MODEL NO. 04353 ~ 51200 thru 60001 & UP FORM NO. 3317742 Rev. A OPERATOR’S MANUAL — Helping you put quality into play.™ THIS UNIT CONFORMS TO ANSI B71.41960 The GREENS MASTER 3100 conforms to the American National Standards Institute’s safety standards for riding mowers when 40 Ibs. of ballasts added o rear wheel; thus Toto proudly displays the ANSI safety seal.
FOREWORD Your New GREENS MASTER 3100 was developed to provide an efficient, trouble free and time—saving method of awing high quality turf on the finest greens. The latest concepts in engineering, design and safely have been incorporated into this machine along with the highest quality parts and workmanship.
TABLE OF CONTENTS SAFETY INSTRUCTIONS . 3-5 SAFETY AND INSTRUCTION DECALS . 56 LOOSE PARTS 7 BEFORE OPERATING . 12 Check Engine Oil 12 SPECIFICATIONS .. 8 SET UP INSTRUCTIONS G—11 Remove, Activate and Charge Battery .. 9 Install Rear Wheel Assembly 9 Mount Seat 8 install Battery 10 Mount Steering Wheel 10 install Cutting Units ., . 10 Rear Ballast 1 BEFORE OPERATING . 12-13 Check Engine Qit . 12 Filling Gas Tank .12 Check Hydraulic System 13 Tire Pressure .
SAFETY INSTRUCTIONS 3. Become familiar with the controls and know how to stop the engine quickly. 4, Keep all shields, safety devices and decals in place. If a shield, safety device or decal is defective or damaged, repair or replace it before operating the machine. 5. Always wear substantial shoes. Do not operate machine while wearing sandals, tennis shoes or sneakers. Do not wear loose fitting clothing because it could get caught in moving parts and possibly cause personal injury. 6.
SAFETY INSTRUCTIONS 25. DON'T 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 led to thrown object injuries. Do not resume awing until area is cleared. 26. Whenever machine is left unattended, make sure putting units arg fully raised and reels are.not spinning, key is removed from ignition switch and parking brake is set. MAINTENANCE 27.
SAFETY AND INSTRUCTION DECALS DEPRESS —re L Alnilam MOW PEDAL T e BELOW MOW AND LIFT PEDALS (Part No. §1-0050) IMPORTANT WARNING HOT ENGINE MAXIMUM GOVERNED SPEED MUST NOT EXCEED 2850 RRM. ¥ ON AIR CLEANER {Part No. 71-3620) ON ENGINE (Part No. 63-8440) DANGER A WARNING] 724 I o AREA WHILE ENGINE 1S RUNNING. [ INSTRUCTIONS \ T CHANGE STEERING ARM POSITION: ON CUTTING UNIT PULL FRAMES 4 e (Part No. 62-5070) ‘ 9 T BANSHEES i o AT ON STEERING ARM Part No. §3-2050! ON STEERING COLUMN { ) (Part No.
LOOSE PARTS Description Gty. Use Seat Hex Nut 5/16 — 18 Seat Cover Mount seat slides and seat cover to seat haj i Wheel Assembly Mount to castor fork Rear Spindle Spacer 1D Steering Wheel Nut Cap Screw Mount steering wheel Cap screw Secure battery cables to battery Nutty 20 Y Gauge Bar Machine Screw 5/8" Ig.
SPECIFICATIONS Configuration: Conforms to ANSI B71 .4 — 1990 specifications. Tricycle vehicle with front two wheels providing drive and rear wheel providing steering. Operator sits in center over No. 1 cutting unit with cutting units in front of vehicle. Power: 4—cycle gasoline engine, electric start, with output 3600 RPM. Maximum no load governed engine speed is 2850 RPM. Traction: All hydraulic drive, consisting of multiple stack pump, valve, and two orbital gear motors to drive front wheels.
SET UP INSTRUCTIONS REMOVE, ACTIVATE AND CHARGE BATTERY 1.7 Remove wing ‘nuts, washers, and battery clamp and [ift out battery. A\ warning Electrolyte gases are explosive and can cause serious injury to eyes, lungs and skin, Wear safety goggles and rubber gloves when working with electrolyte or battery. Charge the battery in a well ventilated place so gasses produced while charging can dissipate. Since the gases are explosive, keep open flames and electrical spark away from the battery; do not smoke.
