Toro GreensPro 1240 User manual

FormNo.14211SLRevA
GreensPro™1240/1260
Models44912/44913
©2018—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
OriginalInstructions(EN)
Contactusatwww.Toro.com.
AllRightsReserved

RevisionHistory
RevisionDateDescription
-2014InitialIssue
A11/2018IncorporatedGreensPro1260.Addedrevisionhistory.
RevisionHistoryPage2GreensPro™1240/1260
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ReaderComments
TheT oroCompanyTechnicalAssistanceCentermaintainsacontinuouseffort
toimprovethequalityandusefulnessofitspublications.Todothiseffectively,
weencourageuserfeedback.Pleasecommentonthecompleteness,accuracy,
organization,usability,andreadabilityofthismanual.
bye-mail:
[email protected]
bymail:
TechnicalPublicationManager,Commercial
TheToroCompany
8111LyndaleAvenueSouth
Bloomington,MN55420-1196
Phone:[phone]
GreensPro™1240/1260Page3ReaderComments
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ReaderCommentsPage4GreensPro™1240/1260
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Preface
Thisservicemanualwaswrittenexpresslyforservicetechnicians.Basicshop
safetyknowledgeandmechanical/electricalskillsareassumed.TheToro
Companyhasmadeeveryefforttomaketheinformationinthismanualcomplete
andcorrect.
Thepurposeofthispublicationistoprovidetheservicetechnicianwith
informationabouttroubleshooting,testing,andrepairingmajorsystemsand
components.Thismanualmaybespeciedforuseonnumerousproducts.
RefertotheT ableofContentsforalistofthesystemsandtherelatedtopics
coveredinthismanual.
RefertothetractionunitandaccessoryOperator’sManualsandInstallation
Instructionsforadditionalinformationaboutinstalling,operating,maintaining,
andadjustingthemachine.KeepacopyoftheOperator’sManuals,Installation
InstructionsandPartsCatalogsforyourmachineanditsaccessorieswiththis
ServiceManualforreference.AdditionalcopiesoftheOperator’sManuals,
InstallationInstructionsandPartsCatalogsareavailableatwww.toro.com.
TheToroCompanyreservestherighttochangetheproductspecicationsor
thispublicationwithoutnotice.
GreensPro™1240/1260Page5Preface
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ServiceProcedureIcons
ThefollowingiconsappearthroughoutthisServiceManualtobringattentionto
specicimportantdetailsofaserviceprocedure.
CriticalProcess
Thisiconisusedtohighlight:
•installingsafetyequipment(shields,guards,seatbelts,brakesandR.O.P .S.
components)thatmayhavebeenremoved
•dimensionsorsettingsthatmustbemaintainedforpropermachineoperation
•aspecicfastenertighteningsequence
•componentorientationthatmaynotbeobvious
CriticalTorque
Thisiconisusedtohighlightanassemblytorquerequirementthatisdifferentthan
whatisrecommendedintheStandardT orqueT ables;refertoStandardTorque
forDry,ZincPlated,andSteelFasteners(InchSeries)(page2–7)orStandard
TorqueforDry,ZincPlated,andSteelFasteners(MetricFasteners)(page2–8).
FluidSpecications
Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless
common,andmaynotappearonthemachineservicedecalorinthemachine
Operator’sManual.
Note:RefertotheservicedecalonthemachineandthemachineOperator’s
Manualforcommonlyuseduidspecicationsandcapacities.
