifold assembly, and orient to matchmarks observed during removal.
3. Label all hydraulic connections and electrical connections for reassembly.
2. Position manifold assembly to the support frame.
Secure assembly to the frame with both cap screws.
IMPORTANT: Before disconnecting any hydraulic
hoses from the hydraulic fittings, make sure each
hose is labeled to ensure it is reconnected to the
correct manifold fitting/port.
3. Connect hose assemblies and their respective O-rings to hydraulic fittings.
Hydraulic
System
4. Disconnect hose assemblies and their respective
O--rings from hydraulic fittings. Allow hoses to drain into
a suitable container.
4. Connect solenoid valve electrical connectors. If a
backlap kit is installed, connect electrical connector for
the ball switch.
5. Remove both cap screws (12) from the hydraulic
manifold. Remove manifold assembly from the machine.
Greensmaster 3250--D
Page 4 -- 89
Hydraulic System (Rev. I)
Hydraulic Manifold Service (Serial Number Under 260999999)
19
15 in--lb
(1.7 N--m)
PLUG TORQUE
1
1
35 ft--lb
(47 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)
SAE #10: 60 to 62 ft--lb (81 to 84 N--m)
19
15 in--lb
(1.7 N--m)
3
18
2
17
Loctite
#242
23
20
1
Loctite
#242
22
4
16
20
21
15
9
16
6
20
7
5
8
17
5
4
20
4
5
35 ft--lb
(47 N--m)
35 ft--lb
(47 N--m)
4
Loctite
#242
5
14
6
7
6
5
5
35 ft--lb
(47 N--m)
4
13
4
11
10
20
7
12
7
6
6
Figure 58
1.
2.
3.
4.
5.
6.
7.
8.
20 watt solenoid
N.O. cartridge (Ports S1 & S2)
4Way/2Position cartridge (Port S3)
Plug (SAE #2)
O--ring
Plug (SAE #6)
O--ring
2400 PSI relief cartridge (Port R1)
9.
10.
11.
12.
13.
14.
15.
16.
N.C. cartridge (Port S4)
Plug (SAE #8)
O--ring
Manifold body
150 PSI relief cartridge (Port R2)
Orifice plug (Port O1)
Cavity plug (Port LC1)
O--ring
17.
18.
19.
20.
21.
22.
23.
Plug (SAE #10)
Cavity plug (Port RD1)
Solenoid seal
Seal kit
Seal kit
Seal kit
Seal kit
Note: Machines with serial number under 260999999 use a hydraulic manifold similar to the one illustrated in Figure
58. For serial numbers above 230001500, an additional solenoid operated cartridge (S6) is included in the manifold.
For serial numbers above 240000000, reel speed and backup valves are included in the manifold (see Flow Control
and Backlap Valves in this section).
Note: The ports on the manifold are marked for easy identification of components. Example: R1 is the reel circuit
relief valve and P1 is the gear pump connection port. See Hydraulic Schematic to identify the function of the hydraulic
lines and cartridge valves at each port location.
Hydraulic System (Rev. I)
Page 4 -- 90
Greensmaster 3250--D
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 solenoid coil. Install solenoid coil to the cartridge
valve. Apply “Loctite 242” or equivalent to the
threads of the valve. Torque nut to 15 in--lb (1.7
N--m).
2. Remove nut securing solenoid to the cartridge
valve. Slide solenoid and both O--rings off the valve.
Note: Use care when handling the cartridge valve.
Slight bending or distortion of the stem tube can cause
binding and malfunction.
4. Visually inspect the port in the manifold for damage
to the sealing surfaces, damaged threads, and contamination.
5. Visually inspect cartridge valve for damaged sealing surfaces and contamination.
A. Contamination may cause valves to stick or
hang up. Contamination can become lodged in
small valve orifices or seal areas causing malfunction.
Cartridge Relief Valves (Fig. 58)
1. Make sure the manifold is clean before removing
the cartridge valve and seal kit.
2. Remove cartridge relief valve.
3. Visually inspect port in the manifold for damage to
the sealing surfaces, damaged threads, and contamination.
4. Visually inspect cartridge relief valve for damaged
sealing surfaces and contamination.
A. Contamination may cause valves to stick or
hang up. Contamination can become lodged in
small valve orifices or seal areas causing malfunction.
B. If spool valve (8) sealing surfaces appear pitted
or damaged, the hydraulic system may be overheating or there may be water in the system.
B. If sealing surfaces appear pitted or damaged,
the hydraulic system may be overheating or there
may be water in the system.
CAUTION
Use eye protection such as goggles when using
compressed air.
6. Clean cartridge valve using clean mineral spirits.
Submerge valve in clean mineral spirits to flush out contamination. Use a probe to push the internal spool in and
out 20 to 30 times to flush out contamination. Particles
as fine as talcum powder can affect the operation of high
pressure hydraulic valves. Use compressed air for
cleaning.
7. Reinstall the cartridge valve:
A. Lubricate new O--rings and backup rings of seal
kit with clean hydraulic oil and install. The O--ring
and backup ring must be arranged properly on the
cartridge valve for proper operation and sealing.
CAUTION
Use eye protection such as goggles when using
compressed air.
5. Clean cartridge relief valve using clean mineral spirits. Submerge valve in clean mineral spirits to flush out
contamination. Particles as fine as talcum powder can
affect the operation of high pressure hydraulic valves.
Use compressed air for cleaning.
6. Reinstall the cartridge relief valve:
B. Thread spool valve carefully into port. The valve
should go in easily without binding.
Note: Use care when handling the cartridge
valve. Slight bending or distortion of the stem tube
can cause binding and malfunction.
Greensmaster 3250--D
Page 4 -- 91
A. Lubricate new O--ring and backup ring of seal kit
with clean hydraulic oil and install. The O--ring and
backup ring must be arranged properly on the cartridge valve for proper operation and sealing.
B. Thread cartridge relief valve carefully into the
applicable port. The valve should go in easily without binding. Torque valve to 35 ft--lb (47 N--m).
Hydraulic System (Rev. I)
Hydraulic
System
3. Remove cartridge valve with a deep socket wrench.
Remove seal kit.
E. If problems still exist, remove valve and clean
again or replace valve.
Hydraulic Manifold Service (Serial Number Over 270000000)
20 ft--lb
(27 N--m)
26
25 ft--lb
(34 N--m)
18
2
25 ft--lb
(34 N--m)
15
13
11
2
60 in--lb
(6.7 N--m)
21
14
16
29
26
29
21
20 ft--lb
(27 N--m)
60 in--lb
(6.7 N--m)
10
17
6
12
6
20 ft--lb
(27 N--m)
40 ft--lb
(54 N--m)
7
7
4
165 in--lb
(18.6 N--m)
198 in--lb
(22 N--m)
1
9
VIEW FROM
BELOW
7
8
41 ft--lb
(55 N--m)
3
6
9
6
6
19
6
22
1
6
UP
20
24
5
23
20 ft--lb
(27 N--m)
8
6
120 in--lb
(13.5 N--m)
15 ft--lb
(20 N--m)
8
6
PLUG TORQUE
7
4
SAE #4: 165 in--lb (18.6 N--m)
Zero Leak #4: 120 in--lb (13.5 N--m)
Zero Leak #6: 198 in--lb (22 N--m)
Zero Leak #8: 41 ft--lb (55 N--m)
7
120 in--lb
(13.5 N--m)
25
27
30
28
31
25 ft--lb
(34 N--m)
Figure 59
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Manifold body
Solenoid coil
Flow control orifice (.060)
Orifice plug (.055) (2 used)
Flow control orifice (.013)
Plug (Zero Leak #4) (12 used)
Plug (Zero Leak #6) (5 used)
Plug (Zero Leak #8) (3 used)
Plug (SAE #4) (2 used)
Rotary cartridge valve (FC1)
Rotary handle assembly
Hydraulic System (Rev. I)
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Pilot piston
Relief cartridge valve (PRV)
Solenoid cartridge valve (S2)
Solenoid relief cartridge valve (S1R1)
Solenoid cartridge valve (S3)
Solenoid cartridge valve (S4)
Relief cartridge valve (R2)
Logic control cartridge valve (OR1)
Ball
Solenoid coil
Page 4 -- 92
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Dowel pin
Ball switch (N.O.)
O--ring
Flow control cartridge valve (FC2)
Nut
Flow control orifice (.025)
Hydraulic fitting
Nut
O--ring
O--ring
Greensmaster 3250--D
NOTE: The hydraulic manifold shown in Figure 59 uses
several zero leak plugs. These plugs have a tapered
sealing surface on the plug head that is designed to resist vibration induced plug loosening. The zero leak
plugs also have an O--ring to provide a secondary seal.
If zero leak plug removal is necessary, lightly rap the
plug head using a punch and hammer before using an
allen wrench to remove the plug: the impact will allow
plug removal with less chance of damage to the socket
head of the plug. When installing plugs into the manifold,
torque plugs to the values identified in Figure 59.
Solenoid Operated, Relief and Logic Control Cartridge Valves
1. Make sure the manifold is clean before removing the
cartridge valve and seal kit.
2. If solenoid valve is to be removed from manifold, remove nut securing solenoid to the cartridge valve. Carefully slide solenoid off the valve.
IMPORTANT: Use care when removing the cartridge
valve. Slight bending or distortion of the stem tube
can cause binding and malfunction. Make sure that
deep well socket fully engages the valve base.
3. Make sure manifold is clean before removing the
cartridge valve. Remove cartridge valve from manifold
with a deep well socket. Note location of O--rings and
backup rings on valve. Remove and discard removed
seal kit.
4. Visually inspect the manifold port and cartridge valve
for damage to sealing surfaces, damaged threads, and
contamination.
A. Contamination may cause valves to stick or hang
up. Contamination can become lodged in small valve
orifices or seal areas causing valve malfunction.
B. If valve sealing surfaces appear pitted or damaged, the hydraulic system may be overheating or
there may be water in the system.
5. Cleaning cartridge valves:
A. For non--solenoid operated valves:
Submerge valve in clean mineral spirits to flush out
contamination. If valve design allows, use a probe to
push the internal spool in and out 20 to 30 times to
flush out contamination. Particles as fine as talcum
powder can affect the operation of high pressure hydraulic valves. Clean and dry cartridge with compressed air.
B. For solenoid operated valves:
Temporarily install solenoid on cartridge valve and
connect a 12 volt power source to the solenoid. While
energized, flush out any contamination with a nonflammable aerosol brake cleaner. De-energize the
solenoid. Repeat the flush while energized procedure 5 or 6 times. Particles as fine as talcum powder
can affect the operation of high pressure hydraulic
valves. Remove solenoid from cartridge.
6. Reinstall the cartridge valve into the manifold:
A. Lubricate new O-rings and backup rings of seal
kit with clean hydraulic oil and install on cartridge.
The O-rings and backup rings must be arranged
properly on the cartridge valve for proper operation
and sealing.
IMPORTANT: Use care when installing the cartridge valve. Slight bending or distortion of the
stem tube can cause binding and malfunction.
Make sure that deep well socket fully engages
the valve base.
B. Lubricate cartridge threads with clean hydraulic
oil. Thread cartridge valve carefully into correct manifold port. The valve should go in easily without binding.
C. Torque cartridge valve using a deep well socket
to specification shown in Figure 59.
7. For solenoid valve, slide solenoid coil onto the cartridge valve. Install and torque nut to 60 in--lb (6.7 N--m).
8. If problems still exist, remove valve and clean again
or replace valve.
CAUTION
Use eye protection such as goggles when using
compressed air.
Greensmaster 3250--D
Page 4 -- 93
Hydraulic System (Rev. I)
Hydraulic
System
NOTE: The ports on the hydraulic manifold are marked
for easy identification of components. Example: FC1 is
the flow control valve and P1 is the gear pump connection port (See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each
port location).
Rotary Cartridge Valves
IMPORTANT: Use care when installing the rotary
cartridge valve. Slight bending or distortion of
the stem tube can cause binding and malfunction. Make sure that deep well socket fully engages the valve base.
1. Remove rotary handle from valve (Fig. 60):
A. Loosen two (2) set screws that secure handle
cap.
B. Lubricate cartridge threads with clean hydraulic
oil. Thread rotary cartridge valve carefully into the
manifold port. The valve should go in easily without
binding. Torque valve with a deep well socket to 40
ft--lb (54 N--m).
B. Remove screw and then lift handle cap from
valve.
C. Locate and retrieve detent pin, compression
spring, bushing and lip seal. The sleeve bearing
should stay in the cap.
6. Install rotary handle (Fig. 60):
D. Loosen two (2) set screws that secure handle
base to flow control valve and remove base.
A. Place handle base on flow control valve and position alignment mark on base with number 1 on manifold. Secure base with two (2) set screws. Apply a
light coating of grease to chamfer on top of base to
ease seal installation.
IMPORTANT: Use care when removing the rotary
cartridge valve. Slight bending or distortion of the
stem tube can cause binding and malfunction. Make
sure that deep well socket fully engages the valve
base.
B. Make sure that sleeve bearing is in handle cap. If
necessary, press sleeve bearing into cap. Install lip
seal on cap with seal lip facing down.
2. Make sure manifold is clean before removing the
rotary cartridge valve. Remove cartridge valve from
manifold with a deep well socket. Note location of O-rings and backup rings on valve. Remove and discard
removed seal kit.
C. While pressing on the cap to keep the lip seal in
place, rotate cap in a clockwise direction until the arrow on the cap aligns with number 1 on the manifold.
By rotating the cap clockwise, the valve will remain
closed. Install screw to retain cap.
3. Visually inspect the manifold port and cartridge valve
for damage to sealing surfaces, damaged threads, and
contamination.
D. Make sure that alignment marks on cap and base
are in line and that arrow on cap is pointing to number
1 on manifold. Tighten two (2) set screws to secure
handle cap.
A. Contamination may cause valves to stick or hang
up, it can become lodged in small valve orifices or
seal areas causing valve malfunction.
8
B. If sealing surfaces appear pitted or damaged, the
hydraulic system may be overheating or there may
be water in the system.
2
6
9
CAUTION
10
11
4
Use eye protection such as goggles when using
compressed air.
3
5
7
4. If necessary, clean cartridge valve using clean mineral spirits. Submerge valve in clean mineral spirits to
flush out contamination. Particles as fine as talcum powder can affect the operation of high pressure hydraulic
valves. Clean and dry with compressed air.
5. Reinstall rotary cartridge valve into manifold port:
A. Lubricate new O-rings and backup rings of seal
kit with clean hydraulic oil and install. The O-rings
and backup rings of seal kit must be arranged properly on the cartridge valve for proper operation and
sealing.
Hydraulic System (Rev. I)
1
Figure 60
1.
2.
3.
4.
5.
6.
Page 4 -- 94
Handle Base
Handle Cap
Detent Pin
Compression Spring
Bushing
Set Screw (2 used)
7.
8.
9.
10.
11.
Set Screw (2 used)
Screw
Lip Seal
Sleeve Bearing
Flow Control Valve
Greensmaster 3250--D
Mow/Backlap Spool (Fig. 61)
1
1. Remove mow/backlap spool from manifold:
2
4
A. Remove backlap switch from manifold before removing mow/backlap spool. Remove dowel pin and
ball from manifold port after switch is removed. Remove and discard O--ring from switch.
Loctite 603
3
6
B. Remove lower retaining ring from mow/backlap
spool. Raise mow/backlap spool to allow access to
retaining ring on upper end of spool. Remove upper
retaining ring.
5
C. Push spool down until lower O--ring and back--up
ring are exposed on bottom of manifold. Remove
lower O--ring and back--up ring from spool.
D. Pull spool up and out of manifold. Remove O-rings and back--up ring from spool.
E. Discard removed O--rings and back--up rings.
2. Visually inspect the spool and manifold port for damage to the sealing surfaces and contamination.
4
3. Install mow/backlap spool into manifold:
3
B. Carefully push spool down into manifold port until
lower O--ring and back--up ring groove is exposed on
bottom of manifold. Install lower O--ring and back--up
ring to spool. Apply a light coating of grease to O-ring.
1
Figure 61
1. Retaining ring
2. O--ring
3. Back--up ring
4. O--ring
5. Spool handle
6. Rotary spool
C. Install lower retaining ring to spool.
D. Carefully raise mow/backlap spool until upper retaining ring groove on spool is exposed on top of
manifold. Install upper retaining ring.
E. If handle was removed from spool, position spool
so handle location of spool is between stop pins in
manifold. Apply Loctite 603 Retaining Compound (or
equivalent) to threads on handle and install handle
into spool.
F. Place ball and dowel pin in backlap switch manifold port. Install new O--ring onto backlap switch.
Thread backlap switch into port and torque 15 ft--lb
(20 N--m).
Greensmaster 3250--D
Page 4 -- 95
Hydraulic System (Rev. I)
Hydraulic
System
A. Install O--rings and back--up ring to upper
grooves on spool. Apply a light coating of grease to
O--rings.
Flow Control and Backlap Valves (If Equipped on Serial Number Under 260999999)
16
14
17
15
18
12
3
35 ft--lb
(47 N--m)
4
5
19
6
21
20
22
23
24
26
35 ft--lb
(47 N--m)
25
7
13
8
2
1
11
10
9
35 ft--lb
(47 N--m)
27
Figure 62
1.
2.
3.
4.
5.
6.
7.
8.
9.
Backlap bracket
N.O. ball switch
Socket head screw
Flat washer
Detent kit
Indicator kit
Directional cartridge valve (Port RD1)
Seal kit
Seal kit
10.
11.
12.
13.
14.
15.
16.
17.
18.
Logic cartridge (Port LC1)
Seal kit
Detent kit
Flow control cartridge (Port FC1)
Jumper wire
Harness
Relay
Knob
Jam nut
19.
20.
21.
22.
23.
24.
25.
26.
27.
Indicator plate
Spring
Spring
Detent plate
Set screw
Ball
Locating plate
Locating plate
Manifold
Note: The ports on the manifold are marked for easy identification of components. Example: LC1 is for the reel logic
cartridge and RD1 is for the directional cartridge valve. See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port location.
Page 4 -- 96
Greensmaster 3250--D
Hydraulic System (Rev. I)
Flow Control and Two Position Directional Valves
(Fig. 62)
6. Reinstall the cartridge valve (7 or 13):
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
properly on the cartridge valve (7 or 13) for proper
operation and sealing.
CAUTION
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components.
1. Remove knob assembly:
B. Thread valve carefully into the applicable port
(RD1 or FC1). The valve should go in easily without
binding. Torque valve to 35 ft--lb (47 N--m).
7. Reinstall knob assembly:
A. Unscrew and remove knob (17). Remove both
jam nuts (18).
A. Install applicable locating plate (25 or 26) so that
the pin seats into the locating hole.
B. Slide off applicable indicator plate (6 or 19) being
careful not to lose springs (20 or 21). Remove
springs.
B. Turn the threaded cartridge valve (7 or 13) stem
carefully clockwise until it stops.
C. Loosen set screw (23) and slide detent plate (22)
off the applicable cartridge valve (7 or 13) stem.
C. Face detent plate (22) counterbore down.
Thread detent plate down onto the valve stem until it
is stopped by the locating plate. Turn detent plate
back counterclockwise 1/4 turn.
2. Remove cartridge valve (7 or 13) and seal kit (8 or
11).
3. Visually inspect the port in the manifold (27) for
damage to the sealing surfaces, damaged threads, and
contamination.
4. Visually inspect cartridge valve (7 or 13) for damaged sealing surfaces and contamination.
A. Contamination may cause valves to stick or
hang up, it can become lodged in small valve orifices or seal areas causing malfunction.
B. If sealing surfaces appear pitted or damaged,
the hydraulic system may be overheating or there
may be water in the system.
CAUTION
Use eye protection such as goggles when using
compressed air.
5. If necessary, clean cartridge valve (7 or 13) using
clean mineral spirits. Submerge valve in clean mineral
spirits to flush out contamination. Particles as fine as talcum powder can affect the operation of high pressure
hydraulic valves. Use compressed air for cleaning.
Greensmaster 3250--D
Page 4 -- 97
D. Center one detent plate hole over a locating
plate indentation. Drop a ball (24) into each hole,
then drop a spring (20 or 21) into each hole.
E. On flow control valve (7), place indicator plate (6)
over the detent plate. Make sure the arrow points directly at the number 1 on the locating plate.
F. On directional cartridge cartridge valve (13),
place indicator plate (19) over the detent plate.
Make sure the arrow points to the right at 45o.
G. While pushing down on the indicator plate (6 or
19) and compressing the springs, thread down a
jam nut (18). While tightening the set screw (23),
tighten jam nut at the same time using a 7/16 -- inch
wrench
H. Thread second jam nut all the way down the
valve stem. Apply “Loctite 242” or equivalent on the
valve stem threads. Screw knob (17) all the way
down until it hits the upper jam nut.
I. On directional cartridge valve (7), turn knob (17)
counterclockwise so the arrow is 90o with the back
of the manifold (27). Simultaneously tighten upper
jam nut (18) and turn knob so it is tight and the arrow
is pointing 45o to the right in line with the indicator
plate (6).
J. On flow control cartridge valve (13), turn knob
(17) counterclockwise until the arrow points at the
number “5”. Simultaneously tighten upper jam nut
(18) and turn knob so it is tight and the arrow is pointing at the number “1” on the locating plate (19).
Hydraulic System (Rev. I)
Hydraulic
System
D. Remove the applicable locating plate with pin
(25 or 26) from the cartridge valve stem and manifold (27).
Logic Cartridge Valves (Fig. 62)
CAUTION
CAUTION
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components.
1. Remove logic cartridge valve (10) and seal kit (9).
2. Visually inspect the port in the manifold (27) for
damage to the sealing surfaces, damaged threads, and
contamination.
Use eye protection such as goggles when using
compressed air.
4. Clean logic cartridge valve (10) using clean mineral
spirits. Submerge valve in clean mineral spirits to flush
out contamination. Particles as fine as talcum powder
can affect the operation of high pressure hydraulic
valves. Use compressed air for cleaning.
5. Reinstall logic cartridge valve (10):
3. Visually inspect logic cartridge valve (10) for damaged sealing surfaces and contamination.
A. Contamination may cause valves to stick or
hang up, it can become lodged in small valve orifices or seal areas causing malfunction.
B. If sealing surfaces appear pitted or damaged,
the hydraulic system may be overheating or there
may be water in the system.
Hydraulic System (Rev. I)
Page 4 -- 98
A. Lubricate new O--ring and backup ring of seal kit
(9) with clean hydraulic oil and install. The O--ring
and backup ring must be arranged properly on the
cartridge valve for proper operation and sealing.
B. Thread cartridge valve carefully into the port
(LC1). The valve should go in easily without binding.
Torque the valve to 35 ft--lb (47 N--m).
Greensmaster 3250--D
Rear Lift Cylinder Flow Control Valve
8
HYDRAULIC CYLINDER
7
6
5
4
1
2
FLOW CONTROL VALVE
3
Figure 63
1.
2.
3.
Hose assembly
O--ring
90o Hydraulic fitting
4.
5.
6.
O--ring
Flow control valve
O--ring
7.
8.
90o Hydraulic fitting
Hydraulic cylinder
Removal
Hydraulic
System
1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking
brake, lower cutting units, and stop the engine.
CAUTION
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components.
2. Label all hydraulic connections for reassembly. Disconnect hose assembly and O--ring from the hydraulic
fitting. Allow hose to drain into a suitable container.
3. Remove hydraulic fitting and O--ring from flow control valve. Remove valve and O--ring from hydraulic fitting. Put caps or plug on hydraulic cylinder fitting to
prevent contamination.
Figure 64
4. Install O--ring and hose assembly to the hydraulic
fitting.
5. Adjust flow control valve as follows:
Installation
1. Lubricate all new O--rings with clean hydraulic oil.
2. Install O--ring and hydraulic fitting to the flow control
valve.
A. Turn adjustment knob in fully clockwise, and
then turn out counterclockwise 3 turns.
B. Adjust knob no more than 1/2 turn in either direction until the number 8 is aligned with the dimple on
the valve body. Lock adjustment knob by tightening
set screw.
3. Install flow control valve and O--ring to the hydraulic
fitting on the hydraulic cylinder. Make sure adjustment
knob faces forward.
Greensmaster 3250--D
Page 4 -- 99
Hydraulic System (Rev. I)
Steering Control Valve
1
2
ILLUSTRATION FOR MACHINE
WITH SERIAL NUMBER
UNDER 220999999
28
3
27
4
5
10
6
35 ft--lb
(47 N--m)
11
7
12
26
21
8
4
19
20
37
34
35
22
9
17
29
36
14
10
13
33
24
32
18
31
30
15
29
12
11
25
23
13
Antiseize
Lubricant
16
Figure 65
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Knob
Lockup handle
Lockup spacer
Friction disc
Steering wheel
Steering wheel nut
Socket head screw
Lockup spacer
Socket head screw
Cap screw
Flat washer
Bushing
Socket head screw (6 used)
Hydraulic System (Rev. I)
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Steering arm cover
Steering column assembly
Steering valve cover
Hydraulic fitting (2 used)
Cap screw
Steering arm
Decal
Socket head screw (3 used)
Square head screw
Steering control valve
Thrust washer
Speed nut (6 used)
Page 4 -- 100
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
Warning decal
Steering wheel cap
Screw
O--ring
Hose assembly
Hose assembly
Hose assembly
Hose assembly
Hose assembly
O--ring
O--ring
Cable tie
Greensmaster 3250--D
Removal (Fig. 65)
1. Before removing any parts from the hydraulic system, park the machine on a level surface, engage the
parking brake, lower the cutting units, and stop the engine.
ILLUSTRATION FOR MACHINE
WITH SERIAL NUMBER
FROM 230000001 TO
270999999
2
CAUTION
1
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components.
Antiseize
Lubricant
2. Remove screw (28) and steering wheel cap (27)
from the steering wheel (5).
3
3. Remove steering wheel nut (6) from the steering
column assembly (15).
5
4. Remove screws (13) from the speed nuts (25) and
steering valve cover (16). Remove cover from the steering cover assembly (14).
Note: Three different styles of steering control valve
have been used on Greensmaster 3250--D machines.
Figure 65 illustrates machines with serial number under
220999999. Machines with serial number from
230000000 to 270999999 use four hydraulic fittings on
the control valve (Fig. 66). Machines with serial number
above 280000000 use a control valve without a steering
column (Fig. 67). Use appropriate illustration as a guide
when removing steering control valve.
Figure 66
1.
2.
3.
Fitting (2 used)
Cap screw (4 used)
Steering column
4.
5.
Steering control valve
Fitting (2 used)
Hydraulic
System
5. Cut and remove cable tie (37) from the hose assemblies. Label all hydraulic connections for assembly purposes.
4
ILLUSTRATION FOR MACHINE
WITH SERIAL NUMBER
ABOVE 280000000
2
6. For hydraulic hoses that attach to fittings in steering
control valve, disconnect hoses from fittings and remove O--rings. Allow hoses to drain into a suitable container.
1
7. For remaining hydraulic hose(s) that thread directly
into control valve, disconnect opposite end of hose from
fitting on hydraulic manifold or steering cylinder. Allow
hose(s) to drain into a suitable container. Note routing of
hydraulic hose(s) for assembly purposes.
Antiseize
Lubricant
8. Remove cap screws from the steering arm cover
and steering control valve. Carefully pull control valve
with attached hydraulic hose(s) free of the machine.
9. Remove hydraulic fittings and O--rings from the control valve. Remove hydraulic hose(s) and O--rings from
the steering control valve.
3
4
Figure 67
1.
2.
Fitting (2 used)
Cap screw (4 used)
3.
4.
Steering control valve
Fitting (2 used)
10. If equipped, remove steering column assembly
from the steering control valve.
Greensmaster 3250--D
Page 4 -- 101
Hydraulic System (Rev. I)
Installation (Fig. 65)
1. Install removed hose assemblies and O--rings to the
steering control valve. Install removed hydraulic fittings
and O--rings to the control valve.
2. Install steering column assembly to the steering
control valve.
3. While routing hydraulic hoses to machine, position
steering control valve into the steering cover assembly.
Secure control valve to steering arm cover with cap
screws.
4. For hydraulic hose(s) that thread directly into control
valve, correctly connect opposite end of hose to fitting
on hydraulic manifold or steering cylinder.
Hydraulic System (Rev. I)
5. Connect remaining hoses to fittings in steering control valve.
6. Install cable tie to the hose assemblies.
7. Position steering valve cover (16) to the steering
cover assembly (14). Secure cover to assembly with
screws (13) and speed nuts (25).
8. Apply antiseize lubricant to splines of steering column. Install steering wheel and secure with nut. Torque
nut to 35 ft--lb (47 N--m).
9. Secure steering wheel cap to the steering wheel
with screw.
Page 4 -- 102
Greensmaster 3250--D
Hydraulic
System
This page is intentionally blank.
Greensmaster 3250--D
Page 4 -- 103
Hydraulic System (Rev. I)
Steering Control Valve Service (Serial Number Under 220999999)
BOTTOM
5
1
6
2
INNER
RACE
8
3
15
12
13
14
4
OUTER
RACE
7
10
GEAR
WHEEL
16
9
11
18 to 27 ft--lb
(24 to 37 N--m)
20
RIM
16
21
17
18
22
19
18 to 27 ft--lb
(24 to 37 N--m)
Figure 68
1.
2.
3.
4.
5.
6.
7.
8.
Dust seal
Housing
Ball
Threaded bushing
O--ring/kin--ring
Bearing assembly
Ring
Spool
9.
10.
11.
12.
13.
14.
15.
Cross pin
Spring set
Sleeve
Cardan shaft
O--ring
Distributor plate
Gear wheel set
Disassembly (Fig. 68)
1. Make sure caps or plugs are in motor openings to
prevent contamination. Clean motor with solvent.
IMPORTANT: Use caution when using a vise to hold
the control valve. Do not over tighten. Parts may become distorted.
2. Secure control valve in a vise with the screw heads
up. Remove six screws, one special screw, and seven
washers from the valve.
Hydraulic System (Rev. I)
16.
17.
18.
19.
20.
21.
22.
O--ring
End cover
Washer
Special screw
Screw
Name plate
Drive screw
3. Slide end cover off the gear wheel set. Remove gear
wheel set. Remove both O--rings from the rim.
4. Lift and remove cardan shaft from the control valve.
5. Remove distributor plate from the control valve and
O--ring from housing.
6. Screw out threaded bushing from the control valve.
Remove remove valve from the vise and shake out the
ball.
Page 4 -- 104
Greensmaster 3250--D
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. 69).
Note: The outer race of the bearing assembly may
stick in the housing. Make sure race is removed from the
housing.
CROSS PIN
8. Remove ring and bearing assembly from the spool.
Note: There is a small match mark on both the spool
and sleeve near one of the slots for the spring. If the
mark is not visible, match mark both the sleeve and
spool before removing the springs (Fig. 70).
Figure 69
9. Use special screw to press out cross pin from the
sleeve and spool (Fig. 69). Press spool carefully out of
the sleeve.
MARK
10. Press springs out of their slots in the spool.
11. Remove dust seal and O--ring/kin--ring from the
housing. Discard all seals, O--rings, and washers.
Hydraulic
System
12. Remove all nicks and burrs from all parts with an
emery cloth.
CAUTION
Figure 70
Use eye protection such as goggles when using
compressed air.
13. Clean all parts with solvent. Dry all parts with compressed air.
TOP VIEW OF
SPOOL AND SLEEVE
Reassembly (Fig. 68)
1. Lubricate all parts, O--ring/kin--ring, dust seal,
washers, and O--rings with clean hydraulic fluid.
CURVED SPRING
2. Insert two flat springs into the slot of the spool. Insert
two curved springs between the flat springs and press
them into place (Fig. 71).
3. Install spool into the sleeve. Make sure match
marks on each part are aligned. Press springs together
and push them into slot in the sleeve. Line up springs
and center them (Fig. 70 and 71).
FLAT SPRING
Figure 71
Greensmaster 3250--D
Page 4 -- 105
Hydraulic System (Rev. I)
4. Install ring over the sleeve. Make sure ring is able
to rotate free of the springs.
OUTER RACE
5. Insert cross pin into the spool and sleeve (Fig. 69).
NEEDLE BEARING
6. Install bearing assembly onto the spool and sleeve
(Fig. 72).
INNER RACE
7. Coat new O--ring/kin--ring lightly with petroleum jelly. Install ring carefully into the inner bore of the housing
so that they fit snuggly in place (Fig. 73 and 74).
Note: The cross pin should be held horizontal when
inserting the spool and sleeve into the housing.
SLEEVE
Figure 72
Note: The clearance between the sleeve and the
housing bore is very tight. The heat from one’s hand can
cause the sleeve to expand enough so that it will not fit
into the housing. Refrigerate the spool/sleeve assembly
prior to installation. Insulate assembly from one’s hand
when installing.
INNER
BORE
8. Guide spool and sleeve into the housing carefully by
using a light turning motion. Be careful not to damage
the O--ring/kin--ring.
DUST SEAL
O--RING/KIN--RING
HOUSING BOTTOM
9. Place ball into the largest threaded hole. Secure ball
into hole by threading in the bushing. Make sure the top
of the bushing lies just bellow the surface of the housing
(Fig. 74).
10. Coat new O--ring lightly with petroleum jelly. Install
O--ring into groove on housing surface.
CHAMFERED
SIDE
SPOOL
Figure 73
THREADED
BUSHING
11. Mount distributor plate onto housing. Make sure
channel holes in plate match the hole of the housing.
12. Insert cardan shaft carefully into the bore of the
housing. Make sure shaft slot is parallel with the surface
of the connection flange.
13. Coat both new O--rings lightly with petroleum jelly.
Install O--rings into grooves on rim of gear wheel set.
Place rim onto distributor plate.
IMPORTANT: The gear wheel fits into the cardan
shaft from one direction only. The tooth base on the
wheel should be positioned in relation to the shaft
slot (Fig. 75).
O--RING/
KIN--RING
Figure 74
14. Fit gear wheel onto cardan shaft and into the rim.
Make sure holes in rim are aligned with holes in the
housing.
15. Install end cover onto rim of gear wheel.
Figure 75
Hydraulic System (Rev. I)
Page 4 -- 106
Greensmaster 3250--D
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
SCREW
18. Install dust seal carefully into the housing.
Figure 76
SPECIAL
SCREW
Hydraulic
System
Figure 77
Greensmaster 3250--D
Page 4 -- 107
Hydraulic System (Rev. I)
Steering Control Valve Service (Serial Number From 230000000 to 270999999)
1
27
28
5
4
8
26
3
24
2
19
19
23
29
30
7
6
25
20
22
21
150 in--lb
(17 N--m)
9
10
17
18
16
15
14
13
12
11
140 to 160 in--lb
(16 to 18 N--m)
Figure 78
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Steering valve housing
Dust seal
O--ring
Spool
Spring retaining ring
Pin
Sleeve
Centering springs/spacers
Cap screw
End cap
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
O--ring
Seal ring
O--ring
Geroter
O--ring
Spacer
Geroter drive
Wear plate
Bearing race
Thrust bearing
Disassembly
NOTE: Cleanliness is extremely important when
repairing hydraulic components. Work in a clean area.
Before disassembly, drain the oil, then plug the ports
and thoroughly clean the exterior. During repairs,
always protect machined surfaces.
1. Remove the seven cap screws from the steering
valve assembly.
2. Remove end cap, geroter, spacer, geroter drive,
wear plate, seal ring, and O--rings from housing (Fig.
78).
