Toro GREENSMASTER 3100 Operator'S Manual Download

Page: 41 / 48

Troubleshooting

Problem

Possible Causes

Corrective Action

Engine:

1. The fuel tank is empty.

1. Fill the fuel tank.

The engine loses power.

2. A fuel line is clogged or there is

debris in the fuel tank.

2. Clean the fuel tank. Use clean

gasoline.

3. The fuel filter is clogged.

3. Replace the filter.

4. The oil level in the crankcase is

low.

4. Add oil to the proper level. Check

the level more frequently.

5. The oil in the crankcase is

incorrect.

5. Replace it with the correct oil.

6. Carburetor fuel solenoid

6. Check the solenoid and wiring.

7. The throttle cable is set incorrectly.

7. Repair as necessary.

8. The choke is closed.

8. Readjust the choke.

9. The air cleaner element is plugged.

9. Replace the element and service it

more frequently.

10. The carburetor malfunctions.

10. Repair as necessary.

11. The ignition malfunctions.

11. Repair as necessary.

12. The cooling fins are plugged with

debris or the engine is overheating.

12. Clean the fins. Repair the engine

as necessary.

13. The engine has an internal

malfunction.

13. Repair as necessary.

14. The pump coupling is loose.

14. Repair or replace the coupling.

15. The hydraulic system is

malfunctioning.

15. Refer to hydraulic troubleshooting

below.

The engine will not start.

1. The ignition system is faulty.

1. Repair as necessary.

2. The fuel tank is empty.

2. Fill the fuel tank.

3. The starter system is

malfunctioning.

3. Check the connections, solenoid,

starter motor, and ignition switch.

4. Carburetor fuel solenoid

4. Check the solenoid and wiring.

Hydraulic:

1. The control lever is misadjusted.

1. Adjust the control lever.

There is no ground speed increase in

the #2 selection.

2. The rear camshaft is misadjusted.

2. Adjust it by moving the right end or

the rear camshaft forward or the

left end rearward.

3. The mow/lift linkage is binding or

there is a broken lift pivot spring.

3. Lubricate or repair the machine.

4. There are wrong detent parts in the

#4 spool.

4. Remove the valve bank and repair

the #4 spool assembly.

5. The #2 or #3 spool relief valves are

stuck open. (The reel drive RPM

will also be low on the #1 or #3

cutting unit).

5. Remove and repair or replace the

relief cartridge.

In the hydraulic system there is no #1

or reverse traction speed. The #2

speed is normal.

1. The disc seal between the #3 and

#4 valve sections is damaged or

missing.

1. Remove the valve bank and

replace the disc seal.

2. The poppet inside the #4 spool is

stuck open or off its seat.

2. Remove the valve bank and repair

the #4 spool section.

Summary of Contents for GREENSMASTER 3100

Page 1: ...Operator s Manual Original Instuctions EN GB Form No 3352 242 Rev C Greensmaster 3100 Two Wheel Drive Greensmaster Traction Unit Model No 04356 Serial No 250000001 and Up ...

Page 2: ...g 16 Checking the Engine Oil 16 Filling the Gas Tank 16 Servicing the Hydraulic System 17 Tire Pressure 18 Checking the Torque of the Wheel Nuts 18 Page Operation 19 Think Safety First 19 Controls 19 Break in Period 21 Starting the Engine 21 Checking the Interlock System 22 Preparing the Machine for Mowing 23 Training Period 23 Before Mowing 23 Mowing Procedures 24 Transport Operation 24 Inspectio...

Page 3: ...o highlight information Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention Safety This machine meets or exceeds the B71 4 1999 specifications of the American National Standards Institute in effect at time of production when 40 lb of ballast is added to the rear wheel Note The addition of attachments made by other manufact...

Page 4: ...ncluding emptying the grass baskets Stop equipment and inspect the machine after striking objects or if an abnormal vibration occurs Make necessary repairs before resuming operations Keep hands and feet away from the cutting units Look behind and down before backing up to be sure of a clear path Never carry passengers and keep pets and bystanders away Slow down and use caution when making turns an...

