Form No. 17230SL Rev D Greensmaster 3120 © 2018—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision Date A 10/2017 Initial issue. B 01/2018 Added Revision History C 04/2018 Updated Cutting Unit chapter.
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Reader Comments Page 4 Greensmaster 3120 17230SL Rev D
Preface The purpose of this publication is to provide the service technician with the information for troubleshooting, testing, and repair of the major systems and components of the Greensmaster 3120 (Model 04355). Refer to the traction unit and cutting unit Operator’s Manuals for operating, maintenance, and adjustment instructions. Keep a copy of the Operator’s Manuals and Parts Catalogs for your machine with this Service Manual for reference.
Overall Dimensions g219200 Figure 1 Greensmaster 3120 Preface Page 6 Greensmaster 3120 17230SL Rev D
Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S.
Table of Contents Preface ................................................................................................................ 5 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Jacking Instructions ..................................................................................... 1–7 Safety and Instructional Decals .
Wire Harness Diagram - Main (serial numbers below 403410000) ................A–8 Wire Harness Drawing - Main (serial numbers above 403410000) ................A–9 Wire Harness Diagram - Main (serial numbers above 403410000) ..............A–10 Wire Harness - Seat....................................................................................A–11 Wire Harness - Engine ................................................................................
Preface Page 10 Greensmaster 3120 17230SL Rev D
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Supervisor’s Responsibilities ............................................................................................................. 1–2 Before Operating the Machine ........................................................................................................... 1–2 While Operating the Machine ..........
Safety Instructions The Greensmaster 3120 machine meets or exceeds safety standard specifications as identified in the Operator’s Manuals. Although hazard control and accident prevention are dependent partially 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.
Before Operating the Machine (continued) the seat is unoccupied or the parking brake is not applied when the function control lever is in the MOW or TRANSPORT position. • Gasoline (fuel) is highly flammable; handle it carefully. – Store fuel in containers specifically designed for storing fuel. – Do not remove the fuel tank cap of the machine while the engine is hot or running. – Do not smoke while handling fuel.
While Operating the Machine DANGER The exhaust fumes are hazardous and have the potential of injury or death. Do not run the engine in a confined area without adequate ventilation. 1. Sit on the seat when starting and operating the machine. 2. Check the safety interlocks daily for proper operation; refer to Checking the Interlock System Operation (page 5–10). Adjust or replace any malfunctioning switches or interlock mechanisms before operating the machine. 3. To start the engine: A.
While Operating the Machine (continued) A. Make sure the cutting units are disengaged. B. Verify that function control lever is in neutral. C. Set the parking brake. D. Lower the cutting units to the ground. E. Stop the engine and remove key from ignition switch. 12. Whenever machine is left unattended, make sure cutting units are fully raised and reels are not spinning, the key is removed from ignition switch and the parking brake is set.
Maintenance and Service • Before servicing or making any adjustments to the machine, lower the cutting units, set the parking brake, shut off the engine, and remove the key from the key switch. • Ensure that the machine is in safe operating condition by keeping all the nuts, bolts, and screws tight. • Wear gloves and use caution when checking or servicing the cutting units.
Jacking Instructions CAUTION Failing to properly support the machine with appropriate jack stands can cause the machine to move or fall and can result in personal injury. When changing the attachments, tires, or performing other services, do the following steps: • Park the machine on a solid level surface, such as a concrete floor. • Always block the wheels with chocks. • Before you lift the machine, remove all the attachments that may interfere with the safe and correct lift of the machine.
Raising the Machine (continued) g212064 Figure 3 1. Right front jacking point (Roll Over 2. Protection System “ROPS” support bracket behind the RH front wheel) Rear jacking point (rear wheel caster fork) 1. Lower the cutting units, set the parking brake and block the rear wheel with a chock to prevent the machine from moving. 2. Position the jack securely under the desired front jacking point: 3.
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Decimal and Millimeter Equivalents ................................................................................................... 2–2 U.S. to Metric Conversions ................................................................................................................
Specifications Insert a copy of the Operator’s Manuals and Parts Catalogs for your machine (traction unit and cutting units) at the end of this chapter. Additionally, if any optional equipment or accessories are installed to your machine, insert the Installation Instructions, Operator’s Manuals, and Parts Catalogs for those options at the end of this chapter. The maintenance procedures and recommended service intervals for your machine are covered in the Operator’s Manuals.
Decimal and Millimeter Equivalents (continued) Fractions 1/2 Decimals mm 0.5000 12.700 Fractions 1 1 mm = 0.03937 inch Decimals mm 1.000 25.400 0.001 inch = 0.0254 mm U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.914 Feet Meters 0.305 Feet Centimeters 30.48 Inches Meters 0.025 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.
Torque Specifications The 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. These torque specifications for the installation and tightening of the fasteners will apply to all the fasteners which do not have a specific requirement identified in this Service Manual.
Calculating the Torque Values When Using a Drive-Adapter Wrench (continued) The calculated torque conversion factor (A/B) for this example would be 18/19 or 0.947. If the listed torque recommendation for a fastener is 103 to 127 N∙m (76 to 94 ft-lb), the proper torque for this example would be 98 to 121 N∙m (72 to 89 ft-lb). Identifying the Fastener g206089 Figure 5 Metric Bolts and Screws 1. Class 8.8 2. Class 10.9 g206088 Figure 6 Inch Series Bolts and Screws 1. Grade 1 2. Grade 5 3.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric) Thread Size 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 ± 6 in-lb 644 ± 68 N∙cm 78 ± 8 in-lb 881 ± 90 N∙cm M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N∙cm 133 ± 14 in-lb 1503 ± 158 N∙cm M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N∙m 28 ± 3 ft-lb 38 ± 4 N∙m M10 X 1.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch) Thread Size Grade 1, 5 and 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, and Sems with Regular Height Nuts(SAE J995 Grade 2 or Stronger Nuts) in-lb in-lb N∙cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 56 18 ± 2 30 ± 5 339 ± 56 1/4 - 20 UNC 48 ± 7 53 ± 7 1/4 - 28 UNF 53 ± 7 5/16 - 18 UNC 5/16 - 24 UNF SAE Grade 5 Bolts, Screws, Studs, and Sems with Regular Height Nuts(SAE J995 Grade 2 or Stronger Nuts) SAE Gra
Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque 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 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 30 ± 5 in-lb No.
Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants, and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply. IMPORTANT Always follow manufacturers instructions when using or storing shop supplies.
Anti-seize lubricant Used to prevent corrosion, galling, and seizure between metal parts. Most often applied to shafts and bores during assembly. Unless otherwise specified, high viscosity regular grade lithium-graphite based anti-seize lubricant should be used. Grease Can be used to pre-fill (pack) bearings, boots, and seals before assembly, ease installation of components during assembly, or fill cavities between moving parts through grease fittings after assembly.
Special Tools You can order these special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic Pressure Testing Kit K-Line Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick disconnect fittings are provided to attach directly to the mating fittings on the machine test ports without the tools. A high-pressure hose is given for remote readings.
150 LPM (40 GPM) Hydraulic Tester K-Line Part No. AT40002 Use this tester to test the hydraulic circuits and components for flow and pressure capacities. The tester flow measurement maximum is 151 LPM (40 GPM). This tester includes the following: Load Valve – Turn the valve to restrict the flow to create a simulated working load in the circuit. Pressure Gauge – A glycerine filled pressure gauge 0 to 34,500 kPa (0 to 5,000 psi) to provide operating circuit pressure.
Hydraulic Test Fitting Kit K-Line Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system.
High Flow Hydraulic Filter Kit K-Line Part Number: TOR6011 The high flow hydraulic filter kit is designed with large flow (150 L/minute or 40 gallons/minute) and high pressure (34,500 kPa or 5,000 psi) capabilities. This kit provides for bi-directional filtration which prevents filtered unwanted material from entering into the circuit regardless of the flow direction.
Multimeter Obtain this tool locally The meter can test the electrical components and circuits for current, resistance, or voltage. Note: Use a digital multimeter when testing the electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode ensures that the excess current is not allowed through the meter. This excess current can damage the circuits that are not designed to carry it. Battery Terminal Protector Toro Part No.
Wheel Hub Puller (continued) K-Line Part No. TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors. Gauge Bar Assembly Toro Part No. 94–9010 Use gauge bar to verify height-of-cut adjustment. Cutting Reel Shim Toro Part No. 125–5611 Use the 0.05 mm (0.002 in) shim like a feeler gauge to measure the gap between the reel and the bedknife during reel adjustment. Cutting Performance Paper Toro Part No.
Reel Thread Repair Taps 15/16–16 Right-Hand Thread – Toro Part No. 137–0926 15/16–16 Left-Hand Thread – Toro Part No. 137–0927 Use to clean or repair the internal threads of cutting unit reels. Backlapping Brush Assembly Toro Part No. 29–9100 For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel. Components for the brush assembly are also available individually.
Angle Indicator and Magnetic Mount (continued) Angle Indicator: Toro Part No. 131–6828 Magnetic Mount: Toro Part No. 131–6829 Because the top grind angle on bedknives is critical for edge retention, and therefore after− cut appearance, Toro has develop these service tools for accurately measuring the top grind angle on all bedknives. Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar. g223327 Figure 7 1. 2.
Diameter/Circumference Measuring Tape (continued) K-Line Part No. TOR6023 Spring steel measuring tape for accurately measuring the circumference and outside diameter of cutting reel and other spherical components. Tape calibration is in fixed inch readings (no adjustments). Roller Rebuilding Tools The following combination of washers and spacers can be used to install bearings and seals into the front and rear rollers (2 each required).
Drive Shaft Removal Tool (continued) Toro Part No. 137-0920 Use to remove the optional Universal Groomer drive shaft from the reel if the drive shaft hex is damaged. Adapter Wrench Toro Part No. 137-0921 Use to hold the optional Universal Groomer drive shaft securely when removing or installing the drive adapter. Syringe – 50cc (2 ounce) Toro Part No. 137-0872 Aids in accurately filling the optional Universal Groomer gear box with oil.
Chapter 3 Engine Table of Contents Specifications ....................................................................................................................................... 3–2 Engine................................................................................................................................................ 3–2 General Information ..............................................................................................................................
Specifications Engine Item Description Make/Designation Briggs and Stratton, 4–cycle, V–Twin Cylinder, OHV, Air Cooled, Gasoline Engine – Model 305447. Bore 68 mm (2.68 inches) Stroke 66 mm (2.60 inches) Total displacement 479 cc3 (29.2 in3) Mechanical Governor Carburetor Float Controlled Fuel Pump Pulsating Crankcase Vacuum Fuel Refer to the Traction Unit Operator’s Manual Fuel tank capacity 26.6 L (7.
General Information This chapter gives information about specifications and repair of the gasoline engine used in the Greensmaster 3120 machine. The general maintenance procedures are described in the Operator’s Manual. Detailed information on engine troubleshooting, testing, disassembly, and assembly is identified in the Briggs & Stratton Vanguard V-Twin OHV Repair Manual. Most repairs and adjustments require tools which are commonly available in many service shops.
Service and Repairs Fuel Tank g206706 Figure 9 1. Fuel filter 2. Hose clamp (4 each) Cap screw (4 each) 17. Fuel hose (tank to valve) 10. 3. 4. Cap screw 18. Spacer Fuel hose (filter to engine) 11. Hose clamp 19. Hose clamp Fuel cap 12. Frame 20. Vent hose (tank to canister) 5. Fuel tank 13. Vent fitting 21. Grommet 6. Grommet (4 each) 14. Fuel hose (valve to filter) 22. Fuel gauge (if equipped) 7. Flat washer (4 each) 15. Fuel shut-off valve 23.
DANGER Gasoline is highly flammable and explosive. A fire or an explosion from the fuel can burn you, burn other people, and damage property. • Use caution whenever you store or handle gasoline. • Do not smoke while handling gasoline. • Do not fill the fuel tank while the engine is running, while the engine is hot, or when the machine is in an enclosed area. • Always fill the fuel tank outside and wipe up any spilled gasoline before starting the engine.
Installing the Fuel Tank IMPORTANT After fuel tank is installed, make sure that clearance between fuel tank and hydraulic tank is from 3.2 to 9.5 mm (0.125 to 0.375 inches). 1. Secure the fuel tank to the vehicle frame: A. Apply anti-seize lubricant to the threads of the four (4) cap screws. B. Install the cap screws through the fuel hose clamps, the flat washers and the bushings. Make sure the bushings are between the flat washers and the frame. C. Tighten the cap screws from 3.4 to 6.
Engine g206314 Figure 10 1. Engine 13. Evaporative system hose (air cleaner to tee) 2. Fuel hose and clamp 14. Evaporative system hose (manifold 26. to canister) Spacer (2 each) 3. Spacer 15. Cap screw (2 each) Lock nut (2 each) 25. 27. Flange head screw (2 each) 4. Positive (+) cable 16. Flat washer (2 each) 28. Engine mount (3 each) 5. Regulator shield 17. Pump adapter 29. Spacer (2 each) 6. Regulator ground 18. Socket head screw (2 each) 30. Flat washer (2 each) 7.
Removing the Engine 1. Park the machine on a level surface, lower the cutting units, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Close fuel shut-off valve below fuel tank. 3. Disconnect the negative (–) battery cable at the battery. 4. Remove the fuel hose and clamp (item 2 in Figure 10) and disconnect the fuel hose at the fuel pump. Drain any fuel trapped in the fuel filter and hose into a suitable container. 5.
Installing the Engine IMPORTANT Ensure that all parts removed from the engine during maintenance are installed. 1. If the exhaust manifold was removed during maintenance, use new exhaust gaskets and tighten the manifold screws from 20 to 22 N·m (170 to 200 in-lb). g206388 Figure 11 1. Rubber coupler 5. Spacer (4 each) 2. Pump hub 6. Flat washer (4 each) 10. Square key – pump 3. Engine hub 7. Cap screw (2 each) 11. Square key – engine 4. Set screw (4 each) 8. Lock nut (2 each) 9.
Installing the Engine (continued) IMPORTANT Make sure to not damage engine, fuel hoses, hydraulic hoses, electrical harnesses, control cables or other parts while installing the engine. 3. Move the engine assembly into position and loosely install the three (3) engine mount cap screws (item 31 Figure 10) with flat washers, spacers (bottom engine mounts only) and flange nuts. 4. Secure the pump assembly to the adapter plate with two (2) cap screws and hardened washers. 5.
Evaporative Control System g206712 Figure 12 1. Carbon canister 8. Vent hose (canister to engine) 15. Vent hose (filter to tee) 2. Tie wrap (2 each) 9. Check valve (2 each) 16. Vent hose (canister to tee) 3. Cap screw (2 each) 10. Hose clamp (5 each) 17. Vent hose (tank to canister) 4. Bracket 11. Hose clamp (3 each) 18. Fresh air filter 19. Clamp 5. Spacer (2 each) 12. Barb fitting (2 each) 6. Hose clamp (2 each) 13. Vent hose (tee to engine) 7. Convoluted tubing 14.
Evaporative Control System (continued) The carbon canister is mounted on the hydraulic tank. The evaporative system includes two (2) connections to the engine: one to the engine purge valve near the intake manifold and one to the air cleaner. The evaporative control system vent hose assembly between the engine purge valve and the carbon canister (item 8 Figure 12) and the vent hose between the fresh air filter and the tee fitting (item 15 Figure 12) include check valves to control the direction of flow.