3. Remove the plug and relief valve.
Hydraulic System (Rev. I)
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Plug
O--ring
Relief valve (R5)
Quad seal
Ring
T port
E port
R port
L port
P port
4. Slide the spool and sleeve assembly from the housing.
5. Remove the thrust bearing and bearing races (2).
6. Remove the quad seal.
7. Use a small blade screwdriver to carefully pry the
dust seal from the housing. Be careful to not damage the
dust seal seat in the housing.
8. Remove the pin that holds the spool and sleeve together.
9. Carefully slide the spool out of the sleeve. The centering springs and spring retaining ring will stay with the
spool as it is removed.
Page 4 -- 108
Greensmaster 3250--D
8. Put the thrust bearing and races into the housing.
The thrust bearing goes between the two races
(Fig. 79).
CAUTION
The centering springs are under tension. Remove the retaining ring carefully.
IMPORTANT: Do not damage the dust or quad seals
when installing the spool and sleeve assembly.
10.Remove the spring retaining ring and centering
springs from the spool.
9. Apply a light coating of clean hydraulic fluid to the
spool and sleeve assembly and slide carefully the assembly into the housing.
Reassembly
Check all mating surfaces. Replace any parts with
scratches or burrs that could cause leakage. Wash all
metal parts in clean solvent. Blow them dry with pressurized air. Do not wipe parts dry with paper towels or cloth.
Lint in a hydraulic system will cause damage.
NOTE: Always use new seals and O--rings when
reassembling the steering control unit.
IMPORTANT: During reassembly, lubricate the new
seals with petroleum jelly. Also, lubricate machined
surfaces and bearings with clean hydraulic fluid.
10.Clamp the housing in a vise. Use only enough clamping force to hold the housing securely.
11. Lubricate and install a new o-ring seal in the groove
in the housing.
12.Install the wear plate and align screw holes in the
wear plate with threaded holes in the housing.
NOTE: The holes in the wear plate are symmetrical.
13.Install the geroter drive, making sure the slot in the
drive engages the pin.
14.Lubricate and install new o-ring in wear plate groove.
A. Put one of the bearing races and sleeve into the
housing.
B. Together, the housing and bearing race create a
groove into which the quad seal will be installed.
C. Hold the bearing race tightly against the input end
of the housing by pushing on the gerotor end of the
sleeve.
15.Install the gerotor and align the screw holes.
16.Lubricate and install new o-ring in gerotor ring
groove.
17.Lubricate and install new o-ring and seal ring in gerotor star groove.
18.Install the spacer.
D. Fit the quad seal into its seat through the input end
of the housing. Be sure the seal is not twisted.
19.Install the end cap and seven cap screws. Tighten
the cap screws, in a crossing pattern, from 140 to 160
in-lb (16 to 18 N--m).
E. Remove the sleeve and bearing race.
20.Remove the steering control unit from the vise.
2. Lubricate and install the dust seal.
3. Install the centering springs in the spool. It is best to
install the two flat pieces first. Next, install the curved
pieces, three at a time.
4. Fit the retaining ring over the centering springs.
21.Install the relief valve and plug. Tighten the plug to
150 in-lb (17 N--m).
Thrust Bearing
and Race (2)
Dust Seal
5. Apply a light coating of clean hydraulic fluid to the
spool and slide it into the sleeve. Be sure the centering
springs fit into the notches in the sleeve.
Quad Seal
6. Install the pin.
7. Apply a light coating of petroleum jelly to the inner
edge of the dust and quad seals.
Greensmaster 3250--D
Page 4 -- 109
Figure 79
Hydraulic System (Rev. I)
Hydraulic
System
1. Install the quad seal:
Steering Control Valve Service (Serial Number Over 280000000)
14
13
11
16
15
12
11
7
8
10
9
6
25
5
3
26
v
4
27
2
29
24
28
23
22
21
18
1
20
17
18
19
20 to 24 ft--lb
(27 to 33 N--m)
18
Figure 80
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Plug
Plug
Spring
Relief valve
Dust seal
T port
Housing
R port
E port
Shaft seal
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Thrust washer
Bearing
Cross pin
Ring
Sleeve
Spool
Cardan shaft
O--ring
Distribution plate
Outer gearwheel
21.
22.
23.
24.
25.
26.
27.
28.
29.
Inner gearwheel
End cover
O--ring (5 used)
Cap screw (5 used)
Spring set
Ball stop
Ball
P port
L port
NOTE: For service of the steering control valve shown
in Figure 80, see the Sauer/Danfoss Steering Unit Type
OSPM Service Manual at the end of this chapter.
Hydraulic System (Rev. I)
Page 4 -- 110
Greensmaster 3250--D
Hydraulic
System
This page is intentionally blank.
Greensmaster 3250--D
Page 4 -- 111
Hydraulic System (Rev. I)
Steering Cylinder
CYLINDER
ASSEMBLY
2
65 to 85 ft--lb
(88 to 115 N--m)
1
3
27
26
28
30
24
21
32
31
25
17
22
22
19 18
20
28
27
3
4
23
33
19
15
17
18
65 to 85 ft--lb
(88 to 115 N--m)
26
37
16
39
36
35
38
29
34
6
7
5
8
9
RIGHT
FRONT
HUB
ASSEMBLY
10
12
14
13
8
7
6
29
WHEEL ASSEMBLY
11
Figure 81
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Slotted hex nut
Cotter pin
Steering washer
Castor fork
Bolt
Oil seal
Bearing cone
Bearing cup
Wheel hub
Grease fitting
Drive stud
Tire
Rim
Hydraulic System (Rev. I)
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Valve stem
Lug nut
Lock nut
Ball joint
Grease fitting
Retaining ring
Steering cylinder
Hydraulic hose
90o Hydraulic fitting
O--ring
O--ring
Hydraulic hose
Jam nut
Page 4 -- 112
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Bearing cone
Bearing cup
Rear spindle spacer
Grease fitting
Decal
Hose clamp
Hex washer head screw
Motor adapter plate
Adapter plate
Cap screw
Lock nut
Lock nut
Cap screw
Greensmaster 3250--D
Removal (Fig. 81)
1. Before removing any parts from the hydraulic system, park machine on a level surface, set brake, lower
cutting units, and stop engine.
CAUTION
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components.
CAUTION
Support rear wheel to prevent dropping and
causing personal injury while removing hex nut.
Use two people to remove steering cylinder.
8. If the rear ball joint needs to be removed, accomplish the following:
A. Block front wheels. Jack up rear wheel off the
ground by the frame. Secure the frame with the
wheel off the ground.
2. Label all hose connections for reassembly purposes
B. Remove lock nut, bolt, spacers, and wheel from
the castor fork.
3. Remove hose assemblies and O--rings from hydraulic fittings. Allow hoses to drain into a suitable container.
4. Gain access to front ball joint.
C. Remove jam nuts and ball joint from the castor
fork.
Installation (Fig. 81)
A. Remove three cap screws and flat washers securing the fuel tank base plate to frame. Two screws
are on the top of the plate at the front corners of the
tank. The third screw is in front of the castor fork and
below the plate.
1. If the rear ball joint was removed, accomplish the
following:
B. Tilt fuel tank base up by lifting at the right of the
machine to gain access to the top of the jam nuts
and ball joint. Prop up tank securely.
B. Install wheel to the castor fork by inserting the
bolt through the fork, spacer, wheel, spacer, and
fork. Secure bolt with lock nut.
5. Remove both jam nuts from the ball joint. Rotate
steering cylinder and detach ball joint from frame bracket.
6. Pivot steering cylinder out from the frame. Remove
retaining ring from the rear of the cylinder. Remove cylinder from rear ball joint.
7. Remove front retaining ring and ball joint from the
steering cylinder. Remove hydraulic fittings and O--rings
from the cylinder.
C. Lower wheel to ground
2. Install hydraulic fittings and O--rings to the steering
cylinder. Install front ball joint to the cylinder and secure
with retaining ring.
3. Install steering cylinder to the rear ball joint. and secure with retaining ring.
4. Pivot steering cylinder into the frame. Rotate steering cylinder and install ball joint to the frame bracket. Secure ball joint to the bracket with jam nuts. Torque nuts
from 65 to 85 ft--lb (88 to 115 N--m).
5. Lower fuel tank base to the frame. Secure base to
the frame with the three cap screws and flat washers.
6. Connect hydraulic hoses and O--rings to the hydraulic fittings. Tighten hose connections.
Greensmaster 3250--D
Page 4 -- 113
Hydraulic System (Rev. I)
Hydraulic
System
A. Secure ball joint to the castor fork with jam nuts.
Torque nuts from 65 to 85 ft--lb (88 to 115 N--m).
Steering Cylinder Service
9
10
14
11
13
12
10
11
9
5
2
5 6
4
3
8
7
3
4
2
6
1
SERIAL NUMBER BELOW 260999999
Figure 82
1.
2.
3.
4.
5.
Seal kit
Rod wiper
U--cup
Back--up ring
O--ring
6.
7.
8.
9.
10.
Wear ring
Piston ring
O--ring
Set screw
Threaded cap
11.
12.
13.
14.
Head
Piston
Barrel
Rod
4
12
v
15
12
16
13
3
14
7
2
3
7
5
6
8
9
10
6
2
5
11
1
SERIAL NUMBER ABOVE 270000000
Figure 83
1.
2.
3.
4.
5.
6.
Seal kit
Rod wiper
Seal
Head (non--ball joint end)
Back--up ring
O--ring
7.
8.
9.
10.
11.
Wear ring
O--ring
Back--up ring
Seal
Wear ring
NOTE: On machines with serial number above
270000000 (Fig. 83), the steering cylinder design does
not allow removal of the piston (item 13) from the rod.
This cylinder design prevents replacing the O--ring on
the inside of the piston and also the seals on the ball joint
end head (item 16). If a steering cylinder leak exists on
Hydraulic System (Rev. I)
12.
13.
14.
15.
16.
Retaining ring
Piston
Rod
Barrel
Head (ball joint end)
the non--ball joint end head (item 4), all seals on that
head can be replaced. The piston outer seals (items 9
and 10) and wear ring (item 11) can be replaced as well.
If leakage or damage exists at other cylinder locations
that cannot be disassembled, steering cylinder replacement will be necessary.
Page 4 -- 114 Rev. J
Greensmaster 3250--D
Disassembly (Figs. 82 and 83)
Assembly (Figs. 82 and 83)
IMPORTANT: To prevent damage when clamping
cylinder barrel in a vise, clamp only on pivot end. Do
not clamp the vise jaws against the shaft surface.
NOTE: Due to steering cylinder design for serial numbers above 270000000, the seal kit may include several
O--rings, backup rings and wear rings that cannot be accessed.
2. Mount cylinder in a vise by clamping vise on center
mounting location of cylinder. Do not close vise so firmly
that cylinder barrel could become distorted.
3. Remove both heads from the barrel:
A. For serial numbers below 260999999, loosen
set screws and remove threaded cap from each end
of the cylinder barrel.
B. For serial numbers above 270000000, use a
spanner wrench to rotate head clockwise until the
edge of the retaining ring appears in the barrel
opening. Insert a screwdriver under the beveled
edge of the retaining ring to start the retaining ring
through the opening. Rotate the head counter-clockwise to remove retaining ring from barrel and
head.
C. Grasp end of rod and use a twisting and pulling
motion to carefully extract rod assembly and head
from cylinder barrel. Remove head from other end
of barrel.
4. For serial numbers below 260999999, loosen set
screws that secure piston to shaft and carefully remove
piston. Slide head and threaded cap from shaft. Piston
for serial numbers above 270000000 is not removable
from shaft.
5. Remove and discard all accessible seals, back--up
rings, and O--rings from piston and both heads.
1. Put a coating of clean hydraulic oil on all new seals,
back--up rings, and O--rings that are to be installed in cylinder.
2. Install new u--cup, rod wiper, back up ring, and O-ring onto each head. Position O--ring(s), piston ring, and
both wear rings to the piston.
3. For serial numbers below 260999999, lubricate
shaft, ball joint end head and piston with clean hydraulic
oil. Carefully slide ball joint end head and then piston
onto shaft. Install thread locker on set screw threads and
tighten two set screws to secure piston to shaft.
4. Lubricate shaft assembly with clean hydraulic oil
and carefully slide shaft assembly into cylinder barrel.
5. Lubricate non--ball joint end head assembly with
clean hydraulic oil and carefully slide it onto shaft and
into barrel.
6. Secure heads to barrel:
A. For serial numbers below 260999999, install
and tighten threaded caps. Secure both caps to barrel with set screws.
B. For serial numbers above 270000000, align retaining ring hole in the head with the access slot in
the barrel. Insert the retaining ring hook into the hole
and rotate head clockwise until the retaining ring is
completely pulled into the barrel and the ring ends
are covered. Apply silicone sealer to barrel access
slot.
CAUTION
Use eye protection such as goggles when using
compressed air to dry cylinder parts.
6. Wash parts in clean solvent. Dry parts with compressed air. Do not wipe parts dry with paper towels or
cloth. Lint in a hydraulic system will cause damage.
7. Carefully inspect internal surface of barrel for damage (deep scratches, out--of--round, etc.). Replace entire cylinder if barrel is damaged. Inspect shaft, both
heads, and piston for evidence of excessive scoring, pitting, or wear. Replace any damaged parts.
Greensmaster 3250--D
Page 4 -- 115 Rev. J
Hydraulic System (Rev. I)
Hydraulic
System
1. Pump oil out of cylinder into a drain pan by slowly
moving rod in and out of cylinder bore. Plug ports and
clean outside of cylinder.
Hydraulic Reservoir
5
18
24 20
17
15
3
18
15
6
25
2
14
30 to 60 in--lb
(3.4 to 6.8 N--m)
29
16
11
1
4
28
19
13
12
16
9
22
23
10
21
26
7
27
8
9
23
Figure 84
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Hydraulic barb fitting
Hydraulic straight fitting
Fuel tank clamp
Hex washer head screw
Tank cap
Hydraulic tank
Hydraulic straight fitting
Oil filter assembly
Hydraulic barb fitting
Oil filter mount
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
O--ring
Flat washer
Grommet
O--ring
Flat washer
Cap screw
Filter screen
Cap screw
Plug
Air breather
Removing Hydraulic Reservoir (Fig. 84)
1. Before removing any parts from the hydraulic system, park machine on a level surface, set brake, lower
cutting units, and stop engine.
CAUTION
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components.
Hydraulic System (Rev. I)
21.
22.
23.
24.
25.
26.
27.
28.
29.
Return hose
Tube assembly
Hose clamp
Serrated plug
O--ring
O--ring
O--ring
O--ring
Mounting plate
v
2. Place a suitable container under the hydrostat to
collect hydraulic oil. Clamp pump inlet hose to prevent
drainage. Remove pump inlet hose from hydrostat and
direct to container. Release clamp from hose (Fig. 85).
3. Disconnect hose assembly from the hydraulic fitting
welded to the reel motor case drain tube located below
the right side of the frame. Allow hose to drain to a suitable container (Fig. 86).
4. Disconnect return hose (21) from hydraulic barb fitting (9). Allow hose to drain to a suitable container.
Page 4 -- 116
Greensmaster 3250--D
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. Two
screws are located on the top of the plate at the front corners of the fuel tank. The third screw is in front of the castor fork and below the plate.
PUMP INLET HOSE
7. Tilt mounting plate (29) up by lifting at the rear of the
machine. Prop up plate securely. Remove four cap
screws (16) and flat washers (12) securing the hydraulic
tank (6) to the mounting plate.
8. Remove hydraulic tank (6) from the mounting plate
(29).
Figure 85
Inspecting Reservoir Parts (Fig. 84)
1
1. Clean tank and filler screen with solvent.
2. Inspect tank for leaks, cracks, or other damage.
4. Make sure cap screws are secure. If loose, remove
and reinstall cap screws with “Loctite 242” or equivalent.
WELDED
FITTING
5. Make sure all bracket fasteners are tight.
2
Installing Hydraulic Reservoir (Fig. 84)
1. Place antiseize lubricant into all four inserts at the
bottom of the hydraulic tank (6). Position tank onto the
mounting plate (29).
Figure 86
1.
2. Secure hydraulic tank to the mounting plate with
four cap screws (16) and flat washers (12). Torque cap
screws from 30 to 60 in--lb (3.4 to 6.8 N--m).
3. Secure mounting plate (29) to the frame with three
hex head screws and flat washers Two screws go on the
top of the plate at the front corners of the fuel tank. The
third screw goes in front of the castor fork and below the
plate.
Hose assembly
4
1
Case drain tube
3
3
2
4. Secure console shroud to the hydraulic tank with
cap screw and flat washer, and to the lower panel with
both cap screws and flat washers (Fig. 87).
5
6
5. Secure return hose (21) to hydraulic barb fitting (9)
with hose clamp (23).
6. Secure pump inlet hose to hydrostat with hose
clamp (Fig. 85).
2.
Figure 87
1.
2.
3.
Cap screw
Cap screw
Flat washer
4.
5.
6.
Console shroud
Hydraulic tank
Lower panel
7. Connect hose assembly to the hydraulic fitting
welded to the reel motor case drain tube located below
the right side of the frame (Fig. 86).
Greensmaster 3250--D
Page 4 -- 117
Hydraulic System (Rev. I)
Hydraulic
System
3. Replace hydraulic hoses if worn or leaking.
Leak Detector
1
2
3
9
17 to 21 ft--lb
(23 to 28 N--m)
4
10
33
8
5
38
7
6
11
5
9
34
35
10
28
37
35
36
12
32
100 to 125 in--lb
(11.3 to 14.1 N--m)
13
31
30 to 60 in--lb
(3.4 to 6.8 N--m)
17 to 21 ft--lb
(23 to 28 N--m)
30
29
14
15
16
16
26
28
6
7
17
27
7
18
25
19
20
24
18
21
39
23
22
9
10
Figure 88
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Clamp
Lock nut
Delay timer
Cover plate
Audio alarm assembly
Hydraulic barb fitting
O--ring
Pipe plug
Cap screw
Flat washer
Leak detection tank
Cap screw
Flat washer
Hydraulic System (Rev. I)
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Mounting plate
Formed outlet hose
Hose clamp
Idler washer
Valve assembly
Lock nut
O--ring
Leak detector harness
R--clamp
Oil level sensor
O--ring
Cartridge valve with O--ring
Formed inlet hose
Page 4 -- 118
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Hydraulic barb fitting
O--ring
Plug
Cap screw
Flat washer
Grommet
Hydraulic oil cap
Sight gauge
Toggle switch
Leak detector decal
Toggle switch boot
Socket head screw
Hydraulic tank
Greensmaster 3250--D
Removal (Fig. 88)
3
1. Before removing any parts from the hydraulic system, park machine on a level surface, set brake, lower
cutting units, and stop engine.
1
2
5
4
CAUTION
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components.
2. Place clean container, large enough to collect 2 gallons (7.6 liters), under the oil filter assembly to collect hydraulic oil.
Figure 89
1.
2.
3.
4. Remove five cap screws and flat washers securing
the cover plate and cap tether to the leak detection tank.
Remove cover plate from tank (Fig. 89).
Cap screw
Flat washer
Cover plate
4.
5.
Cap tether
Leak detection tank
9
5. Remove cap screw and flat washer securing R-clamp and leak detector harness to the underside of the
hydraulic tank. Pull clamp free of harness (Fig. 90).
6. Unplug leak detector harness from 2--pin plug, with
yellow/orange and black wires, on the main tractor harness. Pull leak detector harness out of the access hole
on the hydraulic tank.
6
11
5
Hydraulic
System
3. Crack open oil filter and allow at least 2 gallons (7.6
liters) of hydraulic oil to drain into the container, then
tighten oil filter to stop drainage. Uncap hydraulic oil tank
and allow enough time for the hydraulic oil to drain out
of the leak detection tank into the hydraulic oil tank.
7
4
12
10
7. Loosen four cap screws securing the valve assembly to the fill neck on the hydraulic tank. Lift leak detection tank from the hydraulic tank. Remove O--ring from
fill neck boss (Fig. 90).
8
1
Installation (Fig. 88)
1. Top off main hydraulic tank until fluid is visible at
base of breather port. This will ensure that the maximum
amount of air is purged from the main tank before installing the leak detector.
2. Make sure filler screen is placed in neck of auxiliary
tank.
3. Make sure five capscrews and washers securing
the cover plate to auxiliary hydraulic tank are removed
with the cover plate (Fig. 89).
4. Clean mating surfaces of block and fill neck with a
clean, dry rag. Carefully place new O--ring over fill neck
boss (Fig. 90).
Greensmaster 3250--D
2
3
1.
2.
3.
4.
5.
6.
1
Figure 90
Cap screw
Flat washer
R--ring
Leak detector harness
Hydraulic tank
Cap screw
7.
8.
9.
10.
11.
12.
Valve assembly
Fill neck
Leak detection tank
O--ring
Plug
Sight gauge
5. Route wire harness through access hole in hydraulic tank. Align valve assembly with fill neck. Secure valve
to hydraulic tank fill neck with four capscrews (Fig. 90).
Page 4 -- 119
Hydraulic System (Rev. I)
IMPORTANT: Do not over tighten cap screw.
Threads in tank may become damaged.
6. Locate plugged 2--pin connector with yellow/orange
and black wires in main tractor harness. Attach leak detector harness. Secure leak detector harness to underside of leak detection tank with R--clamp and capscrew.
7. Remove plug from top of the valve assembly. Carefully fill float cavity to the top of the threads. Replace and
tighten fill plug. Clean up any spilled oil (Fig. 90).
8. Before reattaching cover plate, test leak detector
switch with ignition key switch in ON/RUN position. The
buzzer should sound with toggle switch held down for 1
second.
9. If the buzzer fails to sound, check to see if the ignition key switch is in ON/RUN position, all connections
are secure, and the test switch is held for 1 full second.
IMPORTANT: Do not over tighten cap screws.
Threads in tank may become damaged.
10. Secure cover plate and cap tether to the leak detection tank with five cap screws and flat washers (Fig. 90).
Note: Monitor hydraulic fluid level in sight glass and as
air is removed from the hydraulic circuit, auxiliary tank
may need to be topped off after initial fill.
11. Fill leak detection tank to the top of sight gauge (Fig.
90).
IMPORTANT: If a leak occurs or oil is removed from the
hydraulic system for service, the lost oil must be replaced. If a large amount of oil is lost, remove leak detection tank cover plate and follow steps 7 through 11 for
refilling instructions. For small amounts of oil, simply
add oil to auxiliary tank.
2. Secure sight gauge (34) and new O--ring (28) to the
leak detection tank (11). Torque gauge from 100 to 125
in--lb (11.3 to 14.1 N--m).
3. Secure both hydraulic barb fittings (6) and new O-rings (7) to the leak detection tank. Torque both fittings
from 17 to 21 ft--lb (23 to 28 N--m).
4. Apply antiseize lubricant to threaded holes on bottom of leak detection tank. Secure mounting plate (14)
to tank with two grommets (32), flat washers (31), and
cap screws (30). Torque both screws from 30 to 60 in--lb
(3.4 to 6.8 N--m).
5. Secure formed inlet hose (26) to the hydraulic barb
fitting (6) attached to the end of the tank with hose clamp
(16). Secure formed outlet hose (15) to the hydraulic
barb fitting (6) attached to the inner side of the tank with
hose clamp (16).
6. Secure both hydraulic barb fittings (27) and O--rings
(28) to the valve assembly (18). Secure oil level sensor
(23) and O--ring (24) to the assembly. Secure cartridge
valve with O--ring (25) to assembly. Hand tighten plug
(29) and O--ring (28) to the assembly.
7. Position valve assembly (18) under the mounting
bracket (14). Insert four cap screws (12) with two flat
washers (13) and two idler washers (17) through the
bracket and assembly. Hand tighten four M8--1.25 lock
nuts to the cap screws.
8. Secure toggle switch (35) to cover plate (4) with nut,
then secure toggle switch boot (37) to switch. Secure
audio alarm (5) to plate with cap. Secure delay timer (3)
to the plate with clamp (1), socket head screw (38), and
lock nut (2).
9. Connect leak detector harness to the following:
A. The connector with red and black wires to the
delay timer (3).
Disassembly and Inspection (Fig. 88)
1. The leak detector can be disassembled using the
leak detector assembly drawing (Fig. 88) as a guide.
B. The black/white and black wires to the negative
terminal of the audio alarm (5). Connect red and yellow wires to the positive terminal.
2. Clean tank and filler screen with solvent. Inspect
parts for the following:
C. The black and gray wires to the negative terminal of the toggle switch (35). Connect red and yellow
wires to the positive terminal.
A. Leaking, cracked, or damaged leak detection
tank.
D. The red/white and red wires to the positive terminal of the valve solenoid (18). Connect black wires
to the negative terminal.
B. Worn or leaking hydraulic hoses. Replace if necessary.
C. Visibly worn or damaged parts.
E. The connector with yellow and gray wires to the
oil level sensor (23).
Assembly (Fig. 88)
1. Coat all O--rings with clean hydraulic oil.
Hydraulic System (Rev. I)
10. Verify leak detector operation (see Leak Detector in
Chapter 7 -- Electrical System).
Page 4 -- 120
Greensmaster 3250--D
Chapter 5
Electrical System
Table of Contents
Functional Control Lever Reed Switches
and Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Backlap Switch (If Equipped) . . . . . . . . . . . . . . . .
Leak Detector (Optional) . . . . . . . . . . . . . . . . . . . .
Warning Light Cluster . . . . . . . . . . . . . . . . . . . . . . .
High Temperature Shutdown Switch . . . . . . . . . .
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . .
Lower Reels Time Delay . . . . . . . . . . . . . . . . . . . .
Diode Circuit Boards . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Valve Coils . . . . . . . . . . . . . . . . . . . . . . . .
Glow Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . .
Verify Interlock System Operation . . . . . . . . . . . .
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
13
16
17
18
19
20
21
22
23
23
24
Electrical
System
ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Run & Transport Problems . . . . . . . . . . . . 6
Cutting Unit Operating Problems . . . . . . . . . . . . . . 7
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . . 8
Battery Test (Open Circuit) . . . . . . . . . . . . . . . . . . . 8
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . 9
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Greensmaster 3250−D
Page 5 − 1
Rev. H
Electrical System (Rev. C)
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)
Page 5 − 2
Greensmaster 3250−D
Special Tools
Order special tools from your Toro Distributor. Some
tools may also be available from a local supplier.
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 meter in the voltage mode will make sure that excess current is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.
Figure 1
Skin--Over Grease
Special non--conductive grease which forms a light protective skin which helps waterproof electrical switches
and contacts.
Figure 2
Greensmaster 3250--D
Page 5 -- 3 Rev. I
Electrical System (Rev. C)
Electrical
System
Toro Part Number: 505--165
Troubleshooting
For effective troubleshooting and repairs, you must
have a good understanding of the electrical circuits and
components used on this machine (see Wiring Schematics section of this chapter).
CAUTION
Remove all jewelry, especially rings and
watches, before doing any electrical troubleshooting or testing. Disconnect the battery
cables unless the test requires battery voltage.
If the machine has any interlock switches by−passed,
they must be reconnected for proper troubleshooting
and safety.
Starting Problems
Problem
Possible Causes
Starter solenoid clicks, but starter will not crank
(if solenoid clicks, problem is not in safety interlock
system).
Battery charge is low.
Battery cables are loose or corroded.
Battery ground to frame is loose or corroded.
Wiring at starter is faulty.
Starter solenoid is faulty.
Starter mounting bolts are loose or not supplying a
sufficient ground for solenoid.
Starter is faulty and causing an incomplete circuit for
the solenoid.
Relay R4 or R8 has intermittent ground.
Nothing happens when start attempt is made.
Battery is dead.
Wiring to the start circuit (see Wiring Schematics)
components is loose, corroded, or damaged.
Battery cables are loose or corroded.
Battery ground to frame is loose or corroded.
Fuselink 2 is open.
Fuse block is faulty.
10 ampere fuse to the run relay is loose or blown.
Diode D6, safety relay, or start relay is faulty.
15 ampere fuse to the ignition switch is loose or blown.
The ignition switch is faulty.
Starter solenoid is faulty.
High temperature relay, run relay, and/or high
temperature switch are faulty.
Neutral sensor is out of adjustment or faulty.
The ETR solenoid is faulty.
Electrical System (Rev. C)
Page 5 − 4
Greensmaster 3250−D
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.
Glow plugs are faulty.
Engine or fuel system is malfunctioning (see Chapter 4
− Engine).
Engine and fuel may be too cold.
Neutral sensor is out of adjustment, faulty, or short
circuited.
Electrical
System
Engine cranks (but should not) with the Functional
Control Lever in the MOW or TRANSPORT position.
Greensmaster 3250−D
Page 5 − 5
Electrical System (Rev. C)
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.
Seat hinge, support pin, or spring binding is preventing
the seat switch from closing.
Seat switch is faulty or out of adjustment.
Seat switch wiring is loose, corroded, or damaged.
Battery does not charge.
Wiring to the charging circuit (see Wiring Schematics)
components is loose, corroded, or damaged.
Voltage regulator/alternator is faulty.
Fuselink 1 is open.
Ignition switch is faulty.
Battery is dead.
Engine kills during operation (operator sitting on seat).
Operator moved too far forward on the seat (seat
switch not depressed).
Engine overheated.
Wiring to the run circuits (see Wiring Schematics)
components became broken or disconnected.
Electrical System (Rev. C)
Page 5 − 6
Greensmaster 3250−D
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
Functional Control Lever in the MOW or NEUTRAL
position.
Wiring to run/mow/backlap circuits (see Wiring
Schematics) components is loose, corroded, or
damaged.
Fuse block or fuse is faulty.
Solenoid valve S1 is faulty.
Mow sensor and/or mow relay is faulty or grounded.
Raise switch and/or joystick relay R7 is faulty or
grounded.
Cutting units will not raise.
Wiring to run/mow/backlap circuits (see Wiring
Schematics) components is loose, corroded, or
damaged.
Fuse block or fuse is faulty.
Solenoid valve S3 and/or S2 is faulty.
Diode D1 is open.
Cutting units will not lower.
Wiring to run/mow/backlap circuits (see Wiring
Schematics) components is loose, corroded, or
damaged.
Fuse block or fuse is faulty.
Diode D2 is open.
Raise switch is faulty.
Lower switch is faulty.
Joystick relay is faulty.
6 second timer is faulty.
Solenoid valve S2 or S4 is faulty.
Lower relay is faulty.
Greensmaster 3250−D
Page 5 − 7
Electrical System (Rev. C)
Electrical
System
Raise switch and/or raise relay is faulty or grounded.
Electrical System Quick Checks
Battery Test
Use a multimeter to measure the voltage between the
battery terminals.
Set the multimeter to the DC volts setting. The battery
should be at a temperature of 60o to 100o F. The ignition
key should be off and all accessories turned off. Connect
the positive (+) meter lead to the positive battery post
and the negative (--) meter lead the the negative battery
post.
Voltage Measured
Battery Charge Level
12.68 V (or higher)
Fully charged (100%)
12.45 V
75% charged
12.24 V
50% charged
12.06 V
25% charged
11.89 V
0% charged
Note: This test provides a relative condition of the battery. Load testing of the battery will provide additional
and more accurate information.
Charging System Test
This is a simple test used to determine if a charging system is functioning. It will tell you if a charging system has
an output, but not its capacity.
Start the engine and run at high idle. Allow the battery
to charge for at least three (3) minutes. Record the battery voltage.
Use a multimeter set to the DC volts setting. Connect the
positive (+) meter lead to the positive battery post and
the negative (--) meter lead to the negative battery post.
Leave the test leads connected and record the battery
voltage.
An example of a charging system that is functioning:
At least 0.50 volt over initial battery voltage.
Initial Battery Voltage
= 12.30 v
Battery Voltage after 3 Minute Charge
= 12.85 v
Difference
= +0.55 v
Page 5 -- 8 Rev. I
Greensmaster 3250--D
NOTE: Upon starting the engine, the battery voltage
will drop and then should increase once the engine is
running.
NOTE: Depending upon the condition of the battery
charge and battery temperature, the charging system
voltage will increase at different rates as the battery
charges.
Electrical System (Rev. C)
Component Testing
For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the
circuit (e.g. unplug the ignition switch connector before
doing a continuity check).
Note: See the Briggs and Stratton Vanguard/Daihatsu Repair Manual for 3 Cylinder Water−Cooled
Diesel Engines for additional component testing information.
CAUTION
When testing electrical components for continuity with a multimeter (ohms setting), make sure
that power to the circuit has been disconnected.
Ignition Switch
The ignition (key) switch has three positions (OFF, RUN,
and START). The terminals are marked as shown. The
circuitry of the ignition switch is shown in the chart. With
the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each position.
Verify continuity between switch terminals.
POSITION
B
CIRCUIT
OFF
NONE
RUN
B + I + A, X + Y
START
A
Y
S
X
B+I+S
I
KEY
Electrical
System
HEX NUT
SWITCH
LOCK WASHER
Figure 3
Greensmaster 3250−D
Page 5 − 9
Electrical System (Rev. C)
Safety Relays
Two styles of safety relays have been used on Greensmaster 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 terminal layout.
87
87A
86
1. Verify coil resistance between terminals 86 and 85
with a multimeter (ohms setting). Resistance should be
from 80 to 90 ohms. There should be continuity between
terminals 87A and 30.
85
30
EARLY PRODUCTION
2. Connect multimeter (ohms setting) leads to relay
terminals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85.
86
3. Disconnect voltage from terminal 85 and multimeter
lead from terminal 87.
LATER PRODUCTION
87A
85
4. Connect multimeter (ohms setting) lead to relay terminal 30 and 87A. Apply +12 VDC to terminal 85. The
relay should break and make continuity between terminals 30 and 87A as 12 VDC is applied and removed from
terminal 85.
87
30
Figure 4
SAFETY
RELAY
LOCATION
5. Disconnect voltage from and multimeter leads from
relay terminals.
FRONT
4
5
3
6
2
7
1
8
RIGHT
Figure 5
1.
2.
3.
4.
Electrical System (Rev. C)
Page 5 − 10
Run relay
High temp relay
Mow
relay
Start
relay
Rev. H
5.
6.
7.
8.
Raise
relay
Lower
relay
Joystick
relay
Safety
(neutral)
relay
Greensmaster 3250−D
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 electrical connector are located directly under the seat.
2
1. Make sure the engine is off. Remove seat from the
support assembly by removing four lock nuts from the
seat bolts.
3
2. Disconnect electrical connector from the seat
switch.
3. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the connector terminals.
1
Figure 6
1. Seat bolts
2. Electrical connector
3. Seat switch
4. With no operator in the seat, there should be no continuity between the terminals.
5. Press directly onto the seat switch through the seat
cushion. There should be continuity as the seat cushion
approaches the bottom of its travel.
6. Connect switch electrical connector. Reinstall seat.
Hour Meter
1. Connect the positive (+) terminal of a 12 VDC
source to the positive terminal of the hour meter.
Electrical
System
2. Connect the negative (−) terminal of the voltage
source to the other terminal of the hour meter.
3. The hour meter should move a 1/10 of an hour in six
minutes.
4. Disconnect the voltage source from the hour meter.
Figure 7
Fuse Block
Fuses can be removed to check continuity. The test meter should read less than 1 ohm.
Fuses supply power to the following (Fig. 8):
1. The top 10 ampere fuse supplies power to the run
and mow relays.
2. The middle 10 ampere fuse supplies power to the
raise and lower relays.
3. The bottom 15 ampere fuse supplies power to terminal B of the ignition switch.
Greensmaster 3250−D
Page 5 − 11
Figure 8
Electrical System (Rev. C)
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 Control Lever in either the NEUTRAL or MOW position.
