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Toro 3000 Lawn Mower User Manual

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4. Figure 22 1 Slide back to mount 2 Ball stud 3 Swing up to remove down to install 2 4 Slide cutting unit out from under pull frame disengag ing the lift arm from the lift bail Fig 23 o 5 Reverse steps 1 4 to install the cutting unit 5 3 A 4 Figure 23 1 Lift bail 3 Pull frame NY 2 Lift arm 4 Pull arm Greensmaster 3000 3000 D Page 9 19 Repairs Reel Lapping Check reel bearing adjustment and correct if necessary before backlapping Connect lapping machine to cutting unit with an extension coupler and a 9 16 in socket The 9 16 in socket can be installed onto the capscrew CAUTION the reel shaft inside the counter balance weight on the Be careful when lapping the reel because end of the cutting unit Backlap according to procedures tact with the reel or other moving parts can in the Toro publication Sharpening Reel amp Rotary result in personal injury Mowers Form No 80 300 PT NOTE For a better cutting edge run a file across front face of bedknife when lapping operation is completed This will remove any burrs or rough edges that may have built up on the cutting edge Bedbar Removal and Installation 1 Loosen pivot screws securing bedknife pivot assemb ly to reel frame supports Fig 24 2 Rotate adjustment knob and pivot assembly clock wise left hand thread until it is unthreaded from bedbar p
5. put Es 15 UP AND 5 7 Cutting Unit Removal and Installation 15 Adjustment Summary and Check List 7 Reel 0 16 Reel Bearing Service and Adjustment 8 Bedbar Removal and Installation 17 Bedknife To Reel Adjustment 9 Bedknife Replacement 18 Leveling Rear Roller to Reel 10 Preparing Reel For Grinding 18 Height Of Cutts 11 Reel Removal and Bearing Replacement 19 Front Roller Scraper Adjustment 12 Lift Bail 20 Comb 12 Greensmaster 3100 Page 7 1 Table of Contents Specifications Height of Cut 3 16 0 1875 in to 11 16 0 6875 in Clip Frequency and Optimum Height of Cut Range Model Clip Optimum Height No max of Cut Range Model 04407 04408 0 25 in 3 16 5 16 Roller Adjustment Front Micrometer hand adjustment with bolted camp lock 1 turn 0 025 in height of cut change Rear Pivot arm change on slot in side plate with locking nuts for paralleling roller to reel and adjusting bedknife attitude 1 Lift bail 2 Grease fittings reel bearings 3 Grease fittings roller 4 Height of cut adjustment knob 2 Specifications 6 Scraper adjusting nut 4 7 Pull rod studs 2
6. Factors Affecting Grooming There are a number of factors that can affect the perfor mance of grooming These factors vary for different golf courses and from green to green on the same golf course It is important to inspect the turf frequently and vary the grooming practice with the need Itisimportantto rememberthat Factors Affecting Quality of Cut also affect grooming performance IMPORTANT Improper or over aggressive use of the groomer reel i e too deep or too frequent groom ing may cause unnecessary stress on the turf lead ing to severe turf damage Use the groomer cautiously READ AND UNDERSTAND THE OPERATOR S MANUAL BEFORE OPERATING OR TESTING GROOMER PERFORMANCE Variables That Affect The Use and Performance of Grooming Reels 1 Time or year growing season and weather patterns 2 General turf conditions 3 Frequency of grooming cutting how many cuttings per week and how many passes per cutting 4 Grooming reel blade spacing 5 Height of cut NOTE Because of weight difference bench set height of cut should be approximately 0 020 to 0 040 in higher on groomer equipped cutting units to get the same effective height of cut as cutting units without groomer reels 6 Grooming depth 7 How long grooming reel has been in use on a particular turf area 8 Type of grass 9 Overall turf management program i e irrigation fertilizing weed disease and pest control coring over
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9. Preparing Reel For Grinding IMPORTANT Adjust reel bearings before grinding reel See Reel Bearing Service and Adjustment in the Adjustments section of this chapter C 1 Remove bedbar NOTE Some reel grinders may require rear roller as sembly be mounted to the cutting unitfor proper support in reel grinder Rear roller must be parallel to reel shaft to remove taper when grinding 2 If necessary remove front roller assembly A Loosen the locknuts securing height of cut adjust ing rods at both ends of the cutting unit and the roller shaft clamp bolts Fig 26 B Turn height of cut adjustment knobs until they are Figure 26 disconnected from the height of cut adjusting rods Fig 26 The roller assembly can then be removed 1 Rear roller height of cut bracket from the cutting unit by pulling evenly on both sides 2 Allen set screw 3 Bedbar mounting boits For proper grinding of reel follow procedures inthe Toro 4 a ir UM publication Sharpening Reel amp Rotary Mowers Form S Height of cut rod ue 6 Roller shaft clamp bolts No 80 300 PT 7 Height of cut adjustment knob 3 Instali bedbar After grinding assemble cutting unit do all adjustments Back lap if necessary to get desired fit between reel and bedknife DAAR anaon Voy Pane 1 __ Greensmaster 3000 3000 D Reel Removal and Bearing Replacement 1 Remove the front and rear roller assembly Remove bedbar 2 Remove counterbalance end ca
10. 2 Press the seal squarely into the roller body The seal face should be flush with the end of the roller body when correctly installed Greensmaster 3100 Page 10 21 Rev D Dual Point Adjust Cutting units Bearing Removal Note Replace both roller bearings as a set after a bearing failure 1 Remove the roller seals see Roller Seal Removal in this chapter of this manual 2 Remove both spiral retaining rings from the roller shaft Note Roller bearings have a press fit into the roller body and a slip fit on the roller shaft 3 Loosely secure roller body in a vise Lightly tap one end of the roller shaft with a plastic hammer to drive the shaft and one of the bearings from the roller body 4 Use the roller shaft to remove the remaining bear ing 5 Clean roller bearing cavity and remove any rust or corrosion with an abrasive cloth 6 Inspect bearings roller shaft spiral retaining rings and roller body for wear or damage Replace compo nents as necessary Bearing Installation 1 Pressing against the outer race of the bearing only drive one bearing all the way into either end of the roller body Fig 26 2 Slide roller shaft through roller body and installed bearing 3 Install spiral retaining ring against installed bearing 4 Slide the remaining bearing onto the roller shaft Pressing against the outer race of the bearing only drive the remaining bearing all the way into the end of the roll er b
11. For proper grinding follow procedures in Toro publica tion Sharpening Reel and Rotary Mowers Form No 80 300 PT 3 Do steps 8 16 under Bedbar Removal and Installation in this section of the book After grinding assemble cutting unit check bearing adjustment and adjust top shield and bar Back lap if necessary to get desired fit between reel and bedknife Greensmaster 3000 3000 D Page 9 23 Figure 35 1 Height of cut locknut 2 Roller shaft clamp bolt 3 Height of cut knob 4 End cap mounting nuts 5 Counterbalance end cap 6 Reel bearing adjustment nut Repairs _______ Reel Removal and Bearing Replacement 1 Do steps 1 4 under Bedbar Removal and Installation in this section of the book 2 Remove counterbalance end cap from left hand side of the cutting unit Fig 35 Remove large bearing ad justment nut from one end of reel shaft Fig 35 and special spline nut at opposite end of reel shaft 3 Remove machine screws securing bearing housing on each end of cutting unit Fig 36 The machine screw heads will have to be cut off before the screw can be completely removed A Unscrew machine screw approximately two turns B Cut off machine screw head C Back out remaining part of screw from side plate with a screw driver outwards not inwards towards reel If machine screw does not have a screw driver slot use a pliers to back out screw IM
12. If pressure is not in listed range remove traction relief cartridge and examine for contamination or damage Greensmaster 3100 Page 4 29 Testing TEST HOOK UP NO 2 Traction Motors Mechanical Drag Valve Bank Leakage Traction Motors Efficiency TESTER CONNECTION Disconnect hydraulic hose that leads to front right wheel motor from T fitting on rear outlet port of valve bank section No 5 Connect tester in series between fitting and disconnected hose Tester Flow Control Valve Open Note On machines that have a U tube between the elbow fitting on rear outlet port of valve bank section No 5 and hydraulic tube leading to front wheel motors remove U tube and install tester in series between the two exposed fittings CAUTION Keep everyone away from the front of the machine during traction system tests Op erator must be on seat or the safety interlock will stop the engine when the traction lever is en gaged Nu mc CAP a TEST 77 TEST B AND C m lt m m TEST A TRACTION MOTORS MECHANICAL DRAG PROCEDURE Block up the machine so traction wheels are off floor If machine is equipped with 3WD rear wheel needs to be off floor as well Disconnect brake control rod on wheel being tested Apply brake and engage park lock Engine RPM 2800 Hydraulic oil at normal operating temperature Engage transmission lever to No 1 position Push tr
13. Problem 11 Engine does not stop when ig nition key is rotated to OFF posi tion Cause Loose wire s in electrical system Ignition switch is malfunctioning Engine timing or carburetor out of adjustment Correction Check all connections and repair as necessary Replace ignition switch Adjust carburetor or engine tim ing 12 Battery does not charge Open or missing fuse Loose wire s in electrical system Malfunctioning regulator or engine charging circuit Install new fuse Check all connections and make all necessary repairs Install new regulator or repair en gine charging circuit Faulty battery Test and replace if necessary Verify Interlock Operation The interlock system is designed to stop the engine when the operator is off of the seat while the traction selector is in the No 1 or No 2 position or the mow pedal is pushed down The system also prevents the engine from starting in the same situation A CAUTION Do not disconnect or bypass the interlock switches Check the operation of the switches to assure that the interlock system is operat ing correctly If a switch is malfunctioning or out of adjustment adjust or replace it before operating the machine To assure maximum safety replace all interlock switches every two years or 1000 hours whichever comes first To check the operation of the interlock switches 1 Set on the seat and engage
14. Specifications Item Description Hydraulic Pump Steering relief pressure Greensmaster 3100 External gear type 5 section Greensmaster 3100 4 section Greensmaster 3050 850 psi Wheel Motor 2 Orbit rotor type Reel Motor 3 External gear type Control Valve Main and No 1 section port relief pressure No 2 and 3 section port relief pressure No 4 traction section port relief pressure 5 section spool type 2000 psi 2000 psi 1850 psi Power Steering Control Gerotor type steering control unit Hydraulic Oil See Operator s Manual Reservoir Capacity See Operator s Manual Oil filter Screw on cartridge type 10 micron Specifications 4 2 Rev D Greensmaster 3100 General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such pressure differentials during operation and exposure to weather sun chemicals very warm storage condi tions or mishandling during operation or maintenance These conditions can cause damage or premature de terioration Some hoses such as reel motor hoses are more susceptible to these conditions than others In spect the hoses frequently for signs of deterioration or damage To prevent possible problems it is recom mended that hoses are replaced periodically regardless of condition When replacing a hydraulic hose be sure that the hose is straight nottwisted before tig
15. 5 Remove the detent sleeve Reassemble With the Following Procedures 1 Mount the detent sleeve and the detent adapter Lock the adapter securely to the spool 2 Apply alight coat of grease to the adapter holes insert the small spring the four balls and the ball follower 3 Stand the valve bank assembly up so the front clevis end of No 4 spool is facing downward 4 Slide the detent sleeve up to the four balls Apply light pressure against the balls with the sleeve Push against the center of the ball follower with a drift punch to allow the balls to slip into the adapter holes and the sleeve to slide over the assembly IMPORTANT Do not push spool too far or the rear spool seal may be cut by the spool 5 Assemble the stop collar large spring and bonnet to the valve body Check the spool for proper detent op eration and mount the valve bank onto the machine 6 Adjust the traction switch See Traction Switch Re moval Installation and Adjustment in the Repairs sec tion of Chapter 5 Electrical System Greensmaster 3100 Page 4 49 1 Bonnet 2 Spring 3 Stop collar 4 Detent sleeve Figure 30 5 Balls 4 6 Detent adapter 7 Spring 8 Ball follower Repairs Lift Cylinder Removal and Installation No 1 Center Lift Cylinder Fig 32 Figure 32 1 Put drain pan under machine 2 Remove hydraulic lines 3 Remove capscrew Item 25 and locknut Item 29
16. Chapter 1 Safety While Doing Maintenance Troubleshooting Testing Adjustments or Repairs 3 A CAUTION Obey the following safety instructions Read and understand these instructions before op erating the Greensmaster 3100 or doing main tenance troubleshooting testing adjustments or repairs Failure to comply with the safety instructions may result in per sonal injury 3 Become familiar with the controls and know how to stop the machine and engine quickly 4 Keep all shields safety devices and decals in place If a shield safety device or decal is defective or dam aged repair or replace it before operating the machine 5 Always wear substantial shoes Do not operate ma chine wearing sandals tennis shoes sneakers or when barefoot Do not wear loose fitting clothing that could get caught in moving parts and possibly cause personal injury 6 Wearing safety glasses safety shoes long pants and a helmet is advisable and required by some local ordi nances and insurance regulations 7 Make sure the work area is clear of objects which might be picked up and thrown by the reels Safety Instructions 8 Do not carry passengers on the machine Keep everyone especially children and pets away from the areas of operation 9 Since gasoline is highly flammable handle it carefully A Use an approved fuel container While Operating 10 Do not run engine in a confined area without ade qua
17. Install Variable Speed Traction Kit if necessary to con trol traction speed in varying conditions or with dif ferent attachments Will allow change in traction speed while maintaining full engine rpm and reel motor rpm Center cutting unit must drop after front cutting unit See Troubleshooting in Chapter 5 Hydraulic System 17 Cutting drop speed and sequence Troubleshooting Page 8 6 Greensmaster 3000 3000 D Set Up and Adjustments Adjustment Summary and Check List DETAILED ADJUSTMENT INSTRUCTIONS FOLLOW THIS SUMMARY AND CHECK LIST Study this informa tion and refer to it often to get maximum life and perfor mance from the cutting units Daily Performance Checks NOTE It is not necessary to remove the cutting units from the traction unit to perform these daily checks It is recommended that mowers be washed after each use Always remove key from ignition switch when working on the machine 1 Purge all water and debris from all of the bearings by greasing them Use No 2 multi purpose lithium base grease 2 Visually check for sharp reel and bedknife Remove burrs nicks and rounded edges 3 Lower cutting units to the ground setting on both rollers Remove reel motor and rotate the reel back wards by hand Light contact between the bedknife and reel should be felt and heard t should be possible to pinch newspaper when inserted form the front and cut paper when inserted at a rig
18. Page 10 10 Monthly Adjustments NOTE Remove cutting unit from traction unit 1 Parallel bedknife to reel Use newspaper as a feeler gauge Dot on eccentric bolt must face rear of mower Turn bedknife adjustment knob to hold paper on right hand end of bedknife Turn eccentric left bedbar bolt to hold paper on left hand end of bedknife Hold eccentric bedbar bolt while securing locknut 2 Adjust rear roller parallel to reel eccentric bolt faces to rear 3 Check grass shield adjustment 4 3 4 in from crossbar normal Dry grass lower shield Wet grass raise shield 4 Set top bar cut off bar adjustment 0 060 in from reel normal 5 Set cutting unit on ground setting on both rollers and remove reel motor Adjust bedknife to reel contact 6 Use a gauge bar to check height of cut and adjust as necessary 7 Use a gauge bare to check groomer depth and adjust as necessary Special Notes 1 Replace bedbar bushings and nylon flange bushings every two years 2 A rifled reel and or bedknife must be corrected by grinding 3 After extended running notches will develop at both ends of bedknife These notches must be rounded off or filed flush with cutting edge of bedknife to assure smooth operation 4 If reel bearings will not hold adjustment during opera tion loosen adjustment nut tighten reel shaft spline nut on right hand end of reel shaft to a torque of 40 to
19. Preface This publication provides the service technician with information for troubleshooting testing and repair of major systems and components on the Greensmaster 3100 and 3050 REFER TO THE TRACTION UNIT CUTTING UNIT AND ACCESSORY OPERATOR S MANUALS FOR OPERATING MAINTENANCE AND ADJUSTMENT INSTRUCTIONS Space is provided at the end of Chapter 2 in this publication to insert the Operator s Manuals and Parts Catalogs for your machine Replace ment Operator s Manuals are available by sending com plete Model and Serial Number of traction unit and cutting unit to The Toro Company 8111 Lyndale Avenue South Minneapolis MN 55420 The Toro Company reserves the right to change product specifications or this publication without notice Part No 9278451 Rev E Service Manual Greensmaster 3100 3050 This safety symbol means DANGER WARN ING or CAUTION PERSONAL SAFETY IN STRUCTION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE A NOTE will give general information about the correct operation maintenance service testing or re pair of the machine IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 1991 1998 2002 2004 2005 This page is intentionally blank Table Of Contents Ch
20. Rm Aad 88 WO OS OM WO 08 07 ISd 0002 154 0002 7 A3u WO no 99 NI gt 2 OS OM ANYA INVA 08 9 061 L 18 0002 0981 4 HOLIMS AL3aVS XNVL x 4 4 L N lu z NC gt ES Y 9 HH 7 A3u WO 691 A3U NI NO 601 SHOLOM MOOTHALNI HOLIMS ALAAVS HI YALNAD 77 CA3u WO 2 SHOLOW 7334 Hydraulic Schematics 4 12 3 Rev Greensmaster 3100 This page is blank Hydraulic Schematics 4 12 4 Rev E Greensmaster 3100 Special Tools NOTE Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PRODUCTS Some tools may be lis
21. washer and seal retainer 4 Install the breather washer boot and chain link Start the engine and check for leaks Rear Bonnet Side Fig 26 1 Remove the bonnet NOTE The valve bank must be removed in order to replace the spool seal under the bonnet on No 4 spool 3 2 Disassemble the components attached to the rear of the spool See Control Valve No 1 Spool Detent Re placement and Control Valve No 4 Spool Detent Re Figure 26 placement in this section of the book 1 Seal retainer NOTE The assemblies under each spool bonnet are 2 Back up washer different from one another Pay close attention to how they disassembled so they will be reassembled correctly 3 Remove the seal retainer back up washer and lip seal from the valve body and clean the seal groove 4 Soak the new seal in clean hydraulic fluid INSTALL THE SEAL WITH THE OPEN LIP SIDE FACING IN TOWARDS THE VALVE BODY Install the back up washer seal retainer and remaining components IMPORTANT Make sure the switch is correctly po sitioned and adjusted when bonnet is installed on No 2 or No 4 spool See Mow Lift Switch Replace ment and Adjustment or Traction Switch Replace ment and Adjustment in Chapter 6 Electrical System Repairs Page 4 46 Greensmaster 3100 Control Valve Internal Seal Replacement Fig 27 1 5 in spring These components changed locations after serial no 210000701
22. 13 3 Use scraper to remove all rust scale and corrosion from bedbar surface before installing bedknife Replacement 1 Make sure bedbar threads are clean Use new screws Apply clean SAE 30 oil to the screws before installing IMPORTANT Do not use an impact wrench to tight en screws into the bedbar 2 Using a torque wrench and bedknife screw tool tighten screws to a torque of 200 to 250 in Ib 22 to 28 Nm Use a torquing pattern working from the center toward each end of the bedknife Fig 14 3 Install bedbar to frame see Bedbar Installation Grinding Since there can be variations in the mounting surface of the bedbar a new bedknife will not be perfectly flat after it is installed Because of this it is necessary to backlap or grind a new bedknife after installing it to the bedbar Follow the existing angle that was ground into the bed knife and grind only enough to make sure the top surface is true Fig 15 1 Remove bedbar from the cutting unit see Bedbar Removal Note When grinding be careful to not overheat the bedknife Remove small amounts of material with each pass of the grinder 2 Use Toro Service Training Book Sharpening Reel and Rotary Mowers part no 80300SL for bedknife grinding information Bedknife Grinding Specifications Bedknife relief angle 3 see Fig 15 Front Angle Range 13 to 17 3 Reinstall bedbar to cutting unit see Bedbar Installa tion Greensmaster 3
23. 21 828 38 0 3750 9 525 78 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 322 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 716 0 4375 11 112 1516 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 322 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 12 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 0 001 0 0254 0 6 to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1
24. 4 from ad juster shaft and remove adjuster shaft from cutting unit frame 5 Inspect flange bushings 2 and remove if necessa ry 6 Ifthe detent 7 is damaged remove it from the cut ting unit frame by removing the cap screw 9 and lock washer 8 Dual Point Adjust Cutting Units Adjuster screw Page 10 12 Rev D 9 Capscrew 10 Washer 11 Spring 12 Lock nut Installation Fig 12 1 Ifthe detent 7 was removed install the cap screw 9 and secure detent to the cutting unit frame with cap screw and lock washer 2 If flange bushings 2 were removed align key on bushing to slot in frame and install bushings 3 Apply antiseize lubricant on internal threads of ad juster shaft 1 and slide into flange bushings in cutting unit frame 4 Install wave washer 4 Apply Loctite 242 or equiva lent to the threads of the jam nut 5 Tighten jam nut from 15 to 20 ft lbs 20 to 27 Nm 5 Screw adjuster 6 into adjuster shaft 6 Install washer 10 spring 11 and lock nut 12 onto adjuster screw 7 Install bedbar see Bedbar Installation in this sec tion of this manual 8 Adjust cutting unit see Cutting Unit Operator s Manual Greensmaster 3100 Bedknife Replacement and Grinding Removal 1 Remove bedbar from frame see Bedbar Removal 2 Remove screws from bedbar using a socket wrench and bedknife screw tool see Special Tools Discard screws Remove bedknife from the bedbar Fig
25. 5 5 1 Before 1 While Operating 2 Safety Instructions The Greensmaster 3100 has been tested and certified for compliance with the B71 4 1984 specifications of the American National Standards Institute ANSI for riding mowers when 40 Ibs of ballast is added to rear wheel Hazard control and accident prevention are dependent upon the awareness concern and proper training of the personnel involved in the operation transport mainte nance and storage of the machine Improper use or maintenance of the machine can result in personal in jury or death To reduce the potential for injury or death comply with the following safety instructions Before Operating 1 Read and understand the Operator s Manual before starting operating maintaining or repairing the ma chine Replacement Operator s Manuals are available by sending complete Model and Serial Number of trac tion unit and cutting units to The Toro Company 8111 Lyndale Avenue South Minneapolis MN 55420 Use the Model and Serial Number when referring to your machine If you have questions about this Service Infor mation please contact The Toro Company Commercial Service Department 8111 Lyndale Avenue South Minneapolis MN 55420 2 Never allow children to operate the machine or adults to operate it without proper instruction Greensmaster 3100 Page 1 1
26. IMPORTANT To prevent damage to wheel motor DO NOT hit wheel hub with a hammer during removal or installation 3 Mount a wheel puller to the wheel mount studs and remove wheel hub Remove key Item 11 from motor shaft 4 Remove brake shoe springs Item 7 and brake shoes Item 8 Disconnect brake linkage 5 Repair or replace parts as necessary Repairs Page6 4 Reassembly 1 Insert small hook end of tension springs into the hole in each brake shoe plate from the outside Connect large spring ends into opposite shoe plate The springs should be in opposite direction from each other 2 Install brake cam Item 27 Connect actuating link age and secure clevis locknut with a cotter pin 3 Mount key in wheel shaft so top of key is in line with taper of shaft and install wheel hub and nut Tighten nut to a torque of 250 to 400 ft Ib 4 Install wheel assembly Tighten wheel nuts to a torque of 40 to 50 ft Ib 5 Adjust and check brakes See Brake Adjustment in the Adjustments section of this chapter Greensmaster 3100 Steering Arm Greensmaster 3050 1 Remove 1 2 13 3 4 capscrew and 53 I D wash er mounted to outside steering arm frame bracket 2 Pivot steering arm upward aligning mounting holes in arm with holes in frame bracket 3 Select desired mounting hole for operator comfort and secure with a 2 1 2 13 x 3 4 capscrews and 53 1 0 washers one each in loose parts Steering Cable G
27. Page 4 25 Install orifice ducer in cylinder line Replace crows foot itting with correct fit ting Troubleshooting Steering Loss Steering Wander or Free Play Check steering cyl Tighten castle nuts Replace ball inder and jam nut joint s ball joints Disconnect cylin Repair and der and check cas lubricate castor fork tor fork movement and bushings Binding Check steering inder for internal leakage Repair or replace Leakage steering cylinder Check for Restriction Replace restricted restriction in hy line or fitting draulic hose or fit ting Check steering Defective Check for Repair or replace pump flow Test restriction in pump pump hook up No 5 intake line Test Check for dam aged steering wheel or shaft Replace steering Defective wheel or shaft Worn or damaged Repair or replace steering control steering unit Thermal control unit Defective shock Thermal shock A condition caused when the hydraulic system is operated for some time without turning the steering wheel so that fluid in the reservoir and system is hot and the steering control unit is relatively cool more than 50 F temperature differential This can also happen when washing the machine When the steering wheel is turned quickly the result is temporary seizure and possible damage to internal parts of the steering control unit The temporary seizure may be followed by total free wheeling Tro
28. Subract 329 2 Multiply by 5 9 Equivalents and Conversions Page2 2 Greensmaster 3100 Torque Specifications Use these torque values when specific torque values The torque values listed below are for lubricated are not given DO NOT use these values in place of threads Plated threads are considered to be lubricated specified values Capscrew Markings and Torque Values U S Customary SAE Grade Number 5 8 Capscrew Head Markings E C O Capscrew Torque Grade 5 Capscrew Torque Grade 8 Capscrew Body Size Cast Iron Aluminum Cast Iron Aluminum ft Ib Nm ft Ib Nm ft Ib Nm ft Ib Nm 1 4 20 7 9 6 8 11 15 9 12 28 9 12 7 9 13 18 10 14 5 16 18 15 20 12 16 22 30 18 24 24 17 23 14 19 24 33 19 25 3 8 16 30 40 20 25 40 55 30 40 24 30 40 25 35 45 60 35 45 7 16 14 45 60 35 45 65 90 50 65 20 50 65 40 55 70 95 55 75 1 2 13 70 95 55 75 95 130 75 100 20 75 100 60 80 110 150 90 120 9 16 12 100 135 80 110 140 190 110 150 18 110 150 85 115 155 210 125 170 5 8 11 135 180 110 150 190 255 150 205 18 155 210 120 160 215 290 170 230 3 4 10 240 325 190 255 340 460 270 365 16 270 365 210 285 380 515 300 410 7 8 9 360 490 280 380 550 745 440 600 14 390 530 310 420 610 825 490 660 1 8 530 720 420 570 820 1100 660 890 14 590 800 480 650 890 1200 710 960 Capscrew Markings Torque Values Metric Commercial Steel Class 8 8 10 9 12 9 Capscrew Head Ma
29. Wash the parts in a safe solvent Dry the parts with compressed air DO NOT wipe them dry with a cloth or paper as lint and dirt may remain 8 Inspect the internal surface of the barrel for damage deep scratches out of round etc Inspect the head shaft and piston for evidence of excessive scoring pitting or wear Replace any defective parts 9 Puta light coating of hydraulic oil on all new seals and back up washers Install the new seals and back up washers Items 4 5 12 7 8 11 Install the head Item 9 onto the shaft Item 6 Install the piston Item 3 onto the shaft and tighten the lock nut Item 2 10 Puta light coating of hydraulic oil on all cylinder parts to ease assembly Slide the piston shaft and head into the barrel Install the retaining ring Item 10 to secure the assembly in the barrel Repairs Wheel Motor Removal and Installation Fig 36 Figure 36 1 Put blocks on each side off opposite drive wheel Lift the frame with a jack and use blocks or a jack stand to support the frame 2 Remove wheel nuts Item 29 and remove wheel Item 3 Remove large nut Item 4 from wheel hub Item 5 IMPORTANT To prevent damage to wheel motor DO NOT hit wheel hub with a hammer during removal or installation 3 Mount a wheel puller to wheel mount studs and remove wheel hub Item 5 and brake drum Item 6 Remove key Item 11 from wheel motor shaft 4 Disconnect hydraulic li
30. both sides 3 Install the repair lift bail Part No 71 1600 Repairs Page 8 20 Greensmaster 3000 3000 D 8 Single Point Adjust Cutting Units TORO Table of Contents SPECIFICATIONS 3 Top Bar 17 SPECIAL 4 Pull Frame Adjustment 18 6 REPAIRS enisi 19 UP AND ADJUSTMENTS 8 Cutting Unit Removal and Installation 19 Adjustment Summary and Check List 8 Reel 0 20 Bedknife to Reel Contact 9 Bedbar Removal and Installation 20 Reel Bearing Service and Adjustment 10 Bedbar Bushing Replacement 22 Parallel Bedknife to 11 Bedknife Replacement 23 Leveling Rear Roller to 12 Preparing Cutting Unit for Reel Grinding 23 Height of Cut 14 Reel Removal Bearing Replacement 24 Front Roller Scraper Adjustment 16 Bedknife Adjustment Knob Bearing Service 25 Comb Adjustment 16 Lift Bail 26 Shield Height 17 Greensmaster 3100 Page 8 1 Table of Contents introduction Page 9 2
31. intake line s Check for flow re striction Repair or replace reel drive relief valve Repair or replace reel drive motor Page 4 20 Greensmaster 3100 Greensmaster 3100 All Reels Slow or Will Not Turn Check Adjust engine use tachometer RPM Check Fill to proper hydraulic level oil level Check hydraulic oil filter Replace Clogged filter Check linkage Woner Repair and roll pin linkage on end of mow broken pedal shaft Check reel pump Repair or flow Test hook up replace pump No 3 Test A Page 4 21 Troubleshooting Troubleshooting Mow Pedal Won t Stay Engaged Reels Slow Down or Stop Check linkage cv from pedal Misadjusted to valve bank or damaged Adjust repair and lubricate linkage Check roll pin in Replace end of mow pedal pin shaft or broken Check rearward valve spool travel Adjust rear Insufficient camshaft Check the Defective Lubricate or spool detent repair valve spool detent Page 4 22 Greensmaster 3100 Greensmaster 3100 Cutting Unit s Drop During Transport Check that valve spool returns to neutral Check for internal lift cylinder leakage Check lift check plug o rings in 1 valve section Check valve spool detent for binding Binding Leaking Leaking Binding Page 4 23 Lubricate and adjust camshaft Repair or replace cylinder s Replace o ring Lubricate or repair valve spool detent
32. securing pin Item 26 in barrel end of cylinder Item 10 4 Remove pin Item 26 securing barrel end of cylinder to the frame 5 Remove cylinder Item 10 by lowering barrel end and sliding shaft clevis end off of the lift arm Item 21 6 Reverse steps 2 5 to install the cylinder Coat cylinder pivot on lift arm Item 21 with Never Seez or grease to achieve free pivot action of lift arm in cylinder clevis before reinstalling Repairs Page 4 50 IMPORTANT When disassembling hydraulic lines make sure hydraulic plugs are placed in the open end of the hydraulic line to prevent foreign debris from contaminating hydraulic oil It is also a good idea to tag the hydraulic lines when disassembling so they can be properly reassembled Keep all hy draulic lines clean and free from foreign debris During replacement of lift cylinder avoid overtight ening fittings Check hydraulic lines for cracks or breaks If a hydraulic leak should appear after re placement of lift cylinder replace the fitting or line that is leaking Check hydraulic reservoir for level of hydraulic fluid after replacement of lift cylinder Greensmaster 3100 No 2 and 3 Lift Cylinders Fig 33 Figure 33 L H side shown 1 Remove the tool box to gain access to No 2 cylinder Remove the cover plate to gain access to No 3 cylinder Other disassembly procedures are the same for both cylinders 2 Put drain pan under machine and remo
33. then torque screws to 275 inch pounds in sequence shown a Le Greensmaster 3100 Page 4 71 Figure 67 Repairs Repairs Page 4 72 Greensmaster 3100 5 TORO Electrical System Table of Contents WIRING SCHEMATIC 2 12 TURF GUARDIAN LEAK DETECTION SYSTEM Turf Guardian Leak Detection System 12 SPECIAL TOOLS che nat eie 4 REPAIRS tst tuus EEUU Iu n nbi bi 13 5 6 General Safety Interlock Switch Service 13 Verify Interlock Operation 8 Seat Switch Replacement and Adjustment 13 i xen 9 Traction Neutral Switch Ignition Key Switch 9 Replacement and Adjustment 14 Seat 10 Mow Lift Switch Replacement and Adjustment 15 Traction Neutral 10 Wiring Harness 15 Mow Lift 5 11 Battery Service 16 Interlock Module 11 up 12 See Chapter 3 Engine for information about the engine electrical system and components Greensmaster 3100 Page 5 1 HOLIMS NOILOVYL BROWN ORANGE HOLIMS 1v3s ORANGE BLACK RED WHITE 3NIVA GI
34. top screw on each side of cutting unit Fig 8 then tighten bottom adjustment screw on each side of cutting unit Fig 9 2 After adjusting bedknife to reel make sure that both a the top and the bottom adjustment screws are secured gt 2 at both ends of cutting unit Fig 8 9 Figure 9 3 After adjustment check to see reel can pinch paper when inserted from the front and cut paper when in 1 Bedknife closer to reel 4 3 8 inch wrench serted at a right angle Fig 10 It should be possible to 2 Bedknife further from reel 5 Bedknife cut paper with minimum contact between the bedknife 3 Top adjustment screw and reel blades IMPORTANT If excessive bedknife to reel contact is maintained bedknife and reel wear will be ac celerated Uneven wear can result and quality of cut may be adversely affected n Figure 10 Figure 8 1 Bedknife 2 Bottom adjustment screw 3 3 8 inch wrench 4 Top adjustment screw Greensmaster 3000 3000 D 8 9 Set Up and Adjustments Leveling Rear Roller Reel 1 Loosen rear roller brackets Adjust one bracket and tighten the nut on the capscrew See the table below for the proper adjustment Leave bracket on the other side mounted loosely Fig 11 Distance from bottom of rear roller bracket not bolt Height of Cut to bottom of slot 1 8 0 125 in or below 5 32 0 156 to 1 8 0 125 in 1 4 0 25 in or above 1 16 0 0625 in 1 8 0
35. 10 Reel 8 2 Bedknife To Reel Adjustment Bedknife adjusts against reel with opposed screw adjustment on each end of bedbar Reel Speed 1940 rpm engine speed 2800 rpm Bedknife Screw Torque 200 in Ib Reel Splined Drive Nut Torque 40 to 60 ft Ib Reel Bearing Rolling Torque 7 max Front or Rear Roller Run Out 0 14 in max 5 Height of cut adjustment 8 Grass shield 9 Adjustable grass shield bar Greensmaster 3000 3000 D Special Tools NOTE Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PRODUCTS Some tools may be listed in the Greensmaster 3000 or 3000 D Parts Catalog Some tools may also be available from a local supplier Roller Bearing Replacement Tool Puller is used to remove bearings from front and rear rollers Driving tubes are used to install bearings into rollers Refer to instructions supplied with tool Used on swaged full and wiehle rollers Figure 1 Plastic Plug Insert plug in cutting unit bearing housing in place of reel motor when sharpening or grinding the reel Figure 2 Greensmaster 3000 3000 D Page8 3 Special Tools Handle Assembly For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel assembly Figure 3 Bedknife Screw Tool Fits Toro bedknife attaching screws Use with torque wrench to secure bedknife to bedbar With clean bed
36. 35ivug SNDIHVd NOILISOd 340 NI 38079 MS JAVY ONIMYVd 9340990 Q3S019 MS 193 na Qr vb A9 UA 440 G3s010 NI 93 079 TID MS TWHLNAN AD NO 98 S8 27 N IONOS M HOLVNHALTY OIA ES ze al QNO 4 GION3IOS H3LHYLS M Hals HH NA N Vas yaan 9 6 e pd ds 1 ds NS 15311 a Uus 354515 SIHOMSHLOL _________ i lt voL Mi yeh gk B na v lt L ong Y a 1HMS NNY 440 301195 dS AD O MOTA A NHiSISnd 13 M ama ex vie E 4016 CH Wiring Schematics Page5 2 3 Rev D Greensmaster 3100 3050 Wiring Schematic Greensmaster 3050 S N Below 80000 HOLIMS MOW MOTI3A GIONTIOS ualuvis RED
37. 4 3 4 in from crossbar normal Dry grass lower shield Wet grass raise shield 6 Set top bar cut off bar adjustment 0 060 in from reel normal 7 Set cutting unit on ground setting on both rollers and remove reel motor Adjust bedknife to reel contact 8 Use a gauge bar to set the height of cut Special Notes 1 Replace the bedbar bushings and nylon flange bush ings every two years 2 A rifled reel and or bedknife must be corrected by grinding 3 After extended running notches will eventually develop at both ends of the bedknife These notches must be rounded off or filed flush with cutting edge of bedknife to assure smooth operation 4 If reel bearings will not hold adjustment during opera tion loosen adjustment nut tighten reel shaft spline nut on right hand end of reel shaft to a torque of 40 to 60 ft lb then adjust reel bearings Greensmaster 3000 3000 D Bedknife to Reel Contact NOTE The single knob bedknife to reel adjustment sys tem simplifies the adjustment procedure needed to get the best mowing performance The precise adjustment possible with the single knob bedbar design gives the necessary control to provide a continual self sharpening action thus maintaining sharp cutting edges assuring good quality of cut and greatly reducing the need for routine backlapping In addition the rear roller position ing system permits optimum bedknife attitude and loca tion for va
