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14211SL - Toro Media

1. Figure 24 1 Brake band 4 Bandlining 2 Chassis 5 Brake hub 3 Shim 3 Place shims between brake band and chassis until adding one more shim would cause the band lining to contact the brake hub Fig 24 4 Install the brake band and shims if any with cap screws flat washers and lock nuts 5 Tighten the socket head screw item 2 securing the brake hub to the drive roller shaft 6 Install brake rod item 15 to brake pivot arm with hair pin 7 Pass brake rod through brake band and install flat washer and lock nut on end of brake rod 8 Connect brake return spring item 6 to chassis 9 Adjust parking brake see Operator s Manual Drive Train 2 p This page is intentionally blank Drive Train Page 5 28 GreensPro 1240 Chapter 6 Chassis Table of Contents SPECIFICATIONS 2 GENERAL INFORMATION 3 Operator s Manual 3 Steering Operation 4 Transport Frame Operation 5 ADJUSTMENTS 6 Steering Linkage 6 Tow Bar Height 7 Auto Hitch 8 SERVICE AND REPAIRS 9 Steering Wheel 9 Steering Column 10 Steering Linkage
2. 12 Steering Rollers 14 Steering Roller Service 15 Steering Heads 16 Steering Head Service 18 Transport Wheels and Hubs 20 Transport Frame 22 TOW Bali icc cma esee Pe Rem 26 Transmission Cover 27 GreensPro 1240 Page 6 1 Chassis Specifications Item Description Steering Wheel Nut Torque 20 to 26 ft lb 28 to 35 N m Transport Wheel Lug Nut Torque 80 ft lb 108 Transport Wheel Tire Size 16x6 5 84 ply Transport Wheel Tire Pressure 10 psi 0 65 bar Tow Bar Mounting Bolt Torque 10 mm bolt 50 to 60 ft Ib 68 to 81 12 mm bolt 120 to 130 ft lb 162 to 176 Chassis Page 6 2 GreensPro 1240 General Information Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your GreensPro machine Refer to the Op erator s Manual for additional information when servi cing the machine GreensPro 1240 Page 6 3 Chassis Steering Operation Figure 1 4 Steering disc assembly 5 Front steering head linkage arm 6 Steering pivot rod 1 Rear steering head 2 Front steering head 3 Rear steering head linkage arm The GreensPro steering system includes a number of components that cause the front and rear steeri
3. 2 2 Maintenance 2 2 Equivalents and Conversions 2 3 Torque Specifications 2 4 Chapter 3 Gasoline Engine Introductions iccirco dri rt war acr hr era 3 2 Specifications 3 3 General Information 3 4 Service and Repairs 3 6 Chapter 4 Electrical System General Information 4 2 Electrical Drawings And Diagrams Serial Number Above 315000000 4 3 Special TOONS ssc e ebesehrbeted ew e eS 4 6 Troubleshooting 4 7 Electrical System Quick Checks 4 8 Component Testing 4 9 Chapter 5 Drive Train Introduction aana E aA REARS 5 2 Specifications 5 3 General Information 5 4 Hydraulic 5 5 5 Adjustments 5 10 Service and Repairs 5 12 HYDRO GEAR BDR SERVICE AND REPAIR MANUAL Chapter 6 Chassis Specifications 6 2 General Information 6 3 Adjustments 6 6 Service and Repairs 6 9 GreensPro 1240 Product Records and Maintenance Gasoline T 2 Drive Train Engine N gt N
4. Cap screw Hex nut Flat washer Lock nut Hex nut Flat washer GreensPro 1240 This page is intentionally blank GreensPro 1240 Page 5 19 Drive Train Motion Control Linkage Initial Assembly Lengths prior to final adjustment 180 lt 10 11 8 in 300 gt 8 6 2 Figure 17 1 Pedal 2 Rod pivot assy 12 Hex nut LH or RH thread 4 2 Motion pedal assy RH 8 Linkage rod quadrant 13 Washer thick 5 3 Motion pedal assy LH 9 Quadrant lever assy 14 Collar 4 Bushing 8 10 Linkage rod transmission 15 Flat washer 4 5 Pivot bushing 4 11 Rod end LH or RH thread 4 16 Flat washer 14 6 Linkage rod pedal 2 Drive Train Page 5 20 GreensPro 1240 The entire motion control linkage assembly must be se cure and move freely in both directions Repair or re place motion control linkage assembly components as necessary Use a suitable lifting device to safely raise and support the machine to allow access to compon ents under the chassis Each linkage rod includes two ball joints and two hex nuts To allow adjustment one ball joint and hex nut has GreensPro 1240 Page 5 21 left hand threads and one ball joint and hex nut has right hand threads Before attempting to loosen the hex nuts for linkage disassembly or adjustment
5. Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is injected into the skin it must be surgi cally removed within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury For additional hydraulic hose information refer to Toro Service Training Book Hydraulic Hose Servicing Part Number 9481350 GreensPro 1240 Page 5 7 Hydraulic Hose Installation 1 Make sure threads and sealing surfaces of the hose tube and the fitting are free of burrs nicks scratches or any foreign material 2 Place the hose tube against the fitting body so that the face of the hose tube sleeve fully contacts the face of the fitting 3 Thread the swivel nut onto the fitting by hand While holding the hose tube with a wrench use a torque wrench to tighten the swivel nut to 24 Ib ft 32 N m This tightening process may require the use of an offset wrench e g crowfoot wrench Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offset wrench will be lower than the listed installation torque see Using a Torque Wrench with an Offset Wrench in Chapter 2
6. 1 Clean all components prior to assembly 2 If a bearing or a drive stud item 9 is removed make sure it is pressed into position fully during installation 3 Apply a thin coat of anti seize lubricant to spindle and install hub assembly using cap screw lock washer and collar item 5 4 Install wheel and tire assembly and tighten lug nuts in an alternating pattern to 80 ft Ib 108 5 Adjust tire pressure to 10 psi 0 65 bar GreensPro 1240 This page is intentionally blank GreensPro 1240 Page 6 21 Chassis Transport Frame Transport frame Damper Gas spring Washer 4 Lock nut 4 Clamp 3 Clamp plate 3 Flat washer 6 Lock washer 6 Cap screw 6 Latch raised Sleeve 2 Flat washer 4 Cap screw 2 Chassis RONDO Figure 20 Lock nut 2 Slide bracket Cap screw 2 Flat washer 4 Lock nut 2 Roller 2 Flat washer 4 Lock nut 2 Cap screw 2 Latch lowered Pin Retaining ring Torsion spring Page 6 22 Pedal pivot Lift lever Cap screw Torsion spring Pivot bushing Washer Lock nut Roll pin Torsion spring Pedal Pad Safety pin Washer head screw GreensPro 1240 The transport frame must be secure and move freely in both the raise and lower directions The latches must hold the transport frame securely in both the
7. 57 9 Steering pivot Woodruff key Set screw Flat washer 4 Flat washer 6 Lock nut 6 DARON Chassis Initial Assembly Lengths prior to final adjustment 6 5 in 166 mm 13 2 21 in 535 mm T Lf Figure 13 Ball joint LH or RH 6 Hex nut LH or RH 6 Linkage rod steering pivot Cap screw 2 Steering disc Bushing 2 Page 6 12 13 Linkage rod steering head 2 14 Spacer 4 15 Cap screw 4 16 Pivot bushing 17 Flat washer 18 Cap screw GreensPro 1240 The entire steering linkage assembly must be secure and move freely in both directions Repair or replace steering linkage assembly components as necessary 1 25 32 Use a suitable lifting device to safely raise and support the machine to allow access to compon ents under the chassis Each linkage rod includes two ball joints and two hex nuts To allow adjustment one ball joint and hex nut has left hand threads and one ball joint and hex nut has right hand threads Before attempting to loosen the hex nuts for linkage disassembly or adjustment inspect the threads on the linkage rod to determine thread direction 1 Steering pivot 2 Setscrew Figure 14 NOTE Leave linkage rod hex nuts l
8. Check wire harness terminals for corrosion and clean if necessary 4 Use a multimeter ohms setting and test the switch The switch is closed continuity exists between the ter minals when both the motion control pedals are in the NEUTRAL position and open no continuity exists be tween the terminals when the motion control pedals are ina MOVE position 5 Replace the neutral switch if testing determines that it is faulty Electrical System Page 4 14 Figure 9 1 Transmission 2 Neutral switch 6 If the neutral switch tests correctly and a circuit prob lem still exists check wire harness for circuit continuity see ELECTRICAL DRAWINGS AND DIAGRAMS in this Chapter 7 After testing is complete apply a film of dielectric grease to the switch terminals and connect machine wire harness the neutral switch GreensPro 1240 Seat Switch Serial Number Above 315000000 An Operator s seat switch as part of the machine inter lock system The seat switch is attached to the under side of the seat Fig 10 When an Operator sits in the seat the seat cushion de presses the switch plunger and closes the switch When the seat is empty the switch is allowed to return to its nor mally open position Testing 1 Park machine on a level surface engage parking brake and stop engine 2 Disconnect wire harness connectors from the seat switch 3
9. Check wire harness terminals for corrosion and clean if necessary 4 Use a multimeter ohms setting and test the switch The switch is closed continuity exists between the ter Figure 10 minals when weight is applied to the seat cushion and open no continuity exists between the terminals when the seat is empty 1 Seat 2 Seat switch 2 5 Replace the seat switch if testing determines that it is faulty 6 If the seat switch tests correctly and a circuit problem still exists check wire harness for circuit continuity see ELECTRICAL DRAWINGS AND DIAGRAMS in this Chapter 7 After testing is complete apply a film of dielectric grease to the switch terminals and connect machine wire harness to the seat switch GreensPro 1240 Page 4 15 Electrical System This page is intentionally blank Electrical System Page 4 16 GreensPro 1240 Chapter 5 TORO Drive Train Table of Contents 2 Transmission Service Manual 2 SPECIFIGATIONS em mem eem 3 GENERAL INFORMATION 4 HYDRAULIC SYSTEM 5 General Precautions for Removing and Installing Hydraulic System Components 5 Hydraulic System Component Failure 5 Hydraulic Components 6 Hydraulic Hoses 7 Hydraulic Fitting Installat
10. Drive coupling 4 Spacer 2 Cap screw 2 5 Lock nut 2 Flat washer 4 T Figure 11 Hex nut 9 Spacer Spacer 10 Pivot bushing Compression spring 11 Retaining ring Tension rod 12 Cap screw 3 Cap screw 13 Cap screw Flat washer 10 14 Lock nut Lock nut 5 15 Flat washer Idler arm assembly Drive Train Installation Fig 9 12 1 If previously removed apply anti seize lubricant to transmission input shaft and position fan key and trans mission drive collar on input shaft Fig 12 Do Not tight en drive collar set screw at this time 2 Place transmission in position on the chassis Fig 11 3 Apply a thin coat of anti seize lubricant to transmis sion output shaft 4 Position sprocket in the drive chain Move the trans mission toward the mounting bracket while guiding the sprocket onto the output shaft 5 Secure the transmission to the mounting bracket and the lower transmission mount using cap screws lock nuts and flat washers 6 Secure the sprocket to the transmission output shaft with the retaining ring Fig 11 item 11 NOTE If the idler arm assembly requires service see Drive Chain Idler Arm in this chapter 7 Install flat washer and hex nut Fig 11 item 14 amp 15 on idler adjustment rod Thread nut 1 25 in 32 mm onto rod 8 Install idler arm assembly Fig 11 item 8 using cap screw flat washers pivot bushing space
11. Repair or replace tow bar components as ne slide after assembly see Auto Hitch Slide in this cessary chapter With the exception of the tow bar itself tow bar compon ents can be removed for repair or replacement without removing the tow bar from the transport frame Chassis Page 6 26 GreensPro 1240 Transmission Cover Figure 24 1 Transmission cover 3 Alignment 2 4 Screw retainer 2 2 Quick release screw 2 Removal Fig 24 Installation Fig 24 1 Tilt steering column to the full forward position 1 Tilt steering column to the full forward position 2 Release latch and pivot seat pan forward 2 Release latch and pivot seat pan forward 3 Turn quick release screws counterclockwise 1 4 turn Lower transmission cover over alignment pins and lift transmission cover off of machine 9 Align quick release screws with screw retainers slide retainers forward or backward if necessary and ighten quick release screws o GreensPro 1240 Page 6 27 Chassis This page is intentionally blank Chassis Page 6 28 GreensPro 1240
12. for lubricated fasteners Lubricated fasteners are de fined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite 57 5 in lb 96 9 in lb 19 2 ft lb 38 4 ft lb 66 7 ft lb 166 15 ft lb 325 33 ft lb Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fasten er size the aluminum or base material strength length of thread engagement etc Product Records and Maintenance Class 8 8 Bolts Screws and Studs with Class 8 or Stronger Nuts 640 60 N cm 1018 100 N cm 26 3 N m 52 5 N m 90 10 N m 225 20 440 45 N m Page2 6 Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 310 30 610 50 N m The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 10 of the nominal torque value 78 7 in lb 133 13 in lb 27 2 ft lb 53 ft lb 92 9 ft lb 229 22 ft lb 450 37 ft lb GreensPro 1240 Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Recommended Torque 7 16 20 UNF 65 10 ft lb 88 14 N m Grade 5 1 2 20 UNF 80 10 ft lb f 108 14 Grade 5 Recommended Torque Thread Size Square Head 1 4 20 UNC 140 20 in lb 73 12 in lb 5 16 18 UNC