3
1. Make sure the engine is off. Disconnect electrical
connectors to both switches. Check continuity of both
switches by connecting a multimeter (ohms setting)
across the connector terminals.
1
2
2. Place the Functional Control Lever in the NEUTRAL
position. The NEUTRAL reed switch should have continuity and the MOW switch should be open (Fig. 9).
3. Place the Functional Control Lever in the MOW
position. The NEUTRAL reed switch should be open
and the MOW switch should have continuity (Fig. 9).
Figure 9
1. Mow reed switch
2. Neutral reed switch
4. The distance between the sensing end of each
switch and the traction bracket should be 0.725 to 0.775
inch (18.4 to 19.7 mm) (Fig. 10).
3. Actuator
0.725 to 0.775 inch
(18.4 to 19.7 mm)
REED SWITCH
5. To adjust or install actuator, place lever in neutral,
position actuator in lever until the NEUTRAL switch just
closes, and then rotate actuator two complete turns
closer to switch.
6. When adjusting switches or actuator, tighten jam
nuts 30o past finger tight.
CONNECTOR
TRACTION BRACKET
Figure 10
7. After switch or actuator adjustment, check continuity of both switches and interlock operation (See Verify
Interlock System Operation). Readjust switch or actuator if necessary.
Backlap Switch (If Equipped)
The backlap switch is located on the hydraulic manifold
(when the Backlap Kit is installed). The switch is normally open and closes when the backlap knob is turned to
the backlap position.
2
1. With the engine off, disconnect electrical connector.
3
1
2. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the connector terminals.
3. Turn the backlap knob clockwise to the backlap
position while watching the multimeter. Continuity
should be made as the switch closes.
4. Turn the backlap knob counterclockwise to the mow
position while watching the multimeter. Continuity
should be broken as the switch opens.
5. Reconnect the electrical connector.
Electrical System (Rev. C)
Figure 11
1. Connector
2. Backlap switch
Page 5 − 12
Rev. H
3. Backlap knob
Greensmaster 3250−D
Leak Detector (Optional)
Operation
The leak detector system is designed to assist in the early detection of hydraulic oil system leaks. If the oil level
in the main tank is lowered by 4 to 5 ounces, the level
switch in the leak detection tank will close. After a 1 second delay, the alarm will sound alerting the operator.
Expansion of oil from the normal heating of the hydraulic
oil during machine operation will cause oil to transfer into
the leak detection tank. The oil is allowed to return to the
main tank when the ignition switch is turned off (see Fig.
12, 13, and 14).
FILLER CAP
FLUID LEVEL
COLD
SIGHT
WINDOW
ÉÉÉÉÉ
ÉÉÉ
ÉÉ
ÉÉÉ
ÉÉ ÉÉ
SOLENOID
RETURN
VALVE
OPEN
NO SOUND
FLOAT RAISED
SWITCH OPEN
BEFORE START (oil cold)
Figure 12
FLUID LEVEL
WARM
ÉÉÉÉÉ
ÉÉÉ
ÉÉ
ÉÉÉ
ÉÉ ÉÉ
ÉÉ ÉÉ
NO SOUND
FLOAT RAISED
SWITCH OPEN
NORMAL OPERATION (oil warm)
Figure 13
FLUID LEVEL
WARM
SOLENOID
RETURN
VALVE
CLOSED
WARNING
BUZZER
SOUNDS
ÉÉÉ
ÉÉ
ÉÉÉÉÉ
ÉÉ ÉÉ
FLOAT DOWN, SWITCH CLOSED
(FLUID LEVEL DOWN 4 TO 5 OUNCES)
LEAK ALERT!
Figure 14
Greensmaster 3250−D
Page 5 − 13
Electrical System (Rev. C)
Electrical
System
SOLENOID
RETURN
VALVE
CLOSED
Test Operation
CLEAN ROD
OR
SCREWDRIVER
1. Place ignition switch in the ON position. DO NOT
START ENGINE. Move leak detector switch downward
and hold. After the one second time delay elapses, the
alarm should sound.
VALVE ASSEMBLY
PLUG REMOVED
SOLENOID
RETURN
VALVE
CLOSED
2. Release leak detector switch.
3. Remove cover plate from leak detector. Remove
plug from valve assembly.
4. Insert clean rod or screw driver into valve assembly
and gently push down on switch float (Fig. 15). Alarm
should sound after one second delay.
5. Release float; alarm should stop sounding.
WARNING
BUZZER
SOUNDS
ÉÉÉ
ÉÉ
ÉÉÉ
ÉÉ ÉÉ
ÉÉ ÉÉ
PRESS DOWN ON
SWITCH FLOAT
TESTING SWITCH FLOAT
6. If alarm fails to stop sounding, turn ignition switch to
OFF position. Locate solenoid on leak detector. Swap
solenoid wires and repeat steps 4 and 5.
Figure 15
7. Install plug to valve assembly and cover plate to
tank. Move ignition switch to OFF position.
Electrical System (Rev. C)
Page 5 − 14
Greensmaster 3250−D
RED/WHT
CONNECTOR
+
RED
VALVE SOLENOID
−
TEST SWITCH
BLACK
BLACK
CONNECTOR
GRAY
YELLOW
CONNECTOR
LEVEL SWITCH
+
1 SEC.
DELAY
TIMER
−
RED
RED
AUDIO ALARM
−
+
270 OHM
RESISTOR
YELLOW
LEAK DETECTOR CIRCUIT
BLACK
BLK/WHT
BLACK
Figure 16
Components can be tested by isolating them from the
rest of the circuit and individually testing the suspected
component.
6
5
This is a solid state device with no moving parts. Upon
the application of power, the time delay is initiated. At the
completion of the 1 second delay, the audio alarm becomes energized. When power is removed the timer is
reset.
3
1
2
1. Isolate timer from the circuit. Connect 12VDC
source in series with voltmeter to connector of timer.
Make sure to observe polarity.
2. The voltmeter should jump from 0 to 12VDC after
the 1 second delay. Remove voltage source from the
timer. Reconnect timer to the circuit.
4
Figure 17
1. 270 ohm resistor
2. Audio alarm
3. Delay timer
4. Toggle switch
5. Level detector
6. Valve solenoid
Audio Alarm
Valve Solenoid
1. Isolate alarm from the circuit. Connect 12VDC
source to terminals. Make sure to observe polarity.
1. Isolate solenoid from the circuit. Connect multimeter (Ohms setting) to connector. Make sure to observe
polarity.
2. Alarm should sound. Remove voltage source from
the alarm. Reconnect alarm to the circuit.
2. Resistance should about 7.2 ohms.
Greensmaster 3250−D
Page 5 − 15
Electrical System (Rev. C)
Electrical
System
Delay Timer
Warning Light Cluster
Two styles of warning light clusters have been used on
the Greensmaster 3250--D. On machines with serial
number below 250000000, the four warning lights are
included in one component (Fig. 18). On machines with
serial number above 250000000, the four warning lights
are included in two components (Fig. 20).
OIL
(RED)
Serial Number Below
250000000
WATER
(RED)
Note: Individual light bulbs can be tested by removing
them from the light cluster and applying 12 VDC to their
wiring terminals.
A
F
B
E
Oil Pressure Light
The oil pressure light should come on when the ignition
switch is in the ON position with the engine not running.
Also, it should light with the engine running when the oil
pressure drops below 4 PSI (0.3 kg/cm2).
GLOW
BATT
(AMBER) (AMBER)
A
FRONT
1. Disconnect white/red wire from the oil pressure
switch.
B C
D
E
F
BACK
Figure 18
2. Ground white/red wire to the engine block.
3. Turn the ignition switch to ON; the light should come
on.
B
GLOW
4. Turn the ignition switch to OFF. Connect white/red
wire to the oil pressure switch.
E
BATT
F
OIL
A
WATER
C
High Temperature (Water) Shutdown Light
When the coolant temperature is above 238oF (114oC),
the temperature light comes on as the high temperature
shutdown switch and relay stopped the engine. The ignition switch must be in either the ON or START position
for the light to come on.
D
Glow Light
Figure 19
The glow light comes on when the ignition switch is
placed in RUN prior to placing the ignition switch in
START, and stays lit for approximately ten (10) seconds
while left in RUN.
3
2
4
1
Battery Light
The battery light should come on when the ignition
switch is in ON with the engine not running, or with an
improperly operating charging circuit while the engine is
running.
Serial Number Above
250000000
1. Turn ignition switch to ON; the light should come on.
2. Turn ignition switch to OFF.
Figure 20
1. Battery light
2. Oil pressure light
Electrical System (Rev. C)
Page 5 -- 16
Rev. I
3. High temperature light
4. Glow light
Greensmaster 3250--D
High Temperature Shutdown Switch
The high temperature shutdown switch is located on the
water pump, which is located on the rear end of the engine block. The high temperature shutdown switch has
a yellow/red wire connected to it (Fig. 20).
2
CAUTION
Make sure engine is cool before removing the
temperature switch.
1
1. Lower coolant level in the engine and remove the
temperature switch.
2. Put switch in a container of oil with a thermometer
and slowly heat the oil (Fig. 21).
Figure 20
1. Temperature switch
2. Water pump
CAUTION
Handle the hot oil with extreme care to prevent
personal injury or fire.
3. Check continuity of the switch with a multimeter
(ohms setting). The high temperature shutdown switch
is normally open and should close at about 238F
(114C).
Figure 21
Electrical
System
4. Allow oil to cool while observing temperature. The
high temperature shutdown switch should open at about
232F (111C).
5. Replace switch if necessary.
Greensmaster 3250−D
Page 5 − 17
Electrical System (Rev. C)
Oil Pressure Switch
The switch is located on the front cylinder head above
the injection pump and governor assembly. It is a normally closed switch and opens with pressure.
1
Testing with the engine off
1. Turn the ignition switch to ON. The oil pressure lamp
should be on.
2. If the lamp is not on, disconnect the white/red wire
from the switch and ground it to the engine block.
2
3. If the lamp comes on the switch is bad.
4. If the lamp does not come on after step 2, check the
indicating circuit (see Electrical Schematic in Chapter 8
− Electrical Diagrams).
Figure 22
1. Flywheel
2. Oil pressure switch
Testing with the engine on
1. If the lamp is on with the engine running, shut off the
engine immediately.
2. Disconnect the white/red wire from the switch.
3. Turn the ignition switch to ON. The oil pressure lamp
should go out.
4. If the light is still on, check for short circuiting in the
indication circuit (see Circuit Drawings in Chapter 8 −
Electrical Diagrams).
5. Return ignition switch to OFF and connect the white/
red wire to the switch.
6. Remove switch and install test gauge in the oil pressure switch port.
7. Start the engine and check for a minimum of 14 psi
at 1000 RPM. If the engine oil pressure is low, shut off
the engine immediately.
8. Shut off the engine and remove the test gauge.
9. If the engine oil pressure is good, replace the switch.
Electrical System (Rev. C)
Page 5 − 18
Greensmaster 3250−D
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. Connect 12VDC source to timer and load. Make
sure to observe polarity. After 6 seconds, there should
be no voltage across the load.
TIME
DELAY
2. Disconnect timer from 12VDC source and test load.
Figure 23
+
−
INPUT VOLTAGE
LOAD
3
2
4
1
5
Figure 24
Greensmaster 3250−D
Page 5 − 19 Rev. H
Electrical System (Rev. C)
Electrical
System
TIMING
RESISTOR
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.
D2
D6
D4
Diode D1
D8
D3
This diode prevents current flow to solenoid S3 when solenoids S2 and S4 are energized through lower relay R6.
D7
D1
D5
Diode D2
DIODE
DIAGRAM
This diode prevents current flow to solenoid S4 when solenoids S2 and S3 are energized through Raise relay
R5.
Figure 25
Diode D3
Prevents a negative spike from damaging the Mow and
Backlap switches by allowing a ground path for the mow
relay when it de−energizes.
Diode D4
This component is not used.
DIODE
CIRCUIT BOARDS
Diode D5
Figure 26
Allows the engine to start only with the Functional Control Lever in NEUTRAL (neutral sensor closed). Also, it
allows the engine to continue to run with either the Functional Control Lever in NEUTRAL (Neutral Sensor
closed) or the operator sitting in the seat (Seat switch
closed).
Red Lead (+)
on Terminal
Black Lead (−)
on Terminal
Continuity
H
A
YES
A
H
NO
Diode D6
G
B
YES
Prevents a negative spike from damaging the Neutral
Sensor and Seat switch by allowing a ground path for
the Run relay when it de−energizes.
B
G
NO
F
C
YES
C
F
NO
E
D
YES
D
E
NO
Diode D7
Maintains current flow to the Joystick relay after the momentary Lower switch of the Joystick opens.
Diode D8
This component is not used.
DIODE CIRCUIT BOARD
Testing
The diodes can be individually tested using a digital
multimeter (ohms setting) and the table to the right.
Figure 27
Electrical System (Rev. C)
Page 5 − 20
Greensmaster 3250−D
Solenoid Valve Coils
Note: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value
from from the measured value of the component you are
testing.
1. Make sure engine is off. Disconnect solenoid valve
electrical connector.
2
1
2. Apply 12VDC source directly to the solenoid. Listen
for solenoid to switch on. Remove voltage source from
solenoid.
3. Measure resistance between the two solenoid coil
connector terminals. The coil resistance for machines
with serial numbers under 260999999 is identified in
Figure 29. The coil resistance for machines with serial
numbers above 270000000 is identified in Figure 30.
Figure 28
1. Electrical connector
2. Solenoid
1
3
2
4. Replace solenoid if necessary. Reconnect solenoid
valve electrical connector.
4
5
Serial Number 240000001 To
260999999 Shown
Figure 29
1. Solenoid S1 (7.2 ohm)
2. Solenoid S2 (7.2 ohm)
3. Solenoid S3 (7.2 ohm)
4. Solenoid S4 (7.2 ohm)
5. Solenoid S6 (8.1 ohm)
3
1
4
2
Serial Number Above
270000000 Shown
Figure 30
1. Solenoid S1R1 (7.1 ohm)
2. Solenoid S2 (8.6 ohm)
Greensmaster 3250--D
Page 5 -- 21 Rev. H
3. Solenoid S3 (7.1 ohm)
4. Solenoid S4 (8.6 ohm)
Electrical System (Rev. C)
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 number below 250000000, two of the four relay connections
are secured with screws (Fig. 33). Machines with serial
number above 250000000 use relays that are connected to the wire harness with a four wire connector
(Fig. 34).
GLOW
RELAY
1. Verify coil resistance between terminals 86 and 85
with a multimeter (ohms setting). Resistance should be
from 41 to 51 ohms.
2. Connect multimeter (ohms setting) leads to relay
terminals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85.
Figure 32
86
87
85
30
87
3. Disconnect voltage and multimeter leads from relay
terminals.
85
30
86
Figure 33
86
87
30
85
85
86
87
30
Figure 34
Electrical System (Rev. C)
Page 5 -- 22
Rev. I
Greensmaster 3250--D
Service and Repairs
Note: See the Briggs and Stratton Vanguard/Daihatsu Repair Manual for 3 Cylinder Water−Cooled
Diesel Engines for more component repair information.
Verify Interlock System Operation
CAUTION
The interlock switches are for the operator’s
protection; do not disconnect them. Check the
operation of the interlock switches daily for
proper operation. Replace any malfunctioning
switches before operating the machine.
The purposes of the interlock switches are to:
A. Prevent the engine from cranking or starting unless the Functional Control Lever is in NEUTRAL.
B. Prevent operating the traction pedal with the
Functional Control Lever in NEUTRAL.
C. Shut off the engine if the operator leaves the seat
without the Functional Control Lever in NEUTRAL.
2. Sit on the seat, engage parking brake, keep traction
pedal in neutral, and place Functional Control Lever in
MOW or TRANSPORT. Try to start the engine. If the engine does not crank, the interlock system is operating
correctly. Correct problem if not operating properly.
3. Sit on the seat and start engine. Move Functional
Control Lever to Mow. Raise off the seat. If the engine
stops, the interlock system is operating correctly. Correct problem if not operating properly.
4. Sit on the seat, engage parking brake, keep traction
pedal in neutral, and place Functional Control Lever in
NEUTRAL. Start the engine. Move Raise / Lower − Mow
Control Lever forward to lower the cutting units. If the
units do not start rotating, the interlock system is operating correctly. Correct problem if not operating properly.
Electrical
System
D. Shut off the reels if the Functional Control Lever
is moved to NEUTRAL or TRANSPORT.
1. Sit on the seat, engage parking brake, and move
Functional Control Lever to NEUTRAL. Try to depress
traction pedal. If the pedal does not depress, the interlock system is operating correctly. Correct problem if not
operating properly.
Greensmaster 3250−D
Page 5 − 23 Rev. H
Electrical System (Rev. C)
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
1
When working with batteries, use extreme caution to avoid splashing or spilling electrolyte.
Electrolyte can destroy clothing and burn skin or
eyes. Always wear safety goggles and a face
shield when working with batteries.
2
Figure 34
1. Cap screw & washer
Electrolyte Specific Gravity
Fully charged: 1.265 corrected to 80F (26.7C)
Discharged: less than 1.240
2. Battery retainer
FILLER CAPS
CAP TUBES
Battery Specifications
BCI Group Size 26:
Type 26 SMF−5
530 Amp Cranking Performance at 0 F (−17.8 C)
85 Minute Reserve Capacity at 80F (26.7C)
CORRECT
WATER
LEVEL
COVER SEAL
Removal (Fig. 34 and 35)
IMPORTANT: Be careful not to damage terminal
posts or cable connectors when removing the battery cables.
Figure 35
1. Remove cap screw, washer, and battery retainer.
2. Disconnect the ground cable (−) first to prevent
short circuiting the battery, other components, or the operators hands. Disconnect the positive (+) cable.
3. Make sure that the filler caps are on tightly.
4. Remove battery from the battery compartment to a
service area. This will minimize possible battery damage and allow better access for inspection and service.
Inspection, Maintenance, and Testing
1. Perform following inspections and maintenance:
A. Check for cracks caused by overly tight or loose
hold−down clamp. Replace battery if cracked and
leaking.
C. Check for signs of wetness or leakage on the top
of the battery which might indicate a loose or missing filler cap, overcharging, loose terminal post, or
overfilling. Also, check the battery case for dirt and
oil. Clean the battery with a solution of baking soda
and water, then rinse it with clean water.
D. Check that the cover seal is not broken away.
Replace the battery if the seal is broken or leaking.
E. Check the electrolyte level in each cell. If the level is below the tops of the plates in any cell, fill all
cells with distilled water to the bottom of the cap
tubes. Charge at 15 to 25 amps for 15 minutes to allow sufficient mixing of the electrolyte.
2. Conduct a hydrometer test of the battery electrolyte.
B. Check battery terminal posts for corrosion. Use
a terminal brush or steel wool to clean corrosion
from the battery terminal posts.
IMPORTANT: Make sure the area around the cells is
clean before opening the battery caps.
IMPORTANT: Before cleaning the battery, tape or
block the vent holes to the filler caps and make sure
the caps are on tightly.
A. Measure the specific gravity of each cell with a
hydrometer. Draw electrolyte in and out of the
hydrometer barrel prior to taking a reading to warm−
up the hydrometer. At the same time take the temperature of the cell.
Electrical System (Rev. C)
Page 5 − 24 Rev. H
Greensmaster 3250−D
B. Temperature correct each cell reading. For each
10F (5.5C) above 80F (26.7C) add 0.004 to the
specific gravity reading. For each 10F (5.5C) below 80F (26.7C) subtract 0.004 from the specific
gravity reading.
Cell Temperature 100F
Cell Gravity
ADD (20 above 80F)
Correction to 80F
1.245
0.008
1.253
C. If the difference between the highest and lowest
cell specific gravity is 0.050 or greater or the lowest
cell specific gravity is less than 1.225, charge the
battery. Charge at the recommended rate and time
given in Charging or until all cells specific gravity is
1.225 or greater with the difference in specific gravity between the highest and lowest cell less than
0.050. If these charging conditions can not be met,
replace the battery.
3. Perform a high−discharge test with an adjustable
load tester.
This is one of the most reliable means of testing a battery
as it simulates the cold−cranking test. A commercial battery load tester is required to perform this test.
Battery Electrolyte
Temperature
9.6
70F (and up)
21.1C (and up)
9.5
60F
15.6C
9.4
50F
10.0C
9.3
40F
4.4C
9.1
30F
−1.1C
8.9
20F
−6.7C
8.7
10F
−12.2C
8.5
0F
−17.8C
I. If the test voltage is below the minimum, replace
the battery. If the test voltage is at or above the minimum, return the battery to service.
Installation
IMPORTANT: To prevent possible electrical problems, install only a fully charged battery.
1. Make sure the ignition switch and all accessories
are off.
CAUTION
Follow the manufacturer’s instructions when using a battery tester.
A. Check the voltage across the battery terminals
prior to testing the battery. If the voltage is less than
12.0 VDC, recharge the battery.
B. If the battery has been charged, apply a 150 amp
load for 15 seconds to remove the surface charge.
Use a battery load tester following the manufacturer’s instructions.
C. Make sure the battery terminals are free of corrosion.
D. Measure the temperature of the center cell.
E. Connect a battery load tester to the battery terminals following the manufacturer’s instructions. Connect a digital multimeter to the battery
terminals.
F. Apply a test load of one half the Cranking Performance (see Battery Specifications) rating of the battery for 15 seconds.
G. Take a voltage reading at 15 seconds, then remove the load.
Greensmaster 3250−D
Minimum
Voltage
2. Make sure the battery compartment is clean and repainted if necessary.
3. Make sure all battery cables and connection are in
good condition and that the battery hold down clamp has
been repaired or replaced.
4. Lift seat and place the battery in its compartment.
Make sure battery is level and flat. Push the positive
cable connector onto positive battery post. Do not hammer; this will damage the battery. Tighten bolts with two
wrenches.
5. Secure battery retainer to the battery with the washer and cap screw. Do not overtighten to prevent cracking
or distorting the battery case (Fig. 34).
6. Apply a light coat of grease on all battery posts and
cable connectors to reduce corrosion after connections
are made.
7. Connect a digital multimeter (set to amps) between
the negative battery post and the negative (ground)
cable connector. The reading should be less than 0.1
amp. If the reading is 0.1 amp or more, the unit’s electrical system should be tested and repaired.
8. Connect the negative (ground) cable connector to
the negative battery post.
Page 5 − 25 Rev. H
Electrical System (Rev. C)
Electrical
System
Example:
H. Using the table below, determine the minimum
voltage for the cell temperature reading.
Charging
To minimize possible damage to the battery and allow
the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger
which is available in most shops.
CAUTION
Follow the manufacturer’s instructions when using a battery charger.
Note: Using specific gravity of the battery cells is the
most accurate method of determining battery condition.
1. Determine the battery charge level from either its
open specific gravity or circuit voltage.
Battery Charge
Level
Specific
Gravity
Open Circuit
Voltage
100%
1.265
12.68
75%
1.225
12.45
50%
1.190
12.24
25%
1.155
12.06
0%
1.120
11.89
2. Determine the charging time and rate using the
manufacturer’s battery charger instructions or the
following table.
Battery
Reserve
Capacity
(Minutes)
CAUTION
Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to
60F (15.5 C) before connecting to a charger.
Charge the battery in a well−ventilated place to
dissipate gases produced from charging. These
gases are explosive; keep open flame and electrical spark away from the battery. Do not smoke.
Nausea may result if the gases are inhaled. Unplug the charger from the electrical outlet before
connecting or disconnecting the charger leads
from the battery posts.
3. Following the manufacturer’s instructions, connect the charger cables to the battery. Make sure a good
connection is made.
4. Charge the battery following the manufacturer’s
instructions.
5. Occasionally check the temperature of the battery
electrolyte. If the temperature exceeds 125F (51.6C)
or the electrolyte is violently gassing or spewing, the
charging rate must be lowered or temporarily stopped.
6. Three hours prior to the end of the charging, measure the specific gravity of a battery cell once per hour.
The battery is fully charged when the cells are gassing
freely at a low charging rate and there is less than a
0.003 change in specific gravity for three consecutive
readings.
Battery Charge Level
(Percent of Fully Charged)
75%
50%
25%
0%
80 or less
3.8 hrs
@
3 amps
7.5 hrs
@
3 amps
11.3 hrs
@
3 amps
15 hrs
@
3 amps
81 to 125
5.3 hrs
@
4 amps
10.5 hrs
@
4 amps
15.8 hrs
@
4 amps
21 hrs
@
4 amps
126 to
170
5.5 hrs
@
5 amps
11 hrs
@
5 amps
16.5 hrs
@
5 amps
22 hrs
@
5 amps
171 to
250
5.8 hrs
@
6 amps
11.5 hrs
@
6 amps
17.3 hrs
@
6 amps
23 hrs
@
6 amps
above
250
6 hrs
12 hrs
18 hrs
24 hrs
@
@
@
@
10 amps 10 amps 10 amps 10 amps
Electrical System (Rev. C)
Page 5 − 26
Rev. H
Greensmaster 3250−D
Chapter 6
Chassis
Table of Contents
Chassis
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4
Rear Wheel (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rear Wheel (3WD) . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Front Wheels and Brakes . . . . . . . . . . . . . . . . . . . 10
Front Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Center Lift Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Greensmaster 3250−D
Page 6 − 1
Chassis (Rev D)
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 − TOR4097
The wheel hub puller allows safe removal of the wheel
hub from the shaft of wheel motors.
Figure 1
Chassis (Rev. D)
Page 6 − 2
Greensmaster 3250−D
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.
3
5
6
1
Note: The brake adjustment rods are located on each
side of the machine. Adjust each brake equally.
1. While driving the machine, depress the brake pedal.
Both wheels should lock equally.
2
2. Park machine on a level surface. Make sure engine
is off.
4
3. Remove cotter pin and clevis pin from the clevis and
brake pedal tab.
Figure 2
1. Cotter pin
2. Clevis pin
3. Clevis
4. Loosen jam nut on the brake rod.
4. Brake pedal tab
5. Jam nut
6. Brake rod
5. Adjust clevis for proper amount of free travel.
A. Loosen clevis by exposing more threads on the
brake rod to decrease free travel of the brake pedal.
B. Tighten clevis by exposing fewer threads on the
brake rod to increase free travel of the brake pedal.
8. Drive the machine and depress the brake pedal.
Both wheels should lock equally. Readjust brake if
necessary.
Chassis
6. Assemble clevis to the brake pedal by installing clevis pin and cotter pin.
7. Check the amount of free travel of the brake pedal
when the adjustment is complete. There should be
from1/2 to 1 inch (1.3 to 2.5 cm) of travel before the
brake shoes make contact with the brake drums. Readjust brake if necessary to achieve this setting.
Greensmaster 3250−D
Page 6 − 3
Chassis (Rev D)
Service and Repairs
Rear Wheel (2WD)
2
1
3
26
27
28
30
31
25
17
24
21
32
22
22
19 18
20
28
27
3
4
23
33
70 to 90 ft−lb
(95 to122 N−m)
19
17
18
26
15
37
16
39
36
35
38
34
29
5
6
7
8
9
HUB
ASSEMBLY
10
RIGHT
8
7
FRONT
12
13
6
14
29
WHEEL ASSEMBLY
11
Figure 3
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Slotted hex nut
Cotter pin
Steering washer
Castor fork
Bolt
Oil seal
Bearing cone
Bearing cup
Wheel hub
Grease fitting
Drive stud
Tire
Rim
Chassis (Rev. D)
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Valve stem
Lug nut
Lock nut
Ball joint
Grease fitting
Retaining ring
Steering cylinder
Hydraulic hose
90_ Hydraulic fitting
O−ring
O−ring
Hydraulic hose
Jam nut
Page 6 − 4
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Bearing cone
Bearing cup
Rear spindle spacer
Grease fitting
Decal
Hose clamp
Hex washer head screw
Motor adapter plate
Adapter plate
Cap screw
Lock nut
Lock nut
Cap screw
Greensmaster 3250−D
Removal (Fig. 3)
1. Park machine on a level surface. Make sure engine
is off. Set brake and block front wheels.
4
2. Jack up and secure the rear wheel off the ground.
1
Note: The wheel assembly consists of the tire (12),
rim (13), and valve stem (14) with cap. The hub assembly consists of the wheel hub (9), oil seals (6), bearing
cones (7), bearing cups (8), grease fitting (10), and drive
studs (11).
3. Remove lock nut (16) from bolt (5). Pull bolt from
both adapter plates (35 and 34), rear spindle spacers
(29), and the wheel and hub assemblies.
4. Remove wheel and hub assemblies from the castor
fork (4).
5. If damage to the bearings in the castor fork pivot
housing is suspected, remove castor fork (4) from the
frame as follows:
A. Remove three hex head screws and flat washers
securing the fuel tank base plate to the frame. The
two screws are located on the top of the plate at the
front corners of the tank. The third screw is in front of
the castor fork and below the plate.
3
2
5
Figure 4
1. Bearing cup
2. Wheel hub
3. Bearing cone
4. Shaft seal
5. Drive stud
Disassembly (Fig. 3)
1. If drive studs (11) are bent or damaged, press studs
from the wheel hub (9).
2. Pull oil seals (6), bearing cones (7), and bearing
cups (8) from the wheel hub (9).
Assembly (Fig. 4)
1. Press new bearing cups into the wheel hub with the
thick edges towards the inside.
B. Tilt fuel tank base up by lifting at the rear of the
machine to gain access to the top of the castor fork.
Prop up tank securely.
2. Install new bearing cones into the wheel hub. Press
new shaft seals into the hub with the lip of the seals facing towards the inside.
C. Remove both jam nuts (26) securing the ball joint
(17) to the castor fork (4).
3. If removed. press new drive stud (11) into the wheel
hub (9).
Installation (Fig. 3)
Support castor fork (4) while removing the
slotted hex nut (1) to prevent the fork from dropping and causing personal injury.
D. Remove cotter pin (2) and slotted hex nut (1)
from the castor fork (4) shaft. Lower castor fork from
the frame and make sure ball joint (17) releases
from the shaft ring of the steering cylinder (20).
1. Slide wheel assembly onto the drive studs (11).
Tighten lug nuts (15) to the drive studs (11) evenly in a
crossing pattern to a torque of 70 to 90 ft−lb (95 to 122
N−m).
2. If the bearings in the castor fork pivot housing were
removed, install castor fork (4) to the frame as follows:
E. Inspect bearing cones (27) and bearing cups
(28) for damage, and replace if necessary.
F. Remove bearing cones (27) and bearing cups
(28) from the castor fork pivot housing on the frame.
6. Remove lug nuts (15) from the drive studs (11) of the
wheel hub (9). Separate wheel and hub assemblies.
Greensmaster 3250−D
Page 6 − 5
A. Press new bearing cups (28) into the castor fork
pivot housing with the thick side of the cups facing
each other.
B. Pack both bearing cones (27) with No. 2 multipurpose lithium base grease. Place two steering
washers (3) onto the castor fork (4) shaft. Place
bearing cone on top of washers with the thick edge
touching the washers.
C. Insert castor fork shaft up through the pivot
housing and bearing cups.
Chassis (Rev D)
Chassis
CAUTION
D. Place second bearing cone on the castor fork
shaft with the wide edge up. Place remaining steering washer on top of the bearing cone.
E. Run slotted hex nut (1) onto castor fork shaft until
drag is felt while rotating the castor fork. Back−off
hex nut to align the hole to the slot. Install and secure cotter pin (2) into the shaft.
3. Install wheel and hub assemblies into the castor fork
(4). Insert bolt (5) into motor adapter plate (34) mounting
hole. Install a spacer (29), and slide bolt through the
wheel and hub assemblies.
4. Install another spacer (29) onto the bolt (5). Route
the bolt through the adapter plate (35) mounting hole.
F. Secure ball joint (17) to the castor fork (4) with
both jam nuts (26). Torque 65 to 85 ft−lbs (88 to 115
N−m).
5. Position bent lip of the bolt (5) head under the bottom edge of the motor adapter plate (34). Install and
tighten locknut (16) to secure wheel to the castor fork.
Do not overtighten locknut, the wheel must rotate freely.
G. Secure fuel tank base plate to the frame with
three hex head screws and flat washers. The two
screws and flat washers go on the top of the plate at
the front corners of the tank. The third screw goes
through support from under the plate.
6. Wipe grease fitting (10) clean on hub (9) and pivot
housing. Pump grease into hub until grease is seen exiting at both oil seals (6). Pump grease into pivot housing
until grease is seen exiting at both ends of the housing.
Wipe up excess grease.
Chassis (Rev. D)
Page 6 − 6
Greensmaster 3250−D
Rear Wheel (3WD)
18
16
20
3
4
15
17
19
14
9
1
11
80 to 100 in−lb
(9.0 to 11.3 N−m)
23
21
6
24
7
RIGHT
22
5
8
13
10
3
4
FRONT
12
30 ft−lb
(41 N−m)
85 ft−lb
(115 N−m)
2
25
Figure 5
Castor fork
Hub and motor assembly
Hydraulic hose
Hydraulic hose
Bearing
Relube flangette
Grease fitting
Standard flangette
Bearing tab
10.
11.
12.
13.
14.
15.
16.
17.
Cap screw
Lock nut
Hex socket head screw
Lock nut
Cable tie
Tube clamp
Cover plate
Cap screw
18.
19.
20.
21.
22.
23.
24.
25.
Lock nut
Clamp bracket
Hex washer head screw
Bearing adapter plate
Grease fitting
Lug nut
Set screw
Wheel/tire assembly
B. Remove both socket head screws (12) and lock
nuts (13) securing the hydraulic motor and hub assembly to the castor fork (1).
Removal (Fig. 5)
1. Park machine on a level surface. Make sure engine
is off. Set brake and block front wheels.
C. Lower wheel and hydraulic motor and hub assembly from the castor fork.
2. Jack up and secure the rear wheel off the ground.
4. Loosen set screws (24) on bearing (5). Pull flangettes (6 and 8) and bearing from the hydraulic motor
shaft.
CAUTION
Support wheel (25) and motor and hub assembly
(2) to prevent dropping them and causing personal injury while removing hex head screws
(10) and socket head screws (12).
3. Remove wheel (25) and hydraulic motor and hub
assembly (2) from the castor fork (1) as follows:
5. Remove grease fitting (22) from the hydraulic motor
and hub assembly (2). Remove four lug nuts (23) and
wheel (25) from the hub drive studs.
6. If the castor fork (1) requires removal, see Rear
Wheel (2WD) Removal.
A. Remove hex head screws (10) and lock nuts (11)
securing flangettes (6 and 8) and bearing tab (9).
Greensmaster 3250−D
Page 6 − 7
Chassis (Rev D)
Chassis
1.
2.
3.
4.
5.
6.
7.
8.
9.
9
6
8
5
12
6
9
11
10
10
11
12
1
3
2
4
7
1.
2.
3.
4.
Hydraulic motor
45_ Hydraulic fitting
O−ring
O−ring
5.
6.
7.
8.
Figure 6
9.
10.
11.
12.
Hub
Clutch roller bearing
Drive stud
Grease fitting
Disassembly (Fig. 6)
1. Remove grease seal (12) and snap ring (12) from
the long end of hub (5).
Thrust washer
Washer
Snap ring
Grease seal
OUTER BEARING EDGE
MUST BE FLUSH WITH EDGE
2. Remove washer (10), two thrust washers (9), and
hub (5) from the hydraulic motor (1) shaft. Remove remaining two thrust washers (9), washer (10), snap ring
(11), and grease seal (12) from the shaft.
3. If drive studs (7) are bent or damaged, press studs
from the wheel hub (5).
