Page 2 Revision History Revision Date Description Initial issue. 10/2017 01/2018 Added Revision History 04/2018 Updated Cutting Unit chapter. Revision History Page 2 Greensmaster 3120 17230SL Rev C...
Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.com...
Page 4 NOTES: Revision History Page 4 Greensmaster 3120 17230SL Rev C...
Page 5 Manuals and Parts Catalogs for your machine with this Service Manual for reference. Additional copies of the Operator’s Manuals and Parts Catalogs are available at www.toro.com. The Toro Company reserves the right to change the product specifications or this publication without notice. DANGER This safety symbol means danger.
Page 6 Overall Dimensions g219200 Figure 1 Greensmaster 3120 Preface Page 6 Greensmaster 3120 17230SL Rev C...
Page 7 Operator’s Manual. Note: Refer to the service decal on the machine and the machine Operator’s Manual for commonly used fluid specifications and capacities. Greensmaster 3120 Page 7 Preface 17230SL Rev C...
Page 8: Table Of Contents
General Information ..................9–3 Service and Repairs ..................9–5 Appendix A ......................A–1 Hydraulic Schematic (machines without backlap) .........A–3 Hydraulic Schematic (machines with backlap) ..........A–4 Electrical Schematic ..................A–5 Wire Harness Drawing - Main ...............A–6 Preface Page 8 Greensmaster 3120 17230SL Rev C...
Page 9: Preface
Briggs & Stratton Vanguard V-Twin OHV Repair Manual Hydro-Gear® P Series Hydrostatic Pumps Service and Repair Manual Parker Torqmotor™ Service Procedure (TC, TB, TE, TJ, TF, TG, TH and TL Series) Danfoss Steering Unit Type OSPM Service Manual Greensmaster 3120 Page 9 Preface 17230SL Rev C...
Page 10 Preface Page 10 Greensmaster 3120 17230SL Rev C...
Page 11 Supervisor’s Responsibilities ......................1–2 Before Operating the Machine ......................1–2 While Operating the Machine ......................1–4 Maintenance and Service........................1–6 Jacking Instructions ..........................1–7 Raising the Machine .......................... 1–7 Safety and Instructional Decals ......................1–8 Greensmaster 3120 Page 1–1 Safety 17230SL Rev C...
Page 12: Safety Instructions
Safety Instructions The Greensmaster 3120 machine meets or exceeds safety standard specifications as identified in the Operator’s Manuals. Although hazard control and accident prevention are dependent partially upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
Page 13 – If you spill fuel, do not attempt to start the engine but move the machine away from the spill. Avoid creating any source of ignition until fuel vapors have dissipated. Wipe up any spilled fuel. Greensmaster 3120 Page 1–3 Safety: Safety Instructions...
Page 14: While Operating The Machine
STOP MOWING. Careless operation, combined with terrain angles, ricochets or improperly positioned guards can lead to thrown object injuries. Do not resume mowing until the area is cleared. 11. Before getting off the seat: Safety: Safety Instructions Page 1–4 Greensmaster 3120 17230SL Rev C...
Page 15 12. Whenever machine is left unattended, make sure cutting units are fully raised and reels are not spinning, the key is removed from ignition switch and the parking brake is set. Greensmaster 3120 Page 1–5 Safety: Safety Instructions 17230SL Rev C...
Page 16: Maintenance And Service
At the time of manufacture, the machine conformed to the safety standards for riding mowers. To ensure the optimum performance and continued safety certification of the machine, use genuine Toro replacement parts and accessories. The replacement parts and accessories of other manufacturers can result in non-conformance with the safety standards and can void the warranty.
Page 17: Jacking Instructions
• Do Not use a cutting unit as a jacking point. Raising the Machine g212063 Figure 2 Left front jacking point (frame channel under the step behind the left front wheel) Rear jacking point (rear wheel caster fork) Greensmaster 3120 Page 1–7 Safety: Jacking Instructions 17230SL Rev C...
Page 18: Safety And Instructional Decals
Safety and Instructional Decals Numerous safety and instructional decals are affixed to the traction unit and the cutting units of the Greensmaster 3120. If any decal becomes illegible or damaged, replace it with a new decal. Part numbers are listed in your Parts Catalog and Operator’s Manual.
Page 19: Chapter 2: Specifications And Maintenance
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric) ........... 2–6 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch) ............2–7 Other Torque Specifications ....................... 2–8 Conversion Factors..........................2–8 Shop Supplies ............................2–9 Special Tools ............................2–11 Greensmaster 3120 Page 2–1 Specifications and Maintenance 17230SL Rev C...
Page 20: Specifications
0.421875 10.716 59/64 0.921875 23.416 7/16 0.4375 11.112 15/16 0.9375 23.812 0.453125 11.509 0.953125 24.209 29/64 61/64 15/32 0.46875 11.906 31/32 0.96875 24.606 31/64 0.484375 12.303 63/64 0.984375 25.003 Specifications and Maintenance: Specifications Page 2–2 Greensmaster 3120 17230SL Rev C...
Page 21: U.s. To Metric Conversions
0.138 Inch-pounds Kilogram-Centimeters 1.152 Liquid Volume Ounces Milliliters 29.57 Quarts Liters 0.946 Gallons Liters 3.785 Liquid Flow Gallons/Minute Liters/Minute 3.785 Temperature Fahrenheit Celsius Subtract 32 then multiply by 0.555 Greensmaster 3120 Page 2–3 Specifications and Maintenance: Specifications 17230SL Rev C...
Page 22: Torque Specifications
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual.
Page 23: Identifying The Fastener
Toro recommends replacing fasteners with a locking feature once they have been removed because the effectiveness of the locking feature diminishes with each reuse. If it is necessary to reuse a fastener with a locking feature; apply a thread locking compound (Loctite for example) to the fastener during installation.
Page 24: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Metric)
Note: Reduce the torque values listed in the table above by 25% for lubricated fasteners. Lubricated fasteners are defined as threads coated with a lubricant, such as engine oil, or a thread locking compound such as Loctite. Specifications and Maintenance: Torque Specifications Page 2–6 Greensmaster 3120 17230SL Rev C...
Page 25: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch)
Note: Reduce the torque values listed in the table above by 25% for lubricated fasteners. Lubricated fasteners are defined as threads coated with a lubricant, such as engine oil, or a thread locking compound such as Loctite. Greensmaster 3120 Page 2–7 Specifications and Maintenance: Torque Specifications...
Page 26: Other Torque Specifications
Conversion Factors in-lb X 11.2985 = N∙cm N∙cm X 0.08851 = in-lb ft-lb X 1.3558 = N∙m N∙m X 0.7376 = ft-lb Specifications and Maintenance: Torque Specifications Page 2–8 Greensmaster 3120 17230SL Rev C...
Page 27: Shop Supplies
Always refer to the written procedure for specific information regarding the type and the application of a shop supply. IMPORTANT Always follow manufacturers instructions when using or storing shop supplies. Greensmaster 3120 Page 2–9 Specifications and Maintenance: Shop Supplies 17230SL Rev C...
Page 28 Standard silicone sealants are designed to perform in temperatures from -51°F to 232°C (-60°F to 400°F), while high temperature variants can preform in temperatures up to 343°C (650°F). Specifications and Maintenance: Shop Supplies Page 2–10 Greensmaster 3120 17230SL Rev C...
Page 29: Special Tools
Special Tools You can order these special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic Pressure Testing Kit Toro Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick...
Page 30 20 to 150 LPM (4 to 40 GPM). Note: This tester does not include any hydraulic hoses or fittings; refer to Hydraulic Hose Kit Toro Part No. TOR6007 and Hydraulic Test Fitting Kit Tor Part No. TOR4079. Hydraulic O-Ring Kit Toro Part No.
Page 31 Hydraulic Test Fitting Kit Toro Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system. FITTING TYPE SIZE PART NUMBER 4 ORFS (9/16–18) TOR4079–3 6 ORFS (11/16–16) TOR4079–12...
Page 32 Note: This kit does not include the hydraulic hoses; refer to Hydraulic Hose Kit (page 2–12). Note: The replacement filter element is Toro Part No. TOR6012. The filter element canister tightening torque is 34 N∙m (25 ft-lb). Remote Starter Switch After flushing the hydraulic system or replacing a hydraulic component (e.g.
Page 33 This excess current can damage the circuits that are not designed to carry it. Battery Terminal Protector Toro Part No. 107-0392 Use this aerosol spray on the battery terminals, ring terminals, and fork terminals to reduce corrosion problems. Apply the...
Page 34 Specifications and Maintenance: Special Tools Page 2–16 Greensmaster 3120 17230SL Rev C...
Page 35 Briggs & Stratton Repair Manual......................3–3 Service and Repairs ..........................3–4 Fuel Tank ............................3–4 Engine..............................3–7 Evaporative Control System......................3–11 Disassembly............................. 3–12 Assembly ............................3–12 Additional Reference Materials Briggs & Stratton Vanguard V-Twin OHV Repair Manual Greensmaster 3120 Page 3–1 Engine 17230SL Rev C...
Page 36: Chapter 3: Engine
Flywheel magneto, twin electronic armatures Ignition System Spark Plugs Champion RC 14YC (or equivalent) Spark Plug Gap 0.76 mm (0.030 inches) Alternator/Regulator 12 VDC, 16A Engine Weight (dry) 38 kg (84 lb) Engine: Specifications Page 3–2 Greensmaster 3120 17230SL Rev C...
Page 37: General Information
Service and repair parts for Briggs & Stratton Vanguard V-Twin OHV engines are supplied through your local Toro distributor. If no parts list is available, be sure to provide your distributor with the Toro model and serial number along with the engine model and serial number.
Page 38: Service And Repairs
Fuel hose (valve to filter) Fuel gauge (if equipped) Flat washer (4 each) Fuel shut-off valve Grommet (machines with fuel gauge) Hose clamp (3 each) Hose clamp (2 each) Engine: Service and Repairs Page 3–4 Greensmaster 3120 17230SL Rev C...
Page 39 4. Disconnect the vent hose from the top of the fuel tank. 5. Remove four (4) cap screws, grommets and flat washers securing the fuel tank to the vehicle frame and remove the fuel tank. Greensmaster 3120 Page 3–5 Engine: Service and Repairs...
Page 40 4. Open the fuel shut-off valve and fill the fuel tank with fuel. Check the fuel system for leaks and repair as necessary before returning the machine to service. Engine: Service and Repairs Page 3–6 Greensmaster 3120 17230SL Rev C...
Page 41: Engine
Cap screw (4 each) Exhaust gasket (2 each) Ground (-) cable Adapter plate Exhaust manifold Engine wire harness ground Flat head screw (2 each) Engine wire harness Hardened washer (2 each) Greensmaster 3120 Page 3–7 Engine: Service and Repairs 17230SL Rev C...
Page 42 11. Carefully move the engine away from the pump assembly until the pump hub clears the adapter plate. Locate and retrieve the two (2) spacers in the drive coupler. 12. Continue to disassemble the engine as necessary. Engine: Service and Repairs Page 3–8 Greensmaster 3120 17230SL Rev C...