Chapter 4 Hydraulic System Table of Contents Specifications ....................................................................................................................................... 4–3 Hydraulic System ............................................................................................................................... 4–3 General Information ..............................................................................................................................
Filtering the Closed-Loop Traction Circuit ........................................................................................ 4–76 Priming the Hydraulic Pumps ........................................................................................................... 4–78 Charging the Hydraulic System........................................................................................................ 4–79 Gear Pump......................................................................................
Specifications Hydraulic System Item Description Piston (traction) pump (P1) Hydro Gear variable displacement piston pump Maximum pump displacement Gear pump 21.8 cc (1.33 in³/rev) per revolution Casappa two section, positive displacement gear type pump Front section (P2) displacement 9.5 cc (0.58 in³) per revolution Rear Section (P3) displacement 5.4 cc (0.33 in³) per revolution Wheel motors Parker TF Series orbital rotor motor, 169 cc (10.
General Information Traction Unit Operator’s Manual The traction unit and cutting unit Operator’s Manuals provide information regarding the operation, general maintenance and maintenance intervals for the Greensmaster 3120 machine. Refer to these publications for additional information when servicing the machine. Relieving Pressure from the Hydraulic System Release all the pressure in the hydraulic system before performing any work on the hydraulic system.
Towing the Traction Unit In case of emergency, the traction unit 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. Drive system damage may occur it the machine is towed too fast of for too far. If the machine must be moved a considerable distance, transport it on a truck or trailer. g212325 Figure 13 1. By-pass valve 1.
Traction Circuit (Closed Loop) Component Failure The traction circuit of the Greensmaster 3120 machine is a closed loop circuit which includes the piston (traction) pump and two (2) wheel motors. If a component in the traction circuit should fail, unwanted material and contamination from the damaged component will circulate throughout the traction circuit. This contamination can damage other components in the circuit.
Hydraulic Hoses The hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions, in addition to mishandling during operation and maintenance. These conditions can cause damage to the hose or deterioration to the hose material. Some hoses are more susceptible to these conditions than others. Examine all of the hydraulic hoses of the machine frequently and repair or replace them as necessary.
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) g212099 Figure 14 1. Tube or hose 2. Swivel nut 3. 4. O-ring Fitting body 1. Ensure that all the threads, the sealing surfaces of the hose/tube, and the fitting are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the face seal O-ring when you open the connection. Ensure that the O-ring is installed and correctly seated in the groove of the fitting.
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (continued) Hose/Tube Installation Torque Table Fitting Dash Size Hose/Tube Side Thread Size (inch(es)—threads per inch) Installation Torque 4 9/16—18 25 to 29 N∙m (18 to 22 ft-lb) 6 11/16—16 37 to 44 N∙m (27 to 33 ft-lb) 8 13/16—16 51 to 63 N∙m (37 to 47 ft-lb) 10 1—14 82 to 100 N∙m (60 to 74 ft-lb) 12 1–3/16—12 116 to 142 N∙m (85 to 105 ft-lb) 16 1–7/16—12 150 to 184 N∙m (110 to 136 ft-lb) 20 1–11/16—12 190 to 233 N∙m (140 to 1
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) Installing a Non-Adjustable Fitting g212226 Figure 16 1. Fitting 2. O-ring 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the O-ring when you open the connection. 3. Lightly lubricate the O-ring with clean hydraulic fluid.
Installing an Adjustable Fitting g212224 Figure 17 1. Locknut 2. Back-up washer 3. O-ring g212225 Figure 18 1. Step 1: clearance the lock nut 3. Step 3: align the fitting 2. Step 2: seat the back-up washer 4. Step 4: tighten the lock nut 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the O-ring when you open the connection. 3.
Installing an Adjustable Fitting (continued) A. Hold the fitting in the correct alignment with a wrench and use a torque wrench and tighten the lock nut to the recommended torque value within the specified range of torque values; refer to the Fitting Installation Torque Table (page 4–12). This tightening procedure requires a drive-adapter wrench (e.g., crowfoot wrench); refer to Calculating the Torque Values When Using a Drive-Adapter Wrench (page 2–4). B.
Hydraulic Schematics Larger versions of the hydraulic schematics can be found in Appendix A (page A–1) g212370 Figure 19 Greensmaster 3120 17230SL Rev D Page 4–13 Hydraulic System: Hydraulic Schematics
g213537 Figure 20 Hydraulic System: Hydraulic Schematics Page 4–14 Greensmaster 3120 17230SL Rev D
Hydraulic Flow Diagrams Traction Circuit The piston (traction) pump is driven directly by the engine. The traction circuit of the hydraulic system acts essentially as a closed loop. With the engine running and the traction pedal in the neutral position, the swash plate of the piston pump is held in the vertical position, providing no flow in either direction and the machine remains stationary. A pair of 0.
Reverse Direction (continued) g213626 Figure 21 Hydraulic System: Hydraulic Flow Diagrams Page 4–16 Greensmaster 3120 17230SL Rev D
Lift Circuit A tandem gear pump is directly coupled to the piston (traction) pump. The rear gear pump section (P3) supplies hydraulic flow for the steering circuit (priority flow), for raising and lowering the cutting units and for the traction system charge circuit. The gear pump takes its suction from the hydraulic tank through a suction strainer. Maximum circuit pressure of 7998 kPa (1160 PSI) is limited by the relief valve located in the steering valve.
Lower Cutting Units (continued) g213625 Figure 22 Hydraulic System: Hydraulic Flow Diagrams Page 4–18 Greensmaster 3120 17230SL Rev D
Lower Cutting Units (continued) g213622 Figure 23 Greensmaster 3120 17230SL Rev D Page 4–19 Hydraulic System: Hydraulic Flow Diagrams
Mow Circuit The tandem gear pump is directly coupled to the piston (traction) pump. The front gear pump section (P2) supplies fluid flow to the mower manifold and to the cutting reel motors. The gear pump takes its suction directly from the hydraulic tank. Mow (machines without backlap) With the engine running and the function control and joystick levers positioned so the reels will not turn; refer to the traction unit Operator’s Manual, solenoid relief valve (S1) in the mower manifold is de-energized.
Mow (machines without backlap) (continued) g213623 Figure 24 Greensmaster 3120 17230SL Rev D Page 4–21 Hydraulic System: Hydraulic Flow Diagrams
Mow (machines with backlap) With the engine running and the function control and joystick levers positioned so the reels will not turn (refer to the traction unit Operator’s Manual), solenoid relief valve (S1R1) in the mower manifold is de-energized. The de-energized (S1R1) by-passes flow from the front gear pump section to the hydraulic filter and tank. Additionally, pilot operated relief valve (PRV) will remain seated to prevent the reel motors (and reels) from rotating.
Backlap (continued) g213624 Figure 25 Greensmaster 3120 17230SL Rev D Page 4–23 Hydraulic System: Hydraulic Flow Diagrams
Steering Circuit The tandem gear pump is directly coupled to the piston (traction) pump. The rear gear pump section (P2) supplies hydraulic flow for the steering circuit (priority flow), for raising and lowering the cutting units and for the traction charge circuit. The gear pump takes its suction from the hydraulic tank. Maximum circuit pressure of 7,998 kPa (1160 PSI) is limited by the relief valve located in the steering unit.
Left Turn (continued) g213627 Figure 26 Greensmaster 3120 17230SL Rev D Page 4–25 Hydraulic System: Hydraulic Flow Diagrams
Special Tools You can order these special tools from your Toro Distributor. Some tools are also available from a local tool supplier. Hydraulic Pressure Testing Kit Toro Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick disconnect fittings are provided to attach directly to the mating fittings on the machine test ports without the tools. A high-pressure hose is given for remote readings.
Hydraulic Test Fitting Kit Toro Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system.
O-Ring Kit Toro Part No. 117-2727 This kit includes O-rings in a variety of sizes for the face seal and port seal hydraulic connections. To help prevent a hydraulic leak, replace the O-rings when you open the hydraulic connection. Hydraulic Hose Kit Toro Part No. TOR6007 This kit includes the fittings and hoses that are used to connect high flow hydraulic filter kit (TOR6011) to the machine hydraulic traction system components.
High Flow Hydraulic Filter Kit Toro Part Number: TOR6011 The high flow hydraulic filter kit is designed with large flow (150 L/minute or 40 gallons/minute) and high pressure (34,500 kPa or 5,000 psi) capabilities. This kit provides for bi-directional filtration which prevents filtered unwanted material from entering into the circuit regardless of the flow direction.
Troubleshooting The following chart contains information to troubleshoot hydraulic circuit problems. There can be more than one cause for a machine malfunction. Refer to Testing the Hydraulic System (page 4–35) for specific hydraulic test procedures. General Hydraulic System Problems Problem Possible Causes The hydraulic fluid is leaking from the system. The fitting(s), hose(s), or tube(s) are loose or damaged. The O-ring(s) or seal(s) are missing or damaged.
Traction Circuit Problems Problem Possible Causes The traction response is sluggish. The hydraulic fluid is very cold. The transmission bypass valve(s) is open or damaged. The brake is dragging or binding. The traction pump relief valves are leaking or damaged. The charge pressure is low; refer to Charge Pressure Relief Valve Pressure Test in the Testing section of this chapter. The traction pump or wheel motor(s) is worn or damaged.
Mow Circuit Problems Problem Gear pump (P2) is noisy (cavitation). Possible Causes Hydraulic tank fluid level is low (other hydraulic circuits affected as well). Hydraulic pump suction line is restricted. Hydraulic pump suction line has an air leak. Cutting reel motors will not turn. Machines without Backlap Mower manifold relief valve R1 is stuck open. An electrical problem exists with solenoid valve S1(see Chapter 5 - Electrical System).
Lift/Lower Circuit Problems Problem Gear pump (P1) is noisy (cavitation). Possible Causes Hydraulic tank fluid level is low (other hydraulic circuits affected as well). Hydraulic pump suction line is restricted. Hydraulic pump suction line has an air leak. Cutting units will not lift or lift slowly. Engine speed is too low. Hydraulic tank fluid level is low. Lift cylinder linkage is binding or broken. Lift cylinder bushings are binding or worn.
Steering Circuit Problems Problem Possible Causes Steering wheel is hard to turn. Oil supply to the steering control valve is insufficient (traction charge and lift circuits affected as well). Emergency steering ball in steering control valve is missing or damaged. Driving in a straight line is difficult . 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.
Testing the Hydraulic System The most effective procedure to isolate the problems in the hydraulic system is to use hydraulic test equipment, such as pressure gauges and flow meters in the circuits during different operational checks; refer to Testing the Hydraulic System (page 4–35). WARNING Opening the hydraulic system without releasing pressure from the system will cause the hydraulic fluid to escape, causing possible injury.
IMPORTANT Use 2 people to perform all the tests, with 1 person in the operators seat and the other available to read and record the test results. 1. Use the Hydraulic Schematic, Hydraulic Flow Diagrams and the Troubleshooting section found in this Chapter to assist with problem identification and solution. 2. Always wear the eye protection when you performing hydraulic system tests. 3. Clean the machine fully before you disconnect or disassemble the hydraulic components.
IMPORTANT Hydraulic component output volume relates directly to engine RPM. For every 100 engine rpm the following component output volumes will change by the volume listed. • Traction Pump: 100 engine RPM = 2.03 LPM (0.54 GPM or 68.7 oz.) of hydraulic fluid displaced per minute • Gear Pump (P1): 100 engine RPM = 0.95 LPM (0.25 GPM or 32.1oz.) of hydraulic fluid displaced per minute. • Gear Pump (P2): 100 engine RPM = 0.54 LPM (0.14 GPM or 18.3 oz.) of hydraulic fluid displaced per minute 6.
Traction Circuit Testing – Charge Pressure Test g216034 Figure 27 Traction Circuit Testing – Charge Pressure Test (machines without backlap) Hydraulic System: Testing the Hydraulic System Page 4–38 Greensmaster 3120 17230SL Rev D
Traction Circuit Testing – Charge Pressure Test (continued) g230546 Figure 28 Traction Circuit Testing – Charge Pressure Test (machines with backlap) The charge pressure test is the first in a series of tests recommended to determine traction circuit performance. A charge pressure drop of more than 20% indicates an internal leak in the traction pump.
Traction Circuit Testing – Charge Pressure Test (continued) • Phototach (non−contact tachometer). • Hydraulic test fittings (early machines with backlap): swivel tee p/n 340-104, test connector p/n 100-5610, dust cap p/n 354-79. 1. Park machine on a level surface. Make sure engine is OFF. 2. Read and adhere to the information provided in Testing the Hydraulic System (page 4–35). 3. Make sure that traction pedal is adjusted to the neutral position. g216685 Figure 29 (machines without backlap) 1.
Traction Circuit Testing – Charge Pressure Test (continued) g230575 Figure 30 (early machines with backlap) 1. Left step 3. 2. Mower manifold PT port Swivel tee fitting and test connector g234335 Figure 31 3. 1. Left step 2. Mower manifold PT port Test connector 4.
Traction Circuit Testing – Charge Pressure Test (continued) • For machines without backlap, connect a pressure gauge with hydraulic hose to the test connector in the G3 port of the mower manifold; refer to Figure 29. • For early machines with backlap, disconnect the hose from the elbow at the PT port of the mower manifold and install a swivel tee and test connector fitting. Connect a pressure gauge with hydraulic hose to the newly installed test connector; refer to Figure 30.
Traction Circuit Testing – Charge Pressure Test (continued) A. The charge relief valve (CV) in the mower manifold is faulty. Repair or replace the charge relief valve (CV); refer to Servicing the Mower Manifold (page 4–99). B. Gear pump (P3) is faulty (steering/lift circuit performance will also be affected). Test gear pump (P3) flow (see Gear Pump (P3) Flow Test in this chapter). 13.
Traction Circuit Testing – Wheel Motor Efficiency Test g216035 Figure 33 Traction Circuit Testing – Wheel Motor Efficiency Test Wheel motor efficiency is the second in a series of tests recommended to determine traction circuit performance. Hydraulic fluid flow of 2.4 LPM (0.
Traction Circuit Testing – Wheel Motor Efficiency Test (continued) GPM) or more through a single stationary wheel motor under load indicates an internal leak in the wheel motor. A worn wheel motor is less efficient. Eventually, enough fluid by−pass will cause the wheel motor to stall under heavy load conditions. Continued operation can generate excessive heat, cause damage to seals and other components in the hydraulic system, and affect overall machine performance.
Traction Circuit Testing – Wheel Motor Efficiency Test (continued) 7. Disconnect hydraulic lines from front wheel motor that is not being tested. Cap disconnected hydraulic lines and plug ports in wheel motor to prevent contamination. 8. Chock front wheel being tested to prevent wheel rotation. 9. Start engine. Move throttle to full speed (2850 ± 50 RPM). 10. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10 minutes. 11.
Traction Circuit Testing – Traction Pump (P1) Flow and Relief Pressure Test g216104 Figure 35 Traction Circuit Testing – Traction Pump (P1) Flow and Relief Pressure Test Greensmaster 3120 17230SL Rev D Page 4–47 Hydraulic System: Testing the Hydraulic System
Traction Circuit Testing – Traction Pump (P1) Flow and Relief Pressure Test (continued) The traction pump flow test is the third in a series of tests recommended to determine traction circuit performance. The final traction circuit test is verifying the traction pump relief valve operation. The traction pump flow test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 12% indicates an internal leak or malfunctioning relief valve in the traction pump.
