Toro Greensmaster eTriFlex 3360 User manual

FormNo.19239SLRevB
Greensmaster®eTriFlex3360and
3370
(Model04580and04590)
©2019—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
OriginalInstructions(EN)
Contactusatwww.Toro.com.
AllRightsReserved

RevisionHistory
RevisionDateDescription
A06/2019InitialIssue
B12/2019Model04590informationadded
RevisionHistoryPage2Greensmaster®eTriFlex3360and3370
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ReaderComments
TheToroCompanyT echnicalAssistanceCentermaintainsacontinuous
efforttoimprovethequalityandusefulnessofitspublications.Todothis
effectively,weencourageuserfeedback.Pleasecommentonthecompleteness,
accuracy,organization,usability,andreadabilityofthismanualbyane-mail
to[email protected]
orMailto:
TechnicalPublicationManager,Commercial
TheToroCompany
8111LyndaleAvenueSouth
Bloomington,MN55420-1196
Phone:[phone]
Greensmaster®eTriFlex3360and3370Page3ReaderComments
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ReaderCommentsPage4Greensmaster®eTriFlex3360and3370
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Preface
Thisservicemanualwaswrittenexpresslyforservicetechnicians.Basicshop
safetyknowledgeandmechanical/electricalskillsareassumed.TheT oro
Companyhasmadeeveryefforttomaketheinformationinthismanualcomplete
andcorrect.
Thepurposeofthispublicationistoprovidetheservicetechnicianwith
informationabouttroubleshooting,testing,andrepairingmajorsystemsand
components.Thismanualmayalsobespeciedforuseonnumerousproducts.
RefertotheT ableofContentsforalistofthesystemsandtherelatedtopics
coveredinthismanual.
RefertothemachineOperator’sManualforadditionalinformationabout
operating,maintaining,andadjustingthemachine.KeepacopyoftheOperator’s
Manuals,InstallationInstructions,andPartsCatalogforyourmachineandits
accessorieswiththisServiceManualforreference.Additionalcopiesofthe
Operator’sManuals,InstallationInstructionsandPartsCatalogsareavailable
atwww.toro.com.
TheToroCompanyreservestherighttochangetheproductspecicationsor
thispublicationwithoutnotice.
Greensmaster®eTriFlex3360and3370Page5Preface
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ServiceProcedureIcons
ThefollowingiconsappearthroughoutthisServiceManualtobringattentionto
specicimportantdetailsofaserviceprocedure.
CriticalProcess
Thisiconisusedtohighlight:
•installingsafetyequipment(shields,guards,seatbelts,brakesandR.O.P .S.
components)thatmayhavebeenremoved
•dimensionsorsettingsthatmustbemaintainedforpropermachineoperation
•aspecicfastenertighteningsequence
•componentorientationthatmaynotbeobvious
CriticalTorque
Thisiconisusedtohighlightanassemblytorquerequirementthatisdifferentthan
whatisrecommendedintheStandardT orqueTables;refertoStandardT orque
forDry,ZincPlated,andSteelFasteners(InchSeries)(page2–8)orStandard
TorqueforDry,ZincPlated,andSteelFasteners(MetricFasteners)(page2–9).
FluidSpecications
Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless
common,andmaynotappearonthemachineservicedecalorinthemachine
Operator’sManual.
Note:RefertotheservicedecalonthemachineandthemachineOperator’s
Manualforcommonlyuseduidspecicationsandcapacities.