ARROWS ON BEARING
TOWARDS LONG END
4. Press clutch roller bearings (6) from the hub (5).
Figure 7
Assembly (Fig. 6)
1. If drive studs (7) were removed, press new studs
into the wheel hub (5).
2. Press roller clutch bearings (6) into the hub (5) as
follows (Fig. 7):
Note: Arrow on the side of the clutch roller bearings
(6) must point to the long side of the end of the hub (5).
A. Press two bearings into each end of the hub.
B. The outer edge of the outer bearings must be
flush with the recessed edge within the hub.
C. Center bearings must not interfere with grease
fitting hole.
4. Slide flat washer (10) and two thrust washers (9)
onto the motor shaft. Slide hub (5) onto the shaft with the
short side first.
5. Slide remaining thrust washers (9) and flat washer
(10) onto the motor shaft. Install remaining snap ring
(11) into the shaft groove. Slide new grease seal (12)
onto motor shaft.
IMPORTANT:The hub (5) should spin freely in the
forward direction, but lock on the hydraulic motor
(1) shaft when it is spun in the reverse direction.
6. Press grease seals (12) into the hub (5) so they are
flush with the end of the hub.
3. Grease inner edge of the new grease seal (12) with
No. 2 multipurpose lithium base grease. Slide seal onto
motor shaft past groove closest to the motor. Install snap
ring (11) into groove.
Chassis (Rev. D)
Page 6 − 8
Greensmaster 3250−D
Installation (Fig. 5)
1. Secure wheel (25) to the four drive studs of the hydraulic motor and hub assembly (2) with four lug nuts
(23). Torque nuts from 70 to 90 ft−lb (95 to 122 N−m).
2. Reinstall grease fitting (22) into hydraulic motor and
hub assembly (2) so it points away from the wheel (25).
5. Secure hydraulic motor and hub assembly (2)
loosely to the left inside of the castor fork (1) with both
socket head screws (12) lock nuts (13).
6. Secure flangettes (6 and 8), bearing (5), and adapter plate (21) loosely to the right inside of the castor fork
(1) with cap screws (10), bearing tab (9), and lock nuts
(11).
3. Install flangette (8), bearing (5), and relube flangette
(6) onto the motor shaft.
A. Position grease fitting (7) facing downward.
B. Torque both socket head screws (12) to 85 ft−lb
(115 N−m).
4. Position hydraulic motor and hub assembly (2), flangettes (6 and 8) with bearing (5), and wheel (25) into the
castor fork (1). Make sure hose fittings on the motor face
to the rear.
C. Torque both cap screws (10) to 30 ft−lb (41
N−m).
Chassis
7. Apply loctite to both set screws (24). Torque both
screws from 80 to 100 in−lb (9 to 11 N−m).
Greensmaster 3250−D
Page 6 − 9
Chassis (Rev D)
Front Wheel and Brake
4
250 to 400 ft−lb
(339 to 542 N−m)
3
24
6
7
5
12
11
RH 15
LH 16
30
8
1
9
32
15 RH
16 LH
14
18
2
17
13
70 to 90 ft−lb
(95 to122 N−m)
12
19
20
26
29
10
RIGHT
23
28
22
FRONT
21
31
25
27
Figure 8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Lug nut
Tire
Rim
Valve stem
Brake drum
Wheel hub
Drive stud
Backing plate
Brake cam
Retaining clip
Return spring
Chassis (Rev. D)
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Brake shoe
Bearing plate
Brake bracket
Hydraulic hose
Hydraulic hose
45_ Hydraulic fitting
O−ring
O−ring
Hydraulic motor
Flat washer
Brake rod
Page 6 − 10
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Brake lever
Lock nut
Jam nut
Cap screw
Cap screw
Lock nut
Lock nut
Cap screw
Swivel clevis
Woodruff key
Greensmaster 3250−D
Removal (Fig. 8)
2
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 motor (20).
3. Remove lug nuts (1), tire (2) and rim (3), and bearing
plate (13). Loosen but do not remove lock nut (24) from
hydraulic wheel motor (20) shaft.
3
1
IMPORTANT: DO NOT hit wheel hub (6) with a hammer during removal or installation. Hammering may
cause damage to the hydraulic wheel motor (20).
4. Use wheel hub puller (see Special Tools) to free
wheel hub (6) and brake drum (5) assembly from motor
shaft. Remove lock nut (24), wheel hub and brake drum
assembly, and key (32) from the hydraulic wheel motor
(20) shaft.
5. Remove return springs (11) from brake shoes (12).
Remove brake shoes from backing plate (8).
6. Remove retaining clip (10) and brake cam (9) from
the brake lever (23) and backing plate (8).
4
Figure 9
1. Return spring
2. Brake shoe
3. Brake cam
4. Backing plate
Installation (Fig. 8 and 9)
1. Secure backing plate (8) to the brake bracket (14)
with the four hex head screws (26) and lock nuts (29).
7. Remove four cap screws (26), lock nuts (29), and
backing plate (8) from the brake bracket (14).
2. Position both brake shoes (12) on the backing plate
(8). Insert return springs (11) into the holes of both brake
shoes (12).
8. Parts should be clean and free of rust. Inspect brake
shoe (12) and brake drum (5) contact surfaces for excessive wear. Replace any worn or damaged parts.
3. Install brake cam (9) into the backing plate (8) and
brake lever (23). Secure cam to the lever with the retaining clip (10).
5. Secure wheel hub (6) to motor shaft with lock nut
(24). Torque nut from 250 to 400 ft--lb (339 to 542
N--m).
6. Install bearing plate (13) and rim (3) onto the wheel
hub (6). Secure rim with lug nuts (1) to the wheel hub (7)
drive studs. Tighten lug nuts evenly in a crossing pattern
to a torque from 70 to 90 ft--lb (95 to 122 N--m).
7. Check and adjust brakes (see Brake Adjustment).
Greensmaster 3250--D
Page 6 -- 11 Rev. I
Chassis (Rev D)
Chassis
4. Make sure that wheel hub bore and wheel motor
shaft are thoroughly cleaned. Install key (32) to the hydraulic wheel motor (20) shaft. Slide hub over shaft and
key.
Front Lift Arms
9
7
6
5
8
4
8
10
5
11
14
3
12
15
14
13
23
2
22
16
22
1
2
21
20
21
12
20
16
19
16
18
24
17
29
25
26
30
27
28
67 to 83 ft−lb
(91 to 112 N−m)
Figure 10
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Front lift frame
Bushing
Grease fitting
Lift arm
Bushing
Grease fitting
Cotter pin
Flat washer
Lift cylinder
Clevis pin
Chassis (Rev. D)
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Cap screw
Jam nut
Carrier spacer
Flange bushing
Torsion spring
Cap screw
Washer head screw
Pin
Link bracket
Flat washer
Page 6 − 12
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Spacer tube
Lock nut
Pull frame spacer
Phillips head screw (3 used)
Wear pad
Transport plate
Lock nut (3 used)
Cap screw (2 used)
Clevis
Cap screw
Greensmaster 3250−D
Disassembly (Fig. 10)
5
1. Park machine on a level surface. Make sure engine
is off and brake is set.
1
2
67 to 83 ft−lb
(91 to 112 N−m)
4
3
2. Remove cutting unit from front lift arm (see Operator’s Manual).
6
3. Disassemble front lift arm as needed using Figures
10 and 11 as guides.
3
Assembly (Fig. 10)
1. Assemble front lift arm using Figures 10 and 11 as
guides.
A. If clevis (item 29) was removed from front lift
frame, torque cap screw from 67 to 83 ft−lb (91 to
112 N−m).
B. If pull frame (item 1 in Fig. 11) was removed from
clevis on lift frame, torque cap screw from 67 to 83
ft−lb (91 to 112 N−m).
Figure 11
1. Pull frame
2. Pivot spacer
3. Bushing
4. Clevis
5. Cap screw
6. Lock nut
2. Attach cutting unit to lift arm (see Operator’s Manual).
Chassis
3. Check that when raised to the transport position, the
cutting units are secured by the transport plate. If necessary, loosen two cap screws (item 28) and reposition
transport plate.
Greensmaster 3250−D
Page 6 − 13
Chassis (Rev D)
Center Lift Arm
100 to 150 ft−lb
(136 to 203 N−m)
36
4
5
3
3
37
2
6
7
1
8
35
2
12
9
11
10
34
11
22
12
24
23
22
25
10
21
20
24
15
13
13
18
19
26
17
14
27
28
29
30
15
18
31
16
33
67 to 83 ft−lb
(91 to 112 N−m)
32
Figure 12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Center lift arm
Bushing
Flat washer
Cotter pin
Lift cylinder
Clevis pin
Grease fitting
Pivot tube
Cap screw
Jam nut
Flange bushing
Thrust washer
Cap screw
Chassis (Rev. D)
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Lock nut
Lock nut
Link bracket
Spacer tube
Flat washer
Spacer
Cap screw (2 used)
Flat washer
Eccentric bushing
Pull frame spacer
Bushing
Lift frame
Page 6 − 14
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
Phillips screw (3 used)
Wear pad
Transport plate
Lock nut (3 used)
Cap screw (2 used)
Clevis
Cap screw
Cap screw
Grease fitting
Spring guide
Cap screw
Torsion spring
Greensmaster 3250−D
Disassembly (Fig. 12)
5
1. Park machine on a level surface. Make sure engine
is off and brake is set.
1
2
67 to 83 ft−lb
(91 to 112 N−m)
4
3
2. Remove center cutting unit from lift arm (see Operator’s Manual).
6
3. Disassemble center lift arm as needed using Figures 12 and 13 as guides.
3
Assembly (Fig. 10)
1. If lift frame (item 25) was removed from machine:
A. Adjust eccentric bushings (item 22) as needed
so that lift frame is level when the lift frame is in the
raised position.
B. Install thrust washers (item 12) as needed so
that lift frame is centered between the front wheel
mounts when the lift frame is in the raised position.
2. Assemble center lift arm using Figures 12 and 13 as
guides.
Figure 13
1. Pull frame
2. Pivot spacer
3. Bushing
4. Clevis
5. Cap screw
6. Lock nut
A. If clevis (item 31) was removed from center lift
frame, torque cap screw from 67 to 83 ft−lb (91 to
112 N−m).
B. If pull frame (item 1 in Fig. 13) was removed from
clevis on lift frame, torque cap screw from 67 to 83
ft−lb (91 to 112 N−m).
3. Attach cutting unit to lift arm (see Operator’s Manual).
Chassis
4. Check that when raised to the transport position, the
cutting unit is secured by the transport plate. If necessary, loosen two cap screws (item 30) and reposition
transport plate.
Greensmaster 3250−D
Page 6 − 15
Chassis (Rev D)
This page is intentionally blank.
Chassis (Rev. D)
Page 6 − 16
Greensmaster 3250−D
Chapter 7
SPA and 4−Bolt Cutting Units
Table of Contents
Backlapping (Units with Backlap/Variable Reel
Speed Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rollers and Bedbar Assembly
(Single Point Adjust Cutting Units) . . . . . . . . . .
Rear Roller and Height−of−Cut Adjuster
Removal and Installation . . . . . . . . . . . . . . . . . .
Front Roller Removal and Installation . . . . . . . . .
Bearing Replacement for Standard Rear Roller
........................................
Bearing Replacement for Standard Front Roller
and Full Front Rollers . . . . . . . . . . . . . . . . . . . . .
Bearing Replacement for Wiehle Rear Roller . .
Bedbar Removal and Installation
(Single Point Adjust Cutting Units) . . . . . . . . . .
Bedknife Adjuster Service
(Single Point Adjust Cutting Units) . . . . . . . . . .
Rollers and Bedbar Assembly
(4−Bolt Adjust Cutting Units) . . . . . . . . . . . . . . .
Bedbar Removal and Installation
(4−Bolt Adjust Cutting Units) . . . . . . . . . . . . . . .
Bedknife Replacement and Grinding . . . . . . . . . .
Preparing a Reel for Grinding . . . . . . . . . . . . . . . .
Reel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reel and Bearing Removal and Installation . . . .
Rear Roller Scraper Removal and Installation . .
Front Roller Brush/Scraper
Removal and Installation . . . . . . . . . . . . . . . . . .
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
36
37
SPA and 4−Bolt
Cutting Units
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4
Lift Roller Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 7
Factors Affecting Quality of Cut . . . . . . . . . . . . . . . 7
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Daily Adjustments
(Single Point Adjust Cutting Units) . . . . . . . . . . . 9
Daily Adjustments
(4−Bolt Adjust Cutting Units) . . . . . . . . . . . . . . . . 9
Adjust Bedknife Parallel to Reel
(Single Point Adjust Cutting Units) . . . . . . . . . . 10
Adjust Bedknife Parallel to Reel
(4−Bolt Adjust Cutting Units) . . . . . . . . . . . . . . . . 11
Adjust and Level Front Roller to Reel . . . . . . . . . 12
Adjust Attitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjust Top Shield Height . . . . . . . . . . . . . . . . . . . . 14
Adjust Top Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Adjust Height−of−Cut . . . . . . . . . . . . . . . . . . . . . . . 15
Adjust Rear Roller Scraper . . . . . . . . . . . . . . . . . . 15
Adjust Front Roller Brush/Scraper . . . . . . . . . . . . 15
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 17
Cutting Unit Removal and Installation . . . . . . . . . 17
Backlapping (Units without Backlap/Variable Reel
Speed Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Greensmaster 3250−D
Page 7 − 1
SPA and 4−Bolt Cutting Units (Rev. A)
Introduction
There are two different types of cutting units covered in
this chapter: the Single Point Adjust and 4−Bolt Adjust.
Both units are similar in design and construction. However, each unit has different bedbars with different methods of bedknife adjustment (see Specifications).
SPA and 4−Bolt Cutting Units (Rev. A)
Maintenance procedures for both cutting units are the
same, except where noted. If a chapter subheading
does not specify a particular type of cutting unit, the procedure can be used for both types of units. A particular
unit may be illustrated, but the component parts and
maintenance procedures are the same for each type of
unit.
Page 7 − 2
Greensmaster 3250−D
Specifications
4−BOLT
ADJUST UNIT
SINGLE POINT
ADJUST UNIT
Figure 14
Reel Construction: Reels are 5 inches (13cm) in diameter, 21 inches (53.3 cm) in length. High carbon steel
blades are welded to 5 stamped steel spiders and heat
treated to RC 48−54 hardness. The reel is ground for diameter, concentricity, and back grind.
Reel Bearings: Two double row ball bearings,
(30 mm I.D.) are press fitted onto the reel shaft. An inverted seal pressed onto reel shaft. Bearing side load
maintained by a wave washer, no adjusting nut.
Reel Drive: The reel weldment shaft is a 1.375−inch diameter tube with drive inserts permanently pressed in
both ends. A replaceable floating coupler with an internal eight tooth spline is factory installed on the right end,
and held in place by a snap ring. The floating coupler
may be moved to the other end when the cutting unit is
used on the tractor front right position.
Frame Construction: Single top tube is welded to two
sideplates. A bolt−in cross rod acts to set the front frame
width and stiffen the assembly. The lift straps have a reGreensmaster 3250−D
placeable roller that may be moved to change transport
height.
Bedknife: Replaceable, 13−screw, single edged, high
carbon steel bedknife austempered to RC 48−55, fastened to a machined cast iron bedbar. Tournament bedknife is standard.
Bedknife Adjustment (Single Point Adjust): A single
control screw has detents corresponding to 0.0007 inch
(0.018 mm) bedknife movement for each indexed position. A linear adjustment on the bedbar left end allows
leveling of bedknife to reel blades. A centered lever arm
regulates knife to reel contact with two rubber bushings
acting as pivots.
Bedknife Adjustment (4−Bolt Adjust): Two opposing
screws on each end of the bed bar are used to level and
regulate bedknife to reel contact.
Front Roller: Standard front roller is a 2.5 inch (6.4 cm)
diameter full radius Wiehle. The right bracket has an eccentric shoulder bolt to provide leveling. A second eccentric may be added to the left bracket for increased
leveling range. Roller has a through shaft with greaseable ball bearings.
Rear Roller: Standard rear roller is a 2 inch (5.2 cm) diameter smooth steel roller. Roller has a through shaft
with greaseable ball bearings.
Counterbalance Weight: The end of cutting unit opposite the reel motor has a weight with a spin flange like the
reel motors for easy installation. The weight seals the
bearing area and balances the reel motor’s weight during cutting.
Page 7 − 3
SPA and 4−Bolt Cutting Units (Rev. A)
SPA and 4−Bolt
Cutting Units
Height−of−Cut (HOC): Cutting height is adjusted on
the rear roller by two vertical screws and held by two
locking capscrews. Bench HOC range is 3/32 inch
(2.4mm) to 1−1/32 inches (26mm). Cutting units will deliver differing effective height−of−cuts depending on
their configuration. In fact, effective cutting height may
be influenced by the following factors; turf conditions,
roller profiles, cutting unit attitude, cutting unit accessories, weight of cutting units and bedknife profile. Therefore bench setting a cutting unit does not equal the
effective (actual) height of cut you achieve. You need to
determine how to adjust your cutter on the bench to
achieve a comparable height of cut to a cutting unit of a
different configuration, model or brand.
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
1. Remove hex head screw and lock nut from the lift
roller and frame.
2
2. Position lift roller to the proper hole on the frame. Insert hex head screw through the frame and roller.
Lower Hole − for increased transport height.
Upper Hole − standard transport height so the cutting unit is level when it touches down upon lowering.
Figure 15
3. Secure hex head screw with the lock nut.
SPA and 4−Bolt Cutting Units (Rev. A)
1. Lift roller
Page 7 − 4
2. Hex head screw
Greensmaster 3250−D
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 available from a local supplier.
Gauge Bar Assembly
Used to verify height--of--cut. Toro Part No. 13--8199.
Figure 3
Backlapping Brush Assembly -- TOR299100
Used to apply lapping compound to cutting units while
keeping the operator’s hands at a safe distance from the
rotating reel.
Figure 4
Bedknife Screw Tool -- TOR510880
This screwdriver--type bit is made to fit Toro bedknife attaching screws. Use this bit with a torque wrench to secure the bedknife to the bedbar.
Figure 5
Greensmaster 3250--D
Page 7 -- 5
Rev. I
SPA and 4--Bolt Cutting Units (Rev. A)
SPA and 4- Bolt
Cutting Units
DO NOT use and air or manual impact wrench with this
tool so damage to the bedbar will be prevented.
Bearing Replacement Tool Kit − TOR238900A
The puller is used to remove the bearings from the
Wiehle Rear Roller kit (Model 04488) rollers only. A driving tube is used to install bearings into the roller. A drill
bushing is used to drill into bearing shafts without a removal hole.
Figure 19
Plastic Plug
This cap is used for placement into the bearing housing
when the reel motor is removed. It prevents dirt and debris from entering the housing. Toro Part No. 2410−30.
Figure 20
SPA and 4−Bolt Cutting Units (Rev. A)
Page 7 − 6
Greensmaster 3250−D
Troubleshooting
There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf
conditions. Turf conditions such as excessive thatch,
“sponginess” or attempting to cut off too much grass
height may not always be overcome by adjusting the
cutting unit. It is important to remember that the lower
the height−of−cut, the more critical these factors are.
See Adjustments and Service and Repairs sections for
detailed adjustments and repair information.
For additional information regarding cutting unit troubleshooting, see Aftercut Appearance Troubleshooting Aid
(Toro part no. 00076SL).
Factors That Can Affect Quality of Cut
Factor
Possible Problem/Correction
Tire pressure
Check pressure of all tires. Pressure must be equal on
both front tires. Adjust pressure as necessary.
See General section in Chapter 6 − Wheels and
Brakes.
Governed engine speed
Check maximum governed engine speed. Adjust
engine to specifications if necessary.
See Adjustments section in Chapter 3 − Engine.
Reel bearing condition
Check bearings for wear and replace if necessary.
Make sure bearing housings are secured properly.
Keep bearings well lubricated.
See Reel and Bearing Removal and Installation.
Reel and bedknife sharpness
A reel and/or bedknife that has rounded cutting edges
or “rifling” (grooved or wavy appearance) cannot be
corrected by tightening the bedknife to reel contact.
Grind reel to remove taper and/or rifling. Grind
bedknife to sharpen and/or remove rifling.
The most common cause of rifling is bedknife to reel
contact that is too tight.
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).
Slightly dull cutting edges may be corrected by
backlapping (see Backlapping).
Excessively dull cutting edges must be corrected by
grinding the reel and bedknife (see Preparing Reel for
Grinding).
Greensmaster 3250−D
Page 7 − 7
SPA and 4−Bolt Cutting Units (Rev. A)
SPA and 4−Bolt
Cutting Units
A new bedknife must be ground or backlapped
after installation to the bedbar.
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.
See Height−of−Cut Adjustment.
Height−of−cut
“Effective” or actual height−of−cut depends on the
cutting unit weight and turf conditions. Effective
height−of−cut will be different from the bench set
height−of−cut.
See Height−of−Cut Adjustment.
Proper bedknife selection for height−of−cut desired
If the bedknife is too thick for effective height−of−cut,
poor quality of cut will result.
Stability of bedbar
Make sure bedbar pivot bolts are seated securely.
Check condition of the bushings in the side plates.
See Bedbar Removal and Installation.
Number of reel blades
Use correct number of blades for clip frequency and
optimum height−of−cut range.
Cutting unit alignment and pull frame ground following
Check pull frames and lift arms for damage, binding, or
bushing wear. Repair if necessary.
Roller condition
Make sure rollers rotate freely. Grease roller as
recommended and repair bearings as necessary.
See Roller Bearing Replacement in Service and
Repairs section.
Reel speed
All reels must rotate at the same speed (within 100
rpm). All cutting units must have equal bedknife to reel,
front roller to reel, attitude, and height−of−cut
adjustments. Check reel speed setting if a
backlap/variable reel speed kit is installed.
See Adjustments in this chapter and Troubleshooting
in Chapter 4 − Hydraulic System.
Traction speed
Check maximum governed engine speed. Adjust
engine to specifications if necessary. See Adjustments
section in Chapter 3 − Engine. Check traction pedal
adjustment.
See Adjusting Transport and Mowing Speed, and
Troubleshooting in Chapter 4 − Hydraulic System.
Cutting Unit drop speed and sequence
Center cutting unit must drop after front cutting units.
See Troubleshooting in Chapter 4 − Hydraulic System.
SPA and 4−Bolt Cutting Units (Rev. A)
Page 7 − 8
Greensmaster 3250−D
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 quality of cut is acceptable.
1
1. Lower cutting units onto a hard surface, shut off engine, and remove the key from the ignition switch.
2. Slowly rotate reel in the reverse direction listening
for reel−to−bedknife contact. If no contact is evident,
turn bedknife adjusting knob clockwise, one click at a
time, until light contact is felt and heard.
3. If excessive contact is felt, turn bedknife adjusting
knob counterclockwise, one click at a time, until no contact is evident. Then turn bedknife adjusting knob clockwise, one click at a time, until light contact is felt and
heard.
IMPORTANT: Light bedknife−to−reel contact is preferred at all times. If light contact is not maintained,
bedknife and reel edges will not sufficiently self−
sharpen, and dull cutting edges will result after a period of operation. Excessive contact can cause
accelerated and/or uneven bedknife and reel wear.
Thus, quality of cut may be adversely affected.
Figure 21
1. Adjuster
Note: As the reel blades continue to run against the
bedknife, a slight burr will appear on the front cutting
edge surface for the full length of the bedknife. If a file
is occasionally run across the front edge to remove this
burr, quality of cut will improve. If this burr is not removed, the quality of cut will appear as if it was cut with
a dull reel (grass will appear torn or ripped).
After extended running, a ridge will eventually develop
at both ends of the bedknife. These ridges must be
rounded off or filed flush with the cutting edge of the bedknife to assure smooth operation.
Daily Adjustments (4−Bolt Adjust Cutting Units)
1. Lower cutting units onto a hard surface, shut off engine, and remove the key from the ignition switch.
2. Slowly rotate reel in the reverse direction listening
for reel−to−bedknife contact. If no contact is evident, adjust bedknife to reel (see Bedknife to Reel Adjustment
(4−bolt Adjust Cutting Units)).
3. If excessive contact is felt, adjust bedknife (see
Bedknife to Reel Adjustment (4−bolt Adjust Cutting
Units)).
bedknife and reel edges will not sufficiently self−
sharpen, and dull cutting edges will result after a period of operation. Excessive contact can cause
accelerated and/or uneven bedknife and reel wear.
Thus, quality of cut may be adversely affected.
Note: As the reel blades continue to run against the
bedknife, a slight burr will appear on the front cutting
edge surface the full length of the bedknife. If a file is occasionally run across the front edge to remove this burr,
improved cutting can be obtained.
After extended running, a ridge will eventually develop
at both ends of the bedknife. These notches must be
rounded off or filed flush with the cutting edge of the bedknife to assure smooth operation.
IMPORTANT: Light bedknife to reel contact is preferred at all times. If light contact is not maintained,
Greensmaster 3250−D
Page 7 − 9
SPA and 4−Bolt Cutting Units (Rev. A)
SPA and 4−Bolt
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 quality of cut is acceptable.
Adjust Bedknife Parallel to Reel (Single Point Adjust Cutting Units)
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).
2. Position cutting unit on a level surface.
3. Make sure reel contact is removed by turning the
bedknife adjuster counterclockwise (Fig. 9).
4. Position cutting unit with the front roller up (Fig. 10).
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 precision cutting. Refer to the Toro General Service
Training Book, Reel Mower Basics (part no.
09168SL) for additional information.
8. When light contact on the paper is evident at each
end of the bedknife, tighten flange lock nuts to securely
retain the pivot hub (Fig. 10).
A. On either end of the front side of the reel, insert a
long strip of newspaper between the reel and bedknife.
3
1
B. While slowly rotating the reel forward, turn bedknife adjuster clockwise, one click at a time, until the
paper is pinched lightly all the way across the reel. A
slight drag should result when the paper is pulled.
This drag should be the same for the entire length of
the bedknife.
4
3
2
2
C. If equal adjustment is not obtained for the entire
length of bedknife, proceed to steps 5. through 8.
5. Loosen both flange lock nuts secured to the frame
tab (Fig. 9). Also, loosen both flange lock nuts securing
the pivot hub to the frame (Fig. 10).
6. Rotate flange lock nuts, on the top and bottom of the
frame tab, clockwise or counterclockwise to raise or lower the end of the bedbar, as required. Do not loosen the
bottom flange nut tightened against the pivot hub. Tighten both flange lock nuts against the frame tab to secure
the adjustment adjustment (Fig. 9).
Figure 9
1. Adjuster
2. Pivot hub (LH)
3. Flange lock nut
4. Frame tab
PINCH
7. Check adjustments by repeating steps 3. and 4. After the adjustments are accomplished, make sure of the
following (Fig. 10):
A. The reel can pinch the paper when inserted from
the front.
B. The reel can cut the paper when inserted at a
right angle. It should be possible to cut the paper
with minimum contact between the bedknife and the
reel blades.
CUT
1
1
Figure 10
1. Flange lock nut
SPA and 4--Bolt Cutting Units (Rev. A)
Page 7 -- 10 Rev. I
Greensmaster 3250--D
Adjust Bedknife Parallel to Reel (4--Bolt Adjust Cutting Units)
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).
2
IMPORTANT: Use only a 13mm wrench, 3 to 6 inches (7.5 to 15 cm) in length, when adjusting the hex
head screws. A longer wrench will provide too much
leverage and may cause distortion of the mounting
plate (Fig. 11).
3
2. Make sure reel contact is removed by loosening the
top hex head screw on each side of cutting.
1
3. Position cutting unit with the front roller up (Fig. 11).
A. On either end of the front side of the reel, insert a
long strip of newspaper between the reel and bedknife.
Figure 11
1. Bottom hex head screw
2. Top hex head screw
B. While slowly rotating the reel forward, adjust top
and bottom hex head screws until the paper is
pinched lightly all the way across the reel. A slight
drag should result when the paper is pulled. This
drag should be the same for the entire length of the
bedknife.
3. Mounting plate
PINCH
4. After adjusting bedknife to reel, make sure that both
top and bottom adjusting screws are secured against
the bedbar tabs on each end of the cutting unit (Fig. 11).
5. After the adjustment is accomplished, make sure of
the following (Fig. 12):
A. The reel can pinch the paper when inserted from
the front.
B. The reel can cut the paper when inserted at a
right angle. It should be possible to cut the paper
with minimum contact between the bedknife and the
reel blades.
CUT
Figure 12
Greensmaster 3250--D
Page 7 -- 11 Rev. I
SPA and 4- Bolt
Cutting Units
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 precision cutting. Refer to the Toro General Service
Training Book, Reel Mower Basics (part no.
09168SL) for additional information.
SPA and 4--Bolt Cutting Units (Rev. A)
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).
1
3
Note: Make sure leveling plate covers the full length
of reel blades. Three blades must contact the plate.
2. Position cutting unit on a cutting leveling plate or a
known flat and level surface.
2
3. Position a 1/4−inch or thicker bar stock under the
reel blades and against the front face of the bedknife.
Note: Make sure both front brackets are in the same
hole (see Attitude Adjustment).
4. Loosen both lock nuts securing the right front bracket.
Note: The right front bracket is secured to the frame
with an eccentric bolt, while the left front bracket is secured with a shoulder bolt. The eccentric bolt has an offset, which when rotated, acts as an eccentric (cam) to
raise or lower the roller. On the bolt head there is an
identification dot which denotes the offset of the bolt.
The dot indicates in which direction the right end of roller
moves when bolt is turned.
Figure 26
1. Lock nuts
2. Right front roller bracket
3. Eccentric bolt
Note: If additional adjustment is required, replace
shoulder bolt on the left front bracket with another eccentric bolt (see cutting unit parts catalog for current part
number). Make sure both front roller brackets are in the
same hole.
6. Verify roller is level. Insert a piece of paper or 0.003
inch (0.076 mm) feeler gauge under each end of the roller.
7. When the roller is level, tighten lock nuts securely.
5. While holding reel securely on plate and maintaining pressure on front roller, rotate upper right roller
mounting bolt. This mounting bolt has an offset, which
when rotated, acts as an eccentric (cam) to raise or lower the roller. On the bolt head there is an I.D. dot which
denotes the offset of the bolt. The dot indicates in which
direction right end of roller moves when bolt is turned.
SPA and 4−Bolt Cutting Units (Rev. A)
Page 7 − 12
Greensmaster 3250−D
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−
of−cut (Fig. 27).
Height−of−Cut (HOC) Range − 1/8 to 1−1/32 inch
(3.2 to 26mm)
Note: The top frame hole and top bracket hole will
yield Position 2 (standard position).
Position 2: The standard position is used for
most conditions (Fig. 28).
HOC Range − 3/32 to 15/16 inch (2.4 to 24mm)
Position 3: A more aggressive position is used on
firm turf (Fig. 29).
HOC Range − 3/32 to 13/16 inch (2.4 to 21mm)
Position 4: The most aggressive position is
used only on very firm greens or at the lowest
height−of−cut (Fig. 30).
HOC Range − 3/32 to 3/4 inch (2.4 to 19mm)
Note: A more aggressive setting will increase grass
removal and provide a cleaner cut, but may cause increased scalping and marking.
Note: A more aggressive setting will be required to
compensate for reel wear.
ÉÉÉ
ÉÉÉ
ÉÉÉÉÉÉ
POSITION 1
Figure 27
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
POSITION 2
Figure 28
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
POSITION 3
Figure 29
Adjusting Attitude
1. If the cutting unit is not already removed from the
machine, remove reel motor from the cutting unit and
cutting unit from lift arm (see Cutting Unit Removal and
Installation).
2. Remove lock nuts from the eccentric (shoulder) bolt
and carriage bolt securing both front brackets.
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
ÉÉÉ
POSITION 4
Figure 30
SPA and 4−Bolt
Cutting Units
Note: The top of the right front bracket is secured to
the frame with an eccentric bolt, while the left front
bracket is secured with a shoulder bolt (Fig. 31).
3. Remove eccentric (shoulder) bolt and carriage bolt
from both front brackets and the side plates.
Greensmaster 3250−D
Page 7 − 13
SPA and 4−Bolt Cutting Units (Rev. A)
4. Position both front brackets as follows:
3
2
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. 31)
so the point on the bracket is at the desired position.
4
B. Screw lock nut onto the eccentric bolt (shoulder
bolt).
C. Insert carriage screw through the bottom hole of
the frame and front bracket. Secure carriage screw
and eccentric bolt (shoulder bolt) with lock nuts.
1
5
Figure 31
1. Front bracket
2. Eccentric (shoulder) bolt
3. Lock nut
4. Lock nut
5. Carriage screw
5. Level front roller to the reel (see Adjust and Level
Front Roller to Reel).
Adjust Top Shield Height
Note: The top shield can be raised for extremely wet
conditions.
1
2
1. Loosen cap screws and nuts securing top shield to
each side plate.
2. Adjust top shield to desired position and secure fasteners.
3. Repeat above steps for the remaining cutting units.
IMPORTANT: The top shield must be adjusted every
time the top shield is adjusted.
Figure 32
1.
Top shield
2.
Lock nut
Adjust Top Bar
Adjust top bar, which is located on the rear bottom of the
top shield, to make sure clippings are cleanly discharged from the reel.
IMPORTANT: The top bar is adjustable to compensate for changes in turf conditions. The bar should
be adjusted closer to the reel when turf is extremely
wet. When turf conditions are dry, adjust the top bar
further away from the reel.
SPA and 4−Bolt Cutting Units (Rev. A)
1. Loosen screws securing the top bar to the top
shield.
Note: Make sure gap between the bar and reel is the
same for the entire length of the reel.
2. Insert 0.060 inch (1.52 mm) feeler gauge between
the top of the reel and top bar. Tighten all screws.
3. Repeat above steps on remaining cutting units.
Page 7 − 14
Greensmaster 3250−D
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. Therefore benchsetting a
cutting unit does not equal the effective (actual) height−
of−cut you achieve. You need to determine how to adjust
your cutter on the bench to achieve a comparable
height−of−cut to a cutting unit of a different configuration, model, or brand.
4
1. If the cutting unit is not already removed from the
machine, remove reel motor from the cutting unit and
cutting unit from lift arm (see Cutting Unit Removal and
Installation).
2. Verify that front roller is level and bedknife to reel
contact is correct (see Adjust Bedknife to Reel, and see
Adjust and Level Front Roller to Reel).
3. Turn cutting unit over (90) and rest it on the rear
roller and top rear tabs. Loosen locknuts on the capscrews retaining the rear roller brackets.
4. On gauge bar (Part no. 13−8199), set head of screw
to desired height−of−cut. This measurement is from bar
face to underside of screw head.
3
1
2
Figure 33
1. Gauge bar
2. Cap screw
3. Rear roller bracket
4. Height−of−cut adjuster
5. Place bar across the front and rear rollers. Adjust
rear roller with height−of−cut adjuster until the underside of screw head engages the bedknife cutting edge.
6. Repeat procedure on each end of bedknife. Tighten
lock nuts to secure rear roller brackets on each end.
Adjust Rear Roller Scraper
1. Park machine on a clean and level surface, lower
cutting units, stop engine, engage parking brake, and
remove key from the ignition switch.
6
4
5
2. Loosen flange nuts securing both bracket assemblies to the hex head screws on each roller bracket.
3. Adjust flange nuts up or down until bottom edge of
scraper is the same height as the top edge of the cutting
unit bedknife at each end or the same as the height−of−
cut setting.
Note: If scraper is not adjusted correctly it will not
properly clean roller, will ruffle the grass or leave large
clumps on the grass.