13. 215 35 in Ib 145 20 in Ib Product Records D i i 8 55 3 8 16 UNC 35 10 ft lb 18 3 ft lb M12 X 1 25 80 10 ft lb f 108 14 Class 8 8 1 2 13 UNC 75 15 ft lb 50 10 ft lb M12 X 1 5 80 10 ft lb 108 14 Thread Cutting Screws Cleese Zinc Plated Steel For steel wheels and non lubricated fasteners Type 1 Type 23 or Type F Thread Cutting Screws Zinc Plated Steel Thread Size Baseline Torque Thread Threads per Inch Size Baseline Torque Type A Type B 15 12 11 No 6 32 UNC 20 5 in lb No 8 32 UNC 30 5 in Ib 18 20 5 in lb No 10 24 UNC 38 7 in lb 1 4 20 UNC 85 15 in Ib 5 16 18 UNC 110 20 in Ib 3 8 16 UNC 200 100 in Ib 38 7 in lb 85 15 in lb Hole size material strength material thickness amp fin ish must be considered when determining specific torque values All torque values are based on non lubri cated fasteners in Conversion Factors in lb X 11 2985 X 0 08851 in Ib in lb X 0 1130 N m X 8 851 in Ib ft Ib X 1 3558 z N m N m X 0 7376 ft lb GreensPro 1240 Page 2 7 Product Records and Maintenance Using a Torque Wrench with an Offset Wrench Crows Foot Use of an offset wrench crows foot will affect torque wrench calibration due to the effective change of torque wrench length When using a torque wrench with an off set wrench multipl
14. If the parking brake switch tests correctly and a cir cuit problem still exists check wire harness for circuit continuity see ELECTRICAL DRAWINGS AND DIA GRAMS in this Chapter 7 After testing is complete apply a film of dielectric grease to the switch terminals and connect machine wire harness the parking brake switch GreensPro 1240 Page 4 13 Electrical System Neutral Switch Serial Number Above 315000000 A neutral switch as part of the machine interlock system The neutral switch is located on the front of the transmis sion Fig 9 NOTE Check motion control linkage operation prior to testing switch see Transmission and Motion Pedals Re turn to Neutral in Chapter 5 Drive Train in this manual When either traction pedal is applied the control linkage moves away from the switch plunger allowing the switch to return to its normally open condition The con trol linkage depresses the switch plunger when either traction pedal is released returning the transmission to neutral and closing the switch The interlock module monitors the position of the neutral switch open or closed Using inputs from the neutral switch and other switches in the interlock system the in terlock module opens or closes the engine ignition cir cuit controls circuit ground Testing 1 Park machine on a level surface engage parking brake and stop engine 2 Disconnect wire harness connectors from the neut ral switch 3
15. Rotate the control arm assembly in the opposite direction of the drive roller rotation in five 5 degree in crements Tighten the RTN adjustment screw from 18 to 22 ft lbs 24 to 30 Recheck for drive roller rota tion beginning with step 5 8 Reattach the control linkage rod Fig 6 9 Start the engine and set the throttle to full engine speed 10 Align the motion pedals by placing a straightedge across the front or back of both motion pedals Fig 7 Drive Train Page 5 10 Figure 6 1 Transmission 7 Hex nut 2 Damper 8 Cap screw 2 3 Linkage rod 9 Flat washer 4 4 Transmission control 10 Spacer linkage arm arm 11 Spacer damper plate 5 Damper plate 12 Lock nut 2 6 Lock washer Figure 7 1 Motion control pedals 2 Straightedge GreensPro 1240 NOTE Each linkage rod includes two ball joints and two hex nuts To allow adjustment one ball joint and hex nut has left hand threads and one ball joint and hex nut has right hand threads Before attempting to loosen the hex nuts for linkage adjustment inspect the threads on z s the linkage rod to determine thread direction ce To stop drive roller 11 Check for drive roller rotation If the drive roller does rotation to LEFT not rotate stop the engine and proceed to step 12 If the MM 4 drive roller rotates stop the engine and adjust the length of the control linkage rod Fig 6 Tighten the control linkage rod hex nuts
16. and recheck for drive roller rotation beginning with step 10 12 Install and secure transmission cover see Trans m NX mission Cover in Chapter 6 Chassis this manual X To stop drive roller TH rotation to RIGHT Figure 8 1 RTN adjustment screw 2 Control arm assembly 2 GreensPro 1240 Page 5 11 Drive Train Service and Repairs Transmission 99 NS vl T rd md Figure 9 1 Transmission 5 Transmission control arm 2 Neutral switch connector 6 Damper plate serial number above 315000000 7 Lock washer 3 Damper 8 Hexnut 4 Linkage rod 9 Cap screw 2 Drive Train Page 5 12 10 Flat washer 4 11 Spacer linkage arm 12 Spacer damper plate 13 Lock nut 2 GreensPro 1240 Removal Fig 9 12 1 Park machine on a clean level surface with the transport wheels in the raised and locked position Make sure engine is OFF Engage parking brake if equipped or remove spark plug wire from the spark plug 2 Move motion pedals to relieve system pressure 3 Remove transmission cover from machine see Transmission Cover in Chapter 6 Chassis in this manu al 4 Thoroughly clean hose end and fittings on the trans mission assembly and oil tank to prevent oil system con tamination 5 Drain oil from oil tank into a suitable container 6 Label all hoses and fittings for assembly purposes Remove hoses from fittin
17. assembly Control arm Flange nut Bypass plate kit Bypass actuator Bypass arm Retaining ring Pin 2 Bolt 3 Helical spring Ball Bolt 9 Plug Gerotor assembly Charge pump housing Socket head screw 2 Relief plate Bolt Before disassembling the transmission make sure that the outside of the transmission is thoroughly cleaned See the HYDRO GEAR BDR SERVICE AND REPAIR MANUAL for detailed information on transmission troubleshooting testing disassembly service and as sembly information GreensPro 1240 Page 5 17 Pivot washer Plug Spacer Seal kit incl Ref 44 51 Lip seal Lip seal Lip seal O Ring Gasket O Ring Retaining ring 2 Lip seal Return arm Screw Neutral return assembly serial number below 315000000 Neutral return assembly serial number above 315000000 Extension spring Drive Train Drive Chain Idler Arm Removal Fig 15 1 Park machine on a clean level surface with the transport wheels in the raised and locked position Make sure engine is OFF Engage parking brake if equipped or remove spark plug wire from the spark plug 2 Remove transmission cover from machine see Transmission Cover in Chapter 6 Chassis in this manu al 3 Remove hex nut spacer and compression spring from idler adjustment rod 4 Remove cap screw flat washers
18. g steering or transmission linkage is necessary raise machine with hoist or other lifting device Support raised machine with appropriate jackstands on all corners of the machine to prevent it from shifting or falling Excessive tilting of the machine should be avoided 12 When lowering machine from transport position make sure that the ground is clean and level This will prevent unexpected movement of the machine and po tential roller damage 13 If major repairs are ever needed or if assistance is desired contact an Authorized Toro Distributor 14 At the time of manufacture the machine conformed to all applicable safety standards To ensure optimum performance and continued safety certification of the machine use genuine TORO replacement parts and ac cessories Replacement parts and accessories made by other manufacturers may result in non conformance with the safety standards and the warranty may be voided 15 When disposing of hazardous waste products fuel engine oil hydraulic oil filters etc take them to an au thorized disposal site Waste products must not be al lowed to contaminate surface water drains or sewer systems GreensPro 1240 Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger Replace any decal that is damaged or lost Decal part numbers are listed in your Parts Catalog Or der replacement decals
19. in Chapter 4 Drive Train in this manual 5 This product may exceed noise levels of 85 dB A at the operator position Ear protectors are recommended for prolonged exposure to reduce the potential of per manent hearing damage GreensPro 1240 Page 1 3 6 To stop the engine A Engage the parking brake if equipped B Reduce engine speed to SLOW C Move ON OFF switch to OFF position to stop en gine 7 Do not touch engine muffler exhaust pipe or hy draulic tank while engine is running or soon after it has stopped because these areas could be hot enough to cause burns 8 Whenever machine is left unattended park machine on a level surface engage parking brake if equipped and be sure engine is stopped 9 Close fuel shutoff valve if machine is not to be used for an extended period of time Close fuel shutoff valve if machine is to be transported Safety Maintenance and Service The Operator s Manual and engine Owner s Manual provide information regarding the operation general maintenance and maintenance intervals for your GreensPro machine Refer to these publications for ad ditional information when servicing the machine 1 Before servicing or making adjustments to the ma chine engage the parking brake if equipped stop the engine and wait for all machine motion to stop Remove the spark plug wire from the spark plug to prevent acci dental starting of the engine 2 If the GreensPro is at
20. in the neutral position The neutral switch is out of adjustment or faulty The engine oil is below the minimum level or the engine oil level shutdown switch is faulty The ground connection is loose or corroded The engine ON OFF switch is faulty The interlock controller is faulty The engine starts but should not with the operator s seat UNOCCUPIED and The seat switch or seat switch circuit wiring is faulty the parking brake DISENGAGED The brake switch is faulty The brake switch circuit wiring is faulty with the motion control pedals in a MOVE The neutral switch is out of adjustment or faulty position The neutral switch circuit wiring is faulty The interlock controller is faulty The engine starts but stops when either traction pedal The parking brake is ENGAGED is pushed to the MOVE position The parking brake switch or operator seat switch is faulty GreensPro 1240 Page 4 7 Electrical System Electrical System Electrical System Quick Checks Check Operation of Interlock Switches Serial Number Above 315000000 Do not disconnect safety interlock switches They are for the operator s protection Check the operation of the interlock switches daily for proper operation Replace any malfunctioning switches or repair any damaged wiring before operating the machine GreensPro 1240 machines with serial number above 315000000 are equipped with an Interlock Module which monitors interlock switch oper
21. move the cap screws lock washers flat washers clamp plates and upper halves of the clamps item 6 from the chassis GreensPro 1240 Page 6 23 Figure 21 1 Parking brake lever 3 E Ring 2 Parking brake cable Figure 22 1 Seat support assembly Chassis Be careful when removing or installing gas spring The gas spring is under heavy load and may cause personal injury 9 Allow the transport frame to roll forward relieving all load from the gas spring Remove the lock nut and flat washer securing the gas spring to the transport frame 10 Use a suitable lifting devise to safely lift the transport frame assembly from the chassis Installation Fig 20 1 Use a suitable lifting device to safely lift the transport frame assembly onto the chassis 2 Install the gas spring item 3 to the transport frame with flat washer and lock nut 3 Center transport frame over chassis left to right and secure the transport frame to the chassis with cap screws lock washers flat washers clamp plates and clamps item 6 Tighten clamp bolts to 35 ft lb 47 5 N m 4 Install damper to transport frame with flat washer and lock nut Chassis Page 6 24 5 Secure the latch lever to the transport frame with a cap screw flat washers sleeve and lock nut 6 Install the seat support to the chassis with seat seat pan manual tube etc attached Fig 22 Use the cap screws lock washers flat washers a
22. raised when transporting the machine Fig 2 See the Operator s Manual for additional information on raising and lower ing the transport frame When moving the transport frame into the lowered transport position a gas spring and lift pedal are provided to help raise the chassis off the ground The as GreensPro 1240 5 Auto hitch slide Page6 5 7T Gas spring 8 Damper 9 Chassis sembly is held in the lowered position by a latch mech anism attached to the transport frame near the tow bar During transport the tow bar includes an auto hitch slide to lock the machine onto the tow vehicle A damper prevents the chassis from lowering too fast when moving the transport frame into the raised posi tion The transport frame is held in the raised position by a latch mechanism attached to the chassis Chassis Adjustments Steering Linkage Use a Suitable lifting device to safely raise and support the machine to allow access to compon ents under the chassis 1 Insert a block between the steering pivot assembly and chassis to prevent steering pivot assembly from moving during adjustment and to position steering pivot assembly square with chassis Fig 3 Block should be approximately 1 in 25 4 mm thick NOTE Each linkage rod includes two ball joints and two hex nuts To allow adjustment one ball joint and hex nut has left hand threads and one ball joint and h
