Greensmaster 3100/3050, Preface | Toro instruction

Part No. 92784SL, Rev. E

Service Manual

Greensmaster® 3100/3050

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.

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

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Toro manual Greensmaster 3100/3050, Preface

Contents

Preface Greensmaster 3100/3050 This page is intentionally blank Table Of Contents This page is intentionally blank Safety Instructions Safety InstructionsChapter Before Operating While Operating Safety Instructions Greensmaster Safety Instructions Safety Instructions Greensmaster 2 1 Rev.. DB Product Records Product Records Decimal and Millimeter Equivalents Equivalents and ConversionsTo Metric Conversions Equivalents and Conversions Greensmaster Torque Specifications Torque SpecificationsCapscrew Markings and Torque Values U.S. Customary Capscrew Markings and Torque Values Metric This page is intentionally blank Specification Specifications3 1 Rev. D Specifications Throttle Control Adjustment Fig AdjustmentsChoke Control Adjustment Fig Adjustments Greensmaster Governor Lever Adjustment Fig Governor Adjustment Before starting engineThrottle Restrictor Adjustment Fig Secondary Spring Adjustments Fig Warnin G Carburetor and Speed Control Adjustment Installing the Engine Engine Removal and InstallationRemoving the Engine Engine Removal and Installation Greensmaster Hydraulic System Table of Contents Description Specifications 4 2 Rev. D General Information Hydraulic Fitting InstallationHydraulic Hoses Ring Face Seal SAE Straight Thread O-Ring Port Adjustable SAE Straight Thread O-Ring Port Non-adjustable FigGeneral Information Greensmaster Traction, No Position Hydraulic Flow Diagrams Hydraulic Flow Diagrams Greensmaster Traction, Reverse Position Reel Drive, Mowing Operation Hydraulic Flow Diagrams 4 8 Rev. E Greensmaster3100 4 9 Rev. E Reel Drive, Lower Cutting Units Reel Drive, Raising Cutting Units Hydraulic Flow Diagrams 4 10 Rev. E 4 11 Rev. E Power Steering, R.H. Turn Greensmaster Hydraulic Schematics Hydraulic Schematic Greensmaster 3100 2WD Serial Rev. E Hydraulic Schematics 4 12.2 Rev. E Hydraulic Schematic Greensmaster 3100 3WD 12.3 Hydraulic Schematic Hydraulic Schematics 4 12.4 Rev. E Greensmaster Hydraulic Tester Fig Special Tools Seal Protector Fig Detent Installation Tool FigSpecial Tools Greensmaster Assembly Studs Fig Seal Installation Tool FigControl Valve Spool Seal Installation Tools Fig Troubleshooting Greensmaster Troubleshooting Slow Groundspeed in All Traction Selections Troubleshooting Slow or No Ground Speed in No and Reverse No Appears Normal No Increase in Speed from No to No One or More Cutting Units Slow or No Reel Drive Action All Reels Slow or Will Not Turn Mow Pedal Won’t Stay Engaged Reels Slow Down or Stop Cutting Units Drop During Transport Cutting Units Lift Too Slowly or Not At All Center #1 Cutting Unit Operates in Raised Position Lift Pedal Binding Steering Loss, Steering Wander or Free Play Testing Testing Engine when the traction lever is engaged Traction Pump Flow Traction Relief SettingTesting Greensmaster Test Hook UP no Test B Relief Valve Setting Procedure Test Hook UP NO.2 4 30 Rev. E Testing Test Hook UP NO.2 Testing 4 31 Rev. E Greensmaster Testing 4 32 Rev. E Greensmaster3100 Engine when the mow pedal is engagedReel Drive Pump Efficiency 4 33 Rev. E Testing Test a Reel Drive Motor Flow Procedure Test Hook UP no Test Hook UP no Greensmaster 4 35 Rev. E TestingSteering Pump Flow and Relief Pressure Lift and Mow Pedal Height Adjustment Fig 4 37 Rev. B Adjustments Traction Pedal Adjustment FigTraction Return Linkage a Reverse Rear Camshaft Adjustment Fig Reel Motor Shaft Seal Replacement Fig Reel Motor Removal and Installation FigRepairs Repairs Repairs 4 40 Rev. B Reel Motor 70-9800 Repair Fig Repairs Repairs 4 41.1 Rev. B Greensmaster Reel Motor 94-3506 Repair a Greensmaster 4-41.2 Rev. B Repairs Reel Motor 105-9770 Repair b DisassemblyRepairs 4 41.3 Rev. D Greensmaster Greensmaster 4-41.4 Rev. D Repairs Inspection Repairs 4 41.5 Rev. D Greensmaster Reassembly This page is intentionally blank Repairs Greensmaster Pump Repair Greensmaster 3100 shown Fig Relief Valve Service Repairs Greensmaster Relief Valve Removal and Installation Fig Control Valve Removal and Installation FigGreensmaster Repairs Rear Bonnet Side Fig Control Valve Spool Seal Replacement Control Valve Internal Seal Replacement Fig Control Valve No Spool Detent Replacement Reassemble With the Following Procedures Control Valve No Spool Detent Replacement Fig No Center Lift Cylinder Fig Lift Cylinder Removal and Installation No and 3 Lift Cylinders Fig Lift Cylinder Repair No Center Fig Lift Cylinder Repair No and 3 Left and Right Fig Wheel Motor