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 m a j o r s y s t e m s a n d c o m p o n e n t s on t he Greensmaster 3100 and 3050. REFER TO THE TRACTION UNIT, CUTTING UNIT AND ACCESSORY OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
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Table Of Contents Chapter 1 - Safety Chapter 5 - Electrical System Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2 Turf Guardian Leak Detection System . . . . . . . . . 5 - 3 Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating. . . . . . . . . . . . . . . . . . . . . . . . . . 2 While Doing Maintenance, Troubleshooting, Testing, Adjustments or Repairs . . . . . . . . . . . . . 3 Safety Instructions The Greensmaster 3100 has been tested and certified for compliance with the B71.
8. Do not carry passengers on the machine. Keep everyone, especially children and pets, away from the areas of operation. 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. 9. Since gasoline is highly flammable, handle it carefully: A. Use an approved fuel container. While Operating 10.
While Doing Maintenance, Troubleshooting, Testing, Adjustments or Repairs 26. Before servicing or making adjustments to the machine, 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.
Safety Instructions Page 1 - 4 Greensmaster® 3100
Chapter 2 Product Records and Manuals Table of Contents PRODUCT RECORD FORM . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . 1 2 2 2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . 3 Capscrew Markings and Torque Values - U.S. . . 3 Capscrew Markings and Torque Values - Metric .
Equivalents and Conversions Decimal and Millimeter Equivalents ___________________________________________________________________________________________________ Fractions Decimals mm Fractions Decimals mm ___________________________________________________________________________________________________ 1/64 0.015625 1/32 ––––– 0.03125 3/64 0.046875 1/16 –––––––––––– 0.0625 5/64 0.078125 3/32 ––––– 0.9375 7/64 0.109275 1/8 ––––––––––––– 0.1250 9/64 0.140625 5/32 ––––– 0.15625 11/64 0.
Torque Specifications Use these torque values when specific torque values are not given. DO NOT use these values in place of specified values. The torque values listed below are for lubricated threads. Plated threads are considered to be lubricated. Capscrew Markings and Torque Values - U.S.
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Chapter 3 Engine Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Control Adjustment. . . . . . . . . . . . . . . . . Choke Control Adjustment . . . . . . . . . . . . . . . . . Governor Adjustment. . . . . . . . . . . . . . . . . . . . . . Carburetor and Speed Control Adjustment . . . . . 1 2 2 2 3 4 ENGINE REMOVAL AND INSTALLATION . . . . . . . . 5 Removing the Engine . . . . . . . . . . . .
Adjustments Throttle Control Adjustment (Fig. 1) Before adjusting carburetor, make sure throttle control is operating properly. 2 1 1. Loosen cable clamp screw securing cable to engine. 2. Move remote throttle control lever forward to FAST position. 4 3 6 5 3. Pull firmly on throttle cable until back of swivel contacts stop. 4. Tighten cable clamp screw. 7 Figure 1 1. Throttle casing clamp screw 2. Throttle cable 3. Swivel 4. Stop 5. Choke casing clamp screw 6. Choke cable 7.
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 link.
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. 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 parts of the body away from the cutter blades and any rotating engine parts. 1.
Engine Removal and Installation Removing the Engine 1. Disconnect the negative (–) and positive (+) battery cables from the battery. 3. Remove the starter cable, throttle and choke cable and ground wire from engine. 2. Close the fuel shut-off valve and disconnect the fuel line. 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.
Engine Removal and Installation Page 3 - 6 Greensmaster® 3100
Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Fitting Installation . . . . . . . . . . . . . . . . 3 HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . 5 Traction, No. 1 Position . . . . . . . . . . . . . . . . . . . . 5 Traction, No. 2 Position . . . . . . . . . . . . . . . . . . . .
Specifications Item Description __________________________________________________________________________________________ Hydraulic Pump External gear type 5 section (Greensmaster 3100) 4 section (Greensmaster 3050) 850 psi Steering relief pressure (Greensmaster 3100) ________________________________________________________________________________________________________________________________________________________ Wheel Motor (2) Orbit rotor type ________________________________________________
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as, pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions or mishandling during operation or maintenance. These conditions can cause damage or premature deterioration. Some hoses, such as reel motor hoses, are more susceptible to these conditions than others. Inspect the hoses frequently for signs of deterioration or damage.
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. O-Ring 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 4 (1/4 in.
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 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.
Traction, No. 2 Position When the traction lever is positioned in No. 2, flow from one pump section passes through same lines as for No. 1 traction position. This flow is joined by additional flow Hydraulic Flow Diagrams from two other pump sections. The additional flow increases the RPM of the wheel motors to increase ground speed.
