Greensmaster® 3120 2-Wheel Drive Traction Unit

Perform the following system checks daily to ensure that the interlock system is operating correctly:

1. Sit on the seat, move the traction pedal to the NEUTRAL position, move the functional-control lever to the NEUTRAL position, and engage the parking brake.

2. Try to move the traction pedal forward or backward.

   The pedal should not move, which indicates that the interlock system is operating correctly. Correct the problem if it is not operating properly.

1. Sit on the seat, move the traction pedal to the NEUTRAL position, move the functional-control lever to the NEUTRAL position, and engage the parking brake.

2. Move the functional-control lever to the MOW position or the TRANSPORT position and try to start the engine.

   The engine should not turnover or start, which indicates that the interlock system is operating correctly. Correct the problem if it is not operating properly.

3. Sit on the seat, move the traction pedal to the NEUTRAL position, move the functional-control lever to the NEUTRAL position, and engage the parking brake.

4. Start the engine and move the functional-control lever to the MOW position or the TRANSPORT position.

   The engine should shut off, which indicates that the interlock system is operating correctly.

   Correct the problem if it is not operating properly.

1. Sit on the seat, move the traction pedal to the NEUTRAL position, move the functional control lever to the NEUTRAL position, and engage the parking brake.

2. Start the engine.

3. Release the parking brake, move the functional control lever to the MOW position, and rise from the seat.

   The engine should shut off, which indicates that the interlock system is operating correctly. Correct the problem if it is not operating properly.

1. Sit on the seat, move the traction pedal to the NEUTRAL position, move the functional control lever to the NEUTRAL position, and engage the parking brake.

2. Start the engine.

3. Move the raise/lower mow control forward to lower the cutting units. The cutting units should lower but not start rotating.

   If they start rotating, the interlock system is not operating correctly; correct the problem before operating the machine.

1. Approach the green with the functional-control lever in the MOW position and the throttle at full speed.

2. Start on 1 edge of the green so that you can use the ribbon procedure of cutting.

   Note: This holds compaction to a minimum and leaves a neat, attractive pattern on the greens.

3. Push forward the raise/lower mow lever as the front edges of the grass baskets cross the outer edge of the green.

   Note: This procedure drops the cutting units to the turf and starts the reels.

   Important: There is a delay raising and lowering the center cutting unit; therefore, you should practice—gaining the required timing necessary to minimize the cleanup mowing operation.

   Note: The delay raising and lowering the center cutting unit depends on hydraulic fluid temperature. Cold hydraulic fluid results in a longer delay. As the temperature increases the delay time becomes shorter.

4. Overlap a minimal amount with the previous cut on return passes.

   Note: To assist in maintaining a straight line across the green and keep the machine an equal distance from the edge of the previous cut, establish an imaginary sight line approximately 1.8 to 3 m (6 to 10 ft) ahead of the machine to the edge of the uncut portion of the green (Figure 24). Some find it useful to include the outer edge of the steering wheel as part of the sight line; i.e., keep the steering wheel edge aligned with a point that is always kept the same distance away from the front of the machine.

5. As the front edges of the baskets cross the edge of the green, pull back the raise/lower mow lever rearward and hold it until all the cutting units have risen. This stops the reels and lifts the cutting units.

   Note: It is important to time this step correctly so that you do not cut into the fringe area yet cut as much of the green as possible to minimize the amount of grass left to mow around the outer periphery.

6. To cut down on operating time and ease lineup for the next pass, momentarily turn the machine in the opposite direction, then turn it in the direction of the uncut portion; a tear-shaped turn (Figure 23) to quickly line up for your next pass.

   

   Figure 23

   Note: Try to make as short of a turn as possible except during warmer weather when a wider arc minimizes the turf bruising.

   

   Figure 24

   1. Alignment strip
   2. Approximately 12.7 cm (5 inches)
   3. Cut grass on the left
   4. Keep a focal spot 2 to 3 m (6 to 10 ft) ahead of the machine.

   Note: The steering wheel does not return to its original position after you complete a turn.

   Important: Never stop the machine on a green with the cutting unit reels operating as damage to the turf may result. Stopping the machine on a wet green may leave marks or indentations from the wheels.

1. Finish cutting the green by mowing the outer periphery. Change the direction of cutting from the previous mowing.

   Note: Always keep weather and turf conditions in mind and be sure to change the direction of mowing from the previous cutting.

2. When finished mowing the outer periphery, tap the raise/lower mow lever rearward to stop the reels, then drive off the green. When all the cutting units are off the green, raise the cutting units.