23. raised and lowered positions Repair or replace transport frame components as necessary With the exception of the transport frame itself transport frame components can be removed for repair or re placement without removing the transport frame from the chassis Removal Fig 20 1 Park machine on a clean level surface with the transport wheels in the raised but unlocked position Make sure engine is OFF Engage the parking brake if equipped or remove spark plug wire from spark plug 2 Remove transmission cover from machine see Transmission Cover in this chapter 3 Disconnect the main wire harness at the following locations A Hourmeter harness B Interlock module serial number above 315000000 C Seat switch serial number above 315000000 D Parking brake switch serial number above 315000000 4 On machines with serial number above 315000000 disconnect the parking brake cable from the brake lever Fig 21 5 Remove the cap screws lock washers flat washers and lock nuts securing the seat support to the chassis and the rear support frame Remove the seat support from the machine with seat seat pan manual tube etc attached Fig 22 6 Remove the cap screw flat washers sleeve and lock nut securing the latch item 11 to the transport frame 7 Remove the lock nut and flat washer securing the damper upper strut to the transport frame 8 Support the hitch end of the transport frame and re
24. spread the taper lock bushing slightly if necessary and slide bushing onto the roller shaft and key with with small end of outer taper toward the roller Rotate drive roller as necessary to align mounting holes in bushing with mounting holes in sprocket 10 threads and end of set screws and install set screws loosely in holes that are threaded on the sprock et side Fig 21 NOTE The small drive sprocket is designed to move slightly along the transmission output shaft Keep this feature in mind when installing and aligning the drive chain and drive roller sprocket 11 Using a straight edge across the drive chain side plates slide sprocket and taper lock bushing on roller shaft so that drive chain and straight edge are aligned to within 0 02 in 57mm Drive Train Page 5 24 Figure 21 1 Set screws in bushing installation holes IMPORTANT When tightening taper lock bushing set screws tighten in three 3 equal steps and in an alternating pattern 12 Secure taper lock bushing and sprocket by tighten ing set screws to a torque of 23 ft Ib 31 in three 3 equal steps and in an alternating pattern 13 Check that roller drive chain alignment is still correct and re adjust if necessary Machines with serial number below 315000000 without parking brake loosen and re adjust the drive roller bearings and locking collars to allow for correct drive chain alignment Machines with serial number above 31500
25. 0000 with parking brake loosen and re adjust sprocket and taper lock bushing location on roller shaft 14 Install the idler arm assembly Fig 19 item 10 using lock nut flat washers cap screw pivot bushing and spacer 15 Install compression spring Fig 19 item 3 spacer and hex nut on idler adjustment rod 16 Adjust drive chain tension and lubricate chain see Operator s Manual Dri Slide Multi Purpose Lubric ant or equivalent is recommended for chain lubrica tion 17 Adjust parking brake if equipped see Operator s Manual 18 Install and secure transmission cover see Trans mission Cover in Chapter 6 Chassis in this manual GreensPro 1240 Drive Roller Service Anti seize lubricant Locking collar 2 15 Lock nut 4 23 Hardened washer Figure 22 1 Drive roller 9 Bearing 2 17 Taper lock bushing 2 Roller shaft drive 10 Set screw 2 18 Set screw 2 3 Roller shaft brake 11 Key 19 Drive chain 4 Cap screw 6 12 Cap screw 4 20 Socket head screw 5 Lock washer 6 13 Flat washer 8 21 Lock washer 6 Flat washer 6 14 Spacer 4 22 Flat washer 7 8 Set screw 2 16 Sprocket Disassembly Fig 22 1 Loosen set screw in each bearing collar and remove bearing assemblies 2 Record the distance from the end of the drive roller to each of the locking collars prior to removal 3 Remove the cap screws lock washers and flat washers securing the drive roller
26. 1 35 2045 8 ovg xovg 8 amp OVE v MOTIAA MOTISA v Y 045 1045 104 20 Sod 2045 SSANNYH SS3NUVH 1 AYYANYLS xm Y x S1H911 OL NIVN 01 2 lt 2 a cor 7109 zor Sof vor 9NI1H911 013 2 00000061 1equinwN sweibeig AIM O1gsusaly Electrical System Page 4 5 GreensPro 1240 Special Tools Order special tools from your Toro distributor Some tools may also be available from a local supplier Multimeter The multimeter can test electrical components and cir cuits for current amps resistance ohms or voltage Obtain this tool locally NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Dielectric Gel Dielectric gel should be used to prevent corrosion of un sealed connection terminals To ensure complete coat ing of terminals liberally apply gel to both component and wire harness connector plug connector to compo nent unplug connector reapply gel to both surfaces and reconnect harness connector to component Connec tors should be thoroughly packed with gel for effective results Do not use dielectric gel on sealed connection terminals as the
27. 2 20 UNF 32 3 5 8 11 UNC 65 10 88 12 119 16 5 8 18 75 10 95 15 129 20 3 4 10 93 12 140 20 190 27 3 4 16 UNF 115 15 165 25 224 34 7 8 9 UNC 140 20 225 25 305 34 7 8 14 UNF 155 25 260 30 353 41 cory 1 46 2 162 euwe r w we eres e Reduce torque values listed in the table above by 2596 for lubricated fasteners Lubricated fasteners are de fined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fasten er size the aluminum or base material strength length of thread engagement etc GreensPro 1240 Page2 5 The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75 of the minimum proof load specified in SAE J429 The tolerance is approximately 10926 of the nominal torque value Thin height nuts in clude jam nuts Product Records and Maintenance Product Records o 2 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Thread Size Regular Height Nuts M16 X 2 0 M20 X 2 5 Reduce torque values listed in the table above by 25
28. 8211199 3 INNT VIA Ord OJdSsueoJt Electrical System Page 4 3 GreensPro 1240 SS3NHVH NIV 0000006 L 1equinw sbuiweiq M 0 211 OJdsueeJ5 i JAVY HILI MS IVALNIN H 0d L 1 kl d 28v E 1102 013NDYH DNI LHOTT ONNO Lor 8313 SS3NHVH YSLAWYNOH QHVONVIS MH Ov 0 8 s s SSINAYH 0 NIV OL Bed HILI MS 24 cor 1v3S Lod z SS3NBYH HL Y SIHOIT OL s lt 1240 4 4 Electrical System jeou 9913 ANNOYS HOLIMS IYYLNIN lor cod 2 5 5 9 SS3NHVH NIV 9 m i ea o a 3yv ug ON IU Yd YILIN YH OV vor or TINGON 204 704 4 1 1 MOTI3A 045 4 J a 39NVHO a g 9 8 MNId yovig HOLIMS
29. 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 16 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Mul
30. INFORMATION 4 a Fuel Evaporative Control System 4 2 SERVICE AND REPAIRS 6 Li ENGINE dob 6 e GreensPro 1240 Page 3 1 Gasoline Engine Introduction This chapter gives information about specifications and repair of the Honda GX200 gasoline engine used in the GreensPro 1240 Described adjustments and repairs require tools that are commonly available in many ser vice shops Some service and repair parts for the engine in your GreensPro machine are supplied through your Author ized TORO Distributor Be prepared to provide your dis tributor with the TORO model and serial number of your machine to obtain parts Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your GreensPro machine Refer to the Op erator s Manual for additional information when servi cing the machine Engine Owner s Manual The engine Owner s Manual provides information re garding the operation general maintenance and main tenance intervals for the Honda GX200 engine used on your GreensPro 1240 Contact your local Honda Engine Dealer or visit http engines honda com to obtain a copy of the engine Owner s Manual Refer to the engine Owner s Manual for additional information when servi cing the machine Engine Service Manual Detailed information on engin
31. Product Records and Maintenance in this manual 4 If a torque wrench is not available or if space at the Swivel nut prevents use of a torque wrench an alternate method of assembly is the Flats From Wrench Resist ance F F W R method Fig 3 A Using a wrench tighten the swivel nut onto the fit ting until light wrench resistance is reached approxi mately 30 B Mark the swivel nut and fitting body Hold the hose tube with a wrench to prevent it from turning C Use a second wrench to tighten the nut to the cor rect Flats From Wrench Resistance F F W R The markings on the nut and fitting body will verify that the connection has been properly tightened Size F F W R 3 8 in nominal hose 1 2 to 3 4 Mark Nut Final and Fitting Position Body Initial Extend Line Position AT WRENCH RESISTANCE AFTER TIGHTENING Figure 3 Drive Train E p Hydraulic Fitting Installation IMPORTANT The hydraulic fittings used on the GreensPro have BSP P British Standard Pipe Parallel threads for the hose connections and both SAE and BSP P threads for the component connec tions If fittings are replaced make sure that the re placement has the correct type of threads or component damage and leakage will occur 1 Make sure all threads and sealing surfaces of fitting and component port are free of burrs nicks scratches or any foreign material 2 As apreventative measure ag
32. Serial Number Above 315000000 8 E COMPONENT TESTING 9 3 Hour 10 Worklight Switch optional 11 Interlock Module Serial Number Above 315000000 12 Parking Brake Switch Serial Number Above 315000000 13 Neutral Switch Serial Number Above 315000000 14 Seat Switch Serial Number Above 315000000 15 GreensPro 1240 Page 4 1 Electrical System General Information Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your GreensPro machine Refer to the Op erator s Manual for additional information when servic ing the machine Electrical System Some of the electrical system components used on the GreensPro 1240 are part of the Honda engine These components include the engine ON OFF switch ignition module lighting coil and low oil level switch Service in formation for these components can be found in the Honda Engine Service Manual Contact your local Honda Engine Dealer or visit http engines honda com for assistance The remainder of the electrical system components used on Greens Pro 1240 machines with serial number below 315000000 are an hour meter and optional work light switch Service information for these components can be found in this chapter In addition to the hour meter and op
33. TORO Preface The purpose of this publication is to provide the service technician with information for troubleshooting testing and repair of major systems and components on the GreensPro 1240 REFER TO THE OPERATOR S MANUAL FOR OPERATING MAINTENANCE AND ADJUSTMENT INSTRUCTIONS Space is provided in Chapter 2 of this book to insert the Operator s Manual and Parts Catalog for your machine Replacement catalogs are available on the Internet at www toro com The Toro Company reserves the right to change product specifications or this publication without notice PART NO 14211SL Service Manual GreensPro 1240 This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine NOTE A NOTE will give general information about the correct operation maintenance service testing or repair of the machine The Toro Company 2014 This page is intentionally blank GreensPro 1240 Table Of Contents Chapter 1 Safety General Safety Instructions 1 2 Safety and Instruction Decals 1 5 Chapter 2 Product Records and Maintenance Product Records
34. This page is intentionally blank GreensPro 1240 Chapter 1 TORO Safety Table of Contents SAFETY INSTRUCTIONS 2 Before Operating 2 While Operating 2 Maintenance and Service 3 SAFETY AND INSTRUCTION DECALS 4 GreensPro 1240 Page 1 1 Safety General Safety Instructions GreensPro 1240 machines have been tested and certi fied by Toro for compliance with existing safety stand ards and specifications Although hazard control and accident prevention are partially dependent 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 opera tion transport maintenance and storage of the ma chine Improper use or maintenance of the machine can Before Operating 1 Operate machine only after reading and understan ding the contents of the Operator s Manual and viewing the Operator s Video Copies of the Operator s Manual are available on the internet at www Copies of the Operator s Video are available through your Toro Distributor 2 Only trained operators who are skilled in slope op eration and who have read the Operator s Manual and viewed the Operator s Video should operate the ma chine Never allow children to operate the machine Never allow adults to operate the machine