Traction, Reverse Position Traction lever is positioned in No. 1 or No. 2. When traction pedal is pushed rearward, flow from one pump section goes through No. 4 selector valve section into Greensmaster® 3100 No. 5 metering section and out the lines at the front of the valve to the traction motors, which drive the traction wheels, to operate in reverse.
Reel Drive, Mowing Operation The MOW pedal is depressed, which causes the No. 1, 2 and 3 spools to be positioned fully out of valve bank. This directs 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.
Reel Drive, Lower Cutting Units The MOW pedal is depressed to start reel drive operation, flow from one pump section passes through No. 3 spool section and out three lines, each leading to a lift cylinder. This actuates the lift cylinders and lowers the cutting units. Oil is returned to a three-way fitting on the No. 1 spool section through lines on the top end of each cylinder, where it passes through the valve section and returns to the reservoir through the main return line.
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 three lines leading to lift cylinders, causing cylinders to raise the cutting units. Oil forced out of cylinders travels through lines leading to No.
Power Steering, R.H. 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.
Hydraulic Schematics Page 4 – 12 Rev. E L R RH LIFT CYLINDERS RH STEERING CYLINDER LH LH REEL MOTORS .43 CU. IN/REV. (7 CU. CM/REV.) P T 2000 PSI (141 KG/SQ CM) CENTER CENTER STEERING CONTROL VALVE 4.5 CU. IN/REV. (75 CU. CM/REV) 2000 PSI (141 KG/SQ CM) 3 .58 IN /REV (9.5 CU CM/REV) 2000 PSI (141 KG/SQ CM) SAFETY INTERLOCK SWITCH N 1ST 2ND 3 850 PSI .33 IN /REV (60 KG/SQ CM) (5.4 CU CM/REV) 1850 PSI (130 KG/SQ CM) SAFETY INTERLOCK SWITCH REV N FWD LH 3 .18 IN /REV (2.
Greensmaster 3100 Page 4 – 12.1 Rev. E L R RH LIFT CYLINDERS RH STEERING CYLINDER LH LH REEL MOTORS .43 CU. IN/REV. (7 CU. CM/REV.) P T 2000 PSI (141 KG/SQ CM) CENTER CENTER STEERING CONTROL VALVE 4.5 CU. IN/REV. (75 CU. CM/REV) 2000 PSI (141 KG/SQ CM) 3 .57 IN /REV (9.3 CU CM/REV) 2000 PSI (141 KG/SQ CM) SAFETY INTERLOCK SWITCH N 1ST 2ND 3 .32 IN /REV (5.
Hydraulic Schematics Page 4 – 12.2 LH RH LIFT CYLINDERS RH Rev. E L R STEERING CYLINDER LH CENTER P T 2000 PSI (141 KG/SQ CM) CENTER REEL MOTORS .43 CU IN/REV (7 CU CM/REV) STEERING CONTROL VALVE 4.5 CU IN/REV (75 CU CM/REV) 2000 PSI (141 KG/SQ CM) SAFETY INTERLOCK SWITCH 3 .58 IN /REV (9.5 CU CM/REV) 2000 PSI (141 KG/SQ CM) N 1ST 2ND REAR RH OIL FILTER 10 MICRON 3 .18 IN /REV (2.9 CU CM/REV) PUMP (DANFOSS) 2850 RPM MAX. 3 .33 IN /REV (5.
Greensmaster 3100 LH LH Page 4 – 12.3 LIFT CYLINDERS RH RH REEL MOTORS .43 CU. IN/REV. (7 CU. CM/REV.) 2000 PSI (141 KG/SQ CM) CENTER CENTER 2000 PSI (141 KG/SQ CM) 2000 PSI (141 KG/SQ CM) 3 .58 IN /REV (9.5 CU CM/REV) SAFETY INTERLOCK SWITCH N 1ST 2ND Rev. E 3 .33 IN /REV (5.4 CU CM/REV) 1850 PSI (130 KG/SQ CM) SAFETY INTERLOCK SWITCH REV N FWD LH RH HYDRAULIC TANK PUMP 2850 RPM MAX 3 .33 IN /REV (5.4 CU CM/REV) VALVE BANK OIL FILTER WHEEL DRIVE MOTORS 10.3 CU. IN/REV.
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Special Tools NOTE: Order special tools from the TO R O S P E C IA L TO O L S A N D A P P LIC AT IO N S G U ID E (C O M M E R C IA L P R O D U C T S ). Some tools may be listed in the Greensmaster 3100 Parts Catalog. Some tools may also be available from a local supplier. Hydraulic Tester (Fig.
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 a light coating of clean oil to the seal protector to ease movement of the seal over the tools. Use the installer (Item 2) and a small hammer to drive the reel motor shaft seal into position in the bore of the reel motor body. Figure 7 Detent Installation Tool (Fig. 8) Use this tool with a 3/8 in. drive torque wrench to tighten the detent stud in the No.