Page 43 Note: Do Not tighten the engine hub set screws until after the engine and the pump have been installed on the machine. CAUTION The engine assembly weighs approximately 45 kg (100 lb). Use an appropriate lift to support the engine assembly. Greensmaster 3120 Page 3–9 Engine: Service and Repairs 17230SL Rev C...
Page 44 13. Check engine oil level and adjust if necessary; refer to traction unit Operator’s Manual. 14. Operate the machine and check for proper operation, hydraulic fluid leaks and fuel leaks before returning the machine to service. Engine: Service and Repairs Page 3–10 Greensmaster 3120 17230SL Rev C...
Page 45: Evaporative Control System
Vent hose (tee to engine) Convoluted tubing Greensmaster 3120 machines are equipped with a fuel evaporative control system designed to collect and store evaporative emissions from the fuel tank. The evaporate control system uses a carbon canister and a series of vent hoses to collect these evaporative emissions.
Page 46: Disassembly
Install all evaporative control system components previously removed. Ensure all evaporative control system hoses are not kinked or pinched and are secured at each end with hose clamps. Engine: Service and Repairs Page 3–12 Greensmaster 3120 17230SL Rev C...
Page 47: Chapter 4: Hydraulic System
Adjusting Relief Valves........................4–70 Service and Repairs ........................... 4–71 General Precautions for Removing and Installing the Hydraulic System Components...... 4–71 Checking the Hydraulic Lines and Hoses ..................4–73 Flushing the Hydraulic System......................4–74 Greensmaster 3120 Page 4–1 Hydraulic System 17230SL Rev C...
Page 48 Hydro-Gear® P Series Hydrostatic Pumps Service and Repair Manual Parker Torqmotor™ Service Procedure (TC, TB, TE, TJ, TF, TG, TH and TL Series) Danfoss Steering Unit Type OSPM Service Manual Hydraulic System: Service and Repairs Page 4–2 Greensmaster 3120 17230SL Rev C...
Page 49: Specifications
1724 kPa (250 psi) above charge pressure Cutting unit reels (R1) 20,700 kPa (3000 psi) Hydraulic filter Spin-on cartridge type Hydraulic fluid Refer to the Traction Unit Operator's Manual Hydraulic tank 18.9 L (20 US qt.) Greensmaster 3120 Page 4–3 Hydraulic System: Specifications 17230SL Rev C...
Page 50: General Information
The traction unit and cutting unit Operator’s Manuals provide information regarding the operation, general maintenance and maintenance intervals for the Greensmaster 3120 machine. Refer to these publications for additional information when servicing the machine. Relieving Pressure from the Hydraulic System Release all the pressure in the hydraulic system before performing any work on the hydraulic system.
Page 51: Towing The Traction Unit
Towing the Traction Unit In case of emergency, the traction unit can be towed for a short distance. However, Toro does not recommend this as a standard practice. IMPORTANT Do not tow the machine faster than 2 to 3 mph. Drive system damage may occur it the machine is towed too fast of for too far.
Page 52: Traction Circuit (Closed Loop) Component Failure
The filter will ensure that contaminates are removed from the closed loop traction circuit and thus, prevent additional component damage. Once the Toro high flow hydraulic filter kit has been placed in the traction circuit, raise and support the machine with the front wheels off the ground. Then, operate the traction circuit to allow fluid flow throughout the circuit.
Page 53: Hydraulic Hoses
Note: If the hose has an elbow at one end, tighten the swivel nut on the elbow end before you tighten the nut on the straight end of the hose. For more hydraulic hose information, refer to the Toro Basics Series Training Book Hydraulic Hose Servicing (Part No. 94813SL).
Page 54: Installing Hydraulic Hoses And Tubes (O-Ring Face Seal)
Calculating the Torque Values When Using a Drive-Adapter Wrench (page 2–4). g212098 Figure 13 Mark swivel nut and fitting Initial position Final position body Hydraulic System: General Information Page 4–8 Greensmaster 3120 17230SL Rev C...
Page 55 C. Use a wrench to tighten the nut to the correct Flats From Wrench Resistance (compare items 2 and 3 in Figure 13). Greensmaster 3120 Page 4–9 Hydraulic System: General Information 17230SL Rev C...
Page 56: Installing The Hydraulic Fittings (Sae Straight Thread O-Ring Fittings)
Flats From Finger Tight (FFFT) Table (page 4–12). C. If the port material is aluminum, tighten the fitting to 60% of the listed value; refer to the Flats From Finger Tight (FFFT) Table (page 4–12). Hydraulic System: General Information Page 4–10 Greensmaster 3120 17230SL Rev C...
Page 57 Installing a fitting into an aluminum port requires reducing the installation torque. 7. Tighten the fitting lock nut (Step 4 in Figure 16): Greensmaster 3120 Page 4–11 Hydraulic System: General Information 17230SL Rev C...
Page 58 6 (3/8 inch) 1.50 ± 0.25 1.50 ± 0.25 8 (1/2 inch) 10 (5/8 inch) 1.50 ± 0.25 12 (3/4 inch) 1.50 ± 0.25 16 (1 inch) 1.50 ± 0.25 Hydraulic System: General Information Page 4–12 Greensmaster 3120 17230SL Rev C...
Page 59: Hydraulic Schematics
Hydraulic Schematics Larger versions of the hydraulic schematics can be found in Appendix A (page A–1) g212370 Figure 17 Greensmaster 3120 Page 4–13 Hydraulic System: Hydraulic Schematics 17230SL Rev C...
Page 60 Figure 18 Hydraulic System: Hydraulic Schematics Page 4–14 Greensmaster 3120 17230SL Rev C...
Page 61: Hydraulic Flow Diagrams
The charge circuit functions the same in reverse as it does in the forward direction. Greensmaster 3120 Page 4–15 Hydraulic System: Hydraulic Flow Diagrams 17230SL Rev C...
Page 62 Reverse Direction (continued) g213626 Figure 19 Hydraulic System: Hydraulic Flow Diagrams Page 4–16 Greensmaster 3120 17230SL Rev C...
Page 63: Lift Circuit
(S2) and (S4) de-energize, spring action returns the valves to their original position and flow is directed back to the traction charge circuit stopping lift cylinder movement. Greensmaster 3120 Page 4–17 Hydraulic System: Hydraulic Flow Diagrams 17230SL Rev C...
Page 64 Lower Cutting Units (continued) g213625 Figure 20 Hydraulic System: Hydraulic Flow Diagrams Page 4–18 Greensmaster 3120 17230SL Rev C...
Page 65 Lower Cutting Units (continued) g213622 Figure 21 Greensmaster 3120 Page 4–19 Hydraulic System: Hydraulic Flow Diagrams 17230SL Rev C...
Page 66: Mow Circuit
Maximum circuit pressure is limited to 20,684 kPa (3000 psi) by relief valve (R1) which is located in the mower manifold. Hydraulic System: Hydraulic Flow Diagrams Page 4–20 Greensmaster 3120 17230SL Rev C...
Page 67 Mow (machines without backlap) (continued) g213623 Figure 22 Greensmaster 3120 Page 4–21 Hydraulic System: Hydraulic Flow Diagrams 17230SL Rev C...
Page 68 Fluid flows through the center reel motor, right front motor and then left front motor as it turns the reel motors in the backlap direction. Hydraulic System: Hydraulic Flow Diagrams Page 4–22 Greensmaster 3120 17230SL Rev C...
Page 69 Backlap (continued) g213624 Figure 23 Greensmaster 3120 Page 4–23 Hydraulic System: Hydraulic Flow Diagrams 17230SL Rev C...
Page 70: Steering Circuit
Fluid leaving the cylinder flows back through the spool valve then out steering unit port (T) and then to the traction charge circuit. When turning is complete, the steering unit returns to the neutral position. Hydraulic System: Hydraulic Flow Diagrams Page 4–24 Greensmaster 3120 17230SL Rev C...
Page 71 Left Turn (continued) g213627 Figure 24 Greensmaster 3120 Page 4–25 Hydraulic System: Hydraulic Flow Diagrams 17230SL Rev C...
Page 72: Special Tools
Special Tools You can order these special tools from your Toro Distributor. Some tools are also available from a local tool supplier. Hydraulic Pressure Testing Kit Toro Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick disconnect fittings...
Page 73: Hydraulic Test Fitting Kit
Hydraulic Test Fitting Kit Toro Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system. PART NUMBER FITTING TYPE SIZE 4 ORFS (9/16–18) TOR4079–3 6 ORFS (11/16–16) TOR4079–12...
Page 74: O-Ring Kit
O-Ring Kit Toro Part No. 117-2727 This kit includes O-rings in a variety of sizes for the face seal and port seal hydraulic connections. To help prevent a hydraulic leak, replace the O-rings when you open the hydraulic connection. Hydraulic Hose Kit Toro Part No.
Page 75: High Flow Hydraulic Filter Kit
Note: This kit does not include the hydraulic hoses; refer to Hydraulic Hose Kit (page 4–28). Note: The replacement filter element is Toro Part No. TOR6012. The filter element canister tightening torque is 34 N∙m (25 ft-lb). Greensmaster 3120 Page 4–29...
Page 76: Troubleshooting
The traction pump, wheel motor(s) or reel motor(s) is worn or damaged. Note: If a traction circuit component has internal wear or damage, it is possible that the other traction components are also damaged. Hydraulic System: Troubleshooting Page 4–30 Greensmaster 3120 17230SL Rev C...
Page 77: Traction Circuit Problems
The traction pump relief valves are leaking or damaged. Note: The piston (traction) pump used on Greensmaster 3120 machines is equipped with relief valves for both the forward and reverse direction. Due to engine output, it is unlikely that traction pressure will reach relief valve settings.
Page 78: Mow Circuit Problems
Mower manifold cartridge valve In the reel circuit is leaking or damaged. Excessive internal wear in reel motor exists; refer to Reel Motor Case Drain Flow Test in the Testing section of this chapter. Hydraulic System: Troubleshooting Page 4–32 Greensmaster 3120 17230SL Rev C...
Page 79: Lift/Lower Circuit Problems
Test in the Testing section of this chapter. Cutting units raise, but will not stay up. Mower manifold solenoid valve (S4) leaks or is damaged. The lift cylinder(s) is leaking internally. Greensmaster 3120 Page 4–33 Hydraulic System: Troubleshooting 17230SL Rev C...
Page 80: Steering Circuit Problems
Steering force (possibly to one side only) is Hydraulic flow to steering control valve is low insufficient. (traction charge and lift circuits affected as well). Relief valve in steering control valve is leaking or damaged. Hydraulic System: Troubleshooting Page 4–34 Greensmaster 3120 17230SL Rev C...
Page 81: Testing The Hydraulic System
Greensmaster 3120 Page 4–35 Hydraulic System: Testing the Hydraulic System 17230SL Rev C...
Page 82 If engine RPM is above or below the specified speed during a test, you will need to adjust the expected hydraulic performance parameters (aprox. 3% per 100 engine rpm at full throttle) Hydraulic System: Testing the Hydraulic System Page 4–36 Greensmaster 3120 17230SL Rev C...
Page 83: Hydraulic Test Selection
Gear Pump (P1) Flow Test, Relief Valve Pressure Test, Lower Cutting Units Relief Valve (R2) Pressure Test, and/or Steering Control Valve and Steering Cylinder Test. Greensmaster 3120 Page 4–37 Hydraulic System: Testing the Hydraulic System 17230SL Rev C...
Page 84: Traction Circuit Testing - Charge Pressure Test
Traction Circuit Testing – Charge Pressure Test g216034 Figure 25 Traction Circuit Testing – Charge Pressure Test (machines without backlap) Hydraulic System: Testing the Hydraulic System Page 4–38 Greensmaster 3120 17230SL Rev C...