35. ainst leakage it is rec ommended that the O Ring or Dowty seal be replaced any time the connection is opened Fig 4 3 Lightly lubricate the O Ring or Dowty seal with clean hydraulic oil Fitting threads should be clean with no lu bricant applied Fitting Dash Size Fitting Port Side Thread Size Installation Torque Into Steel Port IMPORTANT Before installing fitting into port de termine port material If fitting is to be installed into an aluminum port installation torque is reduced 4 Install the fitting into the port Then use a torque wrench and socket to tighten the fitting to the recom mended installation torque Fig 5 Fitting or Dowty Seal Installation Torque Into Aluminum Port 4 BSP P 52 in 13 5 mm 19 33 to 41 ft lb 45 to 55 N m 20 to 25 ft lb 27 to 34 N m 6 BSP P 66 in 16 7 mm 19 38 to 46 ft lb 51 to 62 N m 24 to 28 ft lb 33 to 38 6 SAE 9 16 18 34 to 42 ft lb 47 to 56 N m 20 to 26 ft lb 28 to 35 N m 10 SAE 7 8 14 99 to 121 ft lb 135 to 164 60 to 74 ft lb 82 to 100 Figure 5 Drive Train Page 5 8 GreensPro 1240 This page is intentionally blank GreensPro 1240 Page 5 9 Drive Train Adjustments Transmission and Motion Pedals Return to Neutral The return to neutral mechanism is designed to return the transmission control lever to a neutral posi
36. alue should be determined based on the aluminum or brass material strength fastener size length of thread engagement etc The standard method of verifying torque shall be per formed by marking a line on the fastener head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Class 8 8 Class 10 9 Metric Bolts and Screws GreensPro 1240 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series SAE Grade 8 Bolts Screws Studs amp Sems with Regular Height Nuts Grade 1 5 amp 8 with Thin Height Nuts SAE Grade 1 Bolts Screws Studs amp Sems with Regular Height Nuts Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts 100 10 1125 100 140 15 1580 170 nm ee nm 430 45 583 61 600 60 813 81 475 45 644 61 660 60 895 81 SAE Grade 5 Bolts Screws Studs amp Thread Size 6 32 UNC 147 23 6 40 UNF 8 32 UNC 8 36 UNF 10 24 UNC 339 56 10 32 UNF 1 4 20 UNC 48 7 53 7 599 79 1 4 28 53 7 65 10 734 113 5 16 18 UNC 115 15 105 17 1186 169 5 16 24 138 17 128 17 1446 192 3 8 16 UNC 16 2 3 8 24 UNF 7 16 14 UNC 27 3 7 16 20 UNF 29 3 1 2 13 UNC 30 3 1
37. ation 1 Test parking brake input A Engage the parking brake and start the engine B With the Operator s seat unoccupied disengage the parking brake The engine should stop Electrical System Page 4 8 2 Test seat switch input A Engage the parking brake and start the engine B Sit in the operators seat and disengage the park ing brake C Lift your weight from the operators seat The en gine should stop 3 Test neutral switch input A Engage the parking brake and start the engine B Sit in the operators seat C With the parking brake engaged move the mo tion control pedals into a MOVE position The engine should stop If the machine does not react as described in the previ ous procedure test the individual switches in the inter lock system as described in the Component Testing in this chapter GreensPro 1240 Component Testing Some of the electrical system components used on the GreensPro 1240 are part of the Honda engine These components include the engine ON OFF switch ignition module lighting coil and low oil level switch Service in formation for these components can be found in the Honda Engine Service Manual Contact your local Honda Engine Dealer or visit http engines honda com for assistance The remainder of the electrical system components used on Greens Pro 1240 machines with serial number below 315000000 are an hour meter and optional work light switch Service inform
38. ation for these components can be found in this chapter In addition to the hour meter and optional worklight switch GreensPro 1240 machines with serial number above 315000000 include a number of electrical inter lock system components The interlock system consists of various switches inputs and a microprocessor based interlock module Service information for inter lock system components can be found in this chapter 9 5 NOTE For accurate resistance and or continuity checks disconnect the component being tested from the wire harness e g unplug the seat switch connector before checking continuity on the switch terminals GreensPro 1240 Page 4 9 Electrical System Hour Meter The hour meter is located on the right side of the seat pan Fig 4 The hour meter has a digital display that shows the total hours of machine operation at all time The hour meter is powered by the engine lighting coil and records whenever the engine is running An hour glass icon flashes on the display when the hour meter is recording Testing 1 Park machine on a level surface engage parking brake if equipped 2 Unlatch and lift the operator seat pan forward to ac cess the back of the hourmeter 3 Disconnect the wire harness terminals from the hourmeter 4 Start engine and set to high idle 5 Use a multimeter AC voltage setting and check for approximately 20 VAC at the wire harness hourmet
39. aulic oil reservoir 5 Record the individual connections and disconnect the wire harness from the engine A Ground wire ring terminal to blower housing B Two 2 connectors to lighting coil C Two 2 connectors to magneto ignition 6 Remove lock nuts flat washers and cap screws se curing engine to chassis Remove engine from chassis 7 Remove rubber drive coupling and engine drive col lar item 16 if necessary Installation Fig 2 1 If previously removed apply a thin coat of anti seize lubricant to engine output shaft and install engine drive collar item 16 and rubber drive coupling to engine Tighten lock nuts from 17 to 21 ft Ib 23 to 29 N m 2 Place engine in position on chassis 3 Install lock nuts flat washers cap screws and spacers securing transmission drive collar item 4 to rubber drive coupling Tighten lock nuts finger tight 4 Install lock nuts flat washers and cap screws secur ing engine to chassis Tighten lock nuts finger tight GreensPro 1240 Page 3 7 Figure 3 1 Hydraulic oil reservoir 2 Cap screw 2 3 Lock washer 2 4 Flat washer 2 IMPORTANT To prevent drive coupling damage make sure that no distortion of coupling exists after securing engine and transmission collars to coup ling If coupling distortion is evident loosen engine and or transmission and reposition engine and or transmission on frame so that coupling is not dis torted 5 Make
40. ck nut and cap screw 3 10 mm Lock nut flat washers 2 The GreensPro 1240 tow bar height can be set to three different heights to suit a variety of tow vehicles Fig 6 1 Park machine on a clean level surface with the transport wheels in the raised and locked position Make sure engine is OFF Engage parking brake if equipped or remove spark plug wire from spark plug 2 Loosen but do not remove the 12 mm lock nut and cap screw securing the tow bar to the transport frame Fig 6 GreensPro 1240 Page6 7 and cap screw 3 Support the hitch end of the tow bar and remove the 10 mm cap screw flat washers and lock nut securing the tow bar to the transport frame 4 Rotate the tow bar to one of the three height settings and reinstall the cap screw flat washers and lock nut 5 Tighten both cap screws and lock nuts securing the tow bar to the transport frame as follows 10 mm bolt 50 to 60 ft lb 68 to 81 12 mm bolt 120 to 130 ft lb 162 to 176 Chassis Auto Hitch Slide The auto hitch mechanism ensures the GreensPro re mains safely connected to the tow vehicle during trans port see Operator s Manual When properly adjusted the auto hitch lever must be allowed to reach its fully de pressed position without restriction from the auto hitch slide Proper adjustment also allows the slide to reach its stop when the lever is fully released Check and ad just the auto hitch mechanism as necessary a
41. d cap screws secur ing roller support to inner chassis plate 4 Install lock nut flat washer spacer cap screw and linkage rod item 7 to steering head assembly Be careful when removing or installing spring The spring is under load and may cause personal injury 5 Install tension spring item 2 with cap screw and hex nut attached using a lock nut and flat washer 6 Install steering rollers see Steering Rollers in this chapter Chassis Steering Head Service Anti seize 7 _lubricant 13 ae FRONT STEERING HEAD ASSEMBLY SHOWN Figure 18 1 Steering head frame 8 Cap screw 14 Lock nut 2 2 Roller support 9 Lock washer 15 Cap 3 Bearing 10 Collar 16 Cap screw 4 Cap screw 4 11 Spacer 17 Hex nut 5 Flat washer 8 12 Cap screw 2 18 Flat washer 2 6 Lock nut 4 13 Flat washer 4 19 Lock nut 7 Pivot shaft Chassis Page 6 18 GreensPro 1240 Disassembly Fig 18 1 Remove cap item 15 from roller support 2 Remove cap screw and lock washer securing collar item 10 to pivot shaft 3 Lift roller support with bearing and collar still at tached from pivot shaft item 7 4 Remove cap screws flat washers and lock nuts se curing bearing item 3 to roller support Separate bear ing from roller support and remove collar 5 Remove spacer item 11 from pivot shaft 6 Remove pivot shaft if necessary 7 Repair or replace steering steering head assemb
42. e GreensPro 1240 5 5 After Repair Replacement of Components 1 Check oil level in the hydraulic tank and add correct hydraulic oil if necessary Drain and refill hydraulic tank and change hydraulic oil filter if component failure was severe or system is contaminated see Operator s Manual 2 Purge air from the hydraulic system any time the sys tem has been opened to facilitate maintenance or any additional oil has been added to the system Follow the procedure found in the HYDRO GEAR SERVICE AND REPAIR MANUAL 3 When disposing of hazardous waste products hy draulic oil take them to an authorized disposal site Waste products must not be allowed to contaminate sur face water drains or sewer systems 4 Check for hydraulic oil leaks Shut off engine and cor rect leaks if necessary Check oil level in hydraulic reser voir and add correct hydraulic oil if necessary 5 Lubricate O rings and dowty seals with clean hy draulic fluid before installing hydraulic components 6 Make sure caps or plugs are removed from the hy draulic tubes hydraulic fittings and components before reconnecting 7 Use proper tightening methods when installing hy draulic hoses and fittings see Hydraulic Fitting Installa tion in this chapter 8 After repairs check control linkages or cables for proper adjustment binding or broken parts If a transmission failure occurs it is critical that the entir
43. e hydraulic system is drained disassembled and thor oughly cleaned to ensure all contamination is removed from the system Replace the hydraulic oil filter If any debris remains in the hydraulic system and the machine is operated the debris can cause additional component failure Drive Train T Hydraulic Components 24 to 28 ft Ib 33 to 38 N m 33 to 38 N m 28 to 34 N m 24 to 28 ft lb d 20 to 25 ft Ib 4 16 22 to 26 ft lb y 30 35 N m amp 24 to 28 ft lb QM 6 33 to 38 x 5 9 22 to 26 ft Ib 10 30 35 N m 24 to 28 ft lb 20 to 26 ft Ib 33 to 38 N m 28 to 35 N m 60 to 74 ft lb 81 to 100 N m Figure 2 1 Transmission 12 Cap screw 2 19 Straight fitting 3 2 Hydraulic oil reservoir 13 Lock washer 2 9 16 SAE to 3 8 BSP hose 3 Reservoir cap 14 Flat washer 2 20 O Ring 3 9 16 SAE 4 Sight glass 3 8 BSP 15 Dowty seal 3 8 21 Hydraulic hose 3 8 BSP 5 Drain plug 1 4 BSP 16 Straight fitting 2 filter to transmission 6 Dowty seal 1 4 3 8 BSP to 3 8 BSP hose 22 O Ring 7 8 SAE 7 Oil filter head 17 Hydraulic hose 3 8 BSP 23 Straight fitting 8 Oil filter element transmission to reservoir 7 8 SAE to 3 8 BSP hose 9 Cap screw 2 18 Hydraulic hose 3 8 BSP 10 Lock washer 2 reservoir to filter 11 Flat washer 2 Drive Train Page 5 6 GreensPro 1240 Hydraulic Hoses IMPORTANT The h
44. e and Repairs Steering Wheel Removal Fig 10 1 Park machine on a clean level surface with the transport wheels in the raised and locked position Make sure engine is OFF Engage parking brake if equipped or remove spark plug wire from spark plug 2 Remove cover from steering wheel by carefully pry ing up on one of the cover spokes 3 Remove lock nut and flat washer that secure steer ing wheel to steering column 4 Remove steering wheel from steering column shaft Use a suitable puller if necessary Installation Fig 10 1 Thoroughly clean tapered surfaces of steering wheel and steering column 2 Apply a thin coating of antiseize lubricant to splines of steering column taking care to keep antiseize lubri cant from column taper Slide steering wheel onto steer ing column 3 Secure steering wheel to steering column with flat washer and lock nut Tighten lock nut from 20 to 26 ft lb 28 to 35 N m 4 Install steering wheel cover to steering wheel GreensPro 1240 6 9 20 to 26 ft Ib 28 to 35 N m Anti seize lubricant N SS DEC 5 Figure 10 Steering wheel cover 4 Steering wheel Lock nut 5 Steering column Flat washer Chassis Steering Column Removal Fig 11 Use a suitable lifting device to safely raise and support the machine to allow access to compon ents under the chassis 1 Remove steering wheel see Steering Wheel
