Instruction/ maintenance manual of the product 3100 Toro
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Service Manual Greensmaster ® 3100/3050 Preface This publication provides the service technician with information for troub leshooting, testing, and repair of major systems and components on th e Greensmas ter 3100 and 3050.
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T able Of Contents Chapter 1 - Safety Safety Inst ructions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Chapter 2 - Product Records and Manuals Product Re cords . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Equivalents an d Conversions .
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Chapter 1 Safety T able of Contents SAFETY INSTRUCT IONS . . . . . . . . . . . . . . . . . . . . 1 Before O perating . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Oper ating. . . . . . . . . . . . . . . . . . . . . . . . . . 2 While Doin g Maintenanc e, T roubleshooting, T esting, Adjustmen ts or Rep airs .
8. Do not carry p assengers o n the machine. Ke ep everyone, especia lly children and pets, away from the areas of ope ration . 9. Since gasoline is highly flammable, handle it carefu lly: A. Use a n approved fu el cont ainer. B. Do not remo ve fuel tank ca p while engine is hot or runn ing.
While Doing Maintenance, T roubleshooti ng, T es ting, Adjustments or Repairs 26. Before servicing or making adjustment s to the ma- chine, stop the engine, remove k ey from ignitio n switch and pull wires off spark plugs to prevent accidental starti ng of the engi ne.
Safety Ins tructio ns Page 1 - 4 Greens master ® 31 00.
Chapter 2 Product Records and Manuals T able of Contents PRODUCT RECORD FORM . . . . . . . . . . . . . . . . . . 1 EQUIV A LENTS AND CONVERSIONS . . . . . . . . . . 2 Decimal an d Millimete r Equivale nts . . . . . . . . . . 2 U.S. to M etric Conversio ns .
Equivalents and Conversions Decimal and Millimeter Equivalents U.S to Metric Conversions ________________________ ___________________ ___________________ ________________________ _____________ Fractions Decimals mm Fractions Decimals mm ________________________ ___________________ ___________________ ________________________ _____________ 1/64 0.
T orque Specifications Use these torque values when specific torque value s are not given. DO NOT use these values in place of specified values . The torque values liste d below are for lubricated threads. Plated th reads are consider ed to be lubricated.
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Chapter 3 Engine T able of Contents SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Throttle Control Adjustment . . . . . . . . . . . . . . . . . 2 Choke Control Adjustmen t .
Adjustments Throttle Control Adjustment (Fig. 1) Before adjusting ca rburetor , make sure throttle control is operati ng properly . 1. Loose n cable clamp scre w securing cable to e ngine. 2. Move remote throttle con trol lever forward to F AST position.
Governor Adjustment (Before starti ng engine) IMPORT ANT : If carburetor has been removed or governor linkage disassembled, the governor lever , throttle restrictor and secondary governor s pring must be adjusted before the engine is started. Governor Lever Adjustment (Fig.
Carburetor and Speed Control Adjustment (Fig. 5, 6) IMPORT ANT : Before carburetor and speed control are adjusted, the throttle and c hoke controls must be adju sted pr oper ly . Engine must be running during adjustm ent of carbure tor and speed control.
Engine Removal and Installation Removing the Engine 1. Disconnect the nega tive (–) and po sitive (+) ba ttery cables from the battery . 2. Close th e fuel shut-of f valve and disconn ect the fuel line. Gasoline is highly flammable. Use cauti on while handling it.
Engine Removal and Installation Page 3 - 6 Greensma ster ® 3100.
Chapter 4 Hydraulic System T able of Contents SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMA TION . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hose s . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic F itting Installa tion .
Specifications Item Description _______________ ____________ ____________ _______________ ____________ _____________ ___________ Hydraulic Pump External gear type 5 section (Greensmaster 3100) 4 secti.
General Information Hydraulic Hoses Hydraulic hoses are sub ject to extreme conditions suc h as, pressure differentials during operation and exposure to weather , sun, chem icals, very warm st orage condi- tions or mish andling durin g operation or maintenan ce.
SAE Straight Thread O-Ring Port (Non-adjustable) (Fig. 3) 1. Make sure both threads and se aling surfaces are free of burrs, nicks, scr atches, or any foreign ma terial. 2. Always replace th e O-ring seal when this type of fitting shows signs o f leakage.
Hydraulic Flow Diagrams T raction, N o. 1 Position When engine is sta rted, pump draws oil from reservo ir through two suction lines. Oil from one section of pump passes through fitting in No. 4 spool valve into valve. T raction lever , when located in No.