38. 60 ft Ib then adjust reel bearings Greensmaster 3000 3000 D pA Bedknife to Reel Contact NOTE The single knob bedknife to reel adjustment sys tem simplifies the adjustment procedure needed to deliver optimum mowing performance The precise ad justment possible with the single knob bedbar design gives the necessary control to provide a continual self sharpening action thus maintaining sharp cutting edges assuring good quality of cut and greatly reduc ingthe need for routine backlapping In addition the rear roller positioning system permits optimum bedknife at titude and location for varying heights of cut and turf conditions IMPORTANT Bedknife to reel contact must be checked and adjusted every day even though quality of cut is acceptable 1 Shut off engine and lower cutting units to ground Remove the key 2 Remove grass baskets 3 Make sure the groomer reel is in the raised position Raisethe groomer reel by rotating the right and left quick up levers so they face to the rear Fig 6 4 Make sure the groomer reel is disengaged Push the clutch snubber down and turn the clutch knob clockwise to disengage the clutch Fig 6 IMPORTANT When engaging or disengaging the clutch be sure to turn the knob all the way it will come to a firm stop Failure to do so could cause damage to the clutch 5 On each cutting unit loosen 2 flange nuts securin
39. Brakes 5 6 2 Adjustments ni ih a n 6 3 seks MW ends 6 4 Chapter 7 4 Bolt Adjust Cutting Units 5 7 2 Special 7 3 Troubleshooting 7 5 Set Up and 5 7 7 Repairs coser s RE 7 15 Chapter 8 Single Point Adjust Cutting Units 8 3 Special 8 4 Troubleshooting 8 6 Set Up and 8 6 bed 8 19 Chapter 9 Grooming Reel Cutting Units Specifications 9 3 Special 9 4 Troubleshooting 9 6 Up and 9 10 ves 9 21 Chapter 10 Dual Point Adjust Cutting Units lt 10 2 Special Tools 10 3 10 5 Setup and 10 7 pere eed mes 10 8 Rev D This page is intentionally blank TORO Table of Contents SAFETY
40. Greensmaster 3000 3000 D Specifications Height Of Cut 3 32 0 094 in to 3 4 0 75 in Clip Frequency and Optimum Height of Cut Range Model Clip Optimum Height No max of Cut Range Model 04445 0 40 in 5 16 1 2 Model 04458 04468 0 25 in 3 16 5 16 Model 04450 0 18 in 1 8 7 32 Roller Adjustment Front Micrometer hand adjustment with bolted clamp lock 1 turn 0 025 in height of cut change Rear Roller brackets allow adjustment for different height of cuts Screw adjustment for leveling Bedknife To Reel Adjustment Bedknife adjusts against reel with positive adjustment contro knob lo cated at center of bedbar Adjustment knob contains detent with 001 inch movement of bed knife for each indexed position Pivot point at top of bedbar is greaseable Reel Speed 1940 rpm engine speed 2800 rpm Bedknife Screw Torque 200 in Ib Reel Splined Drive Nut Torque 40 to 60 ft lb Reel Bearing Rolling Torque 7 in Ib maximum with bedknife to reel contact removed Front or Rear Rotler Run Out 0 014 in max 1 Lift bail 4 Pull rod studs 7 Height of cut brackets 2 2 Height of cut adjustment knob 5 Grass shield 8 Bedknife adjusting knob 3 Height of cut adjustment locknut 6 Reel Greensmaster 3000 3000 D Page9 3 Specifications Special Tools NOTE Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PRODUCTS Some tools may be listed in the Green
41. Ib 4 Install groomer reel housing cover Install clutch knob and tighten two 2 set screws against flats on release disk Figure 45 1 Drive pulley and clutch assembly 2 Driven pulley 3 Drive belt backside idler pulley 4 Drive belt Repairs Page 10 28 Greensmaster 3000 3000 D Groomer Reel Removal and Bearing Service 1 Loosen two 2 set screws and remove clutch knob Fig 6 Remove groomer reel housing cover from left side of cutting unit Fig 39 2 Loosenthe backside idler pulley pivot screw Fig 45 Pivot idler to loosen and remove belt 3 Remove groomer driven pulley from groomer reel shaft left hand thread Fig 45 4 Remove locknut from right end of groomer reel shaft Fig 46a 5 Remove three 3 screws and nuts securing bearing housing to right side groomer plate Fig 46a Remove right side bearing bracket from groomer reel shaft Remove groomer reel shaft from bearing support in left side groomer housing Fig 46b 6 Check condition of groomer shaft bearings and replace if necessary Fig 47 Bearings must be installed with seal facing out on each side of bearing housing For each groomer housing R H and L H install outer bearing and spacer first Install inner bearing so it is flush with the housing Fig 47 7 To replace groomer reel blades remove locknut on each end of groomer reel shaft Remove blades and spacers Install new blades and previously removed spacers
42. Install locknut on each end of groomer shaft to secure blades and spacers NOTE Spacers are available for 1 4 in 76 blades or 3 4 in 26 blades blade spacing 8 Reverse steps 1 5 to install groomer reel Check drive belt tension before installing cover See Groomer Reel Drive Belt Replacement in this section of the book Figure 46a 1 Groomer reel shaft 4 R H groomer plate 2 Locknut 5 Bearing 3 R H groomer housing 6 Bearing spacer Figure 46b 1 Groomer reel shaft 3 L H groomer housing 2 Bearing Seal Facing Out Figure 47 1 Groomer reel shaft 5 L H groomer housing 2 Bearing 4 6 Locknut 3 Bearing spacer 2 7 Belt 4 R H groomer housing 8 Driven gear Greensmaster 3000 3000 D Page 10 29 Repairs Groomer Reel Clutch Service Do not use your hand to prevent reel from turning while servicing this can result in per sonal injury Use a 1 2 in thick x 3 in wide x 8 in long piece of hardwood inserted into front of cutting unit between reel blades Removal and Disassembly 1 Loosen two 2 set screws and remove clutch knob Fig 51 Remove groomer reel housing cover from left side of cutting unit Fig 39 2 Loosen idler pulley pivot screw Fig 45 Pivot idler to loosen belt 3 Remove nut and washer from clutch adapter shaft Fig 51 Pull clutch assembly off adapter shaft and slide belt off driven pulley 5 Remove clutch adapter from reel shaft if nec
43. Motor Flow 6 Reel Drive Relief Setting Reel Motor Efficiency 33 7 Test Hook Up No 5 Steering Pump 8 Flow and Steering Pump Relief Setting 35 9 36 10 Lift and Mow Pedal Height 36 11 Traction Pedal 37 12 Rear Camshaft 38 13 oett 39 16 Reel Motor Removal and Installation 39 17 Reel Motor Shaft Seal Replacement 39 Reel Motor 40 18 Pump Removal and Installation 42 19 Pump 43 Control Valve Removal and Installation 44 20 Relief Valve Removal and Installation 45 21 Control Valve Spool Seal Replacement 46 Control Valve Internal Seal Replacement 47 22 Control Valve No 1 Spool Detent Replacement 48 23 Control Valve No 4 Spool Detent Replacement 49 24 Lift Cylinder Removal and Installation 50 25 Lift Cylinder 52 Wheel Motor Removal and Installation 54 25 Wheel Motor 55 Steering Cylinder Removal and Installation 58 25 Steering Cylinder 59 26 Steering Control Unit Removal and Installation 60 27 Steering Control Unit 61 28 Page 4 1 Table of Contents
44. PEDAL DOWN GR3100 WITH DANFOSS PUMP SHOWN l 2 3 SPOOLS IN MACHINES WITH PARKER PUMP USE FOURTH PUMP SECTION FOR LIFT Hydraulic Flow Diagrams 4 10 Rev E Greensmaster 3100 Power Steering Turn Greensmaster 3100 Oil is supplied to port P of the steering control unit from the pump steering section When the steering wheel is turned to the right the control section within the steering valve shifts to direct oil supplied by the pump to the metering section of the steering valve As the steering wheel turns system oil is metered out port R to the steering cylinder Oil displaced by the other end of the STEERING CONTROL UNIT TC e z vw zi xv d Greensmaster 3100 Em en ad um 5 m 4 11 steering cylinder returns to the steering valve through port L which directs it out port T back to reservoir When the steering wheel stops turning the control sec tion within the steering valve shifts back to neutral allowing all oil from the pump to flow through the steering valve out port T back to reservoir Oil in the rest of the Steering circuit is then trapped PRESSURE INT RETURN 2 4 e SUCTION MAIN RETURN STEERING CYLINDER GR3100 WITH DANFOSS PUMP SHOWN DEN MACHINES WITH PARKER P
45. Reel blades 2 1 4 inch 6 mm steel plate 4 Bedknife Figure 12 1 Unit on level surface 2 Hold unit securely 3 Push down on roller Greensmaster 3000 3000 D enn RR RR a Height Of Cut Height of cut as measured in the turf and on the cutting unit is different The grass prevents the cutting unit from settling all the way to the ground line as the machine moves across the turf Because of this the actual effective height of cut is higher than the bench set height of cut Machine conditions such as cutting unit weight roller type bedknife thickness speed of travel and clip in fluence effective height of cut Turf conditions such as grass type grass density and amount of thatch also influence effective height of cut Changing the machine such as adding a wiehle roller will increase penetration into the turf and lower the effective height of cut Changing from a heavier single point adjust cutting unit to a lighter 4 bolt adjust cutting unit will reduce penetration into the turf and raise the effective height of cut Height of Cut Adjustment IMPORTANT Lower heights of cut are limited by thickness of bedknife Select proper bedknife for desired height of cut If bedknife is too thick for height of cut poor quality of cut will result and excessive pressure from turf on bottom of bedknife can cause rifling of bedknife and reel 1 To adjust height of cut cutting unit shou
46. SNDIHVd NOILISOd 440 ND MS 1V3S 9 ug 9 WIS o B wavy D M AD MS 1S3L 1H9I1 SIHON SHLOL 7 v 5 1 N3HM Q3S0 19 40193130 A9 GION3 1OS 440 N3HM 035019 MS MS1WHLNAN AD lt q a 2d 108 1304 aniona on OI3NOVIA ER pu T l 3NION3 GlON3108d3 HM S 2 ill E SS CR yaan AION R enl Ox OIA s 73 ds 14 ce m he 5 A7 ex 6 g voL L r oy 2 HO AN WLS Nn 390 301195 ds NH9 AO MOTHA A ANIJIAISNA 74 S d 31HM M na S I 8 1 6 dOlS Greensmaster 3100 3050 Page5 2 2 Rev D Wiring Schematics Wiring Schematic Greensmaster 3100 S N 230000001 and Up AV T3H
47. See Operator s Manual Fuel Unleaded Regular Gasoline High Idle Speed no load 2800 99 00 RPM Low Idle Speed no load 1400 50 RPM Greensmaster 3100 Page 3 1 Rev Specifications Adjustments Throttle Control Adjustment Fig 1 Before adjusting carburetor make sure throttle control is operating properly 1 Loosen cable clamp screw securing cable to engine 2 Move remote throttle control lever forward to FAST position 3 Pull firmly on throttle cable until back of swivel con tacts stop 4 Tighten cable clamp screw Choke Control Adjustment Fig 1 1 Loosen cable clamp screw securing cable to engine 2 Move remote choke control lever forward to CLOSED position 3 Pull firmly on choke cable until choke butterfly is completely closed then tighten cable clamp screw Adjustments Page 3 2 Figure 1 1 Throttle casing clamp screw 2 Throttle cable 3 Swivel 4 Stop 5 Choke casing clamp screw 6 Choke cable 7 Choke butterfly Greensmaster 3100 Governor Adjustment Before starting engine IMPORTANT If carburetor has been removed or governor linkage disassembled the governor lever throttle restrictor and secondary governor spring must be adjusted before the engine is started Governor Lever Adjustment Fig 2 All linkage must be installed to make adjustment Loosen governor lever bolt and nut Push on governor lever until throttle is wide open DO NOT bend governor
48. Shut off engine After the adjustments have been completed re peat steps 4 through 6 10 When the backlap operation is completed shut off engine and rotate directional valve knob counter clock wise fully 90 from the backlap position to forward position Also rotate flow control valve knob to position 13 for height of cut settings of a 1 4 inch or below Note For additional settings refer to the instructions on the decal that is located on the underside of the seat support 11 Wash all lapping compound off the cutting units 12 For a better cutting edge run a file across the front face of the bedknife when the lapping operation is com pleted This will remove any burrs or rough edges that may have built up on the cutting edge Note Additional instructions and procedures on backlapping are available in the Toro Service Training Book Sharpening Reel and Rotary Mowers part no 8030051 Dual Point Adjust Cutting units Bedbar Assembly 190 to 240 in Ibs dus4 21 to 27 Nm Antiseize Lubricant Figure 10 1 Side plate 7 Bedbar pivot bolt 13 Cap screw 2 Rubber bushing 8 Flange nut 14 Rear roller assembly 3 Flange bushing 9 Flange nut 15 Lock nut 4 Washer plastic 10 Shim 16 Bedknife 5 Washer metal 11 Spacer 17 Bedknife screw 6 Bedbar 12 Retainer Dual Point Adjust Cutting Units Page 10 10 Rev D Greensmaster 3100 Bedbar Removal and Installation Removal Fig 10 1 Positio
49. Troubleshooting Troubleshooting Cutting Units Lift Too Slowly or Not At Check for binding lift assemblies Check forward valve spool travel Check for restriction in lines to or from cylinders Check for leaking cylinder Check lift section of pump Test hook up No 3 Test A Binding Insufficient Restricted Leaking Defective Page 4 24 Loosen and lubricate lift assemblies Adjust rear camshaft Replace restricted line or fitting Repair or replace cylinder Repair or replace pump Greensmaster 3100 Lift Pedal Binding Check pedal linkage Check valve spool detent assembly Binding or Damaged Misadjusted or Damaged Adjust or repair link age and lubricate Lubricate and repair detent Center 1 Cutting Unit Operates in Raised Position Check rear cam shaft for 3 spool too far out of body Check for restric tion in brazed tube assembly on 3 valve section Check for restriction in valve return port between 3 section and R H cover Defective Misadjusted Restricted Adjust camshaft Remove restriction Remove valve bank and disassemle to remove restriction Center 1 Cutting Unit Drops Before Front Cutting Units or Drops Too Fast Check for missing orifce reducer in cylin der line attached to center fitting on crows foot Missing Check for incorrect crows foot fitting Incorrect Greensmaster 3100
50. Used to apply lapping compound to cutting units while keeping the operator s hands at a safe distance from the rotating reel Toro Model Number TOR299100 Bedknife Screw Tool This screwdriver type bit is made to fit Toro bedknife at taching screws Use this bit with a torque wrench to se cure the bedknife to the bedbar IMPORTANT DO NOT use and air or manual impact wrench with this tool so damage to the bedbar will be prevented Toro Model Number TOR510880 Greensmaster 3100 Page 10 3 Rev D Some tools may have been supplied with your mower or available as TORO parts Some tools may also be avail able from a local supplier Figure 2 Figure 3 H Figure 4 Dual Point Adjust Cutting units Inner Grease Seal Installation Washer inner grease seal installation washer Toro Part Number 104 0532 This washer is used when replacing the reel bearing in ner grease seal It enables pressing the grease seal to a depth of 104 in 2 64 mm below the surface of the cutting unit side plate Toro Part Number 104 0532 Figure 5 Plastic Plug This cap is used for placement into the bearing housing when the reel motor is removed It prevents dirt and de bris from entering the housing Toro Part Number 2410 30 Figure 6 Turf Evaluator Tool Many turf discrepancies are subtle and require closer examination In these instances the Turf Evaluator grass viewing tool is helpful It can assist turf managers
51. Washer metal 2 Rubber bushing 6 Bedbar 3 Flange bushing 7 Bedbar pivot bolt 4 Washer plastic 8 Flange nut 4 Slide one metal washer 5 and one plastic washer 4 onto each bedbar pivot bolt The metal washer 5 must contact the flange nut 8 Fig 11 5 Position bedbar 6 into cutting unit Slide the top of the bedbar arms between washers on each adjuster as sembly 6 Position one metal washer 5 and one plastic wash er 4 between bedbar and each side plate The metal washer 5 must contact the bedbar Fig 11 7 Install the bedbar pivot bolt assemblies Tighten each bedbar pivot bolt from 190 to 240 in Ibs 21 to 27 Nm 8 Tighten both flange nuts 8 to remove end play at the outer washers Do not over tighten the flange nuts or distort the side plates 9 Tighten the lock nut 15 on each bedbar adjuster assembly until the adjuster spring is fully compressed then loosen lock nut 1 2 turn 10 Adjust cutting unit see Cutting Unit Operator s Manual Dual Point Adjust Cutting units Bedbar Adjuster Service Figure 12 Adjuster shaft Jam nut Flange bushing Cutting unit frame Wave washer Detent Lock washer Rom Removal Fig 12 1 Remove bedbar see Bedbar Removal in this sec tion of this manual 2 Remove locknut 12 spring 11 and washer 10 from adjuster screw 3 Unscrew adjuster 6 from the adjuster shaft 1 4 Remove jam nut 5 and wave washer
52. a cam to raise orlowerthe roller Onthe bolt head there is an identifica tion dot Fig 13 which denotes the offset ofthe bolt Dot indicates in which direction left end of roller moves when bolt is turned 8 To verify if roller is level try inserting a piece of paper under each end of roller 9 When roller is level tighten left capscrew and pivot Figure 12 bolt securely Hold the eccentric pivot bolt while tighten ing the nut to keep the proper roller position 1 1 4 plate 2 Bedknife Figure 13 1 Pivot bolt Greensmaster 3000 3000 D Page 9 13 Set Up and Adjustments eS Height of Cut Height of cut as measured in the turf and on the cutting unit is different The grass prevents the cutting unit from settling all the way to the ground line as the machine moves across the turf Because of this the actual effective height of cut is higher than the height of cut setting on the cutting unit bench set height of cut Fig 14 Machine conditions such as cutting unit weight roller type bedknife thickness speed of travel and clip Top of Grass Ground Line frequency influence effective height of cut Turf condi tions such as grass type grass density and amount of thatch also influence effective height of cut Changing the machine such as adding a wiehle roller or changing from a 4 bolt adjust cutting unit to a heavier single point adjust cutting unit will increase penetration into the turf an
53. a few hours by a doctor or gangrene may occur 30 Before disconnecting or performing any work on the hydraulic system all pressure in system must be re lieved by stopping engine and lowering cutting units and attachments to the ground 31 To reduce potential fire hazard keep engine area free of excessive grease grass leaves and dirt Do not use flammable solvents for cleaning parts Do not use diesel fuel kerosene or gasoline 32 If the engine must be running to perform an inspec tion or procedure use extreme caution Always use two people with the operator at the controls able to see the person doing the inspection or procedure Keep hands feet clothing and body away from cutting units and other moving parts Greensmaster 3100 Page 1 3 33 Do not overspeed the engine by changing governor settings Maximum governed engine speed should be 2850 rpm 34 Shut engine off before checking or adding oil to the engine crankcase 35 Be sure you understand a service procedure before working on the machine Unauthorized modifications to the machine may impair the function safety and life of the machine If major repairs are ever needed or assis tance is desired contact your TORO Distributor 36 Wear safety glasses goggles or a face shield to prevent possible eye injury when using compressed air for cleaning or drying components 37 When changing attachments or performing other service use the correct blocks a
54. a light coating of clean oil to the seal protector to ease movement of the seal over the tools Use the installer 2 and a small hammer to drive the reel motor shaft seal into position in the bore of the reel motor body Detent Installation Tool Fig 8 Use this tool with a 3 8 in drive torque wrench to tighten the detent stud in the No 1 spool of the control valve Apply Loctite 222 or equivalent to the threads of the detent stud Tighten the stud to a torque of 10 14 ft Ib Special Tools 4 14 Figure 7 Figure 8 Greensmaster 3100 Seal Installation Tool Fig 9 Use to assure proper fit and positioning of lip seals used in the TRW Torqmotor hydraulic wheel motor Put the seal inside the ring Item 2 with the seal lip toward the motor Slide the main tube Item 1 of the tool into the ring Put the tool into position in the bore of the motor housing Tap against the main tube of the tool to seat the seal Assembly Studs Fig 10 Use for proper alignment of internal parts during disas sembly and repair of the TRW Torqmotor hydraulic wheel motor IMPORTANT The wheel motor geroters are indexed and must be kept in their original position amp Nea 332 Figure 9 Control Valve Spool Seal Installation Tools Fig 11 This tool can be made to the dimensions shown Soak new seal in clean hydraulic fluid before installing Install
55. and No 4 valve bank sections TEST C TRACTION MOTOR EFFICIENCY PROCEDURE Tester Flow Control Valve Open Disconnect hydraulic hoses pressure and return that lead to front left motor Install caps to open ends of tubes and hoses Block up the machine so traction wheels are off floor If machine is equipped with 3WD rear wheel needs to be off floor as well Apply brake and engage park lock Engine RPM 2800 Hydraulic oil at normal operating temperature Engage transmission lever to No 1 position Push traction pedal to forward position TESTER READINGS Flow not more than 1 5 GPM at a pressure of 1850 to 1950 PSI If flow is higher than 1 5 GPM remove right wheel motor and repair as necessary If pressure is not in listed range remove traction relief cartridge from valve bank and examine for contamination or damage If needed test left front wheel motor by placing tester in left side pressure hose and blocking flow to right motor Testing Page 4 31 Rev E Greensmaster 3100 3 Reel Drive Pump Efficiency TESTER CONNECTION Tester in series between reel pump outlet hose on suspected bad section and its valve bank fitting Section being checked should be one that supplies oil for reel unit not operating properly Tester Flow Control Open CAUTION Keep everyone away from the front of the machine during reel system tests Operator must be on seat or the safety interlock will stop the engine when t
56. and rifle when no grass is being cut See Troubleshooting in Chapter 5 Hydraulic System 17 Traction speed Check maximum governed engine speed Adjust to specification if necessary See Troubleshooting in Chapter 5 Hydraulic System Install Variable Speed Traction Kit if necessary to con trol traction speed in varying conditions or with dif ferent attachments Will allow change in traction speed while maintaining full engine rpm and reel motor rpm 18 Cutting drop speed and sequence Center cutting unit must drop after front cutting unit See Troubleshooting in Chapter 5 Hydraulic System Greensmaster 3000 3000 D Page 9 7 Troubleshooting Set Up and Adjustments Adjustment Summary and Check List DETAILED ADJUSTMENT INSTRUCTIONS FOLLOW THIS SUMMARY AND CHECK LIST Study this informa tion and refer to it often to get maximum life and perfor mance from the cutting units Daily Performance Checks NOTE It is not necessary to remove the cutting units from the traction unit to perform these daily checks It is recommended that mowers be washed after each use Always remove key from ignition switch when working on the machine 1 Purge all water and debris from all of the bearings by greasing them Use No 2 multi purpose lithium base grease 2 Visually check for sharp reel and bedknife Remove burrs nicks and rounded edges 3 Lower cutting units to ground setting on both rollers and remove ree
57. be affected if the teeth are not installed in the same position during reassembly IMPORTANT To prevent damage to load plate or cover during motor operation do not mark gears with a punch or scribe 6 Be careful when disassembling The needle bearings 5 may be of the loose grease retained type Pack these Repairs Page4 41 1 Rev B with general purpose grease to retain them for re asembly It is recommended NOT to remove the bearing races from the cover and bogy 7 Remove the load plate assembly 9 8 Remove and discard the seal ring 8 snap ring 13 shaft seal 12 and spacer 11 These items are avail able in a repair kit 9 Clean and air dry all parts Check for burrs scoring nicks etc 10 Replace gears as set if excessively scored or worn Replace load plate if worn or scored 11 Apply grease or petroleum jelly to load plate assem bly 9 and install in body 12 Dip gears in oil and install in body maintaining origi nal timing and locations 13 Apply grease or petroleum jelly to ring seal 8 and install in body 14 Apply hydraulic oil to inside of cover 4 and assemble cover to body making sure that none of the parts become displaced Insert the cap screws and washers and hand tighten Greensmaster 3100 15 Before tightening the capscrews rotate the drive 17 Carefully install a new spacer shaft seal and snap shaft in the direction of normal rotation counterclock ring Perf
58. before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hy draulic equipment Greensmaster 3100 Page 4 27 2 Put caps or plugs on any hydraulic lines left open or exposed during testing or removal of components 3 The engine must be in good operating condition ALWAYS use a tachometer when making a hydraulic test Engine speed will affect the accuracy of the tester readings 4 To prevent damage to the tester or components the inlet and the outlet hoses must be properly connected and not reversed tester with pressure and flow capa bilities 5 To minimize the possibility of damaging the compo nents completely open the load valve by turning it counterclockwise tester with pressure and flow capa bilities IMPORTANT The pump used on the Greensmaster 3100 is a positive displacement type If its output flow is completely restricted or stopped damage to the pump or other components could occur 6 Install fittings finger tight far enough to insure that they are not cross threaded before tightening with a wrench 7 Position the tester hoses so that rotating machine parts will not make contact with them and result in hose or tester damage 8 Check the oil level in the reservoir 9 Check the control linkage for improper adjustment binding or broken parts 10 All hydraulic tests should be made with the hydraulic oil at normal operat
59. block snap ring shaft seal spacer seal assembly wear plate and o ring Items 5 6 8 11 14 15 and 17 These items are available in a repair kit 8 Clean all parts and check for burrs scoring nicks etc 9 Rub mating surfaces of body and cover with 400 grit or finer sandpaper to remove any Loctite residue Wash body and cover to remove abrasive material 10 Apply grease to bridging insert and put in cover tab side down 11 Apply grease to gasket insert and put in place over bridging insert 12 Stone gears if wear plate appears scored Replace as set if necessary Oil the inside of cover and insert the gear set maintaining the original timing and locations 13 Apply grease to wear plate and slip over shafts with wider cross section next to bridging insert If the wear plate is made of steel backed bronze the bronze side must face gears Greensmaster 3100 14 Apply grease to anti extrusion block and put in recess of seal assembly with ground face showing 15 Apply grease to seal assembly and put in body counterbore Anti extrusion block must face body on the tank port side when the motor is assembled same side as bridging insert 16 Mating surfaces of body and cover must be clean free of oil and dry Clean both surfaces with Locquick primer or clean shop solvent Spread a thin even coat ing of Loctite 515 Gasket Eliminator or equivalent on one surface 17 Assemble the body to the cover maki
60. bolts 7 to a torque of 17 to 20 ft lbs 23 to 27 Nm D Tighten the cap screws 24 E Tighten each bedbar adjuster assembly until the adjuster spring is fully compressed then loosen lock nut 1 2 turn Note For severely tapered reels a 010 in 254 mm shim Toro Part No 106 6923 is available for the rear roller mount Greensmaster 3100 Preparing a Reel for Grinding Note Check to make sure the reel bearings are in good condition before grinding a reel 1 Remove bedbar assembly see Bedbar Removal and Installation 2 Remove parts as necessary to mount cutting unit into grinder e g front roller front roller brackets Note The cutting unit must be aligned so the grinding wheel will travel parallel to the reel shaft This will result in the the reel being ground to the desired cylinder shape Note When grinding be careful to not overheat the reel blades Remove small amounts of material with each pass of the grinder 3 After completing the grinding process A Install parts removed to mount cutting unit into grinder B Install bedbar assembly see Bedbar Removal and Installation C Complete cutting unit set up and adjustment se quence see Cutting Unit Operator s Manual Reel Grinding Specifications Nominal Reel Diameter 5 06 128 5 mm Service Limit Reel Diameter 4 56 in 118 8 mm Relief Angle Range 20 to 40 Blade Land Width 0 040 in 1 0 mm Land Width Range 0 030 to 0
61. die spring is compressed to a dimen sion of 13 16 in by tightening locknut left hand thread Fig 6b 9 If equipped with hex head type pivot screws tighten pivot screws to 60 ft Ib If equipped with hex socket head Set screws and jam nuts tighten set screws finger tight thentighten 1 2 turn more total not each Tighten jam nut 10 Adjust bedknife to reel contact NOTE If quality of cut has deteriorated or the reel and bedknife have become rifled you must grind the reel and bedknife to remove rifle pattern Figure 52 1 Pivot housing 2 Bearing 2 3 Inner race 2 4 O ring 2 Repairs 5 Spring arm 6 Adjustment knob 7 Bedbar pivot 8 Spring Page 10 32 9 Pivot screw 2 10 Spring arm retaining capscrew Greensmaster 3000 3000 D Lift Bail Replacement q NY 27772 772 N 22222722722 2 Figure 53 1 Use saw to cut the lift bail off of the cutting unit Make 4 Support the lift bail so the bottom radius is 4 546 inches the cut 1 inch from the horizontal frame tube Fig 53 from the top of the horizontal frame tube Make sure the lift bail is square to the side frame 2 Use a grinder to remove burrs from the stubs of the lift bail remaining on the cutting unit 5 Weld all around the bottom of the repair lift bail with mild steel rod both sides 3 Install the repair lift bail Part No 71 1600 Greensmaster 3000 3000 D Page 10 33 Repairs This page is
62. edges See Preparing Cutting Unit for Reel Grinding in this section of the book 8 Check size of hole bedbar bushings every time bedbar is removed Insert flange bushing into rubber bushing Fig 28 Insert clean shoulder bolt into flange bushing rubber bushing assembly If bolt slides easily into bushing replace all four bedbar bushings See Bedbar Bushing Replacement in this section of the book 1 Rubber bushing 3 Shoulder pivot bolt 2 Flange bushing Figure 28 Repairs Page 10 22 Greensmaster 3000 3000 D 9 With frame on level surface and pivot set screws installed measure from flat surface up to end of each setscrew Fig 29 If not within 1 16 in of each other carefully bend frame supports toline up screws Remove pivot set screws Measure distance between frame pivot supports Fig 29 If dimension is not between 1 9 16 in and 1 5 8 in carefully bend supports until correct 10 To install bedbar slide it into position between side plates making sure each end of bedbar is under shield Fig 30 IMPORTANT Always use McLUBE Toro Part No 505 35 on bedbar pivot and pivot bolts 11 Install jam nut on eccentric pivot bolt Put plastic washer between left side of bedbar and side plate Thread pivot bolt into side frame until distance from top of pivot bolt to side plate is 1 5 16 in with identification dot toward the rear Fig 31 Do not tighten jam nut 12 Install jam nut on strai
63. es yeas sioyesodo Jo apis HY Jepur 4 poje201 Jepun Je81 uo poje201 pajeoo 10 uu0 9 40 99UU0D IM uv or 10 qyoauuo 4019euuo2 20129199 1895 youmg uonoei UAMS MON youmg n x gt 0 gt 3 E 4 E Old 6d 8d 0 mE plousjos 5 Jeuels f 8617 UOI 9EJ YOUMS S SN4 a d 9d 8v 8v Jojejeq ee Sd Y isi oig Key youmg Ir punol6 qi 1 TT or 8d apy APN 5 vr ejosuo 2 Wiring Schematics 5 2 7 Rev D Greensmaster 3100 3050 This page is intentionally blank rf Guard ian j Leak Detection System Greensmaster 3100 S N below 230000001 Before Start Up Cold Oil With ignition switch off solenoid valve is open Before start up hydraulic fluid is at level mark of sight gauge oil cold Float is in raised position keeping alarm circuit open To check alarm and delay timer turn ignition switch to ON then move leak detector switch rearward and hold After a one sec
64. for clip frequency and optimum height of cut range Variable speed traction kit can be used to adjust clip frequency 12 Number of reel blades Check pull frame alignment on all cutting units Adjust or repair as necessary 13 Cutting unit alignment and pull frame ground following Check pull frames and lift arms for damage binding and bushing wear Repair if necessary All rollers must rotate freely Grease when needed or repair bearings if necessary All reels must rotate at same speed within 100 rpm All cutting units must have equal bedknife to reel con tact and reel bearing adjustment before checking Do not run the reel to long or it may get hot and rifle when no grass is being cut 14 Roller condition 15 Reel speed See Troubleshooting in Chapter 5 Hydraulic System Check maximum governed engine speed Adjust to specification if necessary 16 Traction speed See Troubleshooting in Chapter 5 Hydraulic System Install Variable Speed Traction Kit if necessary to con trol traction speed in varying conditions or with dif ferent attachments Will allow change in traction speed while maintaining full engine rpm and reel motor rpm Center cutting unit must drop after front cutting unit 17 Cutting drop speed and sequence See Troubleshooting in Chapter 5 Hydraulic System Greensmaster 3000 3000 D Page 10 7 Troubleshooting
65. for the cutting units on the Greensmaster 3150 Dual Point Adjust Cutting units Repairs Hydraulic Reel Motor IMPORTANT When performing maintenance pro cedures on the cutting units store the cutting unit reel motors in support tubes on the frame to prevent damage to the hoses Do not raise suspension to transport position when the reel motors are in the holders in the traction unit frame Damage to the motors or hoses could result Removal 1 Park machine on a clean and level surface lower cutting units completely to the ground stop engine en gage parking brake and remove key from the ignition Switch 2 Remove basket from carrier frame 3 Loosen flange head screws that secure the hydrau lic motor to the motor adapter plate Rotate motor clock wise and remove motor 4 Place protective plastic cap see Special Tools into the hole in the motor adapter plate Inspection 1 Checkreel drive coupler splines for wear Replace if necessary see Reel Removal and Installation in this chapter of this manual Installation 1 Coat spline shaft of the motor with clean No 2 multi purpose lithium base grease 2 Install the flange head screws for the reel drive mo tor into the motor adapter plate and leave approximately 1 2 inch 12 7 mm of threads exposed on each screw 3 Install motor by rotating the motor clockwise so the motor flanges clear the flange head screws 4 Rotate the motor counterclockwise un
66. link Hold lever in this position and rotate governor shaft counterclockwise as far as it will go Hold lever and shaft in position and torque governor lever bolt and nut to 70 in Ib Throttle Restrictor Adjustment Fig 3 Move throttle control lever to SLOW position Hold governor lever so that throttle lever touches idle speed adjustment screw Use tang bender Briggs amp Stratton Tool 19352 and bend throttle restrictor tang so throttle opening is limited to 1 4 in travel when governor lever is released Secondary Spring Adjustments Fig 4 With throttle control lever in SLOW position install adjustment gauge Brigss amp Stratton Tool 19385 over end of governor lever as shown Holding gauge in position bend tab so that all slack is removed from secondary governor spring between its two anchor points DO NOT STRETCH SPRING Remove adjust ment gauge Greensmaster 3100 3 3 5 77 N TORQUE WRENCH Figure 2 1 4 TRAVEL THROTTLE RESTRICTOR TANG Figure 4 Adjustments Carburetor and Speed Control Adjustment Fig 5 6 IMPORTANT Before carburetor and speed control are adjusted the throttle and choke controls must be adjusted properly A WARNIN G Engine must be running during adjustment of carburetor and speed control To guard against possible personal injury shift into neutral and engage parking brake Keep hands feet face and other pa
67. no continuity adjust or replace the switch See Traction Neutral Switch Replacement and Adjustment in the Repairs section of this book 3 Move the shift selector to the No 1 and No 2 posi tions There should not continuity when shift selector is in either of these positions If there is continuity adjust or replace the switch See Traction Neutral Switch Replacement and Adjustment in the Repairs section of this book Testing Page 5 10 Figure 9 1 Seat switch Figure 10 1 Traction neutral switch on bottom of valve bank Greensmaster 3100 Mow Lift Switch Fig 11 1 Disconnect the mow lift switch wire connector and install a continuity tester or ohm meter between the two leads of the mow lift switch 2 Push down on the lift pedal and release it There should be continuity when the mow pedal is disen gaged If there is no continuity adjust or replace the switch See Mow Lift Switch Replacement and Adjust ment in the Repairs section of this book 3 Push down on the mow pedal and release it There should not be continuity If there is continuity adjust or replace the mow lift switch See Mow Lift Switch Re placement and Adjustment in the Repairs section of this book Interlock Module Fig 12 The interlock module Item 26 senses the condition of the seat switch traction switch and mow lift switch The seat switch must remain CLOSED while the traction switch or mow lift switch is OP
68. right from lock to lock several times to get air out of the cylinder IMPORTANT When disassembling hydraulic lines make sure hydraulic plugs are placed in the open end of the hydraulic line to prevent foreign debris from contaminating hydraulic oil It is also a good idea to tag the hydraulic lines when disassembling so they can be properly reassembled Keep all hy draulic lines clean and free from foreign debris During replacement of steering cylinder avoid over tightening fittings Check hydraulic lines for cracks or breaks If a hydraulic leak should appear after replacement of lift cylinder replace the fitting or line that is leaking Check hydraulic reservoir for level of hydraulic fluid after replacement of lift cylinder Greensmaster 3100 Steering Cylinder Repair Greensmaster 3100 Fig 40 Figure 40 IMPORTANT To prevent damage when clamping the cylinder barrel in a vise clamp only onthe pivotend Do not clamp the vise jaws against the smooth shaft surface Protect the shaft surface before mounting in the vise 1 After removing the cylinder pump the oil out of cylinder ports into a drain pan by SLOWLY moving rod in and out of cylinder bore 2 Plug the ports and clean the outside of the cylinder 3 Mount the cylinder in a vise by clamping vise on center mounting location of cylinder 4 Loosen setscrews Item 1 and remove threaded end caps Item 2 from each end of barrel Item 12 5 G
69. the Service and Repairs section in this chapter of this manual Cutting Unit drop speed and sequence Rear cutting unit must drop after front cutting units See Rear Lift Cylinder Flow Control Valve in Chapter 4 Hydraulic System in this manual Dual Point Adjust Cutting Units Page 10 6 Rev D Greensmaster 3100 Set Up and Adjustments Characteristics Never install or work on the cutting units or lift arms with the engine running Always stop en gine and remove key first The dual knob bedknife to reel adjustment system in corporated in this cutting unit simplifies the adjustment procedure needed to deliver optimum mowing perfor mance The precise adjustment possible with this de sign gives the necessary control to provide a continual self sharpening action This feature maintains sharp cutting edges assures good quality of cut and greatly reduces the need for routine backlapping In addition the rear roller positioning system allows for two height of cut ranges Greensmaster 3100 Page 10 7 Rev D If a cutting unit is determined to be out of adjustment complete the following procedures in the specified order to adjust the cutting unit properly 1 Adjust the bedknife parallel to the reel 2 Determine desired height of cut range and install rear roller mounting shim accordingly 3 Adjust the height of cut 4 Adjust the cut off bar See Cutting Unit Operator s Manual for adjustment pro cedures
70. the parking brake Push the lift pedal down all the way and release it Move the shift selector to the No 1 position and try to start the engine The engine should not crank Move the shift selector to the No 2 position and try to start the engine The engine should not crank If the engine did not crank in either position the traction switch is operating prop erly proceed to step 2 If the engine cranked refer to Troubleshooting in this chapter 2 Sit on the seat and engage the parking brake Push the lift pedal down all the way and release it Move the Troubleshooting Page 5 8 shift selector to the neutral N position and try to start the engine The engine should start and continue to run which means that the traction switch and mow lift switch is operating correctly proceed to step 3 If the engine cranked but did not start the problem is not in the interlock system If the engine did not crank refer to Troubleshooting in this chapter 3 Sit on the seat and engine the parking brake Move the shift selector to the neutral N position Push the mow pedal down and try to start the engine The engine should not crank which means the mow lift switch is operating correctly proceed to step 4 If the engine cranked refer to Troubleshooting in this chapter 4 Sit on the seat and engage the parking brake Move the shift selector to neutral N Push lift pedal down and release it Start the engine release the park
71. units Specifications DUAL POINT ADJUST UNIT Figure 1 Height of Cut HOC Cutting height is adjusted on the front roller by two vertical screws and held by two locking capscrews Standard bench height of cut range is 062 inch 1 6 mm to 375 inches 9 5 mm depending on type of bedknife installed Bench height of cut range with the High Height of Cut Kit installed is 285 inch 7 mm to 1 inch 25 mm Effective HOC may vary de pending on turf conditions type of bedknife rollers and attachments installed Reel Construction Reels are 5 inches 13 cm in di ameter 21 inches 53 3 cm in length High strength low alloy steel blades are thru hardened and impact resis tant Reels are available in 8 and 11 blade configura tions Reel Bearings Two double row self aligning ball bear ings 30 1 mm inside diameter slip fit onto reel shaft with lock nut Additional inboard and outboard seals for added protection Reel position maintained by a wave washer with no adjusting nut Reel Drive The reel weldment shaft is a 1 375 inch di ameter tube with drive inserts permanently pressed in both ends A replaceable floating coupler with an inter nal eight tooth spline is factory installed on the right end and held in place by a snap ring Frame Construction Precision machined die cast alu minum cross member with two bolt on die cast alumi num side plates Dual Point Adjust Cutting Units Page 10 2 Rev D Bed
72. will appear on the front cutting Greensmaster 3000 3000 D Page 9 9 edge surface the full length of the bedknife If a file is occasionally run across the front edge to remove this burr improved cutting performance can be obtained NOTE After extended running notches will eventually develop at both ends of the bedknife These notches must be rounded off or filed flush with cutting edge of bedknife to assure smooth operation Figure 6a Tool adjustable knob 1 Bedknife adjusting knob 3 Pivot bar 2 Compression spring Figure 6b Hand adjustable knob 1 Bedknife adjusting knob 2 Compression spring Set Up and Adjustments 3 Locknut left hand thread Reel Bearing Service and Adjustment 1 First make sure bedknife to reel contact is removed by turning bedknife adjustment knob counterclockwise Fig 6 2 Reel bearing rolling torque should not exceed 7 Measure with an inch pound torque wrench Fig 7 If bearing drag does not meet above specifications adjust reel bearings NOTE If you do not have an inch pound torque wrench do steps 1 3 under Reel Bearing Adjustment below Reel Bearing Adjustment 1 Remove mounting nuts from counterbalance end cap and remove end cap from mounting studs Fig 7 2 Remove bolt mounted on the end of reel shaft This Figure 7 will make it possible for a large socket wrench to be mounted onthe reel bearing adjusting nut inside the sid
73. with the palm of clean hand Clean each of the flat surfaces of the meter section parts in a similar way when ready for reassembly Do not use cloth or paper to clean surfaces 19 Install 3 diameter seal in housing 20 Install spacer plate Align bolt holes in spacer plate with tapped holes in housing Figure 62 Greensmaster 3100 Page 4 69 Repairs 21 Rotate spool and sleeve assembly until pin is paral lel with port face Install drive make sure you engage drive with pin To assure proper alignment mark drive as shown in Fig 65 ref B Note relationship between slotted end of drive to splined end of drive when mark ing 22 Install 3 diameter seal in meter 23 With seal side of meter toward spacer plate align star valleys ref A on drive ref B Note the parallel relationship of reference lines A B C and D Align bolt holes without disengaging meter from drive Port Face Drive Pin Parallel with Port Face Figure 63 Seal Meter Gerotor Figure 64 Meter Gerotor Star Valley Drive Marked Port Face Repairs Page 4 70 Figure 65 Greensmaster 3100 24 Install 3 diameter seal in end cap 25 Install end cap on gerotor align holes Seal End Cap Screw Figure 66 26 Install seven 7 DRY cap screws with new seal washers in end cap Pre tighten screws to 150 inch pounds
74. 0 300 PT NOTE For a better cutting edge run a file across front face of bedknife when lapping operation is completed This will remove any burrs or rough edges that may have built up on the cutting edge Bedbar Removal and Installation 1 Loosen pivot screws securing bedknife pivot assemb ly to reel frame supports Fig 27 2 Rotate adjustment knob and pivot assembly clock wise left hand thread until it is unthreaded from bedbar pivot Fig 27 3 Loosen jam nuts retaining right and left bedbar pivot bolts Remove pivot bolts Fig 27 IMPORTANT Note position of plastic washer and steel washer right end of bedbar and plastic washer on left end of bedbar for reinstallation 4 Slide bedbar down and out from under cutting unit Figure 27 Do not misplace washers 1 Pivot screw 7 Left bedbar pivot bolt 5 Replace and or grind bedknifeto renew cutting edges 2 Bedknife pivotass y 8 Right bedbar pivot bolt 3 Frame supports 9 Steel washer NOTE For proper grinding of bedknife follow proce Adjustment knob 10 Flastic washer S ER E 5 Bedbar pivot 11 Spring arm retaining capscrew dures in the Toro publication Sharpening Reel and 6 Jam nuts 12 Compression spring Rotary Mowers Form No 80 300 PT 6 Adjust the reel bearings See Reel Bearing Service and Adjustment in the Adjustments section of this chap ter 7 Grind the reel to remove any taper and renew cutting
75. 060 in 0 7 to 1 5 mm Service Limit Reel Taper 0 040 in 1 0 mm BLADE RELIEF ANGLE REEL DIAMETER TAPER D Figure 22 Greensmaster 3100 Page 10 19 Rev D Dual Point Adjust Cutting units Front Roller Removal and Installation Removal Fig 23 1 Position machine on a clean and level surface low er cutting units stop engine engage parking brake and remove key from the ignition switch Note The front roller can be removed with the cutting unit either attached to the lift arm or removed from the lift arm Determine your maintenance needs 2 Loosen cap screws securing the roller shafts to each front bracket 3 Remove the lock nut tab washer and carriage Screw securing one of the front roller brackets to the cut ting unit frame assembly 4 Remove the front bracket and slide the roller and shaft from the cutting unit Remove the remaining front roller bracket if necessary Installation Fig 23 1 Place cutting unit on a level working surface 2 If both front roller brackets were removed A Insert carriage screw through the cutting unit side plate and front bracket Secure carriage screw and roller bracket with tab washer and lock nut Dual Point Adjust Cutting Units Page 10 20 Rev D Figure 23 1 Cap screw 4 Carriage screw 2 Roller assembly 5 Locknut 3 Front roller bracket 6 Tab washer 3 Slide roller shaft into the front bracket attached to the cutting uni
76. 100 Page 10 13 Rev D Figure 13 1 Screw 3 Bedknife 2 Bedbar Loue d EE 13 1 9 7 5 3 12 4 6 8 10 12 Figure 14 Top Face Remove Burr Front Face Relief Angle Front Angle Figure 15 NOTE Relief angle is 7 for special extended bedknives Dual Point Adjust Cutting units Reel Assembly Ng o RON General Purpose Grease Reel Speedi sleeve V ring Drive coupler Retaining ring Left side plate assembly Shoulder bolt Bearing lock nut Outer grease seal Dual Point Adjust Cutting Units General Purpose Grease Figure 16 Right side plate assembly O ring Bearing Inner grease seal Retaining ring Wave washer Seal strip Frame assembly Page 10 14 Rev D 17 to 20 ft lbs 23 to 27 Nm Flange nut Cap screw Lift hook Cap screw Grass shield Washer Cap screw Lock nut Greensmaster 3100 Reel Removal Fig 16 1 Remove reel motor from the cutting unit see Hy draulic Reel Motor Removal in this chapter 2 Remove the 2 capscrews securing the counter weight to the side plate Fig 17 Remove the counter weight 3 Remove the bedbar assembly see Bedbar Remov al in this chapter Note Depending on tools available it may be neces sary to remove the reel motor adapter plate before re moving the left end bearing lock nut 8 4 Remove the reel bearing lock 8 nut from each end of the reel shaf
77. 125 in center bracket in slot NOTE Position of rear roller bracket determines bedknife angle Recommendations for rear roller brack et position in above chart are designed to give the best rear roller position and bedknife angle for different heights of cut IMPORTANT Rear roller bracket position must be identical on all three 3 cutting units so bedknifes are at the same angle If bedknifes are not at the same angle there will be a difference in the ap pearance of the cut grass mismatch for each cut ting unit 2 Place 1 4 inch 6 mm or thicker plate under the reel blades and against the cutting edge of the bedknife Fig 11 NOTE Be sure the plate covers the full length of reel blades 3 With cutting unit reel blades positioned on the plate hold cutting unit securely and push down on the rear roller assembly until it contacts the working surface across the full length of the roller Fig 12 4 Tighten nut on rear roller bracket that was not tightened in step 1 to secure roller in place Set Up and Adjustments Page 8 10 Figure 11 1 Rear roller bracket 3
78. 2 Flange bushing Repairs Page 9 20 Greensmaster 3000 3000 D 9 With frame on level surface and pivot set screws installed measure from flat surface up to end of each setscrew Fig 26 If not within 1 16 in of each other carefully bend frame supports toline up screws Remove pivot set screws Measure distance between frame pivot supports Fig 26 If dimension is not between 1 9 16 in and 1 5 8 in carefully bend supports until correct distanca 10 install bedbar slide it into into position between side plates making sure each end of bedbar is under shield Fig 27 IMPORTANT Always use McLUBE Toro Part No 505 35 on bedbar pivot and pivot bolts 11 Install jam nut on eccentric pivot bolt Put plastic washer between left side of bedbar and side plate Thread pivot bolt into side frame until distance from top of pivot bolt to side plate is 1 5 16 in with identification dot toward the rear Fig 28 Do not tighten jam nut 12 Install jam nut on straight pivot bolt Put plastic washer and steel washer between right side of bedbar and side plate with plastic washer closest to bedbar Thread pivot bolt into side plate Adjust right hand pivot bolt until left end of bedbar firmly seats against side plate clamping the plastic washer snugly This removes end play from bedbar Bedbar must pivot without bind ing Hold right hand pivot bolt to keep it from moving and tighten jam nut Figure 27 IMPORTA
79. 2 5 in traction spring Figure 27 1 Internal seals 4 between ea sect 2 Main amp No 1 section relief valve NOTE Replace all internal seals whenever valve sec tions are disassembled Original seals may not seal after the valve assembly is installed on the machine 1 Remove the valve bank See Control Valve Removal and Installation in this section of the book 2 Put the valve bank in a vertical position in a bench vise and remove the locknuts from the three 3 bolts securing the sections together Fig 27 3 Slide each section off the studs Identify them so they will not be reassembled in the wrong location 4 Remove all original o ring seals clean the o ring grooves and check the mating surfaces of each section Greensmaster 3100 3 No 2 section relief valve 4 No 3 section relief valve Page 4 47 5 No 4 traction section relief valve for any imperfections or contaminants which could cause leakage to occur 5 Soak the replacement o rings in clean hydraulic fluid and install them into the ring grooves as you stack each section on top of another 6 Install the locknuts onto the studs and torque them to 15 20 ft lb 20 4 27 2 Nm IMPORTANT Do not overtorque This will distort the valve bodies and cause binding of the spools 7 Install the valve bank onto the machine Repairs Control Valve No 1 Spool Detent Replacement Fig 28 29 NOTE These procedures can be done with th
80. 4 Turn back the jam nut as far as possible Make sure the back up washer is not loose and is pushed up as far as possible Step 1 5 Install the fitting into the port and tighten finger tight until the washer contacts the face of the port Step 2 6 To put the fitting in the desired position unscrew it by the required amount but no more than one full turn Step 3 7 Hold the fitting in the desired position with a wrench and turn the jam nut with another wrench to the correct flats from finger tight F F F T Step 4 Size F F F T 4 1 4 in nominal hose or tubing 1 00 25 6 3 8 in 1 50 25 8 1 2 in 1 50 25 10 5 8 1 50 25 12 3 4 1 50 25 16 1 in 1 50 25 General Information Page 4 4 Figure 3 Lock Nut lt Back Up Washer Figure 4 Figure 5 Greensmaster 3100 Hydraulic Flow Diagrams Traction No 1 Position When engine is started pump draws oil from reservoir through two suction lines Oil from one section of pump passes through fitting in No 4 spool valve into valve Traction lever when located in No 1 positions spool so oil is directed to flow into the No 5 metering valve RESERVOIR Greensmaster 3100 section When the traction pedal is pushed forward oil flows out lines at rear of metering valve section to each motor to drive the motors Low pressure oil returns to valve through valve and main r
81. 4 using a 9 16 inch thin wall socket Inspect bolts for damaged threads or sealing ring under bolt head Replace dam aged bolts 3 Remove end cover assembly Item 24 and seal ring Item 5 4 Thoroughly wash cover in solvent and blow dry Make sure cover valve apertures including internal orifice plug are free of contamination Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces Replace cover as necessary Greensmaster 3100 Page 4 55 5 Remove commutator ring Item 23 commutator Item 16 and manifold Item 22 6 Remove commutator seal Item 15 from commutator Item 16 using an air hose to blow air into ring groove until seal ring is lifted out and discard seal Inspect commutator and commutator ring for cracks or burrs Inspect commutator for wear scoring spalling or brinelling If any of these conditions exist replace com mutator and commutator ring as a matched set 7 Remove manifold Item 22 Inspect manifold for cracks surface scoring brinelling or spalling Replace manifold that shows any of these conditions A polished pattern on the ground surfaces from commutator or rotor rotation is normal 8 Remove rotor set Item 19 20 21 and wear plate Item 18 Retain rotor set in its assembled form to maintain the same rotor vane to stator contact surfaces Inspect rotor set in its assembled form for nicks scoring or spalling on any surface and broken or w
82. 5 Clutch assembly 6 Groomer ree housing 1 Clutch adapter shaft 2 Reel shaft and bearing adjustment nut Greensmaster 3000 3000 D Parallel Bedknife to Reel 1 Remove mower from traction unit and put on a level work surface Make sure reel contact is removed by turning bedknife adjustment knob counterclockwise 2 On right hand end of reel insert a long strip of newspaper between the reel and bedknife While slowly rotating reel forward turn bedknife adjusting knob Fig 11 clockwise one click at a time until paper is pinched lightly resulting in a slight drag when paper is pulled 3 Check for light contact at other end of reel using paper If light contact is not evident at both ends bedknife is not parallel to reel proceed to step 4 4 Loosen jam nut on left hand bedbar pivot bolt so bolt can be turned Left hand pivot bolt eccentric bolt has offset thread which when rotated acts as a camto raise or lower the bedbar identification dot on bolt head denotes offset of bolt When dot is in up position Fig 12 left end of bedbar is raised As bolt is turned clockwise and dot is lowered so is left end of bedbar Identification dot must be positioned within rear 180 position when adjusting 5 Rotate left hand eccentric pivot bolt to raise orlower bedbar as required 6 Check adjustments by repeating steps 2 and 3 7 After getting light contact on paper at each end of bedknife hold left hand piv
83. 9 If equipped with hex head type pivot screws tighten pivot screws to 60 ft Ib If equipped with hex socket head set screws and jam nuts tighten set screws finger tight then tighten 1 2 turn more total not each Tighten jam nut 10 Adjust bedknife to reel contact NOTE If quality of cut has deteriorated or the reel and bedknife have become rifled you must grind the reel and bedknife to remove rifle pattern Figure 38 1 Pivot housing 4 O ring 2 7 Bedbar pivot 2 Bearing 2 5 Spring arm 8 Spring 3 Inner race 2 Greensmaster 3000 3000 D 6 Adjustment knob Page 9 25 9 Pivot screw 2 10 Spring arm bolt Repairs Lift Bail Replacement Figure 39 1 Use a saw to cut the lift bail off of the cutting unit Make 4 Support the lift bail so the bottom radius is 4 546 inches the cut 1 inch from the horizontal frame tube Fig 38 from the top of the horizontal frame tube Make sure the lift bail is square to the side frame 2 Use a grinder to remove burrs from the stubs of the lift bail remaining on the cutting unit 5 Weld all around the bottom of the repair lift bail with mild steel rod both sides 3 Install the repair lift bail Part No 71 1600 Repairs Page 9 26 Greensmaster 3000 3000 D Chapter 9 TORO Grooming Reel Cutting Units Table of Contents For Four Bolt Adjust and Single Point Adjust Cutting Units SPECIFICATIONS 3 Groomer Reel Dri
84. 9999 99140990 N3HM Q3S019 MS LVIS 9 NI 5010 MS 310NYH 440 NAHM Q3S0 19 TID NOLLOVH L eg d 58 59 8 a 4 78 0 o ONATOS 14NA iz HO1VNH3LTV 9 Wavy S 98 ga AN o QNO 3NION3 QNO GION3 10S 15 mu d Wi E 313W HH L 1 6 dS 44 m 90 i uaiuvis as 8 80 SLH9 1 MS LSIL LH97 asna 5 2 Y31710 v v voL 35019 YOLOSLAG v31 9 8 I 8 390 1 330 321148 dS 49 MS MOTISA 00 1 ga M ama a r S 8 1491 RA NAY 48 SNON 8015 fd ovig 9 rm GION31OS Wiring Schematics Page5 2 1 Rev D Greensmaster 3100 3050 Wiring Schematic Greensmaster 3100 S N 210000001 220999999 99140990 N3HM Q3S019 JAVY
85. CEDURE Engine RPM 2800 Mow pedal engaged While watching pressure gauges slowly close flow control valve until 1000 PSI is obtained Read flow gauge TESTER READINGS Flow not less than 2 5 GPM at 1000 PSI If unable to get 1000 PSI or flow is below 2 5 GPM check rearward spool travel If spool position is good remove relief cartridge and examine for contamination or wear Greensmaster 3100 Page4 33 Testing TEST HOOK UP 4 continuea TEST B REEL DRIVE RELIEF SETTING AND REEL MOTOR EFFICIENCY PROCEDURE With engine off insert a block of wood between cutting unit reel blades and front cross tube to prevent reel from turning Engine RPM 2800 Hydraulic oil at operating temperature Engage mow pedal TESTER READINGS Flow not more than 0 5 GPM at 2000 to 2100 PSI If flow is above 0 5 GPM remove motor and repair as necessary If pressure is is not in listed range remove relief valve controlling reel being checked and examine for wear or contamination Testing Page 4 34 Greensmaster 3100 5 5 Greensmaster 3100 Steering Pump Flow and Relief Pressure TESTER CONNECTION Tester in series between steering pump outlet line and fitting on P pressure port of steering control unit Tester Flow Control Valve Open CAUTION Keep everyone away from the front of the machine during steering system tests JUNI TESTER GR3100 WITH DANFOSS PUMP SHO
86. EN for the ignition system to operate The closed to operate requirement of the interlock module makes sure that the engine will not run if switch leads are broken or become disconnected Because of the solid state circuitry built into the interlock module there is no direct method to test it The module may be damaged if an attempt is made to test it with an electrical test device such as a volt ohm meter Greensmaster 3100 Page 5 11 Figure 11 1 Mow lift switch Figure 12 Testing Battery Terminal Voltage Test 1 Use a volt ohm meter to measure the voltage be tween the battery terminals 2 If the voltage is less than 12 3 V D C the battery should be charged Hourmeter Test the hourmeter by disconnecting the wires and applying 12 V D C between the terminals Turf Guardian Leak Detector System Alarm and Delay Timer Fig 13 To test alarm Item 25 and delay timer Item 27 turn ignition switch to ON then move leak detector switch Item 6 rearward and hold After a one second time delay alarm should sound Float Switch Fig 14 To test leak detector float switch Item 3 when con nected to circuit remove hydraulic tank cap and strainer from neck of tank Turn ignition switch to ON DO NOT start engine Insert a clean rod or screw driver into tank neck and gently push down on switch float Alarm should sound after a one second time delay To test switch w
87. Loosen capscrews and nuts securing shield to each side plate adjust shield to correct height and tighten fasteners Fig 20 3 Repeat adjustment on remaining cutting units and adjust top bar See Adjusting Top Bar in this section of the book NOTE Shield can be lowered in dry grass conditions clippings fall over top of baskets or raised to allow for heavy wet grass conditions clippings build up on rear edge of baskets Set Up and Adjustments Page 10 18 Figure 20 3 4 3 4 inches 4 Shield fasteners 1 Shield 2 Front crossbar Greensmaster 3000 3000 D Top Cut Off Bar Adjustment Adjust top bar to make sure clippings are cleanly dis charged from reel area 1 Loosen screws securing top bar Fig 21 Insert 0 060 inch feeler gauge between top of reel and bar and tighten screws Make sure bar and reel are equal distance apart across complete reel 2 Repeat settings on remaining cutting units NOTE Bar is adjustable to compensate for changes in turf conditions Bar should be adjusted closer to reel when turf is extremely wet By contrast adjust bar further away from reel when turf conditions are dry Bar should be parallel to reel to get optimum performance and should be adjusted whenever shield height is adjusted or whenever reel is sharpened on a reel grinder Figure 21 2 Bar mounting screws Groomer Reel Drive Belt Adjustment 1 Loosen two 2 set screws and remove clutch
88. NT Apply NEVER SEEZ or equivalent to 1 Bedbar 2 Shield the threads of the handle assembly 13 Thread adjustment knob and pivot assembly into flat side of bedbar pivot left hand thread Make sure there is an equal gap between each side of pivot assembly housing and frame supports Fig 29 Adjust before installing pivot screws by sliding bedbar pivot sideways IMPORTANT On hand adjustable type knobs check to make sure die spring is compressed to 13 16 in by tightening locknut left hand thread Fig 6b 14 If equipped with hex head type pivot screws tighten Figure 28 pivot screws to 60 ft lb If equipped with hex socket head set screws and jam nuts tighten set screws finger tight then tighten an additional 1 2 turn total not each Tighten jam nuts 15 Secure spring arm to pivot assembly If spring arm is adjustable adjust upward until a solid clicking sound is achieved when adjusting knob is turned 16 Level bedknife to reel Level rear roller to reel Set height of cut If necessary backlap to get desired fit Equa gap between reel and bedknife Figure 29 Greensmaster 3000 3000 D Page 9 21 Repairs _ Bedbar Bushing Replacement NOTE Only after making sure that all normal cutting unit adjustments are correct should the bushings be suspected as causing quality of cut problems The bedbar end bushings and pivo
89. ON3110S BLACK any 02 Zu RED RED HOLIMS GREY RED WHITE BLACK MOO IH31NI 31naow EN a o 1 YELLOW ORANGE ania MOTI3A HOLIMS MOW YELLOW 105 ualuvis RED RED N3399 RED WHITE Q3u 31IHM 3ovia BLACK YOLSISSY HOLIMS A33 GREEN WHITE RED 3NION3 WHITE RED qaad Wiring Schematic Greensmaster 3100 S N Below 80000 YALYVLS BLUE BLACK WHITE RED WHITE RED BLACK H313IN BROWN Waviv BROWN GREY GREY S1H9r1 TWNOILdO RED WHITE me e YAWIL HOLIMS 1 1531 1 8 1 15 lt NOILISOd RED ORANGE YALAWNV Greensmaster 3100 Page 5 2 Rev D Wiring Schematics Wiring Schematic Greensmaster 3100 S N 80001 20099
90. OVW e E d NO NONI GNO 3W Q qi N gt GION310S HALYVLS TA M o i x lt e Y uaiaw un E LO 5 E N 0 e H313W 130 m Dion D gt yj OIA e EET dS o Wd 23 a ds o MS 15514 uo uaiuvis SLHDITSHLOL Co x 4 ze x imd fata A na leo Greensmaster 3100 3050 Page5 2 6 Rev D Wiring Schematics Harness Greensmaster 3100 3050 S N 80001 200999999 iring YMS MON Zd es 10109 HUM 10109 91 10109 eps y jo 207 jpes Jo Jo 19 uoo v aM jo 1U0JJ p91e201 10109 jo uo 2009 Jepun 1 enig ania 10109 Jepun 1 enig r1 enig 2009 M 9Josuoo Jepun 1 umoig 2009 jo epis H1 9josuoo ou02 Jepun pajeoo 1
91. PORTANT Remove grease fittings from bearing housing at each end of cutting unit Note that the straight fitting is on the right end and 90 fitting at the left end when viewed in the direction of travel 3 Use a soft face hammer to rotate bearing housing slightly Install bolts from outside of housing and turn bolts alternately against side plate to remove bearing housing Fig 37 Bearing housing will slip out of side plates Reel can be removed as soon as bearing hous ings are disassembled from side plates 4 Before installing reel install new special machine screws from inside of frame to secure bearing housings 5 If necessary install new bearings and seals A Remove outer seal in counterbalance weight bearing cup bearing cone and inner seal B Bearing housing must be completely free of paint and foreign material before installing bearing cup If necessary remove any flash from bearing housing that may interfere with accurate seating of bearing Install new inner seal Install bearing cup C Install bearing housing to frame Pack bearing cone with grease and install over reel shaft into bearing cup Install new outer seal in counterbalance weight Repairs 9 24 Rev C 6 After installing reel tighten spline nut to a torque of 40 to 60 ft lb then adjust bearings See Reel Bearing Ser vice and Adjustment in the Adjustments section of this chapter Use Loctite 271 on spline nut threads 7 Do st
92. Rev D Product Records Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 116 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 9375 2 381 19 322 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 18 0 1250 3 175 58 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 ___ 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 14 02500 6 350 34 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 516 0 3125 7 541 1316 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375
93. Special Tools NOTE Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PRODUCTS Some tools may be available from a local supplier Continuity Tester Fig 5 Battery powered test lamp which is helpful in testing for continuity of circuits and electrical components when the current is off Figure 5 Volt Ohm Amp Meter Fig 6 The meter can test electrical components and circuits for current resistance or voltage draw Figure 6 Special Tools Page5 4 Greensmaster 3100 Skin Over Grease Fig 7 Special non conductive grease which forms a light pro tective skin to help waterproof electrical switches and contacts Recommended for all interlock system con nections Figure 7 Greensmaster 3100 Page5 5 Special Tools Troubleshooting Studying the operating characteristics preceding an electrical failure will help in identifying the area of diffi CAUTION culty Try to isolate the failure to a specific functional system then check that area repairing one component Remove all jewelry especially rings and at a time Attempting to repair two systems at once will watches before doing any electrical trou lead to confusion bleshooting Disconnect battery cables un 4 less the test requires battery voltage NOTE The interlock switches are described as nor mally open NO or normally closed NC The NC NO description indicates th
94. TART and RUN The terminals are marked as shown The circuitry of the ignition switch is shown in the charts With the use of a continuity tester the switch functions may be tested to determine whether all circuits are being completed while the key is moved to each position Greensmaster 3100 A CAUTION When testing electrical components with a volt ohm meter or continuity tester make sure that power to the circuit has been dis connected 5 9 POSITION CONTINUITY AMONG TERMINALS 1 OFF G M A 2 RUN B L A 3 START B L S Figure 8 Testing Seat Switch Fig 9 1 Disconnect the seat switch wire connector and install a continuity tester or ohm meter between the two leads of the seat switch 2 Lower the seat The continuity tester should show no continuity 3 Have the operator sit on the seat slowly depressing the seat switch The continuity tester should indicate a reading as the seat approaches the bottom of its travel NOTE Make sure the compression spring and pin hold the seat up off the seat switch when there is on operator on the seat Traction Neutral Switch Fig 10 1 Disconnect the traction switch wire connector and install a continuity tester or ohm meter between the two leads of the traction switch 2 Make sure the shift selector is in the neutral N position There should be continuity when the shift selector is in the neutral N position If there is
95. UMP USE LAST PUMP SECTION FOR STEERING CIRCUIT x TURNING STEERING WHEEL TO RIGHT Rev E Hydraulic Flow Diagrams Greensmaster 3100 2WD Serial Number Below 230000000 Hydraulic Schematic SZ T NAYNI S t 69 wo 09 SHINO 79 A3U WO 96 JAVA 1OH1NOO ONIH33IS gt XVI 0982 f A3H A3U 89 650 4 did 189 058 o oO NODS DM Le t z e ISd 0002 51 1 H ee A3u WO 99 ee 1 md 165 OS OM Ltt WO 05 55 061 WO 95 95 1 18 0581 WJ E 289005 ISd 0002 HOLIMS pe jos E MOOTHSLNI AL34VS LON 301418 ANYA 3ATVA 5 T AY M INO 5 zl
96. WN SML Uo MACHINES WITH PARKER PUMP USE 2 52 LAST PUMP SECTION FOR STEERING 7 CIRCUIT TEST A STEERING PUMP FLOW PROCEDURE Traction Lever in neutral Engine RPM 2800 Hydraulic oil at operating temperature While watching flow and pressure gauges slowly close flow control valve until 600 PSI is obtained TESTER READINGS Flow not lower than 1 5 GPM at 750 to 850 PSI If flow is less than 1 5 GPM check for restriction in pump intake line If not restricted remove pump and repair as necessary If pressure not within listed range remove steering relief cartridge and examine for contamination or damage Adjust steering relief valve if necessary Greensmaster 3100 Page4 35 Testing Adjustments Lift and Mow Pedal Height Adjustment Fig Adjust the lift and mow pedal to equal height to gain proper spool travel in the valve bank as follows 1 Put 1 2 and 3 spools in neutral center of travel and remove transfer rod guard from foot panel 2 Loosen jam nut securing yoke on front of long control rod remove cotter pin and clevis pin 3 Move adjustment lever by hand to level the mow and lift pedals and adjust yoke on control rod until hole in yoke lines up with the adjustment lever hole 4 Install the clevis pin and cotter pin tighten the jam nut and install the transfer rod guard 5 Actuate the mow pedal by hand Be sure the lift pivot under the pedals clears the stop welded to t
97. acing together 10 Assemble a new commutator seal Item 15 flat side up into commutator Item 16 and assemble commuta tor over end of drive link onto manifold with seal side up 11 Install end cover Item 24 Assemble special bolts Item 14 and screw in finger tight Removal of the two alignment studs should be made after at least two bolts have been assembled Alternately and progressively tighten the bolts to pull end cover assembly into place with final torque of 50 5 ft lbs 68 8 Nm 12 Invert housing in vise so the coupling shaft Item 11 is pointing up and install dust seal Item 1 Seal should be pressing in flush to 0 02 inch below face NOTE Torque required to rotate coupling shaft should not be more than 50 ft lb 68 Nm Rotor Stator and Vane Assembly Fig 37 38 1 Place stator Item 21 onto wear plate Item 18 after doing motor assembly procedures 1 through 7 2 If assembly alignment studs are not being used align stator bolt holes with wear plate bolt holes and turn two 2 bolts Item 14 finger tight into bolt holes 180 apart to keep stator and wear plate stationary 3 Assemble six vanes Item 20 into the stator vane pockets 4 Assemble rotor Item 19 counterbore down if appli cable into stator 21 and onto wear plate Item 18 with rotor splines in mesh with drive link splines 5 Grasp output end of coupling shaft Item 11 and rotate coupling shaft drive link and rot
98. action pedal to forward position Front wheel that is NOT locked by brake should rotate Greensmaster 3100 Page 4 30 Testing TEST HOOK UP NO 2 continued TESTER READINGS Pressure should not exceed 400 PSI If higher reading is obtained check hydraulic line to and from motor for restriction If no restriction remove wheel and brake drum Repeat test If pressure is still excessive remove traction motor and repair as necessary Repeat the test for the opposite wheel if required NOTE Reconnect brake control rod after each test is completed TEST B VALVE BANK LEAKAGE PROCEDURE Disconnect both hydraulic hoses that lead to left front wheel motor from hydraulic tubes on left side of machine Cap open ends of tubes and hoses Block up the machine so traction wheels are off floor If machine is equipped with 3WD rear wheel needs to be off floor as well Disconnect brake control rod on front right wheel Engine RPM 2800 Hydraulic oil at normal operating temperature Engage transmission lever to No 1 position Push traction pedal to forward position Front right wheel should rotate While watching flow and pressure gauges slowly close flow control valve until 1000 PSI is obtained TESTER READINGS Flow not less than 5 GPM at minimum 1000 PSI If flow is lower than 5 GPM or pressure of 1000 PSI cannot be obtained there is internal valve bank leakage Check 1 Relief valve 2 No 4 spool position 3 Disc seal between No 3
99. age is required 1 Loosen front jam nut securing cable assembly to mow lift control rod bracket 2 Move shift lever to No 1 position 3 While holding mow lift control rod in rear position tighten rear locknut to remove almost all slack from cable assembly Do not over tension cable 4 Tighten front jam nut ot lock adjustment 5 Check operation and adjust again as necessary Greensmaster 3100 Page 4 37 Rev B Figure 14 3 Reverse 4 Control rod 1 Fully forward 2 Pedal stop Figure 14a 1 Cable assembly 3 Mow lift control rod 2 Mow lift control rod bracket Adjustments Rear Camshaft Adjustment Fig 15 A camshaft misaligned with the valve bank may cause the following A No increase in ground speed in No 2 transport traction selection B Mow pedal will not stay depressed in detent without foot pressure C Slow lift of the cutting units D Slow or no drive to the cutting units If one or more malfunctions occur loosen the rear camshaft mounting capscrews and relocate the cam shaft until the condition is corrected Figure 15 Retighten the capscrews A CAUTION You must readjust the mow lift switch when the camshaft adjustment is completed See 1 Mounting capscrews Mow Lift Switch Adjustment in the Adjust ments section of Chapter 5 Electrical Sys tem The lift and mow pedal height must also be adjusted See Lift and Mow Pedal Height Adj
100. ailable from a Eaton Hydraulics supplier as Eaton part no 600057 Position 3 pairs of centering springs or 2 sets of 3 each on bench so that extended edge is down and arched center section is together In this position insert one end of entire spring set into spring installation tool with spring notches facing sleeve 8 Compress extended end of centering spring set and push into spool sleeve assembly withdrawing installa tion tool at the same time 9 Center the spring set in the parts so that they push down evenly and flush with the upper surface of the spool and sleeve 10 Install pin through spool and sleeve assembly until pin becomes flush at both sides of sleeve 11 Position the spool and sleeve assembly so that the splined end of the spool enters the 14 hole end of housing first IMPORTANT Be extremely careful that the parts do not tilt out of position while inserting Push parts gently into place with slight rotating action keep pin nearly horizontal Bring the spool assembly entirely within the housing bore until the parts are flush at the meter end or 14 hole end of housing Do not pull the spool assembly beyond this point to prevent the cross pin from dropping into the discharge groove ofthe housing With the spool assembly in this flush position check for free rotation within the housing by turning with light finger tip force at the splined end 12 Place housing on clean lint free cloth Install 2 1 8 diamete
101. airs Page 4 62 Figure 43 Seal Washer End Cap Seal Cap Screw Figure 44 Meter Spacer s Gerotor Figure 45 Greensmaster 3100 7 Remove drive 8 Remove spacer plate 9 Remove seal from housing Control End Disassembly 10 Remove housing from vise Place housing on a clean soft cloth to protect surface finish Use a thin blade screwdriver to pry retaining ring from housing 11 Rotate spool and sleeve until pin is horizontal Push spool and sleeve assembly forward with your thumbs just far enough to free gland bushing from housing Remove bushing Seal Drive Plate Figure 46 Figure 48 Greensmaster 3100 Page 4 63 Repairs 12 Remove quad ring seal from seal gland bushing 13 Use a thin blade screwdriver to pry dust seal from seal gland bushing Do not damage bushing 14 Remove 2 bearing races and the needle thrust bearing from spool and sleeve assembly 15 Remove spool and sleeve assembly from 14 hole end of housing IMPORTANT Do not bind spool and sleeve in hous ing Rotate spool and sleeve assembly slowly when removing from housing 16 Push pin from spool and sleeve assembly Quad Ring 7 Seal Seal Dust Seal EVE Gland Bushing Figure 49 Needle Bearing Thrust Race Bearing Figure 51 Repairs Page 4 64 Greensmaster 3100 17 Push spool
102. and Turn ad justing kn 1 click at a time until first contact be tween reel an knife is felt or heard then tighten 1 more click to get light contact No contact dulls cutting edges Excessive contact increases wear Set to recommendations in chart on Page 9 12 7 Bedknife attitude rear roller bracket hole position 8 Rear roller parallel to reel Check and adjust as necessary 9 Height of cut All cutting units set at same height of cut Set with front roller must be equal at both ends of roller Bench set height of nd actual effective height of re dif ferent Effective height of cut depends on cutting unit weight cutting unit accessories and turf conditions If bedknife is too thick for effective height of cut poor quality of cut will result 10 Proper bedknife for height of cut Set scraper for 1 32 in clearance from roller Set comb the same on all cutting units for height of cut and turf conditions Must be same height at both ends of comb 11 Front roller scraper and comb adjustment Troubleshooting Page9 6 Greensmaster 3000 3000 D Possible Problem Correction 12 Stability and position of bedbar Make sure bedbar bolt plastic washers are snug against bedbar Bedbar must pivot without binding Check bedbar end bushings pivot bushings and nylon flange bushings for wear or damage and replace if necessary Make sure proper bushings
103. and position on a level work surface Make sure reel contact is removed by turning bedknife adjustment knob counterclockwise 2 On right hand end of reel insert a long strip of newspaper between front side of reel and bedknife While slowly rotating reel forward turn bedknife adjust ing knob Fig 8 clockwise one click at a time until paper is pinched lightly which results in a slight drag when paper is pulled 3 Check for light contact at other end of reel using paper If light contact is not evident at both ends bedknife is not parallel to reel proceed to step 4 4 Loosen jam nut on left hand bedbar pivot boit so bolt can be turned Left hand pivot bolt eccentric bolt has offset thread which when rotated acts as a cam to raise or lower the bedbar Identification dot on bolt head denotes offset of bolt When dot is in up position Fig 9 left end of bedbar is raised As bolt is turned clockwise and is lowered so is left end of bedbar Identification dot must be positioned within rear 1809 position when adjusting 5 Rotate left hand eccentric pivot bolt to raise or lower bedbar as required 6 Check adjustments by repeating steps 2 and 3 7 After getting light contact on paper at each end of bedknife tighten left hand jam nut while holding pivot bolt in position Check to make sure pivot bolt did not get out of adjustment when turning jam nut Adjust again if necessary NOTE If the reel has worn so you
104. and service technicians in determining causes for poor reel mower performance and in comparing the effective height of cut of one mowed surface to another This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the TurfEvaluator Toro part no 97931SL Toro Model Number 04399 Figure 7 Dual Point Adjust Cutting Units Page 10 4 Rev D Greensmaster 3100 Troubleshooting There are a number of factors that can contribute to un satisfactory quality of cut some of which may be turf conditions Turf conditions such as excessive thatch sponginess or attempting to cut off too much grass height may not always be overcome by adjusting the cutting unit It is important to remember that the lower the height of cut the more critical these factors are See Adjustments in the Cutting Unit Operator s Manual Factors That Can Affect Quality of Cut Factor Tire pressure Governed engine speed Reel speed Reel bearing condition Reel and bedknife sharpness and the Service and Repairs section in this chapter of this manual for detailed adjustment and repair informa tion For additional information regarding cutting unit trouble shooting see Aftercut Appearance Troubleshooting Aid Toro part no 0007651 Possible Problem Correction Check pressure of all tires Pressure must be equal on both front tires Adjust pressure as necessary See Chapter 6 Wheels and Brakes Check
105. apter 1 Safety Safety Instructions 1 1 Chapter 2 Product Records and Manuals Product 2 1 Equivalents and Conversions 2 2 Torque lt 2 3 Maintenance Interval 2 4 Equipment Operational and Service Historical Report Record Chapter 3 Engine 3 1 Adjustments iere ead ine pL 3 2 xad REY es hota ES 3 5 BRIGGS amp STRATTON VANGUARD V TWIN OHV SERVICE amp REPAIR INSTRUCTIONS Chapter 4 Hydraulic System 4 2 General Information 4 3 Hydraulic Flow 4 5 Hydraulic 5 4 12 Special Tools 4 13 Troubleshooting 4 16 TESI 4 27 Adjustments 4 36 4 39 Greensmaster 3100 Chapter 5 Electrical System Wiring 5 2 Turf Guardian Leak Detection System 5 3 Special 5 4 Troubleshooting 5 6 Testing oa 5 9 nde ge 5 13 Chapter 6 Wheels Steering and
106. apter 7 4 Bolt Adjust Cutting Units for specific information about 4 Bolt Adjust Cutting Units equipped with Grooming Reels Specific information for 4 Bolt Adjust Cutting Units i e bedknife to reel adjust ment bedbar removal and installation and leveling rear roller to reel is not covered in this chapter Greensmaster 3100 Page9 1 Rev D Introduction Introduction Page 10 2 Greensmaster 3000 3000 D Specifications Height Of Cut 3 32 0 094 in to 3 4 0 75 in Clip Frequency and Optimum Height of Cut Range Model Clip Optimum Height No max of Cut Range 04460 8 blade reel 0 25 in 3 16 5 16 04465 11 blade reel 0 18 in 1 8 7 32 Roller Adjustment Front Micrometer hand adjustment with bolted clamp lock 1 turn 0 025 in height of cut change Rear Roller brackets allow adjustment for different height of cuts Single screw adjustment for leveling Bedknife To Reel Adjustment Bedknife adjusts against reel with positive adjustment control knob lo cated at center of bedbar Adjustment knob contains detent with 001 inch movement of bed knife for each indexed position Groomer Reel Depth 0 18 in maximum below height of cut Groomer Reel Raised Height 5 16 0 312 in from grooming reel height depth adjustment Reel Speed 1940 rpm engine speed 2800 rpm Groomer Reel Speed 3200 rpm Bedknife Screw Torque 200 Reel Splined Drive Nut Torque 40 to 60 ft Ib Reel Bearing Roll
107. are installed in each location bedbar end bushings are different Check adjustment knob to make sure detent holds ad justment Repair if necessary With adj knob pivot assembly removed pivot set screws installed and frame on level surface measure from flat surface up to end of each setscrew If not within 1 16 in of each other bend ears on cutting unit frame to line up screws Check to make sure adj knob pivot assembly is centered in bedbar arm yoke and frame ears so that an equal gap exists on each side of pivot housing before pivot screws are installed Make sure bedknife adj knob pivot assembly is held firmly in place between frame supports Tighten pivot screws if necessary 13 Number of reel blades Use cutting unit model with correct number of blades for clip frequency and optimum height of cut range Variable speed traction kit can be used to adjust clip frequency 14 Cutting unit alignment and pull frame Check pull frame alignment on all cutting units Adjust ground following or repair as necessary Check pull frames and lift arms for damage binding or bushing wear Repair if necessary 15 Roller condition All rollers must rotate freely Grease when needed or repair bearings if necessary 16 Reel speed All reels must rotate at same speed within 100 rpm All cutting units must have equal bedknife to reel con tact and reel bearing adjustment before checking Do not run the reel to long or it may get hot
108. aulic fluid after replacement of lift cylinder Greensmaster 3100 Steering Control Unit Repair Greensmaster 3100 Fig 42 Figure 42 1 Dust seal 10 Housing 19 Capscrew 2 Retaining ring 11 Control sleeve 20 Centering pin kit 3 Gland bushing seal 12 Control spool centering springs 21 Check ball retainer 4 O ring 13 Control spool 22 Check ball 5 Backup ring 14 O ring 23 O ring 6 O ring 15 Spacer plate 24 Check ball seat 7 Seal 16 Drive 25 O ring 8 Bearing race 17 Gerotor 26 Setscrew 9 Needle thrust bearing 18 End cap Disassembly Cleanliness is extremely important when repairing a steering control unit Work in a clean area Before disconnecting lines clean port area of unit thoroughly Use a wire brush to remove foreign material and debris from around exterior joints of the unit Although not all drawings show the unit in a vise it is recommended that you keep the unit in the vise during disassembly Follow the clamping procedures explained in the instructions Greensmaster 3100 Page 4 61 Repairs Meter Gerotor Disassembly 1 Clamp unit in vise meter end up Clamp lightly on edges of mounting area Use protective material on vise jaws Housing distortion could result if jaws are over tightened 2 Remove 5 16 cap screws 3 Remove end cap 4 Remove seal from end cap 5 Remove meter Be careful not to drop star 6 Remove seal from meter Rep
109. bar threads and new screws tighten to a torque of 200 in Ib NOTE Remove all rust scale and corrosion from bedbar surface before installing bedknife DO NOT use an air impact wrench with this tool m Figure 4 Special Tools 8 4 Greensmaster 3000 3000 D Troubleshooting There number of factors that can contribute to machine It is important to remember that the lower the unsatisfactory quality of cut some of which may be turf height of cut the more critical these factors are See the conditions Turf conditions such as excessive thatch Adjustments and Repairs sections for detailed adjust sponginess or attempting to cut off too much grass ment and repair information height may not always be overcome by adjusting the Factors Affecting Quality of Cut Possible Problem Correction 1 Tire pressure Check tire pressure adjust to specification if necessary Must be equal in two front tires 2 Engine governed speed Check maximum governed engine speed Adjust to specification if necessary affects reel speed 3 Reel bearing condition adjustment Check and adjust to specification Replace bearings if worn or damaged Bearing cones must be installed square to bearing housing make sure there is no flash paint or other foreign material in housing before installing new bearing cone 4 Reel and bedknife sharpness Reel and or bedknife that has rounded edge cannot be corrected by tightening b
110. cannot get the bedknife parallel to the reel by turning the eccentric bolt the reel will require grinding to remove taper The reel normally wears faster on the lead in side which results in the described taper Greensmaster 3000 3000 D Page 9 11 Figure 8 1 Bedknife adjusting knob Figure 9 Set Up and Adjustments Leveling Rear Roller to Reel 1 Put cutting unit on a flat level surface 2 Assemble rear height of cut brackets to desired posi tion by loosening top capscrew and nut and removing bottom nut on right and left hand sides of cutting unit Fig 10 3 Slide bolts thru each bracket until brackets can be realigned with appropriate mounting hole See table for proper position on brackets NOTE The different rear roller bracket positioning holes B thru E are designed to optimize bedknife location for different heights of cut Rear Roller Bracket Hole Position 8 Blade Cutting Units Figure 10 Height of cut 3 16 187 in and below use the B position 1 Rear height of cut bracket 3 Bottom nut Height of cut 5 32 156 in and above Use the C position 2 Top capscrew and nut Height of cut between 5 32 156 and 3 16 187 in try C first if not satisfactory use B NOTE For Height of Cut 5 32 156 in and lower use 3 32 in tournament bed knife Tournament bed knife should not be necessary with the rear roller in the C position Rear Roller Bracket Hole Position 11 Blade Cutting U
111. ck disk seal between 3 and 314 valve sections Page 4 18 Repair or replace traction pump Remove valve bank and replace disk seal Greensmaster 3100 Increase in Speed from 1 to 2 hydraulic oil level Check traction lever Check rear camshaft Check 2 and 3 pump section flow Test hook up No 3 Test A Check 2 and 3 valve section re liefs Test hook up No 4 Test B Greensmaster 3100 Misadjuste or damaged Misadjusted or damaged Defective Fill to proper level Adjust or repair Adjust or repair Check for restriction in pump intake line Repair or replace relief valve 4 19 Repair or replace pump Troubleshooting trave bedknife adjustment Check for tight reel bearings Check reel pump flow Test hook up No 3 Test A Check reel motor flow Test hook up No 4 Test A Check reel drive relief Test hook up No 4 Test B Check reel motor efficiency Test hook up No 4 Test B Troubleshooting One or More Cutting Units Slow or No Reel Drive Action Misadjusted or Damaged Insufficient Defective Defective Adjust or repair and lubricate Adjust or repair rear camshaft Adjust bedknife Adjust bearings Replace if necessary Check for Repair or restriction in pump replace pump
112. clutch knob and tighten two 2 set screws against flats of clutch release disk 20 Do steps 5 16 under Bedbar Removal and Installa tion in this section of the book Greensmaster 3000 3000 D Page 10 27 Rev c Figure 42 1 Right side groomer plate ass y 4 Special stud 2 2 Right reel frame plate 5 Inside locknut 2 3 Groomer bearing adapter 6 Flange locknut 2 Figure 43 1 Bearing housing 2 Bolt Repairs Groomer Reel Blade Service Inspect grooming reel blades frequently for damage and wear Straighten bent blades with a pliers Either replace worn blades or reverse the grooming reel shaft to put thesharpest blade edge forward Fig 44 See Groomer Reel Removal and Installation in this section of the book During blade inspection procedures check to make sure the right and left blade shaft end nuts are tight Figure 44 1 Grooming blade 2 Dull rounded edge 3 Sharp edge 4 Location mark Groomer Reel Drive Belt Replacement 1 Loosen two 2 set screws and remove clutch knob Fig 6 Remove groomer reel housing cover from left side of cutting unit Fig 39 2 Loosenthe backside idler pulley pivot screw Fig 45 Pivot idler to loosen and remove belt 3 Install the belt The belt should have a deflection of 1 4 in when 5 10 Ib of force is applied midway between the pulleys Pivot the idler to get proper tension and tighten the allen head screw to a torque of 7 10 ft
113. contact the basket at the instant the cutting unit is raised off the ground 5 Make sure each of the three 3 cutting units track straight with the traction unit A On a smooth level surface draw a straight line on the floor Fig 23b Push traction unit forward removing slack from pull arms so center of each front wheel is on top of the line Use a plumb bob or square to make sure each wheel is centered on the line B Measure from each end of cutting unit front roller to chalk line Distance from each end of roller to line must be equal within 3 16 0 187 in C Loosen jam nuts on pull arms and adjust ball sockets so distance from each end of roller to line is within 3 16 0 187 in NOTE If a cutting unit cannot be adjusted to track correctly with the traction unit the pull frame or lift arm is damaged and or the lift arm and pull frame bushings are worn and must be replaced 1 Jam nut 2 Pull arm Draw line on floor and center wheels over line 1 Jam nut 2 Pull arm Set Up and Adjustments Page 10 20 Figure 23a 3 Ball joint adjust for clearance 4 1 4 1 2 in 6 13 mm clearance Measure from each end of cutting unit front roller to line on floor Must be equal within 3 16 0 1867 in Figure 23b 3 Ball joint adjust for clearance 4 1 4 1 2 in clearance Greensmaster 3000 3000 D Repairs Cutting Unit Removal and Installation Remove cutting unit from traction un
114. cylinder into a drain pan by SLOWLY moving the cylin der s piston in and out of the cylinder bore 2 Plug the ports and clean the outside of the cylinder 3 Mount the cylinder in a vise so the shaft end of the cylinder is tilted up slightly Do not close the vise so firmly that the barrel could become distorted 4 Remove the retaining ring Item 10 Grasp clevis end of shaft Item 11 and use a twisting and pulling motion to carefully extract piston Item 4 shaft Item 11 and head Item 8 from the barrel Item 1 5 Securely mount the shaft Item 11 in a vise and remove the lock nut Item 2 from the piston end of the shaft Remove the piston Item 4 Slide the head Item 8 off of the shaft Repairs 4 52 6 Remove and discard all seals and back up rings Items 3 5 6 7 9 7 Wash the parts in a safe solvent Dry the parts with compressed air DO NOT wipe them dry with a cloth or paper as lint and dirt may remain 8 Inspect the internal surface of the barrel Item 1 for damage deep scratches out of round etc Inspect the head Item 8 shaft Item 11 and piston Item 4 for evidence of excessive scoring pitting or wear Replace any defective parts 9 Puta light coating of hydraulic oil on all new seals and back up washers Install the new seals and back up washers Items 3 5 6 7 9 Install the head Item 8 onto the shaft Item 11 Install the piston Item 4 onto the shaft and tighte
115. d lower the effective height of cut Difference between bench set and effective ae height of cut Figure 14 Set Up and Adjustments Page 9 14 Greensmaster 3000 3000 D Height of Cut Adjustment IMPORTANT Lower heights of cut are limited by thickness of bedknife Select proper bedknife for desired height of cut If bedknife is too thick for height of cut poor quality of cut will result and excessive pressure from turf on bottom of bedknife can cause rifling of bedknife and reel 1 Make sure that rear roller brackets are in correct hole positions for desired height of cut and that rear roller is level Also check that bedknife to reel contact is correct 2 Turn cutting unit over and loosen locknuts securing front roller adjusting screws to height of cut brackets Fig 15 3 On gauge bar Part No 1 8789 set head of screw to desired height of cut This measurement is from bar face to underside of screw head 4 Place bar across front and rear rollers and adjust height of cut knob until underside of screw head engages bedknife cutting edge Fig 14 Check and adjust on each end of bedknife then tighten height of cut adjustment locknuts on each end Changing To A Different Type of Cutting Unit or f Adding Cutting Unit Accessories When changing to a different type of cutting unit or adding cutting unit accessories it is recommended that you change only one cutting unit and keep the oth
116. di sleeve surface as seal failure could result 6 Slide the V ring onto the reel shaft with the thick shoulder of the V ring facing inward Fig 20 7 Fillthe drive coupling 4 1 2 to 1 3 full with Mobil High Temperature HP or equivalent grease Also coat the outside of the drive coupling with grease 8 Install the retaining ring 5 Make sure it is seated into the groove Greensmaster 3100 Page 10 17 Rev D Figure 19 1 Reel shaft 3 Adapter spline 2 Drive adapter 4 1 gt 4 104 Seal Depth Figure 20 4 V ring 5 Left side plate 1 Outer seal 2 Inner seal 3 Speedi sleeve Dual Point Adjust Cutting units Reel Installation Fig 16 IMPORTANT Wipe any excess grease from the inner grease seals 13 where the reel shaft V rings 3 make contact The V rings should run dry 1 Slide the left hand side plate 6 onto the reel shaft Make sure the reel shaft threads do not damage the grease seals in the side plate 2 Apply a film of No 2 general purpose grease to the reel shaft threads and install the left side reel bearing locknut 8 3 Slide the right hand side plate 10 onto the reel shaft Make sure the reel shaft threads do not damage the grease seals in the side plate 4 Apply a film of No 2 general purpose grease to the reel shaft threads and install the right side reel bearing locknut 8 5 Mount the frame assembly 17 to the side plates with
117. dway and cannot make it to the top of a slope do not turn machine around Always back slowly straight down the slope 24 DO NOT TAKE AN INJURY RISK When person or pet appears unexpectedly in or near the mowing area STOP MOWING Careless operation combined with terrain angles ricochets or improperly positioned guards can lead to thrown object injuries Do not resume mowing until area is cleared 25 Whenever machine is left unattended make sure cutting units are fully raised and reels are not spinning key is removed from ignition switch and parking brake is set Greensmaster 3100 While Doing Maintenance Troubleshooting Testing Adjustments Repairs 26 Before servicing or making adjustments to the ma chine stop the engine remove key from ignition switch and pull wires off spark plugs to prevent accidental starting of the engine 27 Make sure the entire machine is properly maintained and in good operating condition Frequently tighten all nuts bolts and screws 28 Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system 29 Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Hydraulic fluid escaping under pressure can penetrate the skin and cause injury Fluid accidentally injected into the skin must be surgically removed within
118. e Refer to the Testing section of this Chapter for precau tions and specific test procedures Greensmaster 3100 Slow Groundspeed Traction Selections Check engine RPM Check hydraulic level Check hydraulic oil filter Check shift lever bracket and rear camshaft Check brakes and brake linkage for binding Check traction pump flow Test hook up No 1 Test A Check traction relief Test hook up No 1 Test B Check traction mo tors for mech drag Test hook up No 2 Test A Check traction mo tor efficiency Test hook up No 2 Test C Greensmaster 3100 Improper Improper Clogged Misadjusted or damaged Binding Defective Inefficient restriction in pump intake line pump Remove brake Adjust use tachometer Reels also affected Fill to proper level Replace filter Free linkage and adjust brakes Check for Repair or replace Repair or replace traction relief valve Repair or replace defective motor drum and repeat test Repair or replace defective motor Page 4 17 Troubleshooting Slow or No Ground Speed in 1 and Reverse Check control linkage Check traction pump flow Test hook up No 1 Test A Check for internal valve bank leakage Test hook up No 2 Test B Troubleshooting No 2 Appears Normal Adjust or repair Check for restriction in pump intake line Che
119. e 1 Height of cut locknut plate 2 Roller shaft clamp bolt 3 Height of cut knob 4 End cap mounting nuts 5 Counterbalance end CAUTION 6 Reel bearing adjustment nut Do not use your hand to prevent reel from turning while servicing this can result in per sonal injury Use a 1 2 in thick x 3 in wide x 8 in long piece of hardwood inserted into front of cutting unit between reel blades NOTE If reel bearings will not hold adjustment during operation loosen adjustment nut tighten reel shaft spline nut on right hand end of reel shaft to a torque of 40 to 60 ft lb then adjust reel bearings Use Loctite 271 on spline nut threads 3 Tighten the large reel bearing adjustment nut Fig 7 until all reel shaft end play is removed then tighten an additional 1 16 to 1 8 turn Be certain to remove all end play but do not over tighten NOTE Adjustment nut must have enough resistance against reel shaft threads to retain bearing adjustment Replace adjustment nut if necessary 4 Install bolt into end of reel shaft and check rolling torque with an inch pound torque wrench Reel bearing rolling torque should not exceed 7 Repeat steps 2 and 3 if necessary 5 If bearings require replacement see Reel Removal and Bearing Replacement in the Repairs section of this chapter Set Up and Adjustments 9 10 Rev C Greensmaster 3000 3000 D Parallel Bedknife to Reel 1 Remove mower from traction unit
120. e Cutting Unit Operator s Manual Slightly dull cutting edges may be corrected by backlapping see Backlapping in this chapter of this manual Excessively dull cutting edges must be corrected by grinding the reel and bedknife see Preparing Reel for Grinding in this chapter of this manual Rear roller adjustment Adjust the rear roller brackets to hi or low position depending on the height of cut range desired See Rear Roller Adjustment in the Cutting Unit Operator s Manual Height of cut Effective or actual height of cut depends on the cutting unit weight and turf conditions Effective height of cut will be different from the bench set height of cut See Height of Cut Adjustment in the Cutting Unit Operator s Manual Proper bedknife selection for height of cut desired If the bedknife is too thick for effective height of cut poor quality of cut will result Stability of bedbar Make sure bedbar pivot bolts are seated securely Check condition of the bushings in the side plates See Bedbar Removal and Installation in this chapter of this manual Number of reel blades Use correct number of blades for clip frequency and optimum height of cut range Cutting unit alignment and pull frame ground following Check pull frames and lift arms for damage binding or bushing wear Repair if necessary Roller condition Make sure rollers rotate freely Repair bearings as necessary See Roller Bearing Replacement in
121. e Removal and Installation Removing the Engine 1 Disconnect the negative and positive battery cables from the battery 2 Close the fuel shut off valve and disconnect the fuel line A WARNIN G Gasoline is highly flammable Use caution while handling it Do not smoke cigarettes cigars or pipes Dispose of the gasoline in safe place immediately after draining Installing the Engine 1 Support the engine align it with the engine mounts and instal the pump hub over the engine shaft and key Be sure that the key is properly positioned and aligned with the keyway 2 Install the engine mount bolts washers and nuts 3 Mount the pump to the pump housing and tighten the set screws to secure the hub to the shaft Greensmaster 3100 Page 3 5 3 Remove the starter cable throttle and choke cable and ground wire from engine 4 Disconnect the wiring harness connector 5 Loosen the two 2 set screws securing the pump hub onto the engine shaft Remove the two 2 capscrews securing the pump to the pump mount DO NOT discon nect the hydraulic hoses from the pump 6 Support the engine and remove the engine mount bolts nuts and washers to remove the engine 4 Re connect the fuel line wire connectors and the cables to the engine and battery 5 Make sure the crankcase is filled the correct oil Open the fuel shut off valve Fill the fuel tank Start the engine and check for proper operation E
122. e basket on the pull frame 2 Level baskets to cutting unit by loosening nut at one end of pull frame roller Loosen bolt and move roller shaft in slot as necessary Tighten bolt 3 Loosen the jam nuts on the pull arms and adjust the ball sockets until there is 1 4 in to 1 2 in 6 to 13 mm clearance between the lip of the basket and the reel blades Fig 18a This prevents grass clippings from dropping on the ground 4 Make sure the basket lips are the same distance from the reel blades at both ends of the reel If the basket is too close to the reel it is possible for the reel to contact the basket at the instant the cutting unit is raised off the ground 5 Make sure each of the three 3 cutting units track straight with the traction unit A smooth level surface draw a straight line on the floor Fig 18b Push traction unit forward removing slack from pull arms so center of each front wheel is on top of the line Use a plumb bob or square to make sure each wheel is centered on the line B Measure from each end of cutting unit front roller to chalk line Distance from each end of roller to line must be equal within 3 16 0 187 in C Loosen jam nuts on pull arms and adjust ball Sockets so distance from each end of roller to line is within 3 16 0 187 in NOTE If a cutting unit cannot be adjusted to track correctly with the traction unit the pull frame or lift arm is damaged and or the lift arm and pu
123. e control valve assembly installed on the machine 1 Remove the entire detent assembly from the control valve Keep the backup washer seal retainer and seal with the spool 2 Apply Locktite 222 or equivalent to threads of detent stud Item 9 and assemble into spring and stop collars Items 6 and 8 Thread the assembly into the No 1 spool The spring Item 6 needs to be compressed to get detent stud started Anchor the slotted end of the spool and apply 10 14 ft lb 13 6 19 Nm torque to detent stud Item 9 3 Slip bonnet Item 1 over the entire assembly and secure it to the valve body with the two capscrews Be sure slot in mounting face of bonnet is at bottom before installation 4 Install the thrust plate Item 5 into the bonnet Item 1 so it bottoms out Apply approximately 1 4 in 6 mm of 2 multi purpose Lithium base grease on top of thick washer Item 5 5 Install twelve balls Item 4 into thrust plate Item 5 IMPORTANT If the detent bonnet contains a vent pocket do not let the balls fall into the vent 6 Insert race Item 3 on top of balls with ramp of race facing inward as shown Rotate race Item 3 until you are sure all balls are resting properly against the sur faces of the race and thrust plate Items 3 and 5 7 Insert spring Item 2 into bonnet Item 1 8 Apply Locktite 222 or equivalent to the threads of adjustment cap Item 10 and thread into bonnet Turn adjustment cap in to compre
124. e position Do not touch the gear surfaces as residue on hands may be corrosive to gear finish 7 Place the motor on its side and push on the rear bear ing block to remove the bearing block and gear set Fig 18d 8 Carefully remove and discard o rings pressure seals and back up rings Fig 18e from motor Do not cause any damage to the machined grooves during the removal process IMPORTANT Make sure not to damage the counter bore when removing the shaft seal from the front plate 9 Position front flange with seal side up Remove shaft seal Inspection 1 Remove any nicks and burrs from all motor compo nents with emery cloth A CAUTION Use eye protection such as goggles when using compressed air 2 Clean all motor components with solvent Dry all parts with compressed air Greensmaster 3100 Page 4 41 4 Rev D Figure 18d 1 Motor body 2 Bearing block amp gear set Backup Ring Figure 18e Figure 18f 3 Bearing block 1 Drive gear 2 Idler gear Repairs 3 Inspect drive gear idler gear and bearing blocks Fig 18f for the following A Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas Scoring rough surfaces or wear on gear shafts indi cates need for replacement B Gear teeth should be free of excessive scoring and wear Any broken or nicked gear teeth must be replaced C Inspect gear face edge for sharpness Sha
125. e switch contact position with the For effective troubleshooting and repairs you must switch installed in the machine with MOW OFF have a good understanding of the electrical circuits and TRANSMISSION in NEUTRAL and OPERATOR OFF components used Tools such as a volt ohm multimeter of seat Should the machine being repaired have these will help find problems in the circuitry components by passed they should be reconnected for proper troubleshooting and safety Condition Cause Correction 1 Engine starts but should not Traction switch adjusted incorrectly Adjust or replace traction switch when shift selector is in gear or is malfunctioning 2 Engine starts but should not Mow lift switch adjusted incorrectly Adjust or replace mow lift switch when mow pedal is depressed or is malfunctioning reels engaged 3 Engine fails to crank regard Mow lift switch and or traction Adjust or replace traction switch less of shift selector or mow Switch out of adjustment or mal and or mow lift switch pedal position functioning Loose or corroded battery connec Clean and tighten connections tions Mow lift switch or traction switch Check wires and connect prop wires are loose erly Battery is dead Charge or replace battery Starter solenoid is malfunctioning Replace solenoid Ignition switch is malfunctioning Replace ignition switch Starter is malfunctioning Replace or repair starter Engine is seized Repair engine Key sw
126. eal rings Items 17 and 23 as the pump is disassembled 9 Clean all parts All parts must be check for burrs scoring nicks etc Check the bushings in the plate assemblies Items 22 26 and 28 and cover assembly Item 31 for excessive wear or scoring Replace the assemblies as necessary The bushings are not serv iceable 10 Stone gears if plate surfaces appear scored Re place gears as sets if necessary Oil the inside of gear plates Items 14 25 and 30 and insert gear sets maintaining the original timing and locations Repairs Page 4 44 11 Assemble pump sections starting at the body as sembly Item 15 Install woodruff keys Item 19 and align keyways in gears as they are installed over the shafts Apply grease to new seal rings Item 23 before installing 12 After pump has been assembled tighten locknuts by hand Rotate the drive shaft to check for binding Protect the shaft if using a pliers 13 Tighten the locknuts evenly in a crossing pattern to a torque of 17 to 19 ft lb 14 Before installing oil seal Item 17 put seal protector on pump shaft or apply tape on the shaft 15 Before installing fill volume between lips of new seal with Master Lubricant Co Lubrico M 6 Lubriplate Aero Lube or equivalent Apply grease to inside diame ter of new oil seal Carefully install a new oil seal Assemble spring loaded lip of seal toward bearing Greensmaster 3100 Control Valve Removal and Ins
127. edknife to reel contact Grind reel to remove taper cone shape and or rifling grooved or ribbed appearance Grind bedknife to sharpen and or remove rifling Most common cause of rifling is bedknife to reel contact that is too tight NOTE New bedknife must be ground after installing on bedbar to match bedknife to bedbar 5 Bedknife to reel contact Reel must have light contact all across bedknife No contact will dull the cutting edges Excessive contact accelerates wear quality of cut may be adversely af fected Adjust backlap or grind if necessary 6 Bedknife attitude Adjust rear roller brackets to proper location in slots of side plate See Leveling Rear Roller to Reel in the Ad justments section 7 Rear roller parallel to reel Check and adjust as necessary to avoid mismatch be tween cutting units 8 Height of cut All cutting units set at same height of cut Set with front roller must be equal at both ends of roller Bench set height of cut and actual effective height of cut are dif ferent Effective height of cut depends on cutting unit weight cutting unit accessories and turf conditions 9 Proper bedknife for height of cut If bedknife is too thick for effective height of cut poor quality of cut will result 10 Front roller scraper and comb Adjustment Set scraper 1 32 in clearance from roller Set comb the same on all cutting units for height of cut and turf condi tions Must be same height at both e
128. embly from groomer housing Fig 40 A CAUTION Adjustment knob assembly is spring loaded Figure 39 4 Loosen idler pulley Fig 40 Remove nut and washer 1 Height of cut locknut 4 Grooming reel cover from clutch adapter shaft Pull clutch assembly off 2 Roller shaft clamp bolt 5 Cover screws amp washers adapter shaft and slide belt off driven pulley Remove 3 Height of cut knob clutch adapter from reel shaft Fig 49 5 Remove driven pulley from groomer shaft left hand thread Fig 40 6 Remove two 2 locknuts and flat head socket screws to remove bearing adapter and left side groomer hous ing Fig 41 7 Remove locknut from the right end of groomer reel shaft to remove groomer reel Remove grooming reel adjustment knob assembly from right side groomer plate assembly Fig 42 8 Remove two 2 flange locknuts ree motor mounting nuts Remove two 2 inside locknuts Use a stud Figure 40 removal tool or double nuts to remove special studs Remove groomer bearing adapter and right side 1 Drive belt 4 Groomer driven pulley groomer plate Fig 42 2 Drive belt idler pulley 5 Clutch assembly 3 Grooming reel adjustment 6 Groomer reel housing 9 Remove bearing adjustment locknut from left end of knob assembly reel shaft Remove spline nut from right end of reel shaft IMPORTANT Remove grease fittings from bearing housing at each end of cutting unit Note that the straight fitting is on
129. en reel shaft spline nut on right hand end of reel shaft to a torque of 40 to 60 ft lb then adjust reel bearings Use Loctite 271 on spline nut 3 Loosen large reel bearing adjustment nut Fig 7 Figure 6 Tighten nut until all reel shaft end play is removed then tighten an additional 1 16 to 1 8 turn Be certain to remove all end play but do not overtighten 1 Counterbalance end cap NOTE Adjustment nut must have enough resistance against reel shaft threads to retain bearing adjustment Replace adjustment nut if necessary 4 Install bolt into end of reel shaft and check rolling torque with an inch pound torque wrench Fig 7 Reel bearing rolling torque should not exceed 7 in Ib Repeat setps 2 and 3 if necessary 5 If bearings require replacement see Reel Removal and Bearing Replacement in the Repairs section of this chapter Figure 7 1 Reel bearing adjustment nut Set Up and Adjustments Page8 8 Rev C Greensmaster 3000 3000 D a aa Bedknife To Reel Adjustment IMPORTANT For adjusting bedknife to reel use a 3 8 in open end wrench that is 3 to 6 in in length A longer wrench will provide too much leverage and may cause distortion of the adjustment screw mounting plate or bedbar breakage 1 To move bedbar closer to reel blades loosen bottom screw on each side of cutting unit Fig 8 then tighten top adjustment screw on each side of cutting unit Fig 9 To move bedknife away from reel blades loosen
130. ension coupler and a 9 16 socket The 9 16 socket can be positioned onto the capscrew on the reel shaft inside the counter balance weight on the end of the cutting unit Fig 22 Backlap according to procedures in the Toro publication Sharpening Reel amp Rotary Mowers Form No 80 300 PT NOTE For a better cutting edge run a file across the front face of the bedknife when the lapping operation is completed This will remove any burrs or rough edges that may have built up on the cutting edge A CAUTION Be careful when lapping the ree because con Figure 22 tact with the reel or other moving parts can result in personal injury 1 Counterbalance weight Repairs Page 8 16 Greensmaster 3000 3000 D ENNIO _ __ _ Bedbar Removal and Installation 1 Remove rear roller assembly 2 Remove capscrew and nut anchoring the rear roller height of cut bracket to the side plate on both ends of the cutting unit Fig 23 3 Loosen allen set screws securing the roller shaft Fig 23 4 Remove the rear roller height of cut brackets from both side plates 5 Remove the bedbar mounting bolts from each end of the cutting unit Fig 23 Then loosen the bedknife adjusting screws at each end of the cutting unit Fig 23 The bedknife assembly can then be removed by rotating it away from the reel IMPORTANT When installing the bedbar assembly be sure to position the center portion of the grass
131. eps 5 16 under Bedbar Removal and Installation in this section of the book Figure 36 1 Left reel bearing housing 2 Right reel bearing housing 3 Machine screws Figure 37 1 Bearing housing 2 Bolt Greensmaster 3000 3000 D Bedknife Adjustment Knob Bearing Service 1 Turn bedknife adjustment knob counterclockwise to remove bedknife to reel contact 2 Remove two 2 pivot screws Fig 38 3 Rotate adjustment knob and pivot assembly clock wise left hand thread until it is unthreaded from the bedbar pivot 4 If necessary remove locknut securing die spring to shaft Fig 6b Slide pivot housing off adjustment knob threaded shaft Fig 38 5 Pull inner races from pivot housing Pull bearings from pivot housing Check condition of inner races and bear ings and replace if necessary 6 Install new o ring on each race if necessary 7 Install bearings and races in pivot housing Slide pivot housing onto shaft of knob 8 Install spring over adjusting knob threaded shaft and thread adjustment knob and pivot assembly into flat side of bedbar pivot Make sure there is an equal gap be tween each side of pivot assembly housing and frame supports Fig 29 Adjust before installing pivot screws by sliding bedbar pivot sideways IMPORTANT On hand adjustable type knobs check to make sure die spring is compressed to a dimen sion of 13 16 in by tightening locknut left hand thread Fig 6b
132. er two existing cutting units on the machine 1 Set the new cutting unit to a height of cut approximately 1 16 0 06 in higher than the old cutting unit 2 Do a mowing test and compare results between the new cutting unit and old cutting units 3 Adjust the new cutting unit to match the cut of the old cutting units 4 The other two cutting units can now be replaced Adjust these two new cutting units so they are the same as the other new cutting unit that was tested Greensmaster 3000 3000 D Page 9 15 Figure 15 1 Height of cut knob locknut 3 Height of cut knob 2 Gauge bar 1 87891 5 Roller shaft clamp bolt 3 Gauge bar screw head Set Up and Adjustments Front Roller Scraper Adjustment The front roller scraper should be adjusted so there is a clearance of approximately 1 32 of an inch between the scraper and roller Fig 16 Figure 16 Comb Adjustment 1 Make sure rear roller is in the desired height of cut position Loosen the bolts anchoring the front roller shaft Fig 17 Rotate the shaft 2 To adjust the aggressiveness of the comb teeth Fig 17 proceed as follows A Teeth touching the adjusting gauge bar give an aggressive setting B Teeth midway between the adjusting gauge bar and the cutting edge of the bedknife give a medium setting C Teeth even with the cutting edge of the bedknife Figure 17 give a light setting 1 Rolle
133. ers to lower check ball retainer into check valve hole of housing Make sure retainer is straight not tilted on edge in housing 2 Install check ball in housing 3 Lubricate 5 8 diameter seal and 7 16 diameter seal Install seals on check ball seat as shown 4 Lubricate check ball seat and seals thoroughly before installing seat in housing When installing seat do not twist or damage seals Install check ball seat in housing insert open end of seat first Push check ball seat to shoulder of hole 5 Install set screw Use a 1 4 allen wrench to torque set screw to 100 inch pounds To prevent interference make sure top of set screw is slightly below housing mounting surface 6 Assemble spool and sleeve carefully so that the spring slots line up at the same end Rotate spool while sliding parts together Some spool and sleeve sets have _ Set Screw 5 8 Seal 7 16 Seal Check Ball Seat Da Check Check Ball 5 Retainer Figure 54 Control Sleeve identification marks align these marks as shown Test Spring for free rotation Spool should rotate smoothly in sleeve Slot 2 with finger tip force applied at splined end Identification Control Marks Spool Figure 55 Repairs Page 4 66 Greensmaster 3100 7 Bring spring slots of both parts line and stand parts on end of bench Insert spring installation tool through spring slots of both parts Tool is av
134. es Loosen cap screws and nuts securing shield to each side plate adjust shield to correct height and tighten fasteners Fig 16 3 Repeat adjustment on remaining cutting units and adjust top bar See Top Bar Adjustment in this section of the book NOTE Shield can be lowered in dry grass conditions clippings fly over top of baskets or raised to allow for heavy wet grass conditions clippings build up on rear edge of basket Figure 16 1 Shield 3 4 3 4 Inches 12 1 cm 2 Front crossbar 4 Shield fasteners Top Cut Off Bar Adjustment Adjust top bar to make sure clippings are cleanly dis charged from reel area 1 Loosen screws securing top bar Fig 17 Insert 0 060 inch feeler gauge between top of reel and bar and tighten screws Fig 17 Make sure bar and reel are equal distance apart across complete reel 2 Repeat settings on remaining cutting units NOTE Bar is adjustable to compensate for changes in turf conditions Bar should be adjusted closer to reel when turf is extremely wet By contrast adjust bar further away from reel when turf conditions are dry Bar should be parallel to reel for optimum performance and should be adjusted whenever shield height is adjusted or when Figure 17 ever reel is sharpened on a reel grinder 1 Top bar 2 Bar mounting screws 3 Feeler gauge Greensmaster 3000 3000 D Page 8 13 Set Up and Adjustments Pull Frame Adjustment 1 Put th
135. essary Fig 49 6 To disassemble clutch remove special screw and clutch pin Fig 51 IMPORTANT The special screw and clutch pin were assembled using Loctite 271 It will be necessary to apply heat to these parts before disassembly 7 Check condition of roller bearing and needle bearing Fig 51 Replace bearings if worn or damaged Installation and Assembly New Clutch Assembly 1 Loosen two 2 set screws and remove clutch knob from new clutch assembly Fig 48 Use block of wood to keep the reel from rotating and remove nut and washer from clutch adapter shaft Fig 48 2 Pull clutch adapter out of new clutch assembly and install on reel shaft Tighten clutch adapter to a torque of 170 210 in Ib 3 Hold belt on drive pulley of clutch and slide clutch on clutch adapter while sliding belt on driven pulley IMPORTANT If clutch has come apart since nut and washer were removed in step 1 make sure belleville washers are installed as shown in Figure 50 4 Install washer and nut removed in step 1 on clutch adapter shaft and tighten nut to a torque of 7 10 ft lb Repairs Page 10 30 5 Adjust belt tension See Groomer Reel Drive Belt Adjustment in the Adjustments section of this book Install groomer reel housing cover Fig 39 Install clutch knob and tighten two 2 set screws against flats of clutch release disk Figure 48 1 Belt drive clutch assembly 2 Clutch engage disengage kn
136. eturn line through filter to reservoir nmm m mmm silii S n PRESSURE INT RETURN 444 SUCTION MAIN RETURN 4 SPOOL IN MID OUT POSITION Page4 5 Hydraulic Flow Diagrams Traction No 2 Position When the traction lever is positioned in No 2 flow from from two other pump sections The additional flow in one pump section passes through same lines as for No creases the RPM ofthe wheel motors to increase ground 1 traction position This flow is joined by additional flow speed PRESSURE INT RETURN eeeeeces SUCTION EN MAIN RETURN 4 SPOOL IN OUT POSITION RESERVOIR Hydraulic Flow Diagrams Page4 6 Greensmaster 3100 Traction Reverse Position Traction lever is positioned in No 1 or No 2 When No 5 metering section and out the lines at the front of traction pedal is pushed rearward flow from one pump the valve to the traction motors which drive the traction section goes through No 4 selector valve section into wheels to operate in reverse GER S S zm HEEL ELLA PRESSURE INT RETURN SUCTION EE NE MAIN RETURN RESERVOIR 4 SPOOL IN POSITION Greensmaster 3100 Page4 7 Hydraulic Flow Diagrams Reel Drive Mowing Operation The MOW pedal is depressed which causes the 1 2 and 3 spools to be positioned fully out of valve bank This di
137. f valves The same number and thickness of shims must be installed when reassembling the relief valve 2 Clean and inspect relief valve parts and the valve section housing Replace parts as necessary Install new seals and back up rings Apply hydraulic oil to parts before installing 3 Before operating the machine check the relief pres sure for the affected relief valve See the Testing section of this chapter Adjust relief valve by adding or removing shims between the spring and poppet Figure 24 1 Main amp No 1 section relief 3 No 3 section port relief 2 No 2 section port relief 4 No 4 traction relief Greensmaster 3100 Page 4 45 Repairs Control Valve Spool Seal Replacement IMPORTANT To prevent leakage make sure you keep foreign material such as dirt sand or paint chips out of valve body seal grooves NOTE Except for the seal under No 4 spool bonnet the valve bank does not normally have to be removed from the machine to replace spool seals Front Chain Link Side Fig 25 1 Remove the chain link boot and breather washer from the spool 2 Remove the seal retainer back up washer and lip seal from the valve body Clean the seal groove 3 Soak the new seal in clean hydraulic fluid INSTALL 1 Boot 4 Back up washer THE SEAL WITH THE OPEN LIP SIDE FACING IN 2 Breather washer 5 Lip seal TOWARDS THE VALVE BODY Install the back up 3 Seal retainer
138. g 19 While holding the bar in place lift and turn the micro adjust ment knob until the groomer blade just touches the bar rotating the groomer reel by hand will assist in deter mining if blades are lightly touching the bar 4 Repeat step 3 on the opposite side of the cutting unit then check the adjustment on the other side again Adjust again if necessary 5 Each notch on the micro adjustment knob equals approximately 0 007 in of groomer height depth Divide the desired height depth setting of the groomer reel by 0 007 to determine how many notches to turn the micro adjustment knob Make sure each knob is turned the same number of notches Turn counterclockwise to raise groomer reel and clockwise to lower Example Desired groomer setting of 192 0 03125 in higher than bottom of rollers 0 03125 0 007 4 46 4 or 5 notches 6 Rotate both quick up levers to raise the grooming reel into transport position Make sure the clutch is dis engaged Figure 19 1 Bar 2 Front roller 3 Rear roller 4 Quick up lever 2 5 Micro adjustment knob 2 6 Groomer reel touching bar Shield Height Adjustment Adjust shield to get proper grass clipping discharge into basket 1 Set cutting unit in normal cutting position and measure distance from top of front crossbar to shield at each end of cutting unit Fig 20 2 Height of shield from crossbar for normal cutting conditions should be 4 3 4 inches
139. g reel motor to cutting unit Twist motor clockwise to disengage from cutting unit and remove motor 6 Slowly rotate reel listening for reel to bedknife con tact If no contact is evident TURN BEDKNIFE ADJUST ING KNOB CLOCKWISE ONE 1 CLICK AT A TIME UNTIL FIRST CONTACT IS FELT AND HEARD THEN TIGHTEN ONE 1 MORE CLICK TO GET LIGHT CON TACT Fig 7 7 If contact is felt turn bedknife adjusting knob counterclockwise one 1 click at a time until no contact is evident Turn bedknife adjusting knob one 1 click at atime clockwise until first contact is felt and heard then tighten one 1 more click to get light contact 8 Install hydraulic motor to cutting unit IMPORTANT LIGHT CONTACT MUST BE MAIN TAINED AT ALL TIMES If light contact is not main tained bedknife and reel edges will not self sharpen sufficiently This will result in dull cutting edges after Greensmaster 3000 3000 D Page 10 11 a period of operation If excessive contact is main tained bedknife reel wear will be accelerated Un even wear can result and quality of cut may be adversely affected NOTE As the reel blades continue to run against the bedknife a slight burr will appear on the front cutting edge surface the full length of the bedknife If a file is occasionally run across the front edge to remove this burr improved cutting performance can be obtained NOTE After extended operation notches will eventually develop at both ends
140. ght pivot bolt Put plastic washer and steel washer between right side of bedbar and side plate with plastic washer closest to bedbar Thread pivot bolt into side plate Adjust right hand pivot bolt until left end of bedbar firmly seats against the plastic washer and side plate clamping the plastic washer snugly This removes end play from bedbar Bedbar must pivot without binding Hold right hand pivot bolt to keep it from moving and tighten jam nut IMPORTANT Apply NEVER SEEZ or equivalent to the threads of the handle assembly 13 Thread adjustment knob and pivot assembly into flat side of bedbar pivot left hand thread Make sure there is an equal gap between each side of pivot assembly housing and frame supports Fig 32 Adjust before installing pivot screws by sliding bedbar pivot sideways IMPORTANT On hand adjustable knobs check to make sure die spring is compressed to 13 16 in by tightening locknut left hand thread 14 If equipped with hex head type pivot screws tighten pivot screws to 60 ft Ib If equipped with hex socket head set screws and jam nuts tighten set screws finger tight then tighten an additional 1 2 turn total not each Tighten jam nuts 15 Secure spring arm to pivot assembly If spring arm is adjustable adjust upward until a solid clicking sound is achieved when adjusting knob is turned 16 Level bedknife to reel Level rear roller to reel Set height of cut If necessary backlap t
141. he frame thereby allowing full spool travel 13 Figure 13 1 Jam nut 2 Yoke 3 Control rod 4 Adjustment lever Adjustments Page 4 36 Greensmaster 3100 Traction Pedal Adjustment Fig 14 To check forward and reverse operation of traction pedal use the following procedure Reverse 1 Push down on rear of traction pedal reverse until No 5 section spool valve is completely pushed in 2 Check distance between bottom of pedal and foot rest Distance should be approximately 3 16 in If dis tance is greater or less than 3 16 in dimension an adjustment to the traction control rod is required 3 Remove jamnut and balljoint securing control rod to traction shaft pivot 4 Loosen jamnuts securing balljoints to control rod and adjust balljoints and control rod to get 3 16 in Forward 1 Push the traction pedal fully forward until No 5 section valve spool is completely pulled out 2 Pedal should contact pedal stop If pedal contacts stop before spool is completely out or if pedal does not make contact with stop an adjustment to the stop is necessary 3 Loosen hex nut securing threaded rod to frame Turn flange nut on rod to raise or lower stop rod while checking pedal 4 When completed retighten nut Traction Return Linkage Fig 14a If shift selector does not return to Neutral or No 1 position from No 2 position when mow pedal is en gaged an adjustment to the traction return link
142. he mow pedal is engaged VLL LU AE asumu dummmummmmmmunug E E E TESTER GR3100 WITH DANFOSS PUMP SHOWN TEST A REEL DRIVE PUMP EFFICIENCY MACHINES WITH PARKER PUMP USE PROCEDURE CENTER 3 PUMP SECTIONS FOR REEL Traction lever in neutral position DRIVE CIRCUITS Engine RPM 2800 Hydraulic oil at operating temperature While watching pressure gauges slowly close flow control valve until 1000 PSI is obtained Read flow gauge TESTER READINGS Flow not less than 2 5 GPM at 1000 PSI If unable to get 1000 PSI or flow is below 2 5 GPM check for restriction in intake line to reel drive pump If not restricted remove pump and repair as necessary Page4 32 Rev E Greensmaster 3100 4 Reel Drive Motor Flow Reel Drive Relief Setting Reel Motor Efficiency TESTER CONNECTION Tester in series between pressure hose and motor fitting on suspected bad motor Tester Flow Control Valve Open CAUTION Keep everyone away from the front of the machine during reel system tests Operator must be on seat or the safety interlock will stop the engine when the mow pedal is engaged MIHI B JG nuu E aumudummmuummmmmunug w E GR3100 WITH DANFOSS PUMP SHOWN MACHINES WITH PARKER PUMP USE CENTER 3 PUMP SECTIONS FOR REEL DRIVE CIRCUITS TEST A REEL DRIVE MOTOR FLOW PRO
143. hen isolated from circuit disconnect wiring harness connector at float switch Connect con tinuity tester across wiring terminals of float switch Switch should show continuity when float is pushed down Switch should show no continuity when float is in raised position Solenoid Valve Fig 14 1 Disconnect wiring connector at solenoid valve Item 28 2 Connect a 12 volt battery so positive battery terminal is connected to one one lead of connector and negative is connected to other lead The valve spool should retract completely as 12 V D C is applied be tween the leads 3 lv valve operates smoothly but does not retract when 12 V D C is applied so solenoid leads replace solenoid valve Figure 14 Testing Page 5 12 Greensmaster 3100 Repairs General Safety Interlock Switch Service The following procedures should be followed whenever a switch requires adjustment or replacement 1 Be sure rubber boot is reinstalled in both switch grooves on the button end of seat switch after it is properly adjusted IMPORTANT Rubber boot on button end must be in place to make sure all dirt moisture and grease are kept from the plunger sides 2 Spread Skin Over grease heavily over the terminal end and inside the terminal cover of all switches before installing the connectors and terminal cover Be sure the wires are fully connected 3 Make sure terminal cover is fully installed over end of S
144. hen the cylinders complete their travel oil flow from cylinder This actuates the lift cylinders and lowers the the No 3 spool section is then directed to the rear cutting cutting units Oil is returned to a three way fitting on the unit drive motor No 1 spool section through lines on the top end of each PEDALS PRESSURE MOW PEDAL DOWN INT RETURN SUCTION 2 3 SPOOLS OUT MAIN RETURN REEL MOTOR Monin umm TUTTLE 83100 WITH DANFOSS PUMP SHOWN MACHINES WITH PARKER PUMP USE CENTER 3 PUMP SECTIONS FOR REEL DRIVE CIRCUITS RESERVOIR Greensmaster 3100 Page4 9 Hydraulic Flow Diagrams Reel Drive Raising Cutting Units When the LIFT pedal is depressed No 1 2 and 3 spools are pushed inward When spools pass neutral cutting units stop operation Holding pedal depressed keeps spools fully in This directs flow from one pump section to pass through end cover and No 1 spool valve out PEDALS RESERVOIR three lines leading to lift cylinders causing cylinders to raise the cutting units Oil forced out of cylinders travels through lines leading to No 3 spool section through the valve bank and back to reservoir through main re turn line PRESSURE INT RETURN 4 SUCTION MAIN RETURN LIFT
145. ht angle along entire length of bedknife It should be possible to cut paper with minimum bedknife to reel contact Should excessive reel drag be evident you must back lap or grind the cutting unit No contact will dull the cutting edges Excessive contact accelerates wear and quality of cut may be adversely affected Weekly Checks 1 Check reel bearing adjustment and bearing condi tion 2 Make sure bed bar pivot bolts are securely seated maximum 40 ft Ib 3 Using a gauge bar verify correct height of cut setting and adjust as necessary Greensmaster 3000 3000 D Page 8 7 Monthly Adjustments NOTE Remove cutting unit from traction unit before doing these checks and adjustments See Cutting Unit Removal and Installation in the Repairs section of this chapter 1 Visually check for sharp reel and bedknife Backlap or grind reel and bedknife if necessary 2 Adjust rear roller for proper bedknife angle and parallel to reel 3 Adjust front roller scraper to be 1 32 in from roller 4 Set comb or brush adjustment for desired action on grass Light medium or aggressive setting 5 Check grass shield adjustment 4 3 4 in from crossbar normal Dry grass lower shield Wet grass raise shield 6 Set top bar cut off bar adjustment 0 060 in from reel normal 7 Lower cutting units to the ground setting on both rollers remove reel motor and adjust bedknife to reel co
146. htening the fittings This can be done by observing the imprint on the hose Use two wrenches one to hold the hose straight and one to tighten the hose swivel nut onto the fitting Hydraulic Fitting Installation O Ring Face Seal Fig 1 2 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Make sure the O ring is installed and properly seated in the groove It is recommended that the O ring be replaced any time the connection is opened 3 Lubricate the O ring with a light coating of oil 4 Putthe tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight 5 Mark the nut and fitting body Hold the body with a wrench Use another wrench to tighten the nut to the correct flats from finger tight F F F T The markings on the nut and fitting body will verify that the connection has been tightened Size F F F T 4 1 4 in nominal hose or tubing 75 25 6 3 8 75 25 8 1 2 75 25 10 5 8 1 00 25 12 3 4 75 25 16 1 in 75 25 Greensmaster 3100 A WARNING Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved by stopping the en gine and lowering the cutting units to the ground Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid un der high pressure Use paper or cardboard
147. igure 51 1 Set screw 7 Clutch body drive pulley 13 Set screw 2 Felt seal 8 Roller bearing 14 Clutch knob 3 Clutch adapter 9 Belleville washer 2 15 Flat washer 4 Needle bearing 10 Clutch release disk 16 Lock nut 5 Clutch pin 11 Special screw 6 Compression spring 12 Flange bushing Greensmaster 3000 3000 D Page 10 31 Repairs Bedknife to Adjustment Knob Bearing Service 1 Turn bedknife adjustment knob counterclockwise to remove bedknife to reel contact 2 Remove two 2 pivot screws Fig 38 3 Rotate adjustment knob and pivot assembly clock wise left hand thread until it is unthreaded from the bedbar pivot 4 necessary remove locknut securing die spring to shaft Fig 6b Slide pivot housing off adjustment knob threaded shaft Fig 38 5 Pull inner races from pivot housing Pull bearings from pivot housing Check condition of inner races and bear ings and replace if necessary 6 Install new o ring on each race if necessary 7 Install bearings and races in pivot housing Slide pivot housing onto shaft of knob 8 Install spring over adjusting knob threaded shaft and thread adjustment knob and pivot assembly into flat side of bedbar pivot Make sure there is an equal gap be tween each side of pivot assembly housing and frame supports Fig 29 Adjust before installing pivot screws by sliding bedbar pivot sideways IMPORTANT On hand adjustable type knobs check to make sure
148. il the plates are covered and then 1 Positive terminal charge the battery After charging fill the battery to the 2 Negative terminal proper level FILLER CAPS 7 Electrolyte Specific Gravity CORRECT LEVEL Fully charged 1 250 1 280 Discharged less than 1 240 A WARNING Do not charge a frozen battery because it can explode and cause injury Let the battery warm to 60 F 15 5 C before connecting to a charger Charge the battery in a well ventilated place Figure 19 so that gases produced while charging can dissipate Since the gases are explosive keep open flame and electrical spark away from the battery do not smoke Nausea may result if the gases are inhaled Unplug the charger from the electrical outlet before connecting or disconnecting the charger leads from the bat tery posts Repairs Page 5 16 Greensmaster 3100 Chapter 6 Wheels Steering and Brakes Table of Contents SPECIFICATIONS 2 REPAIRS a conte uade 4 5 3 Brake Service 4 Brake Adjustment 3 Steering Cable Greensmaster 3050 5 See Chapter 4 Hydraulic System for information about the power steering system Greensmaster 3100 Page6 1 Rev B Specifications Item Specification Tire pressure 8 12 PSI front 8 15 PSI rear Wheel nut torque 40 50 ft
149. ination NOTE To ease reassembly tag each of the hoses to show their correct position on the steering valve 3 Remove the steering wheel cap Item 9 from the steering wheel Item 11 Remove the locknut Item 10 that secures the steering wheel to the shaft Pull the steering wheel off the shaft NOTE It may be necessary to use a jaw type puller to remove the steering wheel from the steering shaft IMPORTANT DO NOT hit the steering shaft with a hammer This could damage the steering valve com ponents Repairs Page 4 60 4 Remove four capscrews Item 7 and lower the steer ing valve Item 24 and steering column Item 23 out of the steering arm 5 Reverse steps 1 4 to install the steering valve Tighten the steering wheel nut so the top surface of the nut is flush with the top of the steering column IMPORTANT When disassembling hydraulic lines make sure hydraulic plugs are placed in the open end of the hydraulic line to prevent foreign debris from contaminating hydraulic oil It is also a good idea to tag the hydraulic lines when disassembling so they can be properly reassembled Keep all hy draulic lines clean and free from foreign debris During replacement of steering valve avoid over tightening fittings Check hydraulic lines for cracks or breaks If a hydraulic leak should appear after replacement of lift cylinder replace the fitting or line that is leaking Check hydraulic reservoir for level of hydr
150. ing Torque 7 in Ib maximum with bedknife to reel contact removed Front or Rear Roller Run Out 0 14 in max Groomer Reel Drive Belt Tension 1 4 in deflection when a force of 5 10 Ib is applied midway between drive pulley and driven pulley Clutch Adapter Torque 170 to 210 in Ib Clutch Assembly Locknut Torque 140 in Ib removing all end play 9 Groomer reel 1 Lift bail 2 Height of cut adjustment knob 2 3 Height of cut adj locknut 2 4 Pull rod studs 2 Greensmaster 3000 3000 D 5 Grass shield 6 Reel 7 Groomer micro adj locknut 2 8 Bedknife adjustment knob Page 10 3 10 Groomer clutch snubber 11 Clutch engage disengage knob 12 Groomer quick up down lever 2 Specifications Special Tools NOTE Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PRODUCTS Some tools may be listed in the Greensmaster 3000 or 3000 D Parts Catalog Some tools may also be available from a local supplier McLube Aerosol or liquid lubricant Apply to bedbar pivot and bedbar pivot bolts Figure 1 Roller Bearing Replacement Tool Puller is used to remove bearings from front and rear rollers Driving tubes are used to install bearings into rollers Refer to instructions supplied with tool Used on swaged full and wiehle rollers Special Tools Page 10 4 Figure 2 Greensmaster 3000 3000 D Plastic Plug Insert plug in cutting unit bear
151. ing brake and drive the machine to an open area that is free of debris and foreign objects Keep all people especially children away from the front of the machine and out of the area of operation Move shift selector to neutral N make sure the mow pedal is disengaged set the throttle control at half speed and engage the parking brake Hold the steering wheel brace your feet on the foot deck and brake pedal and move the shift selector to the No 1 position Carefully lift off the seat the engine should stop Repeat procedure with shift selector in No 2 position If engine stops while lifting off the seat with shift selector in No 1 and No 2 positions interlock system is operating correctly If engine does not stop stop the engine and correct the problem before operating the machine Refer to Troubleshooting in this chapter Greensmaster 3100 Testing It is often to the technician s advantage to leave the components intact in the electrical system and by studying the electrical troubleshooting charts and sche matics determine which component is at fault How ever this section will define given components and the tests that can be performed on those components when those parts are isolated from the electrical system For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit Ignition Key Switch Fig 8 The ignition key switch has three positions OFF S
152. ing harness cover with skin over grease and push connectors onto switch terminals Be sure connectors are fully connected and slide cover over bottom of switch body o oe LI Figure 15 1 Seat switch Repairs Traction Neutral Switch Replacement and Adjustment Fig 16 1 Pull connector off switch terminals of traction switch installed in valve bank bonnet on selector valve section 2 Loosen the jam nut and unscrew the switch from the mounting bracket 3 Move shift selector to Neutral 4 Partially screw new switch into bonnet 5 Connect a continuity tester or ohm meter to the switch terminals and continue to turn the switch in until there is continuity Then rotate switch in 1 2 turn 180 6 Secure jam nut to 75 in Ib 8 5 Nm against the bonnet 1 Traction switch IMPORTANT Switch threads will be damaged if the jam nut is over tightened 7 Connect continuity tester or ohm meter to switch terminals and move shift selector to the No 1 and No 2 positions There should not be continuity when shift selector is in either of these positions If there is conti nuity repeat steps 4 and 5 8 Move the shift selector lever to Neutral and connect continuity tester or ohm meter to switch terminals The Switch should show continuity This means the switch is operating correctly 9 Fill terminal end of switch and wiring harness cover with skin over grease and push connectors onto sw
153. ing housing in place of reel motor when sharpening or grinding the reel Figure 3 Handle Assembly For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel assembly Figure 4 Bedknife Screw Tool Fits Toro bedknife attaching screws Use with torque wrench to secure bedknife to bedbar With clean bedbar threads new screws tighten to a torque of 200 in Ib NOTE Remove all rust scale and corrosion from bedbar surface before installing bedknife 47 DO NOT use an air impact wrench with this tool Figure 5 Greensmaster 3000 3000 D Page 10 5 Special Tools Troubleshooting Factors Affecting Quality of Cut There are a number of factors that can contribute to unsatisfactory quality of cut some of which may be turf conditions Turf conditions such as excessive thatch sponginess or attempting to cut off too much grass height may not always be overcome by adjusting the Factor 1 Tire pressure 2 Engine governed speed 3 Reel bearing condition adjustment 4 Reel and bedknife sharpness 5 Bedknife parallel to reel 6 Bedknife to reel contact 7 Bedknife attitude rear roller bracket hole position 8 Rear roller parallel to reel 9 Height of cut 10 Proper bedknife for height of cut Troubleshooting machine It is important to remember that the lower the height of cut the more critical these factors are See the Adjustment
154. ing temperature hoses warm to the touch Testing TEST HOOK UP 1 Traction Pump Flow Traction Relief Setting TESTER CONNECTION Tester in series between traction pump outlet line and valve bank port on No 4 section of valve bank Tester Flow Control Valve Open CAUTION Keep everyone away from the front of the machine during traction system tests Operator must be on seat or the safety interlock will stop the engine when the traction lever is engaged pump mmm ninm emm stu n LLES TTT TEST A TRACTION PUMP FLOW PROCEDURE Traction lever in neutral Engine RPM 2800 RPM Hydraulic oil at operating temperature While watching flow and pressure gauges slowly close flow control valve until 1000 PSI is obtained TESTER READINGS Flow not lower than 5 GPM at 1000 PSI Record pressure and flow readings If flow is lower than 5 GPM or a pressure of 1000 PSI cannot be obtained check for restriction in pump intake line If not restricted remove pump and repair as necessary Testing Page 4 28 Greensmaster 3100 TEST HOOK UP 1 continued TEST B RELIEF VALVE SETTING PROCEDURE Tester flow control valve open Block up traction wheels off floor Apply brakes and engage park lock Engine RPM 2800 Hydraulic oil at normal operating temperature Engage transmission lever to No 1 position Push traction pedal to forward position TESTER READINGS Pressure 1850 to 1950 PSI
155. inside of all harness connectors whenever the harness is disconnected Always disconnect the battery cables negative ca ble first to prevent possible wiring damage from short outs whenever working with the electrical system Greensmaster 3100 Page 5 15 Repairs Battery Service Fig 18 19 IMPORTANT Before welding on the machine dis Battery Specifications connect the negative battery cable from the bat Group U1 Battery tery to prevent damage to the electrical system 200 Amp Cranking Performance at 0 F 17 C 32 min Reserve Capacity at 80 F 27 C IMPORTANT To prevent damage to the electrical components do not operate the engine with the battery cables disconnected Keep the terminals and entire battery case clean To clean the battery wash the entire case with a solution of baking soda and water Rinse with clear water Do not get the soda solution into the battery because damage tothe battery will result Coatthe battery posts and cable connectors with skin over grease or petroleum jelly to prevent corrosion Check for loose battery hold downs Aloose battery may crack or cause the container to wear and leak acid Check the electrolyte solution to make sure the level is above the plates If the level is low but above the plates inside the battery add water so the level is to the 18 bottom of the cap tubes If the level is below the plates add water only unt
156. intentionally blank TORO Table of Contents SPECIFICATIONS SPEGIAE TOOLS baste IE TROUBLESHOOTING Factors Affecting Quality of Cut SET UP AND ADJUSTMENTS Characteristics BEPAIBS bus ap Ie Hydraulic Reel Motor Removal Inspection and Installation Backlapping Units without Optional Backlap Variable Reel Speed Kit Backlapping Units with Optional Backlap Variable Reel Speed Kit Greensmaster 3100 10 1 Chapter 10 Dual Point Adjust Cutting Units Bedbar Assembly 10 Bedbar Removal and Installation 11 Bedbar Adjuster Service 12 Bedknife Replacement and Grinding 13 Reel Assembly 14 Reel Removal 15 Left Side Plate Service 16 Right Side Plate Service 16 Reel Service e Scr lb Ine E 17 Reel Installation 18 Preparing a Reel for Grinding 19 Front Roller Removal and Installation 20 Front and Rear Roller Service 21 Roller Seal Removal and Installation 21 Bearing removal and Installation 22 Dual Point Adjust Cutting
157. ion switch or seat switch out of adjustment or malfunctioning Seat return pin spring broken miss ing or stuck in down position Seat pivot does not rotate freely Adjust or replace traction switch or seat switch Replace loosen and lubricate parts so pin operates freely Loosen and lubricate seat pivot pin to make sure if pivots freely 8 Engine does not continue to run when sitting on seat and shift selector is placed in No 1 or No 2 position or mow pedal is pushed down Seat switch adjusted incorrectly or malfunctioning Seat return spring jammed in up position Adjust or replace seat switch Loosen and lubricate jammed parts so pin operates freely Re place spring if necessary 9 Engine stops regardless of shift selector or mow pedal posi tion even if both are in neutral as you get off of the seat Mow lift switch and or traction switch out of adjustment or mal functioning Rear camshaft out of adjustment Mow lift and or traction switch wires are loose Traction switch extension plug wires are loose Adjust or replace mow lift switch and or traction switch Adjust rear camshaft Connect wires Connect wires 10 Engine seems to cut out too much during transport Seat is lifting off seat switch button too easily Adjust seat switch Instruct operator to sit back in seat during transport Greensmaster 3100 Page 5 7 Troubleshooting
158. is also a good idea to tag hydraulic lines when disassembling so that they can be properly reassembled Keep all hydrau lic and suction lines clean and free from debris During replacement avoid overtightening fittings see the Hydraulic Hose and Fitting Information section of this chapter Check hydraulic lines for breaks or cracks Check the hydraulic reservoir for proper fluid level after replacement of any large component Repairs Page 4 42 3 Loosen the set screws Item 13 securing the pump hub Item 22 to the shaft remove the capscrews Item 24 mounting the pump to the pump mount and remove the pump Reassembly 1 Fill pump with clean hydraulic fluid and cap fittings 2 Assemble the pump to the engine in reverse of the disassembly procedures Check all lines for clearance from the frame and other components 3 Start machine and check for proper performance Greensmaster 3100 Pump Repair Greensmaster 3100 shown Fig 22 E lt lt 3 t7 16 Figure 22 Relief Valve Service 1 Remove cap 10 Remove valve adjuster Item 9 spring Item 8 and ball Item 7 2 Remove o ring Item 32 from cap 3 Inspect ball for burrs or roughness Inspect relief valve bore and seat in bearing plate Item 28 4 Inspect spring for damage 5 Clean and dry all parts Apply hydraulic oil to parts Install ball spring and valve adjuster 6 Install new o ring on cap and i
159. it before doing adjustments or repairs 1 Remove basket from pull frame 2 Loosen reel motor mounting nuts Fig 24 Rotate the motor clockwise so motor flanges clear studs and pull motor off of cutting unit 3 Slide the sleeve back on the ball joint and disconnect the pull arm from each side of the cutting unit Fig 25 4 Slide cutting unit out from under pull frame disengag ing the lift arm from the lift bail Fig 26 5 Reverse steps 1 4 to install the cutting unit Greensmaster 3000 3000 D Page 10 21 Figure 24 1 Motor mount nuts 2 Motor shaft Figure 25 1 Slide back to mount 2 Ball stud 3 Swing up to remove down to install yo 3 4 Figure 26 1 Lift bail 3 Pull frame 2 Lift arm 4 Pull arm Repairs Reel Lapping Check reel bearing adjustment and correct if necessary before backlapping Make sure bedknife is parallel to reel On groomer equipped cutting units backlap by using a length of 3 8 in square stock inserted into the CAUTION center hole in the reel shaft on the reel drive motor end Be careful when lapping the reel because of the cutting unit Attach a socket extension and back tact with the reel or other moving parts can lapping machine Backlap according to procedures in result in personal injury the Toro publication Sharpening Reel amp Rotary Mowers Form No 8
160. itch ammeter or solenoid Connect wires wires loose 4 Engine fails to crank with con Wiring harness connected wrong Connect wiring harness correctly trols in neutral when operator is refer to Electrical Schematic off seat but does crank when op erator is on seat Wiring harness malfunctioning Install new wiring harness Troubleshooting 5 6 Greensmaster 3100 Problem 5 Engine cranks but does not start when shift selector and mow pedal are in neutral Cause If engine cranks cause of problem is UNRELATED to interlock wiring system Engine or rectifier plug loose Key switch wiring connector loose Engine problem or no fuel Correction All interlock switches are OK re fer to next cause Connect wire Connect wire Find problem and correct 6 Engine does not stop when mow pedal is pushed down cut ting units engaged as you get off of the seat Mow lift switch or seat switch out of adjustment or malfunctioning Rear camshaft out of adjustment Seat return pin spring broken miss ing or stuck in down position Seat pivot does not rotate freely Adjust or replace mow lift switch or seat switch Adjust rear camshaft Replace loosen and lubricate parts so pin operates freely Loosen and lubricate seat pivot pin to make sure if pivots freely 7 Engine does not stop when shift selector is in No 1 or No 2 position as you get off of the seat Tract
161. itch terminals Repairs Page 5 14 Greensmaster 3100 Mow Lift Switch Replacement and Adjustment Fig 17 IMPORTANT Spool travel for 1 2 and 3 spools must be correct before Mow Lift switch can be adjusted See Rear Camshaft Adjustment in the Adjustments section of Chapter 4 Hydraulic System 1 Pull connector off switch terminals from end of mow lift switch installed in the valve bank bonnet 2 Loosen jam nut and unscrew switch from valve bank bonnet 3 While holding lift pedal in fully depressed position valve bank spools fully IN partially screw new switch into bonnet Figure 17 4 Connect continuity tester on ohm meter across switch terminals and turn switch in until continuity occurs Then 1 Mow lift switch rotate switch in 1 2 turn 180 and secure jam nut to 75 in Ib 8 5 Nm against the bonnet IMPORTANT Switch threads will be damaged if the jam nut is over tightened 5 Connect continuity tester or ohm meter to switch terminals and depress the mow pedal There should not be continuity If there is continuity repeat step 3 Pro ceed to step 6 if there is no continuity 6 Depress the lift pedal and release it neutral position The switch circuit should have continuity 7 Fill terminal end of switch and wiring harness cover with skin over grease and push connectors onto switch terminals Wiring Harness Service Prevent corrosion of the wiring terminals by applying skin over grease to the
162. itions such as excessive thatch Adjustments and Repairs sections for detailed adjust sponginess or attempting to cut off too much grass ment and repair information height may not always be overcome by adjusting the a Factors Affecting Quality of Cut Factor Possible Problem Correction 1 Tire pressure Check tire pressure and adjust if necessary Must be equal in both front tires 2 Engine governed speed Check maximum governed engine speed Adjust to specification if necessary affects reel speed 3 Reel bearing condition adjustment Check and adjust to specification Replace bearings if worn or damaged Bearing cones must be installed square to bearing housing make sure there is no flash paint or other foreign material in housing before installing new bearing cone 4 Reel and bedknife sharpness Reel and or bedknife that has rounded edge cannot be corrected by tightening bedknife to reel contact Grind reel to remove taper cone shape and or rifling grooved or ribbed appearance Grind bedknife to sharpen and or remove rifling Most common cause of rifling is bedknife to reel contact that is too tight NOTE New bedknife must be ground after installing on bedbar to match bedknife to bedbar 5 Bedknife parallel to reel Check and adjust as necessary 6 Bedknife to reel contact Check before operating with cutting unit on ground Remove reel motor and rotate reel by h
163. ive height of cut Changing the machine such as adding a wiehle roller or changing to a heavier grooming reel cutting unit will increase penetration into the turf and lower the effective height of cut Difference between bench set and effective 1 height of cut Figure 17 Set Up and Adjustments Page 10 16 Greensmaster 3000 3000 D Height of Cut Adjustment IMPORTANT Lower heights of cut are limited by thickness of bedknife Select proper bedknife for desired height of cut If bedknife is too thick for height of cut poor quality of cut will resuit and excessive pressure from turf on bottom of bedknife can cause rifling of bedknife and reel NOTE Because of weight difference bench set height of cut should be approximately 0 020 to 0 040 in higher on grooming reel cutting units to get the same effective height of cut as cutting units without groomers 1 Make sure that rear roller brackets are in correct hole positions for desired height of cut and that rear roller is level Also check that bedknife to reel contact is correct 2 Turn cutting unit over and loosen locknuts securing front roller adjusting screws to height of cut brackets Fig 18 3 On gauge bar Part No 1 8789 set head of screw to desired height of cut This measurement is from bar face to underside of screw head 4 Place bar across front and rear rollers and adjust height of cut knob until underside of screw head e
164. ivot Fig 24 3 Loosen jam nuts retaining right and left bedbar pivot bolts Remove pivot bolts Fig 24 IMPORTANT Note position of plastic washer and steel washer on right end of bedbar and plastic washer on left end of bedbar for reinstallation 4 Slide bedbar down and out from under cutting unit Figure 24 Do not misplace washers 1 Pivot screw 7 Left bedbar pivot bolt 5 Replace and or grind bedknife to renew cutting edges 2 Bedknife pivot ass y 8 Right bedbar pivot bolt 3 Frame supports 9 Steel washer NOTE For proper of knife follow proce 4 Adjustment knob 10 Plastic washer 1 p 2 ja pe ar kh Een d 5 Bedbar pivot 11 Spring arm retaining capscrew p pening 6 Jam nuts 12 Compression spring Rotary Mowers Form No 80 300 PT 6 Adjust the reel bearings See Reel Bearing Service and Adjustment in the Adjustments section of this chap ter 7 Grind the reel to remove any taper and renew cutting edges See Preparing Cutting Unit for Reel Grinding in this section of the book 8 Check size of hole in bedbar end bushings every time bedbar is removed Insert flange bushing into rubber bushing Fig 25 Insert clean shoulder bolt into flange bushing rubber bushing assembly If bolt slides easily into bushing replace all four bedbar bushings See Bedbar Bushing Replacement in this section of the book Figure 25 1 Rubber bushing 3 Shoulder pivot bolt
165. knife Replaceable single edged high carbon steel bedknife is fastened to a machined cast iron bedbar with 13 screws Tournament bedknife is standard Bedknife Adjustment Dual screw adjustment to the reel detents corresponding to 0007 inch 018 mm bedknife movement for each indexed position Front Roller A variety of sealed bearing and through shaft front rollers are available for use with these cutting units The front roller brackets control the height of cut by using two vertical adjustment screws and are held in position by a horizontal locking screw Rear Roller Steel full 2 inch 5 1 cm diameter with sealed bearings and through shaft The rear roller has two positions allowing user to change the cutting unit at titude and the behind center distance of bedknife from reel center line Counterbalance Weight A cast iron weight mounted opposite to the drive motor balances the cutting unit Grass Shield Non adjustable shield with adjustable cut off bar to improve grass discharge from reel in dry conditions Maximum Reel Speed 2200 RPM Weight 8 Blade 11 Blade 72 Ib 32 kg 75 Ib 34 kg Greensmaster 3100 Special Tools OTC Owatonna Tool Company supplies special tools for servicing Toro Commercial Products The TORO SPECIAL TOOLS AND APPLICATIONS GUIDE shows service tool applications Gauge Bar Assembly Used to height of cut Toro Model Number 13 8199 Backlapping Brush Assembly
166. knob Fig 6 Remove groomer reel housing cover from left side of cutting unit Fig 8 2 Apply 5 10 Ib of force on the belt midway between the pulleys to check tension on the drive There should be 1 4 inch belt deflection If deflection is not 1 4 inch loosen the idler pulley pivot screw Fig 22 Pivot the idler to get proper tension and tighten the allen head screw to a torque of 7 10 ft Ib 3 Install groomer reel housing cover Install clutch knob and tighten two 2 set screws against flats on release disk Greensmaster 3000 3000 D Page 10 19 Figure 22 1 Drive pulley and clutch assembly 2 Driven pulley 3 Drive belt backside idler pulley 4 Drive belt Set Up and Adjustments Pull Frame Adjustment 1 Put the basket on the pull frame 2 Level baskets to cutting unit by loosening nut at one end of pull frame roller Loosen bolt and move roller shaft in slot as necessary Tighten bolt 3 Loosen the jam nuts on the pull arms and adjust the ball sockets until there is 1 4 in to 1 2 in 6 to 13 mm clearance between the lip of the basket and the reel blades Fig 23a This prevents grass clippings from dropping on the ground 4 Make sure the basket lips are the same distance from the reel blades at both ends of the reel If the basket is too close to the reel it is possible for the reel to
167. l dowel pins in body IMPORTANT Do not dislodge o rings pressure seals or back up rings during final assembly 9 Gently slide the rear cover onto the assembly using marker or scribe mark for proper location Firm hand pressure should be sufficient to engage the dowel pins 10 Position the motor with rear cover downwards Care fully slide the front flange onto the assembly using mark er or scribe mark for proper location 11 Install the four cap screws and hand tighten IMPORTANT Avoid using excessive clamping pressure on the motor housing to prevent distorting the housing 12 Place motor front flange in a vise and alternately torque the cap screws from 33 to 40 ftHb 45 to 55 13 Put a small amount of hydraulic oil in port on motor and rotate driveshaft one revolution Protect the shaft if using a pliers If drive shaft binds disassemble motor and repeat assembly process 14 Remove motor from vise Greensmaster 3100 This page is intentionally blank Hydraulic Pump Removal and Installation Greensmaster 3100 shown Fig 19 M v ae Figure 19 Disassembly 1 Drain the hydraulic reservoir 2 Remove the hydraulic lines from the pump Fig 9 Put plugs in the pump ports Put covers on the fittings IMPORTANT When disassembling hydraulic lines make sure hydraulic plugs are placed in the open end of the hydraulic line to prevent debris from contaminating hydraulic fluid It
168. l grease from the side plate bore 5 Insert the wave washer 15 into the side plate Note Replacemant Seal Kit Toro Part No 106 6937 is available for side plate service of dual point adjust cut ting units 6 Packthe bearing 12 with Mobil High Temperature HP or equivalent grease Insert the bearing into the side plate against the wave washer 7 Pressthe retaining ring 14 into the groove slightly compressing the bearing and wave washer 8 Pack the cavity of the inner seal 13 with Mobil High Temperature HP or equivalent grease 9 Using inner grease seal installation washer Toro Part Number 104 0532 press the inner seal 13 into the side plate until the washer is flush with the outer edge of the side plate bore Remove the washer When properly installed the seal should be positioned 104 in below the inner edge of the side plate bore 10 Press the outer seal 9 into the side plate until it is flush with the the outer edge of the side plate bore IMPORTANT The outer grease seal 9 should be installed so the lip is facing out This helps keep contamination from entering and allows grease to vent or purge out if necessary Fig 20 11 Fill remaining voids behind inner grease seal 13 and outer grease seal 9 lips with Mobil High Tempera ture HP or equivalent grease Dual Point Adjust Cutting Units Page 10 16 Rev D Right Side Plate Service Fig 16 1 Remove the inner grease seal 13 and o
169. l motor Rotate the reel by hand TURN ADJUSTING KNOB ONE 1 CLICK AT A TIME UNTIL FIRST CONTACT BETWEEN REEL AND BEDKNIFE IS FELT AND HEARD THEN TIGHTEN ONE 1 MORE CLICK TO GET LIGHT CONTACT No contact will dull the cutting edges Excessive contact accelerates wear quality of cut may be adversely affected tis best to make the reel to bedknife adjustment in the morning immediately before each day of mowing Weekly Checks 1 Check reel bearing adjustment and bearing condition 2 Make sure bed bar bolt plastic washers are SNUG against the bedbar 3 Make sure bedknife adjustment knob pivot assembly is held FIRMLY in place between frame supports 4 Using a gauge bar verify the correct height of cut setting Monthly Adjustments NOTE Remove cutting unit from traction unit Set Up and Adjustments Page9 8 1 Parallel bedknife to reel Use newspaper as a feeler gauge Dot eccentric bolt must face rear of mower Turn S P A adjustment knob to hold paper on right hand end of bedknife Turn eccentric left bedbar bolt to hold paper on left hand end of bedknife Hold eccentric bedbar bolt while securing locknut 2 Adjust rear roller parallel to reel eccentric bolt faces to rear 3 Adjust the front roller scraper to be 1 32 in from roller 4 Set comb or brush adjustment for desired action on grass Light medium or aggressive setting 5 Check grass shield adjustment
170. lb Wheel motor spindle nut torque 250 400 ft Ib Specifications 6 2 Greensmaster 3100 Adjustments Brake Adjustment Fig 1 A brake adjustment rod is located on each side of the machine so the brakes can be equally adjusted 1 Push down on the brake pedal while driving the machine both wheels should lock equally A CAUTION As a Safety precaution always check brakes in a wide open spaced flat area which is free of other persons and obstructions before and after adjustment Figure 1 2 If both wheel do not lock equally disconnect the brake rods by removing cotter pin and clevis pin 1 Clevis and cotter pin 3 Clevis 2 Jam nut 4 Brake shaft 3 Loosen jam nut and adjust clevis 4 Assemble clevis to brake shaft 5 Check brake pedal free travel There should be 1 2 in to 1 in travel before the brake shoes make contact with the brake drums Adjust again if necessary to get this setting 6 Push down on the brake pedal while driving the machine both wheels should lock equally Repeat steps 2 5 if necessary Greensmaster 3100 Page 6 3 Adjustments Repairs Brake Service Fig 2 Figure 2 Brake Disassembly 1 Place blocks on each side of opposite wheel jack machine up and place blocks beneath frame under wheel motor 2 Remove wheel nuts Item 29 and remove wheel Remove large nut Item 4 securing wheel hub Item 5 to motor shaft
171. ld be turned over and the locknuts on each end of the cutting unit securing the height of cut adjusting knob loosened Fig 13 2 On gauge bar Part No 1 8789 set head of screw to desired height of cut This measurement is from bar face to underside of screw head 3 Putthe bar across the front and rear rollers and adjust the height of cut knob until the underside of the screw head engages the bedknife cutting edge Fig 10 IMPORTANT Do step 3 on each end of the bedknife Tighten height of cut adjustment locknuts on both ends Greensmaster 3000 3000 D Page 8 11 Changing To A Different Type of Cutting Unit or Adding Cutting Unit Accessories When changing to a different type of cutting unit or adding cutting unit accessories it is recommended that you change only one cutting unit and keep the other two existing cutting units on the machine 1 Set the new cutting unit to a height of cut approximately 1 16 0 06 in higher than the old cutting unit 2 Do a mowing test and compare results between the new cutting unit and old cutting units 3 Adjust the new cutting unit to match the cut of the old cutting units 4 The other two cutting units can now be replaced Adjust these two new cutting units so they are the same as the other new cutting unit that was tested Figure 13 1 Helght of cut knob locknut 4 Height of cut knob 2 Gauge bar 1 8789 5 Roller shaft clamp bolt 3 Gauge bar screwhead 6 Co
172. lddvs LJ H3HJV3H8 TN EL ox went WO OS OM ttt ISd 0002 SHSQNMAD 14 HH mC C A3u WO ND 691 601 SHOLOW TH3HM 7 YALN30 ar A3u WO 2 A3U NI SHOLOW Hydraulic Schematics Rev E Page 4 12 1 Greensmaster 3100 Hydraulic Schematic Greensmaster 3100 3WD OS D 09
173. le holding reel securely on plate level roller by rotating lower left roller pivot bolt The pivot bolt has an offset thread which when rotated acts as a cam to raise orlowerthe roller On the bolt head there is an identifica tion dot Fig 16 which denotes the offset ofthe bolt Dot indicates in which direction left end of roller moves when bolt is turned 8 To verify if roller is level try inserting a piece of paper under each end of roller 9 When roller is level tighten left capscrew and pivot Figure 15 bolt nuts securely Hold the eccentric pivot bolt while tightening the nut to keep the proper roller position 1 1 4 plate 2 Bedknife 3 Reel Figure 16 1 Pivot boit Greensmaster 3000 3000 D Page 10 15 Set Up and Adjustments rr Height of Cut Height of cut as measured on the cutting unit and in the turf is different The grass prevents the cutting unit from settling all the way to the ground line as the machine moves across the turf Because of this the actual effective height of cut is higher than the height of cut setting on the cutting unit bench set height of cut Fig 17 Machine conditions such as cutting unit weight roller type bedknife thickness speed of travel and clip Top of Grass Ground Line frequency influence effective height of cut Turf condi tions such as grass type grass density and amount of thatch also influence effect
174. ll frame bushings are worn and must be replaced Set Up and Adjustments Page 8 14 Figure 18a 1 Jam nut 3 Ball joint adjust for clearance 2 Pull arm 4 1 4 1 2 in 6 13 mm clearance Measure from each end of cutting unit Draw line on floor and center wheels over line front roller to line on floor Must be equal within 3 16 0 1867 in Figure 18b Greensmaster 3000 3000 D Repairs Cutting Unit Removal and Installation v Remove cutting unit from traction unit before doing adjustments or repairs 1 Remove basket from pull frame 2 Loosen reel motor mounting nuts Fig 19 Rotate the motor clockwise so motor flanges clear studs and pull motor off of cutting unit Figure 19 1 Motor mount nuts 2 Motor shaft 3 Slide the sleeve back on the ball joint and disconnect the pull arm from each side of the cutting unit Fig 20 Figure 20 1 Slide back to mount 2 Ball stud 3 Swing up to remove down to install 4 Slide cutting unit out from under pull frame disengag 2 ing the lift arm from the lift bail Fig 21 m a 5 Reverse steps 1 4 to install the cutting unit F X 1 s 4 Figure 21 16 20 1 Lift bail 3 Pull frame 2 Lift arm 4 Pull arm Greensmaster 3000 3000 D Page 8 15 Repairs Reel Lapping Check reel bearing adjustment and correct if necessary before backlapping Connect lapping machine to the cutting unit with an ext
175. maximum governed engine speed Adjust engine to specifications if necessary See Maintenance section in the Traction Unit Operator s Manual and or the Briggs amp Stratton Repair Manual for 4 cycle V Twin Cylinder OHV Head Engines All reels must rotate at the same speed within 100 rpm All cutting units must have equal bedknife to reel and height of cut adjustments Check reel speed setting if an optional backlap variable reel speed kit is installed See Troubleshooting in Chapter 4 Hydraulic System in this manual Check bearings for wear and replace if necessary See Reel and Bearing Removal and Installation in this chapter of this manual A reel and or bedknife that has rounded cutting edges or rifling grooved wavy appearance cannot be corrected by tightening the bedknife to reel contact Grind reel to remove taper and or rifling Grind bedknife to sharpen and or remove rifling The most common cause of rifling is bedknife to reel contact that is too tight A new bedknife must be ground or backlapped after installation to the bedbar Greensmaster 3100 Page 10 5 Rev D Dual Point Adjust Cutting units Bedknife to reel adjustment Check bedknife to reel contact daily The bedknife must have light contact across the entire reel No contact will dull the cutting edges Excessive contact accelerates wear of both edges Quality of cut is adversely affected by both conditions see Bedknife to Reel Adjustment in th
176. mb assembly Set Up and Adjustments Front Roller Scraper Adjustment The front roller scraper should be adjusted so there isa clearance of approximately 1 32 of an inch between the scraper and roller Fig 14 Comb Adjustment 1 Make sure rear roller is in the desired height of cut position Loosen the bolts anchoring the front roller shaft Fig 15 Rotate the shaft 2 To adjust the aggressiveness of the comb teeth Fig 15 proceed as follows A Teeth touching the adjusting gauge bar gives an aggressive setting B Adjustment of the comb assembly so it is midway between the adjusting gauge bar and the cutting edge of the bedknife gives a medium setting C Adjusting the comb assembly so it is even with the Figure 15 cutting edge of the bedknife gives a light setting 1 Roller shaft clamp boit 2 Comb teeth NOTE Securing one end of the comb assembly at a time simplifies the above procedure 3 Tighten the roller shaft bolts Set Up and Adjustments Page 8 12 Greensmaster 3000 3000 D Shield Height Adjustment Adjust shield to get proper grass clipping discharge into basket DN 1 Set cutting unit in normal cutting position and measure distance from top of front crossbar to shield at each end of cutting unit Fig 16 2 Height of shield from crossbar for normal cutting conditions should be 4 34 inch
177. mpensate for changes in turf conditions Bar should be adjusted closer to reel when turf is extremely wet By contrast adjust bar further away from reel when turf conditions are dry Bar should be parallel to reel to get optimum performance and should be adjusted whenever shield height is adjusted or whenever reel is Sharpened on a reel grinder Greensmaster 3000 3000 D Page 9 17 Figure 19 1 Top bar 2 Bar mounting screws Set Up and Adjustments Pull Frame Adjustment 1 Put the basket on the pull frame 2 Level baskets to cutting unit by loosening nut at one end of pull frame roller Loosen bolt and move roller shaft in slot as necessary Tighten bolt 3 Loosen the jam nuts on the pull arms and adjust the ball sockets until there is 1 4 in to 1 2 in 6 to 13 mm clearance between the lip of the basket and the reel blades Fig 20 This prevents grass clippings from dropping on the ground 4 Make sure the basket lips are the same distance from the reel blades at both ends of the reel If the basket is too close to the reel it is possible for the reel to contact the basket at the instant the cutting unit is raised off the ground 5 Make sure each of the three 3 cutting units track straight with the traction unit A smooth level surface draw a straight line on the floor Fig 20b Push traction unit forward removing slack from pull arms so center of each front wheel is o
178. n machine on a clean and level surface low er cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove the basket from the cutting unit carrier frame 3 Disconnect the drive motor from the cutting unit 4 Disconnect the cutting unit from the pull link 5 Unhook the cutting unit from the lift arm and slide the cutting unit out from under the carrier frame 6 Loosen the two lock nuts 15 on the end of each bedbar adjuster assembly 7 Loosen the two flange nuts 8 on each bedbar pivot bolt 7 8 Remove the two bedbar pivot bolts 7 and each of the washers 4 and 5 from the outside of the cutting unit side plates 9 Remove the bedbar 6 and each of the washers 4 and 5 from the inside of the cutting unit side plates 10 Inspect flange bushings 3 and remove if necessa ry 11 Inspect rubber bushings 2 and remove if necessa ry Installation Fig 10 1 If either rubber bushing 2 was removed from the side plate install a new bushing The bushing should be installed flush with the inside of the side plate Fig 11 2 Install the flange bushings 3 with flange facing out ward 3 Thread the flange nuts 8 all the way up to the head of each bedbar pivot bolt 7 and apply antiseize lubri cant to the threads of each bedbar pivot bolt 7 Greensmaster 3100 Page 10 11 Rev D 1 Sideplate 5
179. n the lock nut Item 2 10 Puta light coating of hydraulic oil on all cylinder parts to ease assembly Slide the shaft assembly and head into the barrel Install the retaining ring Item 10 to secure the assembly in the barrel Greensmaster 3100 Lift Cylinder Repair No 2 and 3 Left and Right Fig 35 Figure 35 IMPORTANT To prevent damage when clamping the cylinder barrel in a vise clamp only on the pivot end Do not clamp the vise jaws against the smooth shaft surface Protect the shaft surface before mounting in the vise 1 After removing the cylinder pump the oil out of the cylinder into a drain pan by SLOWLY moving the cylin der s piston in and out of the cylinder bore 2 Plug the ports and clean the outside of the cylinder 3 Mount the cylinder in a vise so the shaft end of the cylinder is tilted up slightly Do not close the vise so firmly that the barrel could become distorted 4 Remove the retaining ring Item 10 Grasp clevis Item 13 at end of shaft and use a twisting and pulling motion to carefully extract piston Item 3 shaft Item 6 and head Item 9 from the barrel Item 1 5 Securely mount the shaft Item 6 in a vise and remove the lock nut Item 2 from the piston end of the shaft Remove the piston Item 3 Slide the head Item 9 off of the shaft Greensmaster 3100 Page 4 53 6 Remove and discard all seals and back up rings Items 4 5 12 7 8 11 7
180. n top of the line Use a plumb bob or square to make sure each wheel is centered on the line B Measure from each end of cutting unit front roller to chalk line Distance from each end of roller to line must be equal within 3 16 0 187 in C Loosen jam nuts on pull arms and adjust ball sockets so distance from each end of roller to line is within 3 16 0 187 in NOTE If a cutting unit cannot be adjusted to track correctly with the traction unit the pull frame or lift arm is damaged and or the lift arm and pull frame bushings are worn and must be replaced 1 Jam nut 2 Pull arm Draw line on floor and center wheels over line Set Up and Adjustments Page 9 18 Figure 20a 3 Ball joint adjust for clearance 4 1 4 1 2 in 6 13 mm clearance Measure from each end of cutting unit front roller to line on floor Must be equal within 3 16 0 1867 in Figure 20b Greensmaster 3000 3000 D Repairs Cutting Unit Removal and Installation 7 Remove cutting unit from traction unit before doing adjustments or repairs 1 Remove basket from pull frame 2 Loosen reel motor mounting nuts Fig 21 Rotate the motor clockwise so motor flanges clear studs and pull motor off of cutting unit Figure 21 1 Motor mount nuts 2 Motor shaft 3 Slide the sleeve back on the ball joint and disconnect the pull arm from each side of the cutting unit Fig 22
181. nd hoists Always use jackstands to safely support the machine when it is raised by a jack or hoist 38 Do not use your hand to prevent cutting unit reel from turning while servicing this can result in personal injury Use a 1 2 in thick x 3 in wide x 8 in long piece of hardwood inserted into front of cutting unit between reel blades 39 For optimum performance and safety use genuine Toro replacement parts and accessories Replacement parts and accessories made by other manufacturers could be dangerous and my void the product warranty of The Toro Company Safety Instructions Safety Instructions 1 4 Greensmaster 3100 Chapter 2 TORO Product Records and Manuals Table of Contents PRODUCT RECORD FORM 1 TORQUE SPECIFICATIONS 3 EQUIVALENTS AND CONVERSIONS 2 Capscrew Markings and Torque Values U S 3 Decimal and Millimeter Equivalents 2 Capscrew Markings and Torque Values Metric 3 U S to Metric 2 Product Records Insert Operator s Manual and Parts Catalog for your Greensmaster 3100 or 3050 at the end of this chapter Refer to Operator s Manual for recommended maintenance intervals Additionally insert Installation Instructions Operator s Manuals and Parts Catalogs for any accessories that have been installed on your Greensmaster 3100 or 3050 at the end of this section Greensmaster 3100 Page2 1
182. nds of comb Greensmaster 3000 3000 D Page 8 5 Troubleshooting Factor Possible Problem Correction Make sure bed bar pivot bolts are securely seated maximum 40 ft Ib 11 Stability of bedbar Make sure opposing bedknife adjustment screws are tight To prevent distortion of the adjustment screw mounting plate and bedbar breakage do not over tighten the screws Use cutting unit model with correct number of blades for clip frequency and optimum height of cut range Variable speed traction kit can be used to adjust clip frequency 12 Number of ree blades Check pull frame alignment on all cutting units Adjust or repair as necessary 13 Cutting unit alignment and pull frame ground following Check lift arms pull frames for binding bushing wear or damage Repair if necessary All rollers must rotate freely Grease when needed or repair bearings if necessary 14 Roller condition All reels must rotate at same speed within 100 rpm All cutting units must have equal bedknife to reel con tact and reel bearing adjustment before checking Do not run the reel to long or it may get hot and rifle when no grass is being cut 15 Reel speed See Troubleshooting in Chapter 5 Hydraulic System Check maximum governed engine speed Adjust to specification if necessary 16 Traction speed See Troubleshooting in Chapter 5 Hydraulic System
183. nes from fittings on wheel motor Item 22 Put caps on open lines and fittings to prevent contamination Repairs 4 54 5 Remove four 4 capscrews Item 9 and lock nuts Item 19 to remove wheel motor Item 22 and brake brackets Item 12 from frame 6 Reverse steps 1 610 install the wheel motor Tighten nut Item 4 to a torque of 250 400 ft Ib IMPORTANT When disassembling hydraulic lines make sure hydraulic plugs are placed in the open end of the hydraulic line to prevent foreign debris from contaminating hydraulic oil It is also a good idea to tag the hydraulic lines when disassembling so they can be properly reassembled Keep all hy draulic lines clean and free from foreign debris During replacement of wheel motor avoid overtight ening fittings Check hydraulic lines for cracks or breaks If a hydraulic leak should appear after re placement of lift cylinder replace the fitting or line that is leaking Check hydraulic reservoir for level of hydraulic fluid after replacement of lift cylinder Greensmaster 3100 Wheel Motor Repair Fig 37 38 Figure 37 Disassembly of Motor Fig 37 1 Place motor in a vise clamping down on housing Item 3 port bosses with coupling shaft Item 11 pointed down A CAUTION If motor is not firmly held in the vise it could be dislodged during the service procedures causing personal injury 2 Remove the seven 7 special bolts Item 1
184. ng sure that none of the parts become displaced Insert the cap screws and washers and hand tighten Greensmaster 3100 Page 4 41 18 Before tightening the capscrews rotate the drive shaft in the direction of normal rotation counterclock wise to check for binding You may not be able to rotate the drive shaft by hand Protect the shaft if using a pliers 19 Tighten the capscrews evenly in a crossing pattern to a torque of 190 210 in Ib 20 Carefully install a new spacer shaft seal and snap ring Perform steps 8 12 under Reel Motor Shaft Seal Replacement in this section of the book 21 Allow 60 minutes for liquid gasket material to harden before operating motor Repairs Reel Motor 94 3506 Repair Fig 18 Figure 18a 1 Plug ports and wash exterior of motor with mineral spirits or solvent Make sure parts and work area are clean IMPORTANT Extreme caution must be used when using a vise to avoid distorting any parts 2 Draw a line across the seam areas on the motor case with a scribe or marker to ensure proper reassembly 3 Remove four socket head capscrews 1 and washers 2 4 Put your hand on the cover assembly 4 and gently tap the drive shaft with a soft face hammer to separate the body 10 from the cover Be careful not to drop parts or disengage gear mesh 5 Before removing gear set apply marking dye to mat ing teeth to retain timing when reassembling Motor efficiency may
185. ngages bedknife cutting edge Fig 18 Check and adjust on each end of bedknife then tighten height of cut adjustment locknuts on each end Changing To A Different Type of Cutting Unit or Adding Cutting Unit Accessories When changing to a different type of cutting unit or adding cutting unit accessories it is recommended that you change only one cutting unit and keep the other two existing cutting units on the machine 1 Setthe new cutting unitto a height of cut approximate ly 1 16 0 06 in higher than the old cutting unit 2 Do a mowing test and compare results between the new cutting unit and old cutting units 3 Adjust the new cutting unit to match the cut of the old cutting units 4 The other two cutting units can now be replaced Adjust these two new cutting units so they are the same as the other new cutting unit that was tested Greensmaster 3000 3000 D Page 10 17 Figure 18 3 Screw head over bedknife 4 Adjustment knob 1 Height of cut knob locknut 2 Gauge bar 1 8789 Set Up and Adjustments Groomer Reel Depth Adjustment 1 Adjust cutting unit height of cut before doing groomer reel depth adjustment 2 Hold clutch snubber down and rotate the clutch clockwise to disengage the clutch Fig 6 Rotate both quick up levers to lower the grooming reel into grooming position 3 Hold a straight bar securely against the front and rear rollers on one side of the cutting unit Fi
186. ngine Removal and Installation Engine Removal and Installation Page 3 6 Greensmaster 3100 TORO Table of Contents SPECIFICATIONS GENERAL INFORMATION Hydraulic Hoses Hydraulic Fitting Installation HYDRAULIC FLOW DIAGRAMS Traction No 1 Position Traction No 2 Position Traction Reverse Position Reel Drive Mowing Operation Reel Drive Lower Cutting Units Reel Drive Raising Cutting Units Power Steering R H Turn HYDRAULIC SPECIAL TOOLS TROUBLESHOOTING Slow Groundspeed in Traction Selections Slow or No Ground Speed in No 1 and Reverse No 2 Appears Normal No Increase in Speed From No 1 to No 2 One or More Cutting Units Slow or No Reel Drive Action Reels Slow or Will Not Turn Mow Pedal Won t Stay Engaged Reels Slow Down or Stop Cutting Unit s Drop During Transport Cutting Units Lift Too Slowly or Not At All Lift Pedal Binding Center 1 Cutting Unit Operates In Raised Position Center 1 Cutting Unit Drops Before Front Cutting Units or Drops Too Steering Loss Steering Wander or Free Play TESTING Test Hook Up No 1 Traction Pump Flow and Traction Relief Setting Greensmaster 3100 Chapter 4 Hydraulic System 2 Test Hook Up No 2 Traction 3 Motors Mechanical Drag Valve 3 Bank Leakage Traction Motors Efficiency 28 3 Test Hook Up No 3 5 Reel Drive Pump Efficiency 32 5 Test Hook Up No 4 Reel Drive
187. nits Height of cut 3 16 187 in and below use the B position Height of cut 5 32 156 in and above Use the C position Ut Height of cut between 5 32 156 and 3 16 187 in try B first if not satisfactory use C NOTE For Height of Cut 3 16 187 in and lower use 3 32 in tournament bed knife Tournament bed knife should not be necessary with the rear roller in the C position J NOTE The B hole position normally is the best rear roller location for most low 3 32 1 8 cutting condi tions Figure 11 It may be necessary to change from the above sug 1 Right rear roller bracket capscrews gested ranges in certain turf conditions 4 After putting bracket into correct height of cut hole position make sure right hand rear roller bracket capscrews are tightened securely Fig 11 5 Left hand rear roller bracket capscrews are to be tightened only enough to remove excessive looseness in assembly but allow bracket to slide freely on side plate Set Up and Adjustments Page 9 12 Greensmaster 3000 3000 D 6 Position a 1 4 inch or thicker plate under the reel blades and against the front face of the bed knife Fig 12 NOTE Make sure plate covers full length of reel blades and 3 blades contact plate 8 blade reel 7 While holding reel securely on plate level roller by rotating lower left roller pivot bolt The pivot bolt has an offset thread which when rotated acts as
188. not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and do serious damage If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result Figure 1 Final Mark Nut Position Initial and Body osition Extend Line Finger Tight After Proper Tightening 4 3 Figure 2 General Information SAE Straight Thread O Ring Port Non adjustable Fig 3 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fitting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 4 Install the fitting into the port and tighten it down full length until finger tight 5 Tighten the fitting to the correct flats from finger tight F F F T Size F F F T 4 1 4 in nominal hose or tubing 1 00 25 6 3 8 in 1 50 25 8 1 2 in 1 50 25 10 5 8 1 50 25 12 3 4 1 50 25 16 1 in 1 50 25 SAE Straight Thread O Ring Port Adjustable Fig 4 5 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fitting shows signs of leakage 3 Lubricate the O ring with a light coating of oil
189. notadjust reels while the engine is running e Ifa reel stalls stop engine before attempting to clear the reel e Reel motors are connected in series moving one motor moves the other two 1 Position machine on a clean and level surface low er cutting units stop engine engage parking brake and remove key from the ignition switch 2 Move functional control lever to the Neutral Backlap position IMPORTANT Do not attempt to rotate the direction al valve knob when the machine or reels are run ning 3 Raise seat and rotate directional valve knob fully clockwise to the backlap position 4 Rotate flow control valve knob to position 6 5 Onall cutting units make initial reel to bedknife ad justments appropriate for backlapping see Bedknife to Reel Adjustment in Cutting Unit Operator s Manual 6 Start engine and move Raise Lower Mow control forward to start the reels 7 Rotate flow control valve knob to position 1 8 Apply lapping compound with a long handled brush see Special Tools Be careful when backlapping the reel because contact with the reel or other moving parts can result in personal injury Greensmaster 3100 Page 10 9 Rev D CLOCKWISE Figure 9 1 Directional valve knob 3 Flow control valve knob 2 Ball switch 4 Hydraulic manifold 9 To make an adjustment to the cutting units while backlapping turn reels OFF by moving the RAISE LOWER MOW control to the RAISE position
190. nstall cap 7 Before operating the machine check steering relief pressure and adjust to 800 psi To adjust remove cap turn adjuster clockwise to increase pressure and coun terclockwise decrease pressure See Test Hook Up No 5 Steering Pump Flow and Steering Pump Relief Set ting in the Testing section of this chapter Greensmaster 3100 Page 4 43 Pump Service 1 Plug ports and wash exterior of pump with mineral spirits or solvent Make sure parts and work area are clean 2 Draw line across the seam areas on the pump case with a scribe or marker to ensure proper reassembly IMPORTANT Use caution when using a vise to avoid distorting any parts 3 Secure the flange end of the pump Item 15 in a vise with the drive shaft Item 20 pointing down 4 Remove the four locknuts Item 1 and lockwashers Item 2 5 Put your hand on the pump case and gently tap the pump case with a soft face hammer to loosen the pump sections Be careful not to drop parts or disengage gear mesh 6 Before removing each gear set apply marking dye to mating teeth to retain timing when reassembling Repairs 7 careful when disassembling The needle bearings in the body assembly Item 15 may be of the loose grease retained type Pack these with general purpose grease to retain them for reassembly It is recommended NOT to remove the bearing races from the flange as sembly 8 Remove and discard the oil seal and s
191. nstallation in this section of the book 2 Remove bedknife screws and remove bedknife 3 Remove all rust scale and corrosion from bedbar surface before installing new bedknife 4 Install new bedknife with the proper bedknife screws 57 4910 Bedknife screws must bottom out on bedknife not bedbar Tighten screws to a torque of 200 in Ib working from the center toward each end of the bedbar Fig 34 5 Grind new bedknife to match it to bedbar NOTE For proper grinding of bedknife follow proce dures in the Toro publication Sharpening Reel and Rotary Mowers Form No 80 300 PT 6 Do steps 6 16 under Bedbar Removal and Installation in this section of the book Figure 34 Preparing Cutting Unit for Reel Grinding IMPORTANT Adjust reel bearings before grinding reel See Reel Bearing Service and Adjustment in the Adjustments section of this chapter 1 Do steps 1 6 under Bedbar Removal and Installation in this section of the book NOTE Some reel grinders require rear roller assembly be mounted to cutting unit for proper support in reel grinder Rear roller must be parallel to reel shaft to remove taper when grinding 2 Raise or remove front roller assembly A Loosen locknuts securing height of cut adjusting rods at both ends of cutting unit and roller shaft clamp bolts Fig 35 B Turn height of cut adjustment knobs to raise roller out of the way or remove roller if necessary Fig 35
192. nt nut tighten reel shaft spline nut on right hand end of reel shaft to a torque of 40 to 60 ft lb then adjust reel bearings Use Loctite 271 5 Loosen large reel bearing adjustment nut Fig 10 Tighten nut until all reel shaft end play is removed then tighten an additional 1 16 to 1 8 turn Be certain to remove all end play but do not over tighten Rolling torque should not exceed 7 NOTE Adjustment nut must have enough resistance against reel shaft threads to retain bearing adjustment Replace adjustment nut if necessary 6 If bearings require replacement see Reel Removal and Bearing Replacement in the Repairs section of this chapter 7 Install clutch adapter on reel shaft Fig 10 and tighten to a torque of 170 210 in lb 8 Hold belt on drive pulley and slide clutch on clutch adapter while sliding belt on driven pulley Install washer and nut removed in step 4 on clutch adapter shaft and tighten nut to a torque of 7 10 ft lb Adjust drive belt tension before installing cover See Groomer Reel Drive Belt Adjustment in this section of the book Set Up and Adjustments Page 10 12 Rev C on spline nut threads Figure 8 1 Height of cut locknut 2 Roller shaft clamp bolt 3 Height of cut knob Figure 9 1 Drive 2 Drive belt idler pulley 3 Grooming reel adjustment knob assembly Figure 10 4 Grooming reel cover 5 Cover screws amp washers 4 Groomer driven pulley
193. ntact 8 Using a gauge bar set the height of cut adjustment Special Notes 1 A rifled reel and or bedknife must be corrected by grinding 2 If reel bearings will not hold adjustment during opera tion loosen adjustment nut tighten reel shaft spline nut to a torque of 40 to 60 46 then adjust reel bearings Set Up and Adjustments Reel Bearing Service and Adjustment 1 Adjust the bedknife so it is not in contact with the reel 2 Reel bearing drag should not exceed 7 in Ib Thiscan 7 WNA amp aE be measured with a torque wrench Fig 5 If bearing drag does not meet above specification adjust the reel bearings d NUR NOTE If you do not have an inch pound torque wrench do steps 1 3 under Reel Bearing Adjustment below Reel Bearing Adjustment 1 Remove the mounting nuts from the counterbalance end cap and remove end cap from the mounting studs Fig 6 2 Remove bolt mounted on the end of reel shaft This will make it possible for a large socket wrench to be mounted on the reel bearing adjusting nut inside the side plate Do not use your hand to prevent reel from Figure 5 turning while servicing this can result in per sonal injury Use a 1 2 in thick x 3 in wide x 8 in long piece of hardwood inserted into front of cutting unit between reel blades NOTE If reel bearings will not hold adjustment during operation loosen adjustment nut tight
194. o get desired fit between reel and bedknife Greensmaster 3000 3000 D Page 10 23 Equal dista unn Vie Surface Tx 3 ay 6 1 5 8 1 9 1 1 29 Figure 30 1 Bedbar 2 Shield Figure 31 Equal gap Figure 32 Repairs _ Bedbar Bushing Replacement NOTE Only after making sure that all normal cutting unit adjustments are correct should the bushings be suspected as causing quality of cut problems The bedbar end bushings and pivot bushings Fig 33 contain rubber and are exposed to severe conditions is recommended to replace these bushings and the plastic flange bushings every two years 1 Do steps 1 4 under Bedbar Removal and Installation in this section of the book 2 Remove bedbar end bushings with a punch and hammer Fig 34 Alternate from one side to other on 2 bushing there are two slots in bedbar bushing boss Figure 34 IMPORTANT Apply Never Seez or equivalent to outside surface of bedbar end bushings and pivot bushings before installing in bedbar 3 Press end bushings into bedbar far enough so plastic sleeve collar is below bedbar end face Fig 35 NOTE Bedbar end bushings have less rubber and more steel which is visible than bedbar pivot bushings Do not use bedbar end bushings in the pivot area as they are too rigid 4 Use an arb
195. ob 3 Allen head set screw 2 4 Nut and washer 5 Clutch adapter shaft Figure 49 1 Clutch adapter shaft 2 Reel shaft Greensmaster 3000 3000 D Installation and Assembly Disassembled Clutch 1 Pack bearings and area inside clutch body with No 2 multi purpose lithium base grease IMPORTANT When assembling clutch make sure belleville washers are installed correctly Fig 50 NI jane H SQ 2 Apply thick coating of grease to special screw do not KS Kis SS S get on threads and cam surface of clutch release disk Apply Loctite 271 or equivalent to threads of special a E screw before assembling to clutch pin Assemble so EM MCE KKK NS clutch pin is 0 240 0 260 in out fromface of clutch body er SS when pin is in fully extended position 3 Install clutch adapter to reel shaft Fig 49 Tighten clutch adapter to a torque of 170 210 in Ib Figure 50 4 Hold belt on drive pulley of clutch and slide clutch on clutch adapter while sliding belt on driven pulley Install 1 Clutch body drive pulley washer and nut on clutch adapter shaft and tighten nut 2 Belleville washer 2 to a torque of 7 10 ft Ib 3 Nut and washer 4 Clutch engage disengage knob 5 Clutch adapter 5 Adjust belt tension Install groomer reel housing cover 6 0 250 in 0 10 pin extended Fig 39 Install clutch knob and tighten two 2 set screws against flats of clutch release disk F
196. ody Fig 26 5 Install remaining spiral retaining ring 6 Install new seals see Roller Seal Installation in this chapter of this manual Figure 26 1 Roller shaft 4 Bearing 2 Roller body 5 Spiral retaining ring 3 Seal Dual Point Adjust Cutting Units Page 10 22 Rev D Greensmaster 3100 This page is intentionally blank TORO Commercial Products The Toro Company
197. of the bedknife These notches must be rounded off or filed flush with cutting edge of bedknife to assure smooth operation Figure 6 1 Clutch snubber 2 Clutch knob 3 Quick up lever 2 Figure 7 1 Bedknife adjusting knob 2 Compression spring 3 Pivot bar Set Up and Adjustments j Reel Bearing Service and Adjustment 1 Remove bedknife to reel contact by turning bedknife adjustment knob counterclockwise Fig 7 2 Loosen two 2 set screws and remove clutch knob Fig 6 Remove groomer reel housing cover from left side of cutting unit Fig 8 Loosen idler pulley and remove drive belt Fig 9 3 Reel bearing rolling torque should not exceed 7 in Ib Measure with a torque wrench at the spline nut on the right hand end of the reel shaft NOTE If bearing drag does not meet above specifica tion or if you do not have an inch pound torque wrench do remaining steps in this procedure 4 Remove nut and washer from clutch adapter shaft Pull clutch assembly off adapter shaft Fig 9 Remove clutch adapter from reel shaft Fig 10 Do not use your hand to prevent reel from turning while servicing this can result in per sonal injury Use a 1 2 in thick x 3 in wide x 8 in long piece of hardwood inserted into front of cutting unit between reel blades NOTE If reel bearings will not hold adjustment during operation loosen adjustme
198. ond time delay alarm should sound To check leak detector float switch remove hydraulic tank cap and strainer from neck of tank Turn ignition Switch to ON DO NOT start engine Insert a clean rod or screw driver into tank neck and gently push down on switch float Alarm should sound after a one second time delay Normal Operation Warm Oil When key switch is turned on solenoid valve closes During normal operation hydraulic fluid expands caus ing it to flow into overflow tank Float stays in raised position keeping alarm circuit open Leak Alert If oil leaks during operation fluid level drops in system hydraulic tank This causes float to lower closing alarm circuit After a one second delay alarm will sound NOTE During normal operation with cutting units low ered approximately 5 oz of oil will leak before float Switch activates alarm Greensmaster 3100 Float Switch 0 0 0 0 0 Float Raised Switch Open p 4 Sight Tad Gauge Sound Solenoid Valve Open LU EHE Before Start Up Cold Figure 2 Float Switch Float Raised Switch Open Sight Alarm Gauge No Sound Solenoid Valve Closed Normal Operation Warm Oil Figure 3 Float Switch Float Lowered Switch Closed Sight Alarm Gauge Sound On Solenoid Valve Closed Leak Alert Figure 4 TM Page5 3 Rev D Turf Guardian Leak Detection System
199. ont roller must be equal at both ends of roller Bench set height of nd actual effective height of cut are dif ferent Effective height of cut depends on cutting unit weight cutting unit accessories and turf conditions Page 10 6 If bedknife is too thick for effective height of cut poor quality of cut will result Greensmaster 3000 3000 D Possible Problem Correction Make sure bedbar bolt plastic washers are snug against bedbar Bedbar must pivot without binding 11 Stability and position of bedbar Check bedbar end bushings and pivot bushings for wear or damage and replace if necessary Make sure proper bushings are installed in each location bedbar end bushings are different from pivot bushings Check adjustment knob to make sure detent holds ad justment Repair if necessary With adj knob pivot assembly removed pivot screws installed and frame on level surface measure from flat surface up to end of each setscrew If not within 1 16 in of each other bend ears on cutting unit frame to line up screws Check to make sure adj knob pivot assembly is centered in bedbar arm yoke and frame ears so that an equal gap exists on each side of pivot housing before pivot screws are installed Make sure bedknife adj knob pivot assembly is held firmly in place between frame supports Tighten pivot screws if necessary Use cutting unit model with correct number of blades
200. or press to remove bedbar pivot bushings Fig 36 DO NOT hammer on pivot boss of bedbar without support You will break the casting Figure 35 5 Press center pivot bushings into place Fig 36 DO NOT hammer on pivot boss of bedbar without support You will break the casting 6 Do steps 5 16 under Bedbar Removal and Installation in this section of the book Figure 36 Figure 33 1 Bedbar end bushing 2 3 Flange bushing 4 2 Bedbar pivot bushing 2 Repairs Page 10 24 Greensmaster 3000 3000 D Bedknife Replacement 1 Do steps 1 4 under Bedbar Removal and Installation in this section of the book 2 Remove bedknife screws and remove bedknife 3 Remove all rust scale and corrosion from bedbar surface before installing new bedknife 4 Install new bedknife with the proper bedknife screws 57 4910 Bedknife screws must bottom out on bedknife not bedbar Tighten screws to a torque of 200 in Ib working from the center toward each end of the bedbar Fig 37 5 Grind new bedknife to match it to bedbar NOTE For proper grinding of bedknife follow proce Figure 37 dures in the Toro publication Sharpening Reel and Rotary Mowers Form No 80 300 PT 6 Dosteps6 16 under Bedbar Removal and Installation in this section of the book Preparing Cutting Unit for Reel Grinding IMPORTANT Adjust reel bearings before grinding reel See Reel Bearing Service and Adjustment in the Adj
201. or to seatthe rotor and assembled vanes into stator creating necessary clearance to assemble seventh 7th vane Assemble the seven 7 vanes using minimum force 6 Remove the two assembled bolts if used to retain stator and wear plate 23 22 19 20 21 4g 12 JA Hr 2777 p 4 PBI za A N AV AR T4 7 A VERI A S 2 gt Press seal in flush to 0 020 inch below face Greensmaster 3100 Page 4 57 Repairs Steering Cylinder Removal and Installation Greensmaster 3100 Fig 39 Figure 39 1 Disconnect the hydraulic hoses Item 28 29 from steering cylinder Item 33 Put caps or plugs on all the fittings and hoses to prevent contamination NOTE To ease reassembly tag each of the hoses to show their correct position on the steering cylinder 2 Remove jam nuts Item 21 securing cylinder end to castor fork Item 19 3 Remove locknut Item 26 and washer Item 27 to remove cylinder from frame IMPORTANT Before installing the cylinder make sure the distance between ball joint centers is 14 4 in with cylinder rod completely retracted Loosen jam nut and adjust ball joint if necessary then tighten jam nut 4 Reverse steps 1 3 to install the steering cylinder Repairs Page 4 58 5 After installing the cylinder start the engine and turn the steering wheel left and
202. orm steps 8 12 under Reel Motor Shaft Seal wise to check for binding You may not be able to rotate Replacement in this section of the book the drive shaft by hand Protect the shaft if using a pliers 16 Tighten the capscrews evenly in a crossing pattern to a torque of 17 ft lb Greensmaster 3100 Page 4 41 2 Rev B Repairs Reel Motor 105 9770 Repair Fig 18b 33 to 40 ft Ib 45 55 Figure 18b 1 Rear cover 5 Pressure seal 9 Idler gear 2 Drive gear 6 Back up ring 10 Cap screw 3 Seal 7 O ring 11 Front flange 4 Tab washer 8 Body Disassembly DIAGONAL MARK 1 Plug motor ports and clean the outside of the motor thoroughly After cleaning remove plugs and drain any oil out of the motor 2 Use a marker or scribe to make a diagonal mark across the front flange body and rear cover for reas sembly purposes Fig 18c Figure 18c Repairs 4 41 3 Rev D Greensmaster 3100 IMPORTANT Avoid using excessive clamping pressure on the motor flange to prevent distorting the casting 3 Clamp mounting flange of motor in a vise with the shaft end down 4 Loosen cap screws on the rear cover 5 Take motor from the vise and remove cap screws 6 Remove front flange from the body then remove rear cover Locate and remove dowel pins from body IMPORTANT Mark the relative positions of the gear teeth and the bearing blocks so they can be re assembled in the sam
203. orn rotor splines If any rotor set component requires replace ment the complete rotor set must be replaced as it is a matched set Inspect the wear plate for cracks brinelling or scoring Repairs 9 Place rotor set a flat surface and center rotor Item 19 in stator Item 21 such that two rotor lobes are 180 apart and a roller vane Item 20 centerline are on the same stator centerline Check the rotor lobe to roller vane clearance with a feeler gage at this common centerline If there is more than 005 inches 0 13 mm of clearance replace rotor set 10 Remove drive link Item 13 from coupling shaft Item 11 if it was not removed with rotor set and wear plate Inspect drive link for cracks and for worn or damaged splines There should be no lash play be tween mating spline parts 11 Remove thrust bearing Item 12 and inspect for wear brinelling corrosion and a complete set of rollers retained in position 12 Remove coupling shaft Item 11 by pushing on the output end of shaft Inspect coupling shaft bearing and seal surfaces for spalling nicks grooves severe wear or corrosion and discoloration Inspect for damaged or worn keyway Replace coupling shaft if any of these conditions exist NOTE Minor shaft wear in seal area is permissible If wear exceeds 020 inches 0 51 mm diametrically replace coupling shaft A slight polish is permissible in the shaft bearing area Anything more would require cou
204. ot bolt in position and tighten jam nut Make sure pivot bolt did not get out of adjust ment when turning jam nut Adjust again if necessary NOTE If the reel has worn so you cannot get the bedknife parallel to the reel by turning the eccentric bolt the reel will require grinding to remove taper The reel normally wears faster on the lead in side which results in the described taper Greensmaster 3000 3000 D Page 10 13 Figure 11 1 Bedknife adjusting knob Figure 12 Set Up and Adjustments Leveling Rear Roller to Reel 1 Put cutting unit on a flat level surface 2 Assemble rear height of cut brackets to desired posi tion by loosening top capscrew and nut and removing bottom nut on right and left hand sides of cutting unit Fig 13 3 Slide bolts thru each bracket until brackets can be realigned with appropriate mounting hole See table for proper position on brackets NOTE The different rear roller bracket positioning holes B thru E are designed to optimize bedknife location for different heights of cut Rear Roller Bracket Hole Position 8 Blade Cutting Units Figure 13 Height of cut 3 16 187 in and below use the B position 1 Rear height of cut bracket 3 Bottom nut Height of cut 5 32 156 in and above Use the C position 2 Top capscrew and nut Height of cut between 5 32 156 and 3 16 187 in try C first if not satisfactory use B NOTE For Height of Cut 5 32 156 in and l
205. ower use 3 32 in tournament bed knife Tournament bed knife should not be necessary with the rear roller in the C position Rear Roller Bracket Hole Position 11 Blade Cutting Units Height of cut 3 16 187 in and below use the B position Height of cut 5 32 156 in and above Use the C position Height of cut between 5 32 156 and 3 16 187 in try B first if not satisfactory use NOTE For Height of Cut 3 16 187 in and lower use 3 32 in tournament bed knife Tournament bed knife should not be necessary with the rear roller in the C position NOTE The B hole position normally is the best rear roller location for most low 3 32 1 8 cutting condi tions Figure 14 It may be necessary to change from the above sug 1 Right rear roller bracket capscrews gested ranges in certain turf conditions 4 After putting bracket into correct height of cut hole position make sure right hand rear roller bracket capscrews are tightened securely Fig 14 5 Left hand rear roller bracket capscrews are to be tightened only enough to remove excessive looseness in assembly but allow bracket to slide freely on side plate Set Up and Adjustments Page 10 14 Greensmaster 3000 3000 D 6 Position a 1 4 inch or thicker plate under the reel blades and against the front face of the bed knife Fig 15 NOTE Make sure plate covers full length of reel blades and 3 blades contact plate 8 blade reel 7 Whi
206. p from left hand side of cutting unit Fig 27 Remove large bearing adjust ment nut from left hand end of reel shaft Fig 27 and special spline nut from opposite end of reel shaft 3 Remove machine screws securing bearing housing on each end of cutting unit Fig 28 Machine screw heads will have to be cut off before screw can be completely removed A Unscrew machine screw approximately two turns Figure 27 B Cut head off of machine screw 1 Reel bearing adjustment nut C Use a screw driver to back out remaining part of screw from side plate outwards not inwards towards reel If machine screw does not have a screw driver slot use a pliers to back out screw IMPORTANT Remove grease fittings from bearing housing at each end of cutting unit Note that the straight fitting is on the right end and 90 fitting at the left end when viewed in the direction of travel 4 Use a plastic headed hammer to rotate bearing hous ing slightly install bolts from outside of housing and turn bolts alternately against side plate to remove bearing housing Fig 29 Bearing housing will slip out of side plates and reel assembly can be removed as soon as bearing housings are disassembled from side plates Figure 28 5 Before installing reel install new special machine 1 Left reel bearing housing 3 Machine screws screws from inside of frame to secure bearing housing 2 Right reel bearing housing 6 If necessary install ne
207. partially from control end of sleeve then remove 6 centering springs from spool carefully by hand 18 Push spool back through and out of sleeve Rotate spool slowly when removing from sleeve 19 Remove seal from housing 20 Remove set screw from housing 21 Screw a 10 24 machine screw into end of check ball seat Then by pulling on screw with a pliers lift seat out of housing 22 Remove two 2 seals from check valve seat 23 Tip housing to remove check ball and check ball retainer Figure 52 Seal 5 8 Seal 6 Set Screw Not used Check Check units with Ball Check Ball integral column Seat 7 16 Seal Ball Retainer Figure 53 Greensmaster 3100 Page 4 65 Repairs Reassembly Check all mating surfaces Replace any parts that have scratches or burrs that could cause leakage Clean all metal parts in clean solvent Blow dry with air Do not wipe dry with cloth or paper towel because lint or other matter can get into the hydraulic system and cause damage Do not use a coarse grit or try to file or grind these parts NOTE Lubricate all seals with clean petroleum jelly such as Vaseline Do not use excessive lubricant on seals for meter section Refer to parts listings covering your steering control unit when ordering replacement parts A good service policy is to replace all old seals with new seals Control End Reassembly 1 Use a needle nose pli
208. perform these daily checks It is recommended that mowers be washed after each use Always remove key from ignition switch when working on the machine 1 Purge all water and debris from all bearings by greas ing them Use No 2 multi purpose lithium base grease 2 Visually check for sharp reel and bedknife Remove burrs nicks and rounded edges 3 Visually check groomer reel for wear and damage Straighten bent blades Replace worn blades or reverse groomer reel to put sharpest blade edge forward Make sure right and left shaft end nuts are tight 4 Lower cutting units to the ground setting on both rollers and remove reel motor Rotate the reel by hand TURN ADJUSTING KNOB ONE 1 CLICK AT A TIME UNTIL FIRST CONTACT BETWEEN REEL AND BEDKNIFE IS FELT AND HEARD THEN TIGHTEN ONE 1 MORE CLICK TO GET LIGHT CONTACT Nocontact will dull the cutting edges Excessive contact accelerates wear quality of cut may be adversely affected It is best to make the reel to bedknife adjustment in the morning immediately before each day of mowing Weekly Checks 1 Check reel bearing adjustment and bearing condition 2 Make sure bed bar bolt plastic washers are SNUG against the bedbar 3 Make sure bedknife adjustment knob pivot assembly is held FIRMLY in place between frame supports 4 Use a gauge bar to check height of cut setting 5 Use a gauge bar to check groomer depth setting Set Up and Adjustments
209. pling shaft replace ment 13 Remove inner seal Item 7 back up washer Item 6 and back up washer Item 4 Discard seal and back up rings 14 Remove housing Item 3 from vise turn over and re clamp in vise with dirt seal Item 1 end pointed up 15 Remove dirt seal Item 1 and discard 16 Inspect housing Item 3 assembly for cracks the machined surfaces for nicks burrs brinelling or corro sion Remove burrs that can be removed without chang ing dimensional characteristics Inspect tapped holes for thread damage 17 Inspect the bearings Item 2 9 10 and thrust washers Item 8 The bearing rollers must be firmly retained in the bearing cages but must rotate and orbit freely rollers and the thrust washers must be free of brinelling and corrosion Repairs Page 4 56 Before Assembling Motor Replace all seals and seal rings with new ones Lubri cate all seals and seal rings with hydraulic oil or clean grease before assembly NOTE Unless otherwise indicated do not oil or grease parts before assembly Wash all parts in clean petroleum based solvents before assembly Blow them dry with compressed air Remove any paint chips from mating surfaces of the end cover sleeve and housing and from port and sealing areas Assembly of Motor Fig 37 38 1 Place housing Item 3 in a vise and clamp down on housing port bosses with large bore end pointed up Apply clean grease to new seal Item and as
210. r seal in housing 13 Install two 2 bearing races and the needle thrust bearing in the order shown Greensmaster 3100 4 67 Figure 56 Figure 57 Needle Thrust Bearing Seal Figure 58 Repairs 14 Install 1 1 4 diameter dust seal seal gland bush ing flat or smooth side of dust seal must face down towards bushing see Fig 60 15 Install the quad ring seal in seal gland bushing Smooth seal in place with your finger Do not use any seal that falls freely into pocket of bushing see Fig 60 16 Install seal gland bushing over the spool end with a twisting motion Tap the bushing in place with a rubber hammer Make sure the bushing is flush against the bearing race 17 Install retaining ring see Fig 59 60 in housing After installing ring tap on ring end or pry with screw driver around entire circumference of ring to properly seat ring in groove Retaining Ring Seal Gland Bushing with seals Figure 59 Screwdriver Teflon Seal Dust Seal Bushing with Ident Groove Repairs Page 4 68 Figure 60 Greensmaster 3100 18 Clamp housing in vise as shown Clamp lightly on edges of mounting area Do not over tighten jaws NOTE Check to insure that the spool and sleeve are flush or slightly below the 14 hole surface of the housing IMPORTANT Clean the upper surface of the hous ing by wiping
211. r shaft clamp bolt 2 Comb teeth NOTE Securing one end ofthe comb assembly at a time simplifies the above procedure 3 Tighten the roller shaft bolts Set Up and Adjustments Page 9 16 Greensmaster 3000 3000 D Shield Height Adjustment Adjust shield to get proper grass clipping discharge into basket 1 Set cutting unit in normal cutting position and measure distance from top of front crossbar to shield at each end of cutting unit Fig 18 2 Height of shield from crossbar for normal cutting conditions should be 4 3 4 inches Loosen capscrews and nuts securing shield to each side plate adjust shield to correct height and tighten fasteners Fig 18 3 Repeat adjustment on remaining cutting units and adjust top bar See Adjusting Top Bar in this section of the book NOTE Shield can be lowered in dry grass conditions clippings fall over top of baskets or raised to allow for heavy wet grass conditions clippings build up on rear edge of baskets Figure 18 1 Shield 3 4 3 4 inches 2 Front crossbar 4 Shield fasteners Top Cut Off Bar Adjustment Adjust top bar to make sure clippings are cleanly dis charged from reel area 1 Loosen screws securing top bar Fig 19 Insert 0 060 inchfeeler gauge between top of reel and bar and tighten screws Make sure bar and reel are equal distance apart across complete reel 2 Repeat settings on remaining cutting units NOTE Bar is adjustable to co
212. rasp flats on threaded end of rod and use a twisting and pulling motion to carefully remove rod assembly Item 9 and head from the barrel Remove head Item 5 from other end of barrel Greensmaster 3100 Page 4 59 6 Slide head off of rod assembly 7 Remove and discard all seals and back up rings 8 Wash parts in solvent Dry the parts with compressed air DO NOT wipe them dry with a cloth or paper as lint and dirt may remain 9 Inspect internal surface of barrel for damage deep scratches out of round etc Inspect head and rod assembly for evidence of excessive scoring pitting or wear Replace any damaged or worn parts 10 Put a light coating of hydraulic oil on all new seals and back up washers Install the new seals and back up washers 11 Puta light coating of hydraulic oil on all cylinder parts to ease assembly Slide rod assembly Item 9 into barrel Install head Item 5 to each end of barrel 12 Install threaded cap Item 2 on each end of barrel and tighten setscrews Item 1 Repairs Steering Control Unit Removal and Installation Greensmaster 3100 Fig 41 Figure 41 1 Remove six 6 capscrews Item 21 and remove the steering cover Item 25 2 Clean the outside of the steering valve and the area around the hydraulic fittings Disconnect the hydraulic hoses from the steering valve Item 24 Put caps or plugs on all the fittings and hoses and tubes to prevent contam
213. re 16 1 Motor mount nuts 2 Motor 10 Apply Loctite 515 Gasket Eliminator or equivalent to outside diameter of new seal 11 Apply generous amount grease to inside diameter of new shaft seal 12 Use seal installation tool to install new shaft seal Make sure seal is installed square with the seal bore Figure 17 1 Seal protector 2 Seal installation tool Repairs Reel Motor 70 9800 Repair Fig 18 Figure 18 1 Plug ports and wash exterior of motor with mineral spirits or solvent Make sure parts and work area are clean IMPORTANT Extreme caution must be used when using a vise to avoid distorting any parts 2 Draw a line across the seam areas on the motor case with a scribe or marker to ensure proper reassembly 3 Remove four socket head capscrews 4 Put your hand on the cover assembly and gently tap the drive shaft with a soft face hammer to separate the body from the cover Be careful not to drop parts or disengage gear mesh 5 Before removing gear set apply marking dye to mating teeth to retain timing when reassembling 6 Be careful when disassembling The needle bearings may be of the loose grease retained type Pack these with general purpose grease to retain them for reassem bly Itis recommended NOT to remove the bearing races from the cover and body Repairs Page 4 40 Rev B 7 Remove and discard the bridging insert gasket in sert anti extrusion
214. rease to vent or purge out if necessary Fig 20 10 Fill remaining voids behind inner grease seal 13 and outer grease seal 9 lips with Mobil High Tempera ture HP or equivalent grease Greensmaster 3100 Reel Service Fig 16 Note Install new reel components on each end of the reel shaft that mates with newly serviced side plate com ponents 1 Remove the retaining ring 5 and the drive coupler 4 from the end of the reel shaft 2 Remove the 3 from the reel shaft 3 Using a flat blade screw driver or similar tool re move the speedi sleeve 2 from the reel shaft Note Seal Kit Toro Part No 106 6937 is available for reel service of dual point adjust cutting units 4 Inspect the reel shaft as follows A Check the reel shaft for bending and distortion by placing the shaft ends in V blocks Replace the reel if necessary B Check the reel blades for bending or cracking Replace the reel if necessary C Check the drive adapter inside of the reel shaft Fig 19 The adapter should be free of bending and distortion Check the splines for excessive cracks or distortion Replace the reel if necessary D Check the service limit of the reel diameter Re place the reel if necessary 5 Using an appropriate 1 0 tube or sleeve press the speedi sleeve onto the reel shaft until it bottoms out on the spider cup Fig 20 IMPORTANT Do not nick or scratch the Spee
215. rects flow from one pump section to pass through left end cover and out line leading to left front cutting unit drive motor Flow causes motor to turn driving reel Flow from separate pump section passes through No 2 valve section and out a line to right front cutting unit motor Return oil from two front cutting units joins to gether and returns to right end of valve section where PEDALS LINEAE REEL MOTOR RESERVOIR Hydraulic Flow Diagrams MOW PEDAL DOWN 1 2223 SPOOLS OUT Page4 8 Rev E is passes into the main return line and flows back to reservoir Flow from another separate pump section passes through No 3 spool section and out through a line to the rear cutting unit drive motor Return oil from the motor passes through a line leading to the right hand end of the valve bank where it also joins with the main return line back to the reservoir PRESSURE INT RETURN 113132 SUCTION MAIN RETURN REEL MOTOR dmm Turm mm a GR3100 WITH DANFOSS PUMP SHOWN MACHINES WITH PARKER PUMP USE CENTER 3 PUMP SECTIONS FOR REEL DRIVE CIRCUITS Greensmaster 3100 Reel Drive Lower Cutting Units The MOW pedal is depressed to start reel drive opera cylinder where it passes through the valve section and tion flow from one pump section passes through No 3 returns to the reservoir through the main return line spool section and out three lines each leading to a lift W
216. reensmaster 3050 Steering cable tension should be adjusted whenever play is felt in the steering wheel A loose steering cable will make it difficult to steer in a straight line however over tightening cable will cause undue wear to pulleys and cause cable to stretch and fail prematurely When properly tensioned cable should deflect 1 2 at mid span when 11 16 of force is applied 1 Tension cable by securing cable end hex with an open end wrench and turning the nut on the cable end with another wrench 2 If all threads on the cable end have been used re place cables If necessary service the pulley and steer ing cable under the steering wheel by removing the cover on the end of the steering column Greensmaster 3100 Page 6 5 Figure 3 1 washer 2 Steering arm 3 Frame bracket Figure 4 Steering cable Hold with wrench Turn to remove slack N Figure 5 1 Cover 2 Pulley and steering cable Rev B Repairs Repairs Page6 6 Rev Greensmaster 3100 Chapter 7 4 Bolt Adjust Cutting Units TORO Table of Contents SPECIFICATIONS 2 Shield Height Adjustment 13 SPECIAL 5 3 Top Bar Cut Off Bar Adjustment 13 5 Pull Frame Adjustment 14 Factors Affecting Quality of Cut 5 REPAIRS
217. rkings gt s EF Ni 7 Thread Capscrew Torque Class 8 8 Capscrew Torque Class 10 9 Capscrew Torque Class 12 9 Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum mm ft Ib Nm ft Ib Nm ft Ib Nm ft Ib Nm ft Ib Nm ft Ib Nm 6 5 9 4 7 9 14 7 11 9 14 7 11 7 9 14 7 11 14 18 11 14 18 23 14 18 8 18 25 14 18 23 32 18 25 27 36 21 28 10 30 40 25 30 45 60 35 45 50 70 40 55 12 55 70 40 55 75 105 60 80 95 125 75 100 14 85 115 65 90 120 160 95 125 145 195 110 150 16 130 180 100 140 175 240 135 190 210 290 165 220 18 170 230 135 180 240 320 185 250 290 400 230 310 Greensmaster 3100 Page2 3 Torque Specifications This page is intentionally blank Chapter 3 TORO Engine Table of Contents SPECIFICATIONS 1 ENGINE REMOVAL AND INSTALLATION 5 5 2 Removing the Engine 5 Throttle Control 2 Installing the Engine 5 Choke Control Adjustment 2 BRIGGS amp STRATTON VANGUARD V TWIN OHV Governor 3 SERVICE amp REPAIR INSTRUCTIONS Carburetor and Speed Control Adjustment 4 Specifications Item Specification Make Designation Briggs amp Stratton Vanguard 9 V Twin OHV air cooled gas engine with cast iron cylinder sleeves Crankcase Oil Capacity See Operator s Manual Oil
218. rp edges of gears will mill into bearing blocks and thus must be replaced D Bearing areas of bearing blocks should not have excessive wear or scoring E Face of bearing blocks that are in contact with gears should be free of wear roughness or scoring 4 Inspect front flange and rear cover for damage or wear Reassembly NOTE When reassembling the motor check the identi fication marks made during disassembly to make sure the parts are properly aligned during reassembly 1 Lubricate o rings pressure seals back up gaskets and seal grooves with a thin coat of petroleum jelly Lu bricate all other internal parts freely with clean hydraulic oil 2 Install new shaft seal into front flange 3 Install lubricated pressure seals into the grooves in the front flange and rear cover Follow by carefully plac ing the back up rings into the grooves 4 Install new o rings to the body Repairs 4 41 5 Rev D 5 Lubricate gear faces and bearing surfaces of drive gear idler gear and bearing blocks Carefully assemble bearing blocks and gears noting identification marks made during disassembly 6 Position the motor body on its side Carefully slide bearing block and gear assembly into the body cavity using identification marks made during disassembly 7 Remove any excess lubrication from mating sur faces of body rear cover and front flange Make sure that these surfaces are clean and dry 8 Instal