1
4. Move scraper in or out to ensure the edge is flush
with the full length of the roller. Tighten top flange nuts
to secure the adjustment.
IMPORTANT: Thoroughly wash cutting unit after
each use. Pull scraper away from the roller when
washing. Failure to follow this practice may result in
pitting of the roller.
Greensmaster 3250−D
2
3
Figure 34
1. Flange nuts
2. Bracket assembly
3. Hex head screw
Page 7 − 15
4. Scraper
5. Lock nut
6. Spring
SPA and 4−Bolt Cutting Units (Rev. A)
SPA and 4−Bolt
Cutting Units
5
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.
3. Adjust aggressiveness of the brush/scraper as follows:
A. Bristles touching the adjusting gauge bar gives
you an aggressive setting.
B. Adjusting the brush assembly so it is midway between the adjusting gauge bar and the cutting edge
of the bedknife will provide a medium setting.
2
3
C. Adjusting the brush assembly so it is even with
the cutting edge of the bedknife will provide a light
setting.
4. Tighten socket head screws securing clamp blocks
to roller shaft.
5. Adjust jam nuts on each scraper rod until there is a
clearance of approximately 1/32 inch (0.8 mm) between
the scraper and roller. Make sure scraper is parallel to
the roller.
SPA and 4−Bolt Cutting Units (Rev. A)
1
5
4
6
Figure 35
1.
2.
3.
Page 7 − 16
Front roller bracket
Front roller
Clamp block
4.
5.
6.
Scraper rod
Socket head screw
Jam nut
Greensmaster 3250−D
Service and Repairs
Cutting Unit Removal and Installation
IMPORTANT: When sharpening, setting height-ofcut, or performing other maintenance procedures
on the cutting units, store the cutting unit reel motors in support tubes on the frame to prevent damage to the hoses. Do not raise suspension to
transport position when the reel motors are in the
holders in the traction unit frame. Damage to the
motors or hoses could result.
3
Removal
1. Park machine on a clean and level surface, lower
cutting units completely to the ground, stop engine, engage parking brake, and remove key from the ignition
switch.
2
1
Figure 36
1. Flange head screws
2. Bearing housing
3. Hydraulic motor
2. Remove basket from carrier frame.
3. Loosen flange head screws that secure the hydraulic motor to the bearing housing. Rotate motor clockwise, and remove motor (Fig. 36).
1
4. Place protective plastic cap (see Special Tools) into
the hole in the bearing housing from which the hydraulic
motor was removed.
5. Slide sleeve back on each ball joint receiver. Remove receiver from each unit’s ball studs (Fig. 37).
6. For the front cutting units, slide cutting unit lift roller
off the lift arm while siding the cutting unit from the pull
frame (Fig. 37).
IMPORTANT: Do not operate the lift system when
the rear cutting unit is in the service position. Damage could result to the pull frame and clevis assembly.
3
2
6.06 inch (15.4 cm)
w/o groomer
Figure 37
1. Shoulder bolt
2. Front roller bracket
3. Carrier frame
2
3
7. For the rear cutting unit: (Fig. 38).
4
A. Slide cutting unit lift roller off the lift arm.
1
C. Lift up on the slotted link and rotate the pull frame
into the wire hook (service position). Pull cutting unit
from the machine.
Rear Pull Frame
Figure 38
1.
2.
Greensmaster 3250−D
Page 7 − 17
Slotted Link
Wire hook
3.
4.
Lift roller
Lift arm
SPA and 4−Bolt Cutting Units (Rev. A)
SPA and 4−Bolt
Cutting Units
B. Lift carrier frame by hand until the anti-scalp rollers clear the brake linkage.
Installation
Note: New cutting units are shipped with the counter
weight mounted to left end and drive coupler mounted
in the right end of cutting unit.
1
1. If a cutting unit is to be mounted in the right front
position, proceed as follows (Fig. 39):
A. Remove both flange head screws and lockwashers securing the counter weight to the left end of cutting unit. Remove counter weight.
B. Remove snap ring securing the drive coupler in
the right bearing housing. Remove drive coupler.
C. Apply No. 2 multipurpose lithium base grease to
the inside of the drive coupler. Install drive coupler
into the left end of the reel shaft with the snap ring.
Note: On units without plastic spacers (Toro P/N
104−2067), spacers can be installed to help direct
grease into the bearings and reduce the amount of
grease used.
D. Install plastic spacer into the bearing housing.
E. Install counter weight to the right end of the cutting unit with the flange head screws and lockwashers. Move RH end screws to the left end.
3
2
5
7
4
6
Figure 39
1.
2.
3.
4.
Flange head screw
Lock washer
Counter weight
Drive coupler
5. Left end of reel shaft
6. Snap ring
7. Plastic spacer
5. Slide sleeve back on each ball joint receiver and
hook onto cutting unit ball studs (Fig. 37).
6. Mount basket onto carrier frame.
7. Adjust pull links until there is 1/4 to 3/8 inch (6.4 to
9.5 mm) clearance between the lip of the basket and the
reel blades. Make sure the basket lips are equidistant
from the reel blades all the way across the reel blades.
8. Install hydraulic motor to bearing housing as follows
(Fig. 36).
2. Make sure ball studs are threaded into each end of
the cutting unit front roller (Fig. 37).
A. Coat spline shaft of the motor with clean No. 2
multipurpose lithium base grease.
3. On the front cutting units, slide cutting unit under the
pull frame while hooking the lift roller onto lift arm (Fig.
38).
B. Assemble the mounting capscrews for the reel
drive motor to each cutting unit. Leave approximately 1/2 inch (12.7 mm) of threads exposed on each
mounting cap screw.
IMPORTANT: Do not operate lift system when the
rear cutting unit is in the service position. Damage
could result to the pull frame and clevis assembly.
C. Install motor by rotating the motor clockwise so
the motor flanges clear the flange head screws.
Note: When installing cutting units with groomers, and groomer carton label does not read “with
extension brackets,” Groomer Extension Kit, part
no. 99−4255, is required.
D. Rotate the motor counterclockwise until the motor flanges are encircling the flange head screws.
Tighten flange head screws.
4. On the rear cutting unit, rotate and latch unit into into
the service position (Fig. 38).
E. Using a hand pump grease gun, fill cavity in the
bearing housing of cutting unit with No. 2 general
purpose grease.
A. Lower the suspension system completely (cylinders extended).
B. Lift the carrier frame by hand until the anti-scalp
rollers clear the brake linkage.
C. Lift up on the slotted link and rotate the pull frame
into the wire hook.
D. With the cutting unit in position, release the wire
hook and rotate the pull frame to operating position.
The slotted link locks automatically.
Page 7 − 18
SPA and 4−Bolt Cutting Units (Rev. A)
Greensmaster 3250−D
Backlapping (Units without Backlap/Variable Reel Speed Kit)
Top Face
CAUTION
Relief Angle
Be careful when backlapping the reel because
contact with the reel or other moving parts can
result in personal injury.
1. Remove reel motors from the cutting units and cutting units from the lift arms and pull frame (see Cutting
Unit Removal and Installation).
Remove
Burr
Front
Face
Front Angle
Figure 27
2. Connect the backlapping machine to the cutting unit
by inserting a piece of 3/8--inch socket extension drive
into the splined coupling at right end of cutting unit. If
coupling is in the left end of cutting unit, move coupling
the right end for backlapping.
3. Attach backlap motor or drive to the socket extension.
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.
SPA and 4- Bolt
Cutting Units
Note: For a better cutting edge, run a file across the
front face of the bedknife when the lapping operation is
completed. This will remove any burrs or rough edges
that may have built up on the cutting edge.
Greensmaster 3250--D
Page 7 -- 19 Rev. I
SPA and 4--Bolt Cutting Units (Rev. A)
Backlapping (Units with Backlap/Variable Reel Speed Kit)
DANGER
2
TO AVOID PERSONAL INJURY OR DEATH:
D Never place hands or feet in the reel area
while the engine is running.
D While backlapping, the reels may stall and
then restart.
D Do not attempt to restart reels by hand or
foot.
D Do not adjust reels while the engine is
running.
D If a reel stalls, stop engine before
attempting to clear the reel.
D Reel motors are connected in series, moving
one motor moves the other two.
1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake, and
remove key from the ignition switch.
2. Move functional control lever to the Neutral/Backlap
position.
IMPORTANT: Do not attempt to rotate the directional valve knob when the machine or reels are running.
3. Raise seat and rotate directional valve knob fully
clockwise to the backlap position.
4. Rotate flow control valve knob to position 6.
5. On all cutting units, make initial reel to bedknife adjustments appropriate for backlapping (see Bedknife to
Reel Parallel Adjustment).
6. Start engine and move Raise / Lower -- Mow control
forward to start the reels.
7. Rotate flow control valve knob to position 1.
8. Apply lapping compound with a long handled brush
(see Special Tools).
CLOCKWISE
1
3
4
Figure 28
1. Directional valve knob
2. Ball switch
3. Flow control valve knob
4. Hydraulic manifold
9. To make an adjustment to the cutting units while
backlapping, turn reels OFF by moving the RAISE/
LOWER--MOW control to the RAISE position. Shut off
engine. After the adjustments have been completed, repeat steps 4 through 6.
10. When the backlap operation is completed, shut off
engine and rotate directional valve knob counter--clockwise fully (90o from the backlap position) to forward position. Also, rotate flow control valve knob to position 13
for height--of--cut settings of a 1/4 inch or below.
Note: For additional settings, refer to the instructions
on the decal that is located on the underside of the seat
support.
11. Wash all lapping compound off the cutting units.
12. For a better cutting edge, run a file across the front
face of the bedknife when the lapping operation is completed. This will remove any burrs or rough edges that
may have built up on the cutting edge.
Note: Additional instructions and procedures on
backlapping are available in the Toro General Service
Training Book, Reel Mower Basics (part no. 09168SL).
CAUTION
Be careful when backlapping the reel because
contact with the reel or other moving parts can
result in personal injury.
SPA and 4--Bolt Cutting Units (Rev. A)
Page 7 -- 20 Rev. I
Greensmaster 3250--D
Rollers and Bedbar Assembly (Single Point Adjust Cutting Units)
37
36
35
34
57
25
29
28
27
26
24
39
38
33
58
10
25
24
23
32
52
31
11
33
54
30
40
8
48
‘
50
2
55
21
15
17
18
14
13 22
12
11
49
48
47
42
56
11
41
49
53
20
19
51
10
46
9
16
3
46
4
8
7
6
5
43
1
44
45
Front roller assembly
Bedbar and bushing
Bedbar
Bedknife
Special screw
Ball stud
Lock washer
Front bracket
Cap screw
Flanged bushing
Lock nut
Flat washer
Pivot hub (LH)
Flange head nut
Cap screw
Bracket position decal
Shoulder bolt
Carriage screw
Cap screw
Height−of−cut tab
Greensmaster 3250−D
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Height−of−cut adjustment bracket
Roller assembly
Compression spring
Thrust washer
Nylon thrust washer
Cap screw
Spring arm
Pivot housing
Single point adjuster
Pivot screw
Plastic bushing
Flat washer
Lock nut
Lock nut
Height−of−cut adjuster
Pivot hub (RH)
Quad−ring
Flat washer
Hex head flange screw
Page 7 − 21
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
Eccentric bolt
Carriage screw
Wiehle roller
Roller shaft
Ball bearing
Retaining ring
Lube fitting
Grease fitting
Rubber brush
Nylon brush
Bedbar pivot
Bushing
Roller tube
Lube fitting
Bearing
Shield washer
Retaining ring
Roller shaft
Bushing
SPA and 4−Bolt Cutting Units (Rev. A)
SPA and 4−Bolt
Cutting Units
Figure 42
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Rear Roller and Height−of−Cut Adjuster Removal and Installation
Note: Figure 42 shows the Rollers and Bedbar
Assembly for a Single Point Adjust (SPA) cutting units.
Both the SPA and 4−Bolt cutting units a similar in
construction. Roller and Height−of−Cut (H−O−C) Adjuster replacement procedures are the same for each
unit.
Installation (Fig. 42)
1. Place cutting unit on a level working surface.
2. If the H−O−C adjusters (35) or H−O−C adjustment
brackets (21) were removed, reinstall brackets as follows:
Removal (Fig. 42)
A. Apply Loctite 242 or equivalent to the threads of
the H−O−C adjusters about 1/4 inch (6 mm) below
the hex.
1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake, and
remove key from the ignition switch.
B. Place H−O−C adjuster through the holes of the
frame tabs. Screw locking nut onto the adjuster, and
run to the bottom of the frame tab. Make sure adjuster is free to rotate with no end play.
2. To remove the cutting unit, remove reel motor from
the cutting unit and the cutting unit from the lift arm (see
Cutting Unit Removal and Installation). Place cutting
unit on a level working surface.
C. Position H−O−C adjustment bracket on the inside of the frame. Screw H−O−C adjuster into the
H−O−C adjustment bracket until the top of the
bracket is 0.68 inch (18 mm) from the bottom of the
frame tab.
3. Remove rear roller as follows:
A. Remove cap screw (19) and lock nut (11) from
both H−O−C adjustment brackets (21).
D. Insert carriage screws (41) through the H−O−C
adjustment bracket and frame. Secure bracket and
screw with flat washer (32) and lock nut (32).
B. Remove height−of−cut tab (20) from both H−
O−C adjustment brackets.
C. Tilt back of the cutting unit up, and remove rear
roller (22) from both H−O−C adjustment brackets.
3. Reinstall rear roller as follows:
A. Tilt back of the cutting unit up, and position rear
roller shaft (57) under each H−O−C adjustment
bracket (21). Lower unit and brackets onto the roller
shafts.
4. If the height−of−cut adjusters (35) or H−O−C adjustment brackets (21) need removing, remove them as follows:
A. Remove lock nut (33), flat washer (32), and carriage screw (41) from the H−O−C adjustment bracket and frame.
B. Attach height−of−cut tab (20) to both H−O−C adjustment brackets so the tab is below the roller shaft.
C. Make sure roller is centered on the cutting unit.
Secure height−of−cut tab to the H−O−C adjustment
bracket with cap screw (19) and lock nut (11).
B. Unscrew H−O−C adjuster from the top block of
the H−O−C adjustment bracket.
C. Unscrew locking nut (34) from the H−O−C adjuster. Slide adjuster from the frame tab.
4. If the H−O−C adjustment brackets (21) were removed, verify height−of−cut (see Adjust Height−of−
Cut).
5. Reinstall reel motor to the cutting unit and the cutting unit to lift arm (see Cutting Unit Removal and Installation).
SPA and 4−Bolt Cutting Units (Rev. A)
Page 7 − 22
Greensmaster 3250−D
Front Roller Removal and Installation
Removal
6
4
1. Position machine on a clean and level surface, lower 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. Determine your maintenance needs.
2. If removing the cutting unit, remove reel motor from
the cutting unit and the cutting unit from lift arm (see Cutting Unit Removal and Installation). Place cutting unit on
a level working surface.
7
1
5
2
3. Remove cap screws securing the roller shafts to
each front bracket (Fig. 43).
Note: The right front bracket is secured to the frame
with an eccentric bolt and carriage screw, while the left
front bracket is secured with a shoulder bolt and carriage screw (Fig. 43).
3
Figure 43
1.
2.
3.
4.
Cap screw
Roller
Front bracket
Eccentric (shoulder) bolt
5. Carriage screw
6. Lock nut
7. Lock nut
4. On either end of the roller, remove eccentric bolt
(shoulder bolt), carriage screw, and lock nuts securing
the front bracket to the frame (Fig. 43).
5. Remove the front brackets and roller from the cutting unit. Remove the front brackets from the roller shaft
(Fig. 43).
6. If the front roller position is to be changed, the remaining front bracket may be removed from the frame
using step 4.
Installation
1. Place cutting unit on a level working surface.
Figure 44
3. If both front brackets were removed, position bracket as follows (Fig. 43):
A. Insert eccentric bolt (shoulder bolt) through the
top hole on the frame and one of the top holes of the
front bracket so the point on the bracket is at the desired position number on the decal (Fig. 44).
4. Place roller shaft into the front bracket. Slide second
front bracket on the other end of roller. Secure bracket
as in step 3. (Fig. 43).
5. Apply Loctite 242 or equivalent to the cap screw
threads. Center roller in the front brackets and secure
into place with the cap screws (Fig. 43).
6. Level front roller to the reel (see Adjust and Level
Front Roller to Reel, also see Adjust Attitude).
B. Screw lock nut onto the eccentric bolt (shoulder
bolt) to hold front bracket in place.
C. Insert carriage screw through the bottom hole of
the frame and front bracket. Secure screw and eccentric bolt (shoulder bolt) with lock nuts.
Greensmaster 3250−D
Page 7 − 23
SPA and 4−Bolt Cutting Units (Rev. A)
SPA and 4−Bolt
Cutting Units
2. Determine desired attitude for cutting unit (see Attitude Adjustment).
Bearing Replacement for Standard Rear Roller
1
6
3
2
5
6
4
1
4
6
1.495 to 1.525 inch
(3.797 to 3.874 cm)
3
5
Figure 45
1. Roller tube
2. Shaft
3. Shield washer
4. Retaining Ring
5. Grease fitting
6. Bearing
B. Make sure dimension of 1.495 to 1.525 inch
(3.797 to 3.874 cm) between washer and the end of
shaft is maintained.
Removal
1. Clean inside of the roller tube around the shaft and
shield washer. Both ends of the roller tube should be free
of dirt and debris.
C. Make sure outer surface of the washer does not
overlap the retaining ring groove.
2. Secure roller tube in a vise keeping it level.
3. Remove both grease fittings from the shaft before
removing the bearings to prevent damage to fittings.
3. Apply antiseize lubricant to the bearing ends of the
shaft. Insert shaft through the roller tube and bearing inner race.
4. Remove retaining rings from both ends of the roller
tube.
4. Press second bearing into the roller tube and onto
the shaft with the seal side facing out.
5. Use a soft hammer to pound the shaft, shield washer, and bearing out of the roller tube. Remove shield
washer and bearing from the shaft.
A. Install shield washer onto the shaft.
B. Make sure dimension of 1.495 to 1.525 inch
(3.797 to 3.874 cm) between washer and the end of
shaft is maintained.
6. Pull remaining shield washer and bearing from the
roller tube.
C. Make sure outer surface of the washer does not
overlap the retaining ring groove.
Installation
IMPORTANT: Replace both bearings with new bearings since both bearings may be damaged during
removal.
1. Clean inside of roller tube around bearing recess.
Both ends inside the roller tube should be free of dirt and
debris.
2. Press bearing into the roller tube with the seal side
facing out.
5. Install both retaining rings so the side with the sharp
edges faces the end of the shaft.
6. Make sure roller tube spins freely with no bearing
end play.
7. Install grease fittings. Lubricate bearings with No. 2
general purpose lithium base grease until the grease
appears from each shield washer. Wipe off excess
grease from each shield washer.
A. Install shield washer onto the shaft.
SPA and 4−Bolt Cutting Units (Rev. A)
Page 7 − 24
Greensmaster 3250−D
Bearing Replacement for Standard Front and Full Front Rollers
5
5
3
4
4
1
2
BEARING
RECESS
1
3
STANDARD FRONT
ROLLER ILL
USTRATED
2
Figure 46
3. Shaft
4. Retaining Ring
5. Grease fitting
Removal
1. Clean inside of roller tube around the shaft and
bearing. Both ends of the roller tube should be free of dirt
and debris.
2. Secure roller tube tube in a vise keeping it level.
3. Remove retaining rings from the both ends of the
shaft.
4. Use a soft hammer to pound the shaft and bearing
out of the roller tube. Remove bearing from the shaft.
Roller Type
TORO
P/N
BEARING
RECESS
Standard Front
Roller
99−4211
0.02 to 0.04 in
(0.51 to 1.02 mm)
Full Front
(Model No. 04486)
94−3478
0.21 to 0.25 in
(5.3 to 6.3 mm)
3. Apply antiseize lubricant to the bearing ends of the
shaft. Insert shaft through the roller tube and bearing inner race.
Installation
4. Press second bearing into the roller tube and onto
the shaft with the seal side facing out. Make sure bearing
is recessed from the end of the roller tube as described
in the table above.
IMPORTANT: Replace both bearings with new bearings since both bearings may be damaged during
removal.
5. Install both retaining rings so the concave side faces
the bearing. Make sure retaining ring is seated in the
groove.
1. Clean inside of roller tube around bearing recess.
Both ends inside the roller tube should be free of dirt and
debris.
6. Make sure roller spins freely with no bearing end
play.
5. Pull remaining bearing from the roller tube.
2. Press bearing into the roller tube with the seal side
facing outward. Make sure bearing is recessed from
the end of the roller tube as described in the following table.
Greensmaster 3250−D
7. Install grease fittings. Lubricate bearings with No. 2
general purpose lithium base grease until the grease
appears from each bearing seal. Wipe off excess grease
from each seal.
Page 7 − 25
SPA and 4−Bolt Cutting Units (Rev. A)
SPA and 4−Bolt
Cutting Units
1. Roller tube
2. Bearing
Bearing Replacement for Wiehle Rear Roller
3
2
1
BEARING AND ROLLER
SURFACE MUST BE FLUSH
1
3
2
Figure 47
1. Wiehle roller
2. Machine bearing
Note: This procedure is for the Wiehle Rear Roller Kit
(Model 04488) only. The Toro part number for the roller
is 94−8150.
Remove Bearings
Note: Use bearing replacement tool kit to remove the
roller bearings (see Special Tools).
3. Grease fitting
Install New Bearings
1. Make sure bearing cavity of Wiehle roller is clean
and free of dirt. Apply No. 2 multipurpose lithium based
grease to the outside diameter of the machine bearing.
2. Press machine bearing into roller tube so that the
outside surface of the bearing is flush with the end of the
roller tube.
Note: It is recommended to replace bearings at both
ends of the roller tube after bearing failure.
3. Repeat above steps for the other machine bearing.
1. If a hole does not go through the bearing shaft, use
drill bushing (supplied with bearing replacement kit) to
drill a hole through the bearing shaft.
4. Grease both bearings with No. 2 multipurpose lithium based grease until grease appears at the seal of the
bearing. Wipe off excess grease from each seal.
2. Remove machine bearing with bearing puller.
5. Make sure roller spins freely with no bearing end
play.
3. Clean roller bearing cavity of Wiehle roller and remove any rust with a crocus cloth.
4. Repeat above steps for the other machine bearing.
SPA and 4−Bolt Cutting Units (Rev. A)
Page 7 − 26
Greensmaster 3250−D
Bedbar Removal and Installation (Single Point Adjust Cutting Units)
Removal
2
1. Remove rear roller (see Rear Roller Removal and
Installation).
1
2. Loosen both flange lock nuts securing the hex head
flange screw to the frame tab (Fig. 48).
3
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. 42).
5
4
4. Remove both pivot screws (30) from the pivot housing (28) and frame. Replace plastic bushings (31) if worn
or damaged (Fig. 42).
5. Remove both lock nuts and flat washers from each
carriage screw securing the pivot hubs to the frame (Fig.
48 and 49).
6. Remove carriage screws (18) from the pivot hubs
(13 and 36) and frame. Remove bedbar (3) from the cutting unit (Fig. 42).
4
Figure 48
1. Flange lock nut
2. Hex head flange screw
3. Frame tab
4. Lock nuts & flat washer
5. Pivot hub (LH)
7. Remove both pivot hubs (13 and 36) from the bedbar (3). Replace bushings (10, 51, and 58) if they are
worn or damaged (Fig. 42).
Installation
1
1. Apply antiseize lubricant to both bedbar pins. Tap
pivot hub (13) to the bedbar pin on the left side of the
bedbar (3) with a soft hammer. Tap pivot hub (36) to the
bedbar pin on the right side of the bedbar with a soft
hammer (Fig. 42).
2. Position bedbar (3) to the cutting unit. Insert carriage screws (18) through the frame and pivot hubs (13
and 36) on each side of the frame (Fig. 42).
2
Figure 49
1. Lock nut & flat washer
2. Pivot hub (RH)
3. Secure carriage screws with flat washers and lock
nuts (Fig. 48 and 49).
4. Secure pivot housing (28) to the frame with both pivot screws (30) (Fig. 42).
SPA and 4−Bolt
Cutting Units
5. Secure quad ring (37) and flat washer (38) to the
right bedbar pin with the hex head flange screw (39)
(Fig. 42).
6. Reinstall rear roller (see Rear Roller Removal and
Installation).
7. Adjust bedbar to reel, and tighten both flange lock
nuts securing the cap screw to the frame tab (see Adjust
Bedknife to Reel).
Greensmaster 3250−D
Page 7 − 27
SPA and 4−Bolt Cutting Units (Rev. A)
Bedknife Adjuster Service (Single Point Adjust Cutting Unit)
Removal (Fig. 42)
1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake, and
remove key from the ignition switch.
2
2. Remove both pivot screws (30) from the pivot housing (28). Replace plastic bushings (31) if worn or damaged.
4
3. Unscrew adjuster (29) from the bedbar pivot (50).
Disassembly (Fig. 50)
7
1. Remove compression spring, adjuster, thrust washers, and nylon thrust washers from the pivot housing.
3
2. If the spring arm is damaged, remove it from the pivot housing by removing both hex head screws.
5
Assembly (Fig. 50)
6
1. If the spring arm was removed, apply Loctite 242 or
equivalent to the threads of both hex head screws. Secure spring arm to the pivot housing with both hex head
screws.
4
3
2. Place thrust washer, new nylon thrust washer, and
second thrust washer onto the adjuster. Insert adjuster
through the pivot housing.
1
3. Slide nylon thrust washer onto adjuster. Slide thrust
washer onto adjuster and over nylon washer. Slide compression spring onto adjuster.
Figure 50
Installation (Fig. 42)
1. Place antiseize lubricant onto the threads of the adjuster (Fig. 50).
1.
2.
3.
4.
Compression spring
Adjuster
Thrust washer
Nylon thrust washer
5. Spring arm
6. Pivot housing
7. Hex head screw
2. Screw adjuster (29) into bedbar pivot (50) enough
to align holes of the frame bracket and pivot housing
(28).
3. Place pivot screws (30) through bushings (31) in the
frame bracket and into the pivot housing (28). Tighten
screws into the pivot housing.
4. Adjust bedbar to reel (see Adjust Bedknife to Reel).
SPA and 4−Bolt Cutting Units (Rev. A)
Page 7 − 28
Greensmaster 3250−D
Rollers and Bedbar Assembly (4−Bolt Adjust Cutting Units)
20
21
35
23
22
16
30
19
23
17
32
33
24
34
6
16
13
12
11
19
18
31
10
15
14
29
25
9
29
RIGHT
8
26
27
28
FRONT
5
1
3
6
7
4
Figure 51
Front roller assembly
Not used
Special screw (13 used)
Bedknife
Bedbar
Front bracket
Lock washer
Ball stud
Cap screw
Wheel bolt
Shoulder bolt
Bracket position decal
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Cap screw
Cap screw
Height−of −cut collar
Lock nut
Height−of−cut adj. bracket (rear)
Rear roller assembly
Carriage screw
Lock nut
Height−of−cut adjuster
Flat washer
Lock nut
Eccentric bolt
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Wiehle roller
Roller shaft
Bearing
Retaining ring
Grease fitting
Roller tube
Grease fitting
Bearing
Shield washer
Retaining ring
Roller shaft
SPA and 4−Bolt
Cutting Units
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Greensmaster 3250−D
Page 7 − 29
SPA and 4−Bolt Cutting Units (Rev. A)
Bedbar Removal and Installation (4−Bolt Adjust Cutting Units)
Removal
1
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).
3
2
Note: The top hex head screws should remain in the
adjustment brackets. This will allow for an easier adjustment of the bedbar when it is reinstalled (Fig. 52).
3. Remove bottom hex head screw from each bedbar
adjustment bracket located on both sides of the frame
(Fig. 52).
4. Remove both wheel bolts (10) from each end of the
bedbar (5) and frame (Fig. 51).
Figure 52
1. Top hex head screw
2. Adjustment bracket
3. Bottom hex head screw
5. Remove bedbar (5) from the cutting unit (Fig. 51).
Installation
1. Apply antiseize lubricant to the threads of both
wheel bolts (10) (Fig. 51).
2. Position bedbar (5) to the cutting unit. Insert wheel
bolts (10) through the frame and screw into the bedbar
(Fig. 51).
3. Torque both wheel bolts (10) from 20 to 40 ft−lbs
(27 to 54 N−m).
4. Start bottom hex head screws into the bottom of the
adjustment brackets. Keep bedknife away from the reel
while running up both screws to contact the bedbar ears
(Fig. 52).
5. Reinstall rear roller (see Rear Roller Removal and
Installation).
6. Adjust bedbar to reel (see Adjust Bedknife to Reel).
SPA and 4−Bolt Cutting Units (Rev. A)
Page 7 − 30
Greensmaster 3250−D
Bedknife Replacement and Grinding
Removal
2
1. Remove bedbar from frame (see Bedbar Removal).
1
2. Remove screws from bedbar using a socket wrench
and bedknife screw tool (see Special Tools). Discard
screws. Remove bedknife from the bedbar (Fig. 40).
3. Use scraper to remove all rust, scale and corrosion
from bedbar surface before installing bedknife.
3
Replacement
1. Make sure bedbar threads are clean. Use new
screws. Apply anti--seize lubricant to the screws before
installing.
Figure 40
1. Screw
2. Bedbar
3. Bedknife
IMPORTANT: Do not use an impact wrench to tighten screws into the bedbar.
2. Using a torque wrench and bedknife screw tool,
tighten screws to a torque of 200 to 250 in--lb (230 to
288 kg--cm). Use a torquing pattern working from the
center toward each end of the bedknife (Fig. 41).
3. Install bedbar to frame (see Bedbar Installation).
Grinding
13 11
9
7
5
3
1
2
4
Top Face
Relief Angle
Front Angle
2. Refer to Toro General Service Training Book, Reel
Mower Basics (part no. 09168SL) for additional bedknife grinding information.
Figure 42
Remove
Burr
Standard Bedknife
Bedknife Grinding Specifications (Fig. 42)
Standard bedknife relief angle
3o
Extended bedknife relief angle
7o (see Fig. 43)
(see Fig. 43)
1.69” (42.9 mm)
13o
Extended Bedknife
13o to 17o
3. Reinstall bedbar to cutting unit (see Bedbar Installation).
Greensmaster 3250--D
10 12
Front
Face
Note: When grinding, be careful to not overheat the
bedknife. Remove small amounts of material with each
pass of the grinder.
Front Angle Range
8
Figure 41
1. Remove bedbar from the cutting unit (see Bedbar
Removal).
Front Angle
6
Page 7 -- 31 Rev. I
1.88” (47.8 mm)
Figure 43
SPA and 4--Bolt Cutting Units (Rev. A)
SPA and 4- Bolt
Cutting Units
Since there can be variations in the mounting surface of
the bedbar, a new bedknife will not be perfectly flat after
it is installed. Because of this, it is necessary to backlap
or grind a new bedknife after installing it to the bedbar.
Follow the existing angle that was ground into the bedknife and grind only enough to make sure the top surface
is true (Fig. 38).
Preparing a Reel for Grinding
Note: Check to make sure the reel bearings are in
good condition before grinding a reel.
4. After completing the grinding process:
A. Install parts removed to mount cutting unit into
grinder.
1. Remove bedbar assembly (see Bedbar Removal
and Installation).
B. Install bedbar assembly (see Bedbar Removal
and Installation).
2. Remove parts as necessary to mount cutting unit
into grinder (e.g., front roller, front roller brackets).
Note: The cutting unit must be aligned so the grinding
wheel will travel parallel to the reel shaft. This will result
in the the reel being ground to the desired cylinder
shape.
Note: When grinding, be careful to not overheat the
reel blades. Remove small amounts of material with
each pass of the grinder.
3. Refer to Toro General Service Training Book, Reel
Mower Basics (part no. 09168SL) for additional reel
grinding information.
C. Complete cutting unit set--up and adjustment sequence (see Adjustments section).
Reel Grinding Specifications
Nominal Reel Diameter
5 in (126 mm)
Service Limit Reel Diameter
4.5 in (114 mm)
Blade Relief Angle
30o
Relief Angle Range
20o to 40o
Blade Land Width
0.040 in (1.0 mm)
Land Width Range
0.030 to 0.060 in (0.7 to 1.5 mm)
Max. Reel Taper
0.040 in (1.0 mm)
BLADE RELIEF ANGLE
REEL DIAMETER
BLADE
LAND
WIDTH
D2
D1
REEL DIAMETER TAPER = D1 -- D2
Figure 44
SPA and 4--Bolt Cutting Units (Rev. A)
Page 7 -- 32
Rev. I
Greensmaster 3250--D
Reel Assembly
12
10
17
29
13 28
27
23
21
20
27
25
30
22
19
18
31
15
32
24
14
16
12
13
10
11
9
8
RIGHT
7
1
3
2
FRONT
4
5
4
6
Figure 58
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Reel
Shield rod
Reel frame
Flat washer
Cap screw
Hex head flange screw
Counter weight
Tapered lock nut
Lube fitting
Bearing housing
Flat wire spring
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Bearing
Grease seal
Tapered screw
Hex washer head screw
Cut−off bar
Seal strip
Rear shield
Cap screw
Roller spacer
Lift roller
Lock nut
Cap screw
Roll pin
Pad
Not used
Flat washer
Lock nut
Spacer
Plastic cap
Retaining ring
Splined coupler
Note: The counterweight (7) and splined coupler (32)
are not installed on the same side of the cutting unit. The
coupler would be installed on the side of the unit accepting the hydraulic motor. The counterweight would be on
the side opposite the motor.
SPA and 4−Bolt
Cutting Units
Note: Figure 58 shows the reel assembly for a Single
Point Adjust (SPA) cutting unit. Both the SPA and 4−Bolt
cutting units a similar in construction with the exception
of reel and reel frame. Reel and bearing replacement
procedures are the same for each unit.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Greensmaster 3250−D
Page 7 − 33
SPA and 4−Bolt Cutting Units (Rev. A)
Reel and Bearing Removal and Installation
Removal (Fig. 58)
3
1. Remove reel motor from the cutting unit and the cutting unit from lift arm (see Cutting Unit Removal and
Installation).
2. Place cutting unit on a level working surface.
3. Remove shield rod (2) from frame by removing both
cap screws (5) and flat washers (4).
4. Remove front roller from the cutting unit (see Front
Roller Removal and Installation).
IMPORTANT: Place strips of wood below the reel to
prevent the reel from dropping out of the cutting
unit when the bearing housings are removed.
Figure 59
1. Reel shaft
2. Drive adapter
3. Adapter spline
2. Inspect reel (1) as follows:
A. Check reel shaft for bending and distortion by
placing the shaft ends in V−blocks. Replace reel if
necessary.
5. Remove both bearing housings (10) by removing
the tapered lock nuts (8) and tapered screws (14) securing the housings to the frame. Pull both housings away
from the frame and away from the reel ends.
B. Check reel blades for bending or cracking. Replace reel if necessary.
6. Remove reel (1) with the bearings (12) and grease
seals (13) from the cutting unit.
C. Check drive adapter inside of reel shaft. Adapter
should be free of bending and distortion. Check
splines for excessive cracks and distortion. Replace
reel if necessary (Fig. 59).
7. Remove bearing spacer (29) and flat wire spring
(11) from their bearing housings (10). Clean inside of
each housing. Both housings should be free of dirt and
debris.
D. Check service limit of reel diameter (see Reel
Grinding Specifications in Preparing Reel for Grinding).