T raction, No. 2 Po sition When the traction lever is positio ned in No. 2, flow from one pump section pa sses through same lines as for No. 1 traction position. This flow is joined by ad ditional flow from two other pump sect ions. The additio nal flow in- creases the RPM of the wheel motors to increase ground speed.
T raction, Reverse Positio n T raction lever is positioned in No. 1 or No. 2. When traction p edal is pushed rearward, flow from one pu mp section goes through No. 4 selector va lve section into No. 5 meterin g section and o ut the lines at th e front o f the valve to th e traction motors, wh ich drive the traction wheels, to operate in rev erse.
Reel Drive, Mowing Operation The MOW pedal is depressed, which causes the No. 1, 2 and 3 spools to be positioned fully out of va lve bank. This directs flow from one pump se ction to pass through left end cove r and out line le ading to left f ront cutting unit drive mo tor .
Reel Drive, Lower Cutting Units The MOW pedal is depressed to start reel drive opera- tion, flow fr om one pum p secti on passes th rough No. 3 spool section and out three lines, each leadin g to a lift cylinder . This actuates the lift cylinders and lowers the cutting un its.
Reel Drive, Raising Cutting Units When the LI FT pedal is depressed, No. 1, 2 and 3 spools are pushed inward. When sp ools pass neutr al, cutting units stop o peration. Ho lding peda l depressed keeps spools fully in. This dire cts flow from o ne pump section to pass th rough end cover and No.
Power Steering, R.H. T urn (Greensmaster 3100) Oil is supplied to port “P” of the steering contr ol unit from the pump steer ing section . When the stee ring wheel is turned to th e right, the contr ol section wit hin the st eering valve shifts to direct oil supplied by th e pump to th e metering section of the steering valve.
Greensmaster 3100 Page 4 – 12 Hydraulic Schematics Rev . E Hydraulic Schematic (Greensmaster 3100 2WD Serial Number Below 230000000) REEL MOT ORS LH RH CENTER LIFT CYLINDERS LH RH CENTER T P STEERING CYLINDER LR PUMP (DANFOSS) LH RH WHEEL DRIVE MOTORS 10.
Greensmaster 3100 Page 4 – 12.1 Hydraulic Schematics Rev . E Hydraulic Schematic (Greensmaster 3100 2WD Serial Number Above 230000000) REEL MOT ORS LH RH CENTER LIFT CYLINDERS LH RH CENTER T P STEERING CYLINDER LR PUMP (P ARKER) LH RH WHEEL DRIVE MOTORS 10.
Greensmaster 3100 Page 4 – 12.2 Hydraulic Schematics Rev . E Hydraulic Schematic (Greensmaster 3100 3WD) BANK 2000 PSI (141 KG/SQ CM) 2000 PSI (141 KG/SQ CM) 2000 PSI STEERING CONTROL VAL VE 4.5 CU IN/REV (75 CU CM/REV) LH LH RH RH CENTER CENTER LIFT CYLINDERS REEL MOT ORS .
Greensmaster 3100 Page 4 – 12.3 Hydraulic Schematics Rev . E Hydraulic Schematic (Greensmaster 3050) REEL MOT ORS LH RH CENTER LIFT CYLINDERS LH RH CENTER PUMP LH RH WHEEL DRIVE MOTORS 10.3 CU. IN/REV . (169 CU. CM/REV) 2000 PSI (141 KG/SQ CM) 2000 PSI (141 KG/SQ CM) 2000 PSI (141 KG/SQ CM) 1850 PSI (130 KG/SQ CM) 2ND 1ST N FWD N REV 3 .
Greensmaster 3100 Page 4 – 12.4 Hydraulic Schematics Rev . E This page is blank..
Special T ools NOTE: Order special too ls from the T O RO SPECI AL T O OL S AND A PPL I CA T I ONS GUI DE ( COM MERCI AL PRODUCTS ) . Some t ools may be listed in the Greensmaster 3100 Parts Catal og. Some tools may also be availab le from a local supp lier .
Seal Protector (Fig. 7 ) Slide the protecto r (Item 1) over the reel motor shaft before insta lling the shaft seal to pro tect the seal fr om damage. App ly a light coating of clean oil to the sea l protecto r to ease mo vement of the seal ove r the tools.
Seal Installation T ool (Fig . 9) Use to assure prop er fit and positionin g of lip seals used in the TRW T orqmotor hydraulic whe el 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 in to the ring.
T roubleshooting The cause of an impr operly functioning hyd raulic sys- tem is best diagnosed with th e use of proper testin g equipment and a th orough unde rstanding of the com- plete hydraulic system. A hydraulic system with an ex cessive increase in heat or noise is a po tential failure .
Slow Groundspeed in All T rac tion Selections Low Misadjusted or damaged Drag Drag * Check engine RPM Improper OK Adjust – use tachometer Fill to proper level * Check hydraul ic oil level Check hydr.
