Page 1: Service Manual
IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- vent damage to systems or components on the machine. © The Toro Company - 1991, 1998, 2002, 2004, 2005 Part No. 92784SL, Rev. E Service Manual 3100/3050...
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Page 3: Table Of Contents
Table Of Contents Chapter 1 - Safety Safety Instructions ......1 - 1 Chapter 2 - Product Records and Manuals Product Records.
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Page 5 While Operating......2 Safety Instructions The Greensmaster 3100 has been tested and certified for compliance with the B71.4-1984 specifications of the American National Standards Institute (ANSI) for riding mowers when 40 lbs.
Page 6 8. Do not carry passengers on the machine. Keep everyone, especially children and pets, away from the areas of operation. 9. Since gasoline is highly flammable, handle it carefully: A. Use an approved fuel container. While Operating 10. Do not run engine in a confined area without ade- quate ventilation.
Page 7 If major repairs are ever needed, or assis- tance is desired, contact your TORO Distributor. 36. Wear safety glasses, goggles or a face shield to prevent possible eye injury when using compressed air for cleaning or drying components.
Page 8: Safety Instructions
® Safety Instructions Page 1 - 4 Greensmaster 3100...
Page 9: Product Records
U.S. to Metric Conversions ....2 Product Records Insert Operator's Manual and Parts Catalog for your Greensmaster 3100 or 3050 at the end of this chapter. Refer to Operator's Manual for recommended maintenance intervals. Additionally, insert Installation...
Page 10: Equivalents And Conversions
Equivalents and Conversions Decimal and Millimeter Equivalents ___________________________________________________________________________________________________ Fractions ___________________________________________________________________________________________________ 1/64 1/32 ––––– 3/64 1/16 –––––––––––– 5/64 3/32 ––––– 7/64 1/8 ––––––––––––– 9/64 5/32 ––––– 11/64 3/16 –––––––––––– 13/64 7/32 ––––– 15/64 1/4 ––––––––––––– 17/64 9/32 ––––– 19/64 5/16 –––––––––––– 21/64 11/32 ––––...
Page 11: Torque Specifications
Torque Specifications Use these torque values when specific torque values are not given. DO NOT use these values in place of specified values. Capscrew Markings and Torque Values - U.S. Customary SAE Grade Number ________________________________________________________________________________________________________________________________________________________ Capscrew Head Markings ________________________________________________________________________________________________________________________________________________________ Capscrew Body Size ft-lb ________________________________________________________________________________________________________________________________________________________ 1/4-20...
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Page 13: Specifications
Table of Contents SPECIFICATIONS ......1 ADJUSTMENTS ......2 Throttle Control Adjustment.
Page 14: Adjustments
Adjustments Throttle Control Adjustment (Fig. 1) Before adjusting carburetor, make sure 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. Pull firmly on throttle cable until back of swivel con- tacts stop.
Page 15: Governor Adjustment
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.
Page 16: Carburetor And Speed Control Adjustment
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.
Page 17: Engine Removal And Installation
Engine Removal and Installation Removing the Engine 1. Disconnect the negative (–) and positive (+) battery cables from the battery. 2. Close the fuel shut-off valve and disconnect the fuel line. WARNIN G Gasoline is highly flammable. Use caution while handling it. Do not smoke cigarettes, cigars or pipes.
Page 18 ® Engine Removal and Installation Page 3 - 6 Greensmaster 3100...
Page 19 Table of Contents SPECIFICATIONS ......2 GENERAL INFORMATION ....3 Hydraulic Hoses .
Page 20: Specifications
Specifications Item __________________________________________________________________________________________ Hydraulic Pump Steering relief pressure (Greensmaster 3100) ________________________________________________________________________________________________________________________________________________________ Wheel Motor (2) ________________________________________________________________________________________________________________________________________________________ Reel Motor (3) ________________________________________________________________________________________________________________________________________________________ Control Valve Main and No. 1 section port relief pressure No. 2 and 3 section port relief pressure No. 4 (traction) section port relief pressure...
Page 21: General Information
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 condi- tions or mishandling during operation or maintenance. These conditions can cause damage or premature de- terioration.
Page 22 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. 3.
Page 23: Hydraulic Flow Diagrams
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.
Page 24: Traction, No. 2 Position
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 in- creases the RPM of the wheel motors to increase ground speed.
Page 25: Traction, Reverse Position
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.