Note: If bearings (12) are removed from the reel (1),
replace grease seals (13).
8. If necessary, remove bearings (12) and grease
seals (13) from the reel (1) as follows (see Inspection below):
1
2
3. Inspect bearings (12) and grease seals (13) as follows (Fig. 58):
A. Seals must be free of cracks and tears. Replace
seals as necessary.
A. Prevent damage to bearings by pulling on the inner bearing race.
B. Bearing roller balls must be free of deformation
and scoring. Replace bearing if necessary.
B. Use bearing puller to remove bearings and
seals.
C. Bearing must spin freely and have minimal axial
play. Replace bearing if necessary.
Inspection
1. Inspect splined coupler (32) as follows (Fig. 58):
A. Remove retaining ring (31) and drive coupler
from the reel shaft (1).
4. Using a hand pump grease gun, fill cavity in the
bearing housing of cutting unit with No. 2 general purpose grease.
B. Clean drive coupler. Coupler should be free of
dirt and debris.
C. Drive coupler should be free of bending and distortion. Check splines for excessive cracks and distortion. Replace coupler if necessary.
SPA and 4−Bolt Cutting Units (Rev. A)
Page 7 − 34
Greensmaster 3250−D
Installation (Fig. 58)
Note: If bearings (12) where removed, grease seals
(13) should be replaced. Both bearings should be replaced as a set.
Press bearing to here.
1. If bearings (12) and grease seals (13) were removed from the reel shaft (1), install seals and bearings
to the shaft as follows:
1
A. Pack both bearings with No. 2 multipurpose lithium base grease.
Bearing Surface
B. Clean bearing surfaces of reel shaft. Apply antiseize lubricant to both bearing surfaces (Fig. 60).
Press seal to here.
2
IMPORTANT: Pressing the seal too far onto the reel
shaft will cause the seal to spread, and not allow it
to be tight on the shaft (Fig. 60).
C. With the lip side of the seal facing the reel spider,
press seal onto each end of the reel shaft (Fig. 60).
Figure 60
1. Reel shaft bearing
2. Reel spider
4. Install left bearing housing (10) as follows:
D. Press bearing onto each end of the reel shaft
(Fig. 60).
A. Insert bearing housing (10) into the left sideplate
of the frame over the bearing (12). Make sure the
grease fitting (9) is facing up.
IMPORTANT: Do not install the flat wire spring (11)
into the right bearing housing. Damage to the spring
may result as well as increased noise and poor quality of cut.
B. Apply Loctite 242 or equivalent to the threads of
the two tapered screws (14).
C. Insert both tapered screws (14) through the side
plate and bearing housing (10). Start tapered nuts
(8) onto the screws.
2. Install right bearing housing (10) as follows:
A. Insert bearing housing (10) into the right sideplate of the frame so that the grease fitting (9) is facing up.
D. Place flat wire spring (11) into the bearing housing (10).
B. Apply Loctite 242 or equivalent to the threads of
the two tapered screws (14).
5. Reinstall shield rod (2) to the frame. Secure rod with
both flat washers (4) and cap screws (5).
C. Insert both tapered screws (14) through the side
plate and bearing housing (10). Start tapered nuts
(8) onto screws.
6. Tap both bearing housings (10) with a soft hammer
to seat bearings (12). Tighten tapered nuts (8) to secure
housings.
D. Place bearing spacer (29) into the bearing housing (10).
7. Insert drive coupler (32) into end of reel shaft (1) to
accept hydraulic reel motor. Make sure splines of coupler mesh with those of the drive adapter. Secure coupler with retaining ring (31) (Fig. 58 and 59).
SPA and 4−Bolt
Cutting Units
3. Position reel (1) into the cutting unit frame. Slide end
of reel into bearing housing (10) while keeping the bearing (12) straight.
Greensmaster 3250−D
Page 7 − 35
SPA and 4−Bolt Cutting Units (Rev. A)
Rear Roller Scraper Removal and Installation
7
8
6
1
4
6
5
9
3
4
2
RIGHT
1
FRONT
2
10
9
Figure 61
1.
2.
3.
4.
Flange head nut
Hex head screw
Bracket (LH)
Height−of−cut adjustment bracket
8. Torsion spring (RH)
9. Lock nut
10. Height−of−cut tab
5. Torsion spring (LH)
6. Scraper
7. Bracket (RH)
Removal
Installation
1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake, and
remove key from the ignition switch.
1. If the rear roller scraper was not previously installed,
remove carriage bolt and nut securing the rear of each
roller collar to roller bracket.
2. Remove flange head nut from the hex head screw
securing the bracket (LH) to the height−of−cut (H−O−C)
adjustment bracket.
2. Insert a 8mm hex head screw through holes in
height−of−cut tab and H−O−C adjustment bracket and
secure with a locknut (Fig 61).
3. Remove bracket (LH) and torsion spring (LH) from
the scraper and hex head screw. Pull scraper from the
bracket (RH).
Note: If screw does not fit through holes in roller collar
and roller bracket, enlarge holes with a 0.328 inch (8.33
mm) diameter drill.
4. Remove torsion spring (RH) from bracket (RH).
3. Thread flange nut (flange up) onto each hex head
screw.
5. Remove flange head nut from the hex head screw
securing the bracket (RH) to the (H−O−C) adjustment
bracket. Remove bracket (RH) from the hex head screw.
6. If the rear roller scraper is to be permanently removed,
A. Remove remaining flange head nut, lock nut,
and hex head screw from the H−O−C adjustment
bracket and collar.
B. Insert carriage screws (M8−1.25 x 20) through
both H−O−C adjustment brackets and collars to secure the rear roller to the brackets. Secure screws
with lock nuts.
SPA and 4−Bolt Cutting Units (Rev. A)
4. Insert bracket (LH) onto the hex head screw on left
H−O−C adjustment bracket; loosely secure with a
flange head nut.
5. Slide torsion spring (LH) with hook outward onto
bracket (LH) and position hook around bracket (LH).
6. Insert left end of scraper into the hole in the bracket
(LH). Place end of torsion spring (LH) behind scraper.
7. Repeat procedure on right end of scraper while
loosely securing bracket (RH) to hex head screw on the
right H−O−C adjustment bracket.
8. Adjust roller scraper to the roller (see Adjust Rear
Roller Scraper).
Page 7 − 36
Greensmaster 3250−D
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. Remove capscrews and locknuts securing the left
front roller bracket to the side plate.
4. Remove front roller from both roller brackets
5. Slide clamp block off each end of the roller shaft.
Note: If the front roller brush/scraper is not to be reinstalled, proceed to steps 6 and 7.
2
1
6. Reinstall roller to cutting unit with left front roller
bracket and fasteners previously removed.
3
7. Level front roller and set Height−of−Cut (see Adjust
and Level Front Roller to Reel, and Adjust Height−of−
Cut).
5
Figure 62
1.
2.
3.
Installation
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
2. Loosen caps crews securing each end of the roller
shaft to the front roller brackets.
3. Remove cap screws and locknuts securing the left
front roller bracket to the side plate.
4. Slide clamp block onto each end of the roller shaft.
Position clamp blocks on roller shaft so the slot is up and
the threaded portion of hole is toward the rear.
5. Thread nut onto each scraper rod.
Front roller bracket
Front roller
Clamp block
4.
5.
6.
Scraper rod
Socket head screw
Jam nut
7. Partially thread a socket head screw into the front of
each clamp block.
Note: Brush/scraper must be positioned with the
scraper to the rear of roller and with the brush downward.
8. Reinstall roller and brush/scraper to the cutting unit
with the front roller bracket and fasteners previously removed.
9. Level front roller and set Height−of−Cut. Refer to
Cutting Unit Operator’s Manual for adjustment procedures.
10. Adjust brush/scraper (see Adjust Front Roller
Brush/Scraper).
SPA and 4−Bolt
Cutting Units
6. Insert both scraper rods through each clamp block.
Loosely secure scraper rods to clamp blocks with a nut.
4
6
Greensmaster 3250−D
Page 7 − 37
SPA and 4−Bolt Cutting Units (Rev. A)
This page is intentionally blank.
SPA and 4−Bolt Cutting Units (Rev. A)
Page 7 − 38
Greensmaster 3250−D
Chapter 7.1
Dual Point Adjust Cutting Units
Table of Contents
2
3
5
5
7
7
8
8
8
Bedbar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bedbar Removal and Installation . . . . . . . . . . . . . . 11
Bedbar Adjuster Service . . . . . . . . . . . . . . . . . . . . 12
Bedknife Replacement and Grinding . . . . . . . . . . 13
Reel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Reel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Left Side Plate Service . . . . . . . . . . . . . . . . . . . 16
Right Side Plate Service . . . . . . . . . . . . . . . . . . 16
Reel Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Reel Installation . . . . . . . . . . . . . . . . . . . . . . . . . 18
Preparing a Reel for Grinding . . . . . . . . . . . . . . . . 19
Front Roller Removal and Installation . . . . . . . . . 21
Roller Service (Roller Shaft with Circlip) . . . . . . . 22
Roller Service (Threaded Roller Shaft) . . . . . . . . 24
9
DPA Cutting
Units
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .
Factors Affecting Quality of Cut . . . . . . . . . . . . . . .
SET UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . .
Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Reel Motor
Removal, Inspection, and Installation . . . . . . . .
Backlapping
(Units without Optional Backlap/Variable Reel
Speed Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Backlapping
(Units with Optional Backlap/Variable Reel
Speed Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Greensmaster 3250−D
Page 7.1 − 1
Dual Point Adjust Cutting Units (Rev. D)
Specifications
DUAL POINT
ADJUST UNIT
Figure 1
Height−of−Cut (HOC): Cutting height is adjusted on
the front roller by two vertical screws and held by two
locking capscrews. Standard bench height of cut range
is .062 inch (1.6 mm) to .375 inches (9.5 mm) depending
on type of bedknife installed. Bench height of cut range
with the High Height of Cut Kit installed is .285 inch
(7 mm) to 1 inch (25 mm). Effective HOC may vary depending on turf conditions, type of bedknife, rollers and
attachments installed.
Reel Construction: Reels are 5 inches (13 cm.) in diameter, 21 inches (53.3 cm.) in length. High strength low
alloy steel blades are thru hardened and impact resistant. Reels are available in 8 and 11 blade configurations.
Reel Bearings: Two double row self−aligning ball bearings, 30 +/−.1 mm inside diameter slip fit onto reel shaft
with lock nut. Additional inboard and outboard seals for
added protection. Reel position maintained by a wave
washer with no adjusting nut.
Reel Drive: The reel weldment shaft is a 1.375 inch diameter tube with drive inserts permanently pressed in
both ends. A replaceable floating coupler with an internal eight tooth spline is factory installed on the right end,
and held in place by a snap ring.
Frame Construction: Precision machined die cast aluminum cross member with two bolt−on die−cast aluminum side plates.
Dual Point Adjust Cutting Units (Rev. D)
Bedknife: Replaceable single edged, high carbon steel
bedknife is fastened to a machined cast iron bedbar with
13 screws. Tournament bedknife is standard.
Bedknife Adjustment: Dual screw adjustment to the
reel; detents corresponding to .0007 inch (.018 mm)
bedknife movement for each indexed position.
Front Roller: A variety of sealed bearing and through−
shaft front rollers are available for use with these cutting
units. The front roller brackets control the height-of-cut
by using two vertical adjustment screws, and are held in
position by a horizontal locking screw.
Rear Roller: Steel full, 2 inch (5.1 cm.) diameter with
sealed bearings and through−shaft. The rear roller has
two positions, allowing user to change the cutting unit attitude and the behind center distance of bedknife from
reel center line.
Counterbalance Weight: A cast iron weight mounted
opposite to the drive motor balances the cutting unit.
Grass Shield: Non−adjustable shield with adjustable
cut−off bar to improve grass discharge from reel in dry
conditions.
Maximum Reel Speed: 2200 RPM
Weight:
Page 7.1 − 2
8 Blade
11 Blade
72 lb. (32 kg)
75 lb. (34 kg)
Greensmaster 3250−D
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 available from a local supplier.
Gauge Bar Assembly
Used to verify height--of--cut.
Toro Model Number: 13--8199
Figure 2
Backlapping Brush Assembly
Used to apply lapping compound to cutting units while
keeping the operator’s hands at a safe distance from the
rotating reel.
Toro Model Number: TOR299100
Figure 3
Bedknife Screw Tool
This screwdriver--type bit is made to fit Toro bedknife attaching screws. Use this bit with a torque wrench to secure the bedknife to the bedbar.
IMPORTANT: DO NOT use and air or manual impact
wrench with this tool so damage to the bedbar will
be prevented.
Toro Model Number: TOR510880
Figure 4
Roller Bearing Installation Tools
Seal installation washer (black): # 107--8133
Seal installation spacer: # 107--3505
Bearing installation washer (yellow): # 104--6126
DPA Cutting
Units
Washers and spacer used to install bearings and seals
into front and rear rollers that have a threaded roller
shaft.
Seal Installation
Washer
Seal Installation
Spacer
Bearing Installation
Washer
Figure 5
Greensmaster 3250--D
Page 7.1 -- 3 Rev. I Dual Point Adjust Cutting Units (Rev. D)
Bearing and Seal Installer (TOR4105)
Used to install bearings and seals into front and rear rollers that have a threaded roller shaft.
NOTE: TOR4105 is an alternative to using washers
and spacers listed above.
Figure 6
Inner Grease Seal Installation Washer
Inner grease seal installation washer Toro Part Number
104-0532
This washer is used when replacing the reel bearing inner grease seal. It enables pressing the grease seal to
a depth of .104 in. (2.64 mm) below the surface of the
cutting unit side plate.
Toro Part Number: 104-0532
Figure 7
Plastic Plug
This cap is used for placement into the bearing housing
when the reel motor is removed. It prevents dirt and debris from entering the housing.
Toro Part Number: 2410−30
Figure 8
Turf Evaluator Tool
Many turf discrepancies are subtle and require closer
examination. In these instances, the Turf Evaluator
grass viewing tool is helpful. It can assist turf managers
and service technicians in determining causes for poor
reel mower performance and in comparing the effective
height−of−cut of one mowed surface to another. This
tool should be used with the Toro Guide to Evaluation
Reel Mower Performance and Using the TurfEvaluator
(Toro part no. 97931SL)
Toro Model Number: 04399
Figure 9
Dual Point Adjust Cutting Units (Rev. D)
Page 7.1 − 4
Greensmaster 3250−D
Troubleshooting
There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf
conditions. Turf conditions such as excessive thatch,
“sponginess” or attempting to cut off too much grass
height may not always be overcome by adjusting the
cutting unit. It is important to remember that the lower
the height−of−cut, the more critical these factors are.
See Adjustments in the Cutting Unit Operator’s Manual
and the Service and Repairs section in this chapter of
this manual for detailed adjustment and repair information.
For additional information regarding cutting unit troubleshooting, see Aftercut Appearance Troubleshooting Aid
(Toro part no. 00076SL).
Factors That Can Affect Quality of Cut
Factor
Possible Problem/Correction
Tire pressure
Check pressure of all tires. Pressure must be equal on
both front tires. Adjust pressure as necessary.
See Chapter 6 − Wheels and Brakes.
Governed engine speed
Check maximum governed engine speed. Adjust
engine to specifications if necessary.
See Maintenance section in the Traction Unit
Operator’s Manual, and/or the Briggs & Stratton
Vanguard/Diahatsu Repair Manual.
Reel speed
All reels must rotate at the same speed (within 100
rpm). All cutting units must have equal bedknife to reel
and height−of−cut adjustments. Check reel speed
setting if an optional backlap/variable reel speed kit is
installed.
See Troubleshooting in Chapter 4 − Hydraulic System
in this manual.
Reel bearing condition
Check bearings for wear and replace if necessary.
See Reel and Bearing Removal and Installation in this
chapter of this manual.
A reel and/or bedknife that has rounded cutting edges
or “rifling” (grooved or wavy appearance) cannot be
corrected by tightening the bedknife to reel contact.
Grind reel to remove taper and/or rifling. Grind
bedknife to sharpen and/or remove rifling.
The most common cause of rifling is bedknife to reel
contact that is too tight.
A new bedknife must be ground or backlapped
after installation to the bedbar.
Greensmaster 3250−D
Page 7.1 − 5
Dual Point Adjust Cutting Units (Rev. D)
DPA Cutting
Units
Reel and bedknife sharpness
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).
Slightly dull cutting edges may be corrected by
backlapping (see Backlapping in this chapter of this
manual).
Excessively dull cutting edges must be corrected by
grinding the reel and bedknife (see Preparing Reel for
Grinding in this chapter of this manual).
Rear roller adjustment
Adjust the rear roller brackets to hi or low position
depending on the height-of-cut range desired.
See Rear Roller Adjustment in the Cutting Unit
Operator’s Manual.
Height−of−cut
“Effective” or actual height−of−cut depends on the
cutting unit weight and turf conditions. Effective
height−of−cut will be different from the bench set
height−of−cut.
See Height−of−Cut Adjustment in the Cutting Unit
Operator’s Manual.
Proper bedknife selection for height−of−cut desired
If the bedknife is too thick for effective height−of−cut,
poor quality of cut will result.
Stability of bedbar
Make sure bedbar pivot bolts are seated securely.
Check condition of the bushings in the side plates.
See Bedbar Removal and Installation in this chapter of
this manual.
Number of reel blades
Use correct number of blades for clip frequency and
optimum height−of−cut range.
Cutting unit alignment and pull frame ground following
Check pull frames and lift arms for damage, binding, or
bushing wear. Repair if necessary.
Roller condition
Make sure rollers rotate freely. Repair bearings as
necessary.
See Roller Bearing Replacement in the Service and
Repairs section in this chapter of this manual.
Cutting Unit drop speed and sequence
Rear cutting unit must drop after front cutting units.
See Rear Lift Cylinder Flow Control Valve in Chapter 4
− Hydraulic System in this manual.
Dual Point Adjust Cutting Units (Rev. D)
Page 7.1 − 6
Greensmaster 3250−D
Set Up and Adjustments
Characteristics
If a cutting unit is determined to be out of adjustment,
complete the following procedures in the specified order
to adjust the cutting unit properly.
CAUTION
Never install or work on the cutting units or lift
arms with the engine running. Always stop engine and remove key first.
The dual knob bedknife−to−reel adjustment system incorporated in this cutting unit simplifies the adjustment
procedure needed to deliver optimum mowing performance. The precise adjustment possible with this design gives the necessary control to provide a continual
self−sharpening action. This feature maintains sharp
cutting edges, assures good quality of cut, and greatly
reduces the need for routine backlapping.
1. Adjust the bedknife parallel to the reel.
2. Determine desired height of cut range and install
rear roller mounting shim accordingly.
3. Adjust the height-of-cut.
4. Adjust the cut-off bar.
See Cutting Unit Operator’s Manual for adjustment procedures for the cutting units on the Greensmaster
3250−D.
DPA Cutting
Units
In addition, the rear roller positioning system allows for
two height-of-cut ranges.
Greensmaster 3250−D
Page 7.1 − 7
Dual Point Adjust Cutting Units (Rev. D)
Service and Repairs
Hydraulic Reel Motor
IMPORTANT: When performing maintenance procedures on the cutting units, store the cutting unit
reel motors in support tubes on the frame to prevent
damage to the hoses. Do not raise suspension to
transport position when the reel motors are in the
holders in the traction unit frame. Damage to the
motors or hoses could result.
Inspection
Removal
1. Coat spline shaft of the motor with clean No. 2 multipurpose lithium base grease.
1. Park machine on a clean and level surface, lower
cutting units completely to the ground, stop engine, engage parking brake, and remove key from the ignition
switch.
2. Install the flange head screws for the reel drive motor into the motor adapter plate and leave approximately
1/2 inch (12.7 mm) of threads exposed on each screw.
2. Remove basket from carrier frame.
3. Install motor by rotating the motor clockwise so the
motor flanges clear the flange head screws.
3. Loosen flange head screws that secure the hydraulic motor to the motor adapter plate. Rotate motor clockwise, and remove motor.
1. Check reel drive coupler splines for wear. Replace
if necessary (see Reel Removal and Installation in this
chapter of this manual).
Installation
4. Rotate the motor counterclockwise until the motor
flanges are encircling the flange head screws. Tighten
flange head screws.
4. Place protective plastic cap (see Special Tools) into
the hole in the motor adapter plate.
Backlapping (Units without Optional Backlap/Variable Reel Speed Kit)
TOP FACE
CAUTION
REMOVE
BURR
RELIEF ANGLE
Be careful when backlapping the reel because
contact with the reel or other moving parts can
result in personal injury.
FRONT
FACE
FRONT ANGLE
1. Remove reel motors from the cutting units and cutting units from the lift arms and pull frame (see Cutting
Unit Removal and Installation).
2. Connect the backlapping machine to the cutting unit
by inserting a piece of 3/8--inch socket extension drive
into the splined reel drive coupling.
3. Attach backlap motor or drive to the socket extension.
Figure 10
Note: For a better cutting edge, run a file across the
front face of the bedknife when the lapping operation is
completed. This will remove any burrs or rough edges
that may have built up on the cutting edge.
4. Follow instructions and procedures for backlapping
in the Toro General Service Training Book, Reel Mower
Basics (part no. 09168SL).
Dual Point Adjust Cutting Units (Rev. D)
Page 7.1 -- 8 Rev. I
Greensmaster 3250--D
Backlapping (Units with Optional Backlap/Variable Reel Speed Kit)
DANGER
2
1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake, and
remove key from the ignition switch.
2. Move functional control lever to the Neutral/Backlap
position.
IMPORTANT: Do not attempt to rotate the directional valve knob when the machine or reels are running.
3. Raise seat and rotate directional valve knob fully
clockwise to the backlap position.
4. Rotate flow control valve knob to position 6.
5. On all cutting units, make initial reel to bedknife adjustments appropriate for backlapping (see Bedknife to
Reel Adjustment in Cutting Unit Operator’s Manual).
6. Start engine and move Raise / Lower -- Mow control
forward to start the reels.
7. Rotate flow control valve knob to position 1.
8. Apply lapping compound with a long handled brush
(see Special Tools).
1
3
4
Figure 11
1. Directional valve knob
2. Ball switch
3. Flow control valve knob
4. Hydraulic manifold
9. To make an adjustment to the cutting units while
backlapping, turn reels OFF by moving the RAISE/
LOWER--MOW control to the RAISE position. Shut off
engine. After the adjustments have been completed, repeat steps 4 through 6.
10. When the backlap operation is completed, shut off
engine and rotate directional valve knob counter--clockwise fully (90o from the backlap position) to forward position. Also, rotate flow control valve knob to position 13
for height--of--cut settings of a 1/4 inch or below.
Note: For additional settings, refer to the instructions
on the decal that is located on the underside of the seat
support.
11. Wash all lapping compound off the cutting units.
12. For a better cutting edge, run a file across the front
face of the bedknife when the lapping operation is completed. This will remove any burrs or rough edges that
may have built up on the cutting edge.
Note: Additional instructions and procedures on
backlapping are available in the Toro General Service
Training Book, Reel Mower Basics (part no. 09168SL).
CAUTION
Be careful when backlapping the reel because
contact with the reel or other moving parts can
result in personal injury.
Greensmaster 3250--D
Page 7.1 -- 9 Rev. I Dual Point Adjust Cutting Units (Rev. D)
DPA Cutting
Units
TO AVOID PERSONAL INJURY OR DEATH:
D Never place hands or feet in the reel area
while the engine is running.
D While backlapping, the reels may stall and
then restart.
D Do not attempt to restart reels by hand or
foot.
D Do not adjust reels while the engine is
running.
D If a reel stalls, stop engine before
attempting to clear the reel.
D Reel motors are connected in series, moving
one motor moves the other two.
CLOCKWISE
Bedbar Assembly
15
6
4
5
15
9
10
1
5
2
3
16
4
4
17
5
8
7
11
190 to 240 in−lbs
(21 to 27 Nm)
14
12
Antiseize
Lubricant
13
Figure 12
1.
2.
3.
4.
5.
6.
Side plate
Rubber bushing
Flange bushing
Washer (plastic)
Washer (metal)
Bedbar
7.
8.
9.
10.
11.
12.
Dual Point Adjust Cutting Units (Rev. D)
Bedbar pivot bolt
Flange nut
Flange nut
Shim
Spacer
Retainer
Page 7.1 − 10
13.
14.
15.
16.
17.
Cap screw
Rear roller assembly
Lock nut
Bedknife
Bedknife screw
Greensmaster 3250−D
Bedbar Removal and Installation
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6
1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake, and
remove key from the ignition switch.
2. Remove the basket from the cutting unit carrier
frame.
3. Disconnect the drive motor from the cutting unit.
4. Disconnect the cutting unit from the pull link.
5. Unhook the cutting unit from the lift arm and slide the
cutting unit out from under the carrier frame.
6. Loosen the two lock nuts (15) on the end of each
bedbar adjuster assembly.
7. Loosen the two flange nuts (8) on each bedbar pivot
bolt (7).
8. Remove the two bedbar pivot bolts (7), and each of
the washers (4 and 5) from the outside of the cutting unit
side plates.
9. Remove the bedbar (6) and each of the washers (4
and 5) from the inside of the cutting unit side plates.
10. Inspect flange bushings (3) and remove if necessary.
11. Inspect rubber bushings (2) and remove if necessary.
Installation (Fig. 12)
1. If either rubber bushing (2) was removed from the
side plate, install a new bushing. The bushing should be
installed flush with the inside of the side plate (Fig. 13).
2. Install the flange bushings (3) with flange facing outward.
3. Thread the flange nuts (8) all the way up to the head
of each bedbar pivot bolt (7) and apply antiseize lubricant to the threads of each bedbar pivot bolt (7).
5
1
4
2
3 4
8
7
5
Figure 13
1.
2.
3.
4.
Sideplate
Rubber bushing
Flange bushing
Washer (plastic)
5.
6.
7.
8.
Washer (metal)
Bedbar
Bedbar pivot bolt
Flange nut
4. Slide one metal washer (5) and one plastic washer
(4) onto each bedbar pivot bolt. The metal washer (5)
must contact the flange nut (8) (Fig. 13).
5. Position bedbar (6) into cutting unit. Slide the top of
the bedbar arms between washers on each adjuster assembly.
6. Position one metal washer (5) and one plastic washer (4) between bedbar and each side plate. The metal
washer (5) must contact the bedbar (Fig. 13).
7. Install the bedbar pivot bolt assemblies. Tighten
each bedbar pivot bolt from 190 to 240 in−lbs. (21 to 27
Nm).
8. Tighten both flange nuts (8) to remove end play at
the outer washers. Do not over tighten the flange nuts
or distort the side plates.
9. Tighten the lock nut (15) on each bedbar adjuster
assembly until the adjuster spring is fully compressed,
then loosen lock nut 1/2 turn.
10. Adjust cutting unit (see Cutting Unit Operator’s
Manual).
Greensmaster 3250−D
Page 7.1 − 11
Dual Point Adjust Cutting Units (Rev. D)
DPA Cutting
Units
Removal (Fig. 12)
Bedbar Adjuster Service
9
6
8
5
7
4
3
2
12
11
10
2
1
15 to 20 ft−lbs
(20 to 27 Nm)
Figure 14
1.
2.
3.
4.
Adjuster shaft
Flange bushing
Cutting unit frame
Wave washer
5.
6.
7.
8.
9.
10.
11.
12.
Jam nut
Adjuster screw
Detent
Lock washer
Cap screw
Washer
Spring
Lock nut
Removal (Fig. 14)
Installation (Fig. 14)
1. Remove bedbar (see Bedbar Removal in this section of this manual).
1. If the detent (7) was removed, install the cap screw
(9) and secure detent to the cutting unit frame with cap
screw and lock washer.
2. Remove locknut (12), spring (11), and washer (10)
from adjuster screw.
2. If flange bushings (2) were removed, align key on
bushing to slot in frame and install bushings.
3. Unscrew adjuster (6) from the adjuster shaft (1).
4. Remove jam nut (5) and wave washer (4) from adjuster shaft and remove adjuster shaft from cutting unit
frame.
5. Inspect flange bushings (2) and remove if necessary.
6. If the detent (7) is damaged, remove it from the cutting unit frame by removing the cap screw (9) and lock
washer (8).
3. Apply antiseize lubricant on internal threads of adjuster shaft (1) and slide into flange bushings in cutting
unit frame.
4. Install wave washer (4). Apply Loctite 242 or equivalent to the threads of the jam nut (5). Tighten jam nut
from 15 to 20 ft−lbs. (20 to 27 Nm).
5. Screw adjuster (6) into adjuster shaft.
6. Install washer (10), spring (11), and lock nut (12)
onto adjuster screw.
7. Install bedbar (see Bedbar Installation in this section of this manual).
8. Adjust cutting unit (see Cutting Unit Operator’s
Manual).
Dual Point Adjust Cutting Units (Rev. D)
Page 7.1 − 12
Greensmaster 3250−D
Bedknife Replacement and Grinding
Removal
2
1. Remove bedbar from frame (see Bedbar Removal).
1
2. Remove screws from bedbar using a socket wrench
and bedknife screw tool (see Special Tools). Discard
screws. Remove bedknife from the bedbar (Fig. 15).
3. Use scraper to remove all rust, scale and corrosion
from bedbar surface before installing bedknife.
3
Replacement
1. Make sure bedbar threads are clean. Use new
screws. Apply clean SAE 30 oil to the screws before
installing.
Figure 15
1. Screw
2. Bedbar
3. Bedknife
IMPORTANT: Do not use an impact wrench to tighten screws into the bedbar.
2. Using a torque wrench and bedknife screw tool,
tighten screws to a torque of 200 to 250 in--lbs. (22 to
28 Nm). Use a torquing pattern working from the center
toward each end of the bedknife (Fig. 16).
3. Install bedbar to frame (see Bedbar Installation).
Grinding
Since there can be variations in the mounting surface of
the bedbar, a new bedknife will not be perfectly flat after
it is installed. Because of this, it is necessary to backlap
or grind a new bedknife after installing it to the bedbar.
Follow the existing angle that was ground into the bedknife and grind only enough to make sure the top surface
is true (Fig. 17).
13 11
9
7
5
3
1
2
4
6
8
10 12
Figure 16
Top Face
Relief Angle
1. Remove bedbar from the cutting unit (see Bedbar
Removal).
Remove
Burr
Front
Face
Front Angle
2. Refer to Toro General Service Training Book, Reel
Mower Basics (part no. 09168SL) for bedknife grinding
information.
Figure 17
DPA Cutting
Units
Note: When grinding, be careful to not overheat the
bedknife. Remove small amounts of material with each
pass of the grinder.
Bedknife Grinding Specifications (see Fig. 17)
3o
Bedknife relief angle
Front Angle
Front Angle Range
13o
13o
to 17o
3. Reinstall bedbar to cutting unit (see Bedbar Installation).
Greensmaster 3250--D
Page 7.1 -- 13 Rev. I Dual Point Adjust Cutting Units (Rev. D)
Reel Assembly
21
24
20
23
19
22
8
9
10
17
11
12
25
13
18
3
16
2
13
#2
General Purpose
Grease
17 to 20 ft−lbs
(23 to 27 Nm)
14
12
15
6
1
7
4
RIGHT
5
FRONT
8
2
#2
General Purpose
Grease
9
3
Figure 18
1.
2.
3.
4.
5.
6.
7.
8.
9.
Reel
Speedi sleeve
V−ring
Drive coupler
Retaining ring
Left side plate assembly
Shoulder bolt
Bearing lock nut
Outer grease seal
10.
11.
12.
13.
14.
15.
16.
17.
Dual Point Adjust Cutting Units (Rev. D)
Right side plate assembly
O−ring
Bearing
Inner grease seal
Retaining ring
Wave washer
Seal strip
Frame assembly
Page 7.1 − 14
18.
19.
20.
21.
22.
23.
24.
25.
Flange nut
Cap screw
Lift hook
Cap screw
Grass shield
Washer
Cap screw
Lock nut
Greensmaster 3250−D
Reel Removal (Fig. 18)
1. Remove reel motor from the cutting unit (see Hydraulic 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.
1
3. Remove the bedbar assembly (see Bedbar Removal in this chapter).
Note: Depending on tools available, it may be necessary to remove the reel motor adapter plate before removing the left end bearing lock nut (8).
4. Remove the reel bearing lock (8) nut from each end
of the reel shaft.
5. Loosen the setscrews securing the front roller to the
height of cut arms (Fig. 20). Do not remove the set
screws.
Figure 19
1. Counter weight
6. Loosen the saddle strap screws and flange nuts securing the rear roller to the the side plates (Fig. 20). Do
not remove the screws and nuts.
7. Remove the capscrew (24), washer (23) and lock
nut (25) securing each end of the grass shield to the side
plates. These are the only capscrews that must to be removed. The grass shield and the lift hook do not need
to be removed.
8. Remove the 2 shoulder bolts (7) securing the right
hand side plate to the cutting unit frame. Remove the
side plate from the reel shaft and roller shafts.
9. Remove the 2 shoulder bolts (7) securing the left
hand side plate to the cutting unit frame. Remove the
side plate from the reel shaft and the roller shafts.
2
1
Figure 20
2. Rear roller saddle strap
screws
DPA Cutting
Units
1. Front roller set screw
Greensmaster 3250−D
Page 7.1 − 15
Dual Point Adjust Cutting Units (Rev. D)
Left Side Plate Service (Fig. 18)
Right Side Plate Service (Fig. 18)
1. Remove the inner grease seal (13) and outer
grease seal (9) from the side plate (6).
1. Remove the inner grease seal (13) and outer
grease seal (9) from the side plate (10).
2. Remove the retaining ring (14) securing the bearing
in the side plate. Remove the bearing (12). Inspect the
bearing to insure that it spins freely and has minimal axial play. The bearing balls must be free of deformation
and scoring. Replace the bearing if necessary.
2. Remove the bearing (12). Inspect the bearing to insure that it spins freely and has minimal axial play. The
bearing balls must be free of deformation and scoring.
Replace the bearing if necessary.
3. Remove the wave washer (15).
3. Remove the O−ring (11) from the groove in the side
plate bore.
4. Remove all grease from the side plate bore.
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 cutting units.
Note: Replacement Seal Kit (Toro Part No. 106-6937)
is available for side plate service of dual point adjust cutting units.
6. Pack the bearing (12) with Mobil High Temperature
HP or equivalent grease. Insert the bearing into the side
plate against the wave washer.
7. Press the retaining ring (14) into the groove, slightly
compressing the bearing and wave washer.
8. Pack the cavity of the inner seal (13) with Mobil High
Temperature HP or equivalent grease.
9. Using inner grease seal installation washer (Toro
Part Number 104-0532) press the inner seal (13) into
the side plate until the washer is flush with the outer
edge of the side plate bore. Remove the washer. When
properly installed, the seal should be positioned .104 in.
below the inner edge of the side plate bore.
10. Press the outer seal (9) into the side plate until it is
flush with the the outer edge of the side plate bore.
IMPORTANT: The outer grease seal (9) should be
installed so the lip is facing out. This helps keep
contamination from entering, and allows grease to
vent or purge out if necessary (Fig. 22).
11. Fill remaining voids, behind inner grease seal (13)
and outer grease seal (9) lips with Mobil High Temperature HP or equivalent grease.
Dual Point Adjust Cutting Units (Rev. D)
5. Insert the O−ring (11) into the groove in the side
plate. Apply a light coating of grease onto the O−ring, after it is installed.
6. Pack the bearing (12) with Mobil High Temperature
HP or equivalent grease. Insert the bearing into the side
plate until it is against the bottom of the bore.