Page 5: ... stop immediately turn the engine off wait for all motion to stop and inspect the machine for damage A damaged reel or bedknife must be repaired or replaced before operation is continued Before getting off of the seat move the shift selector to N neutral depress the lift pedal to raise the cutting units wait for the reels to stop spinning and release lift pedal Set the parking brake Stop the engin...

Page 6: ...ment parts and accessories Replacement parts and accessories made by other manufacturers could be dangerous and such use could void the product warranty Sound Pressure This unit has a maximum sound pressure level at the operator s ear of 86 dBA based on measurements of identical machines per Directive 98 37 EC Sound Power This unit has a guaranteed sound power level of 105 dBA based on measurement...

Page 7: ... reels 2 Press the mow pedal to lower and start the reels 93 9898 1 Lock and unlock the reels 93 8062 1 To lock the parking brake press the brake pedal and the parking brake lock 2 To unlock the parking brake press the brake pedal 3 Parking brake lock 107 2554 1 Read the Operator s Manual 2 Off 3 Choke 4 On 5 Slow 6 Continuous variable setting 7 Fast 8 Failure malfunction Leak detector alarm test ...

Page 8: ...4 for CE 1 Warning read the instructions before servicing or performing maintenance 2 Cutting hazard of foot or hand stop the engine and wait for moving parts to stop 93 6691 1 Read the Operator s Manual 93 8069 1 Hot surface burn hazard stay a safe distance from the hot surface ...

Page 9: ...h eyes immediately with water and get medical help fast 10 Contains lead do not discard 93 8063 for CE 1 Warning read the Operator s Manual 2 Tipping hazard do not use the machine on a slope greater than 15 degrees 3 Thrown object hazard stay a safe distance from the machine 4 Cutting hazard of hand or foot stay away from moving parts 5 Warning lock the parking brake stop the engine and remove the...

Page 10: ...prox 13 0 km h Reverse Speed 1 9 MPH approx 3 1 km h Reel Speed 1975 RPM approx Clip Speed 11 Blade Cutting Unit 0 18 in approx 4 6 mm Clip Speed 8 Blade Cutting Unit 0 25 in approx 6 4 mm Accessories 8 Blade DPA Cutting Unit Model No 04610 11 Blade DPA Cutting Unit Model No 04611 Spiker Model No 04494 Tri Roller Model No 04495 Thatching Reels Model No 04493 Variable Traction Speed Kit Model No 04...

Page 11: ...e height of cut Grass basket 3 Mounts to the pull frame Ignition keys 2 Warning decal 1 Affix over English warning decal 104 2053 for CE Danger decal 3 Affix over English danger decal 62 5070 for CE Service decal 1 Affix over English service decal 106 6367 for CE Operator s Manual traction unit Engine Operator s Manual 2 1 Read before operating the machine Operator video 1 Watch before operating t...

Page 12: ... the battery posts Charge the battery at a rate of 3 to 4 amps until the specific gravity is 1 250 or higher and the temperature is at least 60_F 16_C with all sells gassing freely 6 When the battery is charged disconnect the charger from the electrical outlet and battery posts Note After the battery has been activated add only distilled water to replace normal loss although maintenance free batte...

Page 13: ...ting holes to gain an additional 3 in 7 6 cm in the forward adjustment or in the rear mounting holes for an additional 3 in 7 6 cm in the rearward adjustment 1 Support the seat base in the up position with the seat support rod 2 Remove the locknuts securing the seat slides to the plywood shipping base Discard the locknuts 3 Secure the seat seat panel and seat slides to the seat support with the lo...

Page 14: ...th the wing nuts Installing the Steering Wheel 1 Slide the steering wheel onto the steering shaft and secure it with the jam nut Fig 8 Torque it to 32 ft lb 43 N m 2 Install the cap to the steering wheel with the screw Fig 8 Note The steering wheel may be adjusted fore and aft for operator comfort by loosening the three mounting screws pivoting the steering wheel to the desired operating position ...