PrefacePage6Greensmaster®eTriFlex3360and3370
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TableofContents
Preface................................................................................................................5
Chapter1:Safety............................................................................................1–1
SafetyInstructions.......................................................................................1–2
JackingInstructions.....................................................................................1–6
SafetyandInstructionalDecals....................................................................1–7
Chapter2:SpecicationsandMaintenance....................................................2–1
Specications...............................................................................................2–2
TorqueSpecications...................................................................................2–5
ShopSupplies............................................................................................2–11
SpecialT ools..............................................................................................2–13
Chapter3:Troubleshooting.............................................................................3–1
GEARS–TheSystematicApproachtoDening,DiagnosingandSolving
Problems......................................................................................................3–2
OperatorAdvisories......................................................................................3–3
DialogueMessages......................................................................................3–5
MachineFaults.............................................................................................3–7
UsingtheInfoCenterDisplayforTroubleshooting.......................................3–39
Troubleshooting..........................................................................................3–41
GeneralOperationProblems(Model04580)...............................................3–42
GeneralOperationProblems(Model04590)...............................................3–43
AftercutAppearance...................................................................................3–46
GroomingPerformance..............................................................................3–48
UniversalGroomerProblems(Optional).....................................................3–49
BatteryChargerErrorandFaultCodes(Model04590)................................3–50
Chapter4:Engine(Model04580)....................................................................4–1
GeneralInformation.....................................................................................4–2
ServiceandRepairs.....................................................................................4–3
Chapter5:ElectricalSystem...........................................................................5–1
GeneralInformation.....................................................................................5–3
ElectricalSystemOperation..........................................................................5–4
ElectricalSystemQuickChecks..................................................................5–18
Adjustments................................................................................................5–20
TestingtheElectricalComponents..............................................................5–23
Batteries(Model04580)............................................................................5–103
Batteries(Model04590)............................................................................5–111
ServiceandRepairs.................................................................................5–120
Chapter6:Chassis..........................................................................................6–1
GeneralInformation.....................................................................................6–2
Adjustments.................................................................................................6–3
ServiceandRepairs.....................................................................................6–9
Chapter7:DPACuttingUnits..........................................................................7–1
GeneralInformation.....................................................................................7–2
Adjustments.................................................................................................7–3
ServiceandRepairs.....................................................................................7–6
Chapter8:UniversalGroomer(Optional)........................................................8–1
GeneralInformation.....................................................................................8–2
ServiceandRepairs.....................................................................................8–3
AppendixA......................................................................................................A–1
ElectricalDrawingDesignations....................................................................A–2
ElectricalSchematic–3360..........................................................................A–3
ElectricalSchematic–3370..........................................................................A–4
ElectricalSchematic–3370(continued).......................................................A–5
WireHarnessDrawing–3360......................................................................A–6
WireHarnessDiagram–3360......................................................................A–7
WireHarnessDiagram–3360(continued)...................................................A–8
WireHarnessDrawing–3370......................................................................A–9
Greensmaster®eTriFlex3360and3370Page7Preface
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WireHarnessDiagram–3370....................................................................A–10
WireHarnessDiagram–3370(continued)..................................................A–11
AdditionalReferenceMaterials
KawasakiFS481VServiceManual
PrefacePage8Greensmaster®eTriFlex3360and3370
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Chapter1
Safety
TableofContents
SafetyInstructions................................................................................................................................1–2
ThinkSafetyFirst...............................................................................................................................1–3
JackingInstructions..............................................................................................................................1–6
SafetyandInstructionalDecals............................................................................................................1–7
Greensmaster®eTriFlex3360and3370Page1–1Safety
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SafetyInstructions
DANGER
Thissafetysymbolmeansdanger.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscouldkillorcauseseriouspermanentinjuryordisability.
WARNING
Thissafetysymbolmeanswarning.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinseriousinjury.
CAUTION
Thissafetysymbolmeanscaution.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinminortomoderateinjury.
IMPORTANT
TheImportantnoticewillgivetheimportantinstructionswhichyou
mustfollowtopreventdamagetothesystemsorcomponentson
themachine.
Note:ANotewillgivethegeneralinformationaboutthecorrectoperation,
maintenance,service,testing,orrepairofthemachine.
Safety:SafetyInstructionsPage1–2Greensmaster®eTriFlex3360and3370
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ThinkSafetyFirst
ToroProductsaretestedandcertiedforcompliancewithexistingsafety
standardsandspecications.Althoughhazardcontrolandaccidentprevention
arepartiallydependentuponthedesignandcongurationofthemachine,
hazardcontrolandaccidentpreventionarealsodependentupontheawareness,
concernandpropertrainingofthepersonnelinvolvedintheoperation,transport,
maintenance,andstorageofthemachine.Improperuseormaintenanceofthe
machinecanresultininjuryordeath.
WARNING
Toreducethepotentialofinjuryordeath,complywiththesafety
instructionsinthismanual,aswellasinformationfoundinthe
Operator’sManualsandtheOperatorandSafetyTrainingVideos
foundonwww.toro.com.
•Avoidunexpectedstartingoftheengine…
Alwaysturnofftheengine,removethekeyandunplugthe48Vbattery
disconnectbeforecleaning,adjusting,orrepair.
•Avoidlacerationsandamputations…
Stayclearofallmovingpartswhenevertheengineisrunning.Treatall
normallymovingpartsasiftheyweremovingwhenevertheengineis
runningorhasthepotentialtostart.
•Avoidburns…
Donottouchtheengine,mufer,orothercomponents,whichmaybehot
duringoperation,whiletheunitisrunningorshortlyafterithasbeen
running.