Traction Circuit Testing – Traction Pump (P1) Flow and Relief Pressure Test (continued) 5. Disconnect hose from traction pump “A” port; refer to Figure 36. 6. Install tester in series with the pump and the disconnected hose. Make sure the tester is installed in the correct flow direction and the tester flow control valve is fully open. 7. Start engine. Move throttle to full speed (2850 ± 50 RPM). 8.
Cutting Unit Circuit Testing – Cutting Unit Motor Efficiency/Case Drain Test g216832 Figure 37 Cutting Unit Circuit Testing – Cutting Unit Motor Efficiency/Case Drain Test 1. Return hose 2. Case drain hose The cutting unit motor efficiency/case drain test is the first in a series of tests recommended to check cutting unit circuit performance.
Cutting Unit Circuit Testing – Cutting Unit Motor Efficiency/Case Drain Test (continued) a cutting unit motor can wear internally. This test measures case drain volume while restricting flow across the motor ports. Case drain volume under load of more than 9% of total motor flow indicates the gears and wear plates in the motor have worn. A worn motor may by−pass hydraulic fluid to its case drain causing the motor to be less efficient.
Cutting Unit Circuit Testing – Cutting Unit Motor Efficiency/Case Drain Test (continued) 11. Move the function control lever to the MOW position, engage the cutting units and slowly close tester flow control valve until a pressure of 13789 kPa (2000 PSI) is obtained. 12. Hold 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. 13.
Cutting Unit Circuit Testing – Relief Valve Test g216863 Figure 38 Cutting Unit Circuit Testing – Relief Valve Test Greensmaster 3120 17230SL Rev D Page 4–53 Hydraulic System: Testing the Hydraulic System
Cutting Unit Circuit Testing – Relief Valve Test (continued) Cutting unit circuit pressure and relief valve operation is the first in a series of tests recommended to check cutting deck circuit performance. The results from this test will help determine which component(s) are the cause of cutting unit performance issues. Note: For machines with backlap, the relief valve is part of the solenoid valve (S1R1).
Cutting Unit Circuit Testing – Relief Valve Test (continued) 7. Start engine. Move throttle to full speed (2850 ± 50 RPM). 8. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10 minutes. 9. Verify and record engine speed with a phototach. CAUTION Use extreme caution when performing this test. The cutting unit reels will be rotating during the test. 10. Engage the cutting units and record the unrestricted cutting unit pressure. 11.
Cutting Unit Circuit Testing – Gear Pump (P2) Flow Test g216909 Figure 40 Cutting Unit Circuit Testing – Gear Pump (P2) Flow Test Hydraulic System: Testing the Hydraulic System Page 4–56 Greensmaster 3120 17230SL Rev D
Cutting Unit Circuit Testing – Gear Pump (P2) Flow Test (continued) The gear pump (P2) flow test is the last in a series of tests recommended to determine cutting unit circuit performance. This test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 15% indicates the gears and wear plates in the pump have worn. A worn pump will by−pass hydraulic fluid and make the pump less efficient.
Cutting Unit Circuit Testing – Gear Pump (P2) Flow Test (continued) CAUTION Do not engage the cutting units when performing this test. 6. Start engine. Move throttle to full speed (2850 ± 50 RPM). 7. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10 minutes. 8. Verify and record engine speed with a phototach. 9. Record tester pressure and flow reading with pump At No Load. Unrestricted pump output should be approximately 25.7 LPM (6.8 GPM).
Steering/Lift Circuit Testing – Gear Pump (P3) Flow and Circuit Relief Valve Test g217053 Figure 42 Steering/Lift Circuit Testing – Gear Pump (P3) Flow and Circuit Relief Valve Test Greensmaster 3120 17230SL Rev D Page 4–59 Hydraulic System: Testing the Hydraulic System
Steering/Lift Circuit Testing – Gear Pump (P3) Flow and Circuit Relief Valve Test (continued) Gear pump (P3) is designed to satisfy both steering cylinder and lift cylinder needs simultaneously (at full speed throttle). The Gear Pump (P3) Flow Test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 15% indicates the gears and wear plates in the pump have worn.
Steering/Lift Circuit Testing – Gear Pump (P3) Flow and Circuit Relief Valve Test (continued) g216910 Figure 43 1. Gear pump section (P3) 2. Hydraulic hose 4. Disconnect hose connection on the bottom of gear pump (P3); refer to Figure 43. 5. Install tester between the gear pump and the disconnected hose. Make sure the tester is installed in the correct flow direction and the tester flow control valve is fully open. 6. Start engine. Move throttle to full speed (2850 ± 50 RPM). 7.
Steering/Lift Circuit Testing – Gear Pump (P3) Flow and Circuit Relief Valve Test (continued) C. Record tester pressure and flow readings under load. D. Open flow control valve fully. E. The under load test flow reading (step B) should not drop more than 15% when compared to the pump at no load test flow reading (step A).
Steering/Lift Circuit Testing – Lowering Cutting Units Relief Valve Test g217181 Figure 44 Steering/Lift Circuit Testing – Lowering Cutting Units Relief Valve Test Greensmaster 3120 17230SL Rev D Page 4–63 Hydraulic System: Testing the Hydraulic System
Steering/Lift Circuit Testing – Lowering Cutting Units Relief Valve Test (continued) Special Equipment Required: • Flow Meter with Pressure Gauge that has at least a 16 LPM (5 GPM) capacity. • Phototach (non−contact tachometer). 1. Park machine on a level surface with the cutting units lowered. Make sure engine is OFF and the parking brake is engaged. 2. Read and adhere to the information provided in Testing the Hydraulic System (page 4–35). 3. Measure and record the system charge pressure (without load).
Steering/Lift Circuit Testing – Lowering Cutting Units Relief Valve Test (continued) Note: Lowering the cutting units is an electrically timed function and automatically turns off after approximately six (6) seconds. If the relief pressure cannot be determined within the six (6) second time frame, repeat the test procedure. 10. Watch pressure gauge carefully while moving the joystick control lever to the LOWER position and note pressure that relief valve opens.
Steering/Lift Circuit Testing – Lowering Cutting Units Relief Valve Test (continued) g217170 Figure 46 1. Mower manifold assembly (machines without backlap) 2. Mower manifold assembly (machines with backlap) 3. Lowering cutting units relief valve (R2) 12. If lowering cutting units relief valve pressure is incorrect, adjust the mower manifold relief valve (R2) (refer to Figure 46) and retest. Refer to Adjusting Relief Valves (page 4–70) in this Chapter for additional information.
Steering/Lift Circuit Testing – Steering Control Valve and Steering Cylinder Test g217182 Figure 47 Steering/Lift Circuit Testing – Steering Control Valve and Steering Cylinder Test Unit steering performance will be affected by incorrect rear tire pressure, binding in the hydraulic steering cylinder, and/or binding of the steering fork assembly. Make sure that these conditions are checked and functioning properly before proceeding with any steering system hydraulic testing. 1.
Steering/Lift Circuit Testing – Steering Control Valve and Steering Cylinder Test (continued) B. Steering wheel movements should be followed immediately by a corresponding rear wheel movement without the steering wheel continuing to turn. 4. Stop unit with the engine running. Turn steering wheel with small quick movements in both directions. Let go of the steering wheel after each movement. A. The steering control valve should respond to each steering wheel movement. B.
Steering/Lift Circuit Testing – Steering Control Valve and Steering Cylinder Test (continued) 6. Greensmaster 3120 17230SL Rev D If a steering problem exists and the steering cylinder passes testing, perform Steering/Lift Circuit Testing – Gear Pump (P3) Flow and Circuit Relief Valve Test (page 4–59) to make sure the steering control valve and cylinder are receiving adequate fluid flow and pressure.
Adjustments Adjusting Relief Valves The mower manifold includes one or more adjustable relief valves. Use the following procedure if adjusting to a relief valve is necessary. Note: Do not remove the relief valve from the manifold for adjustment. WARNING Never adjust the relief valve with the hydraulic system pressurized. Hydraulic fluid 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.
Service and Repairs General Precautions for Removing and Installing the Hydraulic System Components Before Repairing or Replacing the Components 1. Before removing any parts from the hydraulic system, park the machine on a level surface, lower the cutting units, turn the engine OFF, set the parking brake, and remove the key from the key switch. 2. Clean the machine before you disconnect, remove, or disassemble the hydraulic components.
After Repairing or Replacing the Components (continued) (page 4–8) and Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 4–10). 5. After you complete the repairs, check the control linkages or cables for proper adjustment, binding, or broken parts. 6. Whenever hydraulic fluid has been drained from the pumps (system drain, flush, or pump removal/installation) it is important to properly prime the hydraulic pumps, refer to Priming the Hydraulic Pumps (page 4–78). 7.
Checking the Hydraulic Lines and Hoses WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid. • Use a piece of cardboard or paper to find hydraulic leaks.
Flushing the Hydraulic System IMPORTANT If a component failure occurs in the traction circuit; refer to Filtering the Closed-Loop Traction Circuit (page 4–76) for additional information. IMPORTANT Flush the hydraulic system whenever there is a severe component failure or the system is contaminated (for example, the fluid appears milky, black, or contains metal particles). 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine.
Flushing the Hydraulic System (continued) g217354 Figure 50 1. 2. Gear pump Inlet hose 3. Clean area around gear pump and pump inlet hose; refer to Figure 50. Clamp pump inlet hose closed and remove hose from gear pump. Release clamp and drain tank into a suitable container. 4. Drain hydraulic system hoses, tubes, lift cylinders and other components from low points in the system. 5. Inspect and clean hydraulic tank; refer to Hydraulic Tank (page 4–137). 6.
Filtering the Closed-Loop Traction Circuit Filtering of a closed−loop hydraulic system after a major component failure (e.g. traction (piston) pump or wheel motor) is required to prevent debris from transmitting throughout the system. If a filtering tool is not used (to ensure system cleanliness), repeat failures and subsequent damage to other hydraulic components in the system will occur.
Filtering the Closed-Loop Traction Circuit (continued) g217377 Figure 52 1. Right side wheel motor 2. Hydraulic tube B. If the right wheel motor was replaced, remove the wheel and thoroughly clean the junction at both ends of the upper hydraulic tube and remove the tube; refer toFigure 52. g217376 Figure 53 1. 2. Left side wheel motor Hydraulic hose C.
Filtering the Closed-Loop Traction Circuit (continued) 6. Fill the hydraulic tank with the correct type and quantity of new hydraulic fluid; refer to the traction unit Operator’s Manual. 7. Start engine and run at low idle speed. Check for and correct any hydraulic leaks before proceeding. CAUTION Use extreme caution when performing this test. The traction unit wheels will be rotating during the test. IMPORTANT While engaging the traction circuit, monitor the indicator on the high flow hydraulic filter.
Priming the Hydraulic Pumps (continued) IMPORTANT If the traction pump was rebuilt or replaced, make sure the traction pump housing is at least half full of clean hydraulic fluid after installation. 1. Make sure all hydraulic connections and lines are secured tightly. 2. Check the hydraulic-fluid level in the hydraulic tank and add correct type and quantity of fluid if necessary; refer to the traction unit Operator’s Manual. 3. Check control linkage for proper adjustment, binding or broken parts. 4.
Charging the Hydraulic System (continued) IMPORTANT Check hydraulic tank fluid level frequently while charging the system and add fluid as necessary. 7. Make sure traction pedal is in neutral. Start the engine and let it idle at low speed. Note: The hydraulic pumps should pick up hydraulic fluid and fill the hydraulic system. If there is no indication of the system filling within 30 seconds, stop the engine and determine the cause. 8. After the hydraulic system starts to show signs of filling: A.
Gear Pump g217547 Figure 54 1. Traction pump assembly 5. Inlet hose 2. O-ring 6. Socket head screw (2 each) 3. Barb fitting 7. 4. Hose clamp 8. 9. Elbow fitting 10. Hydraulic hose Hardened washer (2 each) 11. Hydraulic hose Gear pump 12.
Removing the Gear Pump 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. 2. Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 4–71). 3. Pinch the pump inlet hose closed with a clamp to prevent draining the hydraulic tank prematurely. 4. Remove the inlet hose from the gear pump and drain the hydraulic tank into a suitable container. 5.
Servicing the Gear Pump g217545 Figure 55 1. O-ring Dowel pin 17. Idler gear 2. Front cover 10. O-ring 18. Thrust plate 3. Back-up seal 11. Housing 19. O-ring 4. Pressure seal 12. Coupler 20. End cover 5. Thrust plate 13. Back-up seal 21. Socket head screw (4 each) 6. Drive shaft 14. Pressure seal 22. Washer (4 each) 7. Idler gear 15. Thrust plate 8. Thrust plate 16. Drive gear Greensmaster 3120 17230SL Rev D 9.
Disassembling the Gear Pump Disassemble gear pump for cleaning, inspection and seal replacement only. Individual gears, housings and thrust plates are not available separately. If internal components are worn or damaged, the gear pump must be replaced as a complete assembly. 1. Plug pump ports and thoroughly clean exterior of pump with cleaning solvent. Make sure work area is clean. g217546 Figure 56 1. “V” mark 2.
Disassembling the Gear Pump (continued) 8. Clean all parts. Check all components for burrs, scoring, nicks and other damage. 9. Replace the entire pump assembly if any pump components are excessively worn or scored. Inspecting the Gear Pump 1. Remove any nicks and burrs from all parts with emery cloth. CAUTION Use goggles or other appropriate eye protection when using compressed air for drying parts. 2. Clean all parts with solvent. Dry all parts with compressed air. g217568 Figure 57 1.
Assembling the Gear Pump 1. Apply clean hydraulic fluid to all parts before assembling. Note: Pressure seals and back-up seals fit in grooves machined into the thrust plates. Body O-rings fit in grooves machined into housings. 2. Assemble pump sections starting at front cover end. Apply grease or petroleum jelly to new section seals to hold them in position during gear pump assembly. 3. After pump has been assembled, tighten socket head screws by hand. Rotate the drive shaft to check for binding.
Traction Pump g217579 Figure 58 1. Traction pump 12. Flat washer (2 each) 23. Hardened washer (2 each) 2. Traction cable 13. Cable support 24. Hex nut (2 each) 3. Cable adjuster jam nuts 14. Straight fitting 25. Pump hub 4. Ball joint 15. Hydraulic tube 26. Spacer (2 each) 5. Flat washer (2 each) 16. Straight fitting 27. Adapter plate 6. Flat washer 17. Hydraulic hose 28. Rubber coupler 7. Cap screw 18. Elbow fitting 29. Flat washer (2 each) 8.
Removing the Traction Pump (continued) 2. Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 4–71). 3. Remove the gear pump; refer to Removing the Gear Pump (page 4–82). 4. Disconnect the traction control cable ball joint (item 4 in Figure 58) from the neutral arm. Loosen the cable adjusting jam nuts and position the traction cable away from the pump assembly. 5. Disconnect the hydraulic hoses from the traction pump.
Installing the Traction Pump (continued) 5. Make sure two (2) spacers (item 26 in Figure 58) are fit into the holes of the rubber coupler and secure the pump hub to the rubber coupler with two (2) hex nuts, flat washers, and lock nuts. 6. Connect the traction control cable: A. Secure the traction cable ball joint to the cable bracket. B. Secure the control cable to the cable support with the jam nuts on the cable. Make sure that a washer is positioned on each side of the cable support. 7.