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TableofContents
Preface................................................................................................................5
Chapter1:Safety............................................................................................1–1
SafetyInstructions.......................................................................................1–2
SafetyandInstructionalDecals....................................................................1–5
Chapter2:SpecicationsandMaintenance....................................................2–1
Specications...............................................................................................2–2
TorqueSpecications...................................................................................2–4
ShopSupplies............................................................................................2–10
SpecialT ools..............................................................................................2–12
Chapter3:Troubleshooting.............................................................................3–1
GEARS–TheSystematicApproachtoDening,DiagnosingandSolving
Problems......................................................................................................3–2
StartingandOperatingProblems(machineserialnumberabove
31500000)....................................................................................................3–3
GeneralHydraulicSystemProblems(GreensPro1260)...............................3–5
TractionCircuitProblems(GreensPro1260).................................................3–6
Chapter4:Engine...........................................................................................4–1
GeneralInformation.....................................................................................4–2
ServiceandRepairs.....................................................................................4–5
Chapter5:HydraulicSystem...........................................................................5–1
GeneralInformation.....................................................................................5–2
HydraulicSchematic(GreensPro1260)......................................................5–17
HydraulicFlowDiagrams............................................................................5–18
TestingtheHydraulicSystem......................................................................5–20
Adjustments...............................................................................................5–29
ServiceandRepairs...................................................................................5–35
Chapter6:ElectricalSystem...........................................................................6–1
GeneralInformation.....................................................................................6–2
ElectricalSchematicsandWireHarnessDrawings/Diagrams.......................6–3
ElectricalSystemQuickChecks..................................................................6–13
TestingtheElectricalComponents..............................................................6–14
Chapter7:Chassis..........................................................................................7–1
GeneralInformation.....................................................................................7–2
Adjustments.................................................................................................7–5
ServiceandRepairs...................................................................................7–13
AdditionalReferenceMaterials
HYDRO−GEARBDRSERVICEANDREPAIRMANUAL
HYDRO−GEARPSERIESHYDROSTATICPUMPSSERVICEANDREPAIR
MANUAL
PARKERTORQMOTORSERVICEPROCEDURE
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Chapter1
Safety
TableofContents
SafetyInstructions................................................................................................................................1–2
ThinkSafetyFirst...............................................................................................................................1–3
SafetyandInstructionalDecals............................................................................................................1–5
GreensPro™1240/1260Page1–1Safety
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SafetyInstructions
DANGER
Thissafetysymbolmeansdanger.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscouldkillorcauseseriouspermanentinjuryordisability.
WARNING
Thissafetysymbolmeanswarning.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinseriousinjury.
CAUTION
Thissafetysymbolmeanscaution.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinminortomoderateinjury.
IMPORTANT
TheImportantnoticewillgivetheimportantinstructionswhichyou
mustfollowtopreventdamagetothesystemsorcomponentson
themachine.
Note:ANotewillgivethegeneralinformationaboutthecorrectoperation,
maintenance,service,testing,orrepairofthemachine.
Safety:SafetyInstructionsPage1–2GreensPro™1240/1260
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ThinkSafetyFirst
ToroProductsaretestedandcertiedforcompliancewithexistingsafety
standardsandspecications.Althoughhazardcontrolandaccidentprevention
arepartiallydependentuponthedesignandcongurationofthemachine,
hazardcontrolandaccidentpreventionarealsodependentupontheawareness,
concernandpropertrainingofthepersonnelinvolvedintheoperation,transport,
maintenance,andstorageofthemachine.Improperuseormaintenanceofthe
machinecanresultininjuryordeath.
WARNING
Toreducethepotentialofinjuryordeath,complywiththesafety
instructionsinthismanual,aswellasinformationfoundinthe
Operator’sManualsandtheOperatorandSafetyTrainingVideos
foundonwww.toro.com.
•Avoidunexpectedstartingoftheengine…
Alwaysturnofftheengine,removetheignitionkeyanddisconnectthe
sparkplugwire(s)beforecleaning,adjusting,orrepair.
•Avoidlacerationsandamputations…
Stayclearofallmovingpartswhenevertheengineisrunning.Treatall
normallymovingpartsasiftheyweremovingwhenevertheengineis
runningorhasthepotentialtostart.
•Avoidburns…
Donottouchtheengine,mufer,orothercomponents,whichmaybehot
duringoperation,whiletheunitisrunningorshortlyafterithasbeen
running.
•Avoidresandexplosions…
Useextremecareinhandlingfuel.Fuelisammableanditsvaporsare
explosive.
–Extinguishallcigarettes,cigars,pipes,andothersourcesofignition.
–Avoidspillingfuelandneversmokewhileworkingwithanytypeoffuel
orlubricant.
–Wipeupanyspilledfueloroilimmediately.
–Neverremovethefuelcaporaddfuelwhentheengineisrunning.
–Alwaysuseapproved,labeledcontainersforstoringortransportingfuel
andlubricants.
–Donotaddordrainfuelinanenclosedspace.
–Donotstorethemachineorfuelcontainerwherethereisanopename,
spark,orpilotlight,suchasonawaterheaterorotherappliance.
•Avoidasphyxiation…
Donotoperateanengineinaconnedareawithoutproperventilation.
•Avoidinjuryfrombatteries…
–Batteryacidispoisonousandcancauseburns.Avoidcontactwithskin,
eyesandclothing.
–Batterygasescanexplode.Keepcigarettes,sparksandamesaway
fromthebattery.
•Avoidinjuryduetoinferiorparts…
Useonlyoriginalequipmentpartstoensurethatimportantsafetycriteria
aremet.