Page 15: ...ecure the sockets in position Fig 11 1 2 3 Figure 11 1 Ball joint 2 Pull arm 3 Jam nut 7 Assemble the mounting capscrews for the reel drive motor to each cutting unit Leave approximately 1 2 in 13 mm of threads exposed on each mounting capscrew Fig 12 1 2 Figure 12 1 Capscrews 2 Drive motor 8 Remove the protective covers from the cutting units and the reel drive motor shafts Note Retain the protec...

Page 16: ...e containing methanol or gasohol containing more than 10 ethanol because the fuel system could be damaged Do not mix oil with gasoline Danger In certain conditions gasoline is extremely flammable and highly explosive A fire or explosion from gasoline can burn you and others and can damage property Fill the fuel tank outdoors in an open area when the engine is cold Wipe up any gasoline that spills ...

Page 17: ...E 5W 20 Pennzoil AWX MV46 Phillips Magnus A KV 5W 20 Shell Tellus T 46 Sunoco Sun Hyd Oil 2105 Texaco Rando HDZ 46 Universal Tractor Hydraulic Fluid Mobil Mobilfluid 424 Amoco 1000 Fluid Chevron Tractor Hydraulic Fluid Conoco Hydroclear Powertran Esso Hydraul Gulf Universal Tractor Fluid Kendall Hyken 052 Marathon Marafluid Super HT Pennzoil Hydra Trans Phillips HG Fluid Shell Donax TD 76 Lubrican...

Page 18: ...s cold 2 Remove the cap from the top of the reservoir and check the fluid level The fluid should be approximately 3 1 2 in 89 mm below the top of the fill hole Fig 15 Fluid level 3 1 2 in from top of fill hole 1 2 Figure 15 1 Hydraulic reservoir 2 Screen 3 If the oil level is low slowly fill the reservoir with ISO VG 46 48 or equivalent hydraulic oil until the level is up to the correct level Do n...

Page 19: ...tops the reels from turning and lifts the cutting units The lift pedal must be fully depressed until the cutting units are fully raised and have stopped rotating 1 5 4 3 2 Figure 17 1 Mow pedal 2 Lift pedal 3 Traction pedal 4 Brake pedal 5 Parking brake button Parking Brake Button Depressing the brake pedal to actuate the brake assembly then depressing the small button indicated Fig 17 will keep t...

Page 20: ...use Fig 19 is part of the electrical circuit It contains a 10 amp fuse 15 amp maximum Hour Meter The hour meter Fig 19 indicates the total hours of machine operation It starts to function whenever the key switch is rotated to On Seat Adjusting Handle This lever on the left side of the seat Fig 19 allows a 4 inch fore and aft adjustment Mow Lockout Lever The lockout lever Fig 20 locks the mow pedal...

Page 21: ...l leakage loose fasteners or any other malfunction To ensure optimum performance of the brake system burnish break in the brakes before using the machine To burnish the brakes firmly apply the brakes and drive the machine at mowing speed until the brakes are hot as indicated by their smell An adjustment to the brakes may be required after break in refer to Adjusting the Brakes page 32 Starting the...

Page 22: ...erator off of the seat or the parking brake is engaged 1 2 3 Figure 23 1 Traction switch 2 Seat switch 3 Mow lift switch Perform the following system checks daily to be sure the interlock system is operating correctly 1 Sit on the seat engage the parking brake and move the shift selector to neutral Remove your foot from the traction pedal and make sure the pedal is in neutral Fully depress the lif...

Page 23: ...tions with the parking brake engaged Preparing the Machine for Mowing To assist in aligning the machine for successive cutting passes it is suggested the following be done to the No 2 and No 3 cutting unit baskets 1 Measure in approximately 5 in 12 7 cm from the outer edge of each basket 2 Either place a strip of white tape or paint a line onto each basket paralleling the outer edge of each basket...

Page 24: ...ss left to mow around the outer periphery 5 Cut down on operating time and ease lineup for the next pass by momentarily turning the machine in the opposite direction then turning in the direction of the uncut portion i e if intending to turn right first swing slightly left then right This will assist in getting the machine more quickly aligned for the next pass Follow the same procedure for turnin...

Page 25: ...ecause the drive system may be damaged If the machine must be moved a considerable distance transport it on a truck or trailer Maintenance Note Determine the left and right side of the machine from the normal operating position Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure After First 8 Hours Change the engine oil Replace the engine oil filter Every 50 Hours C...