7. Pack the cavity of the inner seal (13) with Mobil High
Temperature HP or equivalent grease.
8. Using inner grease seal installation washer (Toro
Part Number 104-0532) press the inner seal (13) into
the side plate until the washer is flush with the outer
edge of the side plate bore. Remove the washer. When
properly installed, the seal should be positioned .104 in.
below the inner edge of the side plate bore.
9. Press the outer seal (9) into the side plate until it is
flush with the the outer edge of the side plate bore.
IMPORTANT: The outer grease seal (9) should be
installed so the lip is facing out. This helps keep
contamination from entering, and allows grease to
vent or purge out if necessary (Fig. 22).
10. Fill remaining voids, behind inner grease seal (13)
and outer grease seal (9) lips with Mobil High Temperature HP or equivalent grease.
Page 7.1 − 16
Greensmaster 3250−D
Reel Service (Fig. 18)
3
Note: Install new reel components on each end of the
reel shaft that mates with newly serviced side plate components.
1. Remove the retaining ring (5) and the drive coupler
(4) from the end of the reel shaft.
2. Remove the V−ring (3) from the reel shaft.
2
1
3. Using a flat blade screw driver or similar tool, remove the speedi sleeve (2) from the reel shaft.
Figure 21
Note: Replacement Seal Kit (Toro Part No. 106-6937)
is available for reel service of dual point adjust cutting
units.
1. Reel shaft
2. Drive adapter
4. Inspect the reel shaft as follows:
3. Adapter spline
3
2
5
A. Check the reel shaft for bending and distortion
by placing the shaft ends in V−blocks. Replace the
reel if necessary.
B. Check the reel blades for bending or cracking
Replace the reel if necessary.
C. Check the drive adapter inside of the reel shaft
(Fig. 21). The adapter should be free of bending and
distortion. Check the splines for excessive cracks or
distortion. Replace the reel if necessary.
D. Check the service limit of the reel diameter. Replace the reel if necessary.
5. Using an appropriate I.D. tube or sleeve, press the
speedi sleeve onto the reel shaft until it bottoms out on
the spider cup (Fig. 22).
4
1
.104 Seal Depth
IMPORTANT: Do not nick or scratch the Speedi
sleeve surface as seal failure could result.
6. Slide the V−ring onto the reel shaft with the thick
shoulder of the V−ring facing inward (Fig. 22).
Figure 22
1. Outer seal
2. Inner seal
3. Speedi sleeve
4. V-ring
5. Left side plate
7. Fill the drive coupling (4) 1/2 to 1/3 full with Mobil
High Temperature HP or equivalent grease. Also, coat
the outside of the drive coupling with grease.
DPA Cutting
Units
8. Install the retaining ring (5). Make sure it is seated
into the groove.
Greensmaster 3250−D
Page 7.1 − 17
Dual Point Adjust Cutting Units (Rev. D)
Reel Installation (Fig. 18)
IMPORTANT: Wipe any excess grease from the inner
grease seals (13) where the reel shaft V−rings (3) make
contact. The V−rings should run dry.
1. Slide the left hand side plate (6) onto the reel shaft.
Make sure the reel shaft threads do not damage the
grease seals in the side plate.
2. Apply a film of No. 2 general purpose grease to the
reel shaft threads and install the left side reel bearing
locknut (8).
3. Slide the right hand side plate (10) onto the reel
shaft. Make sure the reel shaft threads do not damage
the grease seals in the side plate.
4. Apply a film of No. 2 general purpose grease to the
reel shaft threads and install the right side reel bearing
locknut (8).
5. Mount the frame assembly (17) to the side plates
with the four shoulder bolts (7). Torque the shoulder
bolts to 17 to 20 ft-lbs. (23 to 27 Nm).
6. Secure the grass shield (22) to the side plates with
two capscrews (24), washers (23), and lock nuts (25).
7. Torque the reel bearing locknuts (8) to 50 to 60 ftlbs. (68 to 81 Nm).
8. Install the bedbar assembly (see Bedbar Installation
in this chapter).
2
1
Figure 23
1. Rear roller
2. Saddle clamp
11. Adjust the cutting unit. See the Cutting Unit Operator’s Manual for adjustment procedures.
Note: The parallel position of the rear roller to the reel
is controlled by the precision machined components of
the assembled cutting unit. Only a limited amount of adjustment is possible if necessary due to tapered reel
wear. To adjust:
A. Place the assembled cutting unit on a surface
plate.
B. Loosen each bedbar adjuster assembly, both
cap screws (24), and all four shoulder bolts (7).
9. Install the rear roller as follows (Fig. 23):
A. On one of the saddle clamps, remove one of the
screws and nuts securing it to the side plate.
C. Adjust the cutting unit and tighten the shoulder
bolts (7) to a torque of 17 to 20 ft-lbs. (23 to 27 Nm).
B. Install rear roller into saddle clamps and loosely
secure it with the screw and nut previously removed.
D. Tighten the cap screws (24).
C. Center the roller between side plates. Tighten
the saddle clamp screws and nuts to secure the roller.
10. Install the front roller (see Front Roller Installation in
this chapter).
Dual Point Adjust Cutting Units (Rev. D)
E. Tighten each bedbar adjuster assembly until the
adjuster spring is fully compressed, then loosen
lock nut 1/2 turn.
Note: For severely tapered reels, a .010 in. (.254 mm)
shim (Toro Part No. 106-6923) is available for the rear
roller mount.
Page 7.1 − 18
Greensmaster 3250−D
Preparing a Reel for Grinding
Note: Check to make sure the reel bearings are in
good condition before grinding a reel.
4. After completing the grinding process:
A. Install parts removed to mount cutting unit into
grinder.
1. Remove bedbar assembly (see Bedbar Removal
and Installation).
B. Install bedbar assembly (see Bedbar Removal
and Installation).
2. Remove parts as necessary to mount cutting unit
into grinder (e.g., front roller, front roller brackets).
Note: The cutting unit must be aligned so the grinding
wheel will travel parallel to the reel shaft. This will result
in the the reel being ground to the desired cylinder
shape.
C. Complete cutting unit set--up and adjustment sequence (see Cutting Unit Operator’s Manual).
Reel Grinding Specifications
Nominal Reel Diameter
5.06 in. (128.5 mm)
Note: When grinding, be careful to not overheat the
reel blades. Remove small amounts of material with
each pass of the grinder.
Service Limit Reel Diameter
4.56 in. (118.8 mm)
3. Refer to Toro General Service Training Book, Reel
Mower Basics (part no. 09168SL) for reel grinding information.
Blade Land Width
0.040 in. (1.0 mm)
Land Width Range
0.030 to 0.060 in. (0.7 to 1.5 mm)
30o
Blade Relief Angle
20o
Relief Angle Range
Service Limit Reel Taper
to 40o
0.040 in. (1.0 mm)
BLADE RELIEF ANGLE
REEL DIAMETER
D2
D1
REEL DIAMETER TAPER = D1 -- D2
Figure 24
Greensmaster 3250--D
Page 7.1 -- 19 Rev. I Dual Point Adjust Cutting Units (Rev. D)
DPA Cutting
Units
BLADE
LAND
WIDTH
This page is intentionally blank.
Dual Point Adjust Cutting Units (Rev. D)
Page 7.1 − 20
Greensmaster 3250−D
Front Roller Removal and Installation
Removal (Fig. 25)
1. Position machine on a clean and level surface, lower 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. Determine your maintenance needs.
6
2. Loosen cap screws securing the roller shafts to
each front bracket.
4
5
2
3. Remove the lock nut, tab washer, and carriage
screw securing one of the front roller brackets to the cutting unit frame assembly.
3
1
Figure 25
4. Remove the front bracket and slide the roller and
shaft from the cutting unit. Remove the remaining front
roller bracket if necessary.
1. Cap screw
2. Roller assembly
3. Front roller bracket
4. Carriage screw
5. Lock nut
6. Tab washer
3. Slide roller shaft into the front bracket attached to
the cutting unit. Slide second front bracket on the other
end of roller. Secure bracket with carriage screw, tab
washer, and lock nut.
Installation (Fig. 25)
1. Place cutting unit on a level working surface.
2. If both front roller brackets were removed:
4. Apply Loctite 242 or equivalent to the cap screw
threads. Center roller in the front brackets and secure
into place with the cap screws.
5. Adjust cutting unit height−of−cut (see Cutting Unit
Operator’s Manual).
DPA Cutting
Units
A. Insert carriage screw through the cutting unit
side plate and front bracket. Secure carriage screw
and roller bracket with tab washer and lock nut.
Greensmaster 3250−D
Page 7.1 − 21
Dual Point Adjust Cutting Units (Rev. D)
Roller Service (Roller Shaft with Circlip)
4
v
1
2
3
6
5
Figure 26
1.
2.
Roller seal
Spiral retaining ring
3.
4.
Roller bearing
Rear roller body
5.
6.
Seal Removal
Roller shaft
Front roller body
.188 in. dia (2)
1. Make a seal removal tool from a 1/4 x 3 x 3 in. (.63
x 7.6 x 7.6 cm) piece of steel as shown (Fig. 27).
2. Slide seal removal over roller end of roller shaft.
3. Use the tool as a template to locate, mark, and drill
two 7/64 in. diameter holes in the outer face of the seal.
.625 in. dia.
.625 in.
.625 in.
4. Thread two No. 8 x 3/4 in. long (.164 in. diameter)
self-tapping screws through the seal removal tool and
into the drilled holes in the seal.
5. Thread two 1/4−20 x 1 in. long cap screws into the
seal removal tool.
1/4−20 UNC (2)
1.05 in.
1.05 in.
Figure 27
6. Alternately tighten the cap screws to pull the seal
from the roller body.
Note: Seals will be destroyed during removal. Do not
re-use seals that have been removed from the roller.
Seal Installation
1. Apply a thin film of clean oil to the inner lip of the seal
and slide the seal over the end of the roller shaft.
2. Press the seal squarely into the roller body. The seal
face should be flush with the end of the roller body when
correctly installed.
Dual Point Adjust Cutting Units (Rev. D)
Page 7.1 − 22
Greensmaster 3250−D
Bearing Removal
2
Note: Replace both roller bearings as a set after a
bearing failure.
3
1
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.
5
Note: Roller bearings have a press fit into the roller
body and a slip fit on the roller shaft.
3. Loosely secure roller body in a vise. Lightly tap one
end of the roller shaft with a plastic hammer to drive the
shaft and one of the bearings from the roller body.
4
Figure 28
1. Roller shaft
2. Roller body
3. Seal
4. Bearing
5. Spiral retaining ring
4. Use the roller shaft to remove the remaining bearing.
5. Clean roller bearing cavity and remove any rust or
corrosion with an abrasive cloth.
6. Inspect bearings, roller shaft, spiral retaining rings,
and roller body for wear or damage. Replace components as necessary.
Bearing Installation
1. Pressing against the outer race of the bearing only,
drive one bearing all the way into either end of the roller
body (Fig. 28).
2. Slide roller shaft through roller body and installed
bearing.
3. Install spiral retaining ring against installed bearing.
4. Slide the remaining bearing onto the roller shaft.
Pressing against the outer race of the bearing only, drive
the remaining bearing all the way into the end of the roller body (Fig. 28).
5. Install remaining spiral retaining ring.
DPA Cutting
Units
6. Install new seals (see Roller Seal Installation in this
chapter of this manual).
Greensmaster 3250−D
Page 7.1 − 23
Dual Point Adjust Cutting Units (Rev. D)
Roller Service (Threaded Roller Shaft)
1
7
6
5
4
2
4
5
6
7
3
Figure 29
1.
2.
3.
Wiehle roller
Smooth roller
Roller shaft
4.
5.
Ball bearing
Seal
6.
7.
Disassembly
1
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. While retaining
shaft, remove bearing lock nut from each end of roller
shaft.
2
V−ring
Bearing lock nut
3
4
5
6
2. Remove v−ring from each end of roller.
3. Carefully inspect seating surface and threads of
bearing lock nuts. Replace lock nut if any damage is
found.
4. Loosely secure roller assembly in bench vise and
lightly tap one end of roller shaft until seal and bearing
are removed from roller cavity. Remove second seal and
bearing from roller cavity by tapping on shaft.
Figure 30
1.
2.
3.
5. Clean bearing cavity in roller and remove any rust
with crocus cloth.
4.
5.
6.
Roller
Ball bearing
Seal
3
V−ring
Bearing lock nut
Roller shaft
2 1
Assembly
1. Place roller shaft into roller.
Note: If bearing lock nuts are being replaced, use
original lock nuts for assembly purposes, if possible.
This will preserve the patch lock feature in the new lock
nuts. Use the new nuts only after new bearings and
seals have been installed.
Dual Point Adjust Cutting Units (Rev. D)
Figure 31
1.
2.
Page 7.1 − 24
Bearing lock nut
Black assembly washer
3.
Bearing
Greensmaster 3250−D
Note: Special tool TOR4105 (see Special Tools) can
be used instead of washers and spacer when installing
bearings and seals in roller.
2
3
1
4
2. Position a new bearing, black assembly washer (see
Special Tools) and original lock nut onto each end of the
roller shaft (Fig. 31).
3. Tighten nuts until the bearings are seated into each
end of the roller.
4. Remove nut and black assembly washer from each
end of the roller.
IMPORTANT: Failure to grease bearing lock nut before seal installation may result in seal damage.
Figure 32
1.
2.
Bearing lock nut
Seal
3.
4.
5. Apply a coating of grease to the nut surface to prevent seal damage during seal installation (Fig. 32).
2
Grease nut surface
Pack with grease
1
6. Carefully install seals onto bearing lock nuts. Pack
the back of the seal 75 to 90% full with #2 grease (Fig.
32).
7. Install a nut with seal onto each end of the roller shaft.
Tighten nuts until they bottom against bearings (Fig. 33).
Remove nuts from roller shaft.
8. Position an assembly spacer and yellow assembly
washer (see Special Tools) on each end of roller shaft
(Fig. 34). Thread nut onto each end of shaft.
Figure 33
1.
9. Tighten each nut until the yellow assembly washers
bottom out against the roller housing. Remove nuts, assembly washers and assembly spacers from roller
shaft.
Bearing lock nut
2.
4
Seal
3 2
1
Note: If original bearing lock nut(s) are being used,
apply Loctite #242 (or equivalent) to threads of lock
nut(s).
10.Insert a V−ring onto each bearing lock nut.
Figure 34
11. Lubricate lips of installed seals with #2 grease.
1.
2.
Bearing lock nut
Yellow assembly washer
3.
4.
Assembly spacer
Seal
DPA Cutting
Units
12.Install bearing lock nut with V−ring onto each end of
the roller shaft. Torque lock nuts from 25 to 30 ft−lbs.
(34 to 41 N−m).
Greensmaster 3250−D
Page 7.1 − 25
Dual Point Adjust Cutting Units (Rev. D)
This page is intentionally blank.
Dual Point Adjust Cutting Units (Rev. D)
Page 7.1 − 26
Greensmaster 3250−D
Chapter 7.2
Groomer (DPA Cutting Unit)
Table of Contents
2
3
3
4
4
5
6
6
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 7
Groomer Belt Replacement . . . . . . . . . . . . . . . . . . . 7
Groomer Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Groomer Reel Service . . . . . . . . . . . . . . . . . . . . . . . 11
Groomer Reel Bearing Replacement . . . . . . . . . 12
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lift Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Groomer Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Groomer
(DPA Cutting Unit)
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . .
Transport Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .
Factors Affecting Grooming . . . . . . . . . . . . . . . . . .
Groomer Reel Mechanical Problems . . . . . . . . . . .
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Height/Depth of Groomer Adjustment . . . . . . . . . .
Greensmaster 3250−D
Page 7.2 − 1
Groomer (DPA Cutting Unit) (Rev. D)
Specifications
MOUNTING: The groomer is mounted to the Dual Point
Adjust (DPA) cutting reel bearing housings and frame.
REEL CONSTRUCTION: 2.375 inch (6 cm) diameter,
41 steel blades with 1/2 inch blade spacing. Blade spacing can be adjusted to 1/4 inch or 3/4 inch by altering the
position of blade spacers on the groomer.
GROOMER PENETRATION: From .410 inch (10.4
mm) above ground level to 0.125 inch (3.2 mm) below
ground level, at mowing HOC range of .062 to .296 inch
(1.6 to 7.5 mm).
Groomer (DPA Cutting Unit) (Rev. D)
WIDTH−OF−GROOMER: 19 inches (48.3 cm).
HEIGHT ADJUSTMENT KNOB: Allows a 0.003 inch
(0.08 mm) increment of height adjustment for each click
of the adjuster.
UP−DOWN FEATURE: At lower height of cut settings,
allows groomer reel to be raised above the height/depth
adjustment for no groomer reel action while cutting. At
higher height of cut settings, groomer may have to be in
the raised position for effective groomer operation.
Page 7.2 − 2
Greensmaster 3250−D
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. Install the lock screw to retain the
groomer reel in the non−grooming position (Fig. 1).
2
To place the groomer reel in the lowered, grooming position, remove the lock screw and rotate the lift arm to lower the groomer reel. Install the lock screw to retain the
groomer reel in the grooming position (Fig. 2).
1
Figure 1
1. Lift arm
2. Lock screw (transport)
2
1
Figure 2
2. Lock screw (grooming)
Groomer
(DPA Cutting Unit)
1. Lift arm
Greensmaster 3250−D
Page 7.2 − 3
Groomer (DPA Cutting Unit) (Rev. D)
Troubleshooting
Factors Affecting Grooming
There are a number of factors that can affect the performance of grooming. These factors vary for different golf
courses and from green to green. It is important to inspect the turf frequently and vary the grooming practice
with turf needs.
It is important to remember that factors affecting quality
of cut also affect grooming performance.
IMPORTANT: Improper or overaggressive use of
the groomer reel, such as too deep or frequent
grooming, may cause unnecessary stress on the
turf leading to severe turf damage. Use the groomer
carefully. READ AND UNDERSTAND THE OPERATION INSTRUCTIONS BEFORE OPERATING OR
TESTING GROOMER PERFORMANCE.
Variables That Affect the Use and Performance of Grooming Reels:
1. The growing season and weather conditions.
2. General turf conditions.
3. The frequency of grooming/cutting − number of cuttings per week and how many passes per cutting.
4. The blade spacing on the groomer reel.
5. The height−of−cut.
6. The grooming depth.
7. The type of grass on the green.
8. The amount of time that a groomer reel has been in
use on a particular turf area.
9. The amount of traffic on the turf.
10.The overall turf management program − irrigation,
fertilizing, weed control, coring, overseeding, sand
dressing and disease and pest control.
11. Stress periods for turf − high temperatures, high humidity, unusually high traffic.
Groomer (DPA Cutting Unit) (Rev. D)
Page 7.2 − 4
Greensmaster 3250−D
Groomer Reel Mechanical Problems
Problem
Possible Causes
Correction
The groomer reel rotates when it is
in the raised, transport position.
The groomer reel should rotate
whenever the cutting reel is engaged.
Normal operation.
No rotation of the groomer reel.
Seized groomer reel or idler bearing(s) in groomer side plate(s).
Identify and replace faulty bearing(s).
Broken or damaged idler spring.
Replace spring.
The groomer belt is worn, broken or If the belt slips, it probably is worn
damaged.
and must be replaced.
Repair or replace belt if necessary.
A broken or worn belt could be the
result of improper belt routing or
seized bearings in groomer assembly.
The groomer reel blades are bent,
damaged or missing.
Repair or replace blades if necessary.
The groomer reel shaft is bent or
damaged.
Replace groomer reel shaft.
Grooming depth is not equal on
both ends of groomer reel.
Adjust depth if necessary. Check
and adjust cutting unit set up (level
bedknife to reel, level rear roller to
reel, set height−of−cut, etc.).
Groomer
(DPA Cutting Unit)
The turf is damaged or has uneven
grooming.
Greensmaster 3250−D
Page 7.2 − 5
Groomer (DPA Cutting Unit) (Rev. D)
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 adjustment procedures for the cutting units on the Greensmaster 3250−D.
Height/Depth of Groomer Adjustment
Note: Grooming is performed above the soil level.
When adjusting groomer height/depth, groomer blades
should never penetrate the soil.
1
2
1. Park machine on a clean and level surface, lower
cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition
switch.
2. Make sure rollers are clean and cutting reel is set to
the desired height−of−cut (See Cutting Unit Operator’s
Manual for cutting unit adjustment procedures).
3. Position the groomer reel to the lowered, grooming
position (Fig. 3).
Figure 3
1. Height adjustment knob
2. Lock screw (lowered)
Note: Improper or over−aggressive use of the groomer reel (i.e. too deep or too frequent grooming) may
cause unnecessary stress on the turf leading to severe
greens damage. Use the groomer cautiously.
4. On one end of the groomer reel, measure the distance from the lowest tip of the groomer blade to the
working surface. Lift and turn height adjustment knob to
raise or lower the blade tip (Fig. 3). Each notch on the
adjustment knob changes the groomer height approximately 0.003 inch (0.08 mm).
5. Repeat step 4 on the opposite end of the groomer.
Then, recheck setting on the first side of groomer.
Height setting on both ends of groomer should be identical.
Groomer (DPA Cutting Unit) (Rev. D)
Page 7.2 − 6
Greensmaster 3250−D
Service and Repairs
Groomer Belt Replacement
1. Park machine on a clean and level surface, lower
cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition
switch.
1
2
2. If equipped, remove rotating rear roller brush from
cutting unit.
3. Remove two (2) lock nuts that secure groomer belt
cover, then remove cover (Fig. 4).
3
4. Pivot idler pulley by placing a 12mm wrench on
pulley nut and rotating idler bracket to relax belt tension.
Slip groomer drive belt off pulleys (Fig. 5). Carefully release idler bracket.
5. Install new drive belt to drive pulley, idler pulley and
driven pulley observing correct belt routing (Fig. 5).
2
Figure 4
1. Groomer belt cover
2. Lock nut
6. Secure belt cover to housing with two (2) lock nuts
(Fig. 4).
3. Cap
1
2
3
7. If equipped, install rotating rear roller brush to cutting
unit.
4
5
Figure 5
4. Driven pulley
5. Groomer drive belt
Groomer
(DPA Cutting Unit)
1. Drive pulley
2. Idler pulley
3. Idler pulley nut
Greensmaster 3250−D
Page 7.2 − 7
Groomer (DPA Cutting Unit) (Rev. D)
Groomer Reel
100 to 120 in−lbs
(11.3 to 13.5 N−m)
19
18
15
16
17
14
13
12
20
Antiseize
Lubricant
21
22
11
23
Loctite #242
24
10
25
27
7
27
28
60 to 80 ft−lbs
(81 to 108 N−m)
100 in−lbs
(11.3 N−m)
9 8
26
6
5
3
31
4
2
1
25
RIGHT
30
29
FRONT
23
24 32
17
100 to 120 in−lbs
(11.3 to 13.5 N−m)
34 35
20 33
36
1
37
Figure 6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Lock nut (2 used)
Cap screw
Groomer belt cover
Flange head screw
Washer
Decal
Drive pulley
Shoulder nut (2 used)
Spring
Drive side plate (LH shown)
Groomer shim
Height−of−cut screw (2 used)
Cutting reel assembly
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Non−drive side plate (RH shown)
Reel motor mount
Allen head screw (2 used)
Flange nut (2 used)
Grease fitting
Non−drive groomer arm assembly
Cap screw
Cap plug
Bearing
Bushing (2 used)
Spring washer (2 used)
Lock nut (2 used)
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
Lock nut (4 used)
Plow bolt (2 used)
Cap screw (2 used)
Front roller assembly
Groomer reel assembly
Square key
Driven pulley
Drive groomer arm assembly
Tab washer
Lock nut
Groomer drive belt
Cap
Remove the groomer reel to reverse the shaft, replace
individual blades or replace the shaft. The shaft can be
reversed so that the sharpest edge of the groomer
blades are forward.
2. Remove hydraulic reel motor from cutting unit (see
Hydraulic Reel Motor Removal in the Service and Repairs section of Chapter 7.1 − Dual Point Adjust Cutting
Units).
Note: The groomer reel drive is located on the opposite side of the cutting unit from the cutting reel hydraulic
motor. Figure 6 shows the groomer reel drive on the left
side of the cutting unit.
3. If equipped, remove rotating rear roller brush from
cutting unit.
Removal
1. Park machine on a clean and level surface, lower
cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition
switch.
Groomer (DPA Cutting Unit) (Rev. D)
4. Remove groomer belt cover (item 3) and groomer
drive belt (item 36) from groomer drive side of mower
(see Groomer Belt Replacement in this section).
5. Loosen cap screws (item 20) that secure front roller
shaft to groomer arms (Figs. 7 and 8).
Page 7.2 − 8
Greensmaster 3250−D
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).
3
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. Do not change height−of−
cut screw adjustment. Remove drive side groomer arm
assembly from cutting unit.
4
8. Remove front roller assembly from cutting unit.
Note: To prevent groomer shaft from turning when removing driven pulley, use wrench on shaft flats to hold
shaft.
9. Remove the flange nut (item 17) that secures driven
pulley (item 32) to groomer shaft. Remove driven pulley
from shaft. Locate and retrieve square key (item 31) that
locates pulley on shaft.
1
2
Figure 7
1. Cap screw
2. Front roller shaft
3. Groomer shaft assembly
4. Locknut/spring washer
Note: To prevent cutting reel from turning when removing drive pulley, block reel with piece of wood.
10.Remove flange head screw (item 4) and washer
(item 5) that secure drive pulley (item 7) to the cutting
reel shaft. Slide drive pulley from cutting reel.
2
11. Remove two shoulder nuts (item 8) that secure the
groomer drive side plate (item 10) to the cutting unit
frame. Remove the groomer drive side plate assembly.
1
12.Remove the cap plug (item 21) from non−drive side
plate (Fig. 8).
Figure 8
1. Roller retaining cap screw
2. Cap plug
13.Remove the flange nut that secures the groomer
shaft to the non−drive side plate.
1
14.Pull the groomer reel from the non−drive side plate.
2
15.Inspect seals, bushings and bearings in side plates
for wear or damage. Replace components as needed.
Installation
2. Apply a light coating of grease to seal lips in RH and
LH side plates. Make sure that seals, bushings and
bearings are properly positioned in side plates.
Figure 9
1. Drive side plate
2. Drive pulley
3. Driven pulley
3. Carefully place groomer reel assembly into the non−
drive side plate bearings taking care not to damage seal
in side plate. Thread flange nut (item 17) onto the shaft
threads but do not tighten.
4. Make sure that groomer shim (item 11) is installed on
groomer drive side of cutting unit.
Greensmaster 3250−D
Page 7.2 − 9
Groomer (DPA Cutting Unit) (Rev. D)
Groomer
(DPA Cutting Unit)
3
1. Park machine on a clean and level surface, lower
cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition
switch.
5. Carefully place drive side plate onto groomer shaft
taking care not to damage seals in side plate. Position
side plate to the cutting unit frame and secure with two
shoulder nuts (item 8).
13.Apply antiseize lubricant to threads of lift arm assembly stud on groomer arm. Install spring washer (item 24)
and lock nut (item 25) to secure drive side groomer arm
assembly to groomer side plate (Fig. 7).
6. Apply grease to drive pulley splines and pulley hub
taking care not to get grease on belt surface. Slide drive
pulley onto the reel shaft.
14.Center front roller and tighten cap screws (item 20)
to secure roller (Figs. 7 and 8).
7. Apply anti−seize lubricant to threads of flange head
screw (item 4) used to attach drive pulley to reel shaft.
Secure drive pulley to reel with washer (item 5) and
flange head screw.
8. Place square key (item 31) in groomer shaft slot and
install driven pulley onto the groomer shaft. Thread
flange nut (item 17) onto the shaft threads.
9. Secure groomer reel by holding the flange nut (item
17) on one end of the reel and tightening the flange nut
on the other end of groomer shaft. Torque flange nuts
from 100 to 120 in−lbs. (11.3 to 13.6 N−m).
10.Apply Loctite #242 (or equivalent) to threads of cap
plug (item 21). Install cap plug into non−drive side plate
and torque cap plug from 60 to 80 ft−lbs. (81 to 108
N−m) (Fig. 8).
11. Insert front roller into non−drive side groomer arm.
15.Install groomer drive belt and belt cover to side of cutting unit (see Groomer Belt Replacement in this section).
16.Install hydraulic reel motor onto cutting unit (see Hydraulic Reel Motor Installation in the Service and Repairs section of Chapter Chapter 7.1 − Dual Point Adjust
Cutting Units).
17.If equipped, install rotating rear roller brush to cutting
unit.
18.Lubricate groomer bearings (see Groomer Reel Kit
Installation Instructions).
Note: After greasing groomer bearings, operate
groomer for 30 seconds, stop machine and wipe excess
grease from groomer shaft and seals.
19.Check groomer reel height and mower height−of−cut
settings. Adjust as needed.
12.Position drive side groomer arm to front roller,
groomer drive side plate and cutting unit frame. Secure
groomer arm to cutting unit with carriage bolt, tab washer and flange nut.
Groomer (DPA Cutting Unit) (Rev. D)
Page 7.2 − 10
Greensmaster 3250−D
Groomer Reel Service
Disassembly (Fig. 10)
200 to 250 in−lbs
(22.6 to 28.3 N−m)
Inspect groomer reel blades frequently for damage and
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. 11).
Blades that are rounded to the midpoint of the blade tip
must be replaced or reversed for best groomer performance.
2
3
1
4
1. Remove groomer reel (see Groomer Reel Removal
in this section).
2. Remove lock nut from either end of the shaft (Fig.
10).
3. Remove spacers and blades as necessary.
Figure 10
1. Groomer reel shaft
2. Groomer blade
3. Spacer
4. Lock nut
Assembly (Fig. 10)
4
1. Start by placing two spacers against a lock nut
installed on one end of groomer shaft. Then, place first
blade against spacers (Fig. 10).
1
Note: Early production groomer shafts were hex
shaped. Later production shafts have a D−shaped
cross−section. When installing groomer blades on earlier, hex shaped shafts, rotate location mark on each
installed blade one flat of the shaft, either in a clockwise
or counterclockwise direction. The direction of location
mark rotation must remain constant on the shaft.
5
3
GROOMER
ROTATION
2. For 1/2 inch (1.3 cm) spacing, make sure there are
two spacers between blades (Fig. 10).
3. When all blades have been installed, place final 2
spacers on shaft and then thread lock nut onto the shaft.
Figure 11
1. Groomer blade (D shaft)
2. Blade (hex shaft)
3. Location mark
5. Install groomer reel back on cutting unit (see Groomer Reel Installation in this section).
4. Sharp edge
5. Dull (rounded) edge
CENTER BLADES
1
3
4
2
Figure 12
1. Lock nut
2. Shaft
Greensmaster 3250−D
Page 7.2 − 11
Rev. H
3. Spacer
4. Blade
Groomer (DPA Cutting Unit) (Rev. D)
Groomer
(DPA Cutting Unit)
4. Position lock nuts to allow blades and spacers to be
centered on the shaft (Fig. 12). Torque lock nuts from
200 to 250 in−lbs. (22.6 to 28.3 N−m) so spacers are
not free to rotate.
2
Groomer Reel Bearing Replacement
6
2
3
5
4
2
3
3
Seal lip
(toward center of
cutting unit)
Seal lip
(toward center of
cutting unit)
5
7
Seal lip
(toward center of
cutting unit)
2
6
1
Figure 13
1. Drive side plate (LH shown)
2. Oil seal
3. Groomer reel bearing
4. Grease fitting
5. Bushing
Note: The groomer reel drive is located on the opposite side of the cutting unit from the cutting reel hydraulic
motor. Figure 13 shows the groomer reel drive from the
left side of the cutting unit.
Bearing Removal
1. Remove front roller, drive side groomer side plate
and groomer reel from cutting unit (see Groomer Reel
Removal in this section).
2. Remove non−drive groomer side plate from cutting
unit:
A. Remove hydraulic reel motor from cutting unit
(see Hydraulic Reel Motor Removal in the Service
and Repairs section of Chapter Chapter 7.1 − Dual
Point Adjust Cutting Units).
Groomer (DPA Cutting Unit) (Rev. D)
6. Side plate bushing
7. Non−drive side plate (RH shown)
B. Remove two (2) socket head screws and lock
nuts that secure motor mount to cutting unit (Fig. 14).
Remove motor mount from cutting unit.
C. Remove lock nut and spring washer that secure
groomer arm lift rod to non−drive groomer side plate
(Fig. 15). Remove non−drive groomer side plate
from mower.
3. Remove bearings in both side plate assemblies
(Fig. 13):
A. Remove seals from groomer side plates. Discard
seals.
B. Push bearings out of side plate housings. Bearings in drive side plate are a press fit. Bearings in
non−drive side plate are slip fit. Discard bearings.
Page 7.2 − 12
Greensmaster 3250−D
Bearing Installation
2
1. Install new bearings in both side plate assemblies
(Fig. 13):
1
3
4
A. Slide new bearings into non−drive side plates.
Position extended inner race of bearings toward center of side plate housing.
B. Press new bearings into drive side plates applying pressure to outer bearing race only. Position extended inner race of bearings toward center of side
plate housing.
C. Install new seals into side plates. Note: Seals
should be installed so the lip side of the seal will face
the center of the cutting reel. When bearings are
greased, grease will purge from inner seals.
5
Figure 14
1. Socket head screw
2. Motor mount
3. Groomer side plate (RH)
4. Cutting unit
5. Lock nut (2 used)
2. Install non−drive groomer side plate to cutting unit:
A. Position non−drive groomer side plate to cutting
unit making sure that groomer arm lift rod is positioned through bushing in side plate.
1
B. Apply antiseize lubricant to threads of lift arm assembly stud. Place spring washer and lock nut on lift
rod threads (Fig. 15). Tighten lock nut.
2
C. Position motor mount to groomer side plate (Fig.
14). Secure motor mount and groomer side plate to
cutting unit with two (2) socket head screws and lock
nuts.
D. Install hydraulic reel motor to cutting unit (see Hydraulic Reel Motor Installation in the Service and Repairs section of Chapter Chapter 7.1 − Dual Point
Adjust Cutting Units).
3
Figure 15
1. LH groomer side plate
2. Lock nut/spring washer
3. LH groomer arm
3. Install groomer reel and drive side groomer side
plate (see Groomer Reel Installation in this section).
4. Lubricate groomer bearings (see Groomer Reel Kit
Installation Instructions).
Note: After greasing groomer bearings, operate
groomer for 30 seconds, stop machine and wipe excess
grease from groomer shaft and seals.
Greensmaster 3250−D
Page 7.2 − 13
Groomer
(DPA Cutting Unit)
5. Check and adjust groomer reel height and mower
height−of−cut settings.
Groomer (DPA Cutting Unit) (Rev. D)
Idler Assembly
6
8
7
14
7
Seal lip
(toward center of
cutting unit)
Seal lip
(toward center of
cutting unit)
5
6
3
2
1
10
11
4
12
9
13
Figure 16
1.
2.
3.
4.
5.
Lock nut
Flat washer
Retaining ring
Idler bearing
Idler pulley
6.
7.
8.
9.
10.
11.
12.
13.
14.
Seal
Bearing
Grease fitting
Groomer drive side plate (LH shown)
Pivot hub
The groomer drive side plate assembly incorporates the
idler system for tensioning the groomer drive belt. The
idler system uses a spring to maintain proper belt tension.
Note: The groomer reel drive is located on the opposite side of the cutting unit from the cutting reel hydraulic
motor. Figure 16 shows the groomer reel drive from the
left side of the cutting unit.
