Toro Greensmaster 3000 Series User manual

FormNo.3408-159RevC
UniversalGroomerDriveKit
Greensmaster®Flex™1800and2100,eFlex®1800and2100or
Greensmaster®3000SeriesDPACuttingUnits
ModelNo.04648
InstallationInstructions
ThisproductcomplieswithallrelevantEuropeandirectives.Fordetails,pleaseseetheDeclarationof
Incorporation(DOI)atthebackofthispublication.
Note:IfyouareinstallingthiskitonaGreensmaster3250tractionunit,youwillneedthePullLinkkit,
112-9248.IfyouareinstallingthiskitonaGreensmaster3050,3100,3120,or3150tractionunit,youwill
needthePullLinkkit,106-2643.
Introduction
Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoid
injuryandproductdamage.Youareresponsiblefor
operatingtheproductproperlyandsafely.
YoumaycontactTorodirectlyatwww.Toro.comfor
productandaccessoryinformation,helpndinga
dealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,or
additionalinformation,contactanAuthorizedService
DealerorToroCustomerServiceandhavethemodel
andserialnumbersofyourproductready.Figure1
identiesthelocationofthemodelandserialnumbers
ontheproduct.Writethenumbersinthespace
provided.
g241111
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
©2018—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3408-159*C

LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
2Nopartsrequired–Preparethecuttingunit.
3Nopartsrequired–Removethedrive-beltassembly.
Weight1
Torx-socketscrew2
Locknut2
Rightreeladapter(silver)1
Leftreeladapter(black)1
Shimwasher1
4
Groomerdrivebox1
Installthegroomerdriveboxandweight.
Stub-shaftassembly1
Bearingshield2
Idlerassembly1
Adjustercollar1
5
Flangenut1
Installtheidlerassembly.
6Groomerpin2Installthegroomerpin.
Leftheight-of-cutbracketassembly1
Rightheight-of-cutbracketassembly1
Adjusterpin2
7Cotterpin2
InstalltheHOCassembliesandthe
frontroller.
Bolt(1/4to11/2inches)4
Jamnut4
8Shaftclamp4
Installthegroomerassembly(ordered
separately).
1
PreparingtheMachine
NoPartsRequired
Procedure
1.Parkthemachineonalevelsurface.
2.Engagetheparkingbrake.
3.Shutofftheengineandremovethekeyorspark
plug;refertoyourOperator’sManual.
2
PreparingtheCuttingUnit
NoPartsRequired
Procedure
1.Separatethecuttingunitfromthetractionunit;
refertotheOperator'sManualforthetraction
unit.
2.Onthecuttingunit,loosenthemountingscrews
securingeachendofthefrontrollertothe
height-of-cutarms(Figure2).
2

g016936
Figure2
1.Height-of-cutarm4.Washer
2.Adjustingscrew5.Flangenut
3.Plowbolt6.Roller-mountingscrew
3.Removetheplowbolts,washers,andlocknuts
securingtheheight-of-cutarmstoeachendof
cuttingunit(Figure2).Removetheheight-of-cut
armsandrollerassembly.
Note:Savetheremovedhardwaretoinstallthe
newheight-of-cutarms.
4.Removetheheight-of-cutadjustingscrewsand
roller-mountingscrewsfromtheheight-of-cut
arms(Figure2).
Note:Savetherollermountingscrewsandthe
rollerforlaterinstallation.
5.Ifyouareinstallingthekitonacuttingunit
ofaTriFlexhybridmachine,removethe2cap
screwsthatsecuretheelectricalcounterweight
tothereel,andremovethecounterweight
(Figure3).
Note:Retaintheelectricalcounterweightand
2capscrewsforinstallationinPreparingthe
Counterweight(page5).
g037842
Figure3
CuttingUnit—HybridTriFlexMachine
1.Capscrews(5/16x2-3/4
inches)
3.Counterweight(cutting
unit)
2.Counterweight(electric
reeldrive—hybridTriFlex
machine)
6.Removethe2bolts(5/16x2-1/4inches)from
the2nuts(captivebythesideplate)securing
thecounterweightonthesideplateofthecutting
unit.Removethecounterweight(Figure4).
Note:Youmaydiscardthecuttingunit
counterweightandthemountingbolts.
g037843
Figure4
1.Bolt(5/16x2-1/4inches)3.Bearingnut
2.Counterweight
(reel-cuttingunit)
3