Page 85 Pressure Gauge (accurate below 300 psi) with hose and quick disconnect coupling • Flow Meter with Pressure Gauge that has at least an 68 LPM (18 GPM) capacity. Greensmaster 3120 Page 4–39 Hydraulic System: Testing the Hydraulic System 17230SL Rev C...
Page 86 Testing the Hydraulic System (page 4–35). 3. Make sure that traction pedal is adjusted to the neutral position. g216685 Figure 27 (machines without backlap) Mower manifold Test connector (G3) Hydraulic System: Testing the Hydraulic System Page 4–40 Greensmaster 3120 17230SL Rev C...
Page 87 Swivel tee fitting and test connector Mower manifold PT port g234335 Figure 29 Left step Test connector Mower manifold PT port 4. Install a hydraulic pressure gauge in the charge circuit: Greensmaster 3120 Page 4–41 Hydraulic System: Testing the Hydraulic System 17230SL Rev C...
Page 88 (not the pressure gauge on the flow meter). Charge pressure (without load) should read approximately 414 kPa (60 PSI). If charge relief pressure specification is not met, consider the following: Hydraulic System: Testing the Hydraulic System Page 4–42 Greensmaster 3120 17230SL Rev C...
Page 89 If specifications are not met, perform Traction Pump (P1) Flow and Traction Relief Pressure Test as described in Traction Circuit Testing – Traction Pump (P1) Flow and Relief Pressure Test (page 4–47). Greensmaster 3120 Page 4–43 Hydraulic System: Testing the Hydraulic System 17230SL Rev C...
Page 90: Traction Circuit Testing - Wheel Motor Efficiency Test
Traction Circuit Testing – Wheel Motor Efficiency Test Wheel motor efficiency is the second in a series of tests recommended to determine traction circuit performance. Hydraulic fluid flow of 2.4 LPM (0.6 Hydraulic System: Testing the Hydraulic System Page 4–44 Greensmaster 3120 17230SL Rev C...
Page 91 Figure 32 Traction pump Hose from traction pump “A” port 5. Disconnect hose from traction pump “A” port; refer to Figure Greensmaster 3120 Page 4–45 Hydraulic System: Testing the Hydraulic System 17230SL Rev C...
Page 92 17. Reconnect hydraulic lines to front wheel motor and repeat procedure for remaining front wheel motor. 18. Check fluid level in hydraulic tank and adjust as necessary; refer to traction unit Operator’s Manual. Hydraulic System: Testing the Hydraulic System Page 4–46 Greensmaster 3120 17230SL Rev C...
Page 93: Traction Circuit Testing - Traction Pump (P1) Flow And Relief Pressure Test
Traction Circuit Testing – Traction Pump (P1) Flow and Relief Pressure Test g216104 Figure 33 Traction Circuit Testing – Traction Pump (P1) Flow and Relief Pressure Test Greensmaster 3120 Page 4–47 Hydraulic System: Testing the Hydraulic System 17230SL Rev C...
Page 94 4. Raise both front wheels off the floor and support the machine. g215375 Figure 34 Traction pump Hose from traction pump “A” port Hydraulic System: Testing the Hydraulic System Page 4–48 Greensmaster 3120 17230SL Rev C...
Page 95 15. Remove tester and reconnect hydraulic hose to pump “A” port. 16. Check fluid level in hydraulic tank and adjust as necessary; refer to traction unit Operator’s Manual. Greensmaster 3120 Page 4–49 Hydraulic System: Testing the Hydraulic System 17230SL Rev C...
Page 96: Cutting Unit Circuit Testing - Cutting Unit Motor Efficiency/Case Drain Test
The cutting unit motor efficiency/case drain test is the first in a series of tests recommended to check cutting unit circuit performance. Over a period of time, Hydraulic System: Testing the Hydraulic System Page 4–50 Greensmaster 3120 17230SL Rev C...
Page 97 10. Verify and record engine speed with a phototach. CAUTION Use extreme caution when performing this test. The cutting unit reels will be rotating during the test. Greensmaster 3120 Page 4–51 Hydraulic System: Testing the Hydraulic System 17230SL Rev C...
Page 98 PSI) is obtained. 12. Hold disconnected motor case drain hose into a container graduated in ounces or milliliters (e.g. Toro #TOR4077) and collect hydraulic fluid for 15 seconds. After 15 seconds, remove hose end from container. 13. Disengage the cutting units, Open the tester flow control, set throttle to low speed and stop engine.
Page 99: Cutting Unit Circuit Testing - Relief Valve Test
Cutting Unit Circuit Testing – Relief Valve Test g216863 Figure 36 Cutting Unit Circuit Testing – Relief Valve Test Greensmaster 3120 Page 4–53 Hydraulic System: Testing the Hydraulic System 17230SL Rev C...
Page 100 6. For machines with backlap, record the current reel speed setting then set the reel speed to the highest speed (fully open). The backlap knob on the mower manifold must be in the MOW position. Hydraulic System: Testing the Hydraulic System Page 4–54 Greensmaster 3120 17230SL Rev C...
Page 101 15. For machines with backlap, adjust cutting unit bedknife to reel clearance and reel speed as necessary. 16. Check the fluid level in the hydraulic tank and adjust as necessary; refer to traction unit Operator’s Manual. Greensmaster 3120 Page 4–55 Hydraulic System: Testing the Hydraulic System 17230SL Rev C...
Page 102: Cutting Unit Circuit Testing - Gear Pump (P2) Flow Test
Cutting Unit Circuit Testing – Gear Pump (P2) Flow Test g216909 Figure 38 Cutting Unit Circuit Testing – Gear Pump (P2) Flow Test Hydraulic System: Testing the Hydraulic System Page 4–56 Greensmaster 3120 17230SL Rev C...
Page 103 4. Install tester between the gear pump and the disconnected hose. Make sure the tester is installed in the correct flow direction and the tester flow control valve is fully open. Greensmaster 3120 Page 4–57 Hydraulic System: Testing the Hydraulic System...
Page 104 14. For machines with backlap, return reel speed adjustment knob to original setting. 15. Check fluid level in hydraulic tank and adjust as necessary; refer to traction unit Operator’s Manual. Hydraulic System: Testing the Hydraulic System Page 4–58 Greensmaster 3120 17230SL Rev C...
Page 105: Steering/Lift Circuit Testing - Gear Pump (P3) Flow And Circuit Relief Valve Test
Steering/Lift Circuit Testing – Gear Pump (P3) Flow and Circuit Relief Valve Test g217053 Figure 40 Steering/Lift Circuit Testing – Gear Pump (P3) Flow and Circuit Relief Valve Test Greensmaster 3120 Page 4–59 Hydraulic System: Testing the Hydraulic System 17230SL Rev C...
Page 106 Testing the Hydraulic System (page 4–35). 3. Measure and record the system charge pressure (without load). Refer to Traction Circuit Testing – Charge Pressure Test (page 4–38) for additional information. Hydraulic System: Testing the Hydraulic System Page 4–60 Greensmaster 3120 17230SL Rev C...
Page 107 B. To verify the pump flow Under Load, watch flow meter pressure gauge carefully while slowly closing the flow control valve until 5516 kPa (800 PSI) is obtained on gauge. Greensmaster 3120 Page 4–61 Hydraulic System: Testing the Hydraulic System...
Page 108 11. When testing is complete, remove tester and connect hose to pump fitting. 12. Check fluid level in hydraulic tank and adjust as necessary; refer to traction unit Operator’s Manual. Hydraulic System: Testing the Hydraulic System Page 4–62 Greensmaster 3120 17230SL Rev C...
Page 109: Steering/Lift Circuit Testing - Lowering Cutting Units Relief Valve Test
Steering/Lift Circuit Testing – Lowering Cutting Units Relief Valve Test g217181 Figure 42 Steering/Lift Circuit Testing – Lowering Cutting Units Relief Valve Test Greensmaster 3120 Page 4–63 Hydraulic System: Testing the Hydraulic System 17230SL Rev C...
Page 110 10 minutes. 8. Verify and record engine speed with a phototach. 9. Make sure that cutting units are fully lowered and then engage the cutting units. Hydraulic System: Testing the Hydraulic System Page 4–64 Greensmaster 3120 17230SL Rev C...
Page 111 (250 PSI) higher than the charge relief pressure (e.g. if the charge relief valve pressure is 414 kPa (60 PSI), the lowering relief valve pressure should be approximately 2137 kPa (310 PSI)). Greensmaster 3120 Page 4–65 Hydraulic System: Testing the Hydraulic System...
Page 112 13. When testing is complete, remove tester and connect hose to pump fitting. 14. Check fluid level in hydraulic tank and adjust as necessary; refer to traction unit Operator’s Manual. Hydraulic System: Testing the Hydraulic System Page 4–66 Greensmaster 3120 17230SL Rev C...
Page 113: Steering/Lift Circuit Testing - Steering Control Valve And Steering Cylinder Test
3. Drive machine slowly in a figure eight on a flat level surface. A. There should be no shaking or vibration in the steering wheel or rear wheel. Greensmaster 3120 Page 4–67 Hydraulic System: Testing the Hydraulic System 17230SL Rev C...
Page 114 F. Remove plug from the hydraulic hose and reconnect the hose. Make sure the hydraulic hoses do not contact any moving parts as the caster fork moves from stop to stop. Hydraulic System: Testing the Hydraulic System Page 4–68 Greensmaster 3120 17230SL Rev C...
Page 115 Based on the results of these tests, repair or replace steering control valve as necessary; refer to Steering Control Valve (page 4–127). Greensmaster 3120 Page 4–69 Hydraulic System: Testing the Hydraulic System 17230SL Rev C...
Page 116: Adjustments
A 1/8 turn on the socket will make a measurable change in relief pressure. 5. Install and tighten cap on relief valve. 6. Recheck relief pressure and readjust as needed. Hydraulic System: Adjustments Page 4–70 Greensmaster 3120 17230SL Rev C...
Page 117: Service And Repairs
3. Remove all the caps or plugs from the hydraulic tubes, hydraulic fittings, and components before connecting them again. 4. Use proper tightening procedures when installing the hydraulic hoses and fittings; refer to Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) Greensmaster 3120 Page 4–71 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 118 Charging the Hydraulic System (page 4–79). 8. Check for hydraulic-fluid leaks. Shut off the engine and repair leaks if necessary. Hydraulic System: Service and Repairs Page 4–72 Greensmaster 3120 17230SL Rev C...
Page 119: Checking The Hydraulic Lines And Hoses
Check the hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Repair the damaged hydraulic equipment before operating the machine. Greensmaster 3120 Page 4–73 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 120: Flushing The Hydraulic System
Do Not operate a machine with contaminated hydraulic fluid to warm the fluid before draining. IMPORTANT Follow all local codes and regulations when recycling or disposing the hydraulic fluid and filters. Hydraulic System: Service and Repairs Page 4–74 Greensmaster 3120 17230SL Rev C...
Page 121 Operator’s Manual. 9. Prime the hydraulic pumps; refer to Priming the Hydraulic Pumps (page 4–78). 10. Charge the hydraulic system; refer to Charging the Hydraulic System (page 4–79). Greensmaster 3120 Page 4–75 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 122: Filtering The Closed-Loop Traction Circuit
To effectively remove contamination from the closed−loop traction circuit, use of a Toro bidirectional high flow hydraulic filter and hydraulic hose kit is recommended; refer to...
Page 123 5. Connect the hydraulic filter in series between the disconnected fitting hose. Use a Hydraulic Hose Kit (page 4–28) if necessary and make sure that fittings and hose connections are properly tightened. Greensmaster 3120 Page 4–77 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 124: Priming The Hydraulic Pumps