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. Figure 9 Assembly Studs (Fig.
Troubleshooting The cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equipment and a thorough understanding of the complete 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.
Slow Groundspeed in All Traction Selections * Check engine RPM Improper Adjust – use tachometer * Reels also affected. OK * Check hydraulic oil level Improper Fill to proper level OK Check hydraulic oil filter Clogged Replace filter Misadjusted or damaged Adjust OK * Check shift lever bracket and rear camshaft OK Check brakes and brake linkage for binding Binding Free linkage and adjust brakes OK Check traction pump flow. Test hook up No.
Slow or No Ground Speed in No. 1 and Reverse No. 2 Appears Normal Check control linkage Misadjusted or damaged Adjust or repair OK Check traction pump flow. Test hook up No. 1 Test A Low Check for restriction in pump intake line OK Repair or replace traction pump Defective Remove valve bank and replace disk seal OK Check for internal valve bank leakage. Test hook up No.
No Increase in Speed from No. 1 to No. 2 Check hydraulic oil level Low Fill to proper level OK Check traction lever Misadjuste or damaged Adjust or repair OK Check rear camshaft Misadjusted or damaged Adjust or repair OK Check #2 and #3 pump section flow. Test hook up No. 3 Test A Low Check for restriction in pump intake line OK Repair or replace pump OK Check #2 and #3 valve section reliefs. Test hook up No.
One or More Cutting Units Slow or No Reel Drive Action Check Pedal Linkage Misadjusted or Damaged Adjust or repair and lubricate Insufficient Adjust or repair rear camshaft Tight Adjust bedknife OK Check rearward valve spool trave OK Check bedknife adjustment OK Check for tight reel bearings Tight Adjust bearings. Replace if necessary. OK Check reel pump flow. Test hook up No. 3 Test A Low Check for restriction in pump intake line(s). OK Repair or replace pump OK Check reel motor flow.
All Reels Slow or Will Not Turn Check engine RPM Low Adjust – use tachometer Low Fill to proper level Clogged Replace filter OK Check hydraulic oil level OK Check hydraulic oil filter OK Check linkage and roll pin on end of mow pedal shaft Worn or broken Repair linkage OK Check reel pump flow. Test hook up No.
Mow Pedal Won’t Stay Engaged – Reels Slow Down or Stop Check linkage from pedal to valve bank Misadjusted or damaged Adjust, repair and lubricate linkage OK Check roll pin in end of mow pedal shaft Worn or broken Replace pin OK Check rearward valve spool travel Insufficient Adjust rear camshaft OK Check the spool detent Troubleshooting Defective Page 4 - 22 Lubricate or repair valve spool detent Greensmaster® 3100
Cutting Unit(s) Drop During Transport Check that valve spool returns to neutral Binding Lubricate and adjust camshaft Leaking Repair or replace cylinder(s) Leaking Replace o-ring Binding Lubricate or repair valve spool detent OK Check for internal lift cylinder leakage OK Check lift check plug o-rings in #1 valve section OK Check valve spool detent for binding Greensmaster® 3100 Page 4 - 23 Troubleshooting
Cutting Units Lift Too Slowly or Not At All Check for binding lift assemblies Binding Loosen and lubricate lift assemblies OK Check forward valve spool travel Insufficient Adjust rear camshaft Restricted Replace restricted line or fitting Leaking Repair or replace cylinder Defective Repair or replace pump OK Check for restriction in lines to or from cylinders OK Check for leaking cylinder OK Check lift section of pump. Test hook up No.
Lift Pedal Binding Check pedal linkage Misadjusted or Damaged Adjust or repair linkage and lubricate OK Check valve spool detent assembly Binding or Damaged Lubricate and repair detent Center (#1) Cutting Unit Operates in Raised Position Check rear camshaft for #3 spool too far out of body Misadjusted Adjust camshaft Restricted Remove restriction OK Check for restriction in brazed tube assembly on #3 valve section OK Check for restriction in valve return port between #3 section and R.H.
Steering Loss, Steering Wander or Free Play Check steering cylinder ball joints Loose Tighten castle nuts and jam nut OK Replace ball joint(s) OK Repair or replace pump OK Disconnect cylinder and check castor fork movement Binding Repair and lubricate castor fork and bushings OK Check steering cylinder for internal leakage Leakage Repair or replace steering cylinder Restriction Replace restricted line or fitting Defective Check for restriction in pump intake line OK Check for restriction
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, construction, 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-powered equipment in the shop.
TEST HOOK UP NO. 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. TESTER TEST A: TRACTION PUMP FLOW PROCEDURE Traction lever in neutral. Engine RPM 2800 RPM.