45. e on a level surface make sure engine is OFF engage the parking brake if equipped or remove the spark plug wire from the spark plug 2 Clean machine before disconnecting removing or disassembling any hydraulic components Make sure hydraulic components hoses connections and fittings are cleaned thoroughly To avoid contaminating the hy draulic system always keep in mind the need for cleanli ness when working on hydraulic components Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved by moving the motion control pedals after the engine is turned OFF 3 Put caps or plugs on any hydraulic lines hydraulic fit tings and components left open or exposed to prevent contamination 4 Put labels on disconnected hydraulic hoses for prop er installation after repairs are completed 5 Note the position of hydraulic fittings especially el bow fittings on hydraulic components before removal Mark parts if necessary to make sure they will be aligned properly when reinstalling hydraulic hoses Hydraulic System Component Failure The GreensPro hydraulic system includes the transmis sion hydraulic oil tank hydraulic oil filter and a series of hydraulic hoses If a component in the transmission should fail debris and contamination from the failed component will circulate throughout the system This contamination must be removed to prevent additional component failur
46. e parking brake is disengaged 2 Disconnect brake return spring item 6 from chassis 3 Remove lock nut and flat washer from the brake rod item 15 4 Remove hair pin item 14 from brake rod and re move brake rod from brake pivot arm 5 Remove cap screws plain washers and lock nuts and remove brake band item 28 and shims if any from chassis 6 Remove the socket head screw lock washer flat washer hardened washer from the drive roller shaft and remove brake hub item 1 7 Remove brake pivot arm item 7 if necessary A Remove cap screw flat washers and lock nut and remove brake pivot arm and pivot bushing from chassis B Remove cap screw flat washers lock nut and sleeve and disconnect brake cable item 16 from brake pivot arm 8 Repair or replace parking brake components as ne cessary Installation Fig 23 1 If previously removed item 7 install brake pivot arm A Connect brake cable item 16 to brake pivot arm with cap screw flat washers sleeve and lock nut B Insert pivot bushing in brake pivot arm and se cure brake pivot arm to chassis with cap screw flat washers and lock nut 2 Apply a thin coat of anti seize lubricant to the brake end of the drive roller shaft Install the brake hub item 1 with the hardened washer flat washer lock washer and socket head screw Tighten the screw finger tight and wipe away any excess lubricant GreensPro 1240 Page 5 27
47. e troubleshooting testing disassembly and assembly is given in the Honda Ser vice Manual The use of some specialized tools and test equipment is explained in the Honda Service Manual Contact your local Honda Engine Dealer to obtain a copy of the engine Service Manual However the spe cialized nature of some engine repairs may dictate that the work be done at a Honda engine repair facility Engine Identification The engine serial number and type are stamped on the engine near the oil filler dipstick The engine serial num ber and type will assist in identifying the correct parts and service information for the Honda engine in your GreensPro machine Gasoline Engine Page 3 2 When disposing of hazardous waste products fuel en gine oil hydraulic oil filters etc take them to an au thorized disposal site Waste products must not be allowed to contaminate surface water drains or sewer systems GreensPro 1240 Specifications Item Description Make Designation Honda 4 stroke OHV Single Cylinder Air Cooled Gasoline Engine GX200 Bore x Stroke 2 68 in X 2 13 in 68 0 mm x 54 0 mm Total Displacement 12 0 cu In 196 cc Carburetor Float Feed Fixed Main Jet Governor Mechanical Flyweight Low idle no load 1250 1600 rpm High Idle no load 3600 rpm Direction of Rotation Counterclockwise facing PTO shaft Fuel Unleaded Gasoline
48. er terminals 6 Stop the engine 7 f voltage is present at the wire harness terminals and the hour meter does not display or record while the engine is running record the machine hours if possible and replace the hourmeter 8 If voltage is not present at the wire harness terminals check wire harness terminals for corrosion and check wire harness for circuit continuity see ELECTRICAL DRAWINGS AND DIAGRAMS in this Chapter 9 Lastly check engine lighting coil see Honda Engine Service Manual 10 After testing is complete apply a film of dielectric grease to the wire harness terminals and reconnect ma chine wire harness Electrical System Page 4 10 Figure 4 1 Hourglass icon 3 Positive terminal Y 2 Negative terminal BK GreensPro 1240 Worklight Switch optional The worklight switch is located on the right side of the seat pan Testing 1 Park machine on a level surface engage parking brake if equipped and stop engine 2 Unlatch and lift the operator seat pan forward to ac cess the worklight switch 3 Disconnect the wire harness from the worklight switch 4 Check the wiring harness connectors for corrosion Clean connectors if necessary 5 Use a multimeter ohms setting and test the switch Fig 5 The switch is closed continuity exists between the terminals used when the switch is set
49. ex nut has right hand threads Before attempting to loosen the hex nuts for linkage adjustment inspect the threads on the linkage rod to determine thread direction 2 Loosen hex nuts and turn steering pivot rod until steering head linkage arm ball joints on steering disc are aligned front to back Fig 4 Do not tighten steering pivot rod hex nuts at this time 3 Loosen hex nuts of both steering head linkage arms Turn steering head linkage arms until the front and rear steering head rollers are aligned with each other 08 in 2 4 Place a straightedge across steering rollers to en Figure 4 sure steering rollers are in alignment Fig 5 Adjust 1 vei ue rod 4 2 2 head linkage i 1 1 ex nu arm steering head linkage arms as necessary to achieve 3 Steering disc 5 Block alignment Figure 3 1 Chassis frame 3 Steering pivot assembly Figure 5 2 Block 1 Straightedge 2 Steering roller Chassis Page6 6 GreensPro 1240 5 If necessary remove and reinstall steering wheel square with machine see Steering Wheel in this Chapter Tow Bar Height 120 to 130 ft lb 162 to 176 N m 50 to 60 ft lb 162 to 176 N m 6 Tighten hex nuts on all linkage rods 7 Remove block from between steering pivot as sembly and chassis Figure 6 1 Tow bar 2 12mm Lo
50. f fuel tank insert Fuel may leak from filler neck when machine is tilted for servicing if tank is overfilled GreensPro 1240 While Operating 1 Do not run the engine in a confined area without ade quate ventilation Exhaust fumes are hazardous and could be deadly 2 Always stand behind the machine when starting the engine Always sit in the operator s seat when operating the machine 3 On machines with serial number above 315000000 check interlock switches daily for proper operation see Chapter 4 Electrical System Do not rely entirely on safety switches shut off engine before getting off seat If a switch fails replace it before operating the machine The interlock system is for your protection so do not by pass it 4 To start the engine A Engage parking brake if equipped B Be sure motion pedals are in neutral C Open fuel shutoff valve Make sure spark plug wire is connected to spark plug D Move engine ON OFF switch to ON position Set choke to full choke position cold start and throttle to half throttle E Pull starter cord to start engine F After engine starts sit in seat release parking brake if equipped and keep feet off motion pedals Machine must not move If movement is evident the motion control linkage is faulty or incorrectly adjus ted Adjust the motion control linkage so machine does not move when motion pedals are released see Transmission and Motion Pedals Return to Neutral
51. from your Authorized TORO Distributor GreensPro 1240 Page 1 5 Safety This page is intentionally left blank Safety Page 1 6 GreensPro 1240 Chapter 2 TORO Product Records and Maintenance Table of Contents 25 PRODUCT RECORDS dis te 2 se MAINTENANCE te ned mte ia 2 EQUIVALENTS AND CONVERSIONS 3 as Decimal and Millimeter Equivalents 3 U S to Metric Conversions 3 TORQUE SPECIFICATIONS 4 Fastener Identification 4 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 5 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners 6 Other Torque Specifications 7 Conversion Factors 7 Using a Torque Wrench with an Offset Wrench Crows Foot 8 GreensPro 1240 Page 2 1 Product Records and Maintenance Product Records Insert a copy of the Operator s Manual and Parts Cata log for your GreensPro 1240 at the end of this chapter Additionally if any optional equipment or accessories have been installed to your machine insert the Installa tion Instructions Operator s Manuals and Parts Cata logs for those options at the end of this chapter Maintenance Maintenance procedures and recommended service in tervals for the GreensPro 1240 are covered in the Oper ator s Manual Refer to tha
52. gel can unseat connector seals during assembly Toro Part Number 107 0342 Terminal Protector Aerosol spray that should be used on battery terminals ring terminals and fork terminals to reduce corrosion problems Apply battery terminal protector to the con nection after the battery cable ring terminal or fork ter minal has been secured Toro Part Number 107 0392 Electrical System Page4 6 7 m IMMEDIATELY WI Figure 1 DOW CORNING 111 SILICONE COMPOUND WATER Figure 2 Figure 3 GreensPro 1240 Troubleshooting For effective troubleshooting and repairs there must be a good understanding of the electrical circuits and com ponents used on this machine see Electrical Drawings and Diagrams in this chapter Remove all jewelry especially rings and watches before doing any electrical trouble shooting or testing Starting Problems Serial Number Above 315000000 Improper starting procedure corroded or damaged in If the machine has any interlock switches by passed terlock system wiring or improperly adjusted or faulty in reconnect the switches for proper safety and trouble terlock system components can cause starting shooting problems Nothing happens when a start attempt is made The fuel tank is empty The parking brake is disengaged and the operator seat is unoccupied The parking brake switch or operator seat switch is faulty The motion control linkage is not
53. gs on transmission assembly Drain hoses into a suitable container 7 Put clean caps and plugs in disconnected hoses and fittings to prevent hydraulic system contamination 8 On machines with serial number above 315000000 disconnect the wire harness from the neutral switch Fig 9 item 2 9 Remove hex nut and lock washer securing damper Fig 9 item 3 to damper plate and disconnect damper from plate 10 Remove cap screws flat washers spacers and lock nuts securing damper plate and linkage rod to transmis sion control arm Fig 9 item 5 11 Remove cap screws flat washers lock nuts and spacers securing fan and transmission drive collar to drive coupling Fig 10 item 1 12 Remove hex nut spacer and compression spring Fig 11 item 3 from tension rod 13 Remove cap screw flat washers and lock nut secur ing idler arm Fig 11 Item 8 to transmission mount and remove idler arm assembly 14 Remove the retaining ring Fig 11 item 11 from the transmission output shaft 15 Support transmission and remove cap screws flat washers and lock nuts securing transmission to chassis 16 Slide transmission away from transmission mount until the sprocket and drive chain are free of the trans mission shaft and remove transmission 17 Remove transmission drive collar and fan if neces sary Fig 12 GreensPro 1240 Page 5 13 ON gt 17 to 21 ft Ib 23 to 29 N m Figure 10
54. ice to safely raise and support the machine to allow access to compon ents under the chassis Be careful when removing or installing spring The spring is under load and may cause personal injury 1 Remove the steering rollers see Steering Rollers in this chapter 2 Remove lock nut and flat washer and disconnect tension spring item 2 with cap screw and hex nut at tached 3 Remove lock nut flat washer spacer cap screw and linkage rod item 7 from steering head assembly Support steering head assembly during removal and installation Steering head assembly weighs approximately 30 Ibs 14 kg 4 Support the steering head assembly 5 Remove lock nuts flat washers and cap screws se curing roller support item 16 to inner chassis plate 6 Remove lock nuts flat washers and carriage bolts securing roller support to top of chassis and remove steering head assembly GreensPro 1240 Page 6 17 Installation Fig 17 Use a Suitable lifting device to safely raise and support the machine to allow access to compon ents under the chassis Support steering head assembly during removal and installation Steering head assembly weighs approximately 30 Ibs 14 kg 1 Support the steering head assembly 2 Position steering head assembly under chassis and install lock nuts flat washers and carriage bolts secur ing roller support item 16 to top of chassis 3 Install lock nuts flat washers an