Slow or No Ground Speed in No. 1 a nd Reverse No. 2 Appears Norma l Low Defective OK OK Misadjusted or damaged Adjust or repair Check traction pump flow. Test hook up No. 1 Test A Remove valve ba nk and replace disk se al Repair or replace traction pump Check for internal valve bank leakage .
No Increase in Speed from No. 1 to No. 2 OK Low Misadjust ed or damaged Misadjuste or damaged OK OK Low Fill to proper level Check traction lever Adjust or repair Check #2 and #3 valve section re- liefs.
One or More Cutting Units Slow or No Reel Drive Action OK Defective Defective Low Tight Insufficient Misadjusted or Damaged OK Adjust or repair and lubricate Check Pedal Linkage Adjust or repair rear camshaft Check reel pump flow.
All Reels Slow or Will Not T urn Clogged Low Low OK Adjust – use tachometer Check engine RPM Fill to proper level Check reel pump flow. Test hook up No.
Mow Pedal Won’t Stay Engaged – Reels Slow Down or Stop Insufficient Worn or broken Misadjusted or damaged OK Adjust, repair and lubricate linkage Check linkage from pedal to valve bank Replace pin.
Cutting Unit(s) Drop During T ransport Leaking Leaking Binding OK Lubricate and adjust cam shaft Check that valve spool return s to neutral Repair or rep lace cylinder(s) Check lift check plug o-rings.
Cutting Units Lift T oo Slowly or No t At All Restricted Insufficient Binding OK Loosen and lubricate lif t assemblies Check for binding lift assemblies Adjust rear camshaft Check lift section of pump.
Lift Pedal Binding Binding or Damaged Misadjusted or Damaged OK Adjust or repair link- age and lubricate Check pedal linkage Lubricate and repair detent Check valve spool detent assembly Center (#1) C.
Steering Loss, Steering W ander or Free Play Loose Restriction Replace restricted line or fitting Defective OK OK OK OK Binding Check for dam- aged steering wheel or shaft Repair and lubricate castor .
T esting The most ef fective method for iso lating troub les in the hydraulic system is by using hydraulic test equipment such as pressur e gauges and flow meters in the circu its during various op erational chec ks. (See the Special T ools section in this Chapte r .
TEST HOOK UP NO. 1 T raction Pump Flow T raction Relief Setting TESTER CONNECTION: T ester in series b etween trac tion pump ou tlet line and va lve bank p ort on No. 4 s ection of valve bank. (T ester Flow Control V alve Open) CAUTION: Keep everyone away from the front of the machin e during traction system tests.
TEST HOOK UP NO. 1 ( cont i nued) TEST B: RELIEF V AL VE SETTING PROCEDURE Tester flow contr ol valve open. Block up trac tion wheels off flo or. Apply brakes and engage p ark lock. Engine RPM 2800. Hydraulic oil at n ormal operat ing temperature . Engage t ransmission le ver to No.
Greensmaster 3100 Page 4 – 30 T esting Rev . E TEST HOOK UP NO.2 T raction Motors Mechanical Drag V alve Bank Leakage T raction 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.
Greensmaster 3100 Page 4 – 31 T esting Rev . E 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.
TEST HOOK UP NO. 3 Reel Drive Pump Ef ficiency TESTER CONNECTION: T ester in series betwe en reel pump outlet ho se on suspected bad sec tion and its valve bank fitting. Section bein g checked should be on e that supp lies oil for reel unit not ope rating properly .
TEST HOOK UP NO. 4 Reel Drive Motor Flow Reel Drive Relie f Setting Reel Motor Efficiency TESTER CONNECTION: T ester in series be tween pressure hose and m otor fitting on suspected b ad motor . (T ester Flow Control V alve Open) CAUTION: Keep everyo ne away from the front of the mac hine during re el system tests.
TEST HOOK UP NO. 4 ( cont i nued) TEST B: REEL DRIVE RELIEF SETTING AND REEL MOT OR EFFICIENCY PROCEDURE With engine off, insert a blo ck of wood between cuttin g unit reel blades and fr ont cross tube to p revent re el from turning. Engine RPM 2800. Hydraulic o il at opera ting tempe rature.
TEST HOOK U P N O. 5 (Greensmaster 3100) Steering Pump Flow and Relief Pre ssu r e TESTER CONNECTION: T este r in series be tween steerin g pump outlet lin e and fitting on P (p ressure) port o f steering control u nit. ( T ester Flow Control V a lv e Op en ) CAUTION: Keep everyone away from the front of the machine during steering system tests .