Page 26: Reel Drive, Mowing Operation
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.
Page 27: Reel Drive, Lower Cutting Units
Reel Drive, Lower Cutting Units The MOW pedal is depressed to start reel drive opera- tion, 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.
Page 28: Reel Drive, Raising Cutting Units
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.
Page 29: Power Steering, R.h. Turn
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.
Page 30: Hydraulic Schematic
Hydraulic Schematic (Greensmaster 3100 2WD Serial Number Below 230000000) Hydraulic Schematics Greensmaster 3100 Page 4 – 12 Rev. E...
Page 31 Hydraulic Schematic (Greensmaster 3100 2WD Serial Number Above 230000000) Greensmaster 3100 Page 4 – 12.1 Rev. E Hydraulic Schematics...
Page 32 Hydraulic Schematic (Greensmaster 3100 3WD) Hydraulic Schematics Page 4 – 12.2 Rev. E Greensmaster 3100...
Page 33 Hydraulic Schematic (Greensmaster 3050) Greensmaster 3100 Page 4 – 12.3 Rev. E Hydraulic Schematics...
Page 34 This page is blank. Hydraulic Schematics Page 4 – 12.4 Rev. E Greensmaster 3100...
Page 35: Special Tools
Hydraulic Tester (Fig. 6) You must have o-ring face seal (ORFS) adapter fittings for this tester to use it on the Greensmaster 3100. 1. INLET HOSE: Hose connected from the system circuit to the inlet side of the hydraulic tester.
Page 36 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.
Page 37 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.
Page 38: Troubleshooting
Troubleshooting The cause of an improperly functioning hydraulic sys- tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com- plete 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.
Page 39: Slow Groundspeed In All Traction Selections
Slow Groundspeed in All Traction Selections * Check Improper engine * Check Improper hydraulic oil level Check Clogged hydraulic oil filter * Check shift Misadjusted lever bracket or damaged and rear camshaft Check brakes and Binding brake linkage for binding Check traction pump flow.
Page 40: Slow Or No Ground Speed In No. 1 And Reverse No. 2 Appears Normal
Slow or No Ground Speed in No. 1 and Reverse Check Misadjusted control linkage or damaged Check traction pump flow. Test hook up No. 1 Test A Check for internal Leaking valve bank leakage. Test hook up No. 2 Test B Troubleshooting No.
Page 41: No Increase In Speed From No. 1 To No. 2
No Increase in Speed from No. 1 to No. 2 Check hydraulic oil level Check traction Check traction Misadjuste lever lever or damaged Check rear Misadjusted camshaft or damaged Check #2 and #3 pump section flow. Test hook up No. 3 Test A Check #2 and #3 Defective...
Page 42: One Or More Cutting Units Slow Or No Reel Drive Action
One or More Cutting Units Slow or Check Misadjusted Pedal or Damaged Linkage Check rear- Insufficient ward valve spool trave Check bedknife adjustment Check for tight reel bearings Check reel pump flow. Test hook up No. 3 Test A Check reel motor flow.
Page 43: All Reels Slow Or Will Not Turn
All Reels Slow or Will Not Turn Check engine Check hydraulic oil level Check hydraulic oil filter Check linkage and roll pin on end of mow pedal shaft Check reel pump flow. Test hook up No. 3 Test A ® Greensmaster 3100 Adjust –...
Page 44: Mow Pedal Won't Stay Engaged - Reels Slow Down Or Stop
Mow Pedal Won’t Stay Engaged – Check linkage from pedal to valve bank Check roll pin in end of mow pedal Check rearward valve spool Check the spool detent Troubleshooting Reels Slow Down or Stop Adjust, repair and Misadjusted lubricate linkage or damaged Replace Worn...
Page 45: Cutting Unit(S) Drop During Transport
Cutting Unit(s) Drop During Transport Check that valve spool returns to neutral Check for internal lift cylinder leakage Check lift check plug o-rings in #1 valve section Check valve spool detent for binding ® Greensmaster 3100 Lubricate and Binding adjust camshaft Repair or replace Leaking cylinder(s)
Page 46: Cutting Units Lift Too Slowly Or Not At All
Cutting Units Lift Too Slowly or Not At All Check for binding lift assemblies Check forward valve spool travel Check for restriction in lines to or from cylinders Check for leaking cylinder Check lift section of pump. Test hook up No. 3 Test A Troubleshooting Loosen and...