55. in this chapter 2 Remove bearing cover item 2 from top of steering column 3 Remove the steering column boot item 3 as fol lows A Set the steering column tilt to the fully rearward position B Gently pull steering column boot over the tilt con trol lever C Set the steering column tilt to the fully forward po sition D Carefully lift boot up and off steering column 4 The steering column gas spring assembly item 4 controls the steering column tilt position If gas spring assembly replacement is required remove the gas spring assembly as follows A Set the steering column tilt to the fully forward po sition B Remove an E ring item 5 from an end of each pivot pin Be careful when removing or installing the gas spring assembly The assembly may extend sud denly and cause personal injury C Drive the pivot pins item 6 out and remove the gas spring assembly 5 Remove cap screw flat washers and lock nut secur ing steering pivot linkage rod item 7 to steering pivot Chassis Page 6 10 Figure 11 1 Steering column 9 Flat washer 2 Bearing cover 10 Steering pivot 3 Steering column boot 11 Woodruff key 4 Gas spring assembly 12 Flat washer 5 E Ring 4 13 Lock nut 6 Pivot pin 2 14 Cap screw 4 7 Steering pivot linkage 15 Flat washer 4 rod 16 Flange nut 4 8 Cap screw 6 Loosen steering pivot set screw and pull steering pivot item 10 a
56. inspect the threads on the linkage rod to determine thread direction NOTE Leave linkage rod hex nuts loose until rod ends have been secured and rod length adjusted After assembly check transmission and motion pedal return to neutral operation and adjust as necessary see Transmission and Motion Pedals Return to Neutral in this chapter Drive Train 2 Drive Roller SERIAL NUMBER BELOW 315000000 Anti seize lubricant Drive roller Roller shaft drive Roller shaft brake Cap screw 6 Lock washer 6 Flat washer 6 Locking collar 2 Set screw 2 Bearing 2 00 9909 RoN Drive Train Figure 18 Set screw 2 Key Cap screw 12 mm 4 Flat washer 12 mm 8 Sleeve 4 Lock nut 12 mm 4 Sprocket Taper lock bushing Set screw 2 Page 5 22 Drive chain Socket head screw Lock washer Flat washer Hardened washer Brake hub Cap Screw 16 mm 4 Flat washer 16 mm 8 Lock Nut 16 mm 4 GreensPro 1240 Removal Fig 18 20 Use a Suitable lifting device to safely raise and support the machine to allow access to compon ents under the chassis 1 Remove transmission cover from machine see Transmission Cover in Chapter 6 Chassis in this manu al 2 Remove hex nut spacer and compression spring Fig 19 item 3 from idler adjustment rod 3 Remove cap screw flat washers lock nut pi
57. ion 8 ADJUSTMENTS 10 Transmission and Motion Pedals Return to Neutral 10 SERVICE AND REPAIRS 12 TRANSMISSION ciu Re pui ERR p Rees 12 Transmission 16 Drive Chain Idler Arm 18 Motion Control Linkage 20 Z Drive Roller dee 22 Drive Roller Service 25 m Parking Brake Serial Number Above 315000000 26 HYDRO GEAR SERVICE AND REPAIR MANUAL GreensPro 1240 Page 5 1 Drive Train Introduction Some service and repair parts for the transmission in your GreensPro machine are supplied through your Au thorized TORO Distributor Be prepared to provide your distributor with the TORO model and serial number of your machine to obtain parts Transmission Service Manual Detailed information on transmission troubleshooting testing disassembly and assembly is given in the HY DRO GEAR MODEL BDR SERVICE MANUAL The use of some specialized tools and test equipment is ex plained in the Hydro Gear Service Manual However the specialized nature of some transmission repairs may dictate that the work be done at an Authorized Hy dro Gear Service Dealer Drive Train Page 5 2 GreensPro 1240 Specifications Item Description Transmission Hydro Gear Hydrostatic Transmission Model Pump Displace
58. lock nut pivot bushing and spacer and remove idler arm assembly 5 Repair and replace idler arm assembly components as necessary Fig 16 Installation Fig 15 1 If removed install the idler sprocket assembly on idler arm using bolt idler gear bushing flat washer and lock nut Fig 16 2 If removed install the adjustment rod on idler arm us ing cap screw hex nut flat washer and lock nut Tighten cap screw to idler arm with hex nut and adjust lock nut so adjustment rod is free to pivot on cap screw 3 Install flat washer and hex nut on idler adjustment rod Thread nut 1 25 in 32 mm onto rod 4 Install the idler arm assembly using lock nut flat washers cap screw pivot bushing and spacer 5 Install compression spring spacer and hex nut on idler adjustment rod 6 Adjust drive chain tension and lubricate chain see Operator s Manual Dri Slide Multi Purpose Lubric ant or an equivalent chain specific lubricant is recom mended 7 Install and secure transmission cover see Trans mission Cover in Chapter 6 Chassis in this manual Drive Train PONS Page 5 18 Hex nut Spacer Compression spring Adjustment rod Cap screw Figure 16 Adjustment rod 9 Idler arm 10 Bushing 2 11 Idler sprocket assembly 12 Spacer 13 Bearing 2 14 Spacer 15 Flat washer 16 Flat washer 2 Lock nut Pivot bushing Spacer Idler Arm Assembly Lock nut Bolt
59. ly components as necessary GreensPro 1240 Page 6 19 Assembly Fig 18 1 Install pivot shaft item 7 if previously removed 2 Apply a thin coat of anti seize lubricant to pivot shaft and install spacer item 11 on pivot shaft 3 Place collar item 10 between bearing and roller support and attach bearing to roller support with cap screws flat washers and lock washers 4 Fit bearing and roller support assembly over pivot shaft and secure collar to pivot shaft with cap screw and lock washer 5 Install cap item 15 in roller support 6 Lubricate bearing through grease fitting until grease is visible on outside of bearing Wipe away any excess grease Chassis Transport Wheels and Hubs Anti seize lubricant 80 ft Ib 108 N m Figure 19 1 Lug nut 4 5 Collar 2 Wheel and tire assembly 6 Hub assembly 3 Cap screw 7 Bearing 2 4 Lock washer Removal Fig 19 1 Park machine on a clean level surface with the transport wheels in the raised and locked position Make sure engine is OFF Engage the parking brake if equipped or remove spark plug wire from spark plug 2 Remove lug nuts and remove wheel and tire as sembly from hub 3 Remove cap screw lock washer and collar item 5 4 Remove transport wheel hub from spindle item 10 5 Inspect bearings and replace as necessary Chassis Page 6 20 8 Bearing spacer 9 Drive stud 4 10 Spindle Installation Fig 19
60. m 7 68 to 91 ft Ib 92 to 124 N m Flocked surface toward bearing NS Flocked surface toward bearing to 91 ft lb 92 to 124 N m Figure 16 1 Roller tube short 5 Roller sleeve 8 Flocked seal 4 2 Axle short 6 O Ring 2 9 Bearing spacer 2 3 Roller tube long 7 Bearing 4 10 Lock nut 2 4 Axle long Disassembly Fig 16 3 Thread roller shafts into roller sleeve item 5 and tighten from 68 to 91 ft Ib 92 to 124 Remove and replace parts as necessary to repair the steering rollers 4 Replace do not reuse flocked seals and O Rings Assembly Fig 16 5 Install flocked seals item 8 with flocked side of seal against bearing 1 Clean all components prior to assembly 6 Thread lock nuts item 10 onto axles and tighten 2 If a bearing item 7 or bearing housing is removed from 68 to 91 ft lb 92 to 124 make sure it is pressed into position fully during installa tion GreensPro 1240 Page 6 15 Chassis Steering Heads SS Figure 17 1 Steering head assembly 7 Steering head linkage rod 2 Spring 8 Spacer 3 Cap screw 9 Flat washer 4 Hex nut 10 Cap screw 5 Flat washer 2 11 Lock nut 6 Lock nut Chassis Page 6 16 FRONT STEERING HEAD ASSEMBLY SHOWN 12 Carriage bolt 2 13 Flat washer 6 14 Lock nut 4 15 Cap screw 2 16 Roller support GreensPro 1240 Removal Fig 17 Use a suitable lifting dev
61. ment per revolution 0 62 cu In 10 2 cc Motor Displacement per revolution 1 33 cu In 21 8 cc Drive Chain Sprocket Alignment 0 0 02 in 0 57 mm Hydraulic Tank Capacity 2 6 U S Qt 2 5 0 Ltr Hydraulic Oil See Operator s Manual Hydraulic Filter Spin on Cartridge Type 10 Micron T GreensPro 1240 Page 5 3 Drive Train General Information Figure 1 1 Transmission 3 Drive roller 2 Motion pedal 2 4 The GreensPro 1240 drive train uses a hydraulic trans mission driven by the engine through a rubber drive coupling to propel the machine The transmission is connected to the drive roller via a double row chain The transmission is a 61 cu In 10 cc variable displace ment bi directional axial hydraulic pump coupled to a fixed displacement 1 28 cu In 21 cc hydraulic motor The operator moves motion control pedals connected to the hydraulic transmission control arm to control ma chine direction and speed With the engine running and the motion control pedals in the NEUTRAL position the transmission supplies no drive to the traction roller so the machine remains stationary When one of the motion control pedals is depressed the traction control linkage moves the transmission control arm so the transmission output turns the drive roller Machine movement occurs in the direction of the motion control pedal applied The two foot operated motion pedals are on ei
62. n Installation Fig 18 19 and 21 NOTE Machine with serial number below 315000000 use 16 mm fasteners to secure the drive roller bearings to the chassis These machines do not require the use of sleeves in the bearing mounting holes 1 Lift drive roller assembly into position in chassis Drive chain must encircle drive end of roller shaft 2 If applicable make sure sleeves Fig 18 item 14 are installed in each bearing housing mounting hole Attach bearings to chassis with cap screws flat washers and lock nuts 3 Loosen locking collar and bearing collar set screws Fig 18 item 8 and 10 4 Tighten bearing collar set screws 5 Move locking collars against bearings and tighten locking collar set screws 6 For machines with serial number above 315000000 install parking brake assembly see Parking Brake in this chapter Verify the entire width of the brake band contacts the brake hub when the brake is engaged Loosen and re adjust the drive roller bearings and locking collars to align brake band to brake hub if necessary 7 Make sure that tapered surfaces of the drive sprock et Fig 18 item 16 and taper lock bushing are thorough ly clean no oil grease dirt rust etc 8 Position sprocket on drive end roller shaft with small end of inner taper toward the roller and drive chain on sprocket 9 Install key Fig 18 item 11 on shaft Use a straight blade screwdriver in the taper lock bushing slot to
63. nd after hitch components are repaired or replaced 1 To adjust the auto hitch slide remove the cap screw and lock nut securing the lever rod to the adjustable yoke Fig 7 2 Loosen the hex nut against the adjustable yoke and turn the yoke as necessary to increase or decrease the the amount of slide travel lever movement 3 Temporarily install the cap screw and lock nut secur ing the adjustable yoke to the lever rod and check the auto hitch slide mechanism as follows A Fully depress the auto hitch lever The lever should reach the fully depressed position with the lever rod contacting the tow bar The auto hitch slide should be as close to the end of the tow bar as pos sible without making contact Fig 8 Adjust as ne cessary B Release the auto hitch lever The lever should re main in the fully released position The auto hitch slide should contact the roll pin stop before the lever contacts the tow bar Fig 9 Adjust as necessary 4 Tighten hex nut against adjustable yoke and tighten cap screw and lock nut securing lever rod to adjustable yoke Figure 7 1 Adjustable yoke 4 Hexnut 2 screw 5 Lever 3 Lock nut 6 Lever rod Figure 8 1 Auto hitch slide 3 Lever depressed 2 Tow bar Figure 9 1 Auto hitch slide 3 Lever released 2 Roll pin stop 4 Tow bar Chassis 6 8 GreensPro 1240 Servic
64. nd lock nuts to se cure the seat support to the chassis and the rear support frame 7 On machines with serial number above 315000000 connect the parking brake cable to the brake lever Fig 21 8 Connect the main wire harness at the following loca tions A Hourmeter harness B Interlock module serial number above 315000000 C Seat switch serial number above 315000000 D Parking brake switch serial number above 315000000 9 Install transmission cover see Transmission Cover in this chapter 10 Check transport frame for proper latch and lift pedal operation see Operator s Manual GreensPro 1240 This page is intentionally blank GreensPro 1240 Page 6 25 Chassis Tow Bar Figure 23 1 Tow bar 11 Lever rod 21 Tow pin 2 Cap screw 12 mm 12 Clevis pin 22 Rubber pad 2 3 Flat washer 2 13 Cotter pin 23 Button head screw 2 4 Lock nut 12 mm 14 Cap screw 24 Roll pin stop 5 Cap screw 10 mm 15 Cap screw 25 Flat washer 2 6 Flat washer 2 16 Lever 26 Lock nut 7 Lock nut 10 mm 17 Flat washer 2 27 Lock nut 8 Cap screw 18 Lock nut 28 Auto hitch slide 9 Adjustable yoke 19 Lock nut 29 Compression spring 10 Hex nut 20 Washer 30 Slide rod The tow bar must be securely attached to the transport Determine desired tow bar height during assembly see frame and the auto hitch slide must move freely in both Tow Bar Height in this chapter Check adjust auto hitch directions