•Avoidresandexplosions…
Useextremecareinhandlingfuel.Fuelisammableanditsvaporsare
explosive.
–Extinguishallcigarettes,cigars,pipes,andothersourcesofignition.
–Avoidspillingfuelandneversmokewhileworkingwithanytypeoffuel
orlubricant.
–Wipeupanyspilledfueloroilimmediately.
–Neverremovethefuelcaporaddfuelwhentheengineisrunning.
–Alwaysuseapproved,labeledcontainersforstoringortransportingfuel
andlubricants.
–Donotaddordrainfuelinanenclosedspace.
–Donotstorethemachineorfuelcontainerwherethereisanopename,
spark,orpilotlight,suchasonawaterheaterorotherappliance.
•Avoidasphyxiation…
Donotoperateanengineinaconnedareawithoutproperventilation.
•Avoidinjuryfrombatteries…
–Batteryacidispoisonousandcancauseburns.Avoidcontactwithskin,
eyesandclothing.
–Batterygasescanexplode.Keepcigarettes,sparksandamesaway
fromthebattery.
•Avoidinjuryduetoinferiorparts…
Useonlyoriginalequipmentpartstoensurethatimportantsafetycriteria
aremet.
Greensmaster®eTriFlex3360and3370Page1–3Safety:SafetyInstructions
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ThinkSafetyFirst(continued)
•Avoidinjurytobystanders…
Alwayscleartheareaofbystandersbeforestartingortestingpowered
equipment.
•Avoidinjuryduetoprojectiles…
Alwayscleartheareaofsticks,rocksoranyotherdebristhatcouldbe
pickedupandthrownbythepoweredequipment.
•Avoidmodications…
Neveralterormodifyanypartunlessitisafactoryapprovedprocedure.
•Avoidunsafeoperation…
Alwaystestthesafetyinterlocksystemaftermakingadjustmentsor
repairsonthemachine.RefertotheElectricalsectioninthismanual
formoreinformation.
•Avoidelectricalshock…
–Nevertouchelectricalwiresorcomponentswhiletheengineisrunning.
Theycanbesourcesofshock.
–De-energizethesystemifyouarehavingtodorepairs.
–Iftestingelectricalcomponentsensureyouareworkinginadry
environment.
•Usepersonalprotectiveequipment…
–Useappropriatepersonalprotectiveequipment(PPE)forprotecting
yourselffrompotentialhazardsintheenvironmentinwhichyouwillwork.
–EachprocessoutlinedinthismanualmayneeddifferentPPEtoprotect
theserviceperson.UsetheproperPPEforthetaskathand.
•Usingtools…
–Alltoolsshouldbeinproperworkingorder.Donotusetoolsthatare
brokenorindisrepair.
–Usethepropertoolfortheproperapplication.
•Usinglifts,hoists,andjacks…
–Alllifts,hoists,andjacksshouldbeusedinaccordancewiththe
manufacturerinformation.
–Inspectlifts,hoists,andjackspriortouse.
–Donotoverloadlifts,hoists,andjacks.
–Donotworkunderasuspendedload.
–Ensurechockblocksareusedonequipmentthatcanmove.
–Useliftsorjacksandjackstandsthatareratedtosupportthetotalweight
ofthemachineandanyattachments.
–Donotrelyonjackstosupportthemachine.
–Ifyouareunfamiliarwithanylifts,hoistsorjacks,donotusethemuntil
youknowhowtooperatethemcorrectly.
•Usingreextinguishers…
Usetheproperclassofreextinguisherincaseofre.
Ensurereextinguishersareservicedregularly,andreplaceanyre
extinguishersthataredischargedorinusebeyondtheirexpirationdates.
–ClassAreextinguishersareforordinarycombustiblematerialssuch
aspaper,wood,cardboard,andmostplastics.Thenumericalratingon
thesetypesofextinguishersindicatestheamountofwateritholdsand
theamountofreitcanextinguish.Geometricsymbol(greentriangle).
Safety:SafetyInstructionsPage1–4Greensmaster®eTriFlex3360and3370
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ThinkSafetyFirst(continued)
–ClassBreextinguishersareforresthatinvolveammableor
combustibleliquidssuchasgasoline,kerosene,greaseandoil.The
numericalratingforclassBextinguishersindicatestheapproximate
numberofsquarefeetofreitcanextinguish.Geometricsymbol(red
square).
–ClassCreextinguishersareforresthatinvolveelectricalequipment
suchasappliances,wiring,circuitbreakersandoutlets.Neverusewater
toextinguishclassCres-theriskofelectricalshockisfartoogreat!