Priming the hydraulic pumps ensures that the gear pumps and piston (traction) pump have sufficient fluid while charging the hydraulic system. Use the following procedure to prime the hydraulic pumps: Hydraulic System: Service and Repairs Page 4–78 Greensmaster 3120 17230SL Rev C...
Page 125: Charging The Hydraulic System
Priming the Hydraulic Pumps (page 4–78). WARNING Review and follow Jacking Instructions (page 1–7) before jacking up the machine. 6. Raise both front wheels off the floor and support the machine. Greensmaster 3120 Page 4–79 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 126 Operator’s Manual. Note: If new fluid shows any signs of contamination, flush hydraulic system again until the fluid is clean; refer to Flushing the Hydraulic System (page 4–74). Hydraulic System: Service and Repairs Page 4–80 Greensmaster 3120 17230SL Rev C...
Page 127: Gear Pump
Hose clamp Gear pump Elbow fitting Note: The gear pump is a single assembly that includes both pumps (P2 – input shaft end) and (P3 – cap end) Greensmaster 3120 Page 4–81 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 128 6. Install pump inlet hose to the gear pump and secure with hose clamp. 7. Prime the gear pump and charge the hydraulic system; refer to Priming the Hydraulic Pumps (page 4–78) Hydraulic System: Service and Repairs Page 4–82 Greensmaster 3120 17230SL Rev C...
Page 129: Servicing The Gear Pump
Pressure seal Coupler End cover Thrust plate Back-up seal Socket head screw (4 each) Drive shaft Pressure seal Washer (4 each) Idler gear Thrust plate Thrust plate Drive gear Greensmaster 3120 Page 4–83 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 130 7. Remove the thrust plates, seals and gears from each pump section. Keep the parts for each pump section together; do not mix parts between sections. Hydraulic System: Service and Repairs Page 4–84 Greensmaster 3120 17230SL Rev C...
Page 131 C. The thickness of each set of thrust plates should be equal. 5. Inspect the front cover and the rear cover for damage or wear. Greensmaster 3120 Page 4–85 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 132 Rotate the drive shaft to check for binding. Protect the shaft if using a pliers to rotate shaft. 4. Tighten the socket head screws evenly in a crossing pattern to a torque of 45 N∙m (33 ft-lb). Hydraulic System: Service and Repairs Page 4–86 Greensmaster 3120 17230SL Rev C...
Page 133: Traction Pump
Flange head screw (2 each) Removing the Traction Pump 1. Park machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. Greensmaster 3120 Page 4–87 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 134 Position the pump assembly to the adapter plate and align pump hub with the rubber coupler. Secure the pump assembly to the adapter plate with two (2) cap screws and hardened washers. Hydraulic System: Service and Repairs Page 4–88 Greensmaster 3120 17230SL Rev C...
Page 135 Tighten the connections as specified; refer to Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (page 4–8). 8. Install the gear pump; refer to Installing the Gear Pump (page 4–82). Greensmaster 3120 Page 4–89 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 136: Servicing The Traction Pump
Cylinder block kit Pin (2 each) IMPORTANT If a transmission fails; refer to Filtering the Closed-Loop Traction Circuit (page 4–76) for information regarding removing contamination from the traction circuit. Hydraulic System: Service and Repairs Page 4–90 Greensmaster 3120 17230SL Rev C...
Page 137: Wheel Motors
The traction pump is a Hydro-Gear® PY series pump. For traction pump repair information, see the Hydro-Gear P Series Hydrostatic Pumps Service and Repair Manual at the end of this chapter. Replacement pump components are available from your Authorized Toro Distributor; refer to the traction unit Parts Catalog. Wheel Motors g217751...
Page 138 4. Install the front wheel and brake assembly; refer to Installing the Front Wheel and Brake Assembly (page 6–6). 5. Charge the hydraulic system; refer to Charging the Hydraulic System (page 4–79). Hydraulic System: Service and Repairs Page 4–92 Greensmaster 3120 17230SL Rev C...
Page 139: Servicing The Wheel Motor
Thrust washer Commutator End cover IMPORTANT If a wheel motor fails; refer to Filtering the Closed-Loop Traction Circuit (page 4–76) for information regarding removing contamination from the traction circuit. Greensmaster 3120 Page 4–93 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 140 For wheel motor repair information, see the Parker Torqmotor™ Service Procedure (TC, TB, TE, TJ, TF, TG, TH and TL Series) at the end of this chapter. Replacement motor components are available from your Authorized Toro Distributor; refer to the traction unit Parts Catalog.
Page 141: Mower Manifold
Example: R1 is the cutting unit circuit relief valve and P1 is the gear pump connection port; refer to the Hydraulic Schematics (page 4–13) to identify the function of the connections and the cartridge valves at each port location). Greensmaster 3120 Page 4–95 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 142 Example: FC1 is the cutting unit circuit flow control valve and P1 is the gear pump connection port; refer to the Hydraulic Schematics (page 4–13) to identify the function of the connections and the cartridge valves at each port location). Hydraulic System: Service and Repairs Page 4–96 Greensmaster 3120 17230SL Rev C...
Page 143 Example: FC1 is the cutting unit circuit flow control valve and P1 is the gear pump connection port; refer to the Hydraulic Schematics (page 4–13) to identify the function of the connections and the cartridge valves at each port location). Greensmaster 3120 Page 4–97 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 144 4. Connect the wire harness connectors to the manifold solenoid coils. For machines with backlap, connect the wire harness connector to the backlap switch. 5. Charge the hydraulic system; refer to Charging the Hydraulic System (page 4–79). Hydraulic System: Service and Repairs Page 4–98 Greensmaster 3120 17230SL Rev C...
Page 145: Servicing The Mower Manifold
Solenoid cartridge valve S4 Pilot operated relief valve PRV Straight fitting Relief valve R2 Pilot piston Orifice disc 0.030 inch Solenoid cartridge valve S3 Solenoid cartridge valve S1 Greensmaster 3120 Page 4–99 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 146 Orifice disc 0.030 inch Coil nut Pressure compensator EP Check valve CV Zero leak plug #4 (13 each) SAE Plug #4 (2 each) Rotary valve Orifice 0.055 inch (2 each) Hydraulic System: Service and Repairs Page 4–100 Greensmaster 3120 17230SL Rev C...
Page 147 Manifold damage is possible if the orifice is cocked in the port. Greensmaster 3120 Page 4–101 Hydraulic System: Service and Repairs...
Page 148 While energized, flush out any contamination with a nonflammable aerosol brake cleaner. De-energize the solenoid. Repeat the flush while energized procedure 5 or 6 times. Remove the solenoid from the cartridge. Hydraulic System: Service and Repairs Page 4–102 Greensmaster 3120 17230SL Rev C...
Page 149 D. For solenoid valves, slide the solenoid coil onto the cartridge valve. Tighten the coil nut to 6.7 N∙m (60 in-lb). If a problem still exists, remove the valve and clean it again or replace the valve. Greensmaster 3120 Page 4–103 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 150 The sleeve bearing should stay in the cap. D. Loosen the two (2) set screws that secure the handle base to the flow control valve and remove the base. Hydraulic System: Service and Repairs Page 4–104 Greensmaster 3120 17230SL Rev C...
Page 151 1 on manifold. Secure the base with the two (2) set screws. Apply a light coating of grease to chamfer on top of the base to ease the lip seal installation. Greensmaster 3120 Page 4–105 Hydraulic System: Service and Repairs...
Page 152 1 on the manifold. Tighten the two (2) set screws to secure the handle cap. If a problem still exists, remove the valve and clean it again or replace the valve. Hydraulic System: Service and Repairs Page 4–106 Greensmaster 3120 17230SL Rev C...
Page 153 D. Pull the spool up and out of the manifold. Remove the O-rings and the back-up ring from the spool. E. Discard the removed O-rings and the back-up rings. Greensmaster 3120 Page 4–107 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 154 F. Place the ball and the dowel pin in the backlap switch manifold port. Install a new O-ring onto the backlap switch. Thread the backlap switch into the port and tighten to 27 N∙m (20 ft-lb). Hydraulic System: Service and Repairs Page 4–108 Greensmaster 3120 17230SL Rev C...
Page 155: Reel Motors
Hydraulic hose, inlet Elbow fitting (4 each) Hydraulic hose, return Hydraulic hose, case drain Straight fitting Hydraulic hose, case drain Hydraulic hose, return Hydraulic hose, return Elbow fitting Greensmaster 3120 Page 4–109 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 156 If hydraulic fittings are to be removed from the motor, mark the fitting location and orientation to allow for correct assembly. Remove the fittings and discard the O−rings. Hydraulic System: Service and Repairs Page 4–110 Greensmaster 3120 17230SL Rev C...
Page 157 Tighten the connections as specified; refer to Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (page 4–8). Charge the hydraulic system; refer to Charging the Hydraulic System (page 4–79). Greensmaster 3120 Page 4–111 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 158: Servicing The Reel Motor
Backup gasket, outer Pressure seal, inner Shaft seal Wear plate, outer Body Front flange Idler gear Cap screw (4 each) Dowel pin (2 each) Drive gear Washer (4 each) Hydraulic System: Service and Repairs Page 4–112 Greensmaster 3120 17230SL Rev C...
Page 159 8. Remove and discard the back−up gaskets and the pressure seals from the wear plates. 9. Turn the front flange over, with the seal side up. Greensmaster 3120 Page 4–113 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 160 10. Carefully remove the dust seal, the retaining ring, the backup washer and the shaft seal from the front flange; refer to Figure 71. Discard the removed seals. Hydraulic System: Service and Repairs Page 4–114 Greensmaster 3120 17230SL Rev C...
Page 161 5. Inspect the front flange and the rear cover for damage or wear. 6. If the internal parts are found to be worn or damaged, replacing the reel motor is necessary. Greensmaster 3120 Page 4–115 Hydraulic System: Service and Repairs...
Page 162 14. Install the four (4) cap screws with the washers and hand tighten the screws. IMPORTANT Prevent damage when clamping the motor into a vise; use a vise with soft jaws and clamp on the front flange only. Hydraulic System: Service and Repairs Page 4–116 Greensmaster 3120 17230SL Rev C...
Page 163 17. Place a small amount of clean hydraulic fluid in the inlet of the motor and rotate the drive shaft away from the inlet one revolution. If any binding is evident, disassemble the motor and check for assembly problems. Greensmaster 3120 Page 4–117 Hydraulic System: Service and Repairs...
Page 164: Front Lift Cylinders
Flat washer (2 each) Lift cylinder (2 each) Torsion spring, right Pivot pin (2 each) Hydraulic hose, left lift Hydraulic hose, right raise Cotter pin (2 each) Grease fitting (2 each) Hydraulic System: Service and Repairs Page 4–118 Greensmaster 3120 17230SL Rev C...