Page 47: Lift Pedal Binding
Check pedal linkage Check valve spool detent assembly Center (#1) Cutting Unit Operates in Raised Position Check rear cam- shaft for #3 spool too far out of body Check for restric- tion in brazed tube assembly on #3 valve section Check for restriction in valve return port between #3 section...
Page 48: Steering Loss, Steering Wander Or Free Play
Steering Loss, Steering Wander or Free Play Check steering cyl- Loose inder ball joints Disconnect cylin- Binding der and check cas- tor fork movement Check steering cyl- Leakage inder for internal leakage Check for Restriction restriction in hy- draulic hose or fit- ting Check steering Defective...
Page 49: Testing
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, con- struction, accuracy, and cost.
Page 50: Test Hook Up No. 1
TEST HOOK UP NO. 1 Traction Pump Flow Traction Relief Setting 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.
Page 51 TEST HOOK UP NO. 1 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.
Page 52 Engine RPM 2800. Hydraulic oil at normal operating temperature. Engage transmission lever to No. 1 position. Push traction pedal to forward position. Front wheel that is NOT locked by brake should rotate. Greensmaster 3100 TESTER CONNECTION: (TEST B AND C) TESTER Page 4 –...
Page 53 If pressure is not in listed range, remove traction relief cartridge from valve bank and examine for contamination or damage. If needed, test left front wheel motor by placing tester in left side pressure hose and blocking flow to right motor. Testing (continued) Page 4 – 31 Rev. E Greensmaster 3100...
Page 54: Reel Drive Pump Efficiency
TEST HOOK UP NO. 3 Reel Drive Pump Efficiency 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.
Page 55: Test Hook Up No. 4, Reel Drive Motor Flow
TEST HOOK UP NO. 4 Reel Drive Motor Flow Reel Drive Relief Setting Reel Motor Efficiency 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.
Page 56 TEST HOOK UP NO. 4 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.
Page 57 If pressure not within listed range, remove steering relief cartridge and examine for contamination or damage. Adjust steering relief valve if necessary. ® Greensmaster 3100 (Greensmaster 3100) TESTER CONNECTION: TESTER GR3100 WITH DANFOSS PUMP SHOWN. MACHINES WITH PARKER PUMP USE LAST PUMP SECTION FOR STEERING CIRCUIT.
Page 58: Adjustments
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: 1. Put 1, 2 and 3 spools in neutral (center of travel) and remove transfer rod guard from foot panel.
Page 59: Traction Pedal Adjustment
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 foot- rest.
Page 60: Rear Camshaft Adjustment
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. C.
Page 61: Repairs
Repairs Reel Motor Removal and Installation (Fig. 16) 1. Disconnect hydraulic lines. Put caps or plugs on fittings and hoses to prevent contamination. Tag hydrau- lic lines for proper reassembly. 2. Loosen motor mount nuts. 3. Rotate motor clockwise so motor flanges clear studs and pull motor out.
Page 62 Reel Motor 70-9800 Repair (Fig. 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.
Page 63 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).
Page 64 14. Apply hydraulic oil to inside of cover (4) and assemble cover to body, making sure that none of the parts become displaced. Insert the cap screws and washers and hand tighten. Page 4 – 41.1 Rev. B Greensmaster 3100...
Page 65 Protect the shaft if using a pliers. 16. Tighten the capscrews evenly in a crossing pattern to a torque of 17 ft–lb. Greensmaster 3100 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).
Page 66 (Fig.18c). Repairs Figure 18b 5. Pressure seal 6. Back–up ring 7. O–ring 8. Body DIAGONAL MARK Page 4 – 41.3 Rev. D 9. Idler gear 10. Cap screw 11. Front flange Figure 18c Greensmaster 3100...
Page 67 CAUTION Use eye protection such as goggles when using compressed air. 2. Clean all motor components with solvent. Dry all parts with compressed air. Greensmaster 3100 Figure 18d 1. Motor body Figure 18e Figure 18f 1. Drive gear 2.
Page 68 13.Put a small amount of hydraulic oil in port on motor and rotate driveshaft one revolution. Protect the shaft if using a pliers. If drive shaft binds, disassemble motor and repeat assembly process. 14.Remove motor from vise. Page 4 – 41.5 Rev. D Greensmaster 3100...
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Page 70: Pump Removal And Installation
Repairs (Fig. 19) - Greensmaster 3100 shown 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.
