Toro Greensmaster 3120 User manual

FormNo.17230SLRevC
Greensmaster3120
©2018—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
OriginalInstructions(EN)
Contactusatwww.Toro.com.
AllRightsReserved

RevisionHistory
RevisionDateDescription
A10/2017Initialissue.
B01/2018AddedRevisionHistory
C04/2018UpdatedCuttingUnitchapter.
RevisionHistoryPage2Greensmaster3120
17230SLRevC

Reader Comments
The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and
usefulness of its publications. To do this effectively, we encourage user feedback. Please comment
on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to
[email protected]
or Mail to:
Technical Publication Manager, Commercial
The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Phone: [phone]
Greensmaster3120Page3RevisionHistory
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NOTES:
RevisionHistoryPage4Greensmaster3120
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Preface
Thepurposeofthispublicationistoprovidetheservicetechnicianwiththe
informationfortroubleshooting,testing,andrepairofthemajorsystemsand
componentsoftheGreensmaster3120(Model04355).
RefertothetractionunitandcuttingunitOperator’sManualsforoperating,
maintenance,andadjustmentinstructions.KeepacopyoftheOperator’s
ManualsandPartsCatalogsforyourmachinewiththisServiceManualfor
reference.AdditionalcopiesoftheOperator’sManualsandPartsCatalogsare
availableatwww.toro.com.
TheToroCompanyreservestherighttochangetheproductspecicationsor
thispublicationwithoutnotice.
DANGER
Thissafetysymbolmeansdanger.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscouldkillorcauseseriouspermanentinjuryordisability.
WARNING
Thissafetysymbolmeanswarning.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinseriousinjury.
CAUTION
Thissafetysymbolmeanscaution.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinminortomoderateinjuryand/ordamage
topropertyorequipment.
IMPORTANT
TheImportantnoticewillgiveimportantinstructionswhichyou
mustfollowtopreventdamagetothesystemsorcomponentson
themachine.
Note:ANotewillgivegeneralinformationaboutthecorrectoperation,
maintenance,service,testing,orrepairofthemachine.
Greensmaster3120Page5Preface
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OverallDimensions
g219200
Figure1
Greensmaster3120
PrefacePage6Greensmaster3120
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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
Thisiconisusedtohighlightanassemblytorquerequirementthatisdifferent
thanwhatisrecommendedintheStandardT orqueTables;refertoTorque
Specications(page2–4).
FluidSpecications
Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless
common,andmaynotappearonthemachineservicedecalorinthemachine
Operator’sManual.
Note:RefertotheservicedecalonthemachineandthemachineOperator’s
Manualforcommonlyuseduidspecicationsandcapacities.
Greensmaster3120Page7Preface
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TableofContents
Preface................................................................................................................5
Chapter1:Safety............................................................................................1–1
SafetyInstructions.......................................................................................1–2
JackingInstructions.....................................................................................1–7
SafetyandInstructionalDecals....................................................................1–8
Chapter2:SpecicationsandMaintenance....................................................2–1
Specications...............................................................................................2–2
TorqueSpecications...................................................................................2–4
ShopSupplies..............................................................................................2–9
SpecialT ools..............................................................................................2–11
Chapter3:Engine...........................................................................................3–1
Specications...............................................................................................3–2
GeneralInformation.....................................................................................3–3
ServiceandRepairs.....................................................................................3–4
Chapter4:HydraulicSystem...........................................................................4–1
Specications...............................................................................................4–3
GeneralInformation.....................................................................................4–4
HydraulicSchematics.................................................................................4–13
HydraulicFlowDiagrams............................................................................4–15
SpecialT ools...............................................................................................4–26
Troubleshooting..........................................................................................4–30
TestingtheHydraulicSystem......................................................................4–35
Adjustments...............................................................................................4–70
ServiceandRepairs...................................................................................4–71
Chapter5:ElectricalSystem...........................................................................5–1
GeneralInformation.....................................................................................5–2
SpecialTools.................................................................................................5–3
Troubleshooting............................................................................................5–5
ElectricalSystemQuickChecks....................................................................5–8
TestingtheElectricalComponents..............................................................5–11
ServiceandRepairs...................................................................................5–30
Chapter6:Chassis..........................................................................................6–1
Specications...............................................................................................6–2