Page 165 Tighten the connections as specified; refer to Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (page 4–8). Charge the hydraulic system; refer to Charging the Hydraulic System (page 4–79). Greensmaster 3120 Page 4–119 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 166: Servicing The Front Lift Cylinders
Servicing the Front Lift Cylinders g218311 Figure 74 Barrel Back-up ring Lock nut Seal Wear ring Dust seal Piston Internal collar O-ring Seal Jam nut Head Rod clevis O-ring Hydraulic System: Service and Repairs Page 4–120 Greensmaster 3120 17230SL Rev C...
Page 167 4. Coat all the internal parts with a light layer of clean hydraulic fluid. Slide the piston, the rod and head assembly into the barrel being careful to not damage the seals. Greensmaster 3120 Page 4–121 Hydraulic System: Service and Repairs...
Page 168: Rear Lift Cylinder
Elbow fitting Torsion spring Hinge pin Hydraulic hose, lower Thrust washer (2 each) Lock washer Hydraulic hose, raise Cap screw Cap screw Clevis pin Pivot pin Lift arm Hydraulic System: Service and Repairs Page 4–122 Greensmaster 3120 17230SL Rev C...
Page 169 Tighten the connections as specified; refer to Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (page 4–8). Charge the hydraulic system; refer to Charging the Hydraulic System (page 4–79). Greensmaster 3120 Page 4–123 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 170: Servicing The Rear Lift Cylinder
Servicing the Rear Lift Cylinder g218363 Figure 76 Barrel O-ring Dust seal Lock nut Head Retaining ring Wear ring O-ring Piston Back-up ring Seal Seal Hydraulic System: Service and Repairs Page 4–124 Greensmaster 3120 17230SL Rev C...
Page 171 3. Mount the cylinder rod securely in a vise by clamping on the clevis of the rod. Using a vise with soft jaws is recommended. A. Coat the rod with a light layer of clean hydraulic fluid. Greensmaster 3120 Page 4–125 Hydraulic System: Service and Repairs...
Page 172 B. Insert the retaining ring hook into the hole and rotate the head clockwise until the retaining ring is completely pulled into the barrel and the ring ends are covered. C. Apply silicone sealer to barrel access slot. Hydraulic System: Service and Repairs Page 4–126 Greensmaster 3120 17230SL Rev C...
Page 173: Steering Control Valve
Flat washer (2 each) Screw (2 each) Screw (6 each) Wave washer (2 each) Steering wheel cover Steering valve cover Lock nut (2 each) Lock nut Bushing (2 each) Greensmaster 3120 Page 4–127 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 174 If hydraulic fittings are to be removed from the valve, mark the fitting location to allow for correct assembly. Remove the fittings and discard the O−rings. Hydraulic System: Service and Repairs Page 4–128 Greensmaster 3120 17230SL Rev C...
Page 175 Tighten lock nut from 28 to 35 N∙m (20 to 26 ft-lb). Charge the hydraulic system; refer to Charging the Hydraulic System (page 4–79). Greensmaster 3120 Page 4–129 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 176: Servicing The Steering Control Valve
Spring set Shaft seal O-ring Ball stop Thrust washer Distribution plate Ball Note: For servicing the steering control valve, see the Danfoss Steering Unit Type OSPM Service Manual. Hydraulic System: Service and Repairs Page 4–130 Greensmaster 3120 17230SL Rev C...
Page 177: Steering Cylinder
Flat washer Hydraulic hose, left turn Grease fitting Hydraulic hose, right turn Jam nut (2 each) Jam nut Elbow fitting (2 each) Dust seal Lock nut Steering cylinder Greensmaster 3120 Page 4–131 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 178 Tighten lock nut from 162 to 217 N∙m (120 to 160 ft-lb). 6. Remove the plugs and the caps from the hydraulic hoses and fittings. Using the labels placed during removal, connect the hydraulic hoses to the cylinder Hydraulic System: Service and Repairs Page 4–132 Greensmaster 3120 17230SL Rev C...
Page 179 Tighten the connections as specified; refer to Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (page 4–8). Charge the hydraulic system; refer to Charging the Hydraulic System (page 4–79). Greensmaster 3120 Page 4–133 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 180: Servicing The Steering Cylinder
Servicing the Steering Cylinder g218411 Figure 81 Back-up ring O-ring External collar Lock nut O-ring Dust seal Barrel Wear ring (2 each) Seal Seal Grease Fitting Head Piston Hydraulic System: Service and Repairs Page 4–134 Greensmaster 3120 17230SL Rev C...
Page 181 6. Coat all the internal parts with a light layer of clean hydraulic fluid. Slide the rod assembly into the barrel being careful to not damage the seals. Greensmaster 3120 Page 4–135 Hydraulic System: Service and Repairs...
Page 182 8. Apply a few drops of high strength thread locker to the threads of the cylinder barrel and install the external collar. Use a pipe wrench to tighten the external collar. Hydraulic System: Service and Repairs Page 4–136 Greensmaster 3120 17230SL Rev C...
Page 183: Hydraulic Tank
Hydraulic Tank g219155 Figure 82 Greensmaster 3120 Page 4–137 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 184 Replace any damaged or worn fittings or hoses. If the hydraulic tank is being installed, replace the spout in the breather neck with a grommet style plug. Hydraulic System: Service and Repairs Page 4–138 Greensmaster 3120 17230SL Rev C...
Page 185 Tighten the connections as specified; refer to Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (page 4–8). Charge the hydraulic system; refer to Charging the Hydraulic System (page 4–79). Greensmaster 3120 Page 4–139 Hydraulic System: Service and Repairs 17230SL Rev C...
Page 186 Hydraulic System: Service and Repairs Page 4–140 Greensmaster 3120 17230SL Rev C...
Page 187: Chapter 5: Electrical System
Delay Timer (Lower Cutting Units) ....................5–25 Hydraulic Solenoid Valve Coils......................5–26 Diodes.............................. 5–28 Service and Repairs ........................... 5–30 Caring for the Battery ........................5–30 Storing the Battery ........................... 5–31 Servicing the Battery ........................5–31 Greensmaster 3120 Page 5–1 Electrical System 17230SL Rev C...
Page 188: General Information
Refer to the Traction Unit Operator’s Manual for additional information when servicing the machine. Electrical Schematics and Diagrams Refer to the Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A (page A–1). Electrical System: General Information Page 5–2 Greensmaster 3120 17230SL Rev C...
Page 189: Special Tools
Special Tools You can order these special tools from your Authorized Toro Distributor. Some tools are also available from a local supplier. Multimeter Obtain this tool locally The meter can test the electrical components and circuits for current, resistance, or voltage.
Page 190: Dielectric Gel
Dielectric Gel Toro Part No. 107-0342 Use the dielectric gel to prevent corrosion of unsealed connection terminals. To ensure complete coating of the terminals, liberally apply the gel to the component and wire harness connector, plug the connector into the component, unplug the connector, apply the gel to both surfaces again, and connect the harness connector to the component again.
Page 191: Troubleshooting
Start safety relay (K2) is faulty. Neutral switch is out of adjustment or faulty. Starter solenoid fusible link is faulty. Ignition switch is faulty. Starter solenoid is faulty. Fuse block is faulty. Battery is faulty. Greensmaster 3120 Page 5–5 Electrical System: Troubleshooting 17230SL Rev C...
Page 192 Electrical Schematics and Wire Harness Drawings/Diagrams inAppendix A (page A–1). Engine or fuel system is malfunctioning; refer to Chapter 3: Engine (page 3–1). Cutting Unit Operating Problems Electrical System: Troubleshooting Page 5–6 Greensmaster 3120 17230SL Rev C...
Page 193 Raise switch is faulty. Lower switch is faulty. Joystick relay (K3) is faulty. Lower relay (K5) is faulty. 6 second delay timer is faulty. Solenoid coil S2 or S4 is faulty. Greensmaster 3120 Page 5–7 Electrical System: Troubleshooting 17230SL Rev C...
Page 194: Electrical System Quick Checks
Note: This test provides a relative condition of the battery. The load testing of the battery provides additional and more accurate information; refer to Inspecting, Maintaining, and Testing the Battery (page 5–33). Electrical System: Electrical System Quick Checks Page 5–8 Greensmaster 3120 17230SL Rev C...
Page 195: Testing The Charging System
Refer to the Battery Voltage Table (page 5–9) for an example of a charging system that is functioning. Greensmaster 3120 Page 5–9 Electrical System: Electrical System Quick Checks 17230SL Rev C...
Page 196: Checking The Interlock System Operation
MOW. If the engine stops, the interlock system is operating correctly. IMPORTANT Adjust or repair any of the interlock system components as necessary so all of the interlock system operations function correctly. Electrical System: Electrical System Quick Checks Page 5–10 Greensmaster 3120 17230SL Rev C...
Page 197: Testing The Electrical Components
(-) cable to the battery. Coat the wire and cable connections at the battery and at the starter solenoid with Battery Terminal Protector (page 5–3). Greensmaster 3120 Page 5–11 Electrical System: Testing the Electrical Components 17230SL Rev C...
Page 198: Fuses
If the fuse tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). Electrical System: Testing the Electrical Components Page 5–12 Greensmaster 3120 17230SL Rev C...
Page 199: Key Switch
If the switch tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). Connect the wire harness to the key switch after testing. Greensmaster 3120 Page 5–13 Electrical System: Testing the Electrical Components 17230SL Rev C...
Page 200: Starter Solenoid
Starter solenoid Solenoid coil post (2 each) The starter solenoid used on the Greensmaster 3120 allows current flow from the battery to the engine starter motor when energized. The starter solenoid coil should energize when both the kill relay (K1) and the start safety relay (K2) are energized.
Page 201 8. Connect the positive (+) cable to the battery first and then connect the negative (-) cable to the battery. Coat the wire and cable connections at the battery and at the starter solenoid with Battery Terminal Protector (page 5–3). Greensmaster 3120 Page 5–15 Electrical System: Testing the Electrical Components 17230SL Rev C...
Page 202: Hour Meter
If the hour meter tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 8. Connect the wire harness to the hour meter before returning the machine to service. Electrical System: Testing the Electrical Components Page 5–16 Greensmaster 3120 17230SL Rev C...
Page 203: Seat Switch
If the seat switch tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 6. Connect the wire harness to the switch before returning the machine to service. Greensmaster 3120 Page 5–17 Electrical System: Testing the Electrical Components 17230SL Rev C...
Page 204: Neutral And Mow Switches
B. Place the function control lever in the M position. The mow switch should be closed (continuity between the switch terminals) and the neutral switch should be open (no continuity between the switch terminals). Electrical System: Testing the Electrical Components Page 5–18 Greensmaster 3120 17230SL Rev C...