Page 71: Pump Repair
Pump Repair - Greensmaster 3100 shown Relief Valve Service 1. Remove cap (Item 10). Remove valve adjuster (Item 9), spring (Item 8), and ball (Item 7). 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).
Page 72 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 as- sembly.
Page 73: Control Valve Removal And Installation
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.
Page 74: Control Valve Spool Seal Replacement
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.
Page 75: Control Valve Internal Seal Replacement
Control Valve Internal Seal Replacement (Fig. 27) These components changed locations after serial no. 210000701 1. Internal seals (4 between ea. sect.) 2. Main & No. 1 section relief valve NOTE: Replace all internal seals whenever valve sec- tions are disassembled. Original seals may not seal after the valve assembly is installed on the machine.
Page 76: Control Valve No. 1 Spool Detent Replacement
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.
Page 77: Control Valve No. 4 Spool Detent Replacement
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.
Page 78: Lift Cylinder Removal And Installation
Lift Cylinder Removal and Installation No. 1 (Center) Lift Cylinder (Fig. 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.
Page 79 No. 2 and 3 Lift Cylinders (Fig. 33) 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.
Page 80: Lift Cylinder Repair
Lift Cylinder Repair – No. 1 (Center) (Fig. 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.
Page 81 Lift Cylinder Repair – No. 2 and 3 (Left and Right) (Fig. 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.
Page 82: Wheel Motor Removal And Installation
Wheel Motor Removal and Installation (Fig. 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. 2. Remove wheel nuts (Item 29) and remove wheel (Item 3).
Page 83: Wheel Motor Repair
Wheel Motor Repair (Fig. 37, 38) Disassembly of Motor (Fig. 37) 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.
Page 84 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.
Page 85: Repairs
9. Assemble manifold (Item 22) and then the commuta- tor ring (Item 23) over the drive link onto rotor set. Be sure swirls in manifold and manifold plate are installed facing together. 10. Assemble a new commutator seal (Item 15), flat side up, into commutator (Item 16) and assemble commuta- tor over end of drive link onto manifold with seal side up.
Page 86: Steering Cylinder Removal And Installation
4. Reverse steps 1 - 3 to install the steering cylinder. Repairs (Fig. 39) - Greensmaster 3100 Figure 39 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.
Page 87: Steering Cylinder Repair
Steering Cylinder Repair - Greensmaster 3100 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.
Page 88: Steering Control Unit Removal And Installation
This could damage the steering valve com- ponents. Repairs (Fig. 41) - Greensmaster 3100 Figure 41 4. Remove four capscrews (Item 7) and lower the steer- ing valve (Item 24) and steering column (Item 23) out of the steering arm.
Page 89: Steering Control Unit Repair
Use a wire brush to remove foreign material and debris from around exterior joints of the unit. ® Greensmaster 3100 (Fig. 42) - Greensmaster 3100 Figure 42 10. Housing 11. Control sleeve 12. Control spool centering springs 13. Control spool 14.
Page 90 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 over- tightened. 2. Remove 5/16" cap screws. 3. Remove end cap. 4.
Page 91 7. Remove drive. 8. Remove spacer plate. 9. Remove seal from housing. Control End Disassembly 10. Remove housing from vise. Place housing on a clean soft cloth to protect surface finish. Use a thin blade screwdriver to pry retaining ring from housing. 11.
Page 92 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. 14. Remove 2 bearing races and the needle thrust bearing from spool and sleeve assembly. 15.
Page 93 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. 19. Remove seal from housing. 20.
Page 94 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.
Page 95 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.
Page 96 14. Install 1-1/4" diameter dust seal in seal gland bush- ing, 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.
Page 97 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 hous- ing by wiping with the palm of clean hand.
Page 98 21. Rotate spool and sleeve assembly until pin is paral- lel 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 mark- ing.
Page 99 24. Install 3" diameter seal in end cap. 25. Install end cap on gerotor, align holes. 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.
Page 100 ® Repairs Page 4 - 72 Greensmaster 3100...
Page 101 Table of Contents WIRING SCHEMATIC ..... . . 2 TURF GUARDIAN LEAK DETECTION SYSTEM. 3 SPECIAL TOOLS ......4 TROUBLESHOOTING .