Page 26: ...cooling fins Inspect the air filter pre cleaner Check any unusual engine noises Check the hydraulic hoses for damage Check for fluid leaks Check the tire pressure Check the reel to bedknife adjustment Check the height of cut adjustment Lubricate all grease fittings 1 Lubricate the mow lift and brake linkage Touch up damaged paint 1immediately after every washing regardless of the interval listed N...

Page 27: ...0 hours of operation The following traction unit bearings and bushings must be lubricated Rear wheel bearings 1 Fig 26 Steering fork shaft 1 Fig 27 Lift arm pivot 3 and pivot hinge 3 Fig 28 Pull frame shaft and roller 12 Fig 29 Power steering cylinder Fig 30 Mow lift pivot Fig 31 Lift cylinders 3 Fig 32 Mow lockout lever Fig 33 1 Wipe the grease fitting clean so foreign matter cannot be forced int...

Page 28: ...28 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 ...

Page 29: ... 100 operating hours More frequent cleaning is required when operating in dusty or dirty conditions 1 Release the locking clips and remove the air cleaner cover Fig 35 Clean the cover thoroughly 2 Remove the wing nut securing the elements to the air cleaner body 1 Figure 35 1 Air cleaner cover 3 If the foam element is dirty remove it from the paper element Fig 36 Clean it thoroughly A Wash the foa...

Page 30: ...d Control Important Before the carburetor and speed control are adjusted the throttle and choke controls must be adjusted properly The engine must be running during adjustment of the carburetor and speed control Contact with moving parts or hot surfaces may cause personal injury Shift into neutral and engage the parking brake before performing this procedure Keep hands feet clothing and other body...

Page 31: ...ll the correctly gapped spark plug w gasket seal and tighten the plug to 200 in lb 23 N m If a torque wrench is not used tighten the plug firmly 0 030 in 0 76 mm Figure 39 Replacing the Fuel Filter An in line filter is incorporated into the fuel line between the fuel tank and carburetor Fig 40 Replace the filter every 800 hours or sooner if the fuel flow is restricted Be sure the arrow on the filt...

Page 32: ...machine and run it at idle for 3 to 5 minutes to circulate the fluid and remove any air trapped in the system Stop the machine and recheck the fluid level 6 Dispose of the used oil properly Checking the Hydraulic Lines and Hoses Hydraulic fluid escaping under pressure can penetrate skin and cause injury Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connectio...

Page 33: ...act with the brake drums Readjust if necessary to achieve this setting 6 Transport the machine and depress the brake pedal both brakes should lock equally Readjust if necessary 7 It is recommended that the brakes be burnished annually refer to Break In Period page 21 Adjusting the Rear Camshaft A camshaft misaligned with the valve bank may cause the following No increase in ground speed in the No ...

Page 34: ...ent lever hole Fig 46 1 2 3 4 m 5101 Figure 46 1 Jam nut 2 Yoke 3 Control rod 4 Adjustment lever 4 Install the clevis pin and cotter pin Tighten the jam nut and install the transfer rod guard 5 Actuate the mow pedal by hand Be sure the lift pivot under the pedals clears the stop welded to the frame thereby allowing full spool travel Leveling the Lift and Mow Pedals If the lift and mow pedals are n...

Page 35: ...ttain the 3 16 in 5 mm dimension when reinstalled Adjusting Cutting Unit Lift and Drop The cutting unit lift drop circuit is equipped with a flow control valve This valve is preset at the factory at approximately 3 1 2 turns open but an adjustment may be required to compensate for differences in hydraulic oil temperatures mowing speeds etc If an adjustment is required proceed as follows Note Allow...

Page 36: ...lug the switch connectors from the traction switch installed in the valve bank bonnet on the selector valve section Fig 50 3 Loosen the jam nut and unscrew the switch from the mounting bracket 4 Move the shift selector to Neutral 5 Partially screw the new switch into the bonnet 6 Connect a continuity tester or ohm meter to the switch terminals and continue to turn the switch in until there is cont...