Servicing the Traction Pump g217732 Figure 59 1. Pump shaft kit 2. Coupling 9. 10. Guide 17. O-ring Front housing kit 18. Relief valve kit (2 each) 3. Retaining ring 11. Thrust bearing 19. Plug, 5/16 SAE 4. Washer 12. End cap kit 20. Bypass valve 5. Seal 13. Pin (2 each) 21. Plug, 3/4-16 (2 each) 6. Heavy-duty return kit 14. O-ring 22. Adapter plate 7. Trunnion seal kit 15. Swashplate 23. Flange head screw (4 each) 8. Trunnion arm 16. Cylinder block kit 24.
Servicing the Traction Pump (continued) The traction pump is a Hydro-Gear® PY series pump. For traction pump repair information, see the Hydro-Gear P Series Hydrostatic Pumps Service and Repair Manual at the end of this chapter. Replacement pump components are available from your Authorized Toro Distributor; refer to the traction unit Parts Catalog. Wheel Motors g217751 Figure 60 (left wheel motor shown) 1. Wheel motor 4. Lock nut (4 each) 2. Brake bracket 5. elbow fitting (2 each) 3.
Removing the Wheel Motors 1. Park the machine on a level surface. Lower the cutting units, stop the engine and remove the key from the ignition switch. 2. Remove the front wheel and brake assembly; refer to Removing the Front Wheel and Brake Assembly (page 6–4). 3. Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 4–71). 4. Disconnect the hydraulic hoses (left wheel motor) or remove the hydraulic tubes (right wheel motor).
Servicing the Wheel Motor g217713 Figure 61 1. Dirt seal 9. Thrust bearing 17. Woodruff key 2. Bearing 3. Housing 10. Bearing 18. Wear plate 11. Coupling shaft 19. Rotor 4. Back-up washer 12. Thrust bearing 20. Vane 5. Seal ring (4 each) 13. Drive link 21. Stator 6. Back-up washer 14. Cap screw (7 each) 22. Manifold 7. Inner seal 15. Commutator seal 23. Commutator ring 8. Thrust washer 16. Commutator 24.
Servicing the Wheel Motor (continued) IMPORTANT Due to the predominant direction of rotation (forward), the right and left wheel motors are not interchangeable. For wheel motor repair information, see the Parker Torqmotor™ Service Procedure (TC, TB, TE, TJ, TF, TG, TH and TL Series) at the end of this chapter. Replacement motor components are available from your Authorized Toro Distributor; refer to the traction unit Parts Catalog.
Mower Manifold g217968 Figure 62 (machines without backlap) 1. Manifold assembly Hydraulic hose, from gear pump P2 19. Elbow fitting 2. Elbow fitting 20. Elbow fitting (3 each) 3. Hydraulic hose, lift cylinder #1 rod 11. end Test fitting 12. 10. Hydraulic hose, to charge filter 21. 4. Cap 13. Elbow fitting (2 each) 22. Hydraulic hose, lift cylinder #1 cap end Hydraulic tube, to return filter 5. Straight fitting (2 each) 14. Hydraulic hose, from steering control valve T port 23.
g217967 Figure 63 (early machines with backlap) 1. Manifold assembly 2. 10. Hydraulic hose, to charge filter 19. Elbow fitting (2 each) 20. 3. Hydraulic hose, lift cylinder #1 rod 11. end Straight fitting (2 each) 12. Hydraulic hose, lift cylinder #1 cap end Hydraulic tube, to return filter Hydraulic hose, from steering control valve T port 21. Elbow fitting 4. Hydraulic tube, from reel motor #1 13. 5. Elbow fitting 14. Hydraulic hose, lift cylinder #3 rod 22. end Elbow fitting 23. 6.
g234336 Figure 64 (later machines with backlap) 1. Manifold assembly 2. 10. Hydraulic hose, to charge filter 19. Elbow fitting (2 each) 20. 3. Hydraulic hose, lift cylinder #1 rod 11. end Straight fitting (2 each) 12. Hydraulic hose, lift cylinder #1 cap end Hydraulic tube, to return filter Hydraulic hose, from steering control valve T port 21. Elbow fitting 4. Hydraulic tube, from reel motor #1 13. 5. Elbow fitting 14. Hydraulic hose, lift cylinder #3 rod 22. end Elbow fitting 23. 6.
Removing the Mower Manifold 1. Park the machine on a level surface. Lower the cutting units, stop the engine, engage the parking brake and remove the key from the ignition switch. 2. Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 4–71). 3. Label all hydraulic connections and electrical connections for proper assembly. 4. Disconnect the wire harness connectors from the manifold solenoid coils.
Servicing the Mower Manifold g218159 Figure 65 (machines without backlap) 1. Manifold block 9. Solenoid cartridge valve S2 17. SAE Plug #4 (2 ea) 2. Solenoid coil (2 each) 10. Zero leak plug #6 (8 each) 18. Orifice 0.055 inch (2 each) 3. Solenoid coil (2 each) 11. Check valve CV 19. Coil nut 4. Coil nut (2 each) 12. Relief valve R1 20. Zero leak plug #8 5. Coil nut 13. Zero leak plug #4 (6 each) 21. Flow control valve FC 6. Solenoid cartridge valve S4 14.
g218160 Figure 66 (machines with backlap) 1. Manifold block 12. Coil nut 23. Backlap switch N.O. 2. Solenoid cartridge valve S4 13. Solenoid coil (2 each) 24. O-ring 3. Solenoid coil (2 each) 14. Solenoid relief valve S1R1 25. Pin 4. Coil nut (2 each) 15. Pilot operated relief valve PRV 26. Ball 5. Relief valve R2 16. Spool valve 27. Zero leak plug #8 (2 each) 6. Solenoid cartridge valve S3 17. Pilot piston 28. Flow control valve FC 7. Zero leak plug #6 (5 each) 18.
The ports on the mower manifold are marked for easy identification of components. Example: FC1 is the flow control valve and P1 is the gear pump connection port; refer to the Hydraulic Schematics in Appendix A (page A–1) to identify the function of the hydraulic lines and cartridge valves at each port location). The mower manifold 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.
Cartridge Valves Note: For solenoid style cartridge valve coil testing information; refer to Testing a Solenoid Valve Coil (page 5–27). 1. Park the machine on a level surface. Lower the cutting units, stop the engine, engage the parking brake and remove the key from the ignition switch. 2. Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 4–71). 3.
Cartridge Valves (continued) 8. Install the cartridge valve: A. Lubricate the new O-rings and the backup rings of the seal kit with clean hydraulic fluid and install them on the cartridge valve. The O-rings and the 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.
Rotary Valve (machines with backlap) g218000 Figure 67 1. Handle base 5. Bushing 9. Lip seal 2. Handle cap 6. Set screw (2 each) 10. Sleeve bearing 3. Detent pin 7. Set screw (2 each) 11. Flow control cartridge valve 4. Compression spring 8. Screw 1. Park the machine on a level surface. Lower the cutting units, stop the engine, engage the parking brake and remove the key from the ignition switch. 2.
Rotary Valve (machines with backlap) (continued) IMPORTANT Carefully handle the rotary valve. Slight bending or distortion of the stem tube can cause binding and malfunction. When removing the rotary valve from the manifold, ensure that the deep well socket fully engages the valve base. E. Remove the rotary valve from the manifold with a deep well socket. 5. Record location of the O-rings and the backup rings on the valve. Remove and discard the seal kit from the rotary valve. 6.
Rotary Valve (machines with backlap) (continued) E. Make sure that the sleeve bearing is in the handle cap. If necessary, press the sleeve bearing into the cap. Install the lip seal on the cap with the lip facing downward. F. While pressing on the cap to keep the lip seal in place, rotate the cap in a clockwise direction until the arrow on the cap aligns with the number 1 on the manifold. By rotating the cap clockwise, the valve will remain closed. Install the screw to retain the cap. G.
Spool Valve (machines with backlap) g218003 Figure 68 1. Retaining ring 5. Handle 2. O-ring 6. Spool 3. Back-up ring 7. Ball 4. O-ring 8. Dowel pin 9. 10. O-ring Backlap switch 1. Park the machine on a level surface. Lower the cutting units, stop the engine, engage the parking brake and remove the key from the ignition switch. 2. Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 4–71). 3.
Spool Valve (machines with backlap) (continued) 5. Visually inspect the manifold port and the spool valve: A. If valve sealing surfaces appear pitted or damaged, the hydraulic system may be overheating or there may be water in the system. B. Contamination may cause the valve to stick or hang up. Contamination can become lodged in small valve orifices or seal areas causing valve malfunction. 6. Install the spool valve: A.
Reel Motors g218175 Figure 69 1. Reel motor #1 7. Hydraulic hose, case drain 13. Hydraulic hose, inlet 2. Reel motor #2 8. Elbow fitting (2 each) 14. Straight fitting 3. Reel motor #3 9. Hydraulic hose, inlet 15. Hydraulic hose, inlet 4. Elbow fitting (4 each) Hydraulic hose, return 16. Hydraulic hose, case drain 17. Hydraulic hose, return 10. 5. Straight fitting 11. Hydraulic hose, case drain 6. Hydraulic hose, return 12.
Removing the Reel Motors 1. Park the machine on a level surface. Lower the cutting units, stop the engine, engage the parking brake and remove the key from the ignition switch. 2. Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 4–71). 3. Label all hydraulic connections for proper assembly.
Installing the Reel Motors Note: Inspect threads and sealing surfaces of the hydraulic fittings and the hydraulic hoses prior to installation. Replace any damaged or worn fittings or hoses. 1. Lubricate and fit new O-rings onto the reel motor fittings. Install the fittings making sure that the fitting location and orientation is as noted during removal. Tighten fittings as specified; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 4–10). 2.
Servicing the Reel Motor g218250 Figure 71 1. Dust seal 7. O-ring 13. Wear plate, inner 2. Retaining ring 8. Pressure seal, outer 14. Backup gasket, inner 3. Backup washer 9. Backup gasket, outer 15. Pressure seal, inner 4. Shaft seal Wear plate, outer 16. Body 5. Front flange 11. Idler gear 17. Cap screw (4 each) 6. Dowel pin (2 each) 12. Drive gear 18. Washer (4 each) Hydraulic System: Service and Repairs 10.
Disassembling the Reel Motor 1. Plug the motor ports and clean the outside of the motor thoroughly. After cleaning the motor, remove the plugs and drain any fluid out of the motor. g218252 Figure 72 1. 2. Reel motor 2. Marker line Use a marker to make a diagonal line across the front flange and the body for assembly purposes; refer to Figure 72. IMPORTANT Prevent damage when clamping the motor into a vise; use a vise with soft jaws and clamp on the front flange only. 3.
Disassembling the Reel Motor (continued) g218253 Figure 73 1. Dust seal 3. Backup washer 2. Retaining ring 4. Shaft seal IMPORTANT Make sure to not damage the front flange counter bore when removing the seals from the front flange. 10. Carefully remove the dust seal, the retaining ring, the backup washer and the shaft seal from the front flange; refer to Figure 73. Discard the removed seals.
Inspecting the Reel Motor 1. Remove any nicks and burrs from all the parts with emery cloth. CAUTION Use goggles or other appropriate eye protection when using compressed air for drying parts. 2. Clean all the parts with solvent. Dry all the parts with compressed air. g218251 Figure 74 1. Gear shaft spline 3. Gear teeth 2. Gear shaft 4. Gear face edge 3. Inspect the drive gears and the idler gears for the following; refer to Figure 74. A.
Assembling the Reel Motor 1. Lubricate the O–rings, the pressure seals, the back−up gaskets and the wear plate grooves with a thin coat of petroleum jelly. Lubricate all the other internal parts freely with clean hydraulic fluid. 2. Install the new seals into the front flange; refer to Figure 73. A. Press a new shaft seal into the front flange until it reaches the bottom of the bore. B. Install the backup washer into the front flange and then install the retaining ring into the groove of the front flange.
Assembling the Reel Motor (continued) 15. Place the front flange of the motor into a vise with soft jaws and alternately torque the cap screws 25 N−m (18 ft−lb). 16. Remove the motor from the vise. 17. Place a small amount of clean hydraulic fluid in the inlet of the motor and rotate the drive shaft away from the inlet one revolution. If any binding is evident, disassemble the motor and check for assembly problems.
Front Lift Cylinders g218299 Figure 75 1. Lift arm, right 8. Clevis pin (2 each) 15. Torsion spring, left 2. 3. Straight fitting (4 each) 9. Lift arm, left 16. Grease fitting (2 each) Hydraulic hose, right lift 10. Spacer, thick (2 each) 17. Hydraulic hose, left raise 4. 5. Cap screw (4 each) 11. Spacer, thin (2 each) 18. Hinge pin (2 each) Flat washer (2 each) 12. Lift cylinder (2 each) 19. Torsion spring, right 20. Hydraulic hose, right raise 6. Pivot pin (2 each) 13.
Removing the Front Lift Cylinders 1. Park the machine on a level surface. Lower the cutting units, stop the engine, engage the parking brake and remove the key from the ignition switch. 2. Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 4–71). 3. Label all hydraulic connections for proper assembly.
Servicing the Front Lift Cylinders g218311 Figure 76 1. Barrel 2. 3. Lock nut Wear ring 10. 11. Seal Dust seal 4. 5. Piston O-ring 12. 13. Internal collar Rod 6. 7. 8. Seal Head O-ring 14. 15. Jam nut Rod clevis Hydraulic System: Service and Repairs 9.
Disassembling the Front Lift Cylinder 1. Remove any fluid from the cylinder by slowly pumping the cylinder rod while holding the cylinder over a drain pan. 2. Plug both cylinder ports and clean the outside of the cylinder. IMPORTANT Do not clamp vise jaws against the cylinder barrel. Clamp on the clevis ONLY. 3. Mount the cylinder securely in a vise by clamping on the clevis end of the barrel. Using a vise with soft jaws is recommended. 4.
Assembling the Front Lift Cylinder (continued) IMPORTANT Do not clamp vise jaws against the cylinder barrel. Clamp on the clevis ONLY. 5. Mount the cylinder securely in a vise by clamping on the clevis end of the barrel. Using a vise with soft jaws is recommended. 6. Use a spanner wrench to rotate the internal collar clockwise until it is tight against the cylinder barrel. Rear Lift Cylinder g218803 Figure 77 1. Rear lift cylinder 7. Straight fitting 13. Flat washer (2 each) 2. Cotter pin 8.
Removing the Rear Lift Cylinder 1. Park the machine on a level surface. Lower the cutting units, stop the engine, engage the parking brake and remove the key from the ignition switch. 2. Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 4–71). 3. Label all hydraulic connections for proper assembly.
Servicing the Rear Lift Cylinder g218363 Figure 78 1. Barrel 6. O-ring 11. Dust seal 2. Lock nut 7. Head 12. Retaining ring 3. Wear ring 8. O-ring 13. Rod 4. Piston 9. Back-up ring 5. Seal Hydraulic System: Service and Repairs 10.
Disassembling the Lift Cylinder 1. Remove any fluid from the cylinder by slowly pumping the cylinder rod while holding the cylinder over a drain pan. 2. Plug both cylinder ports and clean the outside of the cylinder. IMPORTANT Do not clamp vise jaws against the cylinder barrel. Clamp on the clevis ONLY. 3. Mount the cylinder securely in a vise by clamping on the clevis end of the barrel. Using a vise with soft jaws is recommended. 4. Loosen the head from the cylinder barrel. A.