Page 205 If the switch tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 7. Connect the wire harness to the switch and install the console before returning the machine to service. Greensmaster 3120 Page 5–19 Electrical System: Testing the Electrical Components 17230SL Rev C...
Page 206: Parking Brake Switch
If the switch tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 6. Connect the wire harness to the switch before returning the machine to service. Electrical System: Testing the Electrical Components Page 5–20 Greensmaster 3120 17230SL Rev C...
Page 207: Cutting Unit Raise And Lower Joystick Switches
If the switch tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 6. Connect the wire harness to the switch before returning the machine to service. Greensmaster 3120 Page 5–21 Electrical System: Testing the Electrical Components 17230SL Rev C...
Page 208: Backlap Switch (Machines With Backlap)
If the switch tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 6. Connect the wire harness to the switch before returning the machine to service. Electrical System: Testing the Electrical Components Page 5–22 Greensmaster 3120 17230SL Rev C...
Page 209: Relays
Control panel shield Relay K8 Relays K1 – K6 Relay K7 Several relays are used on the Greensmaster 3120 machine. The relays are identical five (5) terminal relays that are located toward the front of the machine; refer to Figure 92).
Page 210 9. If previously removed for testing, install the relay and connect the wire harness to the relay. 10. Install the control panel shield before returning the machine to service. Electrical System: Testing the Electrical Components Page 5–24 Greensmaster 3120 17230SL Rev C...
Page 211: Delay Timer (Lower Cutting Units)
If the timer tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 7. Connect the wire harness to the timer before returning the machine to service. Greensmaster 3120 Page 5–25 Electrical System: Testing the Electrical Components 17230SL Rev C...
Page 212: Hydraulic Solenoid Valve Coils
Solenoid Valve Coil Specifications Coil Diameter Coil Height Coil Resistance 46.7 mm (1.84 inch) 49.9 mm (1.96 inch) 7.1 ohm 35.8 mm (1.41 inch) 36.3 mm (1.43 inch) 8.8 ohm Electrical System: Testing the Electrical Components Page 5–26 Greensmaster 3120 17230SL Rev C...
Page 213 The Greensmaster 3120 hydraulic manifold uses several solenoid actuated cartridge valve for system control. When the solenoid coil is energized, hydraulic cartridge valve shifts and changes the hydraulic circuit flow. Testing a solenoid coil can be done with the coil installed on the hydraulic cartridge valve.
Page 214: Diodes
Mower hydraulic manifold Diode D2 Diode Testing Reference Diode Multimeter Red (+) Probe Multimeter Black (-) Probe Continuity Type D1-A D1-B D1-C D1-D Diode Circuit Board Plug-In Diode Electrical System: Testing the Electrical Components Page 5–28 Greensmaster 3120 17230SL Rev C...
Page 215 Dielectric Gel (page 5–4). 6. Connect the diode(s) to the wire harness before returning the machine to service. Greensmaster 3120 Page 5–29 Electrical System: Testing the Electrical Components 17230SL Rev C...
Page 216: Service And Repairs
Always disconnect the negative (-) cable first. Clean the cable clamps and terminals separately. Connect the battery cables. Always connect the positive (+) cable first. Apply a coating of Toro Part No. 107-0392 battery terminal protector or a light coat of grease to the terminals to reduce corrosion after you make the connections;...
Page 217: Storing The Battery
While working with the batteries, use extreme caution to avoid splashing or spilling of the electrolyte. Always wear the safety goggles and a face shield while working with batteries. Greensmaster 3120 Page 5–31 Electrical System: Service and Repairs 17230SL Rev C...
Page 218 Remove the two (2) wing nuts and the battery hold down rod. Make sure that the battery filler caps are secure and remove the battery from the battery compartment. Electrical System: Service and Repairs Page 5–32 Greensmaster 3120 17230SL Rev C...
Page 219 7. Connect the negative (-) cable connector to the negative (-) battery terminal. Use the 2 wrenches to attach the cable bolt and lock nut. 8. After you make the connections, apply battery terminal protector Toro Part No. 107-0392 or a light layer of grease to the battery terminals and cable connectors to reduce corrosion;...
Page 220 D. Charge at the rate and time given in Battery Charge Rate (page 5–35) or until all cells specific gravity is 1.225 or greater with the difference Electrical System: Service and Repairs Page 5–34 Greensmaster 3120 17230SL Rev C...
Page 221 15 hrs @ 3 A 81 to 125 5.3 hrs @ 4 A 10.5 hrs @ 4 A 15.8 hrs @ 4 A 21 hrs @ 4 A Greensmaster 3120 Page 5–35 Electrical System: Service and Repairs 17230SL Rev C...
Page 222 Note: The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0.003 change in specific gravity for 3 consecutive readings. Electrical System: Service and Repairs Page 5–36 Greensmaster 3120 17230SL Rev C...
Page 223: Chapter 6: Chassis
Wheel Hub Puller ..........................6–4 Service and Repairs ..........................6–5 Front Wheels and Brakes........................6–5 Rear Wheel ............................6–7 Caster Fork ............................6–9 Cutting Unit Pull Frame Rollers, Pivot Hinges and Lift Arms ............. 6–11 Greensmaster 3120 Page 6–1 Chassis 17230SL Rev C...
Page 224: Specifications
55 to 103 kPa (8 to 15 psi) Front wheel lug nut torque 95 to 122 N∙m (70 to 90 ft-lb) Front wheel hub nut torque 339 to 542 N∙m (250 to 400 ft-lb) Chassis: Specifications Page 6–2 Greensmaster 3120 17230SL Rev C...
Page 225: General Information
The Traction Unit Operator’s Manual provides information regarding the operation, general maintenance procedures, and maintenance intervals for your machine. Refer to the Traction Unit Operator’s Manual for additional information when servicing the machine. Greensmaster 3120 Page 6–3 Chassis: General Information 17230SL Rev C...
Page 226: Special Tools
Special Tools Order special tools from your Toro Distributor. Wheel Hub Puller Toro Part No. TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors. Chassis: Special Tools Page 6–4 Greensmaster 3120...
Page 227: Service And Repairs
5. Make sure that the wheel hub lock nut is loosened at least two revolutions. Use the hub puller to loosen the wheel hub assembly from the wheel motor; refer to Wheel Hub Puller (page 6–4). Greensmaster 3120 Page 6–5 Chassis: Service and Repairs 17230SL Rev C...
Page 228 400 ft-lb). Tighten wheel lug nuts from 95 to 122 N∙m (70 to 90 ft-lb). 7. Check and adjust brakes as necessary; refer to Traction Unit Operator’s Manual. Chassis: Service and Repairs Page 6–6 Greensmaster 3120 17230SL Rev C...
Page 229: Rear Wheel
Assembly the rear wheel hub if necessary. A. Press new bearing cups into the hub until seated. B. Pack new bearing cones with #2 multi-purpose lithium base grease and fit in bearing cup. Greensmaster 3120 Page 6–7 Chassis: Service and Repairs 17230SL Rev C...
Page 230 6. Clean grease fitting on hub and pump grease into the hub until grease is seen at both bearing seals. Wipe away excess grease. 7. Lower machine to ground. Chassis: Service and Repairs Page 6–8 Greensmaster 3120 17230SL Rev C...
Page 231: Caster Fork
6. Remove the bearing cones and washers from the caster fork and frame. Inspect the upper and lower bearing cups in the frame for wear or damage and replace them if necessary. Greensmaster 3120 Page 6–9 Chassis: Service and Repairs...
Page 232 9. Install the fuel tank; refer to Installing the Fuel Tank (page 3–6). 10. Clean grease fitting and lubricate steering stem until grease is seen at both ends of the housing. Wipe up excess grease. Chassis: Service and Repairs Page 6–10 Greensmaster 3120 17230SL Rev C...
Page 233: Cutting Unit Pull Frame Rollers, Pivot Hinges And Lift Arms
The pull frame assemblies, pivot hinges and lift arms used on Greensmaster 3120 machines are slightly different depending on location (right front, left front and center positions). Servicing the components is similar regardless of their position on the machine. Greensmaster 3120 Page 6–11 Chassis: Service and Repairs 17230SL Rev C...
Page 234 Figure 102 Pivot hinge Bushing (4 each) 4. Service the pivot hinges as necessary; refer to Figure 102. A. Install new bushings so the grease groove opening is orientated inward. Chassis: Service and Repairs Page 6–12 Greensmaster 3120 17230SL Rev C...
Page 235 Figure 103 Lift arm Bushing (2 each) 5. Service the lift arms as necessary. Install new bushings so the grease groove opening is orientated inward; refer to Figure 103. Greensmaster 3120 Page 6–13 Chassis: Service and Repairs 17230SL Rev C...
Page 236 Chassis: Service and Repairs Page 6–14 Greensmaster 3120 17230SL Rev C...
Page 237 Leveling the Rear Roller........................7–12 Service and Repairs ........................... 7–14 Bedbar Assembly..........................7–14 Bedknife ............................7–19 Reel Assembly ..........................7–23 Roller Assemblies ..........................7–28 Rear Roller Brushes (Optional) ......................7–34 Greensmaster 3120 Page 7–1 DPA Cutting Units 17230SL Rev C...
Page 238: Specifications
Wiehle and narrow spaced Wiehle configurations (narrow spaced Wiehle roller is shown in Figure 104).The rear roller is a 5.1 cm (2 inches) diameter full roller. DPA Cutting Units: Specifications Page 7–2 Greensmaster 3120 17230SL Rev C...
Page 239: Chapter 7: Dpa Cutting Units
35 kg (78 lb) *Cutting unit weights include a narrow spaced aluminum Wiehle front roller Options: Refer to the Cutting Unit Parts Catalog or contact your local Authorized Toro Distributor for available cutting unit options. Greensmaster 3120 Page 7–3 DPA Cutting Units: Specifications...
Page 240: General Information
Whenever the cutting unit has to be tipped to expose the bedknife or cutting reel, support the rear of the cutting unit making sure the back of the bedbar adjuster screws are not resting on the work surface. DPA Cutting Units: General Information Page 7–4 Greensmaster 3120 17230SL Rev C...
Page 241: Special Tools
Special Tools Special tools for servicing Toro Commercial Products are available from your Toro Distributor. Some of these tools may have been supplied with your machine or are available as Toro parts. Gauge Bar Assembly Toro Part No. 94–9010 Use gauge bar to verify height-of-cut adjustment.
Page 242: Backlapping Brush Assembly
Angle Indicator: Toro Part No. 131–6828 Magnetic Mount: Toro Part No. 131–6829 Because the top grind angle on bedknives is critical for edge retention, and therefore after− cut appearance, Toro has develop these service tools for accurately measuring the top grind angle on all bedknives.
Page 243: Bedknife Screw Tool
Bedknife Screw Tool Toro Part No. TOR510880 This screwdriver-type bit is made to fit Toro bedknife attaching screws. Use this bit with a torque wrench to secure the bedknife to the bedbar. IMPORTANT Important: To prevent damage to the bedbar, DO NOT use an air or manual impact wrench with this tool.
Page 244: Turf Evaluator Tool
This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the Turf Evaluator (Toro part no. 97931SL) available from your local authorized Toro Distributor.
Page 245: Aftercut Appearance