TEST HOOK UP NO. 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. If pressure is not in listed range, remove traction relief cartridge and examine for contamination or damage.
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.
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 HOOK UP NO. 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 the mow pedal is engaged.
TEST HOOK UP NO. 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. TESTER GR3100 WITH DANFOSS PUMP SHOWN.
TEST HOOK UP NO. 4 (continued) 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.
TEST HOOK UP NO. 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. TESTER GR3100 WITH DANFOSS PUMP SHOWN. MACHINES WITH PARKER PUMP USE LAST PUMP SECTION FOR STEERING CIRCUIT. TEST A: STEERING PUMP FLOW PROCEDURE Traction Lever in neutral.
Adjustments Lift and Mow Pedal Height Adjustment (Fig. 13) Adjust the lift and mow pedal to equal height to gain proper spool travel in the valve bank as follows: 2 1 3 1. Put 1, 2 and 3 spools in neutral (center of travel) and remove transfer rod guard from foot panel. 4 2. Loosen jam nut securing yoke on front of long control rod, remove cotter pin and clevis pin. 3.
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 footrest. Distance should be approximately 3/16 in. If distance is greater or less than 3/16 in. dimension, an adjustment to the traction control rod is required. 3.
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. 1 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 camshaft until the condition is corrected. Figure 15 Retighten the capscrews. 1.
Repairs Reel Motor Removal and Installation (Fig. 16) 1. Disconnect hydraulic lines. Put caps or plugs on fittings and hoses to prevent contamination. Tag hydraulic lines for proper reassembly. 2. Loosen motor mount nuts. 3. Rotate motor clockwise so motor flanges clear studs and pull motor out. 1 4. Reverse steps 1 - 3 to reinstall motor. 2 Figure 16 1. Motor mount nuts 2. Motor Reel Motor Shaft Seal Replacement (Fig. 17) 1.
Reel Motor 70-9800 Repair (Fig. 18) 1 2 3 4 5 6 7 17 8 9 13 16 15 14 13 12 11 10 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.
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.
Reel Motor 94–3506 Repair (Fig. 18a) 1 2 3 4 5 6 7 8 9 5 14 10 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. with general purpose grease to retain them for re– asembly. It is recommended NOT to remove the bearing races from the cover and body. IMPORTANT: Extreme caution must be used when using a vise to avoid distorting any parts. 7. Remove the load plate assembly (9). 2.
15. 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. 17. 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). 16. Tighten the capscrews evenly in a crossing pattern to a torque of 17 ft–lb. Greensmaster 3100 Page 4–41.2 Rev.
Reel Motor 105–9770 Repair (Fig. 18b) 33 to 40 ft–lb (45 to 55 Nm) 10 1 6 5 7 9 8 7 2 5 6 11 3 4 Figure 18b 1. 2. 3. 4. Rear cover Drive gear Seal Tab washer 5. 6. 7. 8. Pressure seal Back–up ring O–ring Body 9. Idler gear 10. Cap screw 11. Front flange 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.
IMPORTANT: Avoid using excessive clamping pressure on the motor flange to prevent distorting the casting. 1 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. 2 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 reassembled in the same position.
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 indicates 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. Sharp edges of gears will mill into bearing blocks and, thus, must be replaced. D.
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Hydraulic Pump Removal and Installation - Greensmaster 3100 shown (Fig. 19) Figure 19 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. 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.
Pump Repair - Greensmaster 3100 shown (Fig. 22) Figure 22 Relief Valve Service Pump Service 1. Remove cap (Item 10). Remove valve adjuster (Item 9), spring (Item 8), and ball (Item 7). 1. Plug ports and wash exterior of pump with mineral spirits or solvent. Make sure parts and work area are clean. 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). 2.
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 them for reassembly. It is recommended NOT to remove the bearing races from the flange assembly. 8. Remove and discard the oil seal and seal rings (Items 17 and 23) as the pump is disassembled. 9. Clean all parts. All parts must be check for burrs, scoring, nicks, etc.
Control Valve Removal and Installation (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.
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.
Control Valve Internal Seal Replacement (Fig. 27) 2.5 in. traction spring 1.5 in. spring 5 4 3 2 These components changed locations after serial no. 210000701 1 Figure 27 1. Internal seals (4 between ea. sect.) 2. Main & No. 1 section relief valve 3. No. 2 section relief valve 4. No. 3 section relief valve NOTE: Replace all internal seals whenever valve sections are disassembled. Original seals may not seal after the valve assembly is installed on the machine. 1. Remove the valve bank.
Control Valve No. 1 Spool Detent Replacement (Fig. 28, 29) NOTE: These procedures can be done with the 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.
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.
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) 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).
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 remove 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 machine.
Lift Cylinder Repair – No. 1 (Center) (Fig. 34) Figure 34 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 cylinder’s piston in and out of the cylinder bore. 2. Plug the ports and clean the outside of the cylinder. 3.
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 cylinder’s piston in and out of the cylinder bore. 2. Plug the ports and clean the outside of the cylinder. 3.
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. 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. 2. Remove wheel nuts (Item 29) and remove wheel (Item 3). Remove large nut (Item 4) from wheel hub (Item 5). 6. Reverse steps 1 - 6 to install the wheel motor.
Wheel Motor Repair (Fig. 37, 38) Figure 37 Disassembly of Motor (Fig. 37) 5. Remove commutator ring (Item 23), commutator (Item 16), and manifold (Item 22). 1. Place motor in a vise, clamping down on housing (Item 3) port bosses with coupling shaft (Item 11) pointed down. 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 14) using a 9/16 inch thin wall socket.
9. Place rotor set on 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.
9. Assemble manifold (Item 22) and then the commutator ring (Item 23) over the drive link onto rotor set. Be sure swirls in manifold and manifold plate are installed facing together. Rotor, Stator and Vane Assembly (Fig. 37, 38) 10. Assemble a new commutator seal (Item 15), flat side up, into commutator (Item 16) and assemble commutator over end of drive link onto manifold with seal side up. 2.
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. 5. After installing the cylinder, start the engine and turn the steering wheel left and right from lock to lock several times to get air out of the cylinder. NOTE: To ease reassembly, tag each of the hoses to show their correct position on the steering cylinder.
Steering Cylinder Repair - Greensmaster 3100 (Fig. 40) Figure 40 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 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.
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 contamination. NOTE: To ease reassembly, tag each of the hoses to show their correct position on the steering valve. 3.
Steering Control Unit Repair - Greensmaster 3100 (Fig. 42) Figure 42 1. Dust seal 2. Retaining ring 3. Gland bushing seal 4. O-ring 5. Backup ring 6. O-ring 7. Seal 8. Bearing race 9. Needle thrust bearing 10. Housing 11. Control sleeve 12. Control spool centering springs 13. Control spool 14. O-ring 15. Spacer plate 16. Drive 17. Gerotor 18. End cap 19. Capscrew 20. Centering pin kit 21. Check ball retainer 22. Check ball 23. O-ring 24. Check ball seat 25. O-ring 26.
Meter (Gerotor) End 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 overtightened. Figure 43 2. Remove 5/16" cap screws. 3. Remove end cap. 4. Remove seal from end cap. Figure 44 5. Remove meter. Be careful not to drop star. 6. Remove seal from meter.
7. Remove drive. 8. Remove spacer plate. 9. Remove seal from housing. Figure 46 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. Figure 47 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.
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. Figure 49 14. Remove 2 bearing races and the needle thrust bearing from spool and sleeve assembly. Figure 50 15. Remove spool and sleeve assembly from 14 hole end of housing. IMPORTANT: Do not bind spool and sleeve in housing. Rotate spool and sleeve assembly slowly when removing from housing. 16. Push pin from spool and sleeve assembly.
17. Push spool 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. Figure 52 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.
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.
7. Bring spring slots of both parts in line and stand parts on end of bench. Insert spring installation tool through spring slots of both parts. Tool is available 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.
14. Install 1-1/4" diameter dust seal in seal gland bushing, 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. Figure 59 17.
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 housing by wiping 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. Figure 61 19. Install 3" diameter seal in housing. 20.
21. Rotate spool and sleeve assembly until pin is parallel 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 marking. Figure 63 22. Install 3" diameter seal in meter. Figure 64 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.
24. Install 3" diameter seal in end cap. 25. Install end cap on gerotor, align holes. Figure 66 26. Install seven (7) DRY cap screws with new seal washers in end cap. Pre-tighten screws to 150 inch pounds, then torque screws to 275 inch pounds in sequence shown.
Repairs Page 4 - 72 Greensmaster® 3100
Chapter 5 Electrical System Table of Contents WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . 2 TURF GUARDIANTM LEAK DETECTION SYSTEM. 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 6 Verify Interlock Operation . . . . . . . . . . . . . . . . . . 8 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . 9 Seat Switch . .
Wiring Schematics E S A B G ORANGE Page 5 – 2 Rev. D SOLENOID VALVE BLUE RED/WHITE ENGINE ORANGE GREY SEAT SWITCH BLACK BLACK GREY YELLOW BLUE ORANGE MODULE INTERLOCK BROWN LEVEL SWITCH WHITE/RED FUSE (20 AMP) RESISTOR BLACK A – BLACK B BLUE + HOUR METER BATTERY GREEN – GROUND STARTER + RED TRACTION SWITCH YELLOW C YELLOW BLACK RED/WHITE RED/WHITE B ALARM RED D RED ORANGE ORANGE WHITE/RED GREEN L F B+L+S 3.
FRAME GND (+) BLUE FUSIBLE LINK GRAY ORANGE BU FL GY OR Page 5 – 2.1 Rev. D ENGINE ENGINE GND BATTERY STARTER BROWN BN FL SP OR FUSE 10A SPLICE YELLOW WHITE RED PURPLE FL W FUEL SOLENOID BN ALTERNATOR PU BK BN R W W SP X B Y BU BN OR I S B TRACTION HANDLE SW. (CLOSED IN NEUTRAL) PU Y S A I OFF RUN START IGNITION SW STOP –––– NONE RUN –––– B+I+A; X+Y START ––– B+I+S MOW PEDAL SW.
Wiring Schematics BLUE FUSIBLE LINK GRAY ORANGE BU FL GY OR FRAME GND (–) (+) SP Y Page 5 – 2.2 Rev. D ENGINE W VIO BK BN FL R PARKING BRAKE (IN OFF POSITION) NEUTRAL SW.
Greensmaster 3100/3050 FUSIBLE LINK GRAY ORANGE FL GY OR FRAME GND (–) Page 5 – 2.3 Rev. D ENGINE W SP FL SP OR 10A BN FUELSOLENOID ALTERNATOR FL R Y W D2 PARKING BRAKE SW. (CLOSED IN OFF POSITION) NEUTRAL SW.
Wiring Schematics L F B+L+S 3. START M B+L+A E A B G ORANGE Page 5 – 2.4 Rev.
Wiring Schematic (Greensmaster 3050, S/N 80001 – 200999999) Greensmaster 3100/3050 Page 5 – 2.5 Rev.
Wiring Schematics FRAME GND (–) (+) STARTER Page 5 – 2.6 Rev. D ENGINE BN FL PARKING BRAKE (IN OFF POSITION) NEUTRAL SW. (CLOSED IN NEUTRAL) BN W VIO BK STARTER SOLENOID FUEL SOLENOID ALTERNATOR MAGNET O ENGINE GND BATTERY FL SP OR 10A R Y W D2 SP VIO X B W D1 VIO Y S A I X BN S 86 87 87a 85 30 GY VOLT METER MOW SW.
Greensmaster 3100/3050 P1 Key Switch P1 Page 5 – 2.7 Rev.
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Turf Guardian Leak Detection System (Greensmaster 3100 S/N below 230000001) TM Before Start-Up (Cold Oil) Float Switch 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 second time delay alarm should sound.
Special Tools NOTE: Order special tools from the TO R O S P E C IA L TO O L S A N D A P P L IC AT IO N S G U ID E (C O M M E R C IA L P R O D U C T S ). 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.
Skin-Over Grease (Fig. 7) Special non-conductive grease which forms a light protective skin to help waterproof electrical switches and contacts. Recommended for all interlock system connections.
Troubleshooting Studying the operating characteristics preceding an electrical failure will help in identifying the area of difficulty. Try to isolate the failure to a specific functional system; then check that area, repairing one component at a time. Attempting to repair two systems at once will lead to confusion. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting. Disconnect battery cables unless the test requires battery voltage.
Problem Cause Correction 5. Engine cranks but does not start when shift selector and mow pedal are in neutral. If engine cranks, cause of problem is UNRELATED to interlock wiring system. All interlock switches are OK; refer to next cause. Engine or rectifier plug loose. Connect wire. Key switch wiring connector loose. Connect wire Engine problem or no fuel. Find problem and correct. Mow/lift switch or seat switch out of adjustment or malfunctioning.
Problem Cause Correction 11. Engine does not stop when ignition key is rotated to OFF position. Loose wire(s) in electrical system. Check all connections and repair as necessary. Ignition switch is malfunctioning. Replace ignition switch. Engine timing or carburetor out of adjustment. Adjust carburetor or engine timing. Open or missing fuse. Install new fuse. Loose wire(s) in electrical system. Check all connections and make all necessary repairs.
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 schematics, determine which component is at fault. However, 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.
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.
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. 1 2. Push down on the lift pedal and release it. There should be continuity when the mow pedal is disengaged. If there is no continuity, adjust or replace the switch. (See Mow/Lift Switch Replacement and Adjustment in the Repairs section of this book.) 3. Push down on the mow pedal and release it. There should not be continuity.
Battery Terminal Voltage Test 1. Use a volt-ohm meter to measure the voltage between 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 TM 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.
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. 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.
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. 1 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.
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 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.
Battery Service (Fig. 18, 19) IMPORTANT: Before welding on the machine, disconnect the negative (–) battery cable from the battery to prevent damage to the electrical system. Battery Specifications BCI Group U1 Battery 200 Amp Cranking Performance at 0o F (17 o C) 32 min. Reserve Capacity at 80o F (27 o 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.
Chapter 6 Wheels, Steering and Brakes Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 3 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Brake Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Steering Cable (Greensmaster 3050) . . . . . . . . .
Specifications Item Specification __________________________________________________________________________________________ Tire pressure 8 - 12 PSI front 8 - 15 PSI rear ________________________________________________________________________________________________________________________________________________________ Wheel nut torque 40 - 50 ft-lb _______________________________________________________________________________________________________________________________________________________
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. CAUTION 2 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. 3 1 4 2. If both wheel do not lock equally, disconnect the brake rods by removing cotter pin and clevis pin.
Repairs Brake Service (Fig. 2) Figure 2 Brake Disassembly Reassembly 1 Place blocks on each side of opposite wheel, jack machine up and place blocks beneath frame under wheel motor. 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. Remove wheel nuts (Item 29) and remove wheel.
Steering Arm (Greensmaster 3050) 1. Remove 1/2–13 x 3/4 capscrew and .53 I.D. washer mounted to outside steering arm frame bracket. 1 3 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 I.D. washers (one each in loose parts). 2 Figure 3 1. Capscrew and washer 2. Steering arm 3.
Repairs Page 6 – 6 Rev.
Chapter 7 4 Bolt Adjust Cutting Units Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 5 Factors Affecting Quality of Cut. . . . . . . . . . . . . . 5 SET UP AND ADJUSTMENTS. . . . . . . . . . . . . . . . . 7 Adjustment Summary and Check List . . . . . . . . . 7 Reel Bearing Service and Adjustment. . . . . . . . .
Use Loctite 271 on spline nut. Rev.
Use Loctite 271 on spline nut. Rev.
Chapter 8 Single Point Adjust Cutting Units Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 6 SET UP AND ADJUSTMENTS. . . . . . . . . . . . . . . . . 8 Adjustment Summary and Check List . . . . . . . . . 8 Bedknife to Reel Contact . . . . . . . . . . . . . . . . . . 9 Reel Bearing Service and Adjustment. . . . . . . .
Use Loctite 271 on spline nut threads. Rev.
Use Loctite 271 on spline nut threads. Rev.
Chapter 9 Grooming Reel Cutting Units Table of Contents (For Four Bolt Adjust and Single Point Adjust Cutting Units) SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 6 Factors Affecting Quality of Cut. . . . . . . . . . . . . . 6 Factors Affecting Grooming. . . . . . . . . . . . . . . . . 8 Groomer Mechanical Problems. . . . . . . . . . . . . .
Use Loctite 271 on spline nut threads. Rev.
Use Loctite 271 on spline nut threads. Rev.
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Chapter 10 Dual Point Adjust Cutting Units Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . Factors Affecting Quality of Cut . . . . . . . . . . . . . . . SET UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPAIRS . . . . . . . . . . . . . . . . . .
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 depending on turf conditions, type of bedknife, rollers and attachments installed.
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. Some tools may have been supplied with your mower or available as TORO parts. Some tools may also be available from a local supplier. Gauge Bar Assembly Used to verify height–of–cut.
Inner Grease Seal Installation Washer inner grease seal installation washer Toro Part Number 104-0532 This washer is used when replacing the reel bearing inner 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 debris from entering the housing.
Troubleshooting 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 cutting unit. It is important to remember that the lower the height–of–cut, the more critical these factors are.
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. Excessive contact accelerates wear of both edges. Quality of cut is adversely affected by both conditions (see Bedknife to Reel Adjustment in the Cutting Unit Operator’s Manual). Slightly dull cutting edges may be corrected by backlapping (see Backlapping in this chapter of this manual).
Set Up and Adjustments Characteristics 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. CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop engine and remove key first. The dual knob bedknife–to–reel adjustment system incorporated in this cutting unit simplifies the adjustment procedure needed to deliver optimum mowing performance.
Repairs Hydraulic Reel Motor IMPORTANT: When performing maintenance procedures 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. Inspection Removal 1. Coat spline shaft of the motor with clean No. 2 multipurpose lithium base grease. 1.
Backlapping (Units with Optional Backlap/Variable Reel Speed Kit) 2 DANGER CLOCKWISE 1 TO AVOID PERSONAL INJURY OR DEATH: Never place hands or feet in the reel area while the engine is running. While backlapping, the reels may stall and then restart. Do not attempt to restart reels by hand or foot. Do not adjust reels while the engine is running. If a reel stalls, stop engine before attempting to clear the reel. Reel motors are connected in series, moving one motor moves the other two.