SET UP INSTRUCTIONS 3. Connect the two black ground cables, one connected to engine base, the other to the machine frame, to the negative post of the battery. Secure with wrench and coat terminal with petroleum jelly. 4. Install battery clamp, washers, and secure with wing nuts, 5. Place terminal cover over positive battery post. INSTALL STEERING WHEEL (Fig. 5) 1. Slide steering wheel onto steering shaft. Figure 3 1. Seat support 2. Seat slide 3. Seat panel INSTALL BATTERY (Fig. 4) 1.
SET UP INSTRUCTIONS Figure 6 1. Hoop 3. Phil frame 2. Lift arm 4, Pull arm 3. Assemble the mount nuts for the reel drive motor to each cutting unit. Leave approximately 1/2 in. of threads exposed on each mount stud {Fig. 7). Figure 7 1. Motor mount nuts 2. Coat with grease 4. Remove the protective covers from the cutting units and the reel drive motor shafts. Coat the spline shaft of the motor with clean grease and install the motor by rotating the motor clockwise so the motor flanges clear the studs.
BEFORE OPERATING CHECK ENGINE OIL (Fig. 11) The engine is shipped with 1-3/4 quarts (w/ filter) of oil in the crankcase; however, level of oil must be checked before and after engine is first started. 1. Position machine on a level surface, 2. Unscrew dipstick and wipe it with a clean rag. Screw dipstick into the tube and make sure it is seated fully. Unscrew dipstick out of tube and check level of oil.
BEFORE OPERATING CHECK HYDRAULIC SYSTEM (Fig. 13) The hydraulic system Is designed to operate on Mobil DTE 26 or equivalent anti—wear hydraulic fluid. The machines large hydraulic oif tank and smaller auxiliary oil tank are filled at the factory with approximately 8.5 gallons of fluid. However, check level of hydraulic fluid before engine is first started and daily thereafter.
CONTROLS MOW PEDAL (Fig. 14) — Depressing Mow Pedal FULLY during operation lowers the cutting units and starts the reels. The Mow Pedal will stay depressed due to detente action of the valve bank during operation. Operator need not hold pedal down, Figure 14 1. Mow pedal 4, Brake pedal 2. Lift peat 8. Parking brake button 3. Traction pedal BRAKE PEDAL (Fig.14) —The Brake Pedal actuates an automotive drum—type mechanical brake located at each traction wheel. LIFT PEDAL (Fig.
CONTROLS AMMETER (Fig. 16) — The ammeter indicates the rate of battery charge and discharge. Note: During normal operation there will be lite or no movement of the Ammeter needle, FUSE (Fig.16) — Fuse is part of the electrical circuit. it contains a 20 Amp fuse. LEAK DETECTOR TEST / LIGHT SWITCH (Fig.16) — From middle operating position, move switch rearward to check operation of leak detector alarm and time delay. Move switch forward 1o operate optional headlights. HOUR METER (Fig.
INSTRUCTIONS BREAK-IN PERIOD 1. Refer to the Engine Manual supplied with the Greens master 3100 for oif change and maintenance procedures recommended during break—in period. 2. Only 8 hours of mowing operation is required for the Greens master 3100 break—in period. 3. Since the first hours of operation are critical o future dependability of the machine, monitor its functions and performance closely se that minor difficulties, which could deaf to major problems, are noted and can be corrected.
INSTRUCTIONS 2. Synthesis seat, engage parking brake and depress; lift pedal fully and release it. Move shift selector to #1 son. if engine does not stop, stop the engine and find and #2 positions while trying to start the engine in each the problem before operating machine again. If assistant rank; which-means stance required; contact your locate TOR Distributor: traction switch on valve bank is operating correctly. If engine did not crank, proceed to step 3.
INSTRUCTIONS Float Down Bobwhite Closed Fluid Level Down 4 to 6 ounces LEAK ALERT! Figure 21 To check system operation A, With ignition switch in the “ON” position, move Leak detector switch rearward and hold. After the one second time delay elapses the alarm should sound. B. Release leak detector switch. To check leak detector system operation A. Move ignition switch to "ON” position. DO NOT START ENGINE. B. Remove hydraulic tank cap and strainer from neck of tank. C.
OPERATING INSTRUCTIONS BEFORE MOWING inspect the green for debris, remove the flag from the cup, and determine the direction best to mow: Base the direction to mow on the previous mowing direction. Al ways mow in an alternate pattern from the previous mowing, so that the grass blades will be less apt to lay down and therefore be difficult to trap between the reel blades and bed knife. MOWING PROCEDURES 1. Approach the green with the shift selector in the No. 1 position.