   Note: This minimizes grass clumps left on the green.

3. Replace the flag.

4. Empty the grass baskets of all clippings before transporting to the next green.

   Note: Heavy wet clippings place an undue strain on the baskets and add unnecessary weight to the machine, thereby increasing the load on the engine, hydraulic system, brakes, etc.

Note: If you remove the seat assembly frequently, you can replace the roll pin with an R-key pin (Part No. 3290-467).

Remove the seat assembly to access the valve block area of the machine.

1. Unlatch and raise the seat, securing it with the prop rod.

2. Disconnect the 2 wire-harness connectors under the seat.

3. Lower the seat and remove the roll pin securing the seat-pivot rod to the frame (Figure 26).

   

   Figure 26

   1. Roll pin
   2. Seat-pivot rod

4. Slide the seat-pivot rod to the left.

5. Move the seat forward and lift it out of the machine.

6. Reverse the procedure to install the seat.

Before raising the machine, lower the cutting units. The jacking points are as follows:

• Right side—under the jack pad and adjacent to the ROPS-support bracket (Figure 27)

• Left side—under the step

• Rear—at the caster fork

Figure 27

1. Jack pad

Lubricate the grease fittings regularly with No. 2 lithium grease.

Locate the grease fitting as follows:

• Rear-roller-hub assembly or, if equipped with a 3-wheel-drive kit, rear-wheel-roller clutches and external ball bearing (1) (Figure 28)

  

  Figure 28

• Steering-fork shaft (1) (Figure 29)

• Steering-cylinder-rod end (Figure 29)

  

  Figure 29

• Lift-arm pivot (3) and pivot hinge (3) (Figure 30)

  

  Figure 30

• Pull-frame shaft and roller (12) (Figure 31)

  

  Figure 31

• Steering-cylinder end (Figure 32)

  

  Figure 32

• Lift cylinders (3) (Figure 33)

  

  Figure 33

• Traction pedal (Figure 34)

  

  Figure 34

1. Wipe the grease fitting clean.

2. Pump grease into the bearing or bushing until the grease is visible. Clean off excess grease.

3. When you remove the cutting unit(s) for maintenance, apply grease to the spline shaft of the reel motor and to the lift arm.

Apply a few drops of SAE 30 engine oil or spray water displacing lubricant to all pivot points daily after cleaning.

• Shut off the engine before checking the oil or adding oil to the crankcase.

• Do not change the governor speed or overspeed the engine.

1. Clean the air-cleaner cover (Figure 35).

   

   Figure 35

   1. Air-cleaner cover

2. Release the locking clips and remove the air-cleaner cover.

3. Remove the wing nut securing the elements to the air-cleaner body (Figure 36).

4. If the foam element is dirty, remove it from the paper element (Figure 36). Clean it thoroughly, as follows:

   1. Wash the foam element in a solution of liquid soap and warm water. Squeeze it to remove dirt.

   2. Dry it by wrapping it in a clean rag. Squeeze the rag and foam element dry.

      Important: When drying the foam element, do not twist it; the foam may tear.

      

      Figure 36

      1. Foam element
      2. Paper element

5. Check the condition of the paper element. Clean it by gently tapping it on a flat surface or replace it if needed.

6. Install the foam element, paper element, wing nut, and air-cleaner cover.

   Important: Do not operate the engine without the air-cleaner element because extreme engine wear and damage will likely result.

The engine is shipped with oil in the crankcase; however, you must check the oil level before and after starting the engine the first time.

Spark plug specification: Champion RC 14YC

Air gap specification: 0.76 mm (0.030 inch)

1. Clean the area around the spark plugs so that foreign matter cannot fall into the cylinder.

2. Pull the wires off the spark plugs and remove the plugs.

3. Check the condition of the side electrode, center electrode, and center electrode insulator to ensure that there is no damage.

   Important: Replace a cracked, fouled, dirty, or otherwise malfunctioning spark plug. Do not sand blast, scrape, or clean electrodes by using a wire brush because grit may eventually release from the plug, fall into the cylinder, and damage the engine.

4. Set the air gap between the center and side of the electrodes at 0.76 mm (0.030 inch) as shown in Figure 39.

   

   Figure 39

5. Install the spark plug and gasket seal, and torque the plug to 23 N∙m (200 in-lb).

The in-line fuel filter is in the fuel line between the fuel tank and carburetor (Figure 40).

1. Close the fuel-shutoff valve (Figure 40).

   

   Figure 40

   1. Fuel-shutoff valve
   2. Fuel filter

2. Place a drain pan under the filter, loosen the hose clamp on the carburetor side of filter, and remove the fuel line from the filter (Figure 40).

