Form No. 14211SL Rev A GreensPro™ 1240/1260 Models 44912/44913 © 2018—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision Date - 2014 A 11/2018 Revision History Description Initial Issue Incorporated GreensPro 1260. Added revision history.
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 e-mail: servicemanuals@toro.
Reader Comments Page 4 GreensPro™ 1240/1260 14211SL Rev A
Preface This service manual was written expressly for service technicians. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Toro Company has made every effort to make the information in this manual complete and correct. The purpose of this publication is to provide the service technician with information about troubleshooting, testing, and repairing major systems and components. This manual may be specified for use on numerous products.
Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S.
Table of Contents Preface ................................................................................................................ 5 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Safety and Instructional Decals ....................................................................
Preface Page 8 GreensPro™ 1240/1260 14211SL Rev A
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Think Safety First ............................................................................................................................... 1–3 Safety and Instructional Decals ............................................................................................................
Safety Instructions DANGER This safety symbol means danger. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions could kill or cause serious permanent injury or disability. WARNING This safety symbol means warning. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions can result in serious injury. CAUTION This safety symbol means caution.
Think Safety First Toro Products are tested and certified for compliance with existing safety standards and specifications. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, hazard control and accident prevention are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
Think Safety First (continued) • Avoid injury to bystanders… Always clear the area of bystanders before starting or testing powered equipment. • Avoid injury due to projectiles… Always clear the area of sticks, rocks or any other debris that could be picked up and thrown by the powered equipment. • Avoid modifications… Never alter or modify any part unless it is a factory approved procedure.
Think Safety First (continued) • Using fire extinguishers… Use the proper class of fire extinguisher in case of fire. Ensure fire extinguishers are serviced regularly, and replace any fire extinguishers that are discharged or in use beyond their expiration dates. – Class A fire extinguishers are for ordinary combustible materials such as paper, wood, cardboard, and most plastics.
Safety: Safety and Instructional Decals Page 1–6 GreensPro™ 1240/1260 14211SL Rev A
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Overall Dimensions............................................................................................................................ 2–2 Engine................................................................................................................................................
Specifications Overall Dimensions g271353 Figure 1 GreensPro 1240/1260 Engine Item Description Make/Designation Honda, 4-stroke, OHV single cylinder, air-cooled gasoline engine, GX200 Bore x Stroke 68 mm x 54 mm (2.68 x 2.13 inches) Total displacement 196 cc (12 cu in) Compression ratio 8.
Engine (continued) Item Description Ignition system Transistorized flywheel magneto Spark plug NGK BPR6ES Spark plug gap 0.7 to 0.8 mm (0.028 to 0.031 inch) Engine weight (dry) 16.1 kg (35.5 lb) Hydraulic Item Description GreensPro 1240 Transmission Hydro-Gear Model BDR hydrostatic transmission Pump displacement 10.2 cc (0.62 cu in) per revolution Motor displacement 21.8 cc (1.33 cu in) per revolution Drive chain sprocket alignment Hydraulic tank capacity -0.57 to 0.57 mm (-0.02 to 0.
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. These torque specifications for the installation and tightening of the fasteners will apply to all the fasteners which do not have a specific requirement identified in this Service Manual.
Calculating the Torque Values When Using a Drive-Adapter Wrench g205924 Figure 2 Torque Conversion Factor = A / B 1. Torque wrench 3. A (effective length of torque wrench) 2. Drive-adapter wrench (crowsfoot) 4. B (effective length of torque wrench and drive-adapter wrench) Using a drive-adapter wrench (e.g.
Identifying the Fastener g206089 Figure 3 Metric Bolts and Screws 1. Class 8.8 2. Class 10.9 g206088 Figure 4 Inch Series Bolts and Screws 1. Grade 1 2. Grade 5 3. Grade 8 Fasteners with a Locking Feature IMPORTANT If a fastener with a locking feature or previously applied thread locking compound is reused, clean the fastener threads and apply new thread locker to the fastener during installation. Locking features are designed to create friction and prevent a fastener from loosening.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC # 8 - 36 UNF # 10 - 24 UNC # 10 - 32 UNF Grade 1, 5 and 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in-lb in-lb N∙cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 56 18 ± 2 30 ± 5 339 ± 56 SAE Grade 5 Bolts, Screws, Studs, and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 ± 6 in-lb 644 ± 68 N∙cm 78 ± 8 in-lb 881 ± 90 N∙cm M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N∙cm 133 ± 14 in-lb 1503 ± 158 N∙cm M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N∙m 28 ± 3 ft-lb 38 ± 4 N∙m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb Thread Cutting Screws (Zinc Plated Steel) Type 1, Type 23 or Type F Thread Size Baseline Torque** No. 6 - 32 UNC 20 ± 5 in-lb No. 8 - 32 UNC 30 ± 5 in-lb No.
Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants, and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. 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.
Shop Supplies (continued) GASKET COMPOUND Used to create a seal between mating parts. Gasket compounds may be used with or without the presence of a pre-formed gasket. Gasket compounds may be solvent or silicone based, and cure when exposed to air or designed to cure in an air-less environment (anaerobic). Most gasket compounds are designed to be applied to clean surfaces free of oil, chemical residue and previously used gaskets or gasket compounds.
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 disconnect fittings are provided to attach directly to the mating fittings on the machine test ports without the tools. A high-pressure hose is given for remote readings.
Hydraulic 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. TOR6007 This kit includes the fittings and hoses that are used to connect high flow hydraulic filter kit (TOR6011) to the machine hydraulic traction system components.
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.
Multimeter Obtain this tool locally The meter can test the electrical components and circuits for current, resistance, or voltage. Note: Use a digital multimeter when testing the electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode ensures that the excess current is not allowed through the meter. This excess current can damage the circuits that are not designed to carry it. Battery Terminal Protector Toro Part No.
Specifications and Maintenance: Special Tools Page 2–16 GreensPro™ 1240/1260 14211SL Rev A
Chapter 3 Troubleshooting Table of Contents GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems ............................. 3–2 Gather Information ............................................................................................................................. 3–2 Evaluate Potential Causes ................................................................................................................. 3–2 Assess Performance.............................................
GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems Gather Information •Information reported by the customer •Information observed by you •Establish the what, where and when of the issue Evaluate Potential Causes Consider possible causes of the problem to develop a hypothesis •Narrow down the focus of the problem Assess Performance •Ensure you have all the necessary tools for testing •Test all potential causes of the failure •Reevaluate and create a new hypothesis if necessary Re
Starting and Operating Problems (machine serial number above 31500000) Problem Nothing happens when you attempt to start the engine. Possible Cause Corrective Action The fuel tank is empty. Fill the fuel tank; refer to the machine Operator’s Manual. The engine oil is below the minimum level. The engine On/Off switch is in the OFF position. The parking brake is disengaged and the operator seat is unoccupied. The motion control linkage is not properly adjusted.
Starting and Operating Problems (machine serial number above 31500000) (continued) Problem Machine stops intermittently during operation. Possible Cause Corrective Action Parking brake is not properly adjusted. Adjust parking brake; refer to Adjusting the Parking Brake in Chapter 7 – Chassis. Operator weight not sufficient to engage seat switch. Install plunder disc above seat switch; refer to Seat Switch in Chapter 6 – Electrical System.
General Hydraulic System Problems (GreensPro 1260) Problem Hydraulic fluid is leaking from the system. The hydraulic fluid foams excessively causing fluid leakage from the hydraulic tank breather. The hydraulic system operates hot (exceeds 95° C (203° F). Possible Cause The fitting(s), hose(s), or tube(s) are loose or damaged. Secure or replace loose or damaged hydraulic connections. The O-ring(s) or seal(s) are missing or damaged. Install a new O-ring(s) or seal(s).
Traction Circuit Problems (GreensPro 1260) Problem The traction response is sluggish. Possible Cause The hydraulic fluid is very cold. Allow the hydraulic fluid to warm by safely operating the machine at rest. The hydraulic fluid level in the hydraulic tank is low. The hydraulic pump tow (bypass) valve is open or damaged. The charge pressure is low. Adjust the hydraulic fluid level. One or more orifice or screen in the hydraulic pump is partially obstructed or damaged.
Traction Circuit Problems (GreensPro 1260) (continued) Problem No traction exists in either direction. Possible Cause The hydraulic fluid level in the hydraulic tank is low. Adjust the hydraulic fluid level. The hydraulic pump tow (bypass) valve is open or damaged. The charge pressure is low. Close or replace the hydraulic pump bypass valve. Verify charge pressure; refer to Hydraulic Pump Charge Pressure Test in Chapter 5 – Hydraulic System.