Adjustments Lift and Mow Pedal Height Adjustment (Fig. 13) Adjust the lift and mow pedal to equal he ight to ga in proper spool travel in the valve bank as follows: 1. Put 1, 2 and 3 spo ols in neutral (cente r of travel) a nd remove transfe r rod guard from fo ot panel.
T raction Pedal Adjustment (Fig. 14) T o check forward and reve rse 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.
Rear Camshaft Adjustme nt (Fig. 15) A camshaft misaligned with th e valve bank may cause the following: A. No increase in gro und speed in No. 2 (transport) traction se lection. B. Mow pedal will not stay dep ressed (in detent ) without f oot pressur e.
Repairs Reel Motor Removal and Installation (Fig. 16) 1. Disconnect hydr aulic lines. Put caps or plugs on fittings and hoses to prevent conta mination. T ag hydrau- lic lines fo r proper r eassembly . 2. Loosen motor mount nuts. 3. Rotate motor clockwise so motor flanges clea r studs and pull mo tor out.
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. IMPORT ANT : Extreme caution must be used when using a vise to avoid distorting any parts.
14. Apply grease to a nti-extrusion block and put in recess of seal a ssembly , with ground face showing. 15. Apply grease to seal assembly and put in body counterb ore. Anti-e xtrusion bloc k must face bod y on th e tank port side when the mo tor is assembled (same side as bridging insert).
Greensmaster 3100 Page 4 – 41.1 Repairs Rev . B Reel Motor 94–3506 Repair (Fig. 18a) 1 2 3 4 5 6 7 8 9 10 5 14 5 11 12 13 Figure 18a 1. Plug ports and wash exterior of motor with mineral spirits or solvent. Make sure parts and work area are clean.
Greensmaster 3100 Page 4–41.2 Repairs Rev . B 15. Before tightening the capscrews, rotate the drive shaft in the direction of normal rotation (counterclock– wise) to check for binding. Y ou may not be able to rotate th e drive shaft by hand. Protect the shaft if using a pliers.
Greensmaster 3100 Page 4 – 41.3 Repairs Rev . D Reel Motor 105–9770 Repair (Fig. 18b) 1. Rear cover 2. Drive gear 3. Seal 4. T ab washer 5. Pressure seal 6. Back–up ring 7. O–ring 8. Body 9. Idler gear 10. Cap screw 1 1. Front flange Figure 18b 7 4 3 1 2 5 6 9 10 11 (45 to 55 Nm) 33 to 40 ft–lb 8 5 6 7 Disassembly 1.
Greensmaster 3100 Page 4–41.4 Repairs Rev . D IMPORT ANT : 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 .
Greensmaster 3100 Page 4 – 41.5 Repairs Rev . D 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.
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Hydraulic Pump Removal and Ins tallation - Greensmaster 3100 shown (Fig. 19) Figure 19 Disassemb ly 1. Drain th e hydraulic reservoir . 2. Remove the hydra ulic lines from the pump (Fig.
Pump Repair - Greensmaster 3100 shown (Fig. 22) Figure 22 Relief V alve Service 1. Remove cap (Item 10). Remove valve adjuster (Item 9), s pring (It em 8), an d ball ( Item 7). 2. Remove o-ring (Item 32) from c ap. 3. Inspect ball for burrs or roughness.
7. Be 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 th em for reasse mbly . It is recommende d NOT to remove th e bearin g races fro m the flan ge as- sembly .
Control V alve Removal and Installation (Fig. 23) 1. Remove knob from the shift lever and dis assemble the right side panel from th e machine. 2. Remove t he seat or se cure it in an up p osition, disconne ct the wires fro m the safety switch located on the valve bank and place a drain pan under the valve bank.
Control V alve Spool Seal Rep lacement IMPORT ANT : T o prevent leak age, ma ke sure you keep foreign material s uch as dirt, sand or paint chips out of valve body seal grooves. NOTE: Except for the seal under No. 4 spool bonn et, the valve bank does not no rmally have to be remove d from th e machine t o replace spool seals.
Control V alve Internal Seal Replacement (Fig. 27) Figure 27 1. I nternal seals (4 between ea. s ect.) 3. No. 2 section relief valve 5. No. 4 (traction) section relief valve 2. M ain & No. 1 section relief va lve 4. No. 3 section relie f valve NOTE: Replace all internal seals when ever valve sec- tions are disasse mbled.
Control V alve No. 1 Spool Detent Rep lacement (Fig. 28, 29) NOTE: These procedure s can be done with the control valve assembly installed on the machine. 1. Remove the en tire deten t assembly from the contro l valve. Keep the backup wash er , seal retainer and seal with the spoo l.