OPERATING INSTRUCTIONS LEAK DETECTOR OPERATION The leak detector alarm may sound for one of the following reasons: 1. Leak, ounces, has occurred. 2. The oil level, in the main reservoir, is reduced ounces due to contraction of oil by cooling. if the alarm sounds, it should be muted of as quickly as possible and inspected for leaks. if the alarm sounds while operating on a green it may be appropriate to drive off the green first.
LUBRICATION A\ caution Before servicing or making adjustments to the machine, stop engine and remove key from the switch. The traction unit has grease fittings that rust be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hoers of operation. The traction unit bearings and bushings that must be {lubricated are: Rear wheel bearings (1) (Fig. 25), Steer: AR ing fork saith (1) (Fig.
DAILY MAINTENANCE CHECKLIST Daily Maintenance: (duplicate this page for routine use} Maintenance ally Maintenance Check For Week Of Check stem » MON | TUES | WED |THURS | FRI SAT SUN » Safety Interlock Operation instrument Operation Leak Detector Alarm Brake Operation » Fuel Level Engine Oil Level Clean Engine Air Cooling Fins inspect Alr Filter Uncleaner » Unusual Operating Noises » Hydraulic System Oil Level » Hydraulic Hoses for Damage » Fluid Leaks » Tire Pressure =~ Reel-to-Bed knife Adjustment = Heigh
MAINTENANCE A\ caution Before servicing or making adjustments to the machine, stop engine and remove key from the switch, CHANGING ENGINE OIL AND FILTER (Fig. 32) Change oil initially after the first 8 hours of operation, thereafter change ofl every 50 hours and filter every 100 hours. 1. Remove drain plug and let oil flow info drain pan. ‘When oil stops, install drain plug. Figure 32 1, Drain plug 2. il filter 2. Remove oil filter. Apply a light coat of clean oil o the new fitter gasket. 3.
MAINTENANCE ADJUSTING THROTTLE CONTROL (Fig. 35) Proper throttle operation is dependent upon proper adjustment of throttle control. Before adjusting the carburetor, assure the 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. Faultfinder on throttle cable until back of swivel contacts stop. 1. Throttle saving clamp screw 2. Throttle cable 3. Swivel 4. Stop 5. Choke casing clamp screw 8.
MAINTENANCE 4. After the idle mixture has been adjusted, hold governor lever so throttle lever is in idle position (against idle stop screw) and readjust idle stop screw to bring §sped o 1200+ 50 tpm: 8. With governor control lever in governed die position {no tension on high speed spring} bend governed idle spring anchor tang to attain governed idle speed of 1400:+ 80 rpm. 6. Move throttle control to FAST position. Bend high speed spring anchor tang to attain high speed of 2800 + 50 —100 rpm.
MAINTENANCE Figure 39 1. Hydraulic Reservoir Drain Plug 2. Clean area around filter mounting area . Place drain pan under filter and remove filter. Figure 40 1. Hydraulic Filter 3. Fill the replacement filter with Mobil DTE 26 hydraulic fluid, lubricate the sealing gasket and hand tum urinal gasket contacts filter head. Then tighten 3/4 turn further. Filter should now be sealed. 4. Silt large hydraulic tank and small auxiliary tank with approximately 8.5 gallons of hydraulic oil.
MAINTENANCE 5. Check the amount of free travel of the brake pedal when adjustment is completed. There should be 1/2in. to 1in. travel before the brake shoes make contact with the brake it necessary, to-achieve this setting. 6. Transport the Greens master 3100 and depress the 3. Move adjustment lever by hand to level the mow brake pedal, both brakes should lock equally. Read and lift pedals and adjust yoke on control rod until hole just, if necessary. in yoke lines up with the adjustment lever hole, 1.
MAINTENANCE 1. Loosen nut on back side of luff pivot. 2. Rotate eccentric screw to raise or lower [ift pivot spring, leveling lift pivot and pedals. Figure 45 1. Lift Pivot 2. Eccentric Screw 3. While holding screw, tighten nut locking adjustment ADJUSTING TRACTION PEDAL (Fig. 46) To check forward and reverse operation of traction pedal proceed as follows: Forward 1. Press traction pedal fully forward until No. 5 section, valve spool is completely pooled out.
MAINE Figure 47 1, Seat switch 2. Reaction switch 3. Liftoff switch 3. Loosen the jam nut and unscrew the switch from mounting bracket. 4. Screw new switch through mounting bracket unit switch button is about 1/16 inch shorter than the top of the seat return spring pin. Install the boot into the mount grooves. 8. Carefully release the seat to its normally down position, but do not sit or apply force on the seat, There should be a slight gap between the switch and the seat plate. 6.
MAINTENANCE ADJUSTING TRACTION RETURN LINKAGE (Fig. 49) If shift selector lever does not return to Neutral or #1 position from #2 position when warrior pedal is engaged, an adjustment to the traction return linkage is required. 1. Loosen frost jam nut securing cable assembly to mow/lift control rod bracket. 2. Move shift lever to #1 position. 3. While holding mollify control rod in rear position, tighten rear knockout to remove almost all slack from cable assembly. Do not over—tension cable. Figure 49 1.
TROUBLE SHOOTING CONDITION CAUSE CORRECTION ENGINE:; 1. Loss of power Out of fuel, o FAA-fill fuel tank. Clogged fuel line — debris in fuel * Clean fuel tank. Use clean kart, gasoline. Clogged fuel filter. Low crankcase ofl level. Replace filter. Add ol to proper level. Check level more frequently. Wrong oit in crankcase. » Replace with correct oil. © Check solenoid and wiring Carburetor fuel solenoid » Repair as necessary. Throttle cable set incorrectly. » Readjust. Hoke closed. * Replace element.
TROUBLE SHOOTING CONDITION CAUSE CORRECTION Reverse Traction speed. Normal #2 speed, Traction motor lacks efficiency. Fluid leaking past internal gears. Hydraulic pump lacks efficiency. Fluid leaking past internal gears. Test to identify faulty motor. Repair or replace motor. Test to verify diagnosis. Repair or replace pump. 4. Slow or no traction in all selections. Brakes dragging. Faulty O~ring seals around traction relief cartridge or inlet sleeve in #4 spool valve, Fluid teaching by to tank.
TROUBLE SHOOTING CONDITION CAUSE CORRECTION 12.Cutting units drop while making i stored. {Overnight) Normal condition. No repair necessary. 13.0ne or more cutting units slow or no reel drive action. Bed knife to reel adjustment too tight. Tight reel bearings. Rear camshaft maladjusted. Poppet in relief cartridge off seat. Improper suction line(s) installed. Line collapsed Blockages in line fitting. Excessively worn motor, Slow reel rom — No. 1 C.UL Excessively wom pump. Pool loose in valve body.
TROUBLE SHOOTING CONDITION CAUSE CORRECTION 18.Leak detector alarm astounding. | » Leak detector float switch not + Check operation of leak detector operating properly. float switch and wiring. « Time delay operating incorrectly « Replace. o Alarm not operating + Replace. « Electrical malfunction o Testis verify. Repair as necessary. « Solenoid valve fails 16 close. + Repair as necessary. ELECTRICAL: 1.
TROUBLE SHOOTING CONDITION CAUSE CORRECTION 6. Engine does not stop when mow pedal is depressed (reels ent aged} as you get off the seat. Mow/lift or seat switch adjusted . incorrect or are defective. Seat return pin spring broken, . missing or jammed down. Refer to Mow/Lift Switch Maintenance. Refer (0 Seat Switch Maintenance. Seat pivot fails to rotate freely. » Replace, loosen and lubricate parts so pin operates freely. » Loosen and lubricate seat pivot pin to assure free movement, 7.
MAINTENANCE SCHEDULE Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Check Battery Fluid Level Every Check Battery Cable Connections 50 hrs Service Air Filter Uncleaner Lubricate All Grease Fittings T Change Engine Ol Every Eve Every 1 200hrs 800hrs Replace Engine Qil Sifter Replace Air Filter Element Check Reel Bearing Reload Adjustment $ Torque Wheel Lug Nuts Replace Spark Plugs Replace Fuel Filter Carbon Combustion Chambers Torque Heads and Adjust Valves Che
STORAGE if you wish to store the GREENS MASTER 3100 for a long period of dime, the following steps should be accomplished prior o storage: 1. Remove accumulations of dirt and old grass clippings. Sharpen reels and bed knives, if necessary: refer to Cutting Unit Operator's Manual, Use a just preventive on bed knives and reel blades, Grease and oil all fabrication pants: refer to Lubrication. 2. Block up wheels 10 remove tire weight. 3.
g ' 2. The TOR Distributor or Commercial Dealer | routine maintenance of the unit 10 keep it in i will advise you on the arrangements that can be proper operating condition is the responsibility made fo inspect and repair your product. of the owner, i All warranty repairs reimbursable under The Toto g : Promise must be performed by an Authorized . Thi ;Lucile ‘Sfi:ti Toto Catercorner Dealer or Distributor using Toto | ether product is defective and, ¥f sq, make all approved replacement parts.