Troubleshooting: Traction Circuit Problems (GreensPro Page 3–8 GreensPro™ 1240/1260 1260) 14211SL Rev A
Chapter 4 Engine Table of Contents General Information .............................................................................................................................. 4–2 Operator’s Manual ............................................................................................................................. 4–2 Engine Owner’s Manual..................................................................................................................... 4–2 Engine Service Manual ............
General Information g238094 Figure 5 1. 2. Fuel tank Air cleaner 4. 5. Recoil-start handle Spark plug 3. Recoil starter 6. Muffler This chapter gives the information about specifications and repair of the Honda GX200 gasoline engine used in the GreensPro 1240 and 1260 machines. Described adjustments and repairs require tools that are commonly available in many service shops.
Engine Service Manual Detailed information on engine troubleshooting, testing, disassembly, and assembly is given in the Honda Service Manual. The use of some specialized tools and test equipment is explained in the Honda Service Manual. Contact your local Honda Engine Dealer to obtain a copy of the engine Service Manual. However, the specialized nature of some engine repairs may dictate that the work be done at a Honda engine repair facility.
Fuel Evaporative Control System To meet worldwide emission standards, the engine that powers your GreensPro is equipped with a fuel cap that has an integrated carbon canister (Figure 6). This fuel cap captures fuel vapors from the fuel tank before venting to atmosphere. g238093 Figure 6 1. Fuel tank insert To prevent saturating the carbon canister in the fuel cap, it is important to ensure that the fuel tank is not overfilled.
Service and Repairs Engine g238091 Figure 7 GreensPro 1240 1. Engine assembly 10. Rubber drive coupling 19. Bolt (4 each) 2. Transmission assembly 11. Locknut (4 each) 20. Flat washer (8 each) 3. Fan 12. Socket-head screw 21. Locknut (4 each) 4. 5. Transmission drive collar Bolt (2 each) 13. 14. Lock washer Flat washer 22. 23. Ground wire Exhaust guard (serial number above 315000000) 6. Flat washer (8 each) 15. Hardened washer 24. Bolt (3 each) 7. Spacer (2 each) 16.
g238092 Figure 8 GreensPro 1260 1. Engine assembly 2. 3. 8. Engine mount (2 each) 15. Set screw (4 each) Hex nut (10 each) 9. Bolt (2 each) 16. Hydraulic pump drive collar Washer (26 each) 10. Flange-head screw (2 each) 17. Rubber drive coupling 4. Bolt (2 each) 11. Engine mount (2 each) 18. Engine drive collar 5. Engine plate 12. Key 19. Key 6. Bolt (8 each) 13. Hydraulic pump 7. Spring washer (8 each) 14.
Removing the Engine (continued) CAUTION Use a suitable lifting device to safely raise and support the machine to get access to the components under the chassis. 2. Unlatch and lift the operator seat pan forward. 3. Remove the exhaust guard if equipped. 4. Disconnect the transmission/hydraulic pump drive collar from the rubber drive coupling. Note: On GreensPro 1240 machines, move the hydraulic fluid tank to get access to the engine wiring connections and engine mounting fasteners.
Removing the Engine (continued) 7. Remove the engine from the chassis. 8. If necessary, remove the rubber drive coupling and engine drive collar. Installing the Engine Refer to Figure 7 or Figure 8 for this procedure. 1. If previously removed, apply a thin coat of anti-seize lubricant to the engine output shaft and install the engine drive collar and rubber drive coupling to the engine. Tighten the nuts to 23 to 29 N∙m (17 to 21 ft−lb). 2. Place the engine in position on the chassis. 3.
Chapter 5 Hydraulic System Table of Contents General Information .............................................................................................................................. 5–2 Transmission/Hydraulic Pump Service and Repair Manuals .............................................................. 5–2 Drive Train Operation......................................................................................................................... 5–3 Hydraulic System Components...................
General Information The GreensPro Operator's Manual provides information regarding the operation, general maintenance procedures, and maintenance intervals for your machine. Refer to the GreensPro Operator's Manual for additional information when servicing the machine. Some service and repair parts for the transmission in your GreensPro 1240 machine and for the hydraulic pump in your GreensPro 1260 machine are supplied through your Authorized Toro Distributor.
Drive Train Operation GreensPro 1240 g241032 Figure 10 1. 2. Transmission Motion control pedal (2 each) 3. 4. Drive roller Parking brake lever GreensPro 1240 machines use a hydraulic transmission driven by the engine through a rubber drive coupling to propel the machine (Figure 10). The transmission is connected to the drive roller through a double row chain. The transmission is a 10.2 cc (0.62 cu in) variable displacement bidirectional axial hydraulic pump coupled to a fixed displacement 21.8 cc (1.
GreensPro 1240 (continued) Most of the traction control system components are attached to the bottom of the chassis. The motion control pedals extend through the chassis, as does the linkage rod that attaches to the transmission control arm. The transmission and transmission drive components mount to the top of the chassis. The GreensPro 1240 machines with serial number above 315000000 include a parking brake system. The band style parking brake is hand actuated.
GreensPro 1260 g271595 Figure 11 1. Hydraulic pump 3. Parking brake lever 2. Hydraulic motor 4. Drive roller 5. Motion control pedal (2 each) GreensPro 1260 machines use a 10.2 cc (0.62 cu in) variable displacement bidirectional axial hydraulic pump connected to a fixed displacement 2.1 cc (0.13 cu in) hydraulic motor to propel the machine (Figure 11). The hydraulic pump is driven by the engine through a rubber drive coupling. The hydraulic motor is directly coupled to the drive roller.
GreensPro 1260 (continued) traction cable that attaches to the hydraulic pump control arm. The hydraulic pump mounts to the top of the chassis. The GreensPro 1260 machines include a parking brake system. The band style parking brake is hand actuated. The system engages a brake hub mounted on the end of the drive roller axle. These machines include a parking brake switch, operator’s seat switch, and a neutral switch as part of a safety interlock system; refer to Electrical System (page 6–2).
Hydraulic System Components Hydraulic System (GreensPro 1240) g241033 Figure 12 GreensPro 1240 1. Transmission 9. 2. Hydraulic tank 3. Bolt (2 each) 17. Hydraulic hose – 3/8 BSPP (transmission to tank) 10. Lock washer (2 each) 18. Hydraulic hose – 3/8 BSPP (tank to filter) Tank cap 11. Flat washer (2 each) 19. Straight fitting – 9/16 SAE to 3/8 BSPP (3 each) 4. Sight glass – 3/8 BSPP 12. Bolt (2 each) 20. O-ring – 9/16 SAE (3 each) 5. Drain plug – 1/4 BSPP 13.
Hydraulic System (GreensPro 1240) (continued) The hydraulic system of the GreensPro 1240 machines includes the transmission, hydraulic tank, hydraulic fluid filter, and a series of hydraulic hoses (Figure 12). If a component failure occurs in the transmission, unwanted material and contamination from the damaged component will circulate throughout the system. This contamination can damage other components in the system, so remove the contamination to prevent additional component failure.
Hydraulic System (GreensPro 1260) g271652 Figure 13 GreensPro 1260 1. Hydraulic tank 8. Hydraulic fluid filter head 15. Hydraulic hose – 8 ORFS (pump to motor) 2. Cap/breather/dipstick 9. Hydraulic hose – 6 ORFS (tank to 16. filter) Straight fitting – 10 SAE to 8 ORFS (2 each) 3. Straight fitting – 3/8 BSPP to 6 ORFS (2 each) Filter bracket 17. Motor 4. Hydraulic hose – 6 ORFS (pump to 11. tank) Hydraulic fluid filter element 18. Drain plug – 1/4 BSPP 5.
Hydraulic System (GreensPro 1260) (continued) The traction circuit of the GreensPro 1260 machines is a closed loop system that includes the hydraulic pump, hydraulic motor, hydraulic tank, hydraulic fluid filter, and a series of hydraulic hoses (Figure 13). If a component failure occurs in the traction circuit (e.g., hydraulic pump or hydraulic motor), unwanted material and contamination from the damaged component will circulate throughout the traction circuit.
Hydraulic Hoses The hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions, in addition to mishandling during operation and maintenance. These conditions can cause damage to the hose or deterioration to the hose material. Some hoses are more susceptible to these conditions than others. Examine all of the hydraulic hoses of the machine frequently and repair or replace them as necessary.
Installing the Hydraulic Hoses and Tubes g212099 Figure 14 1. Tube or hose 2. Swivel nut 3. 4. O-ring Fitting body 1. Ensure that all the threads, the sealing surfaces of the hose/tube, and the fitting are free of burrs, nicks, scratches, or unwanted material. 2. Align the hose/tube against the body of the fitting so that the face of the hose/tube sleeve fully touches the face of the fitting. Note: It may be necessary to use a drive-adapter wrench (e.g.