ClassCextinguishersdonothaveanumericalrating.TheCclassication
meanstheextinguishingagentisnon-conductive.Geometricsymbol
(bluecircle).
–ClassABCreextinguishersareadrychemicaltypeusedformultiple
purposes.Seeabovedescriptionsforadditionalinformation.
Greensmaster®eTriFlex3360and3370Page1–5Safety:SafetyInstructions
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JackingInstructions
DANGER
Mechanicalorhydraulicjacksmayfailtosupportthemachineand
causeaseriousinjury.
•Usejackstandstosupporttheraisedmachine.
•Useonlymechanicalorhydraulicjackstoliftthemachine.
1.Parkthemachineonalevelsurface,lowerthecuttingunits,shutoffthe
engine,removethekeyfromthekeyswitchandunplugthe48Vbattery
disconnect.
2.Positionthejacksecurelyunderthedesiredjackingpoint:
•Footstepontheleftsideofthemachine
•Jackbracketontherightsideofthemachine
•Casterforkattherearofthemachine
g286954
Figure1
1.Footstep–leftfrontofthemachine2.Jackbracket–rightfrontofthe
machine
3.Casterfork–rearofthemachine
3.Afterraisingthemachine,useanappropriatejackstandatthefollowing
locationstosupportthemachine.
IMPORTANT
Usetwojackstands(oneundereachbatterytray)whensupporting
therearofthemachine.
Safety:JackingInstructionsPage1–6Greensmaster®eTriFlex3360and3370
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g288440
Figure2
1.Cuttingunitpivotmount–supports
leftfrontofmachine
2.Cuttingunitpivotmount–supports
rightfrontofmachine
3.Batterytrays–supportsrearof
machine
SafetyandInstructionalDecals
Numeroussafetyandinstructionaldecalsareafxedtothetractionunitandthe
cuttingunitsoftheGreensmaster3360/3370.Ifanydecalbecomesillegibleor
damaged,replaceitwithanewdecal.PartnumbersarelistedinyourParts
CatalogandOperator’sManual.OrderreplacementdecalsfromyourAuthorized
ToroDistributor
Greensmaster®eTriFlex3360and3370Page1–7Safety:SafetyandInstructionalDecals
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Safety:SafetyandInstructionalDecalsPage1–8Greensmaster®eTriFlex3360and3370
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Chapter2
SpecicationsandMaintenance
TableofContents
Specications.......................................................................................................................................2–2
OverallDimensions............................................................................................................................2–2
Engine(Model04580only)................................................................................................................2–2
Chassis..............................................................................................................................................2–3
DPACuttingUnits..............................................................................................................................2–3
UniversalGroomer(Optional)............................................................................................................2–4
TorqueSpecications...........................................................................................................................2–5
CalculatingtheT orqueValuesWhenUsingaDrive-AdapterWrench.................................................2–6
IdentifyingtheFastener......................................................................................................................2–7
StandardT orqueforDry,ZincPlated,andSteelFasteners(InchSeries)............................................2–8
StandardT orqueforDry,ZincPlated,andSteelFasteners(MetricFasteners)...................................2–9
OtherTorqueSpecications.............................................................................................................2–10
ConversionFactors..........................................................................................................................2–10
ShopSupplies....................................................................................................................................2–11
SpecialTools......................................................................................................................................2–13
Greensmaster®eTriFlex3360and3370Page2–1SpecicationsandMaintenance
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Specications
OverallDimensions
g287052
Figure3
Engine(Model04580only)
ItemDescription
Make/DesignationKawasaki,4-cycle,V-TwinCylinder,OHV ,Air
Cooled,GasolineEngine-ModelFS481V.
BorexStroke73x72mm(2.87x2.83inches)
Totaldisplacement603cc3(36.8in3)
GovernorMechanical
CarburetorSingle-barrel,oatcontrolledwithxedmainjets
ChokeManual
FuelPumpPulseType
FuelRefertotheTractionUnitOperator’sManual
Fueltankcapacity18.5L(4.9USgallons)
OperatingRPM(xed)2,400rpm±100
EngineoilRefertotheTractionUnitOperator’sManual
Crankcase-oilcapacity1.7L(1.8qt)withnewlter
IgnitionSystemFlywheelmagneto,transistortype
SparkPlugsNGKBPR4ES
SparkPlugGap0.75mm(0.030inches)
Alternator/Regulator12VDC,15amp
EngineWeight(dry)37kg(82lb)
SpecicationsandMaintenance:SpecicationsPage2–2Greensmaster®eTriFlex3360and3370
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Chassis
ItemDescription
FrontandReartireStandard=19x10.50x8,4plySmooth
Optional=20x10x8,4plyTurfTread
83to110kPa(12to16psi)
Wheellugnuttorque95to122N∙m(70to90ft-lb)
DPACuttingUnits
ItemDescription
FrameconstructionPrecisionmachineddiecastaluminum
crossmemberwithtwobolt-ondie-cast
aluminumsideplates.