Assembling the Lift Cylinder (continued) B. Carefully slide the head assembly and then the piston assembly onto the rod. Install the lock nut onto the rod and tighten to 54 N−m (40 ft−lb). C. Remove the rod assembly from the vise. 4. Coat all the internal parts with a light layer of clean hydraulic fluid. Slide the piston, the rod and head assembly into the barrel being careful to not damage the seals. IMPORTANT Do not clamp vise jaws against the cylinder barrel. Clamp on the clevis ONLY. 5.
Steering Control Valve g218799 Figure 79 1. Steering control valve 10. Flat washer 19. Flat washer (2 each) 2. Straight fitting (2 each) 11. Steering mount 20. Cap screw (2 each) 3. Straight fitting (2 each) 12. Friction plate 21. Lock nut (2 each) 4. Hydraulic hose, T port 13. Spacer 22. Shoulder bolt 5. cap screw (4 each) 14. Cap screw 23. Steering arm 6. Steering wheel 15. Cap screw (2 each) 24. Flat washer (2 each) 7. Screw (2 each) 16. Screw (6 each) 25.
Removing the Steering Control Valve 1. Park the machine on a level surface. Lower the cutting units, stop the engine, engage the parking brake and remove the key from the ignition switch. 2. Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 4–71). 3. Remove the two (2) screws and the steering wheel cover from the steering wheel. 4. Remove the lock nut and the flat washer from the steering control valve shaft. 5.
Installing the Steering Control Valve Note: Inspect the threads and the sealing surfaces of the hydraulic fittings and the hydraulic hoses prior to installation. Replace any damaged or worn fittings or hoses. 1. Lubricate and fit new O-rings onto the valve fittings. Install the fittings making sure that the fitting location and orientation is as noted during removal. Tighten fittings as specified; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 4–10). 2.
Servicing the Steering Control Valve 27 – 33 N--m (20 – 24 ft--lb) g218375 Figure 81 1. Plug 9. Bearing 17. Outer gearwheel 2. Plug 3. Spring 10. Cross pin 18. Inner gearwheel 11. Ring 19. End cover 4. 5. Relief valve 12. Sleeve 20. O-ring (5 each) Dust seal 13. Spool 21. Cap screw (5 each) 6. Housing 7. Shaft seal 14. Cardan shaft 22. Spring set 15. O-ring 23. Ball stop 8. Thrust washer 16. Distribution plate 24.
Steering Cylinder g218585 Figure 82 1. Rod end 2. Grease fitting 6. Hydraulic hose, right turn 10. Jam nut (2 each) 3. Jam nut 7. Elbow fitting (2 each) 11. Dust seal 4. Steering cylinder 8. Lock nut Greensmaster 3120 17230SL Rev D 5. Flat washer Page 4–131 9.
Removing the Steering Cylinder 1. Park the machine on a level surface. Lower the cutting units, stop the engine, engage the parking brake and remove the key from the ignition switch. 2. Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 4–71). 3. Label all hydraulic connections for proper assembly.
Installing the Steering Cylinder (continued) fittings. Tighten the connections as specified; refer to Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (page 4–8). 7. Greensmaster 3120 17230SL Rev D Charge the hydraulic system; refer to Charging the Hydraulic System (page 4–79).
Servicing the Steering Cylinder g218411 Figure 83 1. Rod 6. Back-up ring 11. O-ring 2. External collar 7. O-ring 12. Lock nut 3. Dust seal 8. Wear ring (2 each) 13. Barrel 4. Seal 9. Seal 14. Grease Fitting 5. Head 10.
Disassembling the Steering Cylinder 1. Remove any fluid from the cylinder by slowly pumping the cylinder rod while holding the cylinder over a drain pan. 2. Plug both cylinder ports and clean the outside of the cylinder. IMPORTANT Do not clamp vise jaws against the center of the cylinder barrel. Clamp on the cap end of the barrel ONLY. 3. Mount the cylinder securely in a vise by clamping on the cap end of the barrel. Using a vise with soft jaws is recommended.
Assembling the Steering Cylinder (continued) IMPORTANT Do not clamp vise jaws against the center of the cylinder barrel. Clamp on the cap end of the barrel ONLY. 7. Mount the cylinder securely in a vise by clamping on the cap end of the barrel. Using a vise with soft jaws is recommended. 8. Apply a few drops of high strength thread locker to the threads of the cylinder barrel and install the external collar. Use a pipe wrench to tighten the external collar.
Hydraulic Tank g219155 Figure 84 Greensmaster 3120 17230SL Rev D Page 4–137 Hydraulic System: Service and Repairs
Figure 84 1. Breather 2. Plug (machine serial numbers before 400000000) (continued) Barb fitting 17. Plug 10. cap screw (3 each) 18. Spacer (2 each) 9. 3. Dipstick 11. Flat washer (3 each) 19. Carbon canister assembly 4. O-ring 12. Rubber bushing (3 each) 20. Cap screw (2 each) 5. Hydraulic tank 13. Hose, return from filter 21. Grommet (machine serial numbers after 400000000) 6. Inlet strainer 14. Hydraulic hose, case drain from traction pump 22.
Installing the Hydraulic Tank (continued) 1. Lubricate and fit new O-rings onto the tank fittings. Install the fittings making sure that the fitting location and orientation is as noted during removal. Tighten fittings as specified; refer to Figure 84. 2. Fit the hydraulic tank onto the machine frame. IMPORTANT After the hydraulic tank is installed, a 3.2 to 9.5 mm (0.125” to 0.375”) clearance should exist between the hydraulic tank and the fuel tank. 3.
Hydraulic System: Service and Repairs Page 4–140 Greensmaster 3120 17230SL Rev D
Chapter 5 Electrical System Table of Contents General Information .............................................................................................................................. 5–2 Electrical Schematics and Diagrams.................................................................................................. 5–2 Special Tools ......................................................................................................................................... 5–3 Multimeter ..........
General Information The Traction Unit Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Traction Unit Operator’s Manual for additional information when servicing the machine. Electrical Schematics and Diagrams Refer to the Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A (page A–1).
Special Tools You can order these special tools from your Authorized Toro Distributor. Some tools are also available from a local supplier. Multimeter Obtain this tool locally The meter can test the electrical components and circuits for current, resistance, or voltage. Note: Use a digital multimeter when testing the electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode ensures that the excess current is not allowed through the meter.
Dielectric Gel Toro Part No. 107-0342 Use the dielectric gel to prevent corrosion of unsealed connection terminals. To ensure complete coating of the terminals, liberally apply the gel to the component and wire harness connector, plug the connector into the component, unplug the connector, apply the gel to both surfaces again, and connect the harness connector to the component again. The connectors must be fully packed with gel for effective results.
Troubleshooting CAUTION Remove all the jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. For the effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components that are used on this machine; refer to the Electrical Schematics in Appendix A (page A–1).
Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Wiring to the start circuit components is loose, corroded or damaged; refer to Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A (page A–1). Engine wiring is loose, corroded or damaged; refer to Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A (page A–1). Diode D1-A circuit is open. Engine or fuel system is malfunctioning; refer to Chapter 3: Engine (page 3–1).
Cutting Unit Operating Problems (continued) Problem Cutting units run (but should not) when raised. Possible Causes Joystick relay (K3) is faulty. Mow relay (K4) is faulty. Mow switch is out of adjustment or faulty. A hydraulic problem exists; refer to Chapter 4: Hydraulic System (page 4–1). Cutting units do not run when lowered with the function control lever in the MOW position.
Electrical System Quick Checks Testing the Battery (Open Circuit Test) Battery Test Table 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 Measure the voltage between the battery terminals. Tools required: Digital multimeter to set the DC volts. 1. The battery temperature should be 16°C to 38°C (60°F to 100°F). 2.
Testing the Charging System Battery Voltage Table At least 0.50 V over the initial battery voltage. Initial battery voltage = 12.30 V Battery voltage after 3 minutes charge = 12.85 V Difference = +0.55 V This is a simple test that determines if a charging system is functioning. It tells you if the charging system has an output, but not its capacity. Tool required: Digital multimeter to set the DC volts. 1.
Checking the Interlock System Operation CAUTION The interlock system is for the operator’s protection; do not disconnect any of the interlock system components. Check the operation of the interlock system daily to assure the system is operating correctly. If an interlock system component is out of adjustment or defective, replace it before operating the machine. The purpose of the interlock system is to: • Prevent the engine from cranking or starting unless the function control lever is in NEUTRAL.
Testing the Electrical Components For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g., unplug the key switch connector before doing a continuity check of the switch). Note: For the engine component testing information; refer to the Briggs & Stratton Engine Repair Manual. IMPORTANT When testing the electrical components for continuity with a multimeter (ohms setting), ensure that you disconnect the power to the circuit.
Fuses g222365 Figure 86 1. Fuse block 3. Fuse F2 (10 Amp) 2. Fuse F1 (20 Amp) 4. Fuse F3 (10 Amp) 5. Fuse F4 (10 Amp) The fuse block is located on the left side of the machine under the operator seat; refer to Figure 86.
Key Switch POSITION CIRCUIT OFF NONE RUN B + I + A, X + Y START B + I + S The key (ignition) switch located on the control panel has three (3) positions (OFF, RUN and START). Testing the Key Switch 1. Park the machine on a level surface, lower the cutting units and stop the engine. 2. Disconnect the wire harness from the key switch and remove the key switch from the control panel if necessary. 3.
Starter Solenoid g222487 Figure 87 1. Battery 3. Main contact post (2 each) 2. Starter solenoid 4. Solenoid coil post (2 each) The starter solenoid used on the Greensmaster 3120 allows current flow from the battery to the engine starter motor when energized. The starter solenoid coil should energize when both the kill relay (K1) and the start safety relay (K2) are energized. The starter solenoid is attached to the rear frame in front of the battery; refer to Figure 87.
Testing the Starter Solenoid (continued) 7. When testing is complete, secure the cables and wires to the solenoid. Tighten the nuts on the solenoid coil posts from 15 to 20 in-lb (1.7 to 2.3 N∙m). Tighten the nuts on the main contact posts from 50 to 60 in-lb (5.7 to 6.8 N∙m). 8. Connect the positive (+) cable to the battery first and then connect the negative (-) cable to the battery. Coat the wire and cable connections at the battery and at the starter solenoid with Battery Terminal Protector (page 5–3).
Hour Meter g222519 Figure 88 The hour meter is located on the operator control panel. Testing the Hour Meter 1. Park the machine on a level surface and lower the cutting units. Make sure the engine is off and the key switch is in the OFF position. 2. Record the wire connections at the hour meter for assembly purposes. Disconnect the wire harness from the hour meter. 3. Connect the positive (+) terminal of a 12 VDC power source to the positive terminal of the hour meter; refer to Figure 88. 4.
Seat Switch g222520 Figure 89 1. 2. Seat switch Harness connector The seat switch is a normally open switch that closes when the operator is on the seat. If the function control lever is moved out of NEUTRAL (the neutral switch opens) when the operator raises out of the seat, the engine magneto will divert the ignition circuit to ground and the engine will stop. The seat switch is mounted to the seat pan directly under the seat. Testing the Seat Switch 1.
Neutral and Mow Switches g222722 Figure 90 1. Function control lever 3. Mow switch 5. Jam nut (2 each) 2. Neutral switch 4. Actuator 6. Function control lever bracket The neutral and mow switches are attached to the function control lever bracket under the console cover; refer to Figure 90. The actuator is attached to the function control lever. The switches are used to determine when the function control lever is in the NEUTRAL or MOW position.
Testing the Neutral and Mow Switches (continued) 4. If the switch does not function as described: A. Adjust the distance between the sensing end of each switch and the function control lever bracket from 18.4 to 19.7 mm (0.725 to 0.775 inch); refer to Figure 90. Tighten the switch jam nuts from 4.5 to 6.7 N∙m (40 to 60 in-lb). B. Use a multimeter (ohms setting) across the switch terminals and adjust the actuator so the opposing switch just closes.
Parking Brake Switch g222884 Figure 91 (view from under foot panel) 1. Parking brake switch 2. Latch assembly The switch is located directly under the operator foot panel. The parking brake switch is used to determine when the parking brake is engaged or disengaged. The switch is a normally closed proximity switch that opens when the operator sets the parking brake (the parking brake latch comes in close proximity to the switch).
Cutting Unit Raise and Lower Joystick Switches g223070 Figure 92 1. Joystick assembly 4. Bracket 7. Thread forming screw (4 each) 2. 3. Lower switch Raise switch 5. 6. Knob Jam nut 8. 9. Pod Flat washer (2 each) Joystick Switch Testing Reference JOYSTICK POSITION RAISE SWITCH CIRCUIT LOWER SWITCH CIRCUIT RAISE 1 + 2 1 + 3 CENTER 1 + 3 1 + 3 LOWER 1 + 3 1 + 2 The cutting unit raise and lower switches are located on the joystick bracket.
Backlap Switch (machines with backlap) g223200 Figure 93 1. Backlap switch 3. O-ring 2. Backlap lever 4. Dowel 5. Ball The backlap switch is located on the front of the mower hydraulic manifold on machines with the backlap feature. The backlap switch is a normally open ball switch. The switch contacts are open when the backlap lever is in the F (forward – mow) position, and closed when the backlap lever is in the R (reverse – backlap) position. Testing the Backlap Switch 1.
Relays g223739 Figure 94 1. Control panel shield 3. Relay K8 2. Relays K1 – K6 4. Relay K7 Several relays are used on the Greensmaster 3120 machine. The relays are identical five (5) terminal relays that are located toward the front of the machine; refer to Figure 94). Identifying the Relays and their Functions Note: Refer to the Electrical Schematics and Wire Harnesses in Appendix A (page A–1) for additional relay circuit information.
Identifying the Relays and their Functions (continued) Lower Relay (K5) When energized by the solid state timer, the lower relay allows current flow to the hydraulic solenoid valve coils S2 and S4 causing the cutting units to lower. The lower relay is located under the control panel on the left side of the operator seat. Raise Relay (K6) When energized by the joystick raise switch, the raise relay allows current flow to hydraulic solenoid valve coils S2 and S3 causing the cutting units to raise.
Delay Timer (Lower Cutting Units) g223804 Figure 95 1. Fuse block 2. Delay timer The delay timer is located on the left side of the machine under the operator seat; refer to Figure 95. The delay timer is a solid state timer used to energize the lower relay (K5) long enough to make sure that the cutting units will fully lower. When the joystick is moved to the LOWER position, the joystick lower switch supplies power to the delay timer. The timer energizes lower relay (K5).
Hydraulic Solenoid Valve Coils g222035 Figure 96 1. Manifold assembly (machines without backlap) 4. Solenoid S1 (reels engage) 7. Coil diameter 2. Manifold assembly (machines with backlap) 5. Solenoid S2 (reels raise/lower) 8. Coil height 3. Solenoid S3 (reels raise) 6. Solenoid S4 (reels lower) Solenoid Valve Coil Specifications Coil Diameter Coil Height Coil Resistance 46.7 mm (1.84 inch) 49.9 mm (1.96 inch) 7.1 ohm 35.8 mm (1.41 inch) 36.3 mm (1.43 inch) 8.
The Greensmaster 3120 hydraulic manifold uses several solenoid actuated cartridge valve for system control. When the solenoid coil is energized, hydraulic cartridge valve shifts and changes the hydraulic circuit flow. Testing a solenoid coil can be done with the coil installed on the hydraulic cartridge valve. Testing a Solenoid Valve Coil 1. Park the machine on a level surface and lower the cutting units. Make sure the engine is off and the key switch is in the OFF position. 2.
Diodes g223898 Figure 97 1. Control panel shield 3. Diodes D1-A, D1-B, D1-C and D1-D 5. 2. Mower hydraulic manifold 4.