Note: For additional information regarding cutting unit troubleshooting, a number of Reel Mower and Aftercut Appearance General Training Books can be found on the Service Reference Set available from your Authorized Toro Distributor. Factors That Can Affect Quality of Cut...
Page 246 A variety of cutting unit rollers are available. Refer to the Cutting Unit Parts Manual for a listing of available accessories, or contact your local Authorized Toro Distributor for additional information. Ensure that the rollers rotate freely. Repair the roller bearings if necessary;...
Page 247: Adjustments
Cutting Unit Operator’s Manual. 3. Adjust the height-of-cut; refer to the Cutting Unit Operator’s Manual. 4. Adjust the cut-off bar; refer to the Cutting Unit Operator’s Manual Greensmaster 3120 Page 7–11 DPA Cutting Units: Adjustments 17230SL Rev C...
Page 248: Leveling The Rear Roller
If the shim will pass under the roller through the rollers entire rotation, the rear roller is not parallel to the reel or is high on one side and an adjustment should be made. DPA Cutting Units: Adjustments Page 7–12 Greensmaster 3120 17230SL Rev C...
Page 249 (contacting the bench plate). 7. Complete the cutting unit set-up and adjustment procedure. Greensmaster 3120 Page 7–13 DPA Cutting Units: Adjustments...
Page 250: Service And Repairs
Nylon bushing (2 each) Detent (2 each) Plastic washer (4 each) Wave washer (2 each) Metal washer (4 each) Retaining ring (2 each) Bedbar pivot bolt (2 each) DPA Cutting Units: Service and Repairs Page 7–14 Greensmaster 3120 17230SL Rev C...
Page 251 7. Remove the bedbar assembly from the cutting unit. 8. Inspect the nylon bushings and rubber bushings in the side plates for wear or damage. Replace the bushings if necessary. Greensmaster 3120 Page 7–15 DPA Cutting Units: Service and Repairs...
Page 252 5. Slide one metal washer and then one plastic washer onto each bedbar pivot bolt. 6. Position one plastic washer between the bedbar and each side plate. DPA Cutting Units: Service and Repairs Page 7–16 Greensmaster 3120 17230SL Rev C...
Page 253 1/2 turn. 10. Adjust the bedknife to reel contact; refer to the Cutting Unit Operator’s Manual. Greensmaster 3120 Page 7–17 DPA Cutting Units: Service and Repairs 17230SL Rev C...
Page 254 5. Install the washer, spring and lock nut onto the adjuster screw. 6. Install the bedbar; refer to Installing the Bedbar (page 7–16). DPA Cutting Units: Service and Repairs Page 7–18 Greensmaster 3120 17230SL Rev C...
Page 255: Bedknife
Use a scraper to remove all rust, scale and corrosion from the bedbar surface under the bedknife. Lightly oil the bedbar surface before installing the bedknife. Make sure that screw threads in bedbar (5/16-18UNC-2A) are clean. g226894 Figure 114 Greensmaster 3120 Page 7–19 DPA Cutting Units: Service and Repairs 17230SL Rev C...
Page 256 6. Working from the center of the bedknife toward each end, tighten screws from 23 to 28 N-m (200 to 250 in-lb). 7. After installing the bedknife to bedbar, grind the bedknife. DPA Cutting Units: Service and Repairs Page 7–20 Greensmaster 3120 17230SL Rev C...
Page 257 When grinding the bedknife, be careful to not overheat the bedknife. Remove small amounts of material with each pass of the grinder. Also, clean and dress grinding stone often during the grinding process. Greensmaster 3120 Page 7–21 DPA Cutting Units: Service and Repairs...
Page 258 Angle Indicator and Magnetic Mount (page 7–6). 1. Use Toro General Service Training Book, Reel Mower Basics (part no. 09168SL) and grinder manufacturer's instructions for bedknife grinding information. After grinding the bedknife, install the bedbar assembly in the cutting unit;...
Page 259: Reel Assembly
If the cutting unit is equipped with an optional groomer or rear roller brush, remove the drive components for those options from cutting unit. Refer to Removing the Drive Plate (page 8–8) for belt drive groomer, Removing the Greensmaster 3120 Page 7–23 DPA Cutting Units: Service and Repairs 17230SL Rev C...
Page 260 10. Thoroughly clean any grease and corrosion from the reel bearing bores in the side plates. 11. Inspect the remaining cutting unit components for corrosion, wear, or damage and replace the components as necessary. DPA Cutting Units: Service and Repairs Page 7–24 Greensmaster 3120 17230SL Rev C...
Page 261 The seal must be installed with the flocked side of the seal toward the bearing. 4. Slide the new flocked seals and the bearings onto the reel shaft until they contact the shoulder of the reel shaft. Greensmaster 3120 Page 7–25 DPA Cutting Units: Service and Repairs 17230SL Rev C...
Page 262 Reel Diameter Service Limit 114.3 mm (4.50 inch) Reel Diameter Taper Limit (D1 – D2) 0.25 mm (0.01 inch) Blade Land Width 0.8 to 1.2 mm (0.03 to 0.05 inch) DPA Cutting Units: Service and Repairs Page 7–26 Greensmaster 3120 17230SL Rev C...
Page 263 7–26). Additional reel grinding information can be found in the Cutting Unit Operator’s Manual. An additional resource is the Toro Basics Series Training Book, Reel Mower Basics (part no. 09168SL) found on the Service Reference Set available from your Authorized Toro Distributor.
Page 264: Roller Assemblies
5. Slide the remaining height-of-cut arm onto the other end of roller shaft. Secure the remaining height-of-cut arm to the side plate with a plow bolt, height-of-cut washer and lock nut. DPA Cutting Units: Service and Repairs Page 7–28 Greensmaster 3120 17230SL Rev C...
Page 265 3. Slide the rear roller shaft into the retainer assembly attached to the cutting unit. Greensmaster 3120 Page 7–29 DPA Cutting Units: Service and Repairs 17230SL Rev C...
Page 266 4. Loosely secure the roller assembly in a bench vise and lightly tap on the roller shaft to remove the seals and bearings. Discard the seals. 5. Clean and carefully remove any corrosion from the bearing cavities of the roller. DPA Cutting Units: Service and Repairs Page 7–30 Greensmaster 3120 17230SL Rev C...
Page 267 3. Tighten the bearing lock nuts until both bearings are seated in the roller. 4. Remove the bearing lock nuts and the black assembly washers. Greensmaster 3120 Page 7–31 DPA Cutting Units: Service and Repairs...
Page 268 6. Install a bearing lock nut with seal onto each end of the roller shaft. Tighten the bearing lock nuts until they bottom against the bearings. Remove and clean any grease from the bearing lock nuts. DPA Cutting Units: Service and Repairs Page 7–32 Greensmaster 3120 17230SL Rev C...
Page 269 (Loctite #242 or equivalent) to the threads of the lock nut. 11. Install the bearing lock nut with V-ring onto each end of the roller shaft. Tighten the lock nuts to 34 to 41 N∙m (25 to 30 ft-lb). Greensmaster 3120 Page 7–33 DPA Cutting Units: Service and Repairs...
Page 270: Rear Roller Brushes (Optional)
Rear Roller Brushes (Optional) There are two different types of rear roller brush kits for Greensmaster 3120 cutting units. The earlier type of kit is designed to fit on cutting units with or without a belt driven groomer. A later type of kit is designed to fit on cutting units with or without a universal groomer.
Page 271 Cover plate Brush shaft Lock nut (2 each) Flange nut (5 each) O-ring Brush element Drive plate Flat washer Direction of brush rotation Driven pulley Bearing spacer Greensmaster 3120 Page 7–35 DPA Cutting Units: Service and Repairs 17230SL Rev C...
Page 272 4. Push down on the idler pulley and secure it to the drive plate. Make sure the cover plate (item Figure 130) is positioned to prevent debris from entering the drive area. DPA Cutting Units: Service and Repairs Page 7–36 Greensmaster 3120 17230SL Rev C...
Page 273 7. Install the brush support. 8. Install the drive pulley. Apply anti-seize lubricant the cap screw threads and tighten from 8 to 9 N∙m (70 to 80 in-lb). Greensmaster 3120 Page 7–37 DPA Cutting Units: Service and Repairs 17230SL Rev C...
Page 274 12. Install and adjust the drive belt and install the cover. 13. Lubricate the grease fittings on the brush support and the drive plate until grease is visible. Wipe up any excess grease. DPA Cutting Units: Service and Repairs Page 7–38 Greensmaster 3120 17230SL Rev C...
Page 275 Servicing the Rear Roller Brush (with or without a universal groomer) g230471 Figure 133 Greensmaster 3120 Page 7–39 DPA Cutting Units: Service and Repairs 17230SL Rev C...
Page 276 Adjust the bearing brackets as necessary. Drive and Support Components Disassemble the roller brush components as necessary. Retrieve and discard the adapter housing O-ring (machines without a universal groomer). DPA Cutting Units: Service and Repairs Page 7–40 Greensmaster 3120 17230SL Rev C...
Page 277 Tighten the lock nut securing the driven pulley from 20 to 26 N∙m (15 to 19 ft-lb). 11. Install and adjust the drive belt and install the cover. Greensmaster 3120 Page 7–41 DPA Cutting Units: Service and Repairs...
Page 278 12. Check that the roller brush is parallel to the rear roller within 0.25 mm (0.010 inch) clearance to light contact. Adjust the bearing brackets as necessary. DPA Cutting Units: Service and Repairs Page 7–42 Greensmaster 3120 17230SL Rev C...
Page 279: Chapter 8: Belt Driven Groomer (Optional)
Replacing the Groomer Drive Belt...................... 8–5 The Groomer Plate Assemblies ......................8–7 The Groomer Reel ........................... 8–16 The Groomer Arm Assemblies ......................8–18 The Grooming Brushes (Optional) ....................8–20 Greensmaster 3120 Page 8–1 Belt Driven Groomer (Optional) 17230SL Rev C...
Page 280: Specifications
Allows grooming reel to be raised above the height/depth adjustment for no grooming reel action while mowing. Groomer drive The groomer drive assembly is attached to the right side of the cutting unit. Belt Driven Groomer (Optional): Specifications Page 8–2 Greensmaster 3120 17230SL Rev C...
Page 281: General Information
9. The overall turf management program–irrigation, fertilizing, weed control, coring, over-seeding, sand dressing, disease control, and pest control. 10. Stress periods for turf–high temperatures, high humidity, and unusually high traffic. Greensmaster 3120 Page 8–3 Belt Driven Groomer (Optional): General Information 17230SL Rev C...
Page 282: Troubleshooting
Check and adjust the cutting reel. unit set up (level bed knife to reel, level rear roller to reel, set the height-of-cut, etc.). Belt Driven Groomer (Optional): General Information Page 8–4 Greensmaster 3120 17230SL Rev C...
Page 283: Service And Repairs
Make sure that the drive belt is centered on the pulleys and correctly aligned with pulley grooves after installation. Install a new drive belt to the drive pulley, idler pulley and the driven pulley observing correct belt routing. Greensmaster 3120 Page 8–5 Belt Driven Groomer (Optional): Service and Repairs 17230SL Rev C...
Page 284 7. If equipped, install the rear roller brush to the cutting unit; refer to Servicing the Rear Roller Brush (with or without a universal groomer) (page 7–39) Belt Driven Groomer (Optional): Service and Repairs Page 8–6 Greensmaster 3120 17230SL Rev C...
Page 285: The Groomer Plate Assemblies
Socket head screw (2 each) Shim Cutting unit side plate – LH O-ring Groomer arm – RH Driven pulley Pinch bolt (2 each) Height adjustment bolt (2 each) Greensmaster 3120 Page 8–7 Belt Driven Groomer (Optional): Service and Repairs 17230SL Rev C...