7.Removethebearingnutfromthereelshaft
(Figure4).
Important:Cleanthethreadsintheendof
thereelshaftofanydebrisorgreasebefore
installingthekitsplinedinsertandgroomer
box.
8.IfyouareinstallingthekitonaTriex
machine,removethe2boltssecuringthemotor
mounttothecuttingunit.Removethemotor
mount(Figure5).
Note:Retaintheboltsandnutsforlater
installation.
g016226
Figure5
1.Bolts2.Motormount
3
RemovingtheBelt-Drive
Assembly
Walk-BehindGreensmowers
NoPartsRequired
Procedure
Note:Retainallpartsinthissectionexceptwhere
noted.
1.Loosenthecaptiveboltsecuringthebeltcover
tothecuttingunituntilyoucanremovethecover
(Figure6).
g017662
Figure6
1.Belt-coverbolt(captive)3.Belt
2.Beltcover4.Belt-tensioningnut
2.Loosenthebelt-tensioningnutandremovethe
belt(Figure6).
3.Loosenthe2setscrewssecuringthelower
pulleyandremovethepulleyfromthereelshaft
(Figure7).
4

g017633
Figure7
1.Lowerpulley2.Setscrews
4.Removethe3boltssecuringthebelt-drive
assemblytothecuttingunit,ifequipped,and
removethewholeassembly(Figure8).
g037772
Figure8
1.Belt-driveassembly2.Bolt
4
Installingthe
Counterweightand
GroomerDriveBox
Partsneededforthisprocedure:
1Weight
2Torx-socketscrew
2Locknut
1Rightreeladapter(silver)
1Leftreeladapter(black)
1Shimwasher
1Groomerdrivebox
PreparingtheCounterweight
TriFlexMachineswithanElectricReel-Cutting
Unit
1.Assembletheelectriccounterweightand2cap
screws(5/16x2-3/4inches)thatyouremoved
instep5of2PreparingtheCuttingUnit(page
2)tothenewweight(Figure9).
g035689
Figure9
1.Capscrew(5/16x2-3/4
inches)
3.Newweight
2.Electricalcounterweight
2.Torquetheboltsto198to254N∙m(175to225
in-lb).
5

InstallingtheCounterweight
1.Securethenewweighttothesideofthecutting
unitusing2bolts(5/16inch)and2nuts(5/16
inch)asshowninFigure10.
Note:Attachtheweighttothesideofthe
cuttingunitonwhichyouintendtomountthe
groomerdrivebox.
g244756
Figure10
1.Torx-socketscrew(5/16x
1-1/4inches)
3.Locknut(5/16inch)
2.Counterweight4.Counterweight(TriFlex
machineswithanelectric
cuttingunit)
2.Torquethescrewsandlocknutsto20to26N∙m
(175to225in-lb).
InstallingtheGroomerDriveBox
1.Applymedium-strengththread-locking
compound(suchasBlueLoctite®243)tothe
internalthreadsofthedrive-boxshaftandtorque
thereeladapterandgroomerdrive-boxshaftto
150to163N∙m(110to120ft-lb).
Note:Usethesilveradapterifyouinstalledthe
counterweightattherightsideofthecuttingunit.
Usetheblackreeladapterifyouinstalledthe
counterweightattheleftsideofthecuttingunit.
Important:Cleanthethreadsintheendof
thereelshaftofanydebrisorgreasebefore
installingthekitsplinedinsert.
g037773
Figure11
1.Groomerdrive-boxshaft3.Reeladapter—black
(groomerdrive-boxand
counterweightattheleft
sideofthecuttingunit)
2.Reeladapter—silver
(groomerdrive-boxand
counterweightattheright
sideofthecuttingunit)
Important:Allowthethread-locking
compoundtocurefor15minutesbefore
continuingtheprocedure.
Note:Whentorquingthereeladapterand
drive-boxshaft,restrainthedrive-boxshaftwith
awrenchonthewrenchatsattheinboardside
ofthegroomerdrivebox(Figure12).
g032791
Figure12
1.Wrenchats(drive-box
shaft)
2.Hexsocket(reeladapter)
6

2.Foragroomerdriveboxinstalledattheleftside
ofthecuttingunit,assembletheshimwasher
overthethreadsoftheblackreeladapter(Figure
13).
Note:Noshimwasherisinstalledwithgroomer
driveboxinstalledatrightsideofthecuttingunit.
g232600
Figure13
1.Applythread-locking
compound
4.Shimwasher
2.Reeladapter(black)into
reelshaft
5.Hex-head
3.Cuttingunit
3.Applymedium-strengththread-locking
compound(suchasBlueLoctite®243)tothe
internalthreadsofthereelshaftthreads.
4.Attachthegroomerdriveboxtothereelshaft
(Figure10).
Important:Thesplinedinsertontheleft
sideofthecuttingunithasleft-handthreads.
Thesplinedinsertontherightsideofthe
cuttingunithasright-handthreads.
5.Usingablockofwoodorhavinganotherperson
restrainthereel,torquethehex-headdriveof
thedrive-boxshaftto135to150N∙m(100to
110ft-lb);refertoFigure14.
Important:Youmusttorquethetorquehex
driveofthedrive-boxshaftto135to150N∙m
(100to110ft-lb).
Important:Youmustusea6-pointsocket
withheavywall.
Important:Donotuseanimpactwrenchfor
thisstep.
Important:Allowthethread-locking
compoundtocurefor15minutesbefore
continuingtheprocedure.
Note:Donotdamagethesealundertheouter
cover.
g244758
Figure14
1.O-ring3.Cotterpin
2.Hex-socketscrew(5/16x
1/2inch)
Note:Theclutch-knobassemblycomes
installedfromthefactoryforarightdrive
installation.
6.Ifyouareinstallingthegroomerattheleftside
ofthemachine,performthefollowing:
A.RemovetheO-ringfromtheclutchknob
(Figure15).
B.Removetheshearpinthatsecuresthe
clutchknobtotheactuatorshaft(Figure15).
C.Removetheclutch-knobassemblyandip
itover.
D.Assembletheclutchknobtotheactuator
shaftwiththeshearpin(Figure15).
E.InstalltheO-ringintothegrooveinthe
clutchknob.
g244757
Figure15
1.Shearpin3.O-ring
2.Clutch-knobassembly
7