Installing the Hydraulic Hoses and Tubes (continued) A. Use a wrench to tighten the swivel nut onto the fitting until you feel light resistance with the wrench; approximately 3.39 N∙m (30 in-lb). B. Put a mark on the swivel nut and body of the fitting. Hold the hose/tube in alignment with a wrench to prevent the hose/tube from turning (Figure 15). g221222 Figure 15 1. Mark nut and fitting body 3. Initial position 2. Final position 4.
Installing the Hydraulic Fittings IMPORTANT The hydraulic fittings used on the GreensPro 1240 have BSPP (British Standard Parallel Pipe) threads for the hose connections, and both SAE and BSPP threads for the component connections. The hydraulic fittings used on the GreensPro 1260 have ORFS (O-Ring Face Seal) threads for the hose connections, and both SAE and BSPP threads for the component connections.
Installing a Non-Adjustable Fitting (continued) B. If the port material is steel, tighten the fitting to the listed value; refer to the Flats From Finger Tight (FFFT) Table (page 5–16). 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 5–16). Installing an Adjustable Fitting g212224 Figure 17 1. Locknut 2. Back-up washer 3. O-ring g212225 Figure 18 1. Step 1: clearance the lock nut 3.
Installing an Adjustable Fitting (continued) IMPORTANT Before tightening the fitting, determine the material used for the port the fitting is being installed in. Installing a fitting into an aluminum port requires reducing the installation torque. 7. Tighten the fitting lock nut (Step 4 in Figure 18): A.
Hydraulic Schematic (GreensPro 1260) g240222 Figure 19 GreensPro™ 1240/1260 Page 5–17 Hydraulic System: Hydraulic Schematic (GreensPro 1260) 14211SL Rev A
Hydraulic Flow Diagrams GreensPro 1260 Traction Circuit g240225 Figure 20 Hydraulic System: Hydraulic Flow Diagrams Page 5–18 GreensPro™ 1240/1260 14211SL Rev A
The hydraulic traction circuit consists of a bidirectional variable displacement piston pump connected in a closed loop to a hydraulic motor. The hydraulic pump is driven by the engine through a rubber drive coupling. Right Direction Pressing down the right motion control pedal, angles the hydraulic pump swash plate to create a flow of fluid. This fluid flow is directed to the hydraulic motor through the “A” port to rotate the drive roller in the right direction.
Testing the Hydraulic System The most effective procedure to isolate the problems in the hydraulic system is to use hydraulic test equipment, such as pressure gauges and flow meters in the circuits during different operational checks; refer to Special Tools (page 2–12). WARNING Opening the hydraulic system without releasing pressure from the system will cause the hydraulic fluid to escape, causing possible injury.
IMPORTANT Use 2 people to perform all the tests, with 1 person in the seat and the other to read and record the test results. 1. Use the following resources to assist with hydraulic system troubleshooting. • The Hydraulic Schematic (GreensPro 1260) (page 5–17) • The Hydraulic Flow Diagrams (page 5–18) • General and system specific troubleshooting tables in Chapter 3 – Troubleshooting 2. Always wear the eye protection when you performing hydraulic system tests. 3.
Testing the Traction Circuit – Hydraulic Pump Charge Pressure Test (GreensPro 1260) g274697 Figure 21 The charge pressure test is the first in a series of two tests recommended to determine traction circuit performance. Charge pressure testing involves recording the charge pressure with the pump under no load (swash plates closed) and comparing that reading to the charge pressure while the pump is under a moderate load (swash plates open).
Test Procedure (continued) CAUTION Before opening the hydraulic system, press the motion control pedals to release the pressure in the system and avoid injury from the pressurized hydraulic fluid. 4. Clean the junction of the hydraulic hoses and straight fittings at the hydraulic pump (Figure 22). Tag the hoses to correspond with the pump ports (A and B) then disconnect the hoses from the fittings. Plug the hoses to prevent contamination from entering the system. g274728 Figure 22 1. Hydraulic pump 4.
Test Procedure (continued) 8. Connect a 0 to 500 psi pressure gauge to the charge circuit test port 9. Connect a 0 to 5000 psi pressure gauge to the pump A port. 10. Start the engine and run it at low-idle speed. Check for hydraulic fluid leaks from the test connections and correct before continuing the test. 11. Set the throttle to full engine speed (3,600 rpm). Use a non-contact tachometer (phototach) to verify the engine speed. 12. Run the engine for approximately 10 minutes to warm the hydraulic oil.
Testing the Traction Circuit – Hydraulic Pump Flow and Relief Pressure Test (GreensPro 1260) g240223 Figure 23 The hydraulic pump flow test is recommended to determine the traction circuit performance. This test compares fluid flow at a No Load with fluid flow Under Load. A drop in flow under load of more than 12% indicates an internal leak or malfunctioning relief valve in the hydraulic pump. A worn hydraulic pump or malfunctioning relief valve is less efficient.
Test Procedure (continued) 3. Clean the junction of the hydraulic hoses and straight fittings at the hydraulic motor (Figure 24). Tag the hoses to correspond with the motor ports (A and B) then disconnect the hoses from the fittings. Cap the motor fittings to prevent contamination from entering the system. g271745 Figure 24 1. Hydraulic motor 2. Hose – motor A port (travel left) 3.
Test Procedure (continued) B. Record the tester pressure and flow readings. No Load pump output should be approximately 34 lpm (9 gpm). 9. Verify the pump flow Under Load as follows: A. With the RIGHT motion control pedal at the full forward position, apply an additional load of 7,600 kPa (1,100 psi) by slowly closing the tester flow control valve. B. Record the tester pressure and flow readings. C.
Test Procedure (continued) The system pressure should reach 15,860 to 17,240 kPa (2,300 to 2,500 psi) before the relief valve opens. Note: The relief valve setting is 16,000 kPa (2,320 psi). An additional 690 to 1,030 kPa (100 to 200 psi) is necessary to overcome the system charge pressure before the relief valve opens. G. Record the tester pressure reading. H. Open the tester flow control valve fully, engage the parking brake, set the throttle to low engine speed, and shut off the engine. 13.
Adjustments Adjusting the Control Pedal Return to Neutral Mechanism The return to neutral mechanism is designed to return the transmission/hydraulic pump control lever to a neutral position (no left or right movement of the drive roller), and return the motion control pedals to a position directly across from each other when the motion control pedals are released.
Adjusting Procedure for GreensPro 1240 (continued) g241035 Figure 25 GreensPro 1240 1. 2. Transmission Damper 7. 8. Hex nut Bolt (2 each) 3. Linkage rod 4. Transmission control arm 9. Flat washer (4 each) 10. 5. Damper plate Spacer (linkage arm) 11. Spacer (damper plate) 6. Lock washer 12. Locknut (2 each) 5. Start the engine and set the throttle to full engine speed. 6.
Adjusting Procedure for GreensPro 1240 (continued) g271843 Figure 26 GreensPro 1240 1. RTN adjustment screw 3. To stop drive roller rotation to the left 2. Control arm assembly 4. To stop drive roller rotation to the right B. Rotate the control arm assembly in the opposite direction of the drive roller rotation in small increments. C. Tighten the RTN adjustment screw to 24 to 30 N·m (18 to 22 ft-lb). D. Start the engine, set the throttle to full engine speed and check for drive roller rotation.
Adjusting Procedure for GreensPro 1240 (continued) g241036 Figure 27 GreensPro 1240 1. Motion control pedal (2 each) 2. Straightedge 11. If the drive roller rotates, adjust the linkage rods so the drive roller does not move when the motion control pedals are aligned with each other. Note: Each linkage rod includes 2 ball joints and 2 hex nuts. 1 ball joint and hex nut has left-hand threads, and 1 ball joint and hex nut has right-hand threads.
Adjusting Procedure for GreensPro 1260 (continued) g271901 Figure 28 GreensPro 1260 1. Traction cable 3. Jam nut (2 each) 2. Pedal rod pivot assembly 4. Pedal stop bolts (2 each) 5. Start the engine and set the throttle to full engine speed. 6. If the drive roller does not rotate, shut off the engine and attach the traction cable to the pedal rod pivot. 7.
Adjusting Procedure for GreensPro 1260 (continued) g271960 Figure 29 GreensPro 1260 1. RTN adjustment screw 3. To stop drive roller rotation to the left 2. Control arm assembly 4. To stop drive roller rotation to the right B. Rotate the control arm assembly in the opposite direction of the drive roller rotation in small increments. C. Tighten the RTN adjustment screw to 24 to 30 N·m (18 to 22 ft-lb). D. Start the engine, set the throttle to full engine speed and check for drive roller rotation.
