Toro GreensPro 1260 Greens Roller User manual

FormNo.14211SLRevA

GreensPro

™

1240/1260

Models44912/44913

8111LyndaleAvenueSouth

Bloomington,MN55420

OriginalInstructions(EN)

Contactusatwww.Toro.com.

AllRightsReserved

RevisionHistory

RevisionDateDescription

-

2014InitialIssue

A

11/2018IncorporatedGreensPro1260.Addedrevisionhistory.

RevisionHistoryPage2

GreensPro

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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:+1952-887-8495

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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.

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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.

Preface

Page6

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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

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Safety

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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:SafetyInstructions

Page1–2

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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.

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Safety: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:SafetyInstructions

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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.

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Safety:SafetyandInstructionalDecals

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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

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Speci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)

Totaldisplacement

196cc(12cuin)

Compressionratio

8.5:1

CarburetorFloatfeedxedmainjet

GovernorMechanicalyweight

Low-idlespeed(noload)GreensPro1240=1,250to1,600rpm

GreensPro1260=1,800rpm

High-idlespeed(noload)

3,600rpm

DirectionofrotationCounterclockwise(facingPTOshaft)

Fuel

unleadedgasolinefuelwithanoctaneratingof87

orhigherwithnomorethan10%Ethanol

Fueltankcapacity

3.1L(0.82USgallons)

Engineoil

RefertotheOperator’sManual

Lubricationsystem

Splashtype

Oilcapacity0.6L(0.63USgallons)

AircleanerDualelement

SpecicationsandMaintenance:Specications

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Engine(continued)

ItemDescription

Ignitionsystem

Transistorizedywheelmagneto

SparkplugNGKBPR6ES

Sparkpluggap0.7to0.8mm(0.028to0.031inch)

Engineweight(dry)16.1kg(35.5lb)

Hydraulic

ItemDescription

GreensPro1240

Transmission

Hydro-GearModelBDRhydrostatictransmission

Pumpdisplacement

10.2cc(0.62cuin)perrevolution

Motordisplacement

21.8cc(1.33cuin)perrevolution

Drivechainsprocketalignment

-0.57to0.57mm(-0.02to0.02inch)

Hydraulictankcapacity

2.5L(0.66USgallons)

GreensPro1260

Hydraulicpump

Hydro-GearModelPGvariabledisplacement

axialpistonpump

Pumpdisplacement

10.2cc(0.62cuin)perrevolution

Tractioncircuitreliefpressure16,000kPa(2,320psi)

Chargepumpdisplacement2.1cc(0.13cuin)perrevolution

Chargecircuitreliefpressure550kPa(80psi)

HydraulicMotor

ParkerHanninTESeriesgerotormotor

Motordisplacement

82cc(5.0in³)perrevolution

Hydraulictankcapacity

3.9L(1.03USgallons)

Hydrauliclter

10micronspin-oncartridgetype

HydraulicuidRefertotheGreensProOperator'sManual

Chassis

ItemDescription

Tires

16×6.5-8,4ply,tubelessat103kPa(15psi)

Steeringwheelnuttorque28to35N∙m(20to26ft-lb)

Steeringrollerlocknuttorque92to124N∙m(68to91ft-lb)

Transportwheellugnuttorque

108N∙m(80ft-lb)

Towbarmountingbolttorque

10mmbolt

68to81N∙m(50to60ft-lb)

12mmbolt

162to176N∙m(120to130ft-lb)

Transportframeclampbolttorque18to24N∙m(13to18ft-lb)

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14211SLRevA

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cations

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CalculatingtheTorqueValuesWhenUsingaDrive-AdapterWrench

g205924

Figure2

TorqueConversionFactor=A/B

1.Torquewrench

3.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).

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Speci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cations

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