GreensPro™1240/1260Page1–3Safety:SafetyInstructions
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ThinkSafetyFirst(continued)
•Avoidinjurytobystanders…
Alwayscleartheareaofbystandersbeforestartingortestingpowered
equipment.
•Avoidinjuryduetoprojectiles…
Alwayscleartheareaofsticks,rocksoranyotherdebristhatcouldbe
pickedupandthrownbythepoweredequipment.
•Avoidmodications…
Neveralterormodifyanypartunlessitisafactoryapprovedprocedure.
•Avoidunsafeoperation…
Alwaystestthesafetyinterlocksystemaftermakingadjustmentsor
repairsonthemachine.RefertotheElectricalsectioninthismanual
formoreinformation.
•Avoidelectricalshock…
–Nevertouchelectricalwiresorcomponentswhiletheengineisrunning.
Theycanbesourcesofshock.
–De-energizethesystemifyouarehavingtodorepairs.
–Iftestingelectricalcomponentsensureyouareworkinginadry
environment.
•HydraulicSystemprecautions...
–Releaseallpressureinthehydraulicsystembeforeperforminganywork
onthesystem.
–Keepyourbodyandhandsawayfrompin-holeleaksornozzlesthateject
hydraulicuidunderhighpressure.Donotuseyourhandstosearchfor
leaks.Hydraulicuidescapingunderpressurecanhavesufcientforce
topenetratetheskinandcauseseriousinjury.
–Seekmedicalattentionrightawayifhydraulicuidgetsintheskin.
•Usepersonalprotectiveequipment…
–Useappropriatepersonalprotectiveequipment(PPE)forprotecting
yourselffrompotentialhazardsintheenvironmentinwhichyouwillwork.
–EachprocessoutlinedinthismanualmayneeddifferentPPEtoprotect
theserviceperson.UsetheproperPPEforthetaskathand.
•Usingtools…
–Alltoolsshouldbeinproperworkingorder.Donotusetoolsthatare
brokenorindisrepair.
–Usethepropertoolfortheproperapplication.
•Usinglifts,hoists,andjacks…
–Alllifts,hoists,andjacksshouldbeusedinaccordancewiththe
manufacturerinformation.
–Inspectlifts,hoists,andjackspriortouse.
–Donotoverloadlifts,hoists,andjacks.
–Donotworkunderasuspendedload.
–Ensurechockblocksareusedonequipmentthatcanmove.
–Useliftsorjacksandjackstandsthatareratedtosupportthetotalweight
ofthemachineandanyattachments.
–Donotrelyonjackstosupportthemachine.
–Ifyouareunfamiliarwithanylifts,hoistsorjacks,donotusethemuntil
youknowhowtooperatethemcorrectly.
Safety:SafetyInstructionsPage1–4GreensPro™1240/1260
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ThinkSafetyFirst(continued)
•Usingreextinguishers…
Usetheproperclassofreextinguisherincaseofre.
Ensurereextinguishersareservicedregularly,andreplaceanyre
extinguishersthataredischargedorinusebeyondtheirexpirationdates.
–ClassAreextinguishersareforordinarycombustiblematerialssuch
aspaper,wood,cardboard,andmostplastics.Thenumericalratingon
thesetypesofextinguishersindicatestheamountofwateritholdsand
theamountofreitcanextinguish.Geometricsymbol(greentriangle).
–ClassBreextinguishersareforresthatinvolveammableor
combustibleliquidssuchasgasoline,kerosene,greaseandoil.The
numericalratingforclassBextinguishersindicatestheapproximate
numberofsquarefeetofreitcanextinguish.Geometricsymbol(red
square).
–ClassCreextinguishersareforresthatinvolveelectricalequipment
suchasappliances,wiring,circuitbreakersandoutlets.Neverusewater
toextinguishclassCres-theriskofelectricalshockisfartoogreat!
ClassCextinguishersdonothaveanumericalrating.TheCclassication
meanstheextinguishingagentisnon-conductive.Geometricsymbol
(bluecircle).
–ClassABCreextinguishersareadrychemicaltypeusedformultiple
purposes.Seeabovedescriptionsforadditionalinformation.
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocated
nearanyareaofpotentialdanger.Ifanydecalbecomesillegibleordamaged,
installanewdecal.DecalpartnumbersarelistedinyourPartsCatalog,
Operator’sManual,andaccessoryInstallationInstructions.Orderreplacement
decalsfromAuthorizedT oroDistributor.