Service and Repairs General Precautions for Removing and Installing the Hydraulic System Components Before Repairing or Replacing the Components CAUTION Before disconnecting or performing any work on the hydraulic system, shut off the engine and press the motion control pedals to release the pressure in the system and avoid injury from the pressurized hydraulic fluid. 1.
After Repairing or Replacing the Components (continued) 4. Lubricate the O-rings, ED seals, and dowty seals with clean hydraulic fluid before installing the hydraulic components. 5. Remove all the caps or plugs from the hydraulic hoses, hydraulic fittings, and components before connecting them. 6. Use proper tightening procedures when installing the hydraulic hoses and fittings; refer to Installing the Hydraulic Hoses and Tubes (page 5–12) and Installing the Hydraulic Fittings (page 5–14). 7.
Checking the Hydraulic Lines and Hoses WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Ensure that all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • Keep your body and hands away from pin-hole leaks or nozzles that eject high-pressure hydraulic fluid. • Use a piece of cardboard or paper to find hydraulic leaks.
Flushing the Hydraulic System Flush the hydraulic system whenever the system is contaminated (for example, the fluid appears milky or black, or contains metal particles). IMPORTANT If a component failure occurs; refer to Hydraulic System Components (page 5–7)for additional information. 1. Park the machine on a clean, level surface with the transport wheels in the raised and locked position, shut off the engine, and engage the parking brake. 2.
Filtering the Closed-Loop Traction Circuit (GreensPro 1260) Filtering a closed-loop hydraulic system after a major component failure (e.g., hydraulic pump or hydraulic motor) is required to prevent debris from transmitting throughout the system. If a filtering tool is not used to ensure the system cleanliness, repeat failures and subsequent damage to other hydraulic components in the system, will occur.
Filtering the Closed-Loop Traction Circuit (GreensPro 1260) (continued) 5. Check and fill the hydraulic tank with the correct quantity of new hydraulic fluid; refer to the Operator’s Manual. 6. Start the engine and run it at low-idle speed. Check for and correct any hydraulic leaks before proceeding. CAUTION Use extreme caution when performing this test. The drive roller will be rotating during the test.
Priming the Hydraulic Pump Whenever hydraulic fluid has been drained from the pump (system drain, flush, or pump removal/installation) it is important to properly prime the hydraulic pump. Priming the hydraulic pump ensures that the pump has sufficient hydraulic fluid while charging the hydraulic system. IMPORTANT If the hydraulic pump was rebuilt or replaced, make sure the pump housing is at least half full of clean hydraulic fluid after installation. 1.
Charging the Hydraulic System IMPORTANT Air must be purged from the system to reduce the chance of component damage. When initially starting the hydraulic system with new or rebuilt components such as motors or pumps, it is important that the hydraulic system is charged properly to remove air from the system. Note: Flush the hydraulic system whenever there is a severe component failure or the system is contaminated; refer to Flushing the Hydraulic System (page 5–38). 1.
Hydraulic Tanks g272504 Figure 31 1. Hydraulic tank (GreensPro 1240) 8. Straight fitting – 3/8 BSPP to 3/8 BSPP (2 each) 2. Tank cap 3. Fiber gasket 4. Sight glass – 3/8 BSPP 11. ED seal – 3/8 (2 each) 5. Dowty seal – 1/4 12. Straight fitting – 3/8 BSPP to 8 ORFS (2 each) 6. Drain plug – 1/4 BSPP 13. O-Ring – 8 ORFS 7. Dowty seal – 3/8 (2 each) 9. 10.
Transmission (GreensPro 1240) g241041 Figure 32 1. Transmission 6. Damper plate 11. Spacer (linkage arm) 2. Neutral switch (serial number above 315000000) 7. Lock washer 12. Spacer (damper plate) 3. Damper 8. Hex nut 13. Locknut (2 each) 4. Linkage rod 9. Bolt (2 each) 5. Transmission control arm 10. Flat washer (4 each) Removing the Transmission Refer to Figure 32 for this procedure. 1.
Removing the Transmission (continued) 4. Read and adhere to the General Precautions for Removing and Installing the Hydraulic System Components (page 5–35). 5. Clean the hydraulic hose ends and fittings being disconnected to prevent hydraulic system contamination. 6. Drain the hydraulic fluid from the hydraulic tank into a suitable container. 7. For assembly purposes, label all the hoses and fittings. Remove the hoses from the fittings on the transmission assembly. Drain the hoses into a suitable container.
Removing the Transmission (continued) g241039 Figure 34 1. Hex nut 6. Flat washer (10 each) 11. Retaining ring 2. Spacer 7. Locknut (5 each) 12. Bolt (3 each) 3. Compression spring 8. Idler arm assembly 13. Bolt 4. Tension rod 9. Spacer 14. Locknut 5. Bolt Pivot bushing 15. Flat washer 10. 14. Remove the bolt, flat washers, and locknut that secure the idler arm to the transmission mount, and remove the idler arm assembly. 15.
Installing the Transmission (continued) g241040 Figure 35 1. 2. 3. 4. Set screw Key Fan Drive collar 2. Place the transmission in position on the chassis. 3. Apply a thin coat of anti-seize lubricant to the transmission output shaft. 4. Position the sprocket in the drive chain. Move the transmission toward the mounting bracket while guiding the sprocket onto the output shaft. 5. Secure the transmission to the mounting bracket and lower the transmission mount with the bolts, locknuts, and flat washers.
Installing the Transmission (continued) 12. Secure the damper plate and linkage rod to the transmission control arm (item 5 in Figure 32) with the bolts, flat washers, spacers, and locknuts. 13. Secure the damper (item 3 in Figure 32) to the damper plate with the lock washer and hex nut. 14. Remove the caps and plugs from the hydraulic hoses and fittings and connect the hydraulic hoses to the fittings on the transmission assembly. Tighten the hose swivel nuts to 32 N∙m (24 ft-lb). 15.
Servicing the Transmission (GreensPro 1240) g241037 Figure 36 GreensPro™ 1240/1260 14211SL Rev A Page 5–49 Hydraulic System: Service and Repairs
Servicing the Transmission (GreensPro 1240) (continued) Figure 36 (continued) 1. Housing (upper) 20. Bearing retainer 39. Bolt 2. Housing (lower) 21. Guide slot 40. Pivot washer 3. Center section kit 22. Trunnion assembly 41. Plug 4. Spacer 23. Control arm 42. Spacer 5. Retaining ring 24. Flange nut 43. Seal kit (Incl. Ref. 44-51) 6. Retaining ring 25. Bypass plate kit 44. Lip seal 7. Ball bearing 26. Bypass actuator 45. Lip seal 8. Swashplate (variable) 27.
Hydraulic Pump (GreensPro 1260) g272542 Figure 37 1. Hydraulic pump 5. Plain washer (4 each) 2. Pump drive collar 6. Square key 3. Set screw (2 each) 7. Cap screw (2 each) 4. Lock nut (2 each) Removing the Hydraulic Pump Refer to Figure 37 for this procedure. CAUTION Before opening the hydraulic system, shut off the engine and press the motion control pedals to release the pressure in the system and avoid injury from the pressurized hydraulic fluid.
Removing the Hydraulic Pump (continued) 6. For assembly purposes, label all the hoses and fittings. Remove the hoses from the fittings on the transmission assembly. Drain the hoses into a suitable container. 7. Install clean caps and plugs on the disconnected hoses and fittings to prevent hydraulic system contamination. 8. Disconnect the wire harness connector from the neutral switch. 9. Remove the traction cable clamp from the engine plate (below the frame plate).
Installing the Hydraulic Pump Refer to Figure 37 for this procedure. 1. If the hydraulic fittings were removed from the pump, lubricate and install new O-rings to the fittings. Install the fittings into the pump; refer to Installing the Hydraulic Fittings (page 5–14). IMPORTANT Ensure that you do not damage the machine components while installing the hydraulic pump. 2. Position the square key (item 4 in Figure 37) to the key slot in the hydraulic pump shaft. 3.
Servicing the Hydraulic Pump (GreensPro 1260) g240236 Figure 39 1. Fan/hub kit 11. Swash plate 21. Headless pin (2 each) 2. Charge pump bolt kit 12. Guide slot 22. O-ring 3. Shock valve kit (2 each) 13. Trunnion arm 23. Plug 4. Charge relief kit 14. Retaining ring 24. End cap 5. Plug 15. Lip seal 25. Plug 6. Valve plate 16. Flat washer 26. Bypass valve 7. Cylinder block 17. Shaft kit 27. Flange-head bolt (4 each) 8. Spring 18. Trunnion seal/retainer kit 28.