Removal and Installation Fig Wheel Motor Repair Disassembly of Motor Fig Before Assembling Motor Assembly of Motor Rotor, Stator and Vane Assembly Reverse steps 1 3 to install the steering cylinder Steering Cylinder Repair Greensmaster 3100 Fig Repairs Greensmaster Steering Control Unit Repair Greensmaster 3100 Fig Meter Gerotor End Disassembly Control End Disassembly Push pin from spool and sleeve assembly Repairs Control End Reassembly Repairs Repairs Greensmaster Repairs Repairs Greensmaster Repairs Repairs Greensmaster Electrical System Wiring Schematics 5 2 Rev. D Greensmaster Wiring Schematic Greensmaster 3100, S/N Below Wiring Schematics Wiring Schematic Greensmaster 3100, S/N 800015 2.1 Rev. D Greensmaster 3100, S/N Wiring Schematic220999999 5 2.2 Rev. D Wiring Schematic Wiring Schematics 5 2.4 Rev. D Greensmaster 3100/3050 Wiring Schematic Greensmaster 3050, S/N Below 5 2.5 Rev. D Wiring Schematics Wiring Schematic Greensmaster 3050, S/N 80001 Wiring Schematics 5 2.6 Rev. D Wiring Schematic Greensmaster 3050, S/N 230000001 and Up 200999999 3100/3050 This page is intentionally blank Normal Operation Warm Oil Before Start-Up Cold OilLeak Alert Volt Ohm Amp Meter Fig Continuity Tester Fig Skin-Over Grease Fig Condition Cause Correction Problem Cause Correction Verify Interlock Operation Ignition Key Switch Fig Traction Neutral Switch Fig Seat Switch Fig Interlock Module Fig Mow/Lift Switch Fig Hourmeter BatteryTurf Guardian TM Leak Detector System Seat Switch Replacement and Adjustment Fig General Safety Interlock Switch Service Traction Neutral Switch Replacement and Adjustment Fig Wiring Harness Service Mow/Lift Switch Replacement and Adjustment Fig Battery Specifications Battery Service 6 1 Rev. B Wheels, Steering and Brakes Specifications Greensmaster Brake Adjustment Fig Brake Disassembly Reassembly Brake Service Fig Steering Cable Greensmaster Steering Arm Greensmaster6 5 Rev. B Repairs Repairs 6 6 Rev. B Greensmaster Bolt Adjust Cutting Units Page Page Page Page Page Page Use Loctite 271 on spline nut Rev. C Page Page Page Page Page Page Page Page Page Page Use Loctite 271 on spline nut Rev. C Page Single Point Adjust Cutting Units Page Page Page Page Page Page Page Page Use Loctite 271 on spline nut threads Rev. C Page Page Page Page Page Page Page Page Page Page Page Page Page Use Loctite 271 on spline nut threads Rev. C Page Page Introduction For Four Bolt Adjust and Single Point Adjust Cutting Units9 1 Rev. D Introduction Page Page Page Page Page Page Page Page Page Page Use Loctite 271 on spline nut threads Rev. C Page Page Page Page Page Page Page Page Page Page Page Page Page Page Use Loctite 271 on spline nut threads Rev. C Page Page Page Page Page Page This page is intentionally blank 10 1 Rev. D Dual Point Adjust Cutting units Dual Point Adjust Cutting Units Dual Point Adjust Cutting Units 10 2 Rev. D WeightMaximum Reel Speed 2200 RPM Backlapping Brush Assembly Gauge Bar Assembly10 3 Rev. D Dual Point Adjust Cutting units Bedknife Screw Tool Dual Point Adjust Cutting Units 10 4 Rev. D Greensmaster Inner Grease Seal Installation WasherPlastic Plug Turf Evaluator Tool After installation to the bedbar Factor Possible Problem/Correction10 5 Rev. D Dual Point Adjust Cutting units Factors That Can Affect Quality of Cut Dual Point Adjust Cutting Units 10 6 Rev. D Greensmaster Characteristics Set Up and Adjustments10 7 Rev. D Dual Point Adjust Cutting units Dual Point Adjust Cutting Units 10 8 Rev. D Greensmaster InstallationHydraulic Reel Motor Removal To Avoid Personal Injury or Death 10 9 Rev. D Dual Point Adjust Cutting units Dual Point Adjust Cutting Units 10 10 Rev. D Greensmaster Bedbar Assembly Installation Fig Bedbar Removal and Installation10 11 Rev. D Dual Point Adjust Cutting units Removal Fig Dual Point Adjust Cutting Units 10 12 Rev. D Greensmaster Bedbar Adjuster Service Replacement Bedknife Replacement and Grinding10 13 Rev. D Dual Point Adjust Cutting units Grinding Dual Point Adjust Cutting Units 10 14 Rev. D Greensmaster Reel Assembly Reel Removal Fig 10 15 Rev. D Dual Point Adjust Cutting units Right Side Plate Service Fig Left Side Plate Service FigDual Point Adjust Cutting Units 10 16 Rev. D Greensmaster 10 17 Rev. D Dual Point Adjust Cutting units Reel Service Fig Dual Point Adjust Cutting Units 10 18 Rev. D Greensmaster Reel Installation Fig Preparing a Reel for Grinding 10 19 Rev. D Dual Point Adjust Cutting units Dual Point Adjust Cutting Units 10 20 Rev. D Greensmaster Front Roller Removal and Installation Seal Installation Front and Rear Roller Service10 21 Rev. D Dual Point Adjust Cutting units Seal Removal Dual Point Adjust Cutting Units 10 22 Rev. D Greensmaster Bearing InstallationBearing Removal This page is intentionally blank Commercial Products