GeneralInformation.....................................................................................6–3
SpecialTools.................................................................................................6–4
ServiceandRepairs.....................................................................................6–5
Chapter7:DPACuttingUnits..........................................................................7–1
Specications...............................................................................................7–2
GeneralInformation.....................................................................................7–4
SpecialTools.................................................................................................7–5
AftercutAppearance.....................................................................................7–9
Adjustments...............................................................................................7–11
ServiceandRepairs...................................................................................7–14
Chapter8:BeltDrivenGroomer(Optional)......................................................8–1
Specications...............................................................................................8–2
GeneralInformation.....................................................................................8–3
ServiceandRepairs.....................................................................................8–5
Chapter9:UniversalGroomer(Optional)........................................................9–1
Specications...............................................................................................9–2
GeneralInformation.....................................................................................9–3
ServiceandRepairs.....................................................................................9–5
AppendixA......................................................................................................A–1
HydraulicSchematic(machineswithoutbacklap).........................................A–3
HydraulicSchematic(machineswithbacklap)..............................................A–4
ElectricalSchematic.....................................................................................A–5
WireHarnessDrawing-Main.......................................................................A–6
PrefacePage8Greensmaster3120
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WireHarnessDiagram-Main........ ....... ....... ....... ....... .... ....... ....... ....... ....... ...A–7
WireHarness-Seat......................................................................................A–8
WireHarness-Engine..................................................................................A–9
AdditionalReferenceMaterials
Briggs & Stratton Vanguard V-Twin OHV Repair Manual
Hydro-Gear® P Series Hydrostatic Pumps Service and Repair Manual
Parker Torqmotor™ Service Procedure (TC, TB, TE, TJ, TF, TG, TH and TL
Series)
Danfoss Steering Unit Type OSPM Service Manual
Greensmaster3120Page9Preface
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PrefacePage10Greensmaster3120
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Chapter1
Safety
TableofContents
SafetyInstructions................................................................................................................................1–2
Supervisor’sResponsibilities.............................................................................................................1–2
BeforeOperatingtheMachine...........................................................................................................1–2
WhileOperatingtheMachine.............................................................................................................1–4
MaintenanceandService...................................................................................................................1–6
JackingInstructions..............................................................................................................................1–7
RaisingtheMachine..........................................................................................................................1–7
SafetyandInstructionalDecals............................................................................................................1–8
Greensmaster3120Page1–1Safety
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SafetyInstructions
TheGreensmaster3120machinemeetsorexceedssafetystandardspecicationsasidentiedinthe
Operator’sManuals.Althoughhazardcontrolandaccidentpreventionaredependentpartiallyuponthe
designandcongurationofthemachine,thesefactorsarealsodependentupontheawareness,concern
andpropertrainingofthepersonnelinvolvedintheoperation,transport,maintenance,andstorageofthe
machine.Theimproperuseormaintenancebytheoperatororownerofthemachinecanresultininjury.
WARNING
Toreducethepotentialofinjuryordeath,complywiththefollowingsafetyinstructions
aswellasinformationfoundintheOperator’sManuals.
Supervisor’sResponsibilities
1.EnsurethattheoperatorsarefullytrainedandfamiliarwiththeOperator’s
Manuals,Operator’sTrainingDVD,andalloftheoperatingandsafetydecals
onthemachine.
2.Establishyourownspecialproceduresandworkrulesforunusualoperating
conditions(e.g.,slopestoosteepformachineoperation).Surveythemowing
sitecompletelytodeterminehillsonwhichyoucanoperatesafely.When
performingthissitesurvey,alwaysunderstandandtakeintoconsideration
theturfconditionandrolloverrisk.T operformasitesurvey,followthe
procedureoutlinedintheOperator’sManuals.
BeforeOperatingtheMachine
•ReviewandunderstandthecontentsoftheOperator’sManualsandallofthe
operatingandsafetydecalsonthemachinebeforestartingandoperating
themachine.AdditionalcopiesoftheOperator’sManualsareavailableat
www.toro.com.
•Neverallowchildrentooperatethemachine.Neverallowadultstooperate
themachinewithoutproperinstructions.
•Becomefamiliarwiththecontrolsandknowhowtostopthemachineand
enginequickly.
•Keepalltheshields,safetydevices,anddecalsinplace.Ifashield,safety
device,ordecalisillegibleordamaged,repairorreplaceitbeforeoperating
themachine.
•Alwayswearsubstantialshoes.Donotoperatemachinewhilewearing
sandals,tennisshoesorsneakers.Donotwearloosettingclothingwhich
couldgetcaughtinmovingpartsandcausepersonalinjury.
•Wearingsafetyglasses,safetyshoes,longpantsandahelmetisadvisable
andrequiredbysomelocalsafetyandinsuranceregulations.