ReelconstructionReelsare53.3cm(21inches)inlengthand
12.7cm(5inch)indiameter.Highstrength,
lowalloysteelbladesarethruhardenedand
impactresistant.Reelsareavailablein8,
11and14bladecongurations.
ReelbearingsTwostainlesssteelballbearingsarepresstonto
thereelshaftandretainedbyathreadedinsert.
Lowdragseals/slingersforaddedprotectionwith
anO-ringsealedcounterweightmountingsurface.
Reelpositionismaintainedbyawavewasher
withnoendplayadjustmentrequired.
ReeldriveThereelshaftis35mm(1.375inch)diametertube
withaninternallysplinedthreadednutoneachend.
Height-of-cutCuttingheightisadjustedonthefrontrollerby
twoverticalscrews.Standardbenchheight
ofcutrangeis1.6to1.1mm(0.062to0.438
inch)dependingontypeofbedknifeinstalled.
Anoptionalhighheight-of-cutkitisavailable
toobtainacutrangeof11.1to25.4mm
(0.438to1.0inch).EffectiveHOCmayvary
dependingonturfconditions,typeofbedknife,
rollers,andattachmentsinstalled.
BedknifeandbedbarReplaceablesingleedgedEdgemax™bedknife
(solidtoolsteelconstruction)isstandard.Bedknife
isfastenedtothebedbarwiththirteenbedknife
screws.Avarietyofoptionalbedknivesanda
moreaggressivebedbarareavailable.
BedknifeadjustmentDualadjustment(oneoneachsideofthe
bedbar)with0.018mm(0.0007inch)bedknife
movementforeachdetent.
RollersThefrontrollerisa6.3cm(2.5inches)diameter
rollerthatisavailableinfull,widespacedWiehle
andnarrowspacedWiehlecongurations.The
rearrollerisa5.1cm(2inches)diameterfullroller.
GrassshieldNon-adjustableshieldwithadjustablecut-off
bartoimprovegrassdischargefromreelin
varyingmoistureconditions.
CounterbalanceweightApairofcastironweightsmountedonrightside
ofthecuttingunitcompensatefortheelectricreel
motormountedontheleftsideofthecuttingunit.
Greensmaster®eTriFlex3360and3370Page2–3SpecicationsandMaintenance:Specications
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DPACuttingUnits(continued)
ItemDescription
Cuttingunitweight(approximate)8blade*=32.7kg(72lb)
11blade*=34kg(75lb)
14blade*=35kg(78lb)
*Cuttingunitweightsdonotincludeafrontroller.
OptionsRefertotheCuttingUnitPartsCatalogor
contactyourlocalAuthorizedToroDistributor
foravailablecuttingunitoptions.
UniversalGroomer(Optional)
ItemDescription
Groomingreeldiameter6cm(2.375inches)
Groomerbladetype51twintipsteelbladeswith3/8inchbladespacing.
Agroomerbrushcanbeinstalledinplaceofa
groomingreel.
GroomermountingThegroomerismountedtothecuttingunitside
plates.Thedriveassemblyforthegroomingreel
islocatedontheoppositesideofthecuttingunit
fromthecuttingunitmotor.
GroomerheightsettingMowing:0.8to15.7mm(0.030to0.620inch).
HOCrange:1.5to19.1mm(0.060to0.750inch).
Width-of-groomer54.6cm(21.5inches).
HeightadjustmentknobAllowsa0.003inch(0.08mm)incrementofheight
adjustmentforeachclickoftheadjuster.
Quick-upfeatureAllowsgroomingreeltoberaisedabovethe
height/depthadjustmentfornogroomingreelaction
whilemowing.
GroomerdriveThegroomerdriveassemblyisattachedtotheright
sideofthecuttingunit.
GroomerrotationForward:thegroomerrotatesinthesamedirection
asthereel
Reverse:thegroomerrotatesintheopposite
directionasthereel
Neutral:thegroomerdoesnotrotate
SpecicationsandMaintenance:SpecicationsPage2–4Greensmaster®eTriFlex3360and3370
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