Control V alve No. 4 Spool Detent Replacement (Fig. 30) NOTE: The co ntrol valve assem bly must be rem oved to replace this asse mbly . (See Control V alve Removal and Installation in t his section of t he book.) 1. Be sure No. 4 spool is in neutral and remove th e bonnet, la rge spring, and stop co llar .
Lift Cylinder Removal and Installation No. 1 (Center) Lift Cylinder (Fig. 32) Figure 32 1. Put dr ain pan under m achine. 2. Remove hydr aulic lines. 3. Remove caps crew (Item 25) and lockn ut (Item 29) securing pin (Item 26) in ba rrel end of cylinder (Item 10) .
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 cylind er . Other disassembly proc edures are the same for both cylinders. 2. Put drain pan under machine and remove hydraulic lines.
Lift Cylinder Repair – No. 1 (Center) (Fig. 34) Figure 34 IMPORT ANT : T o prevent damage when clamping the cylinder barrel in a vise, clamp only on the pivot end. Do not clamp the vise jaws against t he smooth shaft surface. Protect the shaft surface before mounting in the vise.
Lift Cylinder Repair – No. 2 and 3 (Left and Right) (Fig. 35) Figure 35 IMPORT ANT : T o prevent damage w hen clampin g 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.
Wheel Motor Removal and Installation (Fig. 36) Figure 36 1. Put blocks o n each side o ff o pposite drive wheel. L ift the frame with a jack and use blocks or a jack stand to support th e frame. 2. Remove wheel nuts (Item 29) and remove wheel (Item 3).
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 1 1) pointed dow n. If motor is not firmly held in the vise, it could be dislodged during the service procedures, causing personal injury .
9. Place rotor set on a flat surface and center rotor (Item 19) in sta tor (Item 21 ) such that two rot or lobes are 180 ° apart an d a roller vane ( Item 20) centerl ine are on the same stator cente rline. Check the rotor lobe to roller vane clearance with a feeler ga ge at this com mon centerline.
9. Assemble manifold (Item 22) and then th e commuta- tor ring (Item 23) over the drive link onto rotor set. Be sure swirls in manifold and manifold plate are installed facing together .
Steering Cylinder Removal and Installation - Greensmaster 3100 (Fig. 39 ) Figure 39 1. Disconnect the hyd raulic hoses (Item 28, 29) from steering cylinder (Item 33).
Steering Cylinder Repair - Greensmaster 3100 (Fig. 40) Figure 40 IMPORT ANT : T o preven t damage wh en clampin g 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.
Steering Control Unit Removal and Installation - Greensmaster 3100 (Fig. 41) Figure 41 1. Remove six (6) capscr ews (Item 21) and remove the steering cover (It em 25). 2. Clean the outsid e of the steering valve and the area around the hyd raulic fitting s.
Steering Control Unit Repair - Greensmaster 3100 (Fig. 42) Figure 42 1. Dust seal 10. Housing 19. Capscrew 2. Retaining ring 1 1. Control sleeve 20. Centering pin kit 3. Gland bushing seal 12. Control spool centeri ng springs 21. Check ball retainer 4.
Meter (Gerotor) End Disassembly 1. Clamp u nit in vise, meter en d up. Clamp lightly on edges of mounting area. Use protec tive material on vise jaws. Housing distor tion could resu lt if jaws are over- tightened . 2. Remove 5/16" cap scr ews. 3.
7. Remove drive. 8. Remo ve spacer p late. 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 bla de screwdriver to pry re taining ring fr om housing.
12. Remove quad-ring se al from se al gland b ushing. 13. Use a thin b lade screwd river to pr y dust seal from seal gland bushing. Do not damag e bushing. 14. Remove 2 bearin g races and the needle thrust bearing fr om spool and sle eve assembly . 15.
17. Push spool partially from co ntrol end of sleeve, then remove 6 centering springs from spool ca refully by hand 18. Push spool back through an d out of sle eve. Rotate spool slowly when removing from sleeve. 19. Remove seal fr om housing. 20. Remov e set screw fr om housin g.
Reassembly Check all mating surfa ces. Replace any parts th at have scratches o r burrs that co uld cause le akage. Clean a ll metal parts in clean solvent . Blow dry with air . Do not wipe dry with cloth or paper to wel because lint or othe r matter can get into the hydraulic system and cause damage.
7. Bring spring slots of both parts in line and stand parts on end of bench. In sert spring insta llation tool through spring slots of bot h parts. T ool is availa ble from a Eaton Hydraulics supplie r as Eaton part no.