3. Loosen the other hose clamp and remove the filter (Figure 40).

4. Install the new filter with the arrow on the filter body pointing away from the fuel tank.

Inspect the fuel lines for deterioration, damage, or loose connections.

Properly maintain the battery electrolyte and keep the top of the battery clean. Store the machine in a cool place to prevent the battery from running down.

The battery cables must be tight on the terminals to provide good electrical contact.

1. Check the electrolyte level in the in the cells of the battery.

2. If needed, add distilled or demineralized water into the cell of the battery.

   Note: Only to raise the electrolyte level to the bottom of the split ring inside each cell.

3. Clean the top of the battery by washing it periodically with a brush dipped in ammonia or bicarbonate of soda solution.

4. Flush the top surface of the battery with water after cleaning it.

   Important: Do not remove the fill caps while cleaning the battery.

If corrosion occurs at the terminals, disconnect the cables, negative (-) cable first, and scrape the clamps and terminals separately. Connect the cables, positive (+) cable first, and coat the terminals with petroleum jelly.

Properly maintain the battery electrolyte and keep the top of the battery clean. Store the machine in a cool place to prevent the battery from running down.

The battery cables must be tight on the terminals to provide good electrical contact.

1. Check the electrolyte level in the in the cells of the battery.

2. If needed, add distilled or demineralized water into the cell of the battery.

   Note: Only to raise the electrolyte level to the bottom of the split ring inside each cell.

3. Clean the top of the battery by washing it periodically with a brush dipped in ammonia or bicarbonate of soda solution.

4. Flush the top surface of the battery with water after cleaning it.

   Important: Do not remove the fill caps while cleaning the battery.

5. Ensure that the battery cables are tight on the terminals to provide good electrical contact.

If corrosion occurs at the terminals, disconnect the cables, negative (-) cable first, and scrape the clamps and terminals separately. Connect the cables, positive (+) cable first, and coat the terminals with petroleum jelly.

The fuses in the electrical system of the machine are located under the seat (Figure 41).

Figure 41

1. Fuses

Vary the tire pressure for the front wheels, depending upon your turf conditions, from a minimum of 55 kPa (8 psi) to a maximum of 83 kPa (2 psi).

Vary the tire pressure for the rear wheel from a minimum of 55 kPa (8 psi) to a maximum of 103 kPa (15 psi).

Wheel nut torque specification: 95 to 122 N∙m (70 to 90 ft-lb)

Note: To ensure even distribution, torque the wheel nuts in a X pattern.

If the machine creeps when the traction control pedal is in the NEUTRAL position, adjust the neutral-return mechanism.

1. Ensure that the bypass valve is closed.

2. Lift the machine and support it at the frame with jack stands so that the front wheels are off the floor.

3. At the traction-hydraulic pump (inboard) remove the control linkage from the control arm (Figure 42).

   

   Figure 42

   1. Adjustment screw
   2. Control arm

4. Start the engine and move the throttle to the FAST position.

5. If the axle does not rotate, shut off the engine and attach the control linkage.

6. If the axle rotates, proceed as follows:

   1. Note the direction that the axle rotates and shut off the engine.

   2. Loosen the adjustment screw until you can rotate the control arm.

   3. Rotate the control arm until the motor shaft does not rotate.

   4. Tighten the adjustment screw.

   5. Repeat steps 3 and 4 and ensure that the axle does not rotate.

Factory setting: 6.1 km/h (3.8 mph)

1. Loosen the jam nut on the trunnion bolt on the side of the traction pedal (Figure 44).

   

   Figure 44

   1. Trunnion bolt
   2. Jam nut

2. Rotate the trunnion bolt counterclockwise to increase the mowing speed and clockwise to decrease it.

3. Tighten the jam nut without turning the trunnion bolt and check the ground speed. Repeat this procedure, if required.

A brake adjustment rod is located at each side of the machine so that you can adjust the brakes equally.

1. While moving forward in transport speed, press the brake pedal; both wheels should apply equally.

   Caution

   Testing the brakes in a confined area where others are present could cause injury.

   Always check the brakes in a wide, open-spaced, flat area free from people and obstructions before and after the adjustment.

2. If the brakes do not apply equally, adjust the brakes as follows:

   1. Disconnect the brake rods by removing the cotter pin and clevis pin (Figure 45).

      

      Figure 45

      1. Clevis pin and cotter pin
      2. Jam nut
      3. Clevis
      4. Brake shaft

   2. Loosen the jam nut and adjust the clevis accordingly (Figure 45).

   3. Assemble the clevis to the brake shaft (Figure 45).

   4. When you press the brake pedal, the pedal should move 13 to 26 mm (1/2 to 1 inch) travel before the brake shoes contacts the brake drums. Adjust the clevis on the brake shaft, if necessary, to achieve this setting.

   5. While moving forward in transport speed, press the brake pedal; both brakes should apply equally. Adjust them, if necessary.

Important: Burnish the brakes annually; refer to the Burnishing the Brakes section.

The cutting unit lift/drop circuit comes with a flow-control valve (Figure 46). This valve is preset at the factory at approximately 3 turns open, but you may need to adjust it to compensate for differences in hydraulic fluid temperatures, mowing speeds, etc.

Note: Allow the hydraulic fluid to reach full operating temperature before adjusting the flow-control valve.

1. Locate the flow-control valve below the seat (Figure 46).

   

   Figure 46

   1. Flow-control valve

2. Loosen the jam nut at the adjusting knob on the flow control valve.

3. Adjust the flow control valve as follows:

   • Rotate the knob counterclockwise if the center cutting unit is dropping too late or

   • Rotate the knob clockwise if the center cutting unit is dropping too early.

   Note: You should not need to rotate it more than 1/32 to 1/16 of a turn.

4. Test the adjustment and repeat step 3 as needed; when finished, tighten the jam nut.

To regulate the height of the front-cutting units when in the raised (transport) position, you can adjust the front-lift cylinders.

1. Lower the cutting units to the ground.

2. Remove the bolts that secure the cover plate of the lift cylinder that you are adjusting from the support brackets of the chassis (Figure 51).

   

   Figure 47

   1. Bolt
   2. Right cover plate
   3. Left cover plate

3. Loosen the jam nut securing the clevis fitting to the cylinder of the cutting-unit that needs to be adjusted (Figure 48).

   

   Figure 48

   1. Cutting unit-lift arm
   2. Retaining pin
   3. Clevis fitting
   4. Clevis pin

4. Remove the retaining pin and clevis pin (Figure 48)

5. Rotate the clevis until you attain the desired height (Figure 49).

   

   Figure 49

   1. Clevis fitting
   2. Jam nut

6. Assemble the clevis fitting to the lift arm with the clevis pin and retaining pin, and tighten the jam nut (Figure 48 and .Figure 49).

7. Install the cover plate and bolts that you removed in step 2.

Alternate fluids: If the Toro fluid is not available, other fluids may be used provided they meet all the following material properties and industry specifications. We do not recommend the use of synthetic fluid. Consult with your lubricant distributor to identify a satisfactory product

Note: Toro will not assume responsibility for damage caused by improper substitutions, so use only products from reputable manufacturers who will stand behind their recommendation.

Important: The ISO VG 46 Multigrade fluid has been found to offer optimal performance in a wide range of temperature conditions. For operation in consistently high ambient temperatures, 18°C (65°F) to 49°C (120°F), ISO VG 68 hydraulic fluid may offer improved performance.

Premium Biodegradable Hydraulic Fluid-Mobil EAL EnviroSyn 46H

Important: Mobil EAL EnviroSyn 46H is the only synthetic biodegradable fluid approved by Toro. This fluid is compatible with the elastomers used in Toro hydraulic systems and is suitable for a wide-range of temperature conditions. This fluid is compatible with conventional mineral oils, but for maximum biodegradability and performance the hydraulic system should be thoroughly flushed of conventional fluid. The fluid is available in 19 L (5 gallon) containers or 55 gallon drums from your Mobil Distributor.

Important: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic system fluid is available in 20 ml (2/3 oz) bottles. One bottle is sufficient for 15 to 22 L (4 to 6 gallons) of hydraulic fluid. Order Part No. 44-2500 from your authorized Toro distributor. This red dye is not recommended for use with biodegradable fluids. Use food coloring.

Important: To prevent system contamination, clean the top of the hydraulic fluid containers before opening them. Ensure that the pour spout and funnel are clean.

1. Move the machine on a level surface.

2. Allow the machine to cooled down so that the hydraulic fluid is cold.

3. Unscrew the dipstick located at the top of the hydraulic tank, wipe the dipstick clean, install it, and remove it again (Figure 50).

   Note: If the oil level is at or below the groove on the lower end of the dipstick, the oil level is sufficient.

   

   Figure 50

   1. Dipstick
   2. Hydraulic fluid level (good—at or below the groove)
   3. Breather
   4. Filler neck
   5. Dipstick hole

4. If no oil is present on the dipstick, remove the cap from the filler neck of the hydraulic fluid tank (Figure 50) and slowly add the specified hydraulic fluid to the hydraulic tank until the fluid level is at the groove dipstick; refer to Hydraulic Fluid Specification.

   Note: Do not mix different types of hydraulic fluid.

5. Install the dipstick and the breather into the hydraulic tank (Figure 50).

   Note: Make a close visual inspection of the hydraulic components. Inspect them for leaks, loose fasteners, missing parts, improperly routed lines, etc. Make any repairs necessary.

Hydraulic fluid quantity: approximately 18.9 L (5 US gallons)

If the fluid becomes contaminated, have your Toro distributor flush the system. Contaminated fluid looks milky or black when compared to clean fluid.

1. Clean the area around the left filter mounting area (Figure 51). Place a drain pan under the filter and remove the filter.

   

   Figure 51

   1. Hydraulic filter

   Note: If you are not going to drain the hydraulic the fluid, disconnect and plug the hydraulic line going to the filter.

2. Fill the replacement filter with the specified hydraulic fluid, lubricate the sealing gasket, and thread it on to the filter head until the gasket contacts the head. Then tighten the filter 3/4 turn further.

3. Repeat step 1 and 2 for the right hydraulic filter (Figure 52).

   

   Figure 52

   1. Hydraulic filter

4. Fill the hydraulic reservoir with approximately 18.9 L (5 US gallons) of the specified hydraulic fluid; refer to Hydraulic Fluid Specification and Checking the Hydraulic-Fluid Level.

5. Start the machine and run it at idle for 3 to 5 minutes to circulate the fluid and remove any air trapped in the system. Shut off the engine and check the fluid level.

Note: Dispose of the old hydraulic fluid and filter properly.

Check the hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating.

Each day before operating the machine, check the reel-to-bedknife contact, regardless if the quality of cut had previously been acceptable. There must be light contact across the full length of the reel and bedknife; refer to the Cutting Unit Operator’s Manual.

To achieve a consistent, high-quality cut and a uniform, after-cut appearance, you must correctly set the reel speed control (located on the manifold block under the cover to the left of the seat). Adjust the reel speed control as follows:

1. Decide the height-of-cut at which the cutting units are set.

2. Decide the desired ground speed best suited for conditions.

3. Use table that follows to determine the reel-speed setting for your 5-, 8-, 11-, or 14-blade cutting units (Figure 53).

   

   Figure 53

4. Tilt the operator’s seat forward and support it with the prop rod (Figure 54).

   

   Figure 54

5. To adjust the reel speed by rotating the knob of the reel-speed control (Figure 55) until the indicator arrow are in line with the number that you determined in step 3.

   

   Figure 55

   1. Knob (reel-speed control)
   2. Handle (backlap lever)
   3. Indicator arrow

   Note: You can increase or decrease the reel speed to compensate for turf conditions.

1. Position the machine on a level surface, lower the cutting units, shut off the engine, and set the parking brake.

2. Tilt the operator’s seat forward and support it with the prop rod (Figure 56).

   

   Figure 56

3. Make initial reel to bedknife adjustments appropriate for honing all the cutting units that you are backlapping; refer to the Cutting Unit Operator's Manual.

4. Rotate the backlap lever to the R position (Figure 57).

5. 

   Figure 57

   1. Knob (reel-speed control)
   2. Handle (backlap lever)
   3. R position
   4. F position

6. Rotate the reel-speed knob to setting 1 (Figure 57).

7. Start the engine and run at low idle speed.

   Important: Do not change the engine speed while backlapping or the reels may stall. Only backlap at idle engine speed.

8. With the mow/transport lever in the NEUTRAL position, move the raise/lower mow control forward to start the backlapping operation on the reel.

9. Apply lapping compound with a long handle brush. Never use a short-handled brush.

   • If the reels stall or become erratic while backlapping, select a higher reel speed setting until the speed stabilizes, then return the reel speed to setting 1 or to your desired speed.

   • To make an adjustment to the cutting units while backlapping, turn the reels off by moving the raise/lower mow control rearward and shut off the engine. After completing adjustments, repeat steps 4 through 9.

10. Repeat the steps 4 through 9 for all cutting units that you want to backlap.

11. When finished, return the backlap lever to the F position, move the reel speed knob to the desired reel-speed setting, lower the seat, and wash all lapping compound off of the cutting units. Adjust cutting unit reel to bedknife as needed.

    Important: If you do not return the backlap lever to the F position after backlapping, the cutting units will not raise or function properly.