219. rts of the body away from the cutter blades and any rotating engine parts 1 Start engine and let it run at half throttle for approxi mately five 5 minutes to warm up 2 Move throttle control to SLOW position Hold gover nor lever so throttle lever is in the idle position against idle stop screw and turn idle stop screw in or out to get 1400 50 RPM Check speed with a tachometer 3 Adjust idle mixture screw A Turn idle mixture screw slowly clockwise lean mixture until engine speed just starts to decrease Note position of screw B Now turn idle mixture screw slowly counterclock wise rich mixture until engine speed just starts to decrease Note position of screw C Set the idle mixture screw half way between the rich and lean settings 4 After idle mixture has been adjusted hold governor lever so throttle lever is in idle position against idle stop screw and adjust idle stop screw to bring engine speed to 1200 RPM 5 With governor control lever in governed idle position no tension on high speed spring bend governed idle spring anchor tang to get a governed idle speed of 1400 RPM Fig 5 6 Move throttle control to FAST position Bend high speed spring anchor tang to bring engine speed to 2800 50 100 RPM Fig 6 Adjustments THROTTLE RESTRICTION b TOP NO LOAD XX ADJUSTMENT TANG Page 3 4 Figure 6 Greensmaster 3100 Engin
220. rying heights of cut and turf conditions IMPORTANT Bedknife to reel contact must be checked and adjusted every day even though quality of cut is acceptable 1 Shut off engine and remove key Lower cutting units to the ground 2 Remove grass baskets 3 On each cutting unit loosen 2 flange nuts securing reel motor to cutting unit Twist motor clockwise to disengage from cutting unit and remove motor 4 Slowly rotate reel listening for reel to bedknife con tact If no contact is evident TURN BEDKNIFE ADJUST ING KNOB CLOCKWISE ONE 1 CLICK AT A TIME UNTIL FIRST CONTACT 15 FELT AND HEARD THEN TIGHTEN ONE 1 MORE CLICK TO GET LIGHT CON TACT Fig 6 5 If contact is felt turn bedknife adjusting knob counterclockwise one 1 click at a time until no contact is evident Turn bedknife adjusting knob one 1 click at atime clockwise until first contact is felt and heard then tighten one 1 more click to get light contact 6 Install hydraulic motor to cutting unit IMPORTANT LIGHT CONTACT MUST BE MAIN TAINED AT ALL TIMES If light contact is not tained bedknife and reel edges will not self sharpen sufficiently This will result in dull cutting edges after a period of operation If excessive contact is main tained bedknife reel wear will be accelerated Un even wear can result and quality of cut may be adversely affected NOTE As the reel blades continue to run against the bedknife a slight burr
221. s and Repairs sections for detailed adjust ment and repair information Possible Problem Correction Check tire pressure adjust to specification if necessary Must be equal in both front tires Check maximum governed engine speed Adjust if necessary affects reel speed traction speed and clip frequency Check and adjust to specification Replace bearings if worn or damaged Bearing cones must be installed square to bearing housing make sure there is no flash paint or other foreign material in housing before installing new bearing cone Reel and or bedknife that has rounded edge cannot be corrected by tightening bedknife to reel contact Grind reel to remove taper cone shape and or rifling grooved or ribbed appearance Grind bedknife to sharpen and or remove rifling Most common cause of rifling is bedknife to reel contact that is too tight NOTE New bedknife must be ground after installing on bedbar to match bedknife to bedbar Check and adjust as necessary Check before operating with cutting unit on ground Rotate the reel backwards by hand Turn adjusting kn ne 1 click at a time until first contact between reel an knife is felt or heard then tighten one 1 more click to get light contact No contact will dull the cutting edges Excessive contact accelerates wear Set to recommendations in chart on Page 10 14 Check and adjust as necessary All cutting units set at same height of cut Set with fr
222. seal into end of large diameter tool with open side of seal facing out Install small diameter tool into large diameter tool against flat closed side of seal Carefully install seal and tools over valve spool hold large tool against valve body and push seal into bore with small diameter tool Figure 10 ge NOTE REMOVE SHARP EDGES OL 0 997 1 000 DIA TEE Dimensions shown in inches 75 0 994 e 25 0 991 DIA Greensmaster 3100 Page 4 15 Figure 11 Special Tools Troubleshooting The cause of an improperly functioning hydraulic sys tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com plete hydraulic system A hydraulic system with an excessive increase in heat or noise is a potential failure Should either of these conditions be noticed immediately stop the machine turn off the engine locate the cause of the trouble and correct it before allowing the machine to be used again Continued use of an improperly functioning hydraulic system could lead to extensive internal component damage Troubleshooting Page 4 16 The charts that follow contain detailed information to assist in troubleshooting There may possibly be more than one cause for a machine malfunction All causes should be checked in the order in which they are listed on the charts do not deviate from this procedur
223. seed ing sand dressing etc 10 Amount of traffic on turf 11 Stress periods for turf i e high temperatures high humidity unusually high traffic Troubleshooting Page 10 8 Greensmaster 3000 3000 D Grooming Reel Mechanical Problems Problem Possible Cause Correction 1 Groomer rotates when in raised position with Normal condition the groomer may still rotate in clutch disengaged raised position with minimal force when clutch dis engaged because of friction in the clutch assembly This condition may change over a period of time Clutch not fully disengaged Make sure clutch knob set screws are tight against flats on release disk and does not allow knob to slip IMPORTANT When engaging or disengaging clutch be sure to push snubber down and turn knob all the way will come to a firm stop Clutch pulley bearing seized Replace bearing Clutch damaged or assembled incorrectly Repair or replace clutch if necessary Clutch not fully engaged Make sure clutch knob set screws are tight against flats on release disk and does not allow knob to slip IMPORTANT When engaging or disengaging the clutch be sure to push the snubber down and turn the knob all the way it will come to a firm stop 2 Clutch is engaged but does not provide power to groomer reel Clutch damaged or assembled incorrectly Repair or replace clutch if necessary Belt is out of adjus
224. semble into housing with seal lip pointed inward 2 Install back up washer Item 4 into housing Install back up washer Item 6 into housing with beveled side facing out so it will mate to inner seal Item 7 3 Apply a small amount of clean grease to back side of new inner seal Item 7 and assemble into housing 4 Lubricate and assemble coupling shaft Item 11 firmly seating it against thrust washer Item 8 5 Assemble thrust bearing Item 12 onto end of cou pling shaft Item 11 6 Assemble drive link Item 13 into coupling shaft Item 11 with their splines in mesh Align hole in drive link with hole in coupling shaft NOTE Two alignment studs screwed finger tight into housing Item bolt holes approximately 180 apart will facilitate the assembly and alignment of components as required in the following procedures NOTE Make sure new seal rings Item 5 are installed between each section of motor as it is assembled 7 Assemble wear plate Item 18 over drive link and studs onto housing 8 Install assembled rotor set Item 21 with counterbore in rotor Item 19 down if applicable and splines in mesh with drive link splines NOTE If necessary go to Rotor Stator Vane Assem bly procedures on next page Greensmaster 3100 9 Assemble manifold 22 and then the commuta tor ring Item 23 over the drive link onto rotor set Be sure swirls in manifold and manifold plate are installed f
225. shield over the rear edge of the bedbar Fig 24 Securely seat the 2 bedbar pivot bolts to a maxi mum torque of 40 ft Ibs Always check reel bearing adjustment after installing bedbar NOTE For proper grinding of bedknife follow proce dures in the Toro publication Sharpening Reel amp Rotary Mowers Form No 80 300 PT 6 Reverse steps 1 5 to install the bedbar Greensmaster 3000 3000 D Page 8 17 Figure 23 1 Rear roller height of cut bracket 2 Allen set screw 3 Bedbar mounting bolts 4 Bedknife adjusting screws 5 Height of cut rod locknuts 6 Roller shaft clamp bolts 7 Height of cut adjustment knob Figure 24 1 Bedbar under lip of shield Repairs Bedknife Replacement 1 Remove bedbar 2 Remove bedknife screws and remove bedknife 3 Remove all rust scale and corrosion from bedbar surface before installing the bedknife 4 Install new bedknife with the proper bedknife screws 57 4910 Bedknife screws must bottom out on the bedknife not the bedbar Tighten the screwsto atorque of 200 in Ib working from the center toward each end of the bedbar Fig 25 5 Grind the new bedknife to match it to the bedbar Figure 25 NOTE For proper grinding of bedknife follow proce dures in the Toro publication Sharpening Reel and Rotary Mowers Form No 80 300 6 Install the bedbar
226. smaster 3000 or 3000 D Parts Catalog Some tools may also be available from a local supplier McLube Aerosol or liquid lubricant Apply to bedbar pivot and bedbar pivot bolts Figure 1 Roller Bearing Replacement Tool Puller is used to remove bearings from front and rear rollers Driving tubes are used to install bearings into rollers Refer to instructions supplied with tool Used on swaged full and wiehle rollers Figure 2 Special Tools Page9 4 Greensmaster 3000 3000 D Plastic Plug Insert plug in cutting unit bearing housing in place of reel motor when sharpening or grinding the reel Ly Figure 3 Handle Assembly For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel assembly Figure 4 Bedknife Screw Tool Fits Toro bedknife attaching screws Use with torque wrench to secure bedknife to bedbar With clean bedbar threads and new screws tighten to a torque of 200 in Ib NOTE Remove all rust scale and corrosion from bedbar surface before installing bedknife DO NOT use an air impact wrench with this tool Cs Figure 5 Greensmaster 3000 3000 D Page 9 5 Special Tools Troubleshooting There are a number of factors that can contribute to machine It is important to remember that the lower the unsatisfactory quality of cut some of which may be turf height of cut the more critical these factors are See the conditions Turf cond
227. ss the spring Item 2 Actuate the spool assembly then turn the adjustment cap until the desired detent action is obtained This will usually be within three turns from bottoming out the adjustment cap NOTE Each turn of adjustment cap Item 10 changes the Feel of the detent action about 20 Repairs Page 4 48 Figure 28 1 Bonnet 6 Spring 2 Spring 7 Capscrew 3 Race 8 Stop collars 4 Ball 9 Detent stud 5 Thrust plate 10 Adjustment cap DETENT ASSEMBLY SPRING BALL SPRING ADJ DETENT STOP CAPSCREW CAP STUD COLLARS Figure 29 Greensmaster 3100 Control Valve No 4 Spool Detent Replacement Fig 30 NOTE The control valve assembly must be removed to replace this assembly See Control Valve Removal and Installation in this section of the book 1 Be sure No 4 spool is in neutral and remove the bonnet large spring and stop collar 2 Hold one hand in front of detent sleeve and push the front of the spool in very slowly until the detent balls pop out Be sure to remove all four 4 balls 3 Push the front of the spool in carefully until the holes in the detent adapter are just past the edge of the detent sleeve IMPORTANT Do not push the spool too far or the rear spool seal may be cut by the spool 4 Hold the front of the spool from turning insert a drift punch through the holes in the adapter and rotate the adapter counter clockwise to remove it from the spool
228. t 5 Loosen the setscrews securing the front roller to the height of cut arms Fig 18 Do not remove the set Screws 6 Loosen the saddle strap screws and flange nuts se curing the rear roller to the the side plates Fig 18 Do not remove the screws and nuts 7 Remove the capscrew 24 washer 23 and lock nut 25 securing each end of the grass shield to the side plates These are the only capscrews that must to be re moved The grass shield and the lift hook do not need to be removed 8 Remove the 2 shoulder bolts 7 securing the right hand side plate to the cutting unit frame Remove the side plate from the reel shaft and roller shafts 9 Remove the 2 shoulder bolts 7 securing the left hand side plate to the cutting unit frame Remove the side plate from the reel shaft and the roller shafts Greensmaster 3100 Page 10 15 Rev D Figure 17 1 Counter weight Figure 18 1 Front roller set screw 2 Rear roller saddle strap screws Dual Point Adjust Cutting units Left Side Plate Service Fig 16 1 Remove the inner grease seal 13 and outer grease seal 9 from the side plate 6 2 Remove the retaining ring 14 securing the bearing in the side plate Remove the bearing 12 Inspect the bearing to insure that it spins freely and has minimal ax ial play The bearing balls must be free of deformation and scoring Replace the bearing if necessary 3 Remove the wave washer 15 4 Remove al
229. t Slide second front bracket on the other end of roller Secure bracket with carriage screw tab washer and lock nut 4 Apply Loctite 242 or equivalent to the cap screw threads Center roller in the front brackets and secure into place with the cap screws 5 Adjust cutting unit height of cut see Cutting Unit Operator s Manual Greensmaster 3100 Front and Rear Roller Service Figure 24 1 Roller seal 3 Roller bearing 5 Roller shaft 2 Spiral retaining ring 4 Rearroller body 6 Frontroller body Seal Removal 188 in dia 2 1 Make a seal removal tool from a 1 4 x3 x 3 in 63 x 625 in dia 7 6 x 7 6 cm piece of steel as shown Fig 25 i 2 Slide seal removal over roller end of roller shaft 3 Use the tool as a template to locate mark and drill two 7 64 in diameter holes in the outer face of the seal p 1 4 20 2 4 Thread two No 8 x 3 4 long 164 in diameter self tapping screws through the seal removal tool and into the drilled holes in the seal 5 Thread two 1 4 20 x 1 in long cap screws into the Figure 25 seal removal tool 6 Alternately tighten the cap screws to pull the seal from the roller body Note Seals will be destroyed during removal Do not re use seals that have been removed from the roller Seal Installation 1 Apply a thin film of clean oil to the inner lip of the seal and slide the seal over the end of the roller shaft
230. t bushings Fig 30 contain rubber and are exposed to severe conditions It is recommended to replace these bushings and the plastic flange bushings every two years 1 Do steps 1 4 under Bedbar Removal and Installation in this section of the book 2 Remove bedbar end bushings with a punch and hammer Fig 31 Alternate from one side to other on bushing there are two slots in bedbar bushing boss IMPORTANT Apply NEVER SEEZ or equivalent to outside surface of bedbar end bushings and pivot bushings before installing in bedbar 3 Press end bushings into bedbar far enough so plastic sleeve collar is below bedbar end face Fig 32 NOTE Bedbar end bushings have less rubber and more steel which is visible than bedbar pivot bushings Do not use bedbar end bushings in the pivot area as they are too rigid 4 Use an arbor press to remove bedbar pivot bushings Fig 33 DO NOT hammer on pivot boss of bedbar without support You will break the casting 5 Press center pivot bushings into place Fig 33 DO NOT hammer on pivot boss of bedbar without support You will break the casting 6 Dosteps 5 16 under Bedbar Removal and Installation in this section of the book Figure 30 1 Bedbar end bushing 2 3 Flange bushing 4 2 Bedbar pivot bushing 2 Repairs Page 9 22 Figure 31 Figure 32 Figure 33 Greensmaster 3000 3000 D Bedknife Replacement 1 Do steps 1 4 under Bedbar Removal and I
231. tallation Fig 23 1 Remove knob from the shift lever and disassemble the right side panel from the machine 2 Remove the seat or secure it in an up position disconnect the wires from the safety switch located on the valve bank and place a drain pan under the valve bank 3 Disassemble the chain links from all five 5 spools 4 Tag and identify the lines leading to the valve bank disconnect and cap the lines and fittings with plastic plugs 5 Loosen the capscrews securing the valve bank to the 23 frame and remove the valve bank NOTE Shims may be installed between the bank and frame Note the quantity and mounting location and install in proper location upon reassembly 6 Reverse steps 1 5 to install the valve bank Do not over tighten fittings Use two wrenches to secure flex ible line connectors one wrench to prevent the Line from twisting the other to tighten the connection See the Hydraulic Lines and Fittings section of this chapter 7 Check to be sure all lines are routed correctly and are not in contact with one another or other components It should be possible to slip a strip of paper between any lines and other components in close relationship Relo cate if necessary 8 Adjust the traction linkage switches and reel drive camshaft as necessary Relief Valve Removal and Installation Fig 24 1 Be careful not to interchange parts such as springs or shims between relie
232. te ventilation Exhaust is hazardous and could be deadly 11 Sit on the seat when starting and operating the machine 12 Check interlock switches daily for proper operation If a switch fails replace it before operating the machine The interlock system is for your protection so do not bypass it Replace all interlock switches every two years 13 To start the engine A Sit on the seat depress lift pedal and release it to disengage cutting units B Verify that traction system is in neutral C Verify that parking brake is set D Proceed to start the engine 14 Using the machine demands attention To prevent loss of control A Mow only in daylight or when there is good artifi cial light B Watch for holes or other hidden hazards C Be extremely careful when operating close to sand traps ditches creeks steep hillsides or other hazards D Reduce speed when making sharp turns Avoid sudden stops and starts E Look to the rear to assure no one is behind the machine before backing up F Watch for traffic when near or crossing roads Always yield the right of way G Apply the service brakes when going down hill to keep forward speed slow and to maintain control of the machine 15 Keep hands feet and clothing away from moving parts and the reels The grass baskets must be in place during operation of the reels or thatchers for maximum safety Shut the engine off before emptying the baskets 16 Raise c
233. ted in the Greensmaster 3100 Parts Catalog Some tools may also be available from a local supplier Hydraulic Tester Fig 6 Inlet Hose Outlet Hose High Pressure Gauge Figure 6 You must have o ring face seal ORFS adapter fittings for this tester to use it on the Greensmaster 3100 1 INLET HOSE Hose connected from the system circuit to the inlet side of the hydraulic tester 2 LOAD VALVE If required upon turning the valve to restrict flow a simulated working load is created in the circuit 3 LOW PRESSURE GAUGE Low range gauge to provide accurate reading at low pressure 0 1000 psi 0 6895 kPa This gauge has a protector valve which cuts out when pressure is about to exceed the normal range for the gauge The cutout pressure is adjustable Greensmaster 3100 Page 4 13 4 HIGH PRESSURE GAUGE High range gauge to accommodate pressure beyond the capacity of the low pressure gauge 0 5000 0 34475 kPa 5 FLOW METER This meter measures actual oil flow in the operation circuit The reading is given in gallons per minute GPM and liters per minute LPM with a gauge rated at 15 GPM 57 LPM 6 OUTLET HOSE Hose from the outlet side of the hydraulic tester to be connected to the hydraulic system circuit Special Tools Seal Protector Fig 7 Slide the protector Item 1 over the reel motor shaft before installing the shaft seal to protect the seal from damage Apply
234. the four shoulder bolts 7 Torque the shoulder bolts to 17 to 20 ft Ibs 23 to 27 Nm 6 Secure the grass shield 22 to the side plates with two capscrews 24 washers 23 and lock nuts 25 7 Torque the reel bearing locknuts 8 to 50 to 60 ft Ibs 68 to 81 Nm 8 Install the bedbar assembly see Bedbar Installation in this chapter 9 Install the rear roller as follows Fig 21 A On one of the saddle clamps remove one of the screws and nuts securing it to the side plate B Install rear roller into saddle clamps and loosely secure it with the screw and nut previously re moved C Center the roller between side plates Tighten the saddle clamp screws and nuts to secure the roll er Dual Point Adjust Cutting Units Page 10 18 Rev D Figure 21 2 Saddle clamp 1 Rear roller 10 Install the front roller see Front Roller Installation in this chapter 11 Adjust the cutting unit See the Cutting Unit Opera tor s Manual for adjustment procedures Note The parallel position of the rear roller to the reel is controlled by the precision machined components of the assembled cutting unit Only a limited amount of ad justment is possible if necessary due to tapered reel wear To adjust A Place the assembled cutting unit on a surface plate B Loosen each bedbar adjuster assembly both cap screws 24 and all four shoulder bolts 7 C Adjust the cutting unit and tighten the shoulder
235. the right end and 90 fitting at the left end when viewed in the direction of travel 10 Use a soft face hammer to rotate each bearing housing slightly Instali bolts from outside of housings and turn bolts alternately against side plate to remove bearing housings Fig 43 Bearing housings will slip out of side plates Reel can be removed as soon as bearing housings are disassembled from side plates Figure 41 1 Left side groomer housing 4 Flat head screws 2 Bearing adapter 5 Spacer 3 Reel bearing adjustment nut Repairs Page 10 26 Greensmaster 3000 3000 D 11 If necessary install new bearings and seals A Remove bearing cup bearing cone and inner seal B Bearing housing must be completely free of paint and foreign material before installing bearing cup If necessary remove any flash from bearing housing that may interfere with accurate seating of bearing Install inner seal Install bearing cup C Install bearing housing to frame Pack bearing cone with grease and install over reel shaft into bearing cup 12 After installing reel tighten spline nut to 40 60 ft Ib then adjust bearings See Reel Bearing Service and Adjustment in the Adjustments section of this chapter Use Loctite 271 on spline nut threads 13 Install right side groomer plate assembly and bearing adapter Use a stud installation tool or double nuts to tighten two 2 special studs to 17 21 ft lb Make sure a spacer is installed o
236. til the motor flanges are encircling the flange head screws Tighten flange head screws Backlapping Units without Optional Backlap Variable Reel Speed Kit Be careful when backlapping the reel because contact with the reel or other moving parts can result in personal injury 1 Remove reel motors from the cutting units and cut ting units from the lift arms and pull frame see Cutting Unit Removal and Installation 2 Connectthe backlapping machine to the cutting unit by inserting a piece of 3 8 socket extension drive into the splined reel drive coupling 3 Attach backlap motor or drive to the socket exten sion 4 Follow instructions and procedures for backlapping in the Toro Service Training Book Sharpening Reel and Rotary Mowers part no 8030051 Dual Point Adjust Cutting Units Page 10 8 Rev D TOP FACE REMOVE RELIEF ANGLE BURR FRONT FACE FRONT ANGLE Figure 8 Note For better cutting edge run a file across the front face of the bedknife when the lapping operation is completed This will remove any burrs or rough edges that may have built up on the cutting edge Greensmaster 3100 Backlapping Units with Optional Backlap Variable Reel Speed Kit TO AVOID PERSONAL INJURY OR DEATH e Never place hands or feet in the reel area while the engine is running e While backlapping the reels may stall and then restart e Do not attempt to restart reels by hand or foot e Do
237. tment If belt has slipped it will probably be damaged and must be replaced Belt broken or damaged Repair or replace belt if neces sary A broken or worn belt could be the result of im proper belt adjustment or seized groomer reel bearings Bent damaged or missing groomer blades Replace blades if necessary 3 Turf damage or uneven grooming Bent or damaged groomer reel shaft Replace groomer shaft Grooming depth not equal on both ends of groomer reel Adjust if necessary Check and adjust cutting unit set up level bedknife to reel level rear roller to reel set height of cut etc Groomer reel interfering with cutting unit frame side plate Check side plate for proper cut out and modify if necessary 4 Groomer reel does not raise completely to transport position quick up levers do not rotate completely to rear or have free play Incorrect front roller extension plate installed Single Point Adjust and 4 Bolt Adjust cutting units require dif ferent front roller extension plates Greensmaster 3000 3000 D Page 10 9 Troubleshooting Set Up and Adjustments Adjustment Summary and Check List DETAILED ADJUSTMENT INSTRUCTIONS FOLLOW THIS SUMMARY AND CHECK LIST Study this informa tion and refer to it often for maximum life and perfor mance of cutting units Daily Performance Checks NOTE It is not necessary to remove the cutting units fromthe traction unit to
238. ubleshooting Page 4 26 Greensmaster 3100 Testing The most effective method for isolating troubles in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks See the Special Tools section in this Chapter Hydraulic testers may vary significantly in size con struction accuracy and cost The decision as to which tester to purchase should be influenced by what type of tests will be performed on all of the hydraulically pow ered equipment in the shop All obvious areas such as oil supply filter binding linkage loose fasteners or improper adjustments must be checked before assuming that a hydraulic compo nent is the source of the problem being experienced A WARNING Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved by stopping the en gine and lowering the implement to the ground Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid un der high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and do serious dam age If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury or gan grene may result Before Performing Hydraulic Tests 1 Thorough clean the machine
239. ustment in this section Adjustments Page 4 38 Greensmaster 3100 Repairs Reel Motor Removal and Installation Fig 16 1 Disconnect hydraulic lines Put caps or plugs on fittings and hoses to prevent contamination Tag hydrau lic lines for proper reassembly 2 Loosen motor mount nuts 3 Rotate motor clockwise so motor flanges clear studs and pull motor out 4 Reverse steps 1 3 to reinstall motor Reel Motor Shaft Seal Replacement Fig 17 1 Disconnect and reverse hydraulic lines on affected motor connect pressure line to outlet fitting on motor and return line to inlet fitting on motor IMPORTANT Make sure hydraulic lines are con nected properly after shaft seal is replaced 2 Loosen motor mount nuts 3 Rotate motor clockwise so motor flanges clear studs and pull motor out 4 Remove snap ring from motor 5 Start the engine DO NOT engage the mow pedal Back pressure in the hydraulic system will push shaft seal out of motor Stop the engine NOTE Seal may also be removed by punching two holes in face of seal 180 apart installing metal screws and pulling seal out by grasping the screws 6 Disconnect hydraulic lines from motor 7 Remove and discard shaft seal and spacer 8 Install a new spacer on motor shaft 9 Put seal protector on motor shaft or apply tape on the shaft Be careful to prevent the shaft spline from dam aging the new seal Greensmaster 3100 Page 4 39 Figu
240. ustments section of this chapter 1 Do steps 1 6 under Bedbar Removal and Installation in this section of the book NOTE Some reel grinders require rear roller assembly be mounted to cutting unit for proper support in reel grinder Rear roller must be parallel to reel shaft to remove taper when grinding 2 Raise or remove front roller assembly A Loosen locknuts securing height of cut adjusting rods at both ends of cutting unit and roller shaft clamp bolts Fig 38 x Figure 38 B Turn height of cut adjustment knobs to raise rollerr out of the way or remove roller if necessary 1 Height of cut locknut 2 Roller shaft clamp boit For proper grinding of reel follow procedures in the Toro 3 Height of cut knob publication Sharpening Reel and Rotary Mowers Form 4 Grooming reel cover 5 Cover screws and washers No 80 300 PT 3 Do steps 8 16 under Bedbar Removal and Installation in this section of the book After grinding assemble cutting unit check bearing adjustment and adjust top shield and bar Back lap if necessary to get desired fit between reel and bedknife Greensmaster 3000 3000 D Page 10 25 Repairs Reel Removal and Bearing Replacement 1 Do steps 1 4 under Bedbar Removal and Installation in this section of the book 2 Loosen two 2 set screws and remove clutch knob Remove groomer reel housing cover from left side of cutting unit Fig 39 3 Remove grooming reel adjustment knob ass
241. uter grease seal 9 from the side plate 10 2 Remove the bearing 12 Inspect the bearing to in sure that it spins freely and has minimal axial play The bearing balls must be free of deformation and scoring Replace the bearing if necessary 3 Remove the O ring 11 from the groove in the side plate bore 4 Remove all grease from the side plate bore Note Replacemant Seal Kit Toro Part No 106 6937 is available for side plate service of dual point adjust cut ting units 5 Insert the O ring 11 into the groove in the side plate Apply a light coating of grease onto the O ring af ter it is installed 6 Packthe bearing 12 with Mobil High Temperature HP or equivalent grease Insert the bearing into the side plate until it is against the bottom of the bore 7 Packthe cavity of the inner seal 13 with Mobil High Temperature HP or equivalent grease 8 Using inner grease seal installation washer Toro Part Number 104 0532 press the inner seal 13 into the side plate until the washer is flush with the outer edge of the side plate bore Remove the washer When properly installed the seal should be positioned 104 in below the inner edge of the side plate bore 9 Press the outer seal 9 into the side plate until it is flush with the the outer edge of the side plate bore IMPORTANT The outer grease seal 9 should be installed so the lip is facing out This helps keep contamination from entering and allows g
242. utting units when driving from one work area to another Safety Instructions Page 1 2 B Do not remove fuel tank cap while engine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and only to within an inch 25 mm from the top of the tank not the filler neck Do not overfill E Wipe up any spilled fuel 17 Do not touch engine muffler or exhaust pipe while engine is running or soon after itis stopped These areas could be hot enough to cause burns 18 Stay clear of rotating screen at side of engine to prevent direct contact with body or clothing 19 If cutting unit strikes a solid object or vibrates abnor mally stop immediately turn engine off set parking brake and wait for all motion to stop Inspect for damage If reel or bedknife is damaged repair or replace it before operating 20 Before getting off the seat A Move shift selector to N neutral B Depress the lift pedal to raise the cutting units wait for the reels to stop spinning and release lift pedal C Set the parking brake E Stop engine and remove key from switch 21 Traverse slopes carefully Do not start or stop sud denly when traveling uphill or downhill 22 Operator must be skilled and trained in how to drive on hillsides Failure to use caution on slopes or hills may cause loss of control and vehicle to tip or roll possibly resulting in personal injury or death 23 If engine stalls or loses hea
243. ve Belt Adjustment 19 SPECIAL 4 Pull Frame Adjustment 20 6 REPAIRS end 21 Factors Affecting Quality of Cut 6 Cutting Unit Removal and Installation 21 Factors Affecting Grooming 8 Reel 0 22 Groomer Mechanical 9 Bedbar Removal and Installation 22 UP AND ADJUSTMENTS 10 Bedbar Bushing Replacement 24 Adjustment Summary and Check List 10 Bedknife Replacement 25 Bedknife to Reel Contact 11 Preparing Cutting Unit for Reel Grinding 25 Reel Bearing Service and Adjustment 12 Reel Removal and Bearing Replacement 26 Parallel Bedknife to 13 Groomer Reel Blade Service 28 Leveling Rear Roller to Reel 14 Groomer Reel Drive Belt Replacement 28 Height 16 Groomer Reel Removal and Installation 29 Groomer Reel Depth Adjustment 18 Groomer Reel Clutch Service 30 Shield Height 18 Bedknife Adjustment Knob Bearing Service 32 Top Bar 19 Lift Bail 33 Introduction See Ch
244. ve hydraulic lines 3 Remove cotter pin Item 5 and clevis pin Item 4 from cylinder rod 4 Remove capscrew Item 1 securing pin Item 7 to frame and remove pin and cylinder Item 6 from ma chine 5 Reverse steps 2 5 to install the lift cylinder Coat the hinge pin with Never Seez or grease to achieve free pivot action of the cylinder before reassembling Greensmaster 3100 Page 4 51 IMPORTANT When disassembling hydraulic lines make sure hydraulic plugs are placed in the open end of the hydraulic line to prevent foreign debris from contaminating hydraulic oil It is also a good idea to tag the hydraulic lines when disassembling so they can be properly reassembled Keep all hy draulic lines clean and free from foreign debris During replacement of lift cylinder avoid overtight ening fittings Check hydraulic lines for cracks or breaks If a hydraulic leak should appear after re placement of lift cylinder replace the fitting or line that is leaking Check hydraulic reservoir for level of hydraulic fluid after replacement of lift cylinder Repairs Lift Cylinder Repair 1 Center Fig 34 e Figure 34 IMPORTANT To prevent damage when clamping the cylinder barrel a vise clamp only on the pivot end Do not clamp the vise jaws against the smooth shaft surface Protect the shaft surface before mounting in the vise 1 After removing the cylinder pump the oil out of the
245. ver each stud between groomer bearing adapter and reel bearing housing Tighten two 2 inside locknuts to 23 27 ft Ib Install two 2 flange locknuts reel motor mounting nuts Fig 42 14 Install grooming reel adjustment knob assembly to right side groomer plate assembly Fig 42 Install groomer reel shaft to right side groomer plate assembly and install locknut on right end of groomer shaft 15 Install left side groomer housing and bearing adapter Fig 41 Install two 2 flat head socket screws and tighten to 17 21 ft lb Make sure a spacer is installed over each flat head socket screw between groomer bearing adapter and reel bearing housing Install two 2 locknuts and tighten to 23 27 ft lb 16 Install groomer reel driven pulley to groomer reel shaft left hand thread and tighten to 29 35 ft lb Fig 40 17 Install clutch adapter on reel shaft and tighten to 170 210 in Ib Fig 49 Hold belt on drive pulley and slide clutch assembly on clutch adapter while sliding belt onto driven pulley Fig 40 Install washer and nut removed in step 4 on clutch adapter shaft Use a block of wood to keep reel from rotating and tighten nut to a torque of 7 10 ft Ib 18 Install grooming reel adjustment knob assembly to left side groomer housing Fig 40 19 Adjust belt tension See Groomer Reel Drive Belt Adjustment in the Adjustments section of this book Install groomer reel housing cover Fig 39 Install
246. w bearings and seals A Remove outer seal in counterbalance weight bearing cup bearing cone and inner seal B Bearing housing must be completely free of paint and foreign material before installing bearing cup If necessary remove any flash from bearing housing that may interfere with accurate seating of bearing Install new inner seal Install bearing cup C Install bearing housing to frame Pack bearing cone with grease and install over reel shaft into bearing cup Install outer seal in counterbalance weight 7 After installing reel tighten spline nut to 40 60 ft lb Figure 29 then adjust bearings See Reel Bearing Service and Adjustment in the Adjustments section of this chapter 1 Bearing housing rotate slightly Use Loctite 271 on spline nut 2 Bearing housing mount bolts thread against 8 Install bedbar Install front and rear roller assembly side plate to remove housing Greensmaster 3000 3000 D 8 19 nev C Repairs Lift Bail Replacement Figure 30 1 Use a saw to cut the lift bail off of the cutting unit Make 4 Support the lift bail so the bottom radius is 4 546 inches the cut 1 inch from the horizontal frame tube Fig 30 from the top of the horizontal frame tube Make sure the lift bail is square to the side frame 2 Use a grinder to remove burrs from the stubs of the lift bail remaining on the cutting unit 5 Weld all around the bottom of the repair lift bail with mild steel rod
247. witch Seat Switch Replacement and Adjustment Fig 15 1 Pivot seat forward and block or tie it securely to prevent it from falling accidentally and possibly causing injury 2 Remove boot from button end of seat switch and retain for installation on replacement switch Pull con nectors off switch terminals 3 Loosen the jam nut and unscrew the switch from mounting bracket 4 Screw new switch through mounting bracket until switch button is about 1 16 inch 1 6 mm shorter than the top of the seat return spring pin Install the boot into the mount grooves 5 Carefully release the seat to its normally down posi tion but do not sit or apply force on the seat There should be a slight gap between the switch and the seat plate 6 Make sure switch terminals face front of machine and lock switch in place by tightening the jam nut to 75 in Ib 8 5 Nm against the mounting bracket IMPORTANT Switch threads will be damaged if the jam nut is over tightened 7 Connect continuity tester of ohm meter to switch terminals With seat in the down position and no one on the seat the switch circuit should not have continuity If there is continuity repeat steps 4 6 If there is no conti nuity proceed to 8 Sit on the seat The seat switch should have continu ity If there is no continuity repeat steps 4 7 If there is continuity proceed to step 9 Greensmaster 3100 Page 5 13 9 Fill terminal end of switch and wir

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