Page 102: Wiring Schematic
BLACK WHITE/RED WHITE/RED BLUE BLACK WHITE/RED WHITE/RED BLACK BROWN BROWN GREY GREY RED/WHITE ORANGE Wiring Schematics (Greensmaster 3100, S/N Below 80000) BLACK RED/WHITE BLACK GREEN BLUE Page 5 – 2 Rev. D BROWN YELLOW ORANGE ORANGE BLACK RED/WHITE BLACK GREY...
Page 103 Wiring Schematic (Greensmaster 3100, S/N 80001 – 200999999) Greensmaster 3100/3050 Wiring Schematics Page 5 – 2.1 Rev. D...
Page 104 Wiring Schematic (Greensmaster 3100, S/N 210000001 – 220999999) Wiring Schematics Greensmaster 3100/3050 Page 5 – 2.2 Rev. D...
Page 105 Wiring Schematic (Greensmaster 3100, S/N 230000001 and Up ) Greensmaster 3100/3050 Wiring Schematics Page 5 – 2.3 Rev. D...
Page 106 Wiring Schematic BLACK WHITE/RED WHITE/RED BLUE BLACK WHITE/RED WHITE/RED RED/WHITE ORANGE Wiring Schematics (Greensmaster 3050, S/N Below 80000) BLACK RED/WHITE GREEN BLUE Page 5 – 2.4 Rev. D BROWN YELLOW ORANGE ORANGE BLACK RED/WHITE BLACK BLACK BLUE YELLOW ORANGE Greensmaster 3100/3050...
Page 107 Wiring Schematic (Greensmaster 3050, S/N 80001 – 200999999) Greensmaster 3100/3050 Wiring Schematics Page 5 – 2.5 Rev. D...
Page 108 Wiring Schematic (Greensmaster 3050, S/N 230000001 and Up) Wiring Schematics Greensmaster 3100/3050 Page 5 – 2.6 Rev. D...
Page 109 Wiring Harness (Greensmaster 3100/3050, S/N 80001 – 200999999) Greensmaster 3100/3050 Wiring Schematics Page 5 – 2.7 Rev. D...
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Page 111: Turf Guardian Leak Detection System
After a one second delay alarm will sound. NOTE: During normal operation, with cutting units low- ered, approximately 5 oz. of oil will leak before float switch activates alarm. ® Greensmaster 3100 (Greensmaster 3100 S/N below 230000001) Sight Overflow Gauge Tank Solenoid Valve...
Page 112: Special Tools
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 ).
Page 113 Skin-Over Grease (Fig. 7) Special non-conductive grease which forms a light pro- tective skin to help waterproof electrical switches and contacts. Recommended for all interlock system con- nections. Figure 7 ® Greensmaster 3100 Page 5 - 5 Special Tools...
Page 114: Troubleshooting
Troubleshooting CAUTION Remove all jewelry, especially rings and watches, before doing any electrical trou- bleshooting. Disconnect battery cables un- less the test requires battery voltage. For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used.
Page 115 Problem 5. Engine cranks but does not start when shift selector and mow pedal are in neutral. 6. Engine does not stop when mow pedal is pushed down (cut- ting units engaged) as you get off of the seat. 7. Engine does not stop when shift selector is in No.
Page 116: Verify Interlock Operation
Problem 11. Engine does not stop when ig- nition key is rotated to OFF posi- tion. 12. Battery does not charge. Verify Interlock Operation The interlock system is designed to stop the engine when the operator is off of the seat, while the traction selector is in the No.
Page 117: Testing
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 sche- matics, determine which component is at fault. How- ever, 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.
Page 118: Seat Switch
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.
Page 119: Mow/Lift Switch
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. 2. Push down on the lift pedal and release it. There should be continuity when the mow pedal is disen- gaged.
Page 120: Battery
Battery Terminal Voltage Test 1. Use a volt-ohm meter to measure the voltage be- tween 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.
Page 121: Repairs
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.
Page 122: Traction (Neutral) Switch Replacement And Adjustment
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. 3. Move shift selector to Neutral. 4.
Page 123: Mow/Lift Switch Replacement And Adjustment
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. Pull connector off switch terminals from end of mow/lift switch installed in the valve bank bonnet.
Page 124 Battery Service (Fig. 18, 19) IMPORTANT: Before welding on the machine, dis- connect the negative (–) battery cable from the bat- tery to prevent damage to the electrical system. IMPORTANT: To prevent damage to the electrical components, do not operate the engine with the battery cables disconnected.