Page 37: ...tion 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Warning The battery electrolyte level must be properly maintained and the top of the battery kept clean Store the machine in a cool place to prevent the battery from running down Check the electrol...

Page 38: ...d Checking the Hydraulic Lines and Hoses page 32 4 All fuel should be removed from the fuel tank Run the engine until it stops from lack of fuel The small amount of fuel that remains in the bottom of the tank should be removed by absorbing it with a clean dry cloth Replace the fuel filter refer to Replacing the Fuel Filter page 31 5 While the engine is still warm drain the oil from the crankcase R...

Page 39: ...Y BN D2 VIO BK FL STARTER SOLENOID MAGNETO ENGINE GND FRAME GND SP BATTERY VIO VOLT VOLT METER W BK 30 85 87 86 87a KILL RELAY CLOSED WHEN OFF MOW SW GY 30 85 87 86 87a PARKING BRAKE KILL RELAY BK VIO D1 W GN R OR FL W SP 10A STARTER X STOP NONE RUN B I A X Y START B I S Y A B S I OR A X Y S I B RUN START OFF IGNITION SW BN BU TO THE LIGHTS OPTIONAL LIGHT TEST SW BU BU VIO HR HR METER SEAT SW CLOS...

Page 40: ...RING CONTROL VALVE 4 5 CU IN REV 75 CU CM REV 2000 PSI 141 KG SQ CM 2000 PSI 141 KG SQ CM 2000 PSI 141 KG SQ CM 2000 PSI 141 KG SQ CM 2ND 1ST N FWD N REV 57 IN REV 9 3 CU CM REV 850 PSI 60 KG SQ CM 2 9 CU CM REV 3 18 IN REV 3 32 IN REV 5 2 CU CM REV 2900 RPM MAX OIL FILTER 10 MICRON 43 CU IN REV 7 CU CM REV SAFETY INTERLOCK SWITCH VALVE BANK SAFETY INTERLOCK SWITCH HYDRAULIC TANK 3 3 32 IN REV 5 2...

Page 41: ...s malfunctioning 15 Refer to hydraulic troubleshooting below The engine will not start 1 The ignition system is faulty 1 Repair as necessary g 2 The fuel tank is empty 2 Fill the fuel tank 3 The starter system is malfunctioning 3 Check the connections solenoid starter motor and ignition switch 4 Carburetor fuel solenoid 4 Check the solenoid and wiring Hydraulic 1 The control lever is misadjusted 1...

Page 42: ...he reels are affected 2 The shift lever bracket is loose 2 Adjust and tighten the shift lever 3 The rear camshaft is misadjusted 3 Adjust the camshaft 4 The engine lacks power 4 Repair as necessary The shift lever is binding 1 The 4 spool detent assembly is lacking lubrication 1 Remove the valve bank Disassemble the detent assembly and repair it All three cutting units raise and lower too slowly 1...

Page 43: ...s a blockage 6 Repair as necessary 7 A motor is excessively worn 7 Test to verify Repair or replace the motor 8 The 1 cutting unit has slow reel RPM 8 Check the lift cylinders for internal leakage Repair or replace the cylinder 9 The pump is excessively worn 9 Text to verify Repair or replace the pump 10 A spool is loose in the valve body Fluid is leaking past the spool 10 Replace the spool valve ...

Page 44: ...2 The rear camshaft is misadjusted 2 Adjust the camshaft 3 The engine or rectifier plug is loose 3 Connect the wire 4 The I terminal wire of key switch is loose 4 Connect the wire 5 There is engine trouble or the fuel tank is empty 5 Determine the problem and correct it 6 The parking brake kill relay is damaged 6 Replace the relay The engine does not stop when the mow pedal is depressed the reels ...

Page 45: ...res The engine seems to cut out too much during transport Some cut out is normal 1 The seat if lifting off of the seat switch button too easily 1 Adjust the seat switch or instruct the operator to sit back in the seat during transport The engine does not stop when the ignition key is rotated to the Off 1 The ignition switch connection is loose 1 Push the connector onto the ignition switch terminal...

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Page 48: ...t limited to weather storage practices contamination use of unapproved coolants lubricants additives or chemicals etc Normal wear and tