FORM NO. 3324-858 MODEL NO. 04356—200000001 AND UP ® OPERATOR’S MANUAL GREENSMASTER® 3100 To understand this product, and for safety and optimum performance, read this manual before starting operation. Pay special attention to SAFETY INSTRUCTIONS highlighted by this symbol. The safety alert symbol means CAUTION, WARNING or DANGER—personal safety instruction. Failure to comply with the instruction may result in personal injury.
Forward The Greensmaster 3100 was developed to provide an efficient, trouble-free and time-saving method of mowing high-quality turf on the finest greens. The latest concepts in engineering, design and safety have been incorporated into this machine, along with the highest quality parts and workmanship. This product will provide excellent service if you follow proper operation and maintenance practices.
Safety Training • Store fuel in containers specifically designed for this purpose. 1. Read the instructions carefully. Be familiar with the controls and the proper use of the equipment. • Refuel outdoors only and do not smoke while refueling. 2. Never allow children or people unfamiliar with these instructions to use the lawn mower. Local regulations may restrict the age of the operator. • Add fuel before starting the engine.
• stay alert for bumps and hollows and other hidden hazards; • never mow across the face of the slope, unless the lawn mower is designed for this purpose. 6. Use care when pulling loads or using heavy equipment. • Use only approved drawbar hitch points. • Limit loads to those you can safely control. • Do not turn sharply. Use care when reversing. • Use counterweight(s) or wheel weights when suggested in the instruction handbook.
Sound & Vibration Levels Sound Levels This unit has an equivalent continuous A-weighted sound pressure at the operator ear of: 86 dB(A), based on measurements of identical machines per 84/538/EEC. This unit has a sound power level of 100 dB(A)/1pW, based on measurements of identical machines per procedures outlined in Directive 79/113/EEC and amendments. Vibration Levels This unit has a vibration level of 2.5 m/s2 at the posterior, based on measurements of identical machines per ISO 2631 procedures.
Symbol Glossary Caustic liquids, Poisonous Electrical shock, chemical burns to fumes or toxic electrocution fingers or hand gases, asphyxiation Crushing of whole body, applied from above Explosion Shut off engine & remove key before performing maintenance or repair work Crushing of High pressure High pressure Crushing of spray, erosion of spray, erosion of fingers or hand, toes or foot, force flesh flesh force applied from applied from above above Crushing of Crushing of fingers Crushing of leg, Crush
Symbol Glossary 7
Reel 3 Engine coolant pressure Engine coolant f Engine ilter lubricating oil pressure Engine failure/ malfunction Engine rotational Choke speed/frequency Engine intake/ Engine intake/ combustion air combustion air pressure Engine intake/ air filter Engine start Engine stop n/min Primer (start aid) Electrical preheat Transmission oil Transmission oil Transmission oil (low temperature pressure temperature start aid) NH L F RP Transmission Clutch failure/malfunction Neutral High Low Forward Reve
Specifications Configuration: Tricycle vehicle with the front two wheels providing drive and the rear wheel providing steering. The operator sits in the center over the No. 1 cutting unit with the No. 2 & 3 cutting units in front of the vehicle. Drive Wheels: Needle provided in wheel motors. Rear Caster Wheels: Timken tapered roller Electrical & Instrumentation: The engine contains a 18-amp alternator; the circuit is fused at 20 amps. Instruments include ammeter and hour meter.
Set-Up Install the Cutting Units For Cutting Unit Models 04404, 04406, 04408 04450 and 04468. Note: When sharpening, setting height of cut, or performing other maintenance procedures on the cutting units, store the cutting unit reel motors in support tubes on the front of the frame to prevent damage to the hoses. 1. 2. Figure 2 1. Motor mount nuts 2. Coat with grease Remove the cutting units from their cartons. Assemble and adjust according to the operator’s manual for the cutting units.
of cut. 2. Mount a washer and ball stud to each end of the front roller on the cutting units (Fig. 5). 3. Slide the cutting unit under the pull frame while hooking the lift roller onto the lift arm (Fig. 5). Figure 3 1. 2. 3. 4. 7. Jam nut Pull arm Ball joint-adjust for clearance 6–11mm clearance Align the sockets in the ball joints so the open side of the socket is centered toward the ball stud. Tighten the jam nuts to secure the sockets in position (Fig. 3). Figure 5 1. 2. 3. 4. 5. Figure 4 1.
10. Coat the spline shaft of the motor with clean grease and install the motor by rotating the motor clockwise so that the motor flanges clear the studs. Rotate the motor counterclockwise until the flanges encircle the studs, then tighten the mounting capscrews (Fig. 7). Rear Ballast This unit complies with the ANSI B71.4-1999 Standard when 40 lbs. of calcium chloride ballast is added to the rear wheel. Figure 6 1. Ball joint 2. Pull arm 3. Jam nut Important If a puncture occurs in a tire with 6.
Before Operating Check the Engine Oil Fill the Gas Tank DANGER The engine is shipped with 1.7 liter (with filter) of oil in the crankcase; however, the level of oil must be checked before and after you first start the engine. 1. Position the machine on a level surface. 2. Unscrew the dipstick and wipe it with a clean cloth. Screw the dipstick into the tube and make sure it is seated fully. Unscrew the dipstick and check the oil level.
Gulf Kendall Marathon Pennzoil Phillips Shell 76 Lubricants Sunoco Texaco 1 Universal Tractor Fluid Hyken 052 Marafluid Super HT Hydra-trans HG Fluid Donax TD Hydraulic/Tractor Fluid TH Fluid TDH Group 2 Hydraulic Fluid (Hot Climate—Heavy Duty) Figure 9 1. Fuel tank cap Note: The fluids within this group are interchangeable. Check the Hydraulic System ISO VG 68 anti-wear hydraulic fluid The hydraulic system is designed to operate on antiwear hydraulic fluid.
filter back-pressure due to the higher viscosity of these fluids. 2 3 Note: When changing from one type of hydraulic fluid to another, be certain to remove all the old fluid from the system because some brands are not completely compatible with other brands of hydraulic fluid. Group 3 Hydraulic Fluid (biodegradable): ISO VG 32/46 anti-wear hydraulic fluid Mobil 1 EAL 224H Note: This biodegradable hydraulic fluid is not compatible with the fluids in groups 1 or 2 Figure 10 1. Sight gauge 2.
Controls MOW PEDAL (Fig. 11)—Depressing the mow pedal FULLY during operation lowers the cutting units and starts the reels. The mow pedal will stay depressed so the operator need not hold the pedal down. THROTTLE CONTROL (Fig. 13)—The throttle controls the engine speed. Moving the throttle control toward FAST increases engine rpm; moving the throttle toward SLOW decreases engine rpm. BRAKE PEDAL (Fig. 11)—The brake pedal actuates an automotive drum-type mechanical brake at each traction wheel.
the switch and turn it clockwise to the START position to start the engine. Release the key as soon as the engine starts. Turn the key counter-clockwise to OFF to stop the engine 1. Neutral—Used for starting the engine. 2. No. 1 Position—Used for greens mowing operation. 3. No. 2 Position—Used for transport operation. VOLTMETER (Fig. 13)—The ammeter shows the electrical system voltage. NOTE: If you operate the machine in reverse with the cutting units down, they will be pulled off the lift arms.
Operating Instructions 6. Break-In Period 1. Refer to the engine manual supplied with the Greensmaster 3100 for oil change and maintenance procedures recommended during break-in. 2. Only 8 hours of mowing operation is required for the Greensmaster 3100 break-in period. 3. 4. A. Move the throttle control to FAST and momentarily engage the reels by depressing the mow pedal (the cutting units should drop and all reels should turn). B. The first hours of operation are critical to future dependability.
assistance. sure the interlock system operates correctly. CAUTION The interlock switches are for the operator’s protection, so do not disconnect them. Check switch operation daily to assure the interlock system is operating. If a switch is defective, replace it before operating. Regardless of whether the switches are operating properly, replace them every two years to assure maximum safety. Do not rely entirely on safety switches—use common sense! Figure 16 1. 2. 3. 4. 1. Traction switch 2.
engine will stop if the traction shift selector is in #1 or #2 positions with the parking brake engaged. Check the Leak Detector Operation 2 1 The TURF GUARDIAN™ leak detector detects hydraulic oil system leaks. If the oil level in the main hydraulic reservoir is lowered by 12–18 cl, the float switch in the tank will close. After a 1-second delay, the alarm will sound. Expansion of oil, due to normal heating during machine operation, will cause oil to transfer into the auxiliary oil reservoir.
5. Install the strainer screen and the hydraulic tank cap. Move the ignition switch to OFF. Before Mowing Inspect the green for debris, remove the flag from the cup, and determine the best direction in which to mow. Base the direction to mow on the previous mowing direction. Always mow in an alternate pattern from the previous mowing, so that the grass blades will be less apt to lay down and become difficult to trap between the reel blades and bedknife. 1 Mowing Procedures 2 3 1. Figure 20 1.
4. 5. area away from the green. Find out what caused the alarm and correct the problem. As the front of the baskets cross the edge of the green, depress the lift pedal. This will stop the reels and lift the cutting units. Timing of this procedure is important, so the mowers do not cut into the fringe area. However, as much of the green as possible should be cut to minimize the amount of grass left to mow around the outer periphery.
Transport Operation Make sure the cutting units are in the highest UP position. Set the shift selector in No. 2 if conditions will permit faster ground speed. In rough or hilly areas, shift to No. 1 and operate at slower ground speeds. Use the brakes to slow the machine while going down steep hills to avoid loss of control. Always approach rough areas at a reduced speed (shift selector in No. 1), and cross severe undulations carefully. Familiarize yourself with the width of the machine.
Maintenance Maintenance Schedule Maintenance Procedure Check battery fluid level Check battery cable connections Service the air filter pre-cleaner Lubricate all grease fittings ✝Change the engine oil Maintenance Interval & Service Every 50 hours Every 100 hours Every 200 hours Every 800 hours ✝Replace the engine oil filter Replace the air filter element Check the reel bearing preload adjustment Torque the wheel lug nuts Replace the spark plugs Replace the fuel filter Check valve clearance Check the en
Daily Maintenance Checklist ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Safety Interlock Operation Brake Operation Engine Oil & Fuel Level Cooling system Fluid Level Radiator & Screen for Debris Unusual Engine Noises Unusual Operating Noises Hydraulic System Oil Level Hydraulic Hoses for Damage 25 Fluid Leaks Tire Pressure Instrument Operations Lubricate All Grease Fittings Touch-up Damaged Paint
Lubrication Before servicing or making adjustments to the machine, stop the engine and remove the key from the switch. The traction unit has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If the machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation. Figure 23 The traction unit bearings and bushings that must be lubricated are: Rear wheel roller clutches and external ball bearing (1) (Fig.
Figure 29 Figure 26 Figure 27 Figure 28 27
1. CAUTION Release the locking clips and remove the air cleaner cover. Clean the cover thoroughly. Before servicing or making adjustments to the machine, stop the engine and remove the key from the switch. 1 Changing the Engine Oil and Filter Change the oil and filter initially after the first 8 hours of operation, thereafter change the oil every 50 hours and the filter every 100 hours. 1. Remove the drain plug and let oil flow into a drain pan. When oil stops flowing, install the drain plug.
C. SATURATE the element with clean engine oil. Squeeze the element to remove excess oil and to distribute oil thoroughly. An oil damp element is desirable. 4. 5. engine RPM setting. High Idle: 2850 ± 50 rpm Low Idle: 1400 ± 50 rpm Adjusting the Choke Control When servicing the foam element, check the condition of the paper element. Clean by gently tapping on a flat surface or replace as required. Reinstall the foam element, paper element and the air cleaner cover.
2. 3. 3. Move the throttle control to the SLOW setting. Hold the governor lever so that the throttle lever is in the idle position (against idle stop screw) and adjust the idle stop screw to 1400 ± 50 rpm by turning the screw in or out. Check speed with a tachometer. Important A cracked, fouled, dirty or otherwise malfunctioning spark plug must be replaced. Do not sand blast, scrape, or clean electrodes using a wire brush because grit may release from the plug and fall into the cylinder.
hazard. Wipe up any gasoline that may have spilled. Do not drain gasoline near any open flame or where a spark may ignite gasoline fumes. Do not smoke a cigar, cigarette, or a pipe when handling gasoline. 1. Close the fuel shut-off valve, loosen the hose clamp on the carburetor side of the filter and remove the fuel line from the filter. 2. Place a drain pan under the filter, loosen the remaining hose clamp and remove the filter. 3.
CAUTION Keep your 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 skin and cause injury. Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. 5. Check the amount of free travel of the brake pedal when adjustment is completed. There should be 1.2–2.
mow pedal height. 2 Adjusting the Lift and Mow Pedal Height 1 3 4 Adjust the lift and mow pedal to equal height to gain proper spool travel in the valve bank as follows: 1. Place 1, 2 and 3 spools in neutral (center of travel) and remove the transfer rod guard from the foot panel. 2. Loosen the jam nut securing the yoke on the front of the long control rod; remove the cotter pin and clevis pin. 3.
control rod to attain 4.8mm dimension when reinstalled. Forward 1. 2. Press the traction pedal fully forward until the No. 5 section, valve spool is completely pulled out. Adjusting the Cutting Unit Lift/Drop The pedal should contact the pedal stop. If the pedal contacts the stop before the spool is completely out, or if the pedal does not make contact with the stop, the stop must be adjusted. 1. The machine’s cutting unit lift/drop circuit is equipped with a flow control valve.
shorter than the top of the seat return spring pin. Install the boot into the mount grooves. Adjusting the Lift Cylinders To regulate the height of the front cutting units when in the raised (transport) position, the front lift cylinders may be adjusted. 1. Lower the cutting units to the floor. 2. Loosen the jam nut on the clevis of the cutting unit lift cylinder you wish to adjust. 3. Disconnect the cylinder clevis from the lift arm. 4. Rotate the clevis until you attain the desired height. 5.
the jam nut is over-tightened. 8. 9. Connect a continuity tester or ohm meter to the switch terminals and move shift selector to the #1 and #2 positions. There should not be continuity when the shift selector is in either of these positions. If there is continuity, repeat steps 5 and 6. Move the shift selector lever to neutral and connect a continuity tester or ohm meter to the switch terminals. The switch should show continuity. This means the switch is operating correctly.
If the Greensmaster 3100 is stored in a location where temperatures are extremely high, the battery will run down more rapidly than if the machine is stored in a location where temperatures are cool. Since the gasses from the battery and the gasoline fumes are explosive, keep open flame and electrical sparks away from the area; do not smoke. 2. Check the electrolyte level every 50 operating hours or, if the machine is in storage, every 30 days. 3.
Troubleshooting CONDITION CAUSE CORRECTION ENGINE: 1. Loss of power • Out of fuel • Clogged fuel line—debris in the fuel tank • Clogged fuel filter • Low crankcase oil level • • • • • Wrong oil in the crankcase Carburetor fuel solenoid Throttle cable set incorrectly Choke closed Plugged air cleaner element • Carburetor malfunction • Ignition malfunction • Cooling fins plugged with debris.. Engine overheating. • Internal engine malfunction • Engine-pump coupling loose • Hydraulic system malfunction 2.
CONDITION 3. No #1 or Reverse Traction speed. Normal #2 speed. 4. Slow or no traction in all selections. CAUSE • 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 the motor. • Brakes dragging • Faulty O-ring seals around the traction relief cartridge or the inlet sleeve in #4 spool valve. Fluid leaking by the tank. • Worn or weak traction motor(s).
CONDITION 11. Cutting units drop during transport (between greens) CAUSE • Internal lift cylinder leak • Lift check plug seals in the #1 spool body are defective • The detent stud in the #1 spool is loose • #1 spool is loose in valve body Fluid bypassing. CORRECTION • Raise units & block them up. Remove lines from brazed tube & remove blocks. Line which leaks fluid is attached to bad cylinder. Repair cylinder. • Remove lift check plugs. Replace O-ring assemblies.
CONDITION CAUSE CORRECTION 16.Mow pedal won’t stay down unless it is held down with foot. (#1 spool not in “detent”). • The rear camshaft is maladjusted. • Defective #1 spool detent • Readjust the camshaft 17.Leak detector alarm sounds. • Oil leak in the system • Low fluid level • Oil contracting as it cools, due to prolonged idling after heavy use. • Repair as necessary • Add fluid • Turn the engine off for approximately one minute, while the main hydraulic tank is refilled from auxiliary tank.
CONDITION 4. The engine fails to crank, regardless of shift selector or mow pedal position. CAUSE • The mow/lift switch, traction switch and/or seat switch adjusted incorrectly or are defective. • Battery terminals are corroded • The mow/lift or traction switch wires are loose • The battery is dead • The solenoid is defective • The ignition switch is defective • The starter is defective • The engine is seized • The key switch, voltmeter, or solenoid wires are loose • The operator must be on seat. 5.
CONDITION 8. The engine does not continue to run when sifting on seat and shift selector is placed in gear or mow pedal is depressed. CAUSE • The seat switch adjusted incorrectly or is defective. • The seat return pin spring jammed in the up position. • The parking brake switch wires are loose. • The parking brake switch wires are defective 9. The engine stops regardless of shift selector or mow pedal position (even if both are in “Neutral”) as you get off the seat.
Storage Identification and Ordering If you wish to store the Greensmaster 3100 for a long period of time, take the following steps before storage: Model and Serial Numbers 1. Remove accumulations of dirt and old grass clippings. Sharpen the reels and bedknives, if necessary; refer to the cutting unit operator’s manual. Use a rust preventive on bedknives and reel blades. Grease and oil all lubrication points: refer to Lubrication. 2. Block up wheels to remove the tire weights. 3.
