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Chapter 3

Troubleshooting

Table of Contents

GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems ............................. 3–2

Starting and Operating Problems (machine serial number above 31500000)......................................... 3–3
General Hydraulic System Problems (GreensPro 1260)........................................................................ 3–5
Traction Circuit Problems (GreensPro 1260) ......................................................................................... 3–6

The information In this chapter is intended to help troubleshoot machine operation issues. Keep in mind
there can be more than one cause for a machine malfunction.

GreensPro

™

1240/1260

Page 3–1

Troubleshooting

14211SL Rev A

Summary of Contents for GreensPro 1240

Page 1: ...orm 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 All Rights Reserved...

Page 2: ...Revision History Revision Date Description 2014 Initial Issue A 11 2018 Incorporated GreensPro 1260 Added revision history Revision History Page 2 GreensPro 1240 1260 14211SL Rev A...

Page 3: ...ectively we encourage user feedback Please comment on the completeness accuracy organization usability and readability of this manual by e mail servicemanuals toro com by mail Technical Publication Ma...

Page 4: ...Reader Comments Page 4 GreensPro 1240 1260 14211SL Rev A...

Page 5: ...ts for a list of the systems and the related topics covered in this manual Refer to the traction unit and accessory Operator s Manuals and Installation Instructions for additional information about in...

Page 6: ...que This icon is used to highlight an assembly torque requirement that is different than what is recommended in the Standard Torque Tables refer to Standard Torque for Dry Zinc Plated and Steel Fasten...

Page 7: ...al Information 4 2 Service and Repairs 4 5 Chapter 5 Hydraulic System 5 1 General Information 5 2 Hydraulic Schematic GreensPro 1260 5 17 Hydraulic Flow Diagrams 5 18 Testing the Hydraulic System 5 20...

Page 8: ...Preface Page 8 GreensPro 1240 1260 14211SL Rev A...

Page 9: ...Chapter 1 Safety Table of Contents Safety Instructions 1 2 Think Safety First 1 3 Safety and Instructional Decals 1 5 GreensPro 1240 1260 Page 1 1 Safety 14211SL Rev A...

Page 10: ...s can result in serious injury CAUTION This safety symbol means caution When you see this symbol carefully read the instructions that follow Failure to obey the instructions can result in minor to mod...

Page 11: ...tential to start Avoid burns Do not touch the engine muffler or other components which may be hot during operation while the unit is running or shortly after it has been running Avoid fires and explos...

Page 12: ...eaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury Seek medical attention right away if hydraulic fluid gets in the skin Use personal...

Page 13: ...metric symbol red square Class C fire extinguishers are for fires that involve electrical equipment such as appliances wiring circuit breakers and outlets Never use water to extinguish class C fires t...

Page 14: ...Safety Safety and Instructional Decals Page 1 6 GreensPro 1240 1260 14211SL Rev A...

Page 15: ...alues When Using a Drive Adapter Wrench 2 5 Identifying the Fastener 2 6 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 2 7 Standard Torque for Dry Zinc Plated and Steel Fasteners...

Page 16: ...l flyweight Low idle speed no load GreensPro 1240 1 250 to 1 600 rpm GreensPro 1260 1 800 rpm High idle speed no load 3 600 rpm Direction of rotation Counterclockwise facing PTO shaft Fuel unleaded ga...

Page 17: ...16 000 kPa 2 320 psi Charge pump displacement 2 1 cc 0 13 cu in per revolution Charge circuit relief pressure 550 kPa 80 psi Hydraulic Motor Parker Hannifin TE Series gerotor motor Motor displacement...

Page 18: ...t hardness of the surface underneath the head of the fastener or similar condition which affects the installation As noted in the following tables the torque values should be reduced by 25 for lubrica...

Page 19: ...orque When using a torque wrench with a drive adapter wrench the calculated torque will be lower than the listed torque recommendation Example The measured effective length of the torque wrench distan...

Page 20: ...ted into the fastener and pre applied dry thread locking compound Keep in mind a fastener with a locking feature usually means there will be friction during initial installation and during removal Tor...