Bedbar Assembly 15 6 4 5 15 9 10 1 5 2 3 16 4 4 17 5 8 7 11 190 to 240 in–lbs (21 to 27 Nm) 14 12 Antiseize Lubricant 13 Figure 10 1. Side plate 2. Rubber bushing 3. Flange bushing 4. Washer (plastic) 5. Washer (metal) 6. Bedbar Dual Point Adjust Cutting Units 7. 8. 9. 10. 11. 12. Bedbar pivot bolt Flange nut Flange nut Shim Spacer Retainer Page 10 - 10 Rev. D 13. 14. 15. 16. 17.
Bedbar Removal and Installation Removal (Fig. 10) ÂÂÂÂ ÇÇÇÇ ÂÂÂÂ ÇÇÇÇ ÂÂÂÂ ÇÇÇÇ ÂÂÂÂ ÂÂÂÂ ÂÂÂÂ ÂÂÂÂ ÂÂÂÂ ÇÇÇÇ ÂÂÂÂ ÇÇÇÇ ÂÂÂÂ 6 1. Position machine on a clean and level surface, lower 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.
Bedbar Adjuster Service 9 6 8 5 7 4 3 2 12 11 10 2 1 Figure 12 1. Adjuster shaft 2. Flange bushing 3. Cutting unit frame 4. Wave washer 5. 6. 7. 8. Jam nut Adjuster screw Detent Lock washer 9. 10. 11. 12. Cap screw Washer Spring Lock nut Removal (Fig. 12) Installation (Fig. 12) 1. Remove bedbar (see Bedbar Removal in this section of this manual). 1. If the detent (7) was removed, install the cap screw (9) and secure detent to the cutting unit frame with cap screw and lock washer. 2.
Bedknife Replacement and Grinding Removal 2 1. Remove bedbar from frame (see Bedbar Removal). 1 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special Tools). Discard screws. Remove bedknife from the bedbar (Fig. 13). 3. Use scraper to remove all rust, scale and corrosion from bedbar surface before installing bedknife. 3 Replacement 1. Make sure bedbar threads are clean. Use new screws. Apply clean SAE 30 oil to the screws before installing. Figure 13 1. Screw 2.
Reel Assembly 21 24 20 23 19 22 8 9 10 17 11 12 25 13 18 3 16 2 13 #2 General Purpose Grease 17 to 20 ft–lbs (23 to 27 Nm) 14 12 15 6 1 7 4 RIGHT 5 FRONT 8 2 #2 General Purpose Grease 9 3 Figure 16 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 Dual Point Adjust Cutting Units 10. 11. 12. 13. 14. 15. 16. 17.
Reel Removal (Fig. 16) 1. Remove reel motor from the cutting unit (see Hydraulic 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 Removal in this chapter). 1 Note: Depending on tools available, it may be necessary to remove the reel motor adapter plate before removing the left end bearing lock nut (8). 4.
Left Side Plate Service (Fig. 16) Right Side Plate Service (Fig. 16) 1. Remove the inner grease seal (13) and outer grease seal (9) from the side plate (6). 1. Remove the inner grease seal (13) and outer grease seal (9) from the side plate (10). 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 axial play. The bearing balls must be free of deformation and scoring.
Reel Service (Fig. 16) 3 Note: Install new reel components on each end of the reel shaft that mates with newly serviced side plate components. 1. Remove the retaining ring (5) and the drive coupler (4) from the end of the reel shaft. 2. Remove the V–ring (3) from the reel shaft. 2 1 3. Using a flat blade screw driver or similar tool, remove the speedi sleeve (2) from the reel shaft. Figure 19 Note: Replacemant Seal Kit (Toro Part No.
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.
Preparing a Reel for Grinding Note: Check to make sure the reel bearings are in good condition before grinding a reel. A. Install parts removed to mount cutting unit into grinder. 1. Remove bedbar assembly (see Bedbar Removal and Installation). B. Install 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). C.
Front Roller Removal and Installation Removal (Fig. 23) 1. Position machine on a clean and level surface, lower 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. 6 4 5 2 3.
Front and Rear Roller Service 4 v 1 2 3 6 5 Figure 24 1. 2. Roller seal Spiral retaining ring 3. 4. Roller bearing Rear roller body 5. 6. Seal Removal Roller shaft Front roller body .188 in. dia (2) 1. Make a seal removal tool from a 1/4 x3 x 3 in (.63 x 7.6 x 7.6 cm) piece of steel as shown (Fig. 25). 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. 4. Thread two No.
Bearing Removal 2 Note: Replace both roller bearings as a set after a bearing failure. 3 1 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. 5 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.
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