The main wiring harness contains six (6) diodes. The diodes are used for circuit protection from inductive voltage spikes and for safety circuit logic. Diodes D1-A, D1-B, D1-C and D1-D are attached to a circuit board that plugs into the main wire harness located under the control panel shield ;refer to Figure 97. Diodes D2 and D3 are individual plug-in diodes connected to the main harness near the front of the mower hydraulic manifold.
Service and Repairs Caring for the Battery 1. The battery-electrolyte level must be properly maintained. The top of the battery must be kept clean. If the machine is stored in a location where the temperatures are extremely high, the battery will discharge more rapidly than if the machine is stored in a location where the temperatures are cool. WARNING The gases are explosive; also, they can cause nausea. • Wear safety goggles and rubber gloves when working with electrolyte.
Storing the Battery If you store the machine for more than 30 days: 1. Ensure that the key switch is in the OFF position. 2. Disconnect the ground (-) cable from the battery terminal first, then disconnect the positive (+) cable from the battery terminal. 3. Charge the battery fully before storage; refer to Charging the Battery (page 5–35). 4.
Removing the Battery g221472 Figure 98 1. Battery 6. Hold down post (2 each) 11. Drain tube 2. Negative (-) cable 7. Hex nut (2 each) 12. To frame – ground 3. Positive (+) cable 8. Cap screw (2 each) 13. To engine – ground 4. Hold down rod 9. O-ring (2 each) 14. To starter motor 5. Wing nut (2 each) 10. Battery tray IMPORTANT Be careful when removing the battery cables and ensure that you do not damage the terminal posts or cable connectors. 1.
Installing the Battery IMPORTANT To prevent possible electrical problems, install only a fully charged battery. 1. Ensure that the key switch and all accessories are in the OFF position. 2. Ensure that the battery tray is clean and place the battery tray in position. 3. Ensure that all the battery terminals, battery cables and battery hold down components are in good condition. 4. Place the battery into the battery tray. Make sure the battery is level and flat.
Inspecting, Maintaining, and Testing the Battery (continued) Minimum Voltage (continued) 8.7 10°F -12°C 8.5 0°F -18°C 1. Inspect the battery as follows: A. Check for cracks. Replace the battery if cracked or leaking. B. Check the battery terminals for corrosion. Use the wire brush to clean corrosion from the posts. IMPORTANT Before cleaning the battery, tape or block the vent holes of the filler caps and ensure that the caps are secure. C.
Inspecting, Maintaining, and Testing the Battery (continued) in specific gravity between the highest and lowest cell being less than 0.050. If you can not meet these charging conditions, replace the battery. 3. Do a high-discharge test with an adjustable load tester. This is a very reliable means of testing a battery as it simulates the battery cold-cranking capacity. A commercial battery load tester is required to do this test.
Charging the Battery (continued) Battery Charge Rate (continued) 126 to 170 5.5 hrs @ 5 A 11 hrs @ 5 A 16.5 hrs @ 5 A 22 hrs @ 5 A 171 to 250 5.8 hrs @ 6 A 11.5 hrs @ 6 A 17.3 hrs @ 6 A 23 hrs @ 6 A above 250 6 hrs @ 10 A 12 hrs @ 10 A 18 hrs @ 10 A 24 hrs @ 10 A To minimize damage to the battery and allow the battery to charge fully, use the following slow charging procedure. You can accomplish this charging procedure with a constant current battery charger that is available locally.
Chapter 6 Chassis Table of Contents Specifications ....................................................................................................................................... 6–2 Chassis .............................................................................................................................................. 6–2 General Information ..............................................................................................................................
Specifications Chassis Item Description 18 x 9.50 x 8, 4 ply Smooth Front tire 55 to 83 kPa (8 to 12 psi) 18 x 9.
General Information The Traction Unit Operator’s Manual provides information regarding the operation, general maintenance procedures, and maintenance intervals for your machine. Refer to the Traction Unit Operator’s Manual for additional information when servicing the machine.
Service and Repairs Front Wheels and Brakes g225204 Figure 99 8. Wheel and tire assembly 15. Retaining clip Brake backing plate 9. Lug nut (4 each) 16. Brake lever Cap screw (4 each) 10. Wheel hub nut 17. Cotter pin 1. Lock nut (4 each) 2. 3. 4. Drive stud (4 each) 11. Brake shoe (2 each) 18. Brake rod 5. Brake drum 12. Return spring (2 each) 19. Clevis pin 6. 7. Wheel hub Wheel hub assembly 13. 14. Brake cam Woodruff key Removing the Front Wheel and Brake Assembly 1.
Removing the Front Wheel and Brake Assembly (continued) 6. Remove the wheel hub lock nut and the wheel hub assembly. Locate and retrieve the woodruff key. If wheel hub, brake drum or drive studs need replacement, press the drive studs from the wheel hub to separate the hub from the brake drum. 7. Disconnect the brake rod from the brake lever and discard the cotter pin. 8. Remove the return springs and remove the brake shoes from the backing plate. The brake parts should be clean and free of rust.
Rear Wheel g225192 Figure 100 1. Caster bolt 6. Adapter plate LH 11. Seal (2 each) 2. Cap screw (2 each) 7. Lock nut (3 each) 12. Bearing cone (2 each) 3. Lock nut (2 each) 8. Adapter plate RH 13. Bearing cup (2 each) 4. Lock nut 5. Flange head screw (3 each) 9. 10. Wheel and hub assembly Spindle spacer (2 each) Removing the Rear Wheel 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine.
Installing the Rear Wheel (continued) C. Press new bearing seals into hub until seated. 2. Install the wheel and hub assembly into the caster fork. 3. Insert caster bolt into motor adapter plate. Install one spacer and slide the bolt through the wheel and hub assembly. 4. Install a second spindle spacer onto the caster bolt and pass the bolt through the adapter plate. 5. Position bent lip of the caster bolt head under the bottom edge of the motor adapter plate.
Caster Fork g225157 Figure 101 1. Jam nut (2 each) 5. Slotted hex nut 9. 2. Flat washer 6. Washer (4 each) 3. Steering cylinder rod end 7. Bearing cone (2 each) 4. Cotter pin 8. Bearing cup (2 each) 10. Grease fitting Caster fork Removing the Caster Fork 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch. 2. Remove the rear wheel; refer to Removing the Rear Wheel (page 6–6). 3.
Installing the Caster Fork 1. If the bearing cups were removed from the frame, press new cups into the frame making sure that they are fully seated against the shoulder of the frame housing. 2. Pack the bearing cones with #2 multi-purpose lithium base grease. 3. Place two washers and a bearing cone onto the caster fork stem and insert the caster fork stem up through the bottom of the frame. 4. Place the remaining bearing cone and two washers onto the caster fork stem. 5.
Cutting Unit Pull Frame Rollers, Pivot Hinges and Lift Arms g225293 Figure 102 (front right assembly shown) 1. Pull frame 11. Pivot Hinge 21. Flange bushing (4 each) 2. Cap screw (2 each) 12. Bumper (2 each) 22. Pull arm – RH 3. Flat washer (2 each) 13. Flange head screw (2 each) 23. Spring washer 4. Hinge pin 14. Sleeve (2 each) 24. Pull arm – LH 5. Grease fitting 15. Ball joint receiver (2 each) 25. Ball bearing (2 each) 6. Torsion spring 16. Jam nut (2 each) 26.
Servicing the Cutting Unit Pull Frame Rollers, Pivot Hinges and Lift Arms 1. Park machine on a level surface with cutting units lowered to the ground. Make sure engine is off. Engage parking brake. 2. Remove the cutting unit from the machine; refer to the Traction Unit Operator’s Manual. g225205 Figure 103 1. Roller 2. Shaft seal (2 each) 3. Ball bearing (2 each) 3. Service the pull frame rollers as necessary; refer to Figure 103. A. Install shaft seal with seal lip toward end of roller. B.
Servicing the Cutting Unit Pull Frame Rollers, Pivot Hinges and Lift Arms (continued) B. Make sure the side play clearance between the pivot hinge and the machine frame is less than 1.5 mm (0.060”). Adjust the clearance with shims and thrust washers as required. g225291 Figure 105 1. Lift arm 2. Bushing (2 each) 5. Service the lift arms as necessary. Install new bushings so the grease groove opening is orientated inward; refer to Figure 105.
Chapter 7 DPA Cutting Units Table of Contents Specifications ....................................................................................................................................... 7–2 DPA Cutting Units .............................................................................................................................. 7–2 General Information ..............................................................................................................................
Specifications DPA Cutting Units g225943 Figure 106 Frame construction: Precision machined die cast aluminum crossmember with two bolt-on die-cast aluminum side plates. Reel construction: Reels are 53.3 cm (21 inches) in length and 12.7 cm (5 inch) in diameter. High strength, low alloy steel blades are thru hardened and impact resistant. Reels are available in 8, 11 and 14 blade configurations.
DPA Cutting Units (continued) Grass shield: Non-adjustable shield with adjustable cut-off bar to improve grass discharge from reel in varying moisture conditions. Counterbalance weight: A cast iron weight mounted on left end of the cutting unit compensates for the hydraulic drive motor mounted on the right end of the cutting unit. Cutting unit weight (approximate): 8 blade* 32.
General Information Cutting Unit Operator's Manual The Cutting Unit Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for the cutting units on your machine. Additionally, if optional kits have been installed on the cutting units (e.g. groomer or rear roller brush), the Installation Instructions for the kit includes set-up, operation and maintenance information.
Aftercut Appearance 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. Refer to the Cutting Unit Operator’s Manual detailed adjustment procedures.
Factors That Can Affect Quality of Cut (continued) Factor Possible Problem/Correction Stability of bedbar Ensure that the bedbar pivot bolts are securely seated; refer to Bedbar Assembly (page 7–10). Number of reel blades Use correct number of blades for clip frequency and optimum height-of-cut range. Cutting unit alignment and ground following Check pull frames and lift arms for damage, binding conditions or bushing wear. Repair if necessary.
Adjustments DPA Cutting Unit Characteristics CAUTION Never install or work on or near a cutting unit or cutting unit suspension with the engine running. Always stop the engine and remove the key before working on or near a cutting unit. The dual point adjust (DPA) bedknife-to-reel adjustment system incorporated in this cutting unit simplifies the adjustment procedure needed to deliver optimum mowing performance.
Leveling the Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel). If the side plates are disassembled a limited amount of side plate adjustment is possible to make sure that the rear roller and cutting reel remain parallel. Note: Use a pie tape to measure the reel diameter taper; service limit 0.25 mm (0.01 inch).
Leveling the Rear Roller (continued) g226142 Figure 109 1. Side plate 3. Rear roller 2. Shoulder bolt (2 each) 4. Rear roller adjustment kit (optional) Note: If the cutting unit has an optional rear roller adjustment kit (eccentric roller shaft bushing), loosening the cutting unit side plate should not be necessary.
Service and Repairs Bedbar Assembly g226634 Figure 110 1. Bedbar 10. Lock nut (2 each) 2. Bedknife 11. Washer (2 each) 3. Bedknife screw (13 each) 12. Compression spring (2 each) 4. Bedbar adjuster screw (2 each) 13. Lock nut (2 each) 5. Bedbar adjuster shaft (2 each) 14. Rubber bushing (2 each) 6. cap screw (2 used) 15. Nylon bushing (2 each) 7. Detent (2 each) 16. Plastic washer (4 each) 8. Wave washer (2 each) 17. Metal washer (4 each) 9. Retaining ring (2 each) 18.
Removing the Bedbar 1. Position the machine on a clean and level surface, lower the cutting units, stop the engine, engage the parking brake and remove the key from the ignition switch. 2. Remove the cutting unit from the machine and place the cutting unit on a flat work surface. 3. Loosen the lock nuts (item 13 in Figure 110) on the end of each bedbar adjuster screw until the washers (item 11 in Figure 110) are loose. 4.
Installing the Bedbar g226763 Figure 111 1. 5. Side plate Metal washer 2. Rubber bushing 6. Bedbar 3. Nylon bushing 7. Bedbar pivot bolt 4. Plastic washer (2 each) 8. Lock nut 1. If rubber bushing was removed from either side plate, apply grease to outside surface of new bushing and install into side plate. The bushing should be installed flush with the inside surface of the side plate; refer to Figure 111. 2. If removed, install the nylon bushings with flange facing outward. 3.
Installing the Bedbar (continued) 7. Install the bedbar pivot bolt assemblies. Make sure the washers are not caught on the threads of the pivot bolts. Tighten each bedbar pivot bolt from 22 to 27 N∙m (190 to 240 in-lb). IMPORTANT Do not over tighten the lock nuts as this can distort the side plates and affect reel bearing alignment. When the lock nut is correctly tightened, the inside washers may be loose. 8.
Removing the Bedbar Adjuster g226792 Figure 112 1. Bedbar assembly 7. Detent 2. Compression spring 8. Wave washer 3. Lock nut 9. Retaining ring 4. Bedbar adjuster shaft 10. Bedbar adjuster screw 5. Flange bushing 11. Washer 6. Cap screw 1. Remove bedbar; refer to Removing the Bedbar (page 7–11). 2. Remove the lock nut, compression spring and washer from the bedbar adjuster screw. Note: The bedbar adjuster shaft has left-hand threads. 3.
Bedknife Removing the Bedknife g227001 Figure 113 1. Bedknife screw (13 used) 2. Bedbar 3. Bedknife 1. Remove the bedbar from the cutting unit; refer to Removing the Bedbar (page 7–11). 2. Remove screws from bedbar using a socket wrench and bedknife screw tool; refer to Bedknife Screw Tool (page 2–18). Discard the screws. Remove bedknife from the bedbar. 3. Refer to Grinding the Bedknife (page 7–17) for additional information. Installing the Bedknife 1.
Installing the Bedknife (continued) IMPORTANT Do not use an impact wrench to tighten screws into the bedbar. 3. Use new screws to secure bedknife to bedbar. Apply anti-seize lubricant to the threads of new screws. Do not apply anti-seize lubricant to the taper of the screw heads. 4. Install all screws but do not tighten. 5. Using a torque wrench and bedknife screw tool, tighten the 2 outer screws to 1 N-m (10 in-lb). 6.
Grinding the Bedknife Bedknife Grinding Specifications Standard Bedknife Relief Angle 3° minimum Fairway Bedknife Relief Angle 3° minimum Extended Bedknife Relief Angle 7° minimum Front Angle Range 13° to 17° g207289 Figure 115 1. Top angle 4. Front surface 2. Top surface 5. Front angle 3. Remove burr Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar.
Grinding the Bedknife (continued) IMPORTANT EdgeMax® bedknives are extremely hard. Using a diamond grinding wheel is recommended to prevent overheating or damaging the bedknife edge while grinding. Because the top grind angle on bedknives is critical for edge retention, and therefore after−cut appearance, Toro has developed special service tools for accurately measuring the top grind angle on all bedknives; refer to Angle Indicator and Magnetic Mount (page 2–17). 1.
Reel Assembly g227238 Figure 117 1. Cutting reel assembly 9. Left side plate 2. Frame assembly 10. Lock nut (4 each) 3. Flange nut (4 each) 11. Flat wire spring 4. Shoulder bolt (4 used) 12. Right side plate 5. Plug 13. Motor adapter 6. Cap screw (2 each) 14. Socket head screw (2 each) 7. Counterweight 15. Grass shield 8. O-ring (2 each) Removal of the cutting reel requires removal of the left or right side plate from the cutting unit frame.