Page 21: ...5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 6 75 8 77 8 104 11 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 11 142 15 1 2 20 UNF 32 4 53 7 72 9 85 9 115 12 120 12 163 16 5 8 11 UNC 65 10 88 12 119 16...

Page 22: ...m M20 X 2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 N m Note Reduce the torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated w...

Page 23: ...t lb 88 14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5 Class 8 8 80 10 ft lb 108 14 N m For steel wheels and non lubricated fasteners Thread Cut...

Page 24: ...fter fastener installation Most thread locking compounds allow the fastener to be removed with standard tools once cured High strength thread locking compounds may require applying heat to the fastene...

Page 25: ...mical residue and previously used gaskets or gasket compounds SILICONE SEALANT Designed for a broad variety of sealing and bonding requirements silicone sealants are usually room temperature vulcanizi...

Page 26: ...omponents for flow and pressure capacities The tester flow measurement maximum is 57 LPM 15 GPM This tester includes the following Inlet Hose This hose connects the system circuit to the inlet side of...

Page 27: ...rcuit regardless of the flow direction If a component failure occurs in the closed loop traction circuit contamination from the damaged part will remain in the circuit until you remove it Install a hi...

Page 28: ...6 ORFS 11 16 16 TOR4079 18 8 ORFS 13 16 16 TOR4079 19 CAP 2 each 10 ORFS 1 14 TOR4079 20 6 ORFS 11 16 16 to 8 SAE ORB 3 4 16 TOR4079 8 8 ORFS 13 16 16 to 8 SAE ORB 3 4 16 TOR4079 9 UNION 1 each 10 OR...

Page 29: ...Apply the terminal protector to the connection after you secure the battery cable ring terminal or fork terminal Dielectric Gel Toro Part No 107 0342 Use the dielectric gel to prevent corrosion of uns...

Page 30: ...Specifications and Maintenance Special Tools Page 2 16 GreensPro 1240 1260 14211SL Rev A...

Page 31: ...tion Confirmation 3 2 Starting and Operating Problems machine serial number above 31500000 3 3 General Hydraulic System Problems GreensPro 1260 3 5 Traction Circuit Problems GreensPro 1260 3 6 The inf...

Page 32: ...rrow 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 R...

Page 33: ...stance The parking brake switch or operator seat switch has been bypassed Remove any circuit bypass and connect the switch to the machine wire harness The brake switch is not functioning Test the swit...

Page 34: ...s Operator weight not sufficient to engage seat switch Install plunder disc above seat switch refer to Seat Switch in Chapter 6 Electrical System Machine stops intermittently during operation The engi...

Page 35: ...ulic fluid level The suction filter or suction line is damaged loose or clogged Secure clean or replace the suction filter or suction line The hydraulic fluid is contaminated or the fluid viscosity is...

Page 36: ...eration refer to Hydraulic Pump Flow and Relief Pressure Test in Chapter 5 Hydraulic System The hydraulic drive motor is worn or damaged Repair or replace the hydraulic drive motor The traction respon...

Page 37: ...essure Test in Chapter 5 Hydraulic System The hydraulic drive motor is worn or damaged Repair or replace the hydraulic drive motor No traction exists in either direction Note If a traction circuit com...

Page 38: ...Troubleshooting Traction Circuit Problems GreensPro 1260 Page 3 8 GreensPro 1240 1260 14211SL Rev A...

Page 39: ...al Information 4 2 Operator s Manual 4 2 Engine Owner s Manual 4 2 Engine Service Manual 4 3 Engine Identification 4 3 Fuel Evaporative Control System 4 4 Service and Repairs 4 5 Engine 4 5 GreensPro...

Page 40: ...uid filters etc take them to an authorized disposal site Waste products must not be allowed to contaminate surface water drains or sewer systems Operator s Manual The Operator s Manual provides inform...

Page 41: ...opy 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 Engine Identification The engine serial numbe...

Page 42: ...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 The maximum fuel level for the fuel tank is to the bottom of...

Page 43: ...ead screw 21 Locknut 4 each 4 Transmission drive collar 13 Lock washer 22 Ground wire 5 Bolt 2 each 14 Flat washer 23 Exhaust guard serial number above 315000000 6 Flat washer 8 each 15 Hardened washe...

Page 44: ...bber 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 Bolt 4 each Removing the Engine R...

Page 45: ...ine wiring connections and engine mounting fasteners Do not disconnect the hydraulic fluid lines from the hydraulic fluid tank 5 On GreensPro 1240 machines remove the fasteners securing the hydraulic...

Page 46: ...the engine and or transmission hydraulic pump on frame so that the coupling is not distorted 4 Secure the engine to the chassis 5 Ensure that the engine rubber drive coupling and transmission hydrauli...

Page 47: ...Return to Neutral Mechanism 5 29 Service and Repairs 5 35 General Precautions for Removing and Installing the Hydraulic System Components 5 35 Checking the Hydraulic Lines and Hoses 5 37 Flushing the...

Page 48: ...tor with the Toro Model and Serial Number of your machine to obtain parts Transmission Hydraulic Pump Service and Repair Manuals Detailed information on troubleshooting testing disassembly and assembl...

Page 49: ...he transmission supplies no drive to the traction roller so that the machine remains stationary When one of the motion control pedals is pressed the motion control linkage moves the transmission contr...

Page 50: ...ount 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 The system engages a brake hu...

Page 51: ...pressed the traction cable moves the hydraulic pump control arm hydraulic fluid flows from the hydraulic pump to the hydraulic motor and so that the hydraulic motor output turns the drive roller Mach...

Page 52: ...king 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...

Page 53: ...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 Lock washer 2 each 21 Hydraulic hose 3 8 BSPP filter to transmission 6 Dowty seal 1 4 14...

Page 54: ...ystem This contamination can damage other components in the system so remove the contamination to prevent additional component failure If a transmission failure occurs disassemble the entire hydraulic...

Page 55: ...ting 3 8 BSPP to 6 ORFS 2 each 10 Filter bracket 17 Motor 4 Hydraulic hose 6 ORFS pump to tank 11 Hydraulic fluid filter element 18 Drain plug 1 4 BSPP 5 Elbow fitting 6 SAE to 6 ORFS 3 each 12 Pump 1...

Page 56: ...lter should be installed before connecting hydraulic test gauges to test traction circuit components or after replacing a failed traction circuit component The filter will ensure that contaminates are...

Page 57: ...s to release the pressure in the system Keep your body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Do not use your hands to search for leaks use a piec...

Page 58: ...ange of torque values refer to the Hose Tube Installation Torque Table page 5 12 IMPORTANT The hydraulic hoses used on the GreensPro 1240 machines have BSPP British Standard Parallel Pipe threads The...

Page 59: ...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 Extend line Note The markings o...

Page 60: ...htly lubricate the O ring with clean hydraulic fluid Ensure that the threads of the fitting are clean with no lubricant applied IMPORTANT Before tightening the fitting determine the material used for...

Page 61: ...rs nicks scratches or unwanted material 2 To help prevent a hydraulic leak replace the O ring when you open the connection 3 Lightly lubricate the O ring with clean hydraulic fluid Ensure that the thr...

Page 62: ...nut with a second wrench C If the port material is steel tighten the fitting to the listed Flats From Finger Tight FFFT value refer to the Flats From Finger Tight FFFT Table page 5 16 D If the port m...

Page 63: ...Hydraulic Schematic GreensPro 1260 g240222 Figure 19 GreensPro 1240 1260 Page 5 17 Hydraulic System Hydraulic Schematic GreensPro 1260 14211SL Rev A...

Page 64: ...Hydraulic Flow Diagrams GreensPro 1260 Traction Circuit g240225 Figure 20 Hydraulic System Hydraulic Flow Diagrams Page 5 18 GreensPro 1240 1260 14211SL Rev A...

Page 65: ...he hydraulic tank A gerotor charge pump in the pump provides a constant supply of charge fluid to the closed loop traction circuit for lubrication and to make up for fluid that is lost due to internal...