Page 286 7. Remove the lock nut, special washer and plow bolt that secure the LH groomer arm assembly to the cutting unit side plate. 8. Remove the LH groomer arm and the front roller from the cutting unit. Belt Driven Groomer (Optional): Service and Repairs Page 8–8 Greensmaster 3120 17230SL Rev C...
Page 287 14. Inspect the seals, bushings and bearings in the drive plate, support plate and groomer arms for wear or damage. Replace components as needed. Greensmaster 3120 Page 8–9 Belt Driven Groomer (Optional): Service and Repairs 17230SL Rev C...
Page 288 7. Remove the RH groomer arm and the front roller from the cutting unit. Remove the motor adapter and support plate. Belt Driven Groomer (Optional): Service and Repairs Page 8–10 Greensmaster 3120 17230SL Rev C...
Page 289 4. Remove and discard the groomer shaft bearings. 5. Clean and inspect bearing bores in the drive and support plates. Inspect the drive and support plate bushings and replace as necessary. Greensmaster 3120 Page 8–11 Belt Driven Groomer (Optional): Service and Repairs...
Page 290 7. Assemble the reel hub, spacers and idler arm to the drive plate and install the retaining ring. 8. Install a new O-ring on the reel hub. Belt Driven Groomer (Optional): Service and Repairs Page 8–12 Greensmaster 3120 17230SL Rev C...
Page 291 Note: After greasing the groomer bearings, operate the groomer for 30 seconds, stop the machine and wipe any excess grease from the groomer shaft and seals. Greensmaster 3120 Page 8–13 Belt Driven Groomer (Optional): Service and Repairs 17230SL Rev C...
Page 292 C. Secure the groomer arm to the cutting unit side plate with the plow bolt, special washer and lock nut. Belt Driven Groomer (Optional): Service and Repairs Page 8–14 Greensmaster 3120 17230SL Rev C...
Page 293 Note: After greasing the groomer bearings, operate the groomer for 30 seconds, stop the machine and wipe any excess grease from the groomer shaft and seals. Greensmaster 3120 Page 8–15 Belt Driven Groomer (Optional): Service and Repairs 17230SL Rev C...
Page 294: The Groomer Reel
4. Remove the blades and from the groomer shaft. If necessary, remove second lock nut from the shaft. 5. Inspect and replace worn or damaged components. 6. Assemble the groomer reel as follows: Belt Driven Groomer (Optional): Service and Repairs Page 8–16 Greensmaster 3120 17230SL Rev C...
Page 295 4. Carefully fit the groomer reel into the support plate. 5. Install the groomer drive plate; refer to Installing the Drive Plate (page 8–14) Greensmaster 3120 Page 8–17 Belt Driven Groomer (Optional): Service and Repairs 17230SL Rev C...
Page 296: The Groomer Arm Assemblies
A. Install the lock screw before installing the grooved pin. The grooved pin is used to retain the lock screw. B. Apply anti-seize lubricant to the threads of the lift rods before installing the adjusters. Belt Driven Groomer (Optional): Service and Repairs Page 8–18 Greensmaster 3120 17230SL Rev C...
Page 297 6. Insert the front roller into the installed groomer arm. 7. Repeat the procedure for the remaining groomer arm. 8. Center the front roller in the cutting unit and tighten both pinch bolts. Greensmaster 3120 Page 8–19 Belt Driven Groomer (Optional): Service and Repairs...
Page 298: The Grooming Brushes (Optional)
When assembling the spiral brush to the shaft, make sure that the J-bolts are installed with the threaded portion on the outside of the brush and tighten the lock nuts from 2.3 to 2.8 N∙m (20 to 25 in-lb). Belt Driven Groomer (Optional): Service and Repairs Page 8–20 Greensmaster 3120 17230SL Rev C...
Page 299 Service and Repairs ..........................9–5 The Gear Box Assembly ........................9–6 The Idler Assembly .......................... 9–11 The Groomer Reel ........................... 9–13 The Height Adjuster Assembly ......................9–16 The Grooming Brush (Optional) ....................... 9–18 Greensmaster 3120 Page 9–1 Universal Groomer (Optional) 17230SL Rev C...
Page 300: Chapter 9: Universal Groomer (Optional)
Allows grooming reel to be raised above the height/depth adjustment for no grooming reel action while mowing. Groomer drive The groomer drive assembly is attached to the right side of the cutting unit. Universal Groomer (Optional): Specifications Page 9–2 Greensmaster 3120 17230SL Rev C...
Page 301: General Information
9. The overall turf management program–irrigation, fertilizing, weed control, coring, over-seeding, sand dressing, disease control, and pest control. 10. Stress periods for turf–high temperatures, high humidity, and unusually high traffic. Greensmaster 3120 Page 9–3 Universal Groomer (Optional): General Information 17230SL Rev C...
Page 302: Troubleshooting
Check and adjust the cutting reel. unit set up (level bed knife to reel, level rear roller to reel, set the height-of-cut, etc.). Universal Groomer (Optional): General Information Page 9–4 Greensmaster 3120 17230SL Rev C...
Page 303: Service And Repairs
Never work on the groomer with the engine running. Always stop the engine, remove the key from the ignition switch and wait for all machine movement to stop before working on the groomer. Greensmaster 3120 Page 9–5 Universal Groomer (Optional): Service and Repairs...
Page 304: The Gear Box Assembly
(rear roller brush drive shaft) clockwise to remove the gear box. 5. Remove the gear box from the cutting unit as follows: A. Turn the input shaft clockwise to loosen it from the reel. Universal Groomer (Optional): Service and Repairs Page 9–6 Greensmaster 3120 17230SL Rev C...
Page 305 Discard the cotter pin. C. Continue to unscrew the input shaft and remove the gear box from the cutting unit. D. Retrieve the shim (item Figure 150). Greensmaster 3120 Page 9–7 Universal Groomer (Optional): Service and Repairs 17230SL Rev C...
Page 306 Thrust washer Locknut O-ring Driver gear O-ring Bearing (2 each) Dowel pin (2 each) Oil seal Drain/fill plug (4 each) Driven shaft Straight bushing (2 each) Shield Universal Groomer (Optional): Service and Repairs Page 9–8 Greensmaster 3120 17230SL Rev C...
Page 307 The gear box oil capacity is 50 ml (1.7 fluid ounces). 14. Operate the groomer gear box by hand to check for proper operation prior to installation. Greensmaster 3120 Page 9–9 Universal Groomer (Optional): Service and Repairs 17230SL Rev C...
Page 308 Servicing the Rear Roller Brush (with or without a universal groomer) (page 7–39). 5. Install the groomer reel assembly; refer to Installing the Groomer Reel (page 9–15). Universal Groomer (Optional): Service and Repairs Page 9–10 Greensmaster 3120 17230SL Rev C...
Page 309: The Idler Assembly
Retrieve and discard the O-ring and lock nuts. 6. Inspect the shields, bearing, and bushing in the idler assembly. Replace any components that are worn or damaged. Greensmaster 3120 Page 9–11 Universal Groomer (Optional): Service and Repairs 17230SL Rev C...
Page 310 5. Install the clevis pin and a new cotter pin to secure the height adjustment rod to the front of the idler arm. 6. Install the reel motor; refer to Installing the Reel Motors (page 4–111). Universal Groomer (Optional): Service and Repairs Page 9–12 Greensmaster 3120 17230SL Rev C...
Page 311: The Groomer Reel
4. Inspect the shields, stub shaft, driven shaft and shaft bearings for wear or damage and replace components as necessary; refer to The Gear Box Assembly (page 9–6) The Idler Assembly (page 9–11). Greensmaster 3120 Page 9–13 Universal Groomer (Optional): Service and Repairs 17230SL Rev C...
Page 312 B. Install a groomer blade against the lock nut. C. Install the remaining spacers and blades in an alternating manner making sure that all blades are separated by a spacer. Universal Groomer (Optional): Service and Repairs Page 9–14 Greensmaster 3120 17230SL Rev C...
Page 313 Tighten the bolts from 5 to 7 N∙m (45 to 60 in-lb). 4. Check the groomer reel height and mower height-of-cut settings and adjust as necessary. Greensmaster 3120 Page 9–15 Universal Groomer (Optional): Service and Repairs 17230SL Rev C...
Page 314: The Height Adjuster Assembly
6. Disassemble the height adjuster assembly as necessary. 7. Replace components that are worn or damaged. Universal Groomer (Optional): Service and Repairs Page 9–16 Greensmaster 3120 17230SL Rev C...
Page 315 7. Check the groomer reel height and adjust as necessary. g229170 Figure 156 8. Adjust the flange nuts on the groomer height adjustment rods until the springs are compressed to 16 mm (0.625 inch). Greensmaster 3120 Page 9–17 Universal Groomer (Optional): Service and Repairs 17230SL Rev C...
Page 316: The Grooming Brush (Optional)
When assembling the spiral brush to the shaft, make sure that the J-bolts are installed with the threaded portion on the outside of the brush and tighten the lock nuts from 2.3 to 2.8 N∙m (20 to 25 in-lb). Universal Groomer (Optional): Service and Repairs Page 9–18 Greensmaster 3120 17230SL Rev C...
Page 317: Appendix A
Hydraulic Schematic (machines without backlap) ................A–3 Hydraulic Schematic (machines with backlap) ...................A–4 Electrical Schematic...........................A–5 Wire Harness Drawing - Main ......................A–6 Wire Harness Diagram - Main ......................A–7 Wire Harness - Seat...........................A–8 Wire Harness - Engine ........................A–9 Greensmaster 3120 Page A–1 Foldout Drawings 17230SL Rev C...
Page 318: Electrical Drawing Designations
Y or YE YELLOW Numerous harness wires used on the Toro machines include a line with an alternate color. These wires are identified with the wire color and line color with either a / or _ separating the color abbreviations listed above (e.g., R/BK is a red wire with a black line, OR_BK is an orange wire with a black line).
Page 319: Hydraulic Schematic (Machines Without Backlap
Hydraulic Schematic (machines without backlap) g205802 Greensmaster 3120, Drawing 131-2784 Rev D, Sheet 1 of 1 17230SL Rev C Page A–3...
Page 320: Hydraulic Schematic (Machines With Backlap
Hydraulic Schematic (machines with backlap) g213435 Page A–4 17230SL Rev C Greensmaster 3120, Drawing 136-8401 Rev A, Sheet 1 of 1...
Page 321: Electrical Schematic
Electrical Schematic g205801 Greensmaster 3120, Drawing 122-0700 Rev A, Sheet 1 of 1 17230SL Rev C Page A–5...
Page 322: Wire Harness Drawing - Main
Wire Harness Drawing - Main g205799 Page A–6 17230SL Rev C Greensmaster 3120, Drawing 122-0148 Rev B, Sheet 1 of 1...
Page 323: Wire Harness Diagram - Main
Wire Harness Diagram - Main g205798 Greensmaster 3150, Drawing 122-0148 Rev B, Sheet 1 of 1 17230SL Rev C Page A–7...
Page 324: Wire Harness - Seat
Wire Harness - Seat g205800 Page A–8 17230SL Rev C Greensmater 3120, Drawing 108-9466 Rev C, Sheet 1 of 1...
Page 325: Wire Harness - Engine
Wire Harness - Engine g205797 Greensmaster 3120, Drawing 105-8276 Rev H, Sheet 1 of 1 17230SL Rev C Page A–9...

Toro Greensmaster 3120 Service Manual

Table of Contents

Chapter 1 :Safety

Chapter 2: Specifications and Maintenance

Table of Contents

Chapter 3: Engine

Chapter 4: Hydraulic System

Chapter 5: Electrical System

Chapter 6: Chassis

Table of Contents

Chapter 7: DPA Cutting Units

Chapter 8: Belt Driven Groomer (Optional)

Chapter 9: Universal Groomer (Optional)

Appendix A

Quick Links

Chapters

Troubleshooting

Related Manuals for Toro Greensmaster 3120

Summary of Contents for Toro Greensmaster 3120