•Makesureworkareaisclearofobjectswhichmightbepickedupandthrown
bythereels.
•Donotcarrypassengersonthemachine.Keepeveryone,especiallychildren
andpets,awayfromtheareaofoperation.
•Ensurethesafetyinterlocksareadjustedcorrectlysothattheenginedoes
notstartunlessthefunctioncontrolleverisintheNEUTRALposition,the
tractionpedaldoesnotoperatewhenthefunctioncontrolleverisinthe
NEUTRALposition,thecuttingunitsstop(disengage)ifthefunctioncontrol
leverismovedtotheNEUTRALorTRANSPORTposition,andtheenginestopsif
theseatisunoccupiedortheparkingbrakeisnotappliedwhenthefunction
controlleverisintheMOWorTRANSPORTposition.
•Gasoline(fuel)ishighlyammable;handleitcarefully.
Safety:SafetyInstructionsPage1–2Greensmaster3120
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BeforeOperatingtheMachine(continued)
–Storefuelincontainersspecicallydesignedforstoringfuel.
–Donotremovethefueltankcapofthemachinewhiletheengineishot
orrunning.
–Donotsmokewhilehandlingfuel.
–Fillthefueltankoutdoorsandonlytoalevelwithinaninchofthetopof
thetank,notthellerneck.Donotoverllthefueltank.
–Replacethefueltankandfuelcontainercapssecurelyafterrefuelling
themachine.
–Ifyouspillfuel,donotattempttostarttheenginebutmovethemachine
awayfromthespill.Avoidcreatinganysourceofignitionuntilfuelvapors
havedissipated.Wipeupanyspilledfuel.
Greensmaster3120Page1–3Safety:SafetyInstructions
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WhileOperatingtheMachine
DANGER
Theexhaustfumesarehazardousandhavethepotentialofinjury
ordeath.
Donotruntheengineinaconnedareawithoutadequateventilation.
1.Sitontheseatwhenstartingandoperatingthemachine.
2.Checkthesafetyinterlocksdailyforproperoperation;refertoChecking
theInterlockSystemOperation(page5–10).Adjustorreplaceany
malfunctioningswitchesorinterlockmechanismsbeforeoperatingthe
machine.
3.Tostarttheengine:
A.Sitontheseatandmakesurecuttingunitsaredisengaged.
B.Verifythatfunctioncontrolleverisinneutral.
C.Verifythatparkingbrakeisset.
D.Proceedtostartengine.
4.Usingthemachinedemandsoperatorattention.T opreventlossofmachine
control:
A.Mowonlyindaylightorwhenthereisgoodarticiallight.
B.Watchforholesorotherhiddenhazards.
C.Donotdriveclosetosandtraps,ditches,creeksorotherhazards.
D.Reducespeedwhenmakingsharpturns.Avoidsuddenstopsandstarts.
E.Beforebackingup,looktothereartobesurenooneisbehindthe
machine.
F.Watchoutfortrafcwhennearorcrossingroads.Alwaysyieldthe
right-of-way.
G.Applytheservicebrakeswhengoingdownhilltokeepforwardspeedslow
andtomaintaincontrolofthemachine.
5.Keephands,feetandclothingawayfrommovingpartsandthereeldischarge
area.Thegrassbasketsmustbeinplaceduringoperationofthereelsor
thatchersformaximumsafety.Shuttheengineoffbeforeemptyingthe
baskets.
6.Raisethecuttingunitswhendrivingfromoneworkareatoanother.
7.Donottouchtheengine,muferorexhaustpipewhiletheengineisrunning
orsoonafteritisstoppedbecausetheseareascouldbehotenoughto
causeburns.
8.Ifacuttingunitstrikesasolidobjectorvibratesabnormally,stopimmediately,
turntheengineoff,waitforallmotiontostopandinspectfordamage.A
damagedreelorbedknifemustberepairedorreplacedbeforeoperation
iscontinued.
9.Traverseslopescarefully.Donotstartorstopsuddenlywhentravelinguphill
ordownhill.
10.DON’TTAKEANINJURYRISK!Whenapersonorpetappearsunexpectedly
inornearthemowingarea,STOPMOWING.Carelessoperation,combined
withterrainangles,ricochetsorimproperlypositionedguardscanleadto
thrownobjectinjuries.Donotresumemowinguntiltheareaiscleared.
11.Beforegettingofftheseat:
Safety:SafetyInstructionsPage1–4Greensmaster3120
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WhileOperatingtheMachine(continued)
A.Makesurethecuttingunitsaredisengaged.