Hydraulic Motor (GreensPro 1260) g240365 Figure 40 GreensPro 1260 1. Socket-head screw 9. Bearing housing 17. Bolt (4 each) 2. Spring washer 10. Locknut (4 each) 18. Drive roller hub 3. Plain washer (5 each) 11. Plain washer (8 each) 19. Drive roller 4. Hardened washer 12. Bolt (4 each) 20. Bearing 5. Brake hub 13. Carriage screw (2 each) 21. Shim (as required) 6. Bolt (2 each) 14. Wheel motor nut 22. Nut (4 each) 7. Plain washer (6 each) 15. Woodruff key 23.
Removing the Hydraulic Motor and Drive Roller Assembly (continued) CAUTION Before opening the hydraulic system, shut off the engine and press the motion control pedals to release the pressure in the system and avoid injury from the pressurized hydraulic fluid. CAUTION Use a suitable lifting device to safely raise and support the machine to access the components under the chassis. 1. Park the machine on a clean, level surface and set the transport wheels to the lowered and locked position. 2.
Installing the Hydraulic Motor and Drive Roller Assembly (continued) 1. If the hydraulic fittings were removed, lubricate and install new O-rings and properly tighten the fittings; refer to Installing the Hydraulic Fittings (page 5–14). 2. Position the woodruff key in the motor shaft. 3. Install the drive roller hub onto the motor shaft and secure with new wheel motor nut (item 16 in Figure 40). Tighten the wheel motor nut to 240 to 300 N∙m (177 to 221 ft-lb). 4.
Servicing the Hydraulic Motor (GreensPro 1260) g240221 Figure 41 1. 2. Wheel motor nut Dirt and water seal 8. 9. Thrust washer Thrust bearing 15. 16. Manifold Commutator assembly 3. Woodruff key 10. Coupling shaft 17. Commutator seal 4. 5. Housing assembly 11. Seal ring (5 each) 18. End cover Back-up ring 12. Wear plate 19. Special bolt (6 each) 6. Back-up washer 13. Drive link 20. Identification tag 7. Shaft seal 14. Rotor set 21.
Chapter 6 Electrical System Table of Contents General Information .............................................................................................................................. 6–2 Electrical System ............................................................................................................................... 6–2 Electrical Schematics and Wire Harness Drawings/Diagrams ............................................................... 6–3 Electrical Drawing Designations........
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your GreensPro machine. Refer to the Operator’s Manual for additional information when servicing the machine. Electrical System Some of the electrical system components used on GreensPro machines are part of the Honda engine. These components include the engine ON/OFF switch, ignition module, lighting coil, Oil Alert™ unit, and oil level switch.
Electrical Schematics and Wire Harness Drawings/Diagrams Electrical Drawing Designations Note: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire harness diagram (e.g., SP01 is splice number 1). Wire Color The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter.
Electrical Schematic – GreensPro 1240 (s/n 315000000 up) g238132 Electrical System: Electrical Schematics and Wire Page 6–4 GreensPro™ 1240/1260 Harness Drawings/Diagrams 14211SL Rev A
Electrical Schematic – GreensPro 1260 g238394 GreensPro™ 1240/1260 Page 6–5 Electrical System: Electrical Schematics and Wire Harness Drawings/Diagrams 14211SL Rev A
GreensPro 1240 (s/n 315000000 up) Wire Harness Drawing – Main g238134 Electrical System: Electrical Schematics and Wire Page 6–6 GreensPro™ 1240/1260 Harness Drawings/Diagrams 14211SL Rev A
GreensPro 1240 (s/n 315000000 up) Wire Harness Diagram – Main g238133 GreensPro™ 1240/1260 Page 6–7 Electrical System: Electrical Schematics and Wire Harness Drawings/Diagrams 14211SL Rev A
GreensPro 1260 Wire Harness Drawing – Main g238395 Electrical System: Electrical Schematics and Wire Page 6–8 GreensPro™ 1240/1260 Harness Drawings/Diagrams 14211SL Rev A
GreensPro 1260 Wire Harness Diagram – Main g238396 GreensPro™ 1240/1260 Page 6–9 Electrical System: Electrical Schematics and Wire Harness Drawings/Diagrams 14211SL Rev A
GreensPro 1240 Wire Harness – AC Hour Meter (Standard) g272829 Electrical System: Electrical Schematics and Wire Page 6–10 GreensPro™ 1240/1260 Harness Drawings/Diagrams 14211SL Rev A
GreensPro 1240 Wire Harness – AC Lights Kit (Optional) g272830 GreensPro™ 1240/1260 Page 6–11 Electrical System: Electrical Schematics and Wire Harness Drawings/Diagrams 14211SL Rev A
GreensPro Wire Harness – Wireless Hour Meter Kit (Optional) g272831 Electrical System: Electrical Schematics and Wire Page 6–12 GreensPro™ 1240/1260 Harness Drawings/Diagrams 14211SL Rev A
Electrical System Quick Checks Checking the Operation of the Interlock Switches CAUTION Do not disconnect the safety switches. They are for the operator’s protection. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches or repair any damaged wiring before operating the machine.
Testing the Electrical Components Some of the electrical system components used on GreensPro machines are part of the Honda engine. These components include the engine ON/OFF switch, ignition module, lighting coil, Oil Alert™ unit, and oil level switch. Service information for these components can be found in the Honda Engine Service Manual. Contact your local Honda Engine Dealer or visit http://engines.honda.com for assistance.
Interlock Module (machine serial number above 31500000) g238113 Figure 42 1. 2. Seat pan Interlock module An interlock module is used to manage the machine interlock system. The interlock module is attached to the underside of the seat pan (Figure ?). The interlock module is a micro-controller that senses the condition of various machine switches (inputs). Based on the state of the inputs, the module controls the engine ignition system circuit (circuit ground).
Testing the Interlock Module (continued) 4. Check the seat switch, parking brake switch, and neutral switch and their circuit wiring for proper operation; refer to individual component testing procedures. 5. Check the Honda electrical components (engine ON/OFF switch, oil level switch, Oil Alert unit, and ignition module) and their circuit wiring for proper operation; refer to Electrical Schematics and Wire Harness Drawings/Diagrams (page 6–3) and the Honda Engine Service Manual. 6.
Hour Meter g238111 Figure 44 1. Hour meter 2. Seat pan 3. Seat support plate On GreensPro 1240 machines, the hour meter is located on the right side of the seat pan. On GreensPro 1260 machines, the hour meter is located on the right side of the seat support plate (Figure ?). The hour meter has a digital display that shows the total hours of machine operation at all time. The hour meter is powered by the engine lighting coil and records whenever the engine is running.
Testing the Hour Meter (continued) 3. Start the engine and set to high idle. 4. Use a multimeter (AC voltage setting) and check for approximately 20 VAC at the wire harness terminals. 5. Shut off the engine. 6. If voltage is present at the wire harness terminals, and the hour meter does not display or record while the engine is running, record the machine hours if possible and replace the hour meter. 7.
Worklight Switch g238112 Figure 46 1. Worklight switch 2. Seat pan 3. Seat support plate On GreensPro 1240 machines, the worklight switch is optional and is located on the right side of the seat pan. On GreensPro 1260 machines, the worklight switch is standard and is located on the right side of the seat support plate (Figure ?). Testing the Worklight Switch 1. Park the machine on a level surface, engage the parking brake (if equipped), and shut off the engine. 2.
Seat Switch (machine serial number above 31500000) g238117 Figure 47 GreensPro 1240 1. Operator seat 2. Seat switch An operator’s seat switch as part of the machine interlock system. The seat switch is attached to the bottom of the seat (Figure ?). When an operator sits in the seat, the seat cushion presses the switch plunger and closes the switch. When the seat is empty the switch is allowed to return to its normally open position.
Neutral Switch (machine serial number above 31500000) g238115 Figure 48 1. Transmission 2. Neutral switch 3. Hydraulic pump A neutral switch as part of the machine interlock system (Figure ?). The neutral switch is part of the transmission/pump control arm assembly. When either motion control pedal is pressed, the switch is allowed to return to its normally open condition.
Parking Brake Switch (machine serial number above 31500000) g238116 Figure 49 1. Parking brake lever 2. Parking brake switch A parking brake switch as part of the machine interlock system (Figure ?). The parking brake switch is located below the brake lever. When the parking brake is applied, the parking brake lever presses the parking brake switch plunger, closing the switch.
Chapter 7 Chassis Table of Contents General Information .............................................................................................................................. 7–2 Steering Operation............................................................................................................................. 7–2 Transport Frame Operation................................................................................................................ 7–4 Adjustments ......................