65. nd woodruff key from steering column shaft 7 Remove cap screws flat washers and flange nuts securing steering column to chassis and remove steer ing column GreensPro 1240 Installation Fig 11 1 Place steering column in position on chassis and se cure with cap screws flat washers and flange nuts 2 Install steering pivot on steering column shaft with woodruff key Set height of steering pivot to 1 25 in 32 mm below chassis top plate and tighten set screw Fig 12 3 Secure steering pivot linkage rod item 7 to steering pivot with cap screw flat washers and lock nut 4 If removed install the steering column gas spring as sembly item 4 5 Install the steering column boot item 3 Figure 12 A Carefully pull the boot down over the steering 1 Steering pivot 2 Set screw column B Set the steering column tilt to the fully rearward position C Gently pull steering column boot over the tilt con trol lever D Set the steering column tilt to the fully forward po sition E Pull the front of the boot down over the base of the steering column 6 Install the bearing cover item 2 over the top of the steering column 7 Install steering wheel see Steering Wheel in this chapter GreensPro 1240 Page 6 11 Chassis Steering Linkage 15 _ reel use
66. ng head to turn when the operator moves the steering wheel Fig 1 The rotation of the steering heads allows the machine to change direction The amount the steering wheel can be turned is limited so the turning circle of the greens roller is relatively large Steering system components include the steering wheel and attached steering column which is connected to the steering pivot steering pivot rod steering disc as sembly front and rear steering head linkage arms and front and rear steering head assemblies With the ex Chassis Page 6 4 7 Steering pivot 8 Steering column assembly 9 Steering wheel ception of the steering wheel and steering column steering system components are attached to the under side of the chassis When the steering wheel is turned by the operator the steering pivot is rotated Steering pivot movement causes the steering disc assembly to be rotated via the steering pivot rod The steering disc assembly is con nected to two steering heads by steering head linkage arms Rotation of the steering disc assembly causes ro tation of the steering heads which allows the machine to turn while in motion GreensPro 1240 Transport Frame Operation Figure 2 1 Transport frame 4 Tow bar 2 Latch raised 3 Latch lowered 6 Lift pedal The GreensPro 1240 transport frame is placed in the raised position chassis lowered during machine oper ation or in the lowered position chassis
67. octane rating 87 or higher with no more than 1096 Ethanol Fuel Tank Capacity 3 3 U S Quarts 3 1 Ltr Engine Oil See Operator s Manual Lubrication System Splash Type Oil Capacity 0 63 U S Quarts 0 6 Ltr Air Cleaner Dual Element Ignition System Transistorized Flywheel Magneto Spark Plug BPR6ES Spark Plug Gap 0 028 to 0 031 in 0 7 to 0 8 mm Dry Weight 35 5 lbs 16 1 kg GreensPro 1240 Page 3 3 Gasoline Engine o E 5 General Information Fuel Evaporative Control System Fig 1 To meet worldwide emission standards the engine that powers your GreensPro is equipped with a fuel cap that has an integrated carbon canister This fuel cap cap tures fuel vapors from the fuel tank prior to venting to at mosphere Figure 1 1 Fuel tank insert To prevent saturating the carbon canister in the fuel cap it is important to make sure that the fuel tank is not over filled The maximum fuel level for the fuel tank is to the bottom of the fuel tank insert item 1 The insert also prevents the fuel from saturating the fuel cap during ma chine movement Do not overfill the tank when refueling Refer to the Honda GX200 Owner s Manual for addition al information Gasoline Engine Page 3 4 GreensPro 1240 E 5 This page is intentionally left blank GreensPro 1240 Page3 5 Ga
68. oose until rod ends have been secured and rod length adjusted Set height of steering pivot to 1 25 in 32 mm below chassis top plate Fig 14 After assembly check steering operation and adjust as necessary see Steering Linkage in the Adjustment sec tion in this chapter GreensPro 1240 Page 6 13 Chassis Steering Rollers FRONT STEERING HEAD ASSEMBLY SHOWN Figure 15 1 Steering head frame 3 Roller assembly long 5 Lock washer 2 Roller assembly short 4 Cap screw 6 Flat washer Removal Fig 15 Installation Fig 15 1 Turn the steering wheel to the left or right if neces sary to access the steering roller mounting holes 2 Secure the steering roller assembly to the steering Use a suitable lifting device to safely raise and head with cap screws lock washers and flat washers support the machine to allow access to compon ents under the chassis 1 Turn the steering wheel to the left or right if neces sary to access the steering roller cap screws Support steering roller assemblies during re moval Steering roller assemblies weigh approx imately 25 Ibs 11 3 kg 2 Remove cap screws lock washers and flat washers and lower steering roller assembly from steering head Chassis Page 6 14 GreensPro 1240 Steering Roller Service 68 to 91 ft Ib 92 to 124 N m __ 2 Flocked surface toward bearing d Kom Flocked surface NS toward bearing 68 to 91 ft Ib 92 to 124 N
69. r and lock nut Do Not adjust idler adjustment rod chain tension at this time 9 Install compression spring Fig 11 item 3 spacer and hex nut on idler adjustment rod 10 Connect transmission collar to drive coupling Fig 10 item 1 using cap screws flat washers spacers and lock nuts Tighten lock nuts from 17 to 21 ft lb 23 to 29 N m IMPORTANT To prevent drive coupling damage make sure that no distortion of coupling exists after securing transmission collar to coupling If coup ling distortion is evident loosen transmission and or engine and reposition transmission and or engine on frame so that coupling is not distorted 11 Tighten transmission drive collar set screw 12 Secure damper plate and linkage rod to transmission control arm Fig 9 item 5 with cap screws flat washers spacers and lock nuts Drive Train 5 14 Anti seize lubricant Figure 12 1 Setscrew 3 Fan 2 Key 4 Drive collar 13 Secure damper Fig 9 item 3 to damper plate with lock washer and hex nut 14 Remove caps and plugs from hoses and fittings and attach hydraulic hoses to fittings on the transmission as sembly Tighten hose swivel nuts to 24 Ib ft 32 15 Adjust drive chain tension and lubricate chain see Operator s Manual Dri Slide amp Multi Purpose Lubric ant or an equivalent chain specific lubricant is recom mended 16 Fill oil tank with new hydraulic oil see Operator s Manual 17 In
70. shafts to the drive roller and remove the drive roller shafts GreensPro 1240 Page 5 25 24 Brake hub Assembly Fig 22 1 Install drive roller shafts with cap screws lock wash ers and flat washers NOTE It may be necessary to reposition bearings and locking collars during drive roller assembly installation 2 Position locking collars on drive roller shafts in loca tions recorded during disassembly and lightly tighten set Screws 3 Position bearings on drive roller shafts against lock ing collars and lightly tighten bearing collar set screws 4 Lubricate bearing grease fittings until grease is vis ible on outside of bearing Wipe away any excess grease Drive Train T Parking Brake Serial Number Above 315000000 1 Brake hub 2 Socket head screw 3 Lock washer 4 Flat washer 5 Hardened washer 6 Brake return spring 7 Brake pivot arm 8 Bushing 2 9 Pivot bushing 10 Cap screw Drive Train Figure 23 Flat washer Flat washer Lock nut Hair pin Brake rod Brake cable E ring Sleeve Lock nut Page 5 26 Flat washer 2 Cap screw Lock nut 2 Flat washer 4 Shim as required Cap screw 2 Flat washer Lock nut Brake band GreensPro 1240 Removal Fig 23 Use a suitable lifting device to safely raise and support the machine to allow access to compon ents under the chassis 1 Make sur
71. soline Engine Service and Repairs Engine Anti seize lubricant 17 to 21 ft Ib 23 to 29 N m 17 to 21 ft lb Dec 23 to 29 N m d 20 i Figure 2 1 Engine assembly 10 Rubber drive coupling 19 Cap screw 4 2 Transmission assembly 11 Lock nut 4 20 Flat washer 8 3 Fan 12 Socket head screw 21 Lock nut 4 4 Transmission drive collar 13 Lock washer 22 Ground wire 5 screw 2 14 Flat washer 23 Exhaust guard 6 Flat washer 8 15 Hardened washer serial number above 315000000 7 Spacer 2 16 Engine drive collar 24 Cap screw 3 8 Set screw 17 Key 25 Flat washer 4 9 Cap screw 2 18 Key 26 Lock nut Gasoline Engine Page 3 6 GreensPro 1240 Removal Fig 2 1 Remove transmission cover from machine see Transmission Cover in Chapter 6 Chassis in this manu al Use a Suitable lifting device to safely raise and support the machine to allow access to compon ents under the chassis 2 Remove exhaust guard item 23 from machines with serial number above 315000000 3 Remove lock nuts flat washers cap screws and spacers securing transmission drive collar item 4 to rubber drive coupling 4 Remove cap screws lock washers and flat washers nuts securing hydraulic oil reservoir to chassis Fig 3 NOTE Move the hydraulic oil reservoir to gain access to engine wiring connections and engine mounting fasteners Do Not disconnect the hydraulic oil lines from the hydr
72. stall and secure transmission cover see Trans mission Cover in Chapter 6 Chassis in this manual 18 Raise machine onto transport wheels and purge air from the hydraulic system see HYDRO GEAR BDR SERVICE AND REPAIR MANUAL 19 Check oil level and adjust if necessary Check com ponents for leaks and correct as necessary 20 Check transmission and motion pedals return to neutral operation and adjust as necessary see Trans mission and Motion Pedals Return to Neutral in this chapter GreensPro 1240 This page is intentionally blank GreensPro 1240 Page 5 15 Drive Train Transmission Service 210 to 270 in Ib 24 to 30 N m Thick race toward piston 180 to 220 in Ib 21 to 27 N m 44 to 58 ft Ib 60 to 79 N m 00 42 to 62 in IbB N 5 to 7 N m 135 to 185 in Ib 15 to 21 N m 87 to 108 in Ib 10 12 N m Figure 13 Drive Train Page 5 16 GreensPro 1240 Housing upper Housing lower Center section kit Spacer Retaining ring Retaining ring Ball bearing Swashplate variable Thrust bearing Input shaft Washer Compression spring Cylinder block kit Cylinder block assembly Output shaft Thrust bearing Ball bearing Retaining ring Retaining ring Bearing retainer gt N i h aan nana Figure 14 continued Guide slot Trunnion
73. sure engine rubber drive coupling and trans mission are aligned with each other Tighten engine mounting lock nuts and rubber drive coupling lock nuts from 17 to 21 ft lb 23 to 29 6 Connect the wire harness to the the engine as recor ded during disassembly A Ground wire ring terminal to blower housing B Two 2 connectors to lighting coil C Two 2 connectors to magneto ignition Gasoline Engine o E 5 Engine 7 Install cap screws lock washers flat washers nuts securing hydraulic oil reservoir to chassis Fig 3 8 Install exhaust guard item 23 on machines with serial number above 315000000 9 Install and secure transmission cover see Trans mission Cover Chapter 6 Chassis in this manual Gasoline Engine Page 3 8 GreensPro 1240 Chapter 4 TORO Electrical System Table of Contents GENERAL INFORMATION 2 Operator s 2 Interlock Module 2 ELECTRICAL DRAWINGS AND DIAGRAMS 3 Electrical 3 Wire Harness 05 4 Wire Harness Diagrams 5 SPECIAL TOOLS 6 TROUBLESHOOTING 7 Starting Problems Serial Number Above 315000000 7 ELECTRICAL SYSTEM QUICK CHECKS 8 Check Operation of Interlock Switches 8
74. t publication when performing regular equipment maintenance Product Records and Maintenance Page 2 2 GreensPro 1240 Decimal and Millimeter Equivalents Equivalents and Conversions Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 16 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 09375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 6 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 16 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21
75. tached to tow vehicle apply tow vehicle parking brake stop tow vehicle engine and re move key from tow vehicle ignition switch 3 On machines with serial number above 315000000 check performance of all interlock switches daily Do not disable or bypass interlock system components The in terlock system is for your protection 4 To ensure entire machine is in good operating condi tion frequently check and keep all nuts bolts and screws tight 5 Make sure all hydraulic connections are tight and all hydraulic hoses are in good condition 6 To reduce potential fire hazard keep the engine area free of excessive grease grass leaves and accumula tion of dirt 7 If the engine must be running to perform a mainten ance adjustment keep hands feet clothing and any other parts of the body away from moving parts Keep bystanders away 8 Do not overspeed the engine by changing governor settings Recommended engine high idle speed is 3600 rpm To ensure safety and accuracy check engine speed with a tachometer Safety Page 1 4 9 Engine must be shut off and cooled down before checking oil or adding oil to the crankcase 10 When performing general maintenance and service on the machine it is recommended that the machine be parked on a clean level surface with the transport wheels in the raised and locked position The machine will be more stable when positioned on the rollers 11 If service of under deck items e