Page 125 Table of Contents SPECIFICATIONS ......2 ADJUSTMENTS ......3 Brake Adjustment .
Page 126: Specifications
Specifications Item __________________________________________________________________________________________ Tire pressure ________________________________________________________________________________________________________________________________________________________ Wheel nut torque ________________________________________________________________________________________________________________________________________________________ Wheel motor spindle nut torque Specifications Page 6 - 2 Specification 8 - 12 PSI front 8 - 15 PSI rear 40 - 50 ft-lb 250 - 400 ft-lb ® Greensmaster 3100...
Page 127: Adjustments
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 As a safety precaution, always check brakes in a wide, open spaced, flat area which is free...
Page 128: Repairs
Repairs Brake Service (Fig. 2) Brake Disassembly 1 Place blocks on each side of opposite wheel, jack machine up and place blocks beneath frame under wheel motor. 2. Remove wheel nuts (Item 29) and remove wheel. Remove large nut (Item 4) securing wheel hub (Item 5) to motor shaft.
Page 129: Steering Cable (Greensmaster 3050)
2. If all threads on the cable end have been used, re- place cables. If necessary, service the pulley and steer- ing cable under the steering wheel by removing the cover on the end of the steering column Greensmaster 3100 Figure 3 1. Capscrew and washer 2. Steering arm 3.
Page 130 Repairs Greensmaster 3100 Page 6 – 6 Rev. B...
Page 131 Table of Contents SPECIFICATIONS ......2 SPECIAL TOOLS ......3 TROUBLESHOOTING .
Page 138 Use Loctite 271 on spline nut. Rev. C...
Page 149 Use Loctite 271 on spline nut. Rev. C...
Page 151 Single Point Adjust Cutting Units Table of Contents SPECIFICATIONS ......3 SPECIAL TOOLS ......4 TROUBLESHOOTING .
Page 160 Use Loctite 271 on spline nut threads. Rev. C...
Page 174 Use Loctite 271 on spline nut threads. Rev. C...
Page 177 Table of Contents SPECIFICATIONS ......3 SPECIAL TOOLS ......4 TROUBLESHOOTING .
Page 188 Use Loctite 271 on spline nut threads. Rev. C...
Page 203 Use Loctite 271 on spline nut threads. Rev. C...
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Page 211: Specifications
Speed Kit) ....... Greensmaster 3100 Dual Point Adjust Cutting Units...
Page 212 Grass Shield: Non–adjustable shield with adjustable cut–off bar to improve grass discharge from reel in dry conditions. Maximum Reel Speed: 2200 RPM Weight: 8 Blade 11 Blade Page 10 - 2 Rev. D 72 lb. (32 kg) 75 lb. (34 kg) Greensmaster 3100...
Page 213: Special Tools
Toro Model Number: TOR299100 Bedknife Screw Tool This screwdriver–type bit is made to fit Toro bedknife at- taching screws. Use this bit with a torque wrench to se- cure the bedknife to the bedbar. IMPORTANT: DO NOT use and air or manual impact wrench with this tool so damage to the bedbar will be prevented.
Page 214 This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the TurfEvaluator (Toro part no. 97931SL)
Page 215 For additional information regarding cutting unit trouble- shooting, see Aftercut Appearance Troubleshooting Aid (Toro part no. 00076SL). Possible Problem/Correction Check pressure of all tires. Pressure must be equal on both front tires. Adjust pressure as necessary.
Page 216 Repairs section in this chapter of this manual. Rear cutting unit must drop after front cutting units. See Rear Lift Cylinder Flow Control Valve in Chapter 4 – Hydraulic System in this manual. Page 10 - 6 Rev. D Greensmaster 3100...
Page 217: Set Up And Adjustments
In addition, the rear roller positioning system allows for two height-of-cut ranges. Greensmaster 3100 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.
Page 218: Hydraulic Reel Motor
3. Attach backlap motor or drive to the socket exten- sion. 4. Follow instructions and procedures for backlapping in the Toro Service Training Book, Sharpening Reel and Rotary Mowers, part no. 80300SL. Dual Point Adjust Cutting Units Inspection 1.
Page 219: Backlapping (Units With Optional Backlap/Variable Reel Speed Kit)
This will remove any burrs or rough edges that may have built up on the cutting edge. Note: Additional instructions and procedures on backlapping are available in the Toro Service Training Book, Sharpening Reel and Rotary Mowers, part no. 80300SL.