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your GreensPro machine. Refer to the Operator’s Manual for additional information when servicing the machine. Steering Operation The steering system of the GreensPro machines includes a number of components that cause the front and rear steering head to turn when the operator moves the steering wheel.
GreensPro 1240 Steering System (continued) steering heads by the steering head linkage arms. Rotation of the steering disc assembly causes rotation of the steering heads, which allows the machine to turn while in motion. GreensPro 1260 Steering System g273040 Figure 51 GreensPro 1260 1. Rear steering head 5. Steering pivot 2. Front steering head 6. Steering column assembly 3. Steering rod – short 7. Steering wheel 4.
Transport Frame Operation g239312 Figure 52 Transport frame in lowered position (chassis raised) 1. 2. Auto hitch slide Tow bar 6. 7. Chassis Latch (raised) 3. Transport frame 8. Lift pedal 4. Damper 9. Latch (lowered) 5. Gas spring The transport frame of the GreensPro machines is placed in the raised position (chassis lowered) during machine operation, or in the lowered position (chassis raised) when transporting the machine (Figure 52).
Adjustments Adjusting the Steering Linkage CAUTION Use a suitable lifting device to safely raise and support the machine to access the components under the chassis. 1. Insert a block between the steering pivot assembly and chassis to prevent the steering pivot assembly from moving during adjustment, and to position steering pivot assembly square with the chassis (Figure 53). Block should be approximately 19 mm (0.75 inch) thick. g240025 Figure 53 GreensPro 1240 shown 1. Chassis frame 2. Block 3.
Adjusting the Steering Linkage (continued) g239306 Figure 54 GreensPro 1240 1. Block 4. Steering disc 2. Steering pivot assembly 5. Steering head linkage arm (2 each) 3. Steering pivot rod B. Loosen the hex nuts of both steering head linkage arms. Turn the steering head linkage arms until the front and rear steering head rollers are aligned with each other to within 2 mm (0.08 inch).
Adjusting the Steering Linkage (continued) 3. For GreensPro 1260: Note: Each steering linkage rod includes 2 ball joints and 2 hex nuts. To allow adjustment, 1 ball joint and 1 hex nut has left-hand threads, and 1 ball joint and 1 hex nut has right-hand threads. Before attempting to loosen the hex nuts for linkage adjustment, inspect the threads on the linkage rod to determine the thread direction. A.
Adjusting the Steering Linkage (continued) 4. Tighten the hex nuts on all the linkage arms/steering rods. 5. If necessary, remove and install the steering wheel square with the machine; refer to Steering Wheel (page 7–33). 6. Remove the block from the steering pivot assembly and chassis.
Adjusting the Parking Brake Ensure that the parking brake prevents the machine from rolling when it is parked, and that the brake fully disengages when the brake handle is in the disengaged position. Adjust the parking brake as necessary (Figure 58). • To increase the brake force, tighten the brake lock nut. • To decrease the brake force, loosen the brake lock nut. g273283 Figure 58 1.
Adjusting the Tow Bar Height g239310 Figure 59 1. Tow bar 2. Front locknut – 12 mm 3. Rear fasteners – 10 mm The tow bar height of the GreensPro machines can be set to 3 different heights to suit a variety of tow vehicles (Figure 59). 1. Park the machine on a clean, level surface with the transport wheels in the raised and locked position. Shut off the engine. 2. Loosen, but do not remove the front locknut (12 mm) that secures the tow bar to the transport frame. 3.
Auto Hitch Slide The auto hitch mechanism ensures that the GreensPro remains safely connected to the tow vehicle during transport; refer to the Operator’s Manual. When properly adjusted, the auto hitch lever must be allowed to reach its fully pressed position without restriction from the auto hitch slide. Proper adjustment also allows the slide to reach its stop when the lever is fully released. Check and adjust the auto hitch mechanism as necessary, and after the hitch components are repaired or replaced.
Auto Hitch Slide (continued) B. Release the auto hitch lever (Figure 62). The lever should remain in the fully released position. The auto hitch slide should contact the roll pin stop before the lever contacts the tow bar. Adjust as necessary. g239305 Figure 62 1. 2. Tow bar Roll pin stop 3. 4. Auto hitch slide Lever (released) 4. Tighten the hex nut against adjustable yoke, and tighten the bolt and locknut that secure the lever rod to the adjustable yoke.
Service and Repairs Drive Chain Idler Arm (GreensPro 1240) Removing the Drive Chain Idler Arm 1. Park the machine on a clean, level surface with the transport wheels in the raised and locked position. Shut off the engine. Engage the parking brake if equipped, or remove the spark plug wire from the spark plug. 2. Remove the transmission cover from the machine; refer to Removing the Transmission Cover (page 7–59). 3.
Removing the Drive Chain Idler Arm (continued) g241026 Figure 64 1. Idler adjustment rod 9. Locknut 2. 3. Idler arm Bushing (2 each) 10. 11. Bolt Bolt 4. Idler sprocket assembly 12. Hex nut 5. Spacer 13. Flat washer 6. Bearing (2 each) 14. Locknut 7. Spacer 15. Hex nut 8. Flat washer 16. Flat washer 5. Repair and replace the idler arm assembly components as necessary. Installing the Drive Chain Idler Arm 1.
Motion Control Linkages Motion Control Linkage (GreensPro 1240) g241034 Figure 65 GreensPro 1240 1. Pedal (2 each) 7. Rod pivot assembly 13. Thick washer (5 each) 2. Motion pedal assembly (right) 8. Quadrant linkage rod 14. Collar 3. Motion pedal assembly (left) 9. Quadrant lever assembly 15. Flat washer (4 each) 4. Bushing (8 each) 10. Transmission linkage rod 16. Flat washer (14 each) 5. Pivot bushing (4 each) 11. Rod end (left or right-hand thread) 17. (4 each) 6.
Motion Control Linkage (GreensPro 1240) (continued) The entire motion control linkage assembly must be secure and move freely in both directions. Repair or replace the motion control linkage assembly components as necessary (Figure 65). CAUTION Use a suitable lifting device to safely raise and support the machine to get access to the components under the chassis. Each linkage rod includes 2 ball joints and 2 hex nuts.
Motion Control Linkage (GreensPro 1260) g240376 Figure 66 GreensPro 1260 1. Bolt (2 each) 10. Bolt 19. Plated washer (3 each) 2. Spring washer (4 each) 11. Split bushing (2 each) 20. Locknut (3 each) 3. Washer (2 each) 12. Flange nut (4 each) 21. Flange-head screw 4. Pedal (2 each) 13. Pedal rod pivot assembly 22. Traction cable 5. Bolt (2 each) 14. Damper 23. Jam nut (4 each) 6. Plain washer (3 each) 15. Hex nut (2 each) 24. Pedal rod (2 each) 7.
Motion Control Linkage (GreensPro 1260) (continued) The entire motion control linkage assembly must be secure and move freely in both directions. The motion control pedals should contact the pedal stop bolts just before the control arm assembly reaches the end of its rotation (in both directions). Repair or replace the motion control linkage assembly components as necessary (Figure 66).
Drive Roller (GreensPro 1240) g241028 Figure 67 GreensPro 1240 1. Drive roller 11. Key 21. Lock washer 2. Roller shaft (drive) 12. Bolt 12 mm (4 each) 22. Flat washer 3. Roller shaft (brake) 13. Flat washer 12 mm (8 each) 23. Hardened washer 4. Bolt (6 each) 14. Sleeve (4 each) 24. Brake hub 5. Lock washer (6 each) 15. Locknut 12 mm (4 each) 25. Bolt 16 mm (4 each) 6. Flat washer (6 each) 16. Sprocket 26. Flat washer 16 mm (8 each) 7. Bearing collar (2 each) 17.
Removing the Drive Roller (GreensPro 1240) Refer to Figure 67 for this procedure. CAUTION Use a suitable lifting device to safely raise and support the machine to get access to the components under the chassis. 1. Remove the transmission cover from the machine; refer to Removing the Transmission Cover (page 7–59). 2. Remove the hex nut, spacer, and compression spring (item 3 in Figure 68) from the idler adjustment rod. g241029 Figure 68 1. Hex nut 2. Spacer 7. Locknut 3. Compression spring 8.
Removing the Drive Roller (GreensPro 1240) (continued) g241030 Figure 69 1. Set screw in bushing removal hole C. Tighten the set screw until the bushing is loose in the sprocket. Note: It may be necessary to tap on the sprocket to loosen the bushing. 5. Use a straight blade screwdriver in the taper lock bushing slot to spread the bushing slightly if necessary and remove the taper lock bushing, drive chain, sprocket, and key from the driver roller shaft. 6.