GreensPro™1240/1260Page1–5Safety:SafetyandInstructionalDecals
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Safety:SafetyandInstructionalDecalsPage1–6GreensPro™1240/1260
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Chapter2
SpecicationsandMaintenance
TableofContents
Specications.......................................................................................................................................2–2
OverallDimensions............................................................................................................................2–2
Engine................................................................................................................................................2–2
Hydraulic............................................................................................................................................2–3
Chassis..............................................................................................................................................2–3
TorqueSpecications...........................................................................................................................2–4
CalculatingtheT orqueValuesWhenUsingaDrive-AdapterWrench.................................................2–5
IdentifyingtheFastener......................................................................................................................2–6
StandardT orqueforDry,ZincPlated,andSteelFasteners(InchSeries)............................................2–7
StandardT orqueforDry,ZincPlated,andSteelFasteners(MetricFasteners)...................................2–8
OtherTorqueSpecications...............................................................................................................2–9
ConversionFactors............................................................................................................................2–9
ShopSupplies....................................................................................................................................2–10
SpecialTools......................................................................................................................................2–12
GreensPro™1240/1260Page2–1SpecicationsandMaintenance
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Specications
OverallDimensions
g271353
Figure1
GreensPro1240/1260
Engine
ItemDescription
Make/DesignationHonda,4-stroke,OHVsinglecylinder,air-cooled
gasolineengine,GX200
BorexStroke68mmx54mm(2.68x2.13inches)
Totaldisplacement196cc(12cuin)
Compressionratio8.5:1
CarburetorFloatfeedxedmainjet
GovernorMechanicalyweight
Low-idlespeed(noload)GreensPro1240=1,250to1,600rpm
GreensPro1260=1,800rpm
High-idlespeed(noload)3,600rpm
DirectionofrotationCounterclockwise(facingPTOshaft)
Fuelunleadedgasolinefuelwithanoctaneratingof87
orhigherwithnomorethan10%Ethanol
Fueltankcapacity3.1L(0.82USgallons)
EngineoilRefertotheOperator’sManual
LubricationsystemSplashtype
Oilcapacity0.6L(0.63USgallons)
AircleanerDualelement
SpecicationsandMaintenance:SpecicationsPage2–2GreensPro™1240/1260
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Engine(continued)
ItemDescription
IgnitionsystemTransistorizedywheelmagneto
SparkplugNGKBPR6ES
Sparkpluggap0.7to0.8mm(0.028to0.031inch)
Engineweight(dry)16.1kg(35.5lb)
Hydraulic
ItemDescription
GreensPro1240
TransmissionHydro-GearModelBDRhydrostatictransmission
Pumpdisplacement10.2cc(0.62cuin)perrevolution
Motordisplacement21.8cc(1.33cuin)perrevolution
Drivechainsprocketalignment-0.57to0.57mm(-0.02to0.02inch)
Hydraulictankcapacity2.5L(0.66USgallons)
GreensPro1260
HydraulicpumpHydro-GearModelPGvariabledisplacement
axialpistonpump
Pumpdisplacement10.2cc(0.62cuin)perrevolution
Tractioncircuitreliefpressure16,000kPa(2,320psi)
Chargepumpdisplacement2.1cc(0.13cuin)perrevolution
Chargecircuitreliefpressure550kPa(80psi)
HydraulicMotorParkerHanninTESeriesgerotormotor
Motordisplacement82cc(5.0in³)perrevolution
Hydraulictankcapacity3.9L(1.03USgallons)
Hydrauliclter10micronspin-oncartridgetype
HydraulicuidRefertotheGreensProOperator'sManual
Chassis
ItemDescription
Tires16×6.5-8,4ply,tubelessat103kPa(15psi)
Steeringwheelnuttorque28to35N∙m(20to26ft-lb)
Steeringrollerlocknuttorque92to124N∙m(68to91ft-lb)
Transportwheellugnuttorque108N∙m(80ft-lb)
Towbarmountingbolttorque
10mmbolt68to81N∙m(50to60ft-lb)
12mmbolt162to176N∙m(120to130ft-lb)
Transportframeclampbolttorque18to24N∙m(13to18ft-lb)
GreensPro™1240/1260Page2–3SpecicationsandMaintenance:Specications
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TorqueSpecications
Therecommendedfastenertorquevaluesarelistedinthefollowingtables.For
criticalapplications,asdeterminedbyT oro,eithertherecommendedtorqueora
torquethatisuniquetotheapplicationisclearlyidentiedandspeciedinthis
ServiceManual.