Page 66: ...ssure Do not use your hands to search for leaks use a piece of paper or cardboard Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If hy...

Page 67: ...gine rpm at full throttle Hydraulic component output volume relates directly to engine RPM For every 100 engine rpm the following component output volumes will change by the volume listed Traction Pum...

Page 68: ...components in the hydraulic system and affect overall machine performance Special Equipment Required Hydraulic Pressure Test Kit Toro part no TOR47009 Hydraulic Test Fitting Kit Toro part no TOR4079 8...

Page 69: ...he hoses to prevent contamination from entering the system g274728 Figure 22 1 Hydraulic pump 4 Pump B port travel left 2 Charge circuit test port 5 Pressure gauge 0 to 500 psi 3 Pump A port travel ri...

Page 70: ...w and Relief Pressure Test GreensPro 1260 page 5 25 B The hydraulic pump charge relief valve or charge pump is faulty Repair or replace the charge relief valve or charge pump refer to Servicing the Hy...

Page 71: ...hydraulic system and affect overall machine performance Special Equipment Required Hydraulic tester with flow meter with pressure gauge with a minimum 45 lpm 12 gpm capacity Non contact tachometer ph...

Page 72: ...ydraulic hose through the tester and into the disconnected motor A port hydraulic hose 4 Install the hydraulic tester flow and pressure in series with the disconnected hoses 5 Make sure the flow contr...

Page 73: ...0 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 bef...

Page 74: ...e throttle to low engine speed and shut off the engine 13 If either relief pressure can not be met or is greater than specified the specific traction relief valve is damaged and should be cleaned or r...

Page 75: ...raise and support the machine to access the components under the chassis Adjusting Procedure for GreensPro 1240 1 Park the machine on a clean level surface and set the transport wheels to the lowered...

Page 76: ...a serial number above 315000000 have an assistant sit in the operator s seat and disengage the parking brake 7 If the drive roller does not rotate shut off the engine and attach the linkage rod to the...

Page 77: ...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 repeat adjustment if necessary E When the drive roller doe...

Page 78: ...engine and install the transmission cover refer to Installing the Transmission Cover page 7 59 Adjusting Procedure for GreensPro 1260 1 Park the machine on a clean level surface and set the transport...

Page 79: ...rive roller does not rotate shut off the engine and attach the traction cable to the pedal rod pivot 7 If the drive roller rotates note the direction of drive roller rotation then shut off the engine...

Page 80: ...all the traction cable to the pedal rod pivot 8 Start the engine and set the throttle to full engine speed 9 Place a straightedge across the front of both motion control pedals to align the pedals wit...

Page 81: ...moval and ensure that they are aligned properly when installing the hydraulic fittings hoses and tubes 5 The hydraulic fluid may be hot Be careful when you loosen and remove the hydraulic system compo...

Page 82: ...ges or cables for proper adjustment binding or broken parts 8 After you complete the repairs clean any hydraulic fluid from components hose connections and fittings to prevent future accumulation of d...

Page 83: ...at eject high pressure hydraulic fluid Use a piece of cardboard or paper to find hydraulic leaks Release all pressure in the hydraulic system before performing any work on the system Seek immediate me...

Page 84: ...n recycling or disposing the hydraulic fluid and filters 3 Drain the hydraulic fluid from the hydraulic tank Remove the tank cap and clean the tank Consider removing and cleaning the tank if necessary...

Page 85: ...er off the ground 2 Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components page 5 35 3 Install a temporary hydraulic filter dire...

Page 86: ...r to ensure that the green color is showing during operation Note With the engine running at high idle speed and left motion control pedal pressed to the forward direction periodically engage parking...

Page 87: ...pump housing is at least half full of clean hydraulic fluid after installation 1 Make sure all hydraulic connections and lines are secured tightly 2 Check the hydraulic fluid level in the hydraulic t...

Page 88: ...le speed Note The transmission hydraulic pump must pick up the hydraulic fluid and fill the hydraulic system If there is no indication of fill in 30 seconds shut off the engine and determine the cause...

