Toro Greensmaster 3120 (Model 04355) Service Repair Manual

Manuals: Service Repair Manual

Table of Content – Greensmaster 3120 (Model 04355)

Title Page
Revision History
Reader Comments
Preface
Overall Dimensions
Service Procedure Icons

Chapter 1 : Safety

Safety Instructions
Supervisor’s Responsibilities
Before Operating the Machine
While Operating the Machine
Maintenance and Service
Jacking Instructions
Raising the Machine
Safety and Instructional Decals

Chapter 2 : Specifications and Maintenance

Specifications
Decimal and Millimeter Equivalents
U.S. to Metric Conversions
Torque Specifications
Calculating the Torque Values When Using a Drive-Adapter Wrench
Identifying the Fastener
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch)
Other Torque Specifications
Conversion Factors
Shop Supplies
Special Tools

Chapter 3 : Engine

1 Specifications
Engine
General Information
Traction Unit Operator’s Manual
Briggs & Stratton Repair Manual
Service and Repairs
Fuel Tank
Engine
Evaporative Control System
Disassembly
Assembly
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Chapter 4 : Hydraulic System

1 Specifications
Hydraulic System
General Information
Traction Unit Operator’s Manual
Relieving Pressure from the Hydraulic System
Towing the Traction Unit
Traction Circuit (Closed Loop) Component Failure
Hydraulic Hoses
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal)
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings)
Hydraulic Schematics
Hydraulic Flow Diagrams
Traction Circuit
Lift Circuit
Mow Circuit
Steering Circuit
Special Tools
Hydraulic Pressure Testing Kit
Hydraulic Tester Kit
Hydraulic Test Fitting Kit
O-Ring Kit
Hydraulic Hose Kit
Measuring Container
High Flow Hydraulic Filter Kit
Troubleshooting
General Hydraulic System Problems
Traction Circuit Problems
Mow Circuit Problems
Lift, Lower Circuit Problems
Steering Circuit Problems
Testing the Hydraulic System
Hydraulic Test Selection
Traction Circuit Testing – Charge Pressure Test
Traction Circuit Testing – Wheel Motor Efficiency Test
Traction Circuit Testing – Traction Pump (P1) Flow and Relief Pressure Test
Cutting Unit Circuit Testing – Cutting Unit Motor Efficiency, Case Drain Test
Cutting Unit Circuit Testing – Relief Valve Test
Cutting Unit Circuit Testing – Gear Pump (P2) Flow Test
Steering, Lift Circuit Testing – Gear Pump (P3) Flow and Circuit Relief Valve Test
Steering, Lift Circuit Testing – Lowering Cutting Units Relief Valve Test
Steering, Lift Circuit Testing – Steering Control Valve and Steering Cylinder Test
Adjustments
Adjusting Relief Valves
Service and Repairs
General Precautions for Removing and Installing the Hydraulic System Components
Checking the Hydraulic Lines and Hoses
Flushing the Hydraulic System
Filtering the Closed-Loop Traction Circuit
Priming the Hydraulic Pumps
Charging the Hydraulic System
Gear Pump
Servicing the Gear Pump
Traction Pump
Servicing the Traction Pump
Wheel Motors
Servicing the Wheel Motor
Mower Manifold
Servicing the Mower Manifold
Reel Motors
Servicing the Reel Motor
Front Lift Cylinders
Servicing the Front Lift Cylinders
Rear Lift Cylinder
Servicing the Rear Lift Cylinder
Steering Control Valve
Servicing the Steering Control Valve
Steering Cylinder
Servicing the Steering Cylinder
Hydraulic Tank
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Chapter 5 : Electrical System

General Information
Electrical Schematics and Diagrams
Special Tools
Multimeter
Battery Terminal Protector
Battery Hydrometer
Dielectric Gel
Troubleshooting
Electrical System Quick Checks
Testing the Battery (Open Circuit Test)
Testing the Charging System
Checking the Interlock System Operation
Testing the Electrical Components
Fusible Links
Fuses
Key Switch
Starter Solenoid
Hour Meter
Seat Switch
Neutral and Mow Switches
Parking Brake Switch
Cutting Unit Raise and Lower Joystick Switches
Backlap Switch (machines with backlap)
Relays
Delay Timer (Lower Cutting Units)
Hydraulic Solenoid Valve Coils
Diodes
Service and Repairs
Caring for the Battery
Storing the Battery
Servicing the Battery

Chapter 6 : Chassis

1 Specifications
Chassis
General Information
Service and Repairs
Front Wheels and Brakes
Rear Wheel
Caster Fork
Cutting Unit Pull Frame Rollers, Pivot Hinges and Lift Arms

Chapter 7 : DPA Cutting Units

1 Specifications
DPA Cutting Units
General Information
Cutting Unit Operator’s Manual
Supporting the Cutting Unit when Servicing
Aftercut Appearance
Adjustments
DPA Cutting Unit Characteristics
Leveling the Rear Roller
Service and Repairs
Bedbar Assembly
Bedknife
Reel Assembly
Roller Assemblies
Rear Roller Brushes (Optional)

Chapter 8 : Belt Driven Groomer (Optional)

1 Specifications
Belt Driven Groomer (Optional)
General Information
Installation Instructions
Grooming Performance
Troubleshooting
Service and Repairs
Replacing the Groomer Drive Belt
The Groomer Plate Assemblies
The Groomer Reel
The Groomer Arm Assemblies
The Grooming Brushes (Optional)

Chapter 9 : Universal Groomer (Optional)

1 Specifications
Universal Groomer
General Information
Installation Instructions
Grooming Performance
Troubleshooting
Service and Repairs
The Gear Box Assembly
The Idler Assembly
The Groomer Reel
The Height Adjuster Assembly
The Grooming Brush (Optional)
Appendix A: Foldout Drawings
Electrical Drawing Designations
Hydraulic Schematic (machines without backlap)
Hydraulic Schematic (machines with backlap)
Electrical Schematic (serial numbers below 403410000)
Electrical Schematic (serial numbers above 403410000)
Wire Harness Drawing – Main (serial numbers below 403410000)
Wire Harness Diagram – Main (serial numbers below 403410000)
Wire Harness Drawing – Main (serial numbers above 403410000)
Wire Harness Diagram – Main (serial numbers above 403410000)
Wire Harness – Seat
Wire Harness – Engine