14. Install 1- 1/4" diame ter dust seal in seal gland bush- ing, flat or smooth side of dust seal must face down towards bushin g, see Fig. 60 . 15. Install the qu ad-ring seal in seal glan d bushing. Smooth seal in place with your finger . Do not use any seal that falls freely into po cket of bushing, see Fig.
18. Clamp h ousing in vise , as shown. Clamp lightly on edges of mounti ng area. Do not ov er tighten jaws. NOTE: Check to insure that the spool and sleeve are flush or slightly below the 14 hole surfac e of th e housing. IMPORT ANT : Clean the upper surface of the hous- ing by wiping with the palm of clean hand.
21. Rotate sp ool and sleeve as sembly until pin is para l- lel with port face. Insta ll drive, make sure y ou engage drive with pin, T o assure proper alig nment, mark d rive as shown in Fig. 65 (ref. B). Note relationship between slotted end of drive to splined end of drive when mark- ing.
24. Install 3" dia meter seal in end cap. 25. Install end cap on gerotor , align holes. 26. Insta ll seven (7) DR Y cap screws with n ew seal washers in en d cap. Pre-tighte n screws to 150 inch pounds, then torqu e screws to 275 inch pounds in sequence sh own.
Repairs Page 4 - 72 Greensmast er ® 3100.
Chapter 5 Electrical System T able of Contents WIRING SCHEMA TIC . . . . . . . . . . . . . . . . . . . . . . . 2 TURF GUARDIAN TM LEAK DETECTION SYSTEM . 3 SPECIAL T OOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TROUBLESHOOT ING . . . .
Greensmaster 3100 Page 5 – 2 Wiring Schematics Rev . D Wiring Schematic (Greensmaster 3100, S/N Below 80000) – + KEY SWITCH AMMETER TEST/LIGHT SWITCH ALARM HOUR METER ENGINE ST ARTER GROUND ST ART.
Greensmaster 3100/3050 Page 5 – 2.1 Wiring Schematics Rev . D Wiring Schematic (Greensmaster 3100, S/N 80001 – 200999999) BN BN FUEL SOLENOID MOW PEDAL SW . W ENGINE AL TERNA TOR (CLOSED WHEN OFF) MAGNETO PU BK ST ARTER SOLENOID BA TTERY ENGINE GND FRAME GND FL W PU SP 30 85 87 86 87a KILL RELA Y TRACTION HANDLE SW.
Greensmaster 3100/3050 Page 5 – 2.2 Wiring Schematics Rev . D Wiring Schematic (Greensmaster 3100, S/N 210000001 – 220999999) FUSIBLE LINK SPLICE SP Y YELLOW OR ORANGE FL GY GRA Y R PU PURPLE RED W WHITE BK BN BU BLACK BROWN BLUE W BN ENGINE FUEL SOLENOID AL TERNA TOR (CLOSED IN NEUTRAL) NEUTRAL SW .
Greensmaster 3100/3050 Page 5 – 2.3 Wiring Schematics Rev . D Wiring Schematic (Greensmaster 3100, S/N 230000001 and Up ) FUSIBLE LINK SPLICE SP Y YELLOW OR ORANGE FL GY GRA Y R PU PURPLE RED W WHITE BK BN BU BLACK BROWN BLUE W BN ENGINE FUE L S O L E N O ID AL TERNA TOR NEUTRAL SW .
Greensmaster 3100/3050 Page 5 – 2.4 Wiring Schematics Rev . D Wiring Schematic (Greensmaster 3050, S/N Below 80000) – + KEY SWITCH AMMETER LIGHT SWITCH HOUR METER ENGINE ST ARTER GROUND ST ARTER S.
Greensmaster 3100/3050 Page 5 – 2.5 Wiring Schematics Rev . D Wiring Schematic (Greensmaster 3050, S/N 80001 – 200999999).
Greensmaster 3100/3050 Page 5 – 2.6 Wiring Schematics Rev . D Wiring Schematic (Greensmaster 3050, S/N 230000001 and Up) W BN ENGINE FUEL SOLENOID ALTERNAT OR (CLOSED IN NEUTRAL) NEUTRAL SW .
Greensmaster 3100/3050 Page 5 – 2.7 Wiring Schematics Rev . D Wiring Harness (Greensmaster 3100/3050, S/N 80001 – 200999999) P 2 Mow Switch P 3 Traction Switch P 4 Seat Switch J 10 Harness ground .
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T urf Guardian TM Leak Detection System Before Start-Up (Cold Oil) With ignition switch of f, solenoid valve is ope n. Before start-up, hydraulic fluid is at level mar k of sight gauge (oil cold). Float is in raised position, keeping alarm circuit open.