Page 89: ...RTANT The hydraulic tank fittings used on the GreensPro 1240 have BSPP British Standard Parallel Pipe threads for the hose connections and BSPP threads for the tank connection The hydraulic tank fitti...

Page 90: ...lat washer 4 each Removing the Transmission Refer to Figure 32 for this procedure 1 Park the machine on a clean level surfaces shut off the engine and engage the parking brake if equipped or remove th...

Page 91: ...n 9 On machines with serial number above 315000000 disconnect the wire harness connector from the neutral switch 10 Remove the hex nut and lock washer that secure the damper item 3 in Figure 32 to the...

Page 92: ...sion and remove the bolts flat washers and locknuts that secure the transmission to the chassis 17 Slide the transmission away from the transmission mount until the sprocket and drive chain are free o...

Page 93: ...4 on the idler adjustment rod Thread the nut 32 mm 1 25 inches onto the rod 8 Install the idler arm assembly with the bolt flat washers pivot bushing spacer and locknut Do not adjust the idler adjustm...

Page 94: ...lubricant or an equivalent chain specific lubricant is recommended 16 Fill the hydraulic tank with the correct quantity of new hydraulic fluid refer to the Operator s Manual 17 Install the transmissi...

Page 95: ...Servicing the Transmission GreensPro 1240 g241037 Figure 36 GreensPro 1240 1260 Page 5 49 Hydraulic System Service and Repairs 14211SL Rev A...

Page 96: ...each 49 O ring 12 Compression spring 31 Helical spring 50 Retaining ring 2 each 13 Cylinder block kit 32 Ball 51 Lip seal 14 Cylinder block assembly 33 Bolt 9 each 52 Return arm 15 Output shaft 34 Plu...

Page 97: ...itable lifting device to safely raise and support the machine to access the components under the chassis 1 Park the machine on a clean shut off the engine and engage the parking brake 2 Remove the tra...

Page 98: ...n loosen the traction cable jam nuts and remove the traction cable from the frame bracket Figure 38 g271901 Figure 38 GreensPro 1260 1 Traction cable 3 Jam nut 2 each 2 Pedal rod pivot assembly 10 Loo...

Page 99: ...ulic pump refer to Installing the Hydraulic Hoses and Tubes page 5 12 7 Secure the neutral switch item 17 in Figure 37 to the control arm with the 2 slotted head screws and tapped plate 8 Connect the...

Page 100: ...t kit 27 Flange head bolt 4 each 8 Spring 18 Trunnion seal retainer kit 28 Charge pump kit 9 Flat washer 19 Control arm kit 10 Thrust bearing 20 Hydraulic pump housing IMPORTANT If a hydraulic pump fa...

Page 101: ...rew 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 Motor guard 8 Spacer 2 each 16 Hydraulic motor The hydraulic motor and drive roll...

Page 102: ...plugs on the hydraulic hoses and fittings to prevent system contamination 7 Remove the parking brake refer to Removing the Parking Brake page 7 30 CAUTION The weight of the hydraulic motor and drive r...

Page 103: ...Position the hydraulic motor and drive roller assembly in the chassis Ensure that the sleeves are installed in each bearing housing mounting hole and secure the bearing assembly and hydraulic motor to...

Page 104: ...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 Drive screw 2 each IMPORTANT If a hydraulic motor fails refer to Hydraulic Syste...

Page 105: ...60 Wire Harness Diagram Main 6 9 GreensPro 1240 Wire Harness AC Hour Meter Standard 6 10 GreensPro 1240 Wire Harness AC Lights Kit Optional 6 11 GreensPro Wire Harness Wireless Hour Meter Kit Optional...

Page 106: ...ponents can be found in the Honda Engine Service Manual Contact your local Honda Engine Dealer or visit http engines honda com for assistance Service information for the remainder of the electrical sy...

Page 107: ...s 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...

Page 108: ...Electrical Schematic GreensPro 1240 s n 315000000 up g238132 Electrical System Electrical Schematics and Wire Harness Drawings Diagrams Page 6 4 GreensPro 1240 1260 14211SL Rev A...