Removing the Reel Assembly (continued) 3. If the cutting unit is equipped with an optional groomer or rear roller brush, remove the drive components for those options from cutting unit. Refer to Removing the Drive Plate (page 8–8) for belt drive groomer, Removing the Gear Box Assembly (page 9–6) for universal groomer, and Rear Roller Brushes (Optional) (page 7–33) for additional information. 4.
Removing the Reel Assembly (continued) g286353 Figure 118 1. Reel nut (right end shown) 3. Weld side of reel support plate 2. Reel shaft 4. Pry bar B. Insert a long-handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move.
Removing the Reel Assembly (continued) E. Position the pry bar in the same manner on the opposite end of the reel and loosen the remaining reel nut. F. Tip the cutting unit back onto its rollers. 6. Remove the bedbar; refer to Removing the Bedbar (page 7–11). 7. Remove the front roller; refer to Removing the Front Roller (page 7–26). 8. Remove the rear roller; refer to Removing the Rear Roller (page 7–28). 9.
Inspecting the Reel Assembly (continued) 1. Remove the reel nuts from the cutting reel. Check the splines in the reel nuts for excessive wear or distortion and replace them if necessary. 2. Slide the bearings and seals from the reel shaft. Discard the seals and inspect the reel bearings to insure that they spin freely and have a minimal amount of axial play. 3. Inspect the reel as follows: A. Place the reel shaft ends in V-blocks and check the reel shaft for distortion. B.
Installing the Reel Assembly (continued) 6. Install the rear roller; refer to Installing the Rear Roller (page 7–28). 7. Install the front roller; refer to Installing the Front Roller (page 7–27). 8. Install the bedbar assembly; refer to Installing the Bedbar (page 7–12). 9. Tighten the reel nuts: A. Insert a long-handled pry bar (3/8 x 12 inch with a screwdriver handle recommended) through the front of the cutting unit.
Installing the Reel Assembly (continued) D. Position the pry bar in the same manner on the opposite end of the reel and tighten the remaining reel nut. E. Fill the reel nut splines with high temp Mobil XHP−222 grease or equivalent. 10. Check to make sure the rear roller and cutting reel are parallel; refer to Leveling the Rear Roller (page 7–8). 11. Install a new O-ring on the counterweight and secure the counterweight to the left side plate with two cap screws and nuts. 12.
Preparing the Reel for Grinding (continued) Before grinding a cutting reel, make sure that all the cutting unit components are in good condition. Depending on the type of grinder used, faulty cutting unit components can affect the grinding results. When grinding, be careful to not overheat the cutting reel blades. Remove small amounts of material with each pass of the grinder.
Removing the Front Roller (continued) 3. Remove the lock nut, height-of-cut washer and plow bolt that secures one of the height-of-cut arms to the cutting unit side plate and remove the height-of-cut arm. 4. Slide the front roller assembly from the remaining height-of-cut arm. 5. Remove the remaining height-of-cut arm from the cutting unit if necessary. Installing the Front Roller 1. Place the cutting unit on a level work surface.
Removing the Rear Roller g227573 Figure 123 1. Rear roller assembly 4. Spacer 2. Flange nut (2 each) 5. Shaft retainer 3. Shim 6. Socket head screw (2 each) 1. Remove the cutting unit from the machine and place it on a level work surface. Place blocks under the bedbar to raise the rear roller off of the work surface. 2. Loosen the flange nuts that secure the rear roller retainer assemblies (flange nuts, socket head screws, shaft retainer, spacer and shims) to the cutting unit.
Disassembling the Roller g206889 Figure 124 1. Bearing lock nut 5. Wiehle roller 2. V-ring 6. Smooth roller 3. 4. Seal Ball bearing 7. Roller shaft 1. To hold the roller shaft stationary while removing the bearing lock nut, install a 3/8-24 UNF 2B screw with a jam nut into the threaded end of the roller shaft and tighten the jam nut against the roller shaft. Remove the bearing lock nuts. 2. Carefully inspect the seating surface and threads of the bearing lock nuts and replace them if damaged.
Assembling the Roller g206890 Figure 125 1. Roller 4. V-ring 2. Ball bearing 5. Bearing lock nut 3. Seal 6. Roller shaft Note: Special tools are required to assemble the rollers; refer to Roller Rebuilding Tools (page 2–19). The following procedure describes the assembling the rollers using the set of assembly washers and spacers. 1. Place the roller shaft into the roller g206891 Figure 126 1. Bearing 2. Black assembly washer 3.
Assembling the Roller (continued) g206892 Figure 127 1. 2. Seal Bearing lock nut IMPORTANT Failure to grease bearing lock nut before seal installation may result in seal damage. 5. Fill the seal 75 to 90% full with #2 grease and apply a coating of grease to the underside of the bearing lock nut to prevent damaging the seal damage during installation. Carefully fit a seal onto each bearing lock nut. g206893 Figure 128 1. 2. Seal Bearing lock nut 6.
Assembling the Roller (continued) g206894 Figure 129 1. Seal 3. Yellow assembly washer 2. Assembly spacer 4. Bearing lock nut 7. Position an assembly spacer and yellow assembly washer on each end of the roller shaft 8. Tighten the bearing lock nuts until the yellow assembly washers bottom out against the roller housing. Remove the bearing lock nuts, assembly washers, and assembly spacers. g227754 Figure 130 1. Bearing lock nut 2.
Rear Roller Brushes (Optional) There are two different types of rear roller brush kits for Greensmaster 3120 cutting units. The earlier type of kit is designed to fit on cutting units with or without a belt driven groomer. A later type of kit is designed to fit on cutting units with or without a universal groomer. Please take a moment to determine which type of rear roller brush kit is installed on the cutting unit as the service information is different for each rear roller brush type.
Servicing the Rear Roller Brush (with or without a belt driven groomer) g230192 Figure 132 1. Cover 11. Square key 21. Cap screw (2 each) 2. Drive belt 12. Flange head screw (4 each) 22. Cap screw 3. Drive pulley 13. Roller bearing assembly (2 each) 23. Bearing spacer 4. Pulley driver (used without groomer) 14. Grease fitting (2 each) 24. Hex nut (2 each) 5. Cap screw 15. Brush support – RH 25. Counterweight (used without groomer) 6. Idler pulley assembly 16.
Servicing the Rear Roller Brush (with or without a belt driven groomer) (continued) CAUTION Contact with the reel or other cutting unit parts can result in personal injury. Use heavy gloves when handling the cutting reel. Replacing the Roller Brush Element 1. Remove the cutting unit from the machine and place it on a level work surface. 2. Loosen the set screw in the bearing locking collar on right side of brush shaft. 3.
Servicing the Rear Roller Brush (with or without a belt driven groomer) (continued) g229942 Figure 133 5. The drive belt should deflect approximately 6 mm (1/4 inch) when 1 kg (2 lb) of force is applied to the belt halfway between the pulleys. Adjust the idler puller as necessary. Drive and Support Components Refer to Figure 132 for this procedure. 1. Disassemble the roller brush components as necessary. Retrieve and discard the drive plate O-ring. 2.
Servicing the Rear Roller Brush (with or without a belt driven groomer) (continued) g325691 Figure 134 1. Pulley driver 3. Weld side of reel support plate 2. Reel shaft 4. Pry bar B. Insert a long-handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move.
Servicing the Rear Roller Brush (with or without a belt driven groomer) (continued) F. Clean the threads in the end of the reel shaft. A left-hand thread tap is available to clean or repair the threads if necessary; refer to Reel Thread Repair Taps (page 2–17). G. To install the pulley driver, insert a long-handled pry bar through the front of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move. g286366 Figure 135 1.
Servicing the Rear Roller Brush (with or without a belt driven groomer) (continued) 8. Install the brush support. 9. Install the drive pulley. Apply anti-seize lubricant the cap screw threads and tighten from 8 to 9 N∙m (70 to 80 in-lb). IMPORTANT The brush drive belt may fail prematurely if the pulleys are not properly aligned. 10. Using a straight edge, move the roller brush as necessary to align the pulleys. g229943 Figure 136 11. Tighten the roller brush bearing locking collars. A.
Servicing the Rear Roller Brush (with or without a universal groomer) g230471 Figure 137 (shown without Universal Groomer installed) DPA Cutting Units: Service and Repairs Page 7–40 Greensmaster 3120 17230SL Rev D
Servicing the Rear Roller Brush (with or without a universal groomer) (continued) Figure 137 (continued) 1. Lock nut (2 each) 16. Bearing bracket LH 31. Drive pulley 2. Brush shaft 17. Drive housing 32. Retaining ring 3. J-bolt (2 each) 18. Spacer (as required) 33. Flange nut (4 each) 4. Brush element 19. Driven pulley 34. Flange head screw (4 each) 5. O-ring (2 each) 20. Lock nut 35. Flange head screw 6. Lock nut (2 each) 21. Torsion spring 36.
Servicing the Rear Roller Brush (with or without a universal groomer) (continued) 1. Disassemble the roller brush components as necessary. Retrieve and discard the adapter housing O-ring (machines without a universal groomer). 2. Clean and inspect all components for wear or damage and replace as necessary. 3. If the drive shaft and drive adapter (items 40 or 42) require replacement (machines without a universal groomer): A.
Servicing the Rear Roller Brush (with or without a universal groomer) (continued) IMPORTANT The drive shaft and drive adapter have left-hand threads. Turn the drive shaft or drive adapter clockwise to loosen. D. Rest the handle of the pry bar against the front roller and use the large hex (1.375 inch) to loosen the drive shaft assembly. E. Retrieve the shim (item 41 in Figure 137). F. Tip the cutting unit back onto its rollers. G. Clean the threads in the end of the reel shaft.
Servicing the Rear Roller Brush (with or without a universal groomer) (continued) K. Rest the handle of the pry bar against the front roller. Use the large hex (1.375 inch) and tighten the drive shaft from 135 to 150 N·m (100 to 110 ft-lb). 4. For units without a universal groomer, install the counterweight. Note: The screw used to secure the adapter housing has a locking feature to prevent the screw from loosening.
Servicing the Rear Roller Brush (with or without a universal groomer) (continued) IMPORTANT If brush to roller contact is incorrect, brush operation will be adversely affected. 13. Check that the roller brush is parallel to the rear roller within 0.25 mm (0.010 inch) clearance to light contact. Adjust the bearing brackets as necessary.
DPA Cutting Units: Service and Repairs Page 7–46 Greensmaster 3120 17230SL Rev D
Chapter 8 Belt Driven Groomer (Optional) Table of Contents Specifications ....................................................................................................................................... 8–2 Belt Driven Groomer (Optional).......................................................................................................... 8–2 General Information ..............................................................................................................................
Specifications Belt Driven Groomer (Optional) Item Description Grooming reel diameter 6 cm (2.375 inches) Groomer blade type Spring Steel: 42 steel blades with 1/2 inch blade spacing. Carbide: 42 steel blades with 1/2 inch blade spacing. Thin blade: 82 steel blades with 1/4 inch blade spacing. A soft or stiff groomer brush can be installed in place of the grooming reel. Groomer mounting The groomer is mounted to the cutting unit side plates.
General Information Installation Instructions The Installation Instructions for the groomer provides information regarding the set-up, operation, general maintenance procedures, and maintenance intervals for the groomer assembly on your Greensmaster machine. Refer to the Installation Instructions for additional information when servicing the groomer assembly. Grooming Performance There are a number of factors that can affect the performance of grooming.
Troubleshooting Problem The groomer reel does not rotate. Possible Causes Correction Seized grooming reel or idler bearing(s) in groomer side plate(s). Identify and replace faulty bearing(s). Broken or damaged drive belt idler spring. Replace idler . The groomer drive belt is worn, broken or damaged. If the belt slips, it probably is worn and must be replaced. Repair or replace belt if necessary.
Service and Repairs Replacing the Groomer Drive Belt 1. Park the machine on a clean and level surface, lower the cutting units completely to the ground, stop the engine, engage the parking brake and remove the key from the ignition switch. 2. If equipped, remove rear roller brush from cutting unit; refer to Servicing the Rear Roller Brush (with or without a belt driven groomer) (page 7–34). g229353 Figure 141 1. Groomer drive cover 2. Lock nut (3 each) 3.
Replacing the Groomer Drive Belt (continued) 6. Secure the belt cover to the machine with three lock nuts. 7.
The Groomer Plate Assemblies g229416 Figure 143 1. Lock nut (4 each) 11. Bushing (2 each) 21. Lock nut (2 each) 2. Drive cover 12. Spring washer (2 each) 22. Plow bolt (2 each) 3. Drive belt 13. Lock nut (2 each) 23. Grooming reel assembly 4. Drive pulley 14. Support plate assembly 24. O-ring 5. Shoulder bolt (2 each) 15. Groomer arm – LH 25. Front roller assembly 6. Extension spring 16. Tabbed washer (2 each) 26. Motor adapter 7. Drive plate assembly 17.
Removing the Drive Plate Refer to Figure 143 for this procedure. 1. Park the machine on a clean and level surface, lower the cutting units completely to the ground, stop the engine, engage the parking brake and remove the key from the ignition switch. 2. Remove the cutting unit from the machine and place cutting unit on a flat work surface. 3. If equipped, remove rear roller brush from cutting unit; refer to Servicing the Rear Roller Brush (with or without a belt driven groomer) (page 7–34). 4.
Removing the Drive Plate (continued) C. Move the pry bar against the weld side of the reel support plate closest to the drive pulley. IMPORTANT The drive pulley has left-hand threads. Turn the pulley driver or drive adapter clockwise to loosen. D. Rest the handle of the pry bar against the front roller and loosen the drive pulley. E. Tip the cutting unit back onto its rollers. F. Clean the threads in the end of the reel shaft.
Removing the Drive Plate (continued) g229543 Figure 146 1. Driven pulley 2. Idler pulley 3. Idler arm extension spring 11. Remove the idler arm extension spring. 12. Remove the two shoulder bolts that secure the drive plate assembly to the cutting unit and remove the groomer drive plate assembly. Locate and retrieve the shim. 13. Inspect the seals, bushings and bearings in the drive plate, support plate and groomer arms for wear or damage. Replace components as needed.
Removing the Support Plate Refer to Figure 143 for this procedure. 1. Park the machine on a clean and level surface, lower the cutting units completely to the ground, stop the engine, engage the parking brake and remove the key from the ignition switch. 2. Remove the cutting unit from the machine and place cutting unit on a flat work surface. 3. If equipped, remove rear roller brush from cutting unit; refer to Servicing the Rear Roller Brush (with or without a belt driven groomer) (page 7–34). 4.
Servicing the Drive and Support Plates g229556 Figure 148 1. Drive plate 9. Reel hub 2. Support plate 10. Idler pulley 3. Retaining ring 11. Bearing (2 each) 4. Bushing (2 each) 12. Retaining ring 5. Spacer 13. Flange nut 6. Idler arm 14. Shaft seal (3 each) 7. Spacer 15. Shaft bearing (3 each) 8. O-ring 16. Expansion plug 1. Remove the retaining ring and separate the reel hub, spacers and idler arm from the drive plate. 2. Replace idler pulley bearings if necessary. 3.
Servicing the Drive and Support Plates (continued) g229557 Figure 149 1. Drive plate 6. Inner shaft seal 2. Support plate 7. Bearing 3. 4. Outer shaft seal Outer bearing 8. 9. Seal Expansion plug 5. Inner bearing IMPORTANT Bearings should be installed with extended inner races toward center of plate. Apply pressure equally to inner and outer bearing races when installing bearings. Seals should be installed with the face of the seal toward the outside of the plate. 6.
