Toro Greensmaster 3420 TriFlex User manual

FormNo.3396-466RevA
E-ReelsHarnessKit
2011Greensmaster®3320or3420TriFlex®TractionUnit
ModelNo.132-6967
InstallationInstructions
WARNING
CALIFORNIA
Proposition65Warning
ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato
causecancer,birthdefects,orreproductiveharm.
Note:Determinetheleftandrightandfrontandbacksidesofthemachinefromthenormaloperatingposition.
PreparingtheMachine
1.Parkthemachineonalevelsurface,stoptheengine,
andremovethekeyfromtheignitionkeyswitch.
2.Disconnectthenegativebatterycablefromthebattery.
3.Disablethereelbatteriesbypullingapartthebattery
disconnectatthebaseoftheleftsideoftheROPS.
4.Removetheange-headboltssecuringtheleftand
rightconsoles,andremovetheconsoles(Figure1).
Note:Retaintheange-headboltsandtheleft
console.Discardtherightconsole.
Figure1
Rightconsoleshown
1.Flange-headbolts2.Rightconsole
5.Tiptheseatforward.
6.Removetheground-terminalconnectors(J06andJ08)
fromthegroundblock.
7.Cutandremoveallthecabletiessecuringtheexisting
wireharness.
Important:Donotcutanywiresorother
components.
8.Removethemountingbracketthatholdsthefuseblock
undertheseat(Figure2).
Note:Donotremovethefuseblockfromthebracket.
Figure2
1.Flangebolts3.Fuseblock
2.Bracket4.Harnessbracket
9.Disconnecttheharnessfromthe3reelmotors.
Note:Eachreelmotorhas2connectors.
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Registeratwww.T oro.com.OriginalInstructions(EN)
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10.Disconnecttheplugfromthegenerator,whichis
locatedneartheengine(Figure3).
Figure3
1.Generatorplug
11.Disconnectthe2connectors(theCANbus
interconnectandtheinterfacetothemainwireharness)
fromthemainwireharness,whichislocatedunder
theseat.
12.Disconnectthereelspeedswitch(P04)undertheseat.
13.Disconnectthelocation-IDmodule(P08).
14.DisconnecttheCAN-interfacemodule(P10).
15.Onthefrontterminalofthecontactor(48VDC),
disconnectthewiremarked“BatterySide”andthe
battery-disconnectwire.
Note:Youdonotneedtoconnectthe
battery-disconnectwiretothecontactoruntilyou
installthenewwireharness.
16.Disconnectthe2main-contactor-coilconnectorsfrom
thecontactor.
17.Removetheswitched-sidepower(J07)fromtheother
endofthecontactor.
18.RemovetheE-Reels-enable-relayconnector.
19.Disconnecttheterminalfromthefuse(10A,58V).
20.Removeanddiscardthewireharness.
RoutingandConnectingthe
WireHarness
1.Positionthenewwireharnesssothattheextensionto
thegeneratorcanroutealongtherightsideoftherear
frameandthefuseblockhasenoughslacktomountit
totheROPSbracket.
2.Routethewireharnessnexttothemainwireharness
undertheseat.
3.Bendthewireharnesssothatittsbehindthe
mountingbracketforthefuseblockundertheseat.
Note:Followtheproleoftheharnessbracket;refer
toFigure2.
4.Routethewireharnessunderthemaintubeofthe
frameandinfrontofthereelbatteries(Figure4).
Figure4
1.Maintube3.Reelbatteries
2.Wireharness
5.Routethenewwireharnessbackunderthemaintube
betweentheoppositesideofthebatteryplateandthe
leftframetube(Figure4).
6.Pullthewireharnessthroughtheframegap.
Note:Thereshouldbeenoughspacetoattachthe
switchsideconnectorwhileroutingunderandaround
thecontactor.
2