5
InstallingtheIdler
Assembly
Partsneededforthisprocedure:
1Stub-shaftassembly
2Bearingshield
1Idlerassembly
1Adjustercollar
1Flangenut
Procedure
1.Assembletheloosepartstotheidlerassembly
asshowninFigure16.
Note:Installparts1through5inreverseifyou
areinstallingtheidlerassemblyontheopposite
sideinFigure16.
Important:Installthebearingshieldswith
thefabricsidetowardthebearings.
g031454
Figure16
Leftsideshown
1.Stub-shaftassemby4.Adjustercollar—torqueto
23to31N∙m(17to23
ft-lb)
2.Bearingshield5.Flangenut—torqueto37
to45N∙m(27to33ft-lb)
3.Idlerassembly
2.Removethemotormount.
3.Positiontheidlerassemblyontheoppositeside
ofthereelfromthegroomerdrivebox.
4.Ifyouareinstallingthekitonacuttingunit
ofaTriFlexmachine,proceedtostep5.If
youareinstallingthekitonthecuttingunit
ofawalk-behindgreensmower,performthe
followingsteps:
A.Installthebelt-driveassemblytothecutting
unitusingthe3boltsthatyouremoved
previously(Figure8).
B.Installthepulleytothereelshaftusingthe
2setscrewsthatyouremovedpreviously
(Figure7);torquethesetscrewsto8.4to
8.9N∙m(74to79in-lb).
C.Installthebeltandtightenthebelt-tensioning
nut(Figure6).
D.Installthebeltcoverandtightenthecaptive
bolt(Figure6).
5.Ifyouareinstallingthekitonacuttingunit
ofaTriFlexmachine,installthemotormountto
theleftendofthecuttingunitusingthe2bolts
thatyouremovedpreviously(Figure5).
6.Torquetheboltsto20to26N∙m(175to225
in-lb).
8

6
InstallingtheGroomerPins
Greensmaster3120,3150,and
3250D
Partsneededforthisprocedure:
2Groomerpin
Procedure
1.Applyremovablethread-lockingcompoundto
theholeforthegroomerpinifitisnotpresenton
thegroomer-pinthreads.
2.Securethegroomerpintotheheight-of-cutarm
(Figure17).
g038779
Figure17
1.Height-of-cutarm3.Groomerpin(shownwith
orwithoutremovable
thread-lockingcompound)
2.Hole
3.Performthisproceduretotheoppositeside.
7
InstallingtheHeight-of-Cut
BracketAssembliesand
theFrontRoller
Partsneededforthisprocedure:
1Leftheight-of-cutbracketassembly
1Rightheight-of-cutbracketassembly
2Adjusterpin
2Cotterpin
Procedure
1.Threadthepreviouslyremovedheight-of-cut
adjustingscrewsintothetopoftheheight-of-cut
assemblies(Figure18).
g231782
Figure18
1.Height-of-cutadjusting
screw
3.Height-of-cutbracket
assembly
2.Plowbolt,nut,andspecial
washer
2.Installtheheight-of-cutassembliestothecutting
unitsideplatesusingthepreviouslyremoved
plowbolt,nut,andspecialwasher(Figure18).
3.Slidetheadjuster-armassemblyrodnearthe
groomerdriveboxintothegaponthedrivebox
andsecureitwithanadjusterpinandcotterpin
(Figure19).
9

Note:Makesurethatyoubendthelegsofthe
cotterpinsothatthepindoesnotfalloutofthe
adjusterpin.
g033273
Figure19
1.Cotterpin3.Adjuster-armassembly
rod
2.Groomerdrivebox4.Adjusterpin
4.Aligntheadjuster-armassemblyrodnearthe
idlerassemblywiththeadjustercollaronthe
idlerassemblyandsecureitwithanadjusterpin
andcotterpin(Figure20).
Note:Makesurethatyoubendthelegsofthe
cotterpinsothatthepindoesnotfalloutofthe
adjusterpin.
g031457
Figure20
1.Cotterpin3.Adjuster-armassembly
rod
2.Adjustercollar4.Adjusterpin
5.Insertandcenterthefrontrollershaftbetween
theheight-of-cutbracketsandsecureitwith
the2mountingscrewsremovedfromtheold
height-of-cutbrackets(Figure21).
g231793
Figure21
1.Mountingscrew3.Groomerguard
2.Height-of-cutbracket
assembly
6.Attachthegroomerguardstoeithersideofthe
frontrollershaft(Figure21).
7.Torquethegroomerguardsto22to24N∙m(16
to18ft-lb).
10