76. ther side of the steering wheel column These pedals control the motion of the traction roller The pedals are connected to a common pedal rod pivot so the motion pedals can Drive Train 5 4 5 Parking brake assembly Parking brake lever not be pressed down at the same time Depressing the right hand motion pedal will move the machine to the right and depressing the left hand motion pedal will move the machine to the left The farther the pedal is de pressed the faster the machine will move in that direc tion Most of the traction control system components are at tached to the underside of the chassis The motion con trol pedals extend through the chassis as does the linkage rod that attaches to the transmission control arm The transmission and transmission drive compon ents mount to the top of the chassis Machines with serial number above 315000000 include a parking brake system The band style parking brake is hand actuated The system engages a brake hub mounted on the end of the drive roller axle These ma chines include a parking brake switch operator s seat switch and a neutral switch as part of a safety interlock system see Chapter 4 Electrical System in this manu al GreensPro 1240 Hydraulic System General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1 Before removing any parts from the hydraulic sys tem park machin
77. tion no left or right movement of the drive roller and return the motion control pedals to a position directly across from each other when the motion control pedals are released This procedure involves checking adjusting the control arm setting at the transmission first then checking ad justing the motion control linkage 1 Park machine on a clean level surface with the transport wheels in the lowered and locked position The drive roller must be off the ground to allow free rotation Place a jack stand under the front of the chassis to pre vent the the machine from tipping forward 2 Remove transmission cover see Transmission Cov er in Chapter 6 Chassis in this manual 3 Make sure entire motion control linkage assembly is secure and moves freely in both directions see Motion Control Linkage in this chapter 4 Remove the control linkage rod from the transmis sion control arm Fig 6 NOTE For machines with serial number above 315000000 have an assistant sit in the operator s seat while starting and running the engine 5 Start the engine and set the throttle to full engine speed 6 Check for axle rotation If the drive roller does not ro tate stop the engine and proceed to step 8 If the drive roller rotates note the direction of drive roller rotation stop the engine and proceed to step 7 7 Loosen the RTN Return To Neutral adjustment screw until the control arm assembly can be rotated Fig 8
78. tional worklight switch GreensPro 1240 machines with serial number above 315000000 include a number of electrical inter lock system components The interlock system consists of various switches inputs and a microprocessor based interlock module Service information for inter lock system components can be found in this chapter Electrical System Page 4 2 GreensPro 1240 Electrical Drawings and Diagrams 18211299 8 1 E SS3TSYIM B _4 a c 5 o 2 NO 3NON NO Lada LT BEEN SLHOM OL WNOILdO 8 8 LIM YSLSWYNOH SS313HIM 9 1 OV 1VNOLLdO Ly LIM SLHOM OV OL t 9 15 ualdAunoH OV T T T 9aunouo 8 yg 9 JNION3 YOLOANNOO SLIM 440 po H LIM NMOHS o O N HOLIMS 3 ONILHOIT OV VONOH 1v3s 40 LNO 40 LNO NMOHS uoO1VuddO O NHOLIMS WWHLNAN HLIM NMOHS Yd O NHOLIMS 1V3S NO A z z gt e z 2 NMOHS NOILISOd 3NION3 2 3 v 8 HOLIMS 440 NO anew 4 SPUREN 00000091 1equuinw OL3NOVN NOLLINOI
79. tiply by 5 9 GreensPro 1240 2 3 Product Records and Maintenance Product Records o 2 Torque Specifications 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 spe cified in this Service Manual These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of a thread sealant Loctite degree of lubrication on the fastener presence of a prevailing torque feature hard ness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 1 Grade 5 Inch Series Bolts and Screws Product Records and Maintenance Page 2 4 As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque v
80. to the ON pos ition and open no continuity exists between the termin als used when the switch is set to OFF 6 Replace the worklight switch if testing determines that it is faulty 7 lf the worklight switch tests correctly and a circuit problem still exists check wire harness for circuit con tinuity see ELECTRICAL DRAWINGS AND DIA GRAMS in this Chapter 8 After testing is complete apply a film of dielectric grease to the switch terminals and connect machine wire harness to the worklight switch GreensPro 1240 Page 4 11 TERMINALS USED Figure 5 1 Worklight switch Electrical System 9 5 Interlock Module Serial Number Above 315000000 An interlock module is used to manage the machine in terlock system The interlock module is attached to the underside of the seat pan Fig 6 The interlock module is a microprocessor that senses the condition of various machine switches inputs Based on the state of the inputs the module controls the engine ignition system circuit circuit ground The interlock module is a solid state device and there is no method to test the module directly The control module may be damaged if an attempt is made to test it with an electrical test device such as a digital multime ter IMPORTANT Before performing any welding on the machine disconnect the wire harness connector from the Control Mod
81. ule to prevent damage to the machine electrical system Testing 1 Park machine on a level surface engage parking brake and stop engine 2 Check seat switch parking brake switch and neutral switch for proper operation see individual component testing procedures in this manual 3 Make sure wire harness ground connection at en gine blower housing is secure and free of corrosion 4 Unlatch and lift the operator seat pan forward to ac cess the interlock module 5 Disconnect the wire harness from the interlock mod ule 6 Check the wiring harness connectors for corrosion Clean connectors if necessary Fig 7 7 Use a multimeter ohms setting and check all the in terlock module circuits of the wire harness for continuity see ELECTRICAL DRAWINGS AND DIAGRAMS in this Chapter 8 Check the engine lighting coil output see the Honda Engine Service Manual 9 If wire harness lighting coil output and all interlock switches are operating correctly the interlock module may be faulty Replace the interlock module if neces sary 10 After testing is complete apply a film of dielectric grease to the connector terminals before reconnecting the wire harness Electrical System Page 4 12 Figure 6 1 Seat pan 2 Interlock module Figure 7 1 Interlock module
82. vot bushing and spacer and remove idler arm assembly Figure 19 Fig 19 item 10 1 Hex nut 6 Flat washer 2 2 Spacer _ 7 Locknut 4 Remove drive roller sprocket Fig 18 item 16 from B bushing Sn justment ro Spacer the taper lock bushing 5 screw 10 Idler Arm Assembly A Remove two 2 set screws Fig 18 item 18 se curing sprocket to the taper lock bushing B Oil thread and the end of one of the set screws and Insert screw in removal hole Fig 20 The bush ing removal hole is threaded on the bushing side NOTE It may be necessary to tap on the sprocket to loosen the bushing Tighten set screw until the bushing is loose in the sprocket 5 Use a straight blade screwdriver in the taper lock bushing slot to spread the bushing slightly if necessary and remove the taper lock bushing Fig 18 item 17 drive chain sprocket and key from driver roller shaft 6 For machines with serial number above 315000000 remove parking brake assembly see Parking Brake in this chapter Figure 20 1 Set screw in bushing removal hole Support drive roller assembly during removal Drive roller assembly weighs approximately 66 Ibs 30 kg 7 Remove the cap screws flat washers and lock nuts securing the drive roller bearings Fig 18 item 9 to the chassis and lower the drive roller assembly out of the chassis GreensPro 1240 Page 5 23 Drive Trai
83. wire harness connector at wire harness GreensPro 1240 Parking Brake Switch Serial Number Above 31500000 A parking brake switch as part of the machine interlock system The parking brake switch is located below the brake lever Fig 8 When the parking brake is applied the parking brake lever depresses the parking brake switch plunger clos ing the switch The parking brake lever moves away from the switch when the parking brake is released al lowing the switch to return to its normally open condition The interlock module monitors the position of the park ing brake switch open or closed Using inputs from the parking brake switch and other switches in the interlock system the interlock module opens or closes the engine ignition circuit controls circuit ground Testing 1 Park machine on a level surface engage parking brake and stop engine 2 Disconnect wire harness connectors from the park Figure 8 ing brake switch 1 Parking brake lever 2 Parking brake switch 2 3 Check wire harness terminals for corrosion clean if necessary 4 Use a multimeter ohms setting and test the switch The switch is closed continuity exists between the ter minals when the parking brake is applied and open no continuity exists between the terminals when the park ing brake is released 5 Replace the parking brake switch if testing deter mines that it is faulty 6
84. without prop er instructions 3 Become familiar with the controls and know how to stop the machine and engine quickly 4 Do not carry passengers on the machine 5 Keep everyone especially children and pets away from the area of operation 6 Keep all shields and safety devices in place Repair or replace damaged or malfunctioning shields or safety devices before operating the machine 7 Keep all decals in place Replace damaged or il legible decals before operating the machine Safety Page 1 2 result in injury or death To reduce the potential for injury or death comply with the following safety instructions WARNING To reduce the potential for injury or death comply with the following safety instructions 8 Always wear substantial shoes Do not operate ma chine while wearing sandals tennis shoes or sneakers Do not wear loose fitting clothing because it could get caught in moving parts and possibly cause personal in jury 9 Wearing safety glasses safety shoes long pants and a helmet is advisable and required by some local or dinances and insurance regulations 10 Since gasoline is highly flammable handle it care fully A Use an approved gasoline container B Do not remove cap from fuel tank when engine is hot or running C Do not smoke while handling gasoline D Fill fuel tank outdoors E Wipe up any spilled gasoline F Do not fill fuel tank higher than to the bottom o
85. y the listed torque recommendation by the calculated torque conversion factor Fig 1 to de termine proper tightening torque Tightening torque when using a torque wrench with an offset wrench will be lower than the listed torque recommendation Example The measured affective length of the torque wrench distance from the center of the handle to the center of the square drive is 18 in The measured effective length of the torque wrench with the offset wrench installed distance from the center of the handle to the center of the offset wrench is 19 in The calculated torque conversion factor for this torque wrench with this offset wrench would be 18 19 0 947 If the listed torque recommendation for a fastener is from 76 to 94 lb ft the proper torque when using this torque wrench with an offset wrench would be from 72 to 98 lb ft Offset effective length of Torque wrench torque wrench wrench A B effective length of torque Awrench offset wrench TORQUE CONVERSION FACTOR Figure 1 Product Records and Maintenance Page 2 8 GreensPro 1240 Chapter 3 TORO Gasoline Engine Table of Contents 2 Operator s Manual 2 Engine Owner s 2 Engine Service Manual 2 Engine Identification 2 SPECIFICATIONS 3 GENERAL
86. ydraulic hoses used on the GreensPro have BSP P British Standard Pipe Parallel threads If hoses are replaced make sure that the replacement has the correct type of threads or component damage and leakage will occur Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather sun chemicals very warm storage condi tions or mishandling during operation and maintenance These conditions can cause hose damage and deterio ration Some hoses are more susceptible to these con ditions than others Inspect all machine hydraulic hoses frequently for signs of deterioration or damage Hard cracked cut abraded charred leaking or otherwise damaged hose Kinked crushed flattened or twisted hose Blistered soft degraded or loose hose cover Cracked damaged or badly corroded hose fittings When replacing a hydraulic hose be sure that the hose is straight not twisted before tightening the fittings This can be done by observing the imprint layline on the hose Use two wrenches hold the hose straight with one wrench and tighten the hose swivel nut onto the fit ting with the other wrench If the hose has an elbow at one end tighten the swivel nut on that end before tight ening the nut on the straight end of the hose Before disconnecting or performing any work on hydraulic system stop the engine and move the motion control pedals to relieve pressure in the system

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