Installing the Support Plate Refer toFigure 143 for this procedure. 1. Fit the support plate over the motor adapter. 2. Apply a light coating of grease to the support plate end of the groomer reel shaft and to the seal lip in the support plate. 3. Apply a light coating of grease to the O-ring on the motor adapter and the pilot bore of the cutting unit side plate. 4. Carefully fit the support plate and motor adapter onto the groomer shaft and into the pilot bore of the cutting unit side plate.
Installing the Drive Plate Refer to Figure 143 for this procedure. 1. Make sure that all drive plate bearings, bushings and seals are in good condition and properly installed. 2. Apply a light coating of grease to the drive end of the groomer reel shaft and to the seal lips in the drive plate. 3. Position the shim on the drive plate assembly. 4. Apply a light coating of grease to the O-ring on the drive plate pivot hub and the pilot bore of the cutting unit side plate. 5.
Installing the Drive Plate (continued) g229452 Figure 152 1. Pinch bolt 4. Spring washer 2. 3. Groomer reel Lock nut 5. Groomer arm – LH D. Secure the groomer arm to the drive plate with the spring washer and lock nut. 10. Center the front roller in the cutting unit and tighten both pinch bolts. 11. Install the drive pulley: A. Insert a long-handled pry bar through the front of the cutting unit.
Installing the Drive Plate (continued) IMPORTANT The drive pulley has left-hand threads. Turn the drive pulley counterclockwise to tighten. C. Rest the handle of the pry bar against the front roller and tighten the drive pulley from 135 to 150 N·m (100 to 110 ft-lb). 12. Install the groomer drive belt and drive cover. 13. If equipped, install rear roller brush to cutting unit; refer to Servicing the Rear Roller Brush (with or without a universal groomer) (page 7–40). 14.
The Groomer Reel Removing the Groomer Reel 1. Remove the groomer drive plate; refer to Removing the Drive Plate (page 8–8). 2. Carefully pull the grooming reel from the support plate on the right side of the cutting unit. 3. Retrieve and discard the O-ring from the support plate end of the groomer reel shaft. Servicing the Groomer Reel g229531 Figure 154 1. Groomer reel shaft 4. Spacer – thin (82 each) 7. Midpoint 2. Groomer blade (42 each) 5. Locknut (2 each) 8. Centered on shaft 3.
Servicing the Groomer Reel (continued) Note: New lock nuts have an insert to prevent the lock nut from loosening. If a used lock nut is being installed, apply a medium strength thread locker (Loctite #242 or equivalent) to the threads of the lock nut. A. Install a lock nut on one end of the groomer reel shaft. B. Install a single 12 mm (0.46 inch) spacer against the lock nut. Then, place the first blade against the spacer installed. Note: For standard 13 mm (1/2 inch) spacing, fit two 5.6 mm (0.
The Groomer Arm Assemblies g229587 Figure 155 1. Groomer arm – LH 2. Flange nut 3. Grooved pin 4. 5. 6. 7. 8. Lift arm assembly 15. Drive plate 9. Detent spring 16. Lock nut 10. Lock washer 17. Spring washer E-ring 11. Cap screw 18. Bushing Lift rod 12. Bushing 19. Plastic plug Lock screw Bushing (2 each) 13. 14.
Installing the Groomer Arms (continued) 2. Apply anti-seize lubricant to the shoulder of the groomer arm lift rods and the shoulder of the lift arm studs. 3. Position either groomer arm through the drive plate bushing and against the cutting unit side plate. Make sure the cutting unit side plate fits between the height adjustment bolt head and shoulder. 4. Secure the groomer arm to the cutting unit side plate with the plow bolt, special washer and lock nut. 5.
The Grooming Brushes (Optional) g229598 Figure 156 1. Spiral brush 2. Spiral brush shaft 3. J-bolt (2 each) 4. Lock nut (2 each) 7. Grooming brush shaft 5. O-ring 8. Roll pin (2 each) 6. Grooming brush The optional grooming brush attaches to the groomer in place of the groomer reel. The grooming brush is removed and installed from the groomer in the same manner as the groomer reel; refer to The Groomer Reel (page 8–18). The grooming brush elements or shafts can be serviced separately.
Chapter 9 Universal Groomer (Optional) Table of Contents Specifications ....................................................................................................................................... 9–2 Universal Groomer............................................................................................................................. 9–2 General Information ..............................................................................................................................
Specifications Universal Groomer Item Description Grooming reel diameter 6 cm (2.375 inches) Groomer blade type Spring Steel: 40 steel blades with 1/2 inch blade spacing. Carbide: 40 steel blades with 1/2 inch blade spacing. Thin blade: 81 steel blades with 1/4 inch blade spacing. The groomer brush can be installed in place of grooming reel. Groomer mounting The groomer is mounted to the cutting unit side plates.
General Information Installation Instructions The Installation Instructions for the groomer provides information regarding the set-up, operation, general maintenance procedures, and maintenance intervals for the groomer assembly on your Greensmaster machine. Refer to the Installation Instructions for additional information when servicing the groomer assembly. Grooming Performance There are a number of factors that can affect the performance of grooming.
Troubleshooting (continued) Problem The turf is damaged or has uneven grooming. Universal Groomer (Optional): General Information Possible Causes Correction The groomer is set too aggressively. Refer to groomer Installation Instructions for groomer set-up information. The groomer reel blades are bent, damaged, or missing. Repair or replace the blades if necessary. The groomer reel shaft is bent or damaged. Replace the groomer reel shaft.
Service and Repairs g227930 Figure 157 1. Gear box assembly 4. Height adjuster assembly (2 each) 2. Idler assembly 5. Weight 3. Groomer reel 6. Flat head screw (2 each) CAUTION Never work on the groomer with the engine running. Always stop the engine, remove the key from the ignition switch and wait for all machine movement to stop before working on the groomer.
The Gear Box Assembly g228076 Figure 158 1. Gear box assembly 4. Clevis pin 2. Drive shield 5. Input shaft 3. Cotter pin 6. Shim The groomer gear box assembly is located on the opposite side of the cutting unit from the cutting unit hydraulic motor. Removing the Gear Box Assembly IMPORTANT All of the groomer gear boxes for this machine are installed on the left side of the cutting unit. Groomer gear boxes installed on the left side of the cutting unit use a left hand thread.
Removing the Gear Box Assembly (continued) 6. Tip up the cutting unit to access the bottom of the reel to remove the drive shaft assembly. g324486 Figure 159 1. 5/16–18 X 5/8 inch square head set screw 4. Reel shaft 2. Input shaft assembly 5. Unwelded side of reel support plate 3. Groomer gear box assembly 6. Pry bar 7. Insert a long-handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit.
Removing the Gear Box Assembly (continued) IMPORTANT You must use a 6-point socket with a heavy wall to remove the gear box from the reel. Do not use an impact wrench. Groomer gear boxes installed on the left side of the cutting unit use a left hand thread; turn the drive shaft clockwise to remove the gear box. 9. Rest the handle of the pry bar against the front roller and turn the drive shaft clockwise to loosen it from the reel.
Removing the Gear Box Assembly (continued) E. Remove the retaining ring from the drive shaft. F. Slide the groomer housing assembly from the drive shaft. G. Tip up the cutting unit to access the bottom of the reel to remove the drive shaft assembly. g324522 Figure 161 1. Damaged input shaft assembly 4. Unwelded side of reel support plate 2. Drive shaft removal tool 5. Pry bar 3. Reel shaft H.
Removing the Gear Box Assembly (continued) IMPORTANT The drive shaft for groomer gear boxes installed on the left side of the cutting unit use a left hand thread. K. Rest the handle of the pry bar against the front roller and turn the drive shaft clockwise to loosen it from the reel. 12. Retrieve the shim (item 6 in Figure 158. 13. Tip the cutting unit back onto its rollers. 14. Clean the threads in the end of the reel shaft.
Servicing the Gear Box g228166 Figure 162 1. Drive adapter 21. Detent ball 2. Input shaft 22. Detent spring 3. O-ring (3 each) 23. Oil seal 4. V-ring 24. Socket-head screw(4 each) 5. 6. Oil seal Groomer housing 25. 26. Groomer cover Gasket 7. Ball bearing (2 each) 27. Thrust washer 8. Retaining ring 28. Ball bearing 9. Driven gear 29. Ring gear 10. Actuator shaft 30. Flange bushing 11. Pin 31. Sun gear 12. O-ring 32. Bearing 13. Knob 33.
Servicing the Gear Box (continued) 1. Remove the drain/fill plug and drain the oil from the gear box. 2. Remove the 4 socket-head screws and separate the gear box cover and housing. Remove and discard the cover gasket. 3. Slide the sun gear, ring gear, and planet gears from the pins on the gear box housing. 4. Continue to disassemble the gear box as necessary. 5.
Installing the Gear Box Assembly IMPORTANT All of the groomer gear boxes for this machine are installed on the left side of the cutting unit. Groomer gear boxes installed on the left side of the cutting unit use a left hand thread. Turn the input shaft (rear roller brush drive shaft) counter-clockwise to install the gear box. Refer to Figure 158 for this procedure. 1.
Installing the Gear Box Assembly (continued) IMPORTANT Groomer gear boxes installed on the left side of the cutting unit use a left hand thread; turn the drive shaft counterclockwise to install the gear box. 5. Position the gear box assembly against the cutting unit and turn the drive shaft assembly counterclockwise until it is seated against the reel. IMPORTANT You must use a 6-point socket with a heavy wall to install the gear box to the reel. Do not use an impact wrench. 6.
The Idler Assembly g228189 Figure 164 1. Socket-head screw (2 each) 2. 9. 10. Stub shaft Flocked seal (2 each) 3. Motor adapter 11. Bearing 4. Bushing 12. Retaining ring 5. Idler arm 13. Flange nut 6. O-ring 14. Clevis pin 7. Lock nut (2 each) 15. Cotter pin 8. Shield 16. Collar The groomer idler assembly is located on the opposite side of the groomer gear box. Removing the Idler Assembly 1.
Installing the Idler Assembly 1. If the shields, bearing, or bushing was removed from the idler arm: A. Press the bushing into a groomer plate until the bushing is centered in the idler arm bore. B. Press the bearing into the idler arm so that the bearing contacts the shoulder in idler arm bore and install the bearing retaining ring. C. Install the bearing shields with the flocked side of the shield toward the bearing. D. Insert the stub shaft through the shields and bearing.
The Groomer Reel g228732 Figure 165 1. Shaft clamp (4 each) 3. Bolt (4 each) 2. Jam nut (4 each) 4. Groomer reel Remove the groomer reel to replace individual groomer blades or replace the shaft. The groomer reel can be reversed to provide additional blade life. Removing the Groomer Reel 1. Park the machine on a clean and level surface, lower the cutting units completely to the ground, set the parking brake, and remove the key from the key switch.
Servicing the Groomer Reel g229088 Figure 166 1. Groomer reel shaft 5. Rounded edge 2. Groomer blade (40 each) 6. Midpoint 3. Spacer (39 each) 7. Centered on shaft 4. Locknut (2 each) Inspect the groomer reel blades frequently for any damage and wear. Straighten the bent blades. Either replace the worn blades or reverse the individual blades to put the sharpest blade edge forward.
Servicing the Groomer Reel (continued) E. Use the through holes in shaft to prevent the shaft from rotating and tighten the second lock nut to 42 to 48 N∙m (31 to 35 ft-lb). After tightening the lock nut, spacers should not be free to rotate and the groomer blades should be centered on the shaft. 7. Install the groomer reel back onto the cutting unit; refer to Installing the Groomer Reel (page 9–19). Installing the Groomer Reel 1. Position the cutting unit on a level surface.
The Height Adjuster Assembly g229138 Figure 167 1. Clevis pin 8. Flange nut 15. Quick up cover 2. Cotter pin 9. Washer (2 each) 16. Detent spring 3. Tabbed washer 10. Compression spring 17. Button-head screw 4. Lock nut 11. Pinch bolt 18. Height adjuster knob 5. Bumper 12. Height-of-cut bracket 19. Height adjustment bolt 6. Plow bolt 13. Quick up lever 7. Height adjustment rod 14.
Assembling the Height Adjuster 1. Apply anti-seize lubricant to the upper threads of the adjustment rod and lower threads of the height adjusters. Assemble the height adjuster assembly. 2. If both the height adjusters are removed, fit 1 height adjuster assembly to the cutting unit side plate and secure it with a plow bolt, tabbed washer and lock nut. Tighten the lock nut finger tight. 3.
The Grooming Brush (Optional) g229629 Figure 169 1. Spiral brush 4. Lock nut (2 each) 2. Brush shaft 5. Grooming brush 3. J-bolt (2 each) 6. Roll pin (2 each) The optional grooming brush attaches to the groomer in place of the groomer reel. The grooming brush is removed and installed from the groomer in the same manner as the groomer reel; refer to The Groomer Reel (page 9–17). The grooming brush element or shaft can be serviced separately.
Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations.........................................................................................................A–2 Hydraulic Schematic (machines without backlap) ..............................................................................A–3 Hydraulic Schematic (machines with backlap) ...................................................................................A–4 Electrical Schematic (serial numbers below 403410000) ...........
Electrical Drawing Designations Note: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire harness diagram (e.g., SP01 is splice number 1). Wire Color The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter.
Hydraulic Schematic (machines without backlap) g205802 Greensmaster 3120, Drawing 131-2784 Rev D, Sheet 1 of 1 17230SL Rev D Page A–3
Hydraulic Schematic (machines with backlap) g213435 Page A–4 17230SL Rev D Greensmaster 3120, Drawing 136-8401 Rev A, Sheet 1 of 1
Electrical Schematic (serial numbers below 403410000) g205801 Greensmaster 3120 (serial numbers below 403410000), Drawing 122-0700 Rev A, Sheet 1 of 1 17230SL Rev D Page A–5
Electrical Schematic (serial numbers above 403410000) g325786 Page A–6 17230SL Rev D Greensmaster 3120 (serial numbers above 403410000), Drawing 122-1371 Rev B, Sheet 1 of 1
Wire Harness Drawing - Main (serial numbers below 403410000) g205799 Greensmaster 3120 (serial numbers below 403410000), Drawing 122-0148 Rev B, Sheet 1 of 2 17230SL Rev D Page A–7
Wire Harness Diagram - Main (serial numbers below 403410000) g205798 Page A–8 17230SL Rev D Greensmaster 3120 (serial numbers below 403410000), Drawing 122-0148 Rev B, Sheet 2 of 2
Wire Harness Drawing - Main (serial numbers above 403410000) g324321 Greensmaster 3150 (serial numbers above 403410000), Drawing 122-1453/133-1369 Rev A/A, Sheet 1 of 2 17230SL Rev D Page A–9
Wire Harness Diagram - Main (serial numbers above 403410000) g324320 Page A–10 17230SL Rev D Greensmaster 3120 (serial numbers above 403410000), Drawing 122-1453/133-1369 Rev A/A, Sheet 2 of 2
Wire Harness - Seat g205800 Greensmaster 3120, Drawing 108-9466 Rev C, Sheet 1 of 1 17230SL Rev D Page A–11
Wire Harness - Engine g205797 Page A–12 17230SL Rev D Greensmater 3120, Drawing 105-8276 Rev H, Sheet 1 of 1