Special T ools NOTE: Order s pecial too ls from the T O RO SPEC I AL T OO LS AND AP PLI CA TI ON S G UI DE ( CO M M ERC I AL PRODUCT S) . Some tools may be available from a local supplier .
Skin-Over Grease (Fig. 7) Special non-cond uctive grease wh ich forms a light pro- tective skin to help waterproof electr ical switches and contacts. Recom mended for all interlock sy stem con- nections.
T roubleshooting Remo ve all jewelry , especially rings and watches, before doing any electric al trou - bleshooting. Disconnect battery cables un- less the test requires battery voltage. For ef fective troublesh ooting and repairs, you must have a good un derstanding of the electrical circuits and components used.
Problem Cause Correction 5. Engine cran ks but does not start when sh ift selector and mow pedal are i n neutral . If engine cra nks, cause of p roblem is UNRELA TED to interlock wiring system. Engine or r ectifier plug loose . Key switch wiring c onnector loos e.
Problem Ca use Co rrection 1 1. Engine does not stop when ig- nition key is r otated to OFF posi- tion. Loose wire(s) in electrical syst em. Ignition switch is malfunc tioning. Engine tim ing or carbu retor out o f adjustment. Check all connectio ns and repa ir as necessa ry .
T esting It is often to the te chnician’ s advantage to lea ve the components intact in the electrica l system, and by studying the electrical troubles hooting charts and sche- matics, determine which co mponent is at fault.
Seat Switch (Fig. 9) 1. Disconnect the seat switc h wire connector and in stall a continuity tester or ohm meter between th e two leads of the seat switch. 2. Lower the seat. The continuity test er should sh ow no continuity . 3. Have the operator sit on th e seat, slowly depressin g the seat switch.
Mow/Lift Switch (Fig. 1 1) 1. Disconnect the mow/lift swit ch wire connector and install a continuit y tester or ohm meter between the two leads of the mow/ lift switch. 2. Push down on th e lift pedal and release it. There should be con tinuity when the mow pedal is disen- gaged.
Battery T erminal V oltage T est 1. Use a volt-ohm meter to measu re the voltage be- tween the battery te rminals. 2. If the voltage is less th an 12.3 V .D.C., the battery should b e charg ed. Hourmeter T est the hourmeter by disconnecting the wires and applying 12 V .
Repairs General Safety Interl ock Switch Service The following procedures sh ould be followed whenever a switch requires a djustment or r eplacement: 1. Be sure rubber boot is reinstalled in both switch grooves on th e button end of seat sw itch after it is properly ad justed.
T raction (Neutral) Switch Replaceme nt and Adjustme nt (Fig. 16) 1. Pull connector of f switch terminals of traction swit ch installed in v alve bank bon net on selecto r valve section . 2. Loosen the jam nut and un screw the switch fr om the mounting b racket.
Mow/Lift Switch Replaceme nt and Adjustment (Fig. 17 ) IMPORT ANT : Spool travel for 1, 2 and 3 spools must be correct before Mow/Lift swit ch can be adjusted. (See Rear Camsha ft Adjust ment in the Adjustments section of Chapter 4 - Hydrauli c System.
Bat tery Serv ice (Fig. 18, 19) IMPORT ANT : Before welding on the machine, di s- connect the negative (–) battery cable from the bat- tery to preven t damage t o the electrical system. IMPORT ANT : T o prevent damage to the electrical comp onent s, do not operat e th e engine wi th the battery cables disconnected.
Chapter 6 Wheels, Steering and Brakes T able of Contents SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Brake Adjustment . . . . . . . . . . . . . . . . . . .
Specifications Item Specification ______ _______ ______ _______ ______ ______ _______ ______ ________ ______ ______ _______ ______ ______ T ire pressu re 8 - 12 PSI fro nt 8 - 15 PSI rea r ___________.
Adjustments Brake Adjustment (Fig. 1) A brake adjustment rod is located on eac h side of the machine so the brakes can b e equally adjust ed. 1. Push down o n the bra ke pedal while d riving the machine; b oth wheels sh ould lock equ ally .
Repairs Brake Service (Fig. 2) Figure 2 Brake Disassembly 1 Place blocks on each sid e of opposite wheel, jack machine up and place blocks be neath fram e under wheel motor . 2. Remove wheel nuts (It em 29) and remove wh eel. Remove larg e nut (Item 4) securing wh eel hub (I tem 5) to motor sh aft.
Greensmaster 3100 Page 6 – 5 Repairs Rev . B Steering Arm (Greensmaster 3050) 1. Remove 1/2–13 x 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.
Greensmaster 3100 Page 6 – 6 Repairs Rev . B.
Chapter 7 4 Bolt Adjust Cutting Units T able of Contents SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL T OOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOT ING . . . . . . . . . . . . . . . . . . .
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Chapter 8 Single Point Adjust Cutting Units T able of Contents SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL T OOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TROUBLESHOOT ING . . . . . . . . . . . . . . . .
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Chapter 9 Grooming Reel Cutting Units T able of Contents SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL T OOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TROUBLESHOOT ING . . . . . . . . . . . . . . . . . . .
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Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 1 Chapter 10 Dual Point Adjust Cutting Units T able of Contents SPECIFICA TIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL T OOLS 3 . . . . . . . . . . . . . . . . . .
Greensmaster 31 0 0 Dual Point Adjust Cutting Units Page 10 - 2 Specifications Figure 1 DUAL POINT ADJUST UNIT 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 .
Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 3 Special T ools OTC (Owatonna T ool Company) supplies special tools for servicing T oro Commercial Products. The TORO SPECIAL T OOLS AND APPLICA TIONS GUIDE shows service tool applications.
Greensmaster 31 0 0 Dual Point Adjust Cutting Units Page 10 - 4 Inner Grease Seal Installation W asher inner grease seal installation washer T oro 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 .
Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 5 T roubleshooting There are a number of factors that can contribute to un- satisfactory quality of cut, some of which may be turf conditions.
Greensmaster 31 0 0 Dual Point Adjust Cutting Units Page 10 - 6 Factor Possible Problem/Correction 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.
Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 7 Set Up and Adjustments Characteristics CAUTION Never install or work on the cutting units or lift arms with the engine running.
Greensmaster 31 0 0 Dual Point Adjust Cutting Units Page 10 - 8 Repairs Hydraulic Reel Motor IMPORT ANT : 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.
Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 9 Backlapping (Units with Optional Backlap/V ariable Reel Speed Kit) DANGER TO A VOID PERSONAL INJUR Y OR DEA TH: Never place hands or feet in the reel area while the engine is running.
Greensmaster 31 0 0 Dual Point Adjust Cutting Units Page 10 - 10 Bedbar Assembly 1. Side plate 2. Rubber bushing 3. Flange bushing 4. W asher (plastic) 5. W asher (metal) 6. Bedbar 7. Bedbar pivot bolt 8. Flange nut 9. Flange nut 10. Shim 1 1. Spacer 12.
Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 1 1 Bedbar Removal and Installation Removal (Fig. 10) 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.
Greensmaster 31 0 0 Dual Point Adjust Cutting Units Page 10 - 12 Bedbar Adjuster Service Figure 12 1. Adjuster shaft 2. Flange bushing 3. Cutting unit frame 4. W ave washer 5. Jam nut 6. Adjuster screw 7. Detent 8. Lock washer 9. Cap screw 10. W asher 1 1.
Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 13 Bedknife Replacement and Grinding Removal 1. Remove bedbar from frame (see Bedbar Removal). 2. Re m ov e screws from bedbar using a socket wrench and bedknife screw tool (see Special T ools).
Greensmaster 31 0 0 Dual Point Adjust Cutting Units Page 10 - 14 Reel Assembly 1. Reel 2. Speedi sleeve 3. V–ring 4. Drive coupler 5. Retaining ring 6. Left side plate assembly 7. Shoulder bolt 8. Bearing lock nut 9. Outer grease seal 10. Right side plate assembly 1 1.
Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 15 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.
Greensmaster 31 0 0 Dual Point Adjust Cutting Units Page 10 - 16 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.
Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 17 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. Re mov e the retaining ring (5) and the drive coupler (4) from the end of the reel shaft.
Greensmaster 31 0 0 Dual Point Adjust Cutting Units Page 10 - 18 Reel Installation (Fig. 16) IMPORT ANT : Wipe any excess grease from the inner gr ea se 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.
Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 19 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.
Greensmaster 31 0 0 Dual Point Adjust Cutting Units Page 10 - 20 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.
Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 21 Front and Rear Roller Service 1. Roller seal 2. Spiral retaining ring 3. Roller bearing 4. Rear roller body 5. Roller shaft 6. Front roller body Figure 24 v 1 2 3 4 6 5 Seal Removal 1. Make a seal removal tool from a 1/4 x3 x 3 in (.
Greensmaster 31 0 0 Dual Point Adjust Cutting Units Page 10 - 22 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.
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Commercial Products © The Toro Company.
An important point after buying a device Toro 3100 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Toro 3100 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Toro 3100 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Toro 3100 you will learn all the available features of the product, as well as information on its operation. The information that you get Toro 3100 will certainly help you make a decision on the purchase.
If you already are a holder of Toro 3100, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Toro 3100.
However, one of the most important roles played by the user manual is to help in solving problems with Toro 3100. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Toro 3100 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