7.Securethewireharnesstotheharnessbracketwiththe
pushmountandacabletie(Figure5).
Note:Iftheoldpushmountisstillinthehole,
removeit.
Figure5
1.Harnessbracket3.Cabletie
2.Pushmount
8.Plugthegeneratorinterfaceonthewireharnessinto
theterminalonthegenerator,neartheengine.
Note:OnModel04530(gasolineengine),the
generatorislocatedinthecenterofthemachine
frame(Figure6);onModel04540(dieselengine),the
generatorislocatedoutsidethemachineframe(Figure
7).
Figure6
Model04530
1.Frame3.Terminal
2.Generator
Figure7
Model04540
1.Frame3.Terminal
2.Generator
9.Slowlyturntheringonthegenerator-interface
connectorclockwisetoaligntheotherconnectorand
securetheconnection.
Important:Ensurethattheterminalsarefully
connected.Alooseconnectionmaycauseexcess
heatfromtheelectricalcurrent,leadingtoproduct
damage.
10.Connecttheappropriateterminalstothereelmotors
(Figure8).
Note:Ensurethattheconnectorsclicktogetherso
thattheyaresecure.
Figure8
1.Generatorplug4.Terminalstoreel1
2.Terminalstothemainwire
harness
5.Terminalstoreel3
3.Terminalstoreel2
3

11.Removeanddiscardthecapfromthefuse(10A,58
V)asshowninFigure9.
Note:Thefusehasaredwireandayellowwire
Figure9
1.Groundblock9.E-reels-CANdiagnostic
port
2.E-reelsenablerelay10.Protectiondiode
3.E-reelsfuse(60A,58V),
existing
11.IDmodule
4.Battery-sidepower(boot
notshown)
12.Harnessground
5.Main-contactor-coil
connector(white)
13.Harnessground
6.Main-contactor-coil
connector(brown)
14.CAN-interfacemodule
7.Switched-sidepower(boot
notshown)
15.E-reelsbatteriesground
8.Contactor(48VDC)16.Fuse(10A,58V)
12.Inserttheterminalwiththefuse(10A,58V)intothe
existingcapmountedontheframeofthemachine
(Figure9).
13.ConnecttheE-Reelsenablerelayconnector(P07)as
showninFigure9.
14.Connectthe90-degreeswitchedside(J07)connector
onthewireharnesstotherearterminalonthe
contactor(48VDC),andsecureittotheterminal
(Figure9).
15.Routethewireundertheangeonthecontactor(48
VCD).
16.Connectthe2main-contactor-coilconnectorstothe
contactor(48VDC)asshowninFigure9.
17.Connectthewiremarked“BatterySide”andthe
battery-disconnectwiretothefrontterminalofthe
contactor(48VDC)asshowninFigure9.
18.Slidetheinsulatorbootsfortheswitched-sidepower
connectorandthebattery-sideconnectoroverthe
terminalstocoverthem.
19.ConnecttheIDmodule(P08)asshowninFigure9.
20.ConnecttheCAN-interfacemodule(P10)asshown
inFigure9.
21.Connectthereel-speedswitch(P04)undertheseat.
22.Connectthe2terminals(CAN-businterconnectand
interfacetomainwireharness)onthenewwireharness
withthe2terminalsonthemainwireharnessunder
theseat.
23.Installthefuseblock(Figure10).
Note:Routethewireharnessbehindthebracket.
Figure10
1.Bracket2.Wireharness
24.Connecttheground-terminalconnectors(J06andJ08)
tothegroundblock(Figure9).
25.Usecabletiestosecurethewirestothemainwire
harnessandtothemachineframe.
Important:Ensurethatthewiresareawayfrom
movingparts.
26.Securethewireharnesstothemachineframebehind
andinfrontofthefuel-tankbracket.
27.Usecabletiestosecurethenewwireharness.
Important:Ensurethattheseatassemblydoes
notcrushthewires.
4

InstallingtheFuse-Block
Bracket
1.Loosenthe2nutsandboltssecuringtherightsideof
theROPStotheframeofthemachine(Figure11).
Figure11
1.Bracket3.Screws
2.Fuseblock4.ROPSbolts
2.Aligntheslotsinthefuse-blockbracketwiththebolts
asshowninFigure11.
3.TorquetheROPSfastenersto136to149N-m(100
to110ft-lb).
4.Usethe2screwstosecurethefuseblocktothebracket
(Figure11).
InstallingtheSideConsoles
1.Aligntheboltholesinthenewrightconsolewiththe
boltholesonthemachine(Figure12).
Figure12
Rightconsoleshown
1.Flange-headbolts2.Rightconsole
2.Aligntheboltholesintheexistingleftconsolewiththe
boltholesonthemachine.
3.Securethesideconsoleswiththeexistingange-head
bolts.
5

Notes:
6

Notes:
7