Installing the Drive Roller (GreensPro 1240) (continued) 5. Move the bearing collars against the bearings and tighten the bearing collar set screws. 6. Install the parking brake assembly if equipped; refer to Installing the Parking Brake (page 7–31). Ensure that the entire width of the brake band contacts the brake hub when the brake is engaged. Loosen and adjust the drive roller bearings and bearing collars to align the brake band to the brake hub if necessary. 7.
Installing the Drive Roller (GreensPro 1240) (continued) IMPORTANT When tightening the taper lock bushing set screws, tighten in 3 equal steps and in an alternating pattern. 12. Tighten the set screws that secure the taper lock bushing and sprocket; tighten the set screws to 31 N∙m (23 ft-lb) in 3 equal steps and in an alternating pattern. 13. Check that the roller drive chain alignment is still correct and adjust if necessary. A.
Servicing the Drive Roller (GreensPro 1240) g241027 Figure 71 GreensPro 1240 1. Drive roller 2. Roller shaft (drive) Bearing (2 each) 17. Taper lock bushing 10. Set screw (2 each) 18. Set screw (2 each) 3. 4. Roller shaft (brake) 11. Key 19. Drive chain Bolt (6 each) 12. Bolt (4 each) 20. Socket-head screw Lock washer 9. 5. Lock washer (6 each) 13. Flat washer (8 each) 21. 6. Flat washer (6 each) 14. Spacer (4 each) 22. Flat washer 7. Bearing collar (2 each) 15.
Disassembling the Drive Roller (GreensPro 1240) (continued) 2. Loosen the set screws and remove the bearing collars and bearing assemblies. 3. Remove the bolts, lock washers, and flat washers that secure the roller shafts to the drive roller, and remove the roller shafts. Assembling the Drive Roller (GreensPro 1240) Refer to Figure 71 for this procedure. 1. Install the roller shafts with the bolts, lock washers, and flat washers.
Drive Roller (GreensPro 1260) g240365 Figure 72 1. Socket-head screw 10. Locknut (4 each) 19. Bolt (4 each) 2. Spring washer 11. Plain washer (8 each) 20. Drive roller hub 3. Plain washer (5 each) 12. Bolt (2 each) 21. Drive roller 4. Hardened washer 13. Carriage screw (2 each) 22. Bearing 5. Brake hub 14. Bolt (2 each) 23. Spacer 6. Bolt (2 each) 15. Chassis 24. Nut (4 each) 7. Plain washer (6 each) 16. Wheel motor nut 25. Motor guard 8. Spacer (2 each) 17.
Removing the Drive Roller (GreensPro 1260) (continued) 1. Remove the drive roller assembly; refer to Removing the Hydraulic Motor and Drive Roller Assembly (page 5–55). 2. Remove the hydraulic motor and drive hub from the drive roller. Installing the Drive Roller (GreensPro 1260) Refer to Figure 72 for this procedure. 1. Secure the hydraulic motor and drive hub to the drive roller. 2. Install the drive roller assembly; Installing the Hydraulic Motor and Drive Roller Assembly (page 5–56).
Servicing the Drive Roller (GreensPro 1260) g273190 Figure 73 GreensPro 1260 1. Socket-head screw 7. Plain washer (4 each) 13. Drive roller 2. Lock washer 8. Spacer (2 each) 14. Motor and drive hub assembly 3. Plain washer 9. Locknut (2 each) 15. Plain washer (2 each) 4. Hardened washer 10. Shim (as required) 16. Cap screw (2 each) 5. 6. Brake hub Bolt (2 each) 11. 12.
Assembling the Drive Roller (GreensPro 1260) (continued) 2. Lubricate the bearing grease fitting until grease is visible on the outer surface of the bearing. Wipe away any excess grease.
Parking Brake (machine serial number above 315000000) g241043 Figure 74 1. Hairpin cotter 12. Flat washer 23. Bolt 2. 3. Locknut Flat washer (2 each) 13. 14. Brake band Hardened washer 24. 25. Flat washer Brake return spring 4. E-ring 15. Flat washer 26. Brake pivot arm 5. Brake cable 16. Lock washer 27. Bushing (2 each) 6. Sleeve 17. Socket-head screw 28. Pivot bushing 7. Bolt 18. Bolt (2 each) 29. Flat washer 8. Spacer 19. Flat washer (4 each) 30. Locknut 31.
Removing the Parking Brake (continued) CAUTION Use a suitable lifting device to safely raise and support the machine to get access to the components under the chassis. 1. Ensure that the parking brake is disengaged. 2. Disconnect the brake return spring from the chassis. 3. Remove the locknut, flat washer, and spacer from the brake rod. 4. Remove the hairpin cotter from the brake rod, and remove the brake rod from the brake pivot arm. 5.
Installing the Parking Brake (continued) g241042 Figure 75 1. 2. Brake hub Band lining 3. Brake band 4. 5. Shim Chassis 4. Install the brake band and shims (if any) with the 2 bolts, 4 flat washers, and 2 locknuts. Note: On GreensPro 1260 machines, use shims behind the brake hub to center the hub in the brake band if necessary. 5. Tighten the socket-head screw that secures the brake hub to the drive roller shaft. 6. Install the brake rod (item 22) to the brake pivot arm with the hairpin cotter. 7.
Steering Wheel g239308 Figure 76 1. Steering wheel cover 4. Steering wheel 2. Locknut 5. Steering column 3. Flat washer Removing the Steering Wheel Refer to Figure 76 for this procedure. 1. Park the machine on a clean, level surface with the transport wheels in the raised and locked position. Shut off the engine. Engage the parking brake if equipped, or remove the spark plug wire from the spark plug. 2.
Installing the Steering Wheel (continued) 3. Secure the steering wheel to the steering column with the flat washer and locknut; tighten the locknut to 28 to 35 N∙m (20 to 26 ft-lb). 4. Install the steering wheel cover onto the steering wheel.
Steering Column g239519 Figure 77 1. Steering column boot 8. Gas spring assembly 15. Bolt 2. Bearing cover 9. Flange nut (4 each) 16. Woodruff key 3. Steering column 10. Flat washer 17. Steering pivot rod 4. Bolt (4 each) 11. Locknut 18. Steering pivot 5. Flat washer (4 each) 12. Steering pivot 19. Set screw 6. Pivot pin (2 each) 13. Flat washer 7. E-ring (4 each) 14. Steering pivot linkage rod Removing the Steering Column Refer to Figure 77 for this procedure.
Removing the Steering Column (continued) C. Set the steering column tilt to the fully forward position. D. Carefully lift the boot up and off the steering column. 4. The steering column gas spring assembly controls the steering column tilt position. If the gas spring assembly replacement is necessary, remove the gas spring assembly as follows: A. Set the steering column tilt to the fully forward position. B. Remove an E-ring (item 7) from an end of each pivot pin.
Installing the Steering Column (continued) C. Gently pull the steering column boot over the tilt control lever. D. Set the steering column tilt to the fully forward position. E. Pull the front of the boot down over the base of the steering column. 6. Install the bearing cover over the top of the steering column. 7. Install the steering wheel; refer to Installing the Steering Wheel (page 7–33).
Steering Linkage g239520 Figure 79 GreensPro 1240 1. Steering pivot 8. Hex nut (left or right) (6 each) 15. Bolt (4 each) 2. Woodruff key 9. Steering pivot linkage rod 16. Pivot bushing 3. Set screw 10. Bolt (2 each) 17. Flat washer 4. Flat washer (4 each) 11. Steering disc 18. Bolt 5. Flat washer (6 each) 12. Bushing (2 each) 19. Initial assembly lengths (before final adjustment) 6. Locknut (6 each) 13. Steering head linkage rod (2 each) 7.
Steering Linkage (continued) g273282 Figure 80 GreensPro 1260 1. Steering pivot 5. Steering pivot rod – short 2. Flat washer (8 each) 6. Hex nut (right-hand thread) (2 each) 10. Set screw 3. Ball joint (left-hand thread) (2 each) 7. Ball joint (right-hand thread) (2 each) 11. Woodruff key 4. Hex nut (left-hand thread) (2 each) Steering pivot rod – long 12. Initial assembly lengths (before final adjustment) 8. 9.
Steering Linkage (continued) direction. GreensPro 1260 linkage rods have a groove cut in the rod near the end with left-hand threads. Note: Leave the linkage rod hex nuts loose until the rod ends have been secured and the rod length is adjusted. The distance from the top of the steering pivot to the underside of the chassis top plate should be 32 mm (1.25 inches) for GreensPro 1240 machines or 25 mm (1 inch) for GreensPro 1260 machines (Figure 81). Loosen set screw and adjust if necessary.
Steering Rollers g239522 Figure 82 Front steering head assembly shown 1. Steering head frame 4. Bolt (2 each per roller) 2. Roller assembly (short) 5. Lock washer (2 each per roller) 3. Roller assembly (long) 6. Flat washer (2 each per roller) Removing the Steering Roller Refer to Figure 82 for this procedure. CAUTION Use a suitable lifting device to safely raise and support the machine to get access to the components under the chassis. 1.
Servicing the Steering Rollers g239521 Figure 83 1. Roller tube (short) 5. Roller sleeve 2. Roller shaft (short) 6. O-ring (2 each) 3. Roller tube (long) 7. Bearing (4 each) 4. Roller shaft (long) 8. Flocked seal (4 each) 9. 10. Bearing spacer (2 each) Locknut (2 each) 1. Remove the parts as necessary to repair the steering rollers. Discard the flocked seals and O-rings. 2. Clean all the components before assembly. 3.
Steering Heads g240023 Figure 84 Front steering head assembly (GreensPro 1240) 1. Steering head assembly 7. Steering head linkage rod 13. Flat washer (6 each) 2. Spring 8. Spacer 14. Locknut (4 each) 3. Bolt 9. Flat washer 15. Bolt (2 each) 4. Hex nut 10. Bolt 16. Roller support 5. Flat washer (2 each) 11. Locknut 6. Locknut 12.
g240024 Figure 85 Front steering head assembly (GreensPro 1260) 1. 6. Spring Flange-head screw 11. Flat washer (6 each) 2. Steering head assembly 7. Carriage bolt (2 each) 12. Bolt (2 each) 3. Locknut 8. Roller support 13. Flat washer (4 each) 4. Flat washer (2 each) 9. Steering pivot rod (2 each) 14. Locknut (2 each) 5. Hex nut 10. Locknut (4 each) Removing the Steering Head Refer to Figure 84 or Figure 85 for this procedure.
Removing the Steering Head (continued) CAUTION Use a suitable lifting device to safely raise and support the machine to get access to the components under the chassis. 1. Remove the steering roller; refer to Removing the Steering Roller (page 7–41). CAUTION Be careful when removing or installing the spring. The spring is under load and may cause personal injury. 2. Remove the tension spring. 3. Remove the steering head linkage/pivot rod(s) from the steering head. 4.
Servicing the Steering Head (GreensPro 1240) g240022 Figure 86 Front steering head assembly (GreensPro 1240) 1. Steering head frame 8. Bolt 15. Cap 2. Roller support 9. Lock washer 16. Bolt 3. Bearing 10. Collar 17. Hex nut 4. Bolt (4 each) 11. Spacer 18. Flat washer (2 each) 5. Flat washer (8 each) 12. Bolt (2 each) 19. Locknut 6. Locknut (4 each) 13. Flat washer (4 each) 7. Pivot shaft 14.
Disassembling the Steering Head (continued) 1. Remove the cap from the roller support. 2. Remove the bolt and lock washer that secure the collar (item 10) to the pivot shaft. 3. Lift the roller support with the bearing and collar still attached from the pivot shaft. 4. Remove the fasteners that secure the bearing to the roller support. Separate the bearing from the roller support and remove the collar. 5. Remove the spacer from the pivot shaft. 6. Remove the pivot shaft if necessary. 7.
Servicing the Steering Head (GreensPro 1260) g240021 Figure 87 Front steering head assembly (GreensPro 1260) 1. Flange-head screw 6. Rubber pad (4 each) 11. Roller support 2. Hex nut 7. Cap screw (4 each) 12. Ball joint 3. Flat washer (2 each) 8. Flat washer (8 each) 13. Retaining ring 4. Locknut 9. Locknut (4 each) 5. Steering head frame 10. Jam nut Disassembling the Steering Head Refer to Figure 87 for this procedure. 1.
Disassembling the Steering Head (continued) 2. Remove the jam nut and use a ball joint “pickle” fork to separate the ball joint from the roller support. 3. Remove the rubber pads to the roller support if necessary. 4. Repair or replace the steering head assembly components as necessary. Assembling the Steering Head Refer to Figure 87 for this procedure. 1. Secure the 4 rubber pads to the roller support. 2.
Transport Wheels and Hubs g240020 Figure 88 1. Wheel-lug nut (4 each) 5. Collar 9. 2. Wheel and tire assembly 6. Bearing (2 each) 3. Bolt 7. Hub assembly 4. Lock washer 8. Bearing spacer 10. Drive stud (4 each) Spindle Removing the Wheel and Hub Refer to Figure 88 for this procedure. 1. Park the machine on a clean, level surface with the transport wheels in the raised and locked position. Shut off the engine. 2.
Installing the Wheel and Hub (continued) 5. Adjust the tire pressure to 103 kPa (15 psi) before returning the machine to service.
Transport Frame g240029 Figure 89 1. Transport frame 15. Locknut (2 each) 29. Lift lever 2. Damper 16. Slide bracket 30. Bolt 3. Gas spring 17. Bolt (2 each) 31. Torsion spring 4. Washer (4 each) 18. Flat washer (4 each) 32. Pivot bushing 5. Locknut (4 each) 19. Locknut (2 each) 33. Washer 6. Clamp (3 each) 20. Roller (2 each) 34. Locknut 7. Clamp plate (3 each) 21. Flat washer (4 each) 35. Roll pin 8. Flat washer (6 each) 22. Locknut (2 each) 36.
The transport frame must be secure and move freely in both the raise and lower directions. The latches must hold the transport frame securely in both the raised and lowered positions. Repair or replace the transport frame components as necessary. With the exception of the transport frame itself, the transport frame components can be removed for repair or replacement without removing the transport frame from the chassis. Removing the Transport Frame Refer to Figure 89 for this procedure. 1.
Removing the Transport Frame (continued) g240031 Figure 91 GreensPro 1240 4. Hex nut 1. Seat support assembly 2. Bolt 5. Spring washer (2 each) 3. Washer (4 each) 6. Bolt (2 each) 6. Remove the fasteners that secure the latch (item 11 in Figure 89) to the transport frame. 7. Remove the fasteners that secure the damper (upper strut) (item 2 in Figure 89) to the transport frame. CAUTION Be careful when removing or installing the gas spring.
Removing the Transport Frame (continued) 9. Support the hitch end of the transport frame and remove the bolts, lock washers, flat washers, clamp plates, and upper halves of the clamps from the chassis. CAUTION The weight of the transport frame assembly is approximately 47 kg (104 lb). 10. Use a suitable lifting device to safely lift the transport frame assembly from the chassis. Installing the Transport Frame Refer to Figure 89 for this procedure. 1.
Tow Bar g240019 Figure 92 1. Tow bar 12. Clevis pin 23. Button-head screw 2. Bolt (12 mm) 13. Cotter pin 24. Button-head screw 3. Flat washer (2 each) 14. Bolt 25. Roll pin stop 4. Locknut (12 mm) 15. Bolt 26. Flat washer (2 each) 5. Bolt (10 mm) 16. Lever 27. Locknut 6. Flat washer (2 each) 17. Flat washer (2 each) 28. Locknut 7. Locknut (10 mm) 18. Locknut 29. Auto hitch slide 8. Bolt 19. Locknut 30. Compression spring 31. Slide rod Adjustable yoke 20.
Tow Bar (continued) Determine desired tow bar height during assembly; refer to Adjusting the Tow Bar Height (page 7–10). Check and adjust the auto hitch slide after assembly; refer to Auto Hitch Slide (page 7–11).
Transmission Cover g240027 Figure 93 GreensPro 1240 1. Transmission cover 3. Alignment pin with rubber washer (2 each) 2. Quick-release screw (2 each) 4.
g273555 Figure 94 GreensPro 1260 1. Transmission cover 3. Spring washer (3 each) 2. Bolt (3 each) 4. Washer (3 each) Removing the Transmission Cover 1. Tilt the steering column to the full forward position. 2. Release the latch and pivot the seat pan forward. 3. On GreensPro 1240 machines, turn the quick-release screws counterclockwise 1/4 turn and remove the transmission cover from the machine (Figure 93). 4.
Installing the Transmission Cover (continued) 3. On GreensPro 1240 machines, lower the transmission cover over alignment pins and rubber washers, align the quick-release screws with the screw retainers (slide retainers forward or backward if necessary), and tighten the quick-release screws (Figure 93) 4. On GreensPro 1260 machines, secure the transmission cover with the 3 bolts, 3 spring washers, and 3 washers (Figure 94).