Page 220: Bedbar Assembly
Flange nut 10. Shim 11. Spacer 12. Retainer Page 10 - 10 Rev. D 190 to 240 in–lbs (21 to 27 Nm) Antiseize Lubricant 13. Cap screw 14. Rear roller assembly 15. Lock nut 16. Bedknife 17. Bedknife screw Greensmaster 3100...
Page 221: Bedbar Removal And Installation
3. Thread the flange nuts (8) all the way up to the head of each bedbar pivot bolt (7) and apply antiseize lubri- cant to the threads of each bedbar pivot bolt (7). Greensmaster 3100 Â Â Â Â Ç Ç Ç Ç...
Page 222: Bedbar Adjuster Service
7. Install bedbar (see Bedbar Installation in this sec- tion of this manual). 8. Adjust cutting unit (see Cutting Unit Operator’s Manual). Page 10 - 12 Rev. D Cap screw 10. Washer 11. Spring 12. Lock nut Greensmaster 3100...
Page 223: Bedknife Replacement And Grinding
Note: When grinding, be careful to not overheat the bedknife. Remove small amounts of material with each pass of the grinder. 2. Use Toro Service Training Book, Sharpening Reel and Rotary Mowers (part no. 80300SL) for bedknife grinding information. Bedknife Grinding Specifications...
Page 224: Reel Assembly
17. Frame assembly Page 10 - 14 Rev. D 17 to 20 ft–lbs (23 to 27 Nm) 18. Flange nut 19. Cap screw 20. Lift hook 21. Cap screw 22. Grass shield 23. Washer 24. Cap screw 25. Lock nut Greensmaster 3100...
Page 225: Reel Removal
9. Remove the 2 shoulder bolts (7) securing the left hand side plate to the cutting unit frame. Remove the side plate from the reel shaft and the roller shafts. Greensmaster 3100 Figure 17 1. Counter weight Figure 18 1.
Page 226: Left Side Plate Service
4. Remove all grease from the side plate bore. 5. Insert the wave washer (15) into the side plate. Note: Replacemant Seal Kit (Toro Part No. 106-6937) is available for side plate service of dual point adjust cut- ting units.
Page 227: Reel Service
2. Remove the V–ring (3) from the reel shaft. 3. Using a flat blade screw driver or similar tool, re- move the speedi sleeve (2) from the reel shaft. Note: Replacemant Seal Kit (Toro Part No. 106-6937) is available for reel service of dual point adjust cutting units.
Page 228: Reel Installation
E. Tighten each bedbar adjuster assembly until the adjuster spring is fully compressed, then loosen lock nut 1/2 turn. Note: For severely tapered reels, a .010 in. (.254 mm) shim (Toro Part No. 106-6923) is available for the rear roller mount. Page 10 - 18 Rev. D 2.
Page 229: Preparing A Reel For Grinding
3. After completing the grinding process: REEL DIAMETER BLADE LAND WIDTH Greensmaster 3100 A. Install parts removed to mount cutting unit into grinder. B. Install bedbar assembly (see Bedbar Removal and Installation). C. Complete cutting unit set–up and adjustment se- quence (see Cutting Unit Operator’s Manual).
Page 230: Front Roller Removal And Installation
Center roller in the front brackets and secure into place with the cap screws. 5. Adjust cutting unit height–of–cut (see Cutting Unit Operator’s Manual). Page 10 - 20 Rev. D 4. Carriage screw 5. Lock nut 6. Tab washer Greensmaster 3100...
Page 231: Front And Rear Roller Service
2. Press the seal squarely into the roller body. The seal face should be flush with the end of the roller body when correctly installed. Greensmaster 3100 Figure 24 Roller bearing Rear roller body .625 in.
Page 232 6. Install new seals (see Roller Seal Installation in this chapter of this manual). Dual Point Adjust Cutting Units Figure 26 1. Roller shaft 2. Roller body 3. Seal Page 10 - 22 Rev. D 4. Bearing 5. Spiral retaining ring Greensmaster 3100...
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Chapter 1 - Safety

Chapter 2 Product Records

Chapter 3 Engine

Chapter 4 Hydraulic System

Chapter 5 Electrical System

Chapter 6 Wheels, Steering and Brakes

Chapter 10 Dual Point Adjust Cutting Units

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Troubleshooting

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