Page 109: ...Electrical Schematic GreensPro 1260 g238394 GreensPro 1240 1260 Page 6 5 Electrical System Electrical Schematics and Wire Harness Drawings Diagrams 14211SL Rev A...

Page 110: ...GreensPro 1240 s n 315000000 up Wire Harness Drawing Main g238134 Electrical System Electrical Schematics and Wire Harness Drawings Diagrams Page 6 6 GreensPro 1240 1260 14211SL Rev A...

Page 111: ...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...

Page 112: ...GreensPro 1260 Wire Harness Drawing Main g238395 Electrical System Electrical Schematics and Wire Harness Drawings Diagrams Page 6 8 GreensPro 1240 1260 14211SL Rev A...

Page 113: ...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...

Page 114: ...GreensPro 1240 Wire Harness AC Hour Meter Standard g272829 Electrical System Electrical Schematics and Wire Harness Drawings Diagrams Page 6 10 GreensPro 1240 1260 14211SL Rev A...

Page 115: ...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...

Page 116: ...GreensPro Wire Harness Wireless Hour Meter Kit Optional g272831 Electrical System Electrical Schematics and Wire Harness Drawings Diagrams Page 6 12 GreensPro 1240 1260 14211SL Rev A...

Page 117: ...ied disengage the parking brake The engine should stop in approximately 1 second 2 Test the seat switch input A Engage the parking brake and start the engine B Sit in the operator seat and disengage t...

Page 118: ...stance The following are testing procedures for the remainder of the electrical system components used on GreensPro machines The components include the hour meter worklight switch and on machines abov...

Page 119: ...hod to test the module directly The control module may be damaged if an attempt is made to test it with an electrical test device such as a digital multimeter Testing the Interlock Module 1 Park the m...

Page 120: ...s Drawings Diagrams page 6 3 and the Honda Engine Service Manual 6 Check the engine lighting coil output refer to the Honda Engine Service Manual 7 If the lighting coil output all interlock switches a...

Page 121: ...chine operation at all time The hour meter is powered by the engine lighting coil and records whenever the engine is running An hourglass icon flashes on the display when the hour meter is recording g...

Page 122: ...eplace the hour meter 7 If voltage is not present at the wire harness terminals check the wire harness terminals for corrosion and check the wire harness for circuit continuity refer to the Electrical...

Page 123: ...ion and clean the connector if necessary 4 Use a multimeter ohms setting and the following table to determine whether continuity exists between the various terminals for each switch position POSITION...

Page 124: ...seat switch on all GreensPro machines if necessary Testing the Seat Switch 1 Park the machine on a level surface engage the parking brake and shut off the engine 2 Disconnect the wire harness connect...

Page 125: ...anism page 5 29 Testing the Neutral Switch 1 Park the machine on a level surface engage the parking brake and shut off the engine 2 Disconnect the wire harness connector from the neutral switch 3 Chec...

Page 126: ...e machine on a level surface engage the parking brake and shut off the engine 2 Disconnect the wire harness connector from the parking brake switch 3 Check the wire harness connector for corrosion and...

Page 127: ...Roller GreensPro 1240 7 19 Servicing the Drive Roller GreensPro 1240 7 24 Drive Roller GreensPro 1260 7 26 Servicing the Drive Roller GreensPro 1260 7 28 Parking Brake machine serial number above 315...

Page 128: ...ring head 6 Steering pivot rod 2 Front steering head 7 Steering pivot 3 Rear steering head linkage arm 8 Steering column assembly 4 Steering disc assembly 9 Steering wheel 5 Front steering head linkag...

Page 129: ...onnected to the steering pivot 2 steering pivot rods and front and rear steering head assemblies Figure 51 With the exception of the steering wheel and steering column the steering system components a...

Page 130: ...raising and lowering the transport frame When moving the transport frame into the lowered transport position a gas spring and lift pedal are provided to help raise the chassis off the ground The assem...