B.Verifythatfunctioncontrolleverisinneutral.
C.Settheparkingbrake.
D.Lowerthecuttingunitstotheground.
E.Stoptheengineandremovekeyfromignitionswitch.
12.Whenevermachineisleftunattended,makesurecuttingunitsarefullyraised
andreelsarenotspinning,thekeyisremovedfromignitionswitchandthe
parkingbrakeisset.
Greensmaster3120Page1–5Safety:SafetyInstructions
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MaintenanceandService
•Beforeservicingormakinganyadjustmentstothemachine,lowerthecutting
units,settheparkingbrake,shutofftheengine,andremovethekeyfromthe
keyswitch.
•Ensurethatthemachineisinsafeoperatingconditionbykeepingallthe
nuts,bolts,andscrewstight.
•Wearglovesandusecautionwhencheckingorservicingthecuttingunits.
•Ensurethatallofthehydrauliclineconnectorsaretightandthatallthe
hydraulichosesandlinesareingoodconditionbeforeapplyingpressureto
thehydraulicsystem.
•Keepyourbodyandhandsawayfrompin-holeleaksinthehydraulicsystem
thatejecthydraulicuidunderhighpressure.Usecardboardorpapertond
hydraulicleaks.Thehydraulicuidescapingunderpressurecanpenetrate
theskinandcauseinjury.Ifhydraulicuidisaccidentallyinjectedintothe
skin,youmusthaveitsurgicallyremovedwithinafewhoursbyadoctor
familiarwiththistypeofinjury.Otherwise,gangrenemayresult.
•Beforedisconnectingorperforminganyworkonthehydraulicsystem,release
allthepressureinthesystembyparkingthemachineonalevelsurface,
loweringthecuttingunitscompletely,andthenshuttingofftheengine.
•Useeyeprotectionwhenworkingonthehydraulicsystemandits
components.
•Toreducepotentialrehazards,keeptheengineareafreeofexcessive
grease,grass,leaves,anddirt.Neverwashawarmengineorelectrical
connectionswithwater.
•Checkallfuellinesfortightnessandwearonaregularbasis.Tightenor
repairfuellinesasneeded.
•Ifyoumustruntheenginetoperformmaintenanceortomakeanadjustment,
keepyourhands,feet,clothing,andotherpartsofthebodyawayfromthe
cuttingunitsandothermovingparts.Keepbystandersaway.
•Donotover-speedtheenginebychangingtheenginegovernorsetting.
Toensuresafetyandaccuracy,checkthemaximumenginespeedwitha
tachometer.
•Shutofftheenginebeforecheckingoraddingoiltotheenginecrankcase.
•Disconnectthebatteriesbeforeservicingthemachine.Disconnectthe
negativebatterycableandthenthepositivecable.Ifbatteryvoltageis
necessaryfortroubleshootingortestprocedures,temporarilyconnectthe
battery.Connectthepositivebatterycableandthenthenegativecable.
•Batteryacidispoisonousandcancauseburns.Avoidacidcontactwithskin,
eyes,andclothing.Protectyourface,eyes,andclothingwhenworkingwith
thebattery.
•Batterygasescanexplode.Keepcigarettes,sparks,andamesawayfrom
thebattery.
•Ifmajorrepairsarenecessary,contactyourAuthorizedToroDistributor.
•Atthetimeofmanufacture,themachineconformedtothesafetystandards
forridingmowers.Toensuretheoptimumperformanceandcontinued
safetycerticationofthemachine,usegenuineT ororeplacementpartsand
accessories.Thereplacementpartsandaccessoriesofothermanufacturers
canresultinnon-conformancewiththesafetystandardsandcanvoidthe
warranty.
•Whenchangingtheattachments,tires,orperformingotherservice;refer
toJackingInstructions(page1–7).
Safety:SafetyInstructionsPage1–6Greensmaster3120
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JackingInstructions
CAUTION
Failingtoproperlysupportthemachinewithappropriatejackstands
cancausethemachinetomoveorfallandcanresultinpersonal
injury.
Whenchangingtheattachments,tires,orperformingotherservices,
dothefollowingsteps:
•Parkthemachineonasolidlevelsurface,suchasaconcrete
oor.
•Alwaysblockthewheelswithchocks.
•Beforeyouliftthemachine,removealltheattachmentsthatmay
interferewiththesafeandcorrectliftofthemachine.
•Usecorrectblocks,hoists,andjackstoraisethemachine.
•Useappropriatejackstandstosupporttheraisedmachine.
•DoNotuseacuttingunitasajackingpoint.