Side plate bushing
Idler bracket
Retaining ring
Bushing
2. Install drive pulley, drive belt and belt cover to right
side of mower (see Groomer Reel Installation in this section).
3. Check and adjust groomer reel height and mower
height−of−cut settings.
1
2
Removal
4
1. Remove groomer belt cover, drive belt and drive
pulley from groomer drive side of mower (see Groomer
Reel Removal in this section).
2. Using Figures 16 and 17 as guides, remove idler
bracket, idler pulley and/or idler bearings as needed.
3
Installation
1. Reassemble components using Figures 16 and 17
as guides.
Figure 17
1. Groomer side plate
2. Drive pulley
3. Idler bracket
4. Idler pulley w/bearings
Note: When properly installed, the idler pulley should
move freely from side to side on the idler bracket pin.
Groomer (DPA Cutting Unit) (Rev. D)
Page 7.2 − 14
Greensmaster 3250−D
Lift Arm Assembly
1
14
2
13
11
15
7
12
10
8
Antiseize
Lubricant
9
7
6
16
3
4
17
Antiseize
Lubricant
18
5
Antiseize
Lubricant
Figure 18
HOC groomer arm (LH shown)
Flange nut
Grooved pin
E−ring
Groomer lift rod
Lock screw
7.
8.
9.
10.
11.
12.
Bushing
Lift arm assembly (LH shown)
Detent spring
Spring washer
Cap screw
Bushing
13.
14.
15.
16.
17.
18.
Wave washer
Groomer adjuster
Side plate (LH shown)
Lock nut
Spring washer
Bushing
Disassembly
Assembly
1. Remove flange nut (item 2) that secures lift arm to
HOC groomer arm. Remove lock nut (item 16) and
spring washer (item 17) that secure lift arm to side plate.
Loosen lock screw (item 6) completely.
1. Assemble lift arm using Figure 18 as a guide.
2. Remove lift arm from cutting unit.
3. Install lift arm onto cutting unit. Secure with flange nut
(item 2) and lock nut (item 16) with spring washer (item
17).
3. Disassemble lift arm using Figure 18 as a guide.
Note: Right and left side HOC groomer arms (item 1)
and lift arm assemblies (item 8) are different; other components shown in Figure 18 are the same on both sides
of cutting unit.
2. Apply antiseize lubricant to threads of groomer lift
rod (item 5) and lift arm assembly stud (item 8).
4. Secure groomer in raised or lowered position with
lock screw (item 6).
5. Check and adjust groomer reel height and mower
height−of−cut settings.
Note: Grooved pin (item 3) is used to retain lock screw
(item 6) to lift arm assembly.
Greensmaster 3250−D
Page 7.2 − 15
Groomer (DPA Cutting Unit) (Rev. D)
Groomer
(DPA Cutting Unit)
1.
2.
3.
4.
5.
6.
Groomer Brush
3
4
3
2
20 to 25 in−lbs
(2.3 to 2.8 N−m)
1
20 to 25 in−lbs
(2.3 to 2.8 N−m)
2
Figure 19
1. Groomer brush shaft
2. Lock nut
3. J−bolt
4. Groomer brush
The groomer brush attaches to the groomer drive in
place of the groomer reel. Removal and installation of
the groomer brush uses the same procedure as removal
and installation of the groomer reel (see Groomer Reel
in this section).
To remove the groomer brush from the shaft, remove the
lock nut and J−bolt from both ends of the brush and slide
the brush from the shaft. When assembling the brush to
the shaft, secure the assembly with J−bolts and lock
nuts. Make sure that the J−bolts are installed with the
threaded portion on the outside of the brush (Fig. 20).
Torque lock nuts from 20 to 25 in−lbs. (2.3 to 2.8 N−m).
Groomer (DPA Cutting Unit) (Rev. D)
1
2
Figure 20
1. J−bolt
Page 7.2 − 16
2. Lock nut
Greensmaster 3250−D
Chapter 8
Electrical Diagrams
Table of Contents
Greensmaster 3250−D
Page 8 − 1 Rev. H
Electrical
Diagrams
ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . 3
Serial Number Below 210000000 . . . . . . . . . . . . . 3
Serial Number Between 210000000
and 230000600 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Serial Number Between 230000600
and 240999999 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Serial Number Between 250000000
and 250999999 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Serial Number Between 260000000
and 260999999 . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Serial Number Above 270000000 . . . . . . . . . . . . . 8
CIRCUIT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Raise Reels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Lower Reels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lower Reels (Mow) . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lower Reels (Backlap) . . . . . . . . . . . . . . . . . . . . . . 14
ELECTRICAL HARNESS DRAWINGS . . . . . . . . . . 16
Electrical Harness Drawing (Serial Number
Below 210000000) . . . . . . . . . . . . . . . . . . . . . . . 16
Wiring Diagram (Serial Number
Below 210000000) . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical Harness Drawing (Serial Number
Between 210000000 and 230000600) . . . . . . 18
Wiring Diagram (Serial Number Between
210000000 and 230000600) . . . . . . . . . . . . . . 19
Electrical Harness Drawing (Serial Number
Between 230000600 and 240999999) . . . . . . 20
Wiring Diagram (Serial Number Between
230000600 and 240999999) . . . . . . . . . . . . . . 21
Electrical Harness Drawing (Serial Number
Between 250000000 and 250999999) . . . . . . 22
Wiring Diagram (Serial Number Between
250000000 and 250999999) . . . . . . . . . . . . . . 23
Electrical Harness Drawing (Serial Number
Between 260000000 and 260999999) . . . . . . 24
Wiring Diagram (Serial Number Between
260000000 and 260999999) . . . . . . . . . . . . . . 25
Electrical Harness Drawing (Serial Number
Above 270000000) . . . . . . . . . . . . . . . . . . . . . . . 26
Wiring Diagram (Serial Number Above
270000000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Electrical Diagrams
This page is intentionally blank.
Electrical Diagrams
Page 8 − 2
Greensmaster 3250−D
Y
DAIHATSU
GLOW PLUG
CONTROLLER
5
1
4
VIO
R
D6
R
FUSELINK 2
IGNITION
SWITCH
B+
R/W
RUN RELAY (R1)
D5
GN/BK
R
GY/W
HIGH TEMP SWITCH
86
Y/R
OPTIONAL
BACKLAP RELAY (R9)
Y
FUSELINK 1
87
85
BN
FUSELINK 3
87a
30
86
BK
2
HIGH TEMP RELAY (R2)
GLOW PLUGS
87
6
3
(−)
30
(+)
BU/W
GLOW
RELAY
85
BATTERY
ETR
SOLENOID
(PART OF INJECTION PUMP)
HIGH TEMP
OVERRIDE
SWITCH
Y
RED
85
86
85
87a
85
BK
86
30
87a
OFF RUN START
BU/BK
OR/BK
R
Start
MOW RELAY (R3)
87
30
87
Y/BK
BK
86
30
87
GN/R
S1
87a
U4
I
B
Y/BK
W/BU
PK
Y
W
J5
S
ACC.
X
Y
GN/W
JOYSTICK
RELAY (R7)
U44
86
30
Y
86
30
Y
1
SAFETY
RELAY
(R8)
STOP −−−− NONE
2
1
30
JOYSTICK
NEUTRAL
SWITCH
VIO
PK/BU
MOW
SWITCH
OPTIONAL BACKLAP
SWITCH
RED
2
GN/BK
RUN −−−− B+I+A; X+Y
LOWER
1
3
RAISE
1
3
D7
A
START
RELAY
(R4)
D3
85
87
87a
BU
87a
87
OR/BK
GN/BK
2
85
86
2
START −−− B+I+S
GY/BK
85
87
87a
SEAT SWITCH
Y/BK
W/BU
OR/BK
R
ALTERNATOR
B
R
I
W
L
GN
6 SECOND
TIME
DELAY
GN/GY
FUSE BLOCK
86
WATER
FUEL
SWITCH
LOWER
RELAY
(R6)
RAISE
RELAY
(R5)
GN/W
MAX15A
WATER IN
FUEL
LIGHT
85
PK
86
8
W/GY
30
7
W/GY
87
6
87a
5 15A
30
4
PK/BK
87
3 10A
Y/BK
85
2
87a
R
BK
1 10A
W/BK
BU/R
Y
S3
WARNING LIGHTS
D2
D1
S4
BK
GLOW
Y
VIO/BK
S2
HIGH TEMP.
GY/W
GY/W
OIL PRESS. SWITCH
LOW OIL PRESS.
W/R
Y
(+)
HR
(−)
ALTERNATOR
GN
HOURMETER
BK
BLACK
R
BU
BLUE
T
BN
BROWN
GY
GRAY
GN
GREEN
OR
ORANGE
PK
PINK
VIO
W
Y
SP
RED
TAN
VIOLET
WHITE
YELLOW
SPLICE
FUSIBLE LINK
Greensmaster 3250−D
(Serial Number Below 210000000)
Electrical Schematic
All relays and solenoids
are shown as de−energized.
Page 8 − 3
Rev. H
Page 8 − 4
Rev. H
BK
BLACK
R
RED
BU
BLUE
T
TAN
BN
BROWN
GY
GRAY
GN
GREEN
OR
ORANGE
PK
PINK
VIO
W
Y
SP
VIOLET
WHITE
YELLOW
SPLICE
FUSIBLE LINK
Greensmaster 3250−D
(Serial Number Between 210000000 and 230000600)
Electrical Schematic
All relays and solenoids
are shown as de−energized.
BK
BLACK
R
BU
BLUE
T
BN
BROWN
GY
GRAY
GN
GREEN
OR
ORANGE
PK
PINK
VIO
W
Y
SP
RED
TAN
VIOLET
WHITE
YELLOW
SPLICE
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
BK
BLACK
R
RED
BU
BLUE
T
TAN
BN
BROWN
GY
GRAY
GN
GREEN
OR
ORANGE
PK
PINK
VIO
W
Y
SP
VIOLET
WHITE
YELLOW
SPLICE
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
BK
BLACK
R
RED
BU
BLUE
T
TAN
BN
BROWN
GY
GRAY
GN
GREEN
OR
ORANGE
PK
PINK
VIO
W
Y
SP
VIOLET
WHITE
YELLOW
SPLICE
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
BK
BLACK
R
RED
BU
BLUE
T
TAN
BN
BROWN
GY
GRAY
GN
GREEN
OR
ORANGE
PK
PINK
VIO
W
Y
SP
VIOLET
WHITE
YELLOW
SPLICE
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
Y
DAIHATSU
GLOW PLUG
CONTROLLER
5
1
4
VIO
R
GN/BK
FUSELINK 2
IGNITION
SWITCH
B+
R/W
RUN RELAY (R1)
D5
D6
R
R
GY/W
HIGH TEMP SWITCH
86
Y/R
OPTIONAL
BACKLAP RELAY (R9)
Y
FUSELINK 1
87
85
BN
FUSELINK 3
87a
30
86
BK
2
HIGH TEMP RELAY (R2)
GLOW PLUGS
87
6
3
(−)
30
(+)
BU/W
GLOW
RELAY
85
BATTERY
ETR
SOLENOID
(PART OF INJECTION PUMP)
HIGH TEMP
OVERRIDE
SWITCH
Y
RED
85
86
85
87a
85
BK
86
30
87a
OFF RUN START
BU/BK
OR/BK
R
Start
MOW RELAY (R3)
87
30
87
Y/BK
BK
86
30
87
GN/R
S1
87a
U4
I
B
Y/BK
W/BU
PK
Y
W
J5
S
ACC.
X
Y
JOYSTICK
RELAY (R7)
GN/W
U44
86
30
Y
86
30
Y
1
SAFETY
RELAY
(R8)
LOWER
2
1
1
2
GN/BK
OR/BK
GN/BK
85
86
3
1
2
SEAT SWITCH
START −−− B+I+S
GY/BK
85
87
87a
RUN −−−− B+I+A; X+Y
87a
87
3
2
RAISE
STOP −−−− NONE
30
JOYSTICK
NEUTRAL
SWITCH
VIO
PK/BU
MOW
SWITCH
OPTIONAL BACKLAP
SWITCH
RED
D7
A
START
RELAY
(R4)
D3
85
87
87a
BU
Y/BK
W/BU
OR/BK
R
ALTERNATOR
B
R
I
W
L
GN
6 SECOND
TIME
DELAY
FUSE BLOCK
WATER
FUEL
SWITCH
GN/W
WATER IN
FUEL
LIGHT
85
LOWER
RELAY
(R6)
RAISE
RELAY
(R5)
86
MAX15A
PK
86
8
W/GY
30
7
W/GY
87
6
87a
5 15A
30
4
PK/BK
87
3 10A
Y/BK
85
2
87a
R
BK
1 10A
W/BK
BU/R
Y
S3
WARNING LIGHTS
D2
D1
S4
BK
GLOW
Y
VIO/BK
S2
HIGH TEMP..
GY/W
GY/W
OIL PRESS. SWITCH
LOW OIL PRESS.
W/R
Y
(+)
HR
(−)
ALTERNATOR
GN
HOURMETER
Greensmaster 3250−D
Crank
Power Current
Control Current
Indication Current
Current Direction
Page 8 − 9
Rev. H
Y
DAIHATSU
GLOW PLUG
CONTROLLER
6
2
5
1
4
R
HIGH TEMP RELAY (R2)
GLOW PLUGS
87
3
VIO
87a
30
87
85
30
(−)
86
(+)
BU/W
GLOW
RELAY
85
BATTERY
ETR
SOLENOID
(PART OF INJECTION PUMP)
HIGH TEMP
OVERRIDE
SWITCH
Y
GY/W
HIGH TEMP SWITCH
86
Y/R
OPTIONAL
BACKLAP RELAY (R9)
BK
Y
BN
FUSELINK 3
D6
R
GN/BK
FUSELINK 2
IGNITION
SWITCH
FUSELINK 1
R
B+
R/W
RUN RELAY (R1)
D5
RED
85
86
85
87a
85
BK
86
30
87a
OFF RUN START
BU/BK
OR/BK
R
Start
MOW RELAY (R3)
87
30
87
Y/BK
BK
86
30
87
GN/R
S1
87a
U4
I
B
Y/BK
W/BU
Y
W
J5
S
ACC.
X
Y
JOYSTICK
RELAY (R7)
GN/W
U44
86
30
Y
86
30
Y
SAFETY
RELAY
(R8)
JOYSTICK
NEUTRAL
SWITCH
VIO
PK/BU
1
2
1
2
LOWER
1
GN/BK
87a
87
3
GN/BK
85
OR/BK
86
3
1
2
SEAT SWITCH
GY/BK
85
START −−− B+I+S
87
87a
RUN −−−− B+I+A; X+Y
30
2
RAISE
STOP −−−− NONE
MOW
SWITCH
OPTIONAL BACKLAP
SWITCH
RED
D7
PK
D3
A
START
RELAY
(R4)
85
87
87a
BU
Y/BK
W/BU
OR/BK
R
ALTERNATOR
B
R
I
W
L
GN
6 SECOND
TIME
DELAY
FUSE BLOCK
WATER
FUEL
SWITCH
GN/W
WATER IN
FUEL
LIGHT
85
LOWER
RELAY
(R6)
RAISE
RELAY
(R5)
86
MAX15A
PK
86
8
W/GY
30
7
W/GY
87
6
87a
5 15A
30
4
PK/BK
87
3 10A
Y/BK
85
2
87a
R
BK
1 10A
W/BK
BU/R
Y
S3
WARNING LIGHTS
D2
D1
S4
BK
GLOW
Y
VIO/BK
S2
HIGH TEMP..
GY/W
GY/W
OIL PRESS. SWITCH
LOW OIL PRESS.
W/R
Y
(+)
HR
ALTERNATOR
GN
HOURMETER
(−)
Page 8 − 10
Rev. H
Greensmaster 3250−D
Run
Power Current
Control Current
Indication Current
Current Direction
Y
DAIHATSU
GLOW PLUG
CONTROLLER
6
2
5
1
4
R
HIGH TEMP RELAY (R2)
GLOW PLUGS
87
3
VIO
87a
30
87
85
30
(−)
86
(+)
BU/W
GLOW
RELAY
85
BATTERY
ETR
SOLENOID
(PART OF INJECTION PUMP)
HIGH TEMP
OVERRIDE
SWITCH
Y
GY/W
HIGH TEMP SWITCH
86
Y/R
OPTIONAL
BACKLAP RELAY (R9)
BK
Y
BN
FUSELINK 3
D6
R
RUN RELAY (R1)
D5
GN/BK
FUSELINK 2
FUSELINK 1
IGNITION
SWITCH
R
B+
R/W
RED
85
86
85
87a
85
BK
86
30
87a
OFF RUN START
BU/BK
OR/BK
R
Start
MOW RELAY (R3)
87
30
87
Y/BK
BK
86
30
87
GN/R
S1
87a
U4
I
B
Y/BK
W/BU
Y
W
J5
S
ACC.
X
Y
JOYSTICK
RELAY (R7)
GN/W
U44
86
30
Y
86
30
Y
SAFETY
RELAY
(R8)
1
2
1
2
LOWER
1
GN/BK
GN/BK
85
OR/BK
86
3
1
2
SEAT SWITCH
START −−− B+I+S
GY/BK
85
87
87a
RUN −−−− B+I+A; X+Y
87a
87
3
2
RAISE
STOP −−−− NONE
30
JOYSTICK
NEUTRAL
SWITCH
VIO
PK/BU
MOW
SWITCH
OPTIONAL BACKLAP
SWITCH
RED
D7
PK
D3
A
START
RELAY
(R4)
85
87
87a
BU
Y/BK
W/BU
OR/BK
R
ALTERNATOR
B
R
I
W
L
GN
6 SECOND
TIME
DELAY
FUSE BLOCK
WATER
FUEL
SWITCH
LOWER
RELAY
(R6)
RAISE
RELAY
(R5)
WATER IN
FUEL
LIGHT
86
GN/W
85
PK
86
MAX15A
30
8
W/GY
87
7
W/GY
87a
6
30
4
5 15A
PK/BK
87
3 10A
Y/BK
85
2
87a
R
BK
1 10A
W/BK
BU/R
Y
D2
WARNING LIGHTS
D1
S4
S3
BK
GLOW
Y
VIO/BK
S2
HIGH TEMP..
GY/W
GY/W
OIL PRESS. SWITCH
LOW OIL PRESS.
W/R
Y
GN
(+)
HR
(−)
ALTERNATOR
HOURMETER
Greensmaster 3250−D
Raise Reels
Power Current
Control Current
Indication Current
Current Direction
Page 8 − 11
Rev. H
Y
DAIHATSU
GLOW PLUG
CONTROLLER
6
2
5
1
4
R
HIGH TEMP RELAY (R2)
GLOW PLUGS
87
3
VIO
87a
30
87
85
30
(−)
86
(+)
BU/W
GLOW
RELAY
85
BATTERY
ETR
SOLENOID
(PART OF INJECTION PUMP)
HIGH TEMP
OVERRIDE
SWITCH
Y
GY/W
HIGH TEMP SWITCH
86
Y/R
OPTIONAL
BACKLAP RELAY (R9)
BK
Y
BN
FUSELINK 3
D6
R
GN/BK
FUSELINK 2
IGNITION
SWITCH
FUSELINK 1
R
B+
R/W
RUN RELAY (R1)
D5
RED
85
86
85
87a
85
BK
86
30
87a
OFF RUN START
BU/BK
OR/BK
R
Start
MOW RELAY (R3)
87
30
87
Y/BK
BK
86
30
87
GN/R
S1
87a
U4
I
B
Y/BK
W/BU
Y
W
J5
S
ACC.
X
Y
JOYSTICK
RELAY (R7)
GN/W
U44
86
30
Y
86
30
Y
SAFETY
RELAY
(R8)
JOYSTICK
NEUTRAL
SWITCH
VIO
PK/BU
1
2
1
2
LOWER
1
GN/BK
87a
87
3
GN/BK
85
OR/BK
86
3
1
2
SEAT SWITCH
GY/BK
85
START −−− B+I+S
87
87a
RUN −−−− B+I+A; X+Y
30
2
RAISE
STOP −−−− NONE
MOW
SWITCH
OPTIONAL BACKLAP
SWITCH
RED
D7
PK
D3
A
START
RELAY
(R4)
85
87
87a
BU
Y/BK
W/BU
OR/BK
R
ALTERNATOR
B
R
I
W
L
GN
6 SECOND
TIME
DELAY
FUSE BLOCK
WATER
FUEL
SWITCH
GN/W
WATER IN
FUEL
LIGHT
85
LOWER
RELAY
(R6)
RAISE
RELAY
(R5)
86
MAX15A
PK
86
8
W/GY
30
7
W/GY
87
6
BK
PK/BK
87a
5 15A
Y/BK
30
4
87
3 10A
85
2
87a
R
1 10A
BU/R
W/BK
Y
S3
WARNING LIGHTS
D2
D1
S4
BK
GLOW
Y
VIO/BK
S2
HIGH TEMP..
GY/W
GY/W
OIL PRESS. SWITCH
LOW OIL PRESS.
W/R
Y
(+)
HR
ALTERNATOR
GN
HOURMETER
(−)
Page 8 − 12
Rev. H
Greensmaster 3250−D
Lower Reels
Power Current
Control Current
Indication Current
Current Direction
Y
DAIHATSU
GLOW PLUG
CONTROLLER
6
2
5
1
4
R
HIGH TEMP RELAY (R2)
GLOW PLUGS
87
3
VIO
87a
30
87
85
30
(−)
86
(+)
BU/W
GLOW
RELAY
85
BATTERY
ETR
SOLENOID
(PART OF INJECTION PUMP)
HIGH TEMP
OVERRIDE
SWITCH
Y
GY/W
HIGH TEMP SWITCH
86
Y/R
OPTIONAL
BACKLAP RELAY (R9)
BK
Y
BN
FUSELINK 3
D6
R
GN/BK
FUSELINK 2
FUSELINK 1
IGNITION
SWITCH
R
B+
R/W
RUN RELAY (R1)
D5
RED
85
86
85
87a
85
BK
86
30
87a
OFF RUN START
BU/BK
OR/BK
R
Start
MOW RELAY (R3)
87
30
87
Y/BK
BK
86
30
87
GN/R
S1
87a
U4
I
B
Y/BK
W/BU
Y
J5
ACC.
X
Y
JOYSTICK
RELAY (R7)
GN/W
U44
86
30
Y
86
30
Y
1
SAFETY
RELAY
(R8)
JOYSTICK
NEUTRAL
SWITCH
VIO
PK/BU
LOWER
2
1
1
2
GN/BK
87a
87
3
OR/BK
GN/BK
85
86
3
1
2
SEAT SWITCH
START −−− B+I+S
GY/BK
85
87
87a
RUN −−−− B+I+A; X+Y
30
2
RAISE
STOP −−−− NONE
MOW
SWITCH
OPTIONAL BACKLAP
SWITCH
RED
D7
W
S
PK
D3
A
START
RELAY
(R4)
85
87
87a
BU
Y/BK
W/BU
OR/BK
R
ALTERNATOR
B
R
I
W
L
GN
6 SECOND
TIME
DELAY
FUSE BLOCK
WATER
FUEL
SWITCH
GN/W
WATER IN
FUEL
LIGHT
85
LOWER
RELAY
(R6)
RAISE
RELAY
(R5)
86
MAX15A
PK
86
8
W/GY
30
7
W/GY
87
6
BK
PK/BK
87a
5 15A
Y/BK
30
4
87
3 10A
85
2
87a
R
1 10A
BU/R
W/BK
Y
S3
WARNING LIGHTS
D2
D1
S4
BK
GLOW
Y
VIO/BK
S2
HIGH TEMP..
GY/W
GY/W
OIL PRESS. SWITCH
LOW OIL PRESS.
W/R
Y
HR
(−)
ALTERNATOR
GN
(+)
HOURMETER
Greensmaster 3250−D
Lower Reels (Mow)
Power Current
Control Current
Indication Current
Current Direction
Page 8 − 13
Rev. H
Y
DAIHATSU
GLOW PLUG
CONTROLLER
6
2
5
1
4
R
HIGH TEMP RELAY (R2)
GLOW PLUGS
87
3
VIO
87a
30
87
85
30
(−)
86
(+)
BU/W
GLOW
RELAY
85
BATTERY
ETR
SOLENOID
(PART OF INJECTION PUMP)
HIGH TEMP
OVERRIDE
SWITCH
Y
GY/W
HIGH TEMP SWITCH
86
Y/R
OPTIONAL
BACKLAP RELAY (R9)
BK
Y
BN
FUSELINK 3
D6
R
RUN RELAY (R1)
D5
GN/BK
FUSELINK 2
FUSELINK 1
IGNITION
SWITCH
R
B+
R/W
RED
85
86
85
87a
85
BK
86
30
87a
OFF RUN START
BU/BK
OR/BK
R
Start
MOW RELAY (R3)
87
30
87
Y/BK
BK
86
30
87
GN/R
S1
87a
U4
I
B
Y/BK
W/BU
Y
W
J5
S
ACC.
X
Y
JOYSTICK
RELAY (R7)
GN/W
U44
86
30
Y
86
30
Y
SAFETY
RELAY
(R8)
1
2
1
2
LOWER
1
GN/BK
GN/BK
85
OR/BK
86
3
1
2
SEAT SWITCH
START −−− B+I+S
GY/BK
85
87
87a
RUN −−−− B+I+A; X+Y
87a
87
3
2
RAISE
STOP −−−− NONE
30
JOYSTICK
NEUTRAL
SWITCH
VIO
PK/BU
MOW
SWITCH
OPTIONAL BACKLAP
SWITCH
RED
D7
PK
D3
A
START
RELAY
(R4)
85
87
87a
BU
Y/BK
W/BU
OR/BK
R
ALTERNATOR
B
R
I
W
L
GN
6 SECOND
TIME
DELAY
FUSE BLOCK
WATER
FUEL
SWITCH
LOWER
RELAY
(R6)
RAISE
RELAY
(R5)
WATER IN
FUEL
LIGHT
86
GN/W
85
PK
86
MAX15A
30
8
87
7
PK/BK
W/GY
87a
6
BK
W/GY
30
5 15A
Y/BK
87
4
85
2
3 10A
87a
R
1 10A
BU/R
W/BK
Y
S3
WARNING LIGHTS
D2
D1
S4
BK
GLOW
Y
VIO/BK
S2
HIGH TEMP..
GY/W
GY/W
OIL PRESS. SWITCH
LOW OIL PRESS.
W/R
Y
GN
(+)
HR
ALTERNATOR
HOURMETER
(−)
Page 8 − 14
Rev. H
Greensmaster 3250−D
LowerReels (Backlap)
Power Current
Control Current
Indication Current
Current Direction
This page is intentionally blank.
Page 8 − 15
Rev. H
2
1 3 4
5
RELAY #4
P14
SEAT SWITCH
P3
HYD SOLENOID #2 P5
BA
ALTERNATOR
HYD SOLENOID #4 P4
BA
2 1
J4
P2
DIODE CONNECTOR 2
P9
HYD SOLENOID #3
P7
HYD SOLENOID #1
P8
5
4 3 1
2
P13
RELAY #3
5
4 3 1
2
P12
RELAY #2
5
4 3 1
2
P11
RELAY #1
LOWER
TIMER
J16 J17 J18
2
1
3
OPTIONAL
LIGHTS
J7
BACKLAP
KIT J5
HG FE D C BA
HIGH TEMP
J8 OVERIDE
J9
P34 WATER IN
FUEL LIGHT
2
1
NEUTRAL MOW
SENSOR SENSOR
P15
P16
AB
BA
J6
AB
WARNING LIGHT
P18 CLUSTER
BA
P10
RAISE
JOYSTICK
1
2
P19
3
BACKLAP
SWITCH
J3
J2
1
2
P20
3
LOWER
JOYSTICK
STARTER
ETR
P32
J1
LOW OIL
PRESSURE
SWITCH
P31
BA
BA
P1
LEAK
DETECTOR
2
1 3 4
5
P25
RELAY #8
2
1 3 4
5
P26
RELAY #7
2
1 3 4
5
P27
RELAY #6
21
J11
P33
J12
J13
ENGINE
GROUND
P29
P35
FUEL
FILTER
GLOW
RELAY
H
G
F
E
D
C
B
A
4 5 6
1 2 3
P21 DIODE
CONNECTOR 1
P24
GLOW PLUG
CONTROLLER
J14
GLOW PLUGS
2
1
4
6
8
3 5 7
P30
FUSEBLOCK
J10
P28
RELAY #5
IGNITION
SWITCH
1
5 3 2
4
P22
B
J15
WATER TEMP
SWITCH
C(−) A(+)
P23
HOUR
METER
Greensmaster 3250−D
(Serial Number Below 210000000)
Electrical Harness Drawing
Page 8 − 16
Rev. H
P2
J4
B+
P3
1 2
W4
W1
OIL
PRESSURE
P33
W6
W3
SP2
W3
W10
P5
A B
W13 W14
W17
W12
SP3
P4
A B
P7
A B
W23
W29
W27
P9
A B
H
G
F
W34 W35
W32
W33
W31
BACKLAP
BACKLAP KIT
SWITCH
DIODE CONNECTOR #2
P8
A B
W24
W21
HYDRAULIC
SOLENOID #1
E
P10
D C
B
A
J5
A B
W36
W50
W45
RELAY #1
P11
RELAY #2
P12
W49
30
85
87A
87
86
J3
B+
HYDRAULIC
SOLENOID #3
30
85
87A
87
86
J2
B+
HYDRAULIC
SOLENOID #2
W41
W42
J1
B+
HYDRAULIC
SOLENOID #4
W14
W15
W44
W43
P1
SEAT
SWITCH
ALTERNATOR
W40
STARTER
1 2 3 4 5
1 2 3 4 5
W54
W52
W15
W58
W55 W59 W62
W56 W61
W5
1
2
3
4
5
30
85
87A P13 RELAY #3
87
86
W49
W65
5
4
3
2
1
86
87
87A P14 RELAY #4
85
30
W16
W42
A
B
P15
NEUTRAL
SENSOR
W46
W38
A
B
P16
MOW
SENSOR
W53
W37
W72
W7
W56
WATER TEMP
SWITCH
J15
W62
W36
W35
W32
W63
W55
W37
W54
W38
W57
SP9
W64
W1
W94 SP7
W27
W23
W89
GLOW PLUG
J14
ETR
SOLENOID
P32
LEAK
DETECTOR
P31
W17
W69
W70
W88
W31
W33
W90
SP11
W16
W97
W93
SP6
W59
W60
W48
SP8
A
B
ENGINE
GROUND
J13
W45
W46
W47
W11
W92
W58
W63
W47
J17
W66
J16
W95
J18
LOWER
TIMER
W89
W91
W79
SP4
W64
W67
W71
W81
W76
W67
J6
(OPTIONAL)
LIGHT
W90
W91
W68
J7
W57
J8
W60
J9
W61
W69
W71
W20
W12
W72
1
2
3
P18
4
5
6
WARNING
LIGHTS
W13
W73
1
2 P19
3
JOYSTICK
RAISE
1
2 P20
3
JOYSTICK
LOWER
W99
SP5
HIGH TEMP
OVERRIDE
W34
W82
W83
W92
W87 W84
W7
W8
SP10
W5
W52
W53
W85
W86
W74
SP1
W75
W51
W77
W43
W78
1 2 3 4 5
86
87
87A
85
30
P29
J12
GLOW RELAY
J11
P28
RELAY #5
P27
RELAY #6
P26
RELAY #7
P25
RELAY #8
A B
W81 W80
3 2 1 6 5 4
P35
P24
FUEL FILTER/
GLOW PLUG
WATER SEPERATOR CONTROLLER
W98
W97
1 2
P34
IND. LIGHT
H2O IN FUEL
W19
W25
W20
W79
A B C
P23
HOUR
METER
W68
W10
W50
1 2 3 4 5
W18
W19
W98
W78
1 2 3 4 5
W99
W11
1 2 3 4 5
86
87
87A
85
30
1 2
W86
+12V
start
glow
W40 W8
W65
W82
86
87
87A
85
30
W9
gnd
W44 W48
W74
W83
86
87
87A
85
30
W70
W73
W87
W30
W66 W22
W85
W84
W88
W80
W77
FUSE BLOCK
P30
1
2
3
4
5
6
7
8
W24
W93
W51
1 2 3 4 5
X Y A B S
P22
W18
A
W29
W94 W30 W76
B
C
D
E
F
W22
W21
G H
P21
DIODE CONNECTOR #1
I
J10
SWITCH
IGNITION
Greensmaster 3250−D
(Serial Number Below 210000000)
Wiring Diagram
Page 8 − 17
Rev. H
RELAY #4
RELAY #3
RELAY #2
RELAY #1
HYD SOL #2
ALTERNATOR
STARTER B+
HYD SOL #3
HYD SOL #1
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 − 18
Rev. H
GLOW PLUG
CONTROLLER
Greensmaster 3250−D
(Serial Number Between 210000000 and 230000600)
Wiring Diagram
Page 8 − 19
Rev. H
START
RELAY
MOW
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
RELAY
GLOW PLUG
CONTROLLER
GLOW PLUGS
RAISE
RELAY
Greensmaster 3250−D
(Serial Number Between 230000600 and 240999999)
Electrical Harness Drawing
Page 8 − 20
Rev. H
GLOW PLUG
CONTROLLER
Greensmaster 3250−D
(Serial Number Between 230000600 and 240999999)
Wiring Diagram
Page 8 − 21
Rev. H
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 S1
HYD SOL S3
STARTER B+
OIL PRESSURE
ALT ”L”
BACKLAP
SWITCH
OVERTEMP
GLOW
RESISTOR
STARTER
START
SAFETY
RELAY
FUSEBLOCK
JOYSTICK
RELAY
LOWER
RELAY
GLOW PLUG
CONTROLLER
GLOW PLUGS
RAISE
RELAY
GLOW
RELAY
BACKLAP
RELAY
Greensmaster 3250−D
(Serial Number Between 250000000 and 250999999)
Electrical Harness Drawing
Page 8 − 22
Rev. H
GLOW PLUG
CONTROLLER
Greensmaster 3250−D
(Serial Number Between 250000000 and 250999999)
Wiring Diagram
Page 8 − 23
Rev. H
START
RELAY
MOW RELAY
HIGH TEMP
RELAY
HYD SOL S6
HIGH TEMP
OVERRIDE
RUN SAFETY
RELAY
HYD SOL S2
ALTERNATOR
WATER IN FUEL
LIGHT
STARTER B+
HYD SOL S4
HYD SOL S3
HYD SOL S1
STARTER B+
OIL PRESSURE
ALT ”L”
BACKLAP
SWITCH
OVERTEMP
GLOW
RESISTOR
STARTER
START
SAFETY
RELAY
FUSEBLOCK
JOYSTICK
RELAY
LOWER
RELAY
GLOW PLUG
CONTROLLER
GLOW PLUGS
RAISE
RELAY
GLOW
RELAY
BACKLAP
RELAY
Greensmaster 3250−D
(Serial Number Between 260000001 and 260999999)
Electrical Harness Drawing
Page 8 − 24
Rev. H
GLOW PLUG
CONTROLLER
Greensmaster 3250−D
(Serial Number Between 260000001 and 260999999)
Wiring Diagram
Page 8 − 25
Rev. H
Greensmaster 3250−D
(Serial Number Above 270000000)
Electrical Harness Drawing
Page 8 − 26
Rev. H
Greensmaster 3250−D
(Serial Number Above 270000000)
Wiring Diagram
Page 8 − 27
Rev. H
This page is intentionally blank.
Page 8 − 28
Rev. H
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