Page 131: ...is frame 3 Steering pivot assembly 2 Block 2 For GreensPro 1240 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 thread...

Page 132: ...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 Place a straightedge across the steering rollers to ensure that...

Page 133: ...er is aligned with the chassis frame Do not tighten the steering pivot rod hex nuts at this time g274017 Figure 56 GreensPro 1260 1 Block 3 Steering rod short 2 Steering pivot assembly 4 Steering rod...

Page 134: ...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 c...

Page 135: ...ly 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 loo...

Page 136: ...f the engine 2 Loosen but do not remove the front locknut 12 mm that secures the tow bar to the transport frame 3 Support the hitch end of the tow bar and remove the rear fasteners 10 mm that secure t...

Page 137: ...the adjustable yoke Figure 60 g239303 Figure 60 1 Lever 4 Locknut 2 Hex nut 5 Bolt 3 Adjustable yoke 6 Lever rod 2 Loosen the hex nut against the adjustable yoke and turn the yoke as necessary to incr...

Page 138: ...ntact the roll pin stop before the lever contacts the tow bar Adjust as necessary g239305 Figure 62 1 Tow bar 3 Auto hitch slide 2 Roll pin stop 4 Lever released 4 Tighten the hex nut against adjustab...

Page 139: ...achine refer to Removing the Transmission Cover page 7 59 3 Remove the hex nut item 1 in Figure 63 spacer and compression spring from the idler adjustment rod g241025 Figure 63 1 Hex nut 6 Flat washer...

Page 140: ...nut flat washer and locknut Tighten the bolt to the idler arm with the hex nut and adjust the locknut so that the idler adjustment rod is free to pivot on the bolt 3 Install the flat washer and hex n...

Page 141: ...llar 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 ha...

Page 142: ...ment 1 ball joint and hex nut has left hand threads and 1 ball joint and hex nut has right hand threads Before attempting to loosen the hex nuts for linkage disassembly or adjustment inspect the threa...

Page 143: ...lange 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 Split bushing 4 ea...

Page 144: ...to safely raise and support the machine to get access to the components under the chassis Both of the linkage rod ends have right hand threads One of the linkage rod ends must be disconnected from th...

Page 145: ...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 Taper lock bushing...

Page 146: ...Hex nut 6 Flat washer 2 each 2 Spacer 7 Locknut 3 Compression spring 8 Pivot bushing 4 Idler adjustment rod 9 Spacer 5 Bolt 10 Idler arm assembly 3 Remove the bolt flat washers locknut pivot bushing a...

Page 147: ...ers and locknuts that secure the bearings to the chassis and remove the drive roller assembly 8 Retrieve the sleeves from the bearing mounting holes if equipped Installing the Drive Roller GreensPro 1...

Page 148: ...k bushing slot to spread the taper lock bushing slightly if necessary and slide the bushing onto the roller shaft and key with the small end of the outer taper toward the roller Rotate the drive rolle...

Page 149: ...ive chain alignment B Machines with a parking brake loosen and adjust the sprocket and taper lock bushing location on roller shaft 14 Install the idler arm assembly item 10 in Figure 68 with the lockn...

Page 150: ...crew 5 Lock washer 6 each 13 Flat washer 8 each 21 Lock washer 6 Flat washer 6 each 14 Spacer 4 each 22 Flat washer 7 Bearing collar 2 each 15 Locknut 4 each 23 Hardened washer 8 Set screw 2 each 16 S...

Page 151: ...lock washers and flat washers Note It may be necessary to re position the bearings and bearing collars during the drive roller installation 2 Position the bearing collars on the roller shafts in locat...

Page 152: ...Plain washer 6 each 16 Wheel motor nut 25 Motor guard 8 Spacer 2 each 17 Woodruff key 9 Bearing housing 18 Hydraulic motor The hydraulic motor and drive roller should be removed from machine as an as...

Page 153: ...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 I...

Page 154: ...Drive Roller GreensPro 1260 Refer to Figure 73 for this procedure 1 Record the distance from the end of the drive roller to the bearing before removal 2 Loosen the set screw and remove the bearing ass...

Page 155: ...r 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 GreensPro 1240 1260 Page 7 29 Chassis Service...

Page 156: ...e 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 9 Drive roller...

Page 157: ...locknut and sleeve that secure the brake cable to the brake pivot arm and disconnect the brake cable from the brake pivot arm C Remove the brake pivot arm from the machine 8 Repair or replace the park...

Page 158: ...ke 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 Pass the brak...

Page 159: ...eel by carefully prying up on one of the cover spokes 3 Remove the locknut and flat washer that secure the steering wheel to the steering column 4 Remove the steering wheel from the steering column Us...

Page 160: ...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 Chassis Service and...

Page 161: ...ing the Steering Column Refer to Figure 77 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 t...

Page 162: ...e the 4 bolts 4 flat washers and 4 flange nuts that secure the steering column to the chassis and remove the steering column Installing the Steering Column Refer to Figure 77 for this procedure 1 Plac...

Page 163: ...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...

Page 164: ...t 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...

Page 165: ...cure and move freely in both directions Repair or replace the steering linkage assembly components as necessary Figure 79 or Figure 80 CAUTION Use a suitable lifting device to safely raise and support...

Page 166: ...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 a...

Page 167: ...mponents under the chassis 1 Turn the steering wheel to the left or right if necessary to access the steering roller bolts 2 Remove the 2 bolts 2 lock washers and 2 flat washers and lower the steering...

Page 168: ...ean all the components before assembly 3 If a bearing or bearing housing is removed ensure that it is pressed into position fully during installation 4 Thread the roller shafts into the roller sleeve...

Page 169: ...ly 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 Lockn...

Page 170: ...ly 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 St...

Page 171: ...plate and remove the steering head assembly Installing the Steering Head Refer to Figure 84 or Figure 85 for this procedure CAUTION Use a suitable lifting device to safely raise and support the machi...

Page 172: ...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 1...

Page 173: ...sembling the Steering Head Refer to Figure 86 for this procedure 1 Install the pivot shaft if previously removed 2 Apply a thin coat of anti seize lubricant to the pivot shaft and install the spacer o...

Page 174: ...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 thi...

Page 175: ...ng 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 Secure the ball joint to the roller suppo...

Page 176: ...secure the hub assembly to the spindle and remove the hub from the spindle 4 Inspect the bearings in the hub assembly and replace as necessary Installing the Wheel and Hub Refer to Figure 88 for this...

Page 177: ...Installing the Wheel and Hub continued 5 Adjust the tire pressure to 103 kPa 15 psi before returning the machine to service GreensPro 1240 1260 Page 7 51 Chassis Service and Repairs 14211SL Rev A...

Page 178: ...mp 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 Torsion spring 9 Lock washer 6 each 23 Bolt 2 each 37 Pedal 10 Bo...

Page 179: ...quipped 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 Disconnect the main wire harness at the...

Page 180: ...s 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 The gas spring is under heavy load and may cause personal...

Page 181: ...ch and install the gas spring item 3 to the transport frame 4 Install the damper item 2 to the transport frame 5 Secure the latch lever to the transport frame with the fasteners previously removed 6 I...

Page 182: ...19 Locknut 30 Compression spring 9 Adjustable yoke 20 Washer 31 Slide rod 10 Hex nut 21 Tow pin 11 Lever rod 22 Rubber pad 2 each The tow bar must be securely attached to the transport frame and the...

Page 183: ...w 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 GreensPro 1240 1260 Page 7 57 Chas...

Page 184: ...240027 Figure 93 GreensPro 1240 1 Transmission cover 3 Alignment pin with rubber washer 2 each 2 Quick release screw 2 each 4 Screw retainer 2 each Chassis Service and Repairs Page 7 58 GreensPro 1240...

Page 185: ...screws counterclockwise 1 4 turn and remove the transmission cover from the machine Figure 93 4 On GreensPro 1260 machines remove the 3 bolts 3 spring washers and 3 washers that secure the transmissi...

Page 186: ...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 transmis...

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