RaisingtheMachine
g212063
Figure2
1.Leftfrontjackingpoint(framechannelunderthestepbehindtheleftfrontwheel)
2.Rearjackingpoint(rearwheelcasterfork)
Greensmaster3120Page1–7Safety:JackingInstructions
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RaisingtheMachine(continued)
g212064
Figure3
1.Rightfrontjackingpoint(RollOver
ProtectionSystem“ROPS”supportbracket
behindtheRHfrontwheel)
2.Rearjackingpoint(rearwheelcasterfork)
1.Lowerthecuttingunits,settheparkingbrakeandblocktherearwheelwitha
chocktopreventthemachinefrommoving.
2.Positionthejacksecurelyunderthedesiredfrontjackingpoint:
3.Afterraisingthefrontofthemachine,usetheappropriatejackstandsunder
theframeasclosetothewheelaspossibletosupportthemachine.
SafetyandInstructionalDecals
Numeroussafetyandinstructionaldecalsareafxedtothetractionunitand
thecuttingunitsoftheGreensmaster3120.Ifanydecalbecomesillegibleor
damaged,replaceitwithanewdecal.PartnumbersarelistedinyourParts
CatalogandOperator’sManual.OrderreplacementdecalsfromyourAuthorized
ToroDistributor
Safety:SafetyandInstructionalDecalsPage1–8Greensmaster3120
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Chapter2
SpecicationsandMaintenance
TableofContents
Specications.......................................................................................................................................2–2
DecimalandMillimeterEquivalents...................................................................................................2–2
U.S.toMetricConversions................................................................................................................2–3
TorqueSpecications...........................................................................................................................2–4
CalculatingtheT orqueValuesWhenUsingaDrive-AdapterWrench.................................................2–4
IdentifyingtheFastener......................................................................................................................2–5
StandardTorqueforDry,ZincPlated,andSteelFasteners(Metric)...................................................2–6
StandardTorqueforDry,ZincPlated,andSteelFasteners(Inch)......................................................2–7
OtherTorqueSpecications...............................................................................................................2–8
ConversionFactors............................................................................................................................2–8
ShopSupplies......................................................................................................................................2–9
SpecialTools......................................................................................................................................2–11
Greensmaster3120Page2–1SpecicationsandMaintenance
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Specications
InsertacopyoftheOperator’sManualsandPartsCatalogsforyourmachine
(tractionunitandcuttingunits)attheendofthischapter.Additionally,ifany
optionalequipmentoraccessoriesareinstalledtoyourmachine,insertthe
InstallationInstructions,Operator’sManuals,andPartsCatalogsforthose
optionsattheendofthischapter.
Themaintenanceproceduresandrecommendedserviceintervalsforyour
machinearecoveredintheOperator’sManuals.Refertothesepublications
whenperformingregularequipmentmaintenance.RefertotheEngine
Operator’sManualforadditionalenginespecicmaintenanceprocedures.
DecimalandMillimeterEquivalents
FractionsDecimalsmmFractionsDecimalsmm
1/640.0156250.39733/640.51562513.097
1/320.031250.79417/320.5312513.494
3/640.0468751.19135/640.54687513.891
1/160.06251.5889/160.562514.288
5/640.0781251.98437/640.57812514.684
3/320.093752.38119/320.5937515.081
7/640.1092752.77839/640.60937515.478
1/80.12503.1755/80.625015.875
9/640.1406253.57241/640.64062516.272
5/320.156253.96921/320.6562516.669
11/640.1718754.36643/640.67187517.066
3/160.18754.76211/160.687517.462
13/640.2031255.15945/640.70312517.859
7/320.218755.55623/320.7187518.256
15/640.2343755.95347/640.73437518.653
1/40.25006.3503/40.750019.050
17/640.2656256.74749/640.76562519.447
9/320.281257.14425/320.7812519.844
19/640.2968757.54151/640.79687520.241
5/160.31257.93813/160.812520.638
21/640.3281258.33453/640.82812521.034
11/320.343758.73127/320.8437521.431
23/640.3593759.12855/640.85937521.828
3/80.37509.5257/80.875022.225
25/640.3906259.92257/640.89062522.622
13/320.4062510.31929/320.9062523.019
27/640.42187510.71659/640.92187523.416
7/160.437511.11215/160.937523.812
29/640.45312511.50961/640.95312524.209
15/320.4687511.90631/320.9687524.606
31/640.48437512.30363/640.98437525.003
SpecicationsandMaintenance:SpecicationsPage2–2Greensmaster3120
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