Thesetorquespecicationsfortheinstallationandtighteningofthefastenerswill
applytoallthefastenerswhichdonothaveaspecicrequirementidentiedin
thisServiceManual.Thefollowingfactorsmustbeconsideredwhenapplying
thetorque:cleanlinessofthefastener,useofathreadsealant(e.g.,Loctite),
degreeoflubricationonthefastener,presenceofaprevailingtorquefeature
(e.g.,Nylocknut),hardnessofthesurfaceunderneaththeheadofthefastener,
orsimilarconditionwhichaffectstheinstallation.
Asnotedinthefollowingtables,thetorquevaluesshouldbereducedby25%
forlubricatedfastenersorfastenerswithawetthreadlockingcompound
appliedtoachievethesimilarstressasadryfastener.Thetorquevaluesmust
bereducedwhenthefasteneristhreadedintothealuminumorbrass.The
specictorquevalueshouldbedeterminedbasedonthealuminumorbrass
materialstrength,fastenersize,lengthofthreadengagement,etc.
Thestandardmethodofcheckingthetorquecanbeperformedbymarkingaline
onthefastener(headornut)andmatingpart,thenbackoffthefastener1/4
ofaturn.Measurethetorquenecessarytotightenthefasteneruntilthelines
matchup.
SpecicationsandMaintenance:TorqueSpecicationsPage2–4GreensPro™1240/1260
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CalculatingtheTorqueValuesWhenUsingaDrive-AdapterWrench
g205924
Figure2
TorqueConversionFactor=A/B
1.Torquewrench3.A(effectivelengthoftorquewrench)
2.Drive-adapterwrench(crowsfoot)4.B(effectivelengthoftorquewrenchand
drive-adapterwrench)
Usingadrive-adapterwrench(e.g.,crowfootwrench)inanypositionotherthan
90°and270°totheframeofthetorquewrenchwillaffectthetorquevalue
measuredbythetorquewrenchbecauseoftheeffectivelength(lever)ofthe
torquewrenchchanges.Whenusingatorquewrenchwithadrive-adapter
wrench,multiplythelistedtorquerecommendationbythecalculatedtorque
conversionfactor(Figure2)todeterminepropertighteningtorque.Whenusinga
torquewrenchwithadrive-adapterwrench,thecalculatedtorquewillbelower
thanthelistedtorquerecommendation.
Example:Themeasuredeffectivelengthofthetorquewrench(distancefrom
thecenterofthehandletothecenterofthesquaredrive)is457mm(18inches).
Themeasuredeffectivelengthofthetorquewrenchwiththedrive-adapter
wrenchinstalled(distancefromthecenterofthehandletothecenterofthe
drive-adapterwrench)is483mm(19inches).
Thecalculatedtorqueconversionfactorforthistorquewrenchwiththis
drive-adapterwrenchwouldbe18/19=0.947.
Ifthelistedtorquerecommendationforafasteneris103to127N∙m(76to94
ft-lb),thepropertorquewhenusingthistorquewrenchwithadrive-adapter
wrenchwouldbe98to121N∙m(72to89ft-lb).
GreensPro™1240/1260Page2–5SpecicationsandMaintenance:TorqueSpecications
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IdentifyingtheFastener
g206089
Figure3
MetricBoltsandScrews
1.Class8.82.Class10.9
g206088
Figure4
InchSeriesBoltsandScrews
1.Grade12.Grade53.Grade8
FastenerswithaLockingFeature
IMPORTANT
Ifafastenerwithalockingfeatureorpreviouslyappliedthread
lockingcompoundisreused,cleanthefastenerthreadsandapply
newthreadlockertothefastenerduringinstallation.
Lockingfeaturesaredesignedtocreatefrictionandpreventafastenerfrom
loosening.Lockingfeaturescanbefoundonexternallyorinternallythreaded
fasteners.Commonexamplesareplasticinsertsincorporatedintothefastener
andpre-applied“dry”threadlockingcompound.Keepinmind,afastenerwith
alockingfeatureusuallymeanstherewillbefrictionduringinitialinstallation
andduringremoval.
Tororecommendsreplacingfastenerswithalockingfeatureoncetheyhave
beenremovedbecausetheeffectivenessofthelockingfeaturediminisheswith
eachreuse.Ifitisnecessarytoreuseafastenerwithalockingfeature;applya
threadlockingcompound(Loctiteforexample)tothefastenerduringinstallation.
Usetheappropriatestrengthandtypeofthreadlockingcompoundbasedon
application,fastenersizeorinformationfoundintheproductOperatorsManual,
ServiceManualorInstallationInstructions.
SpecicationsandMaintenance:TorqueSpecicationsPage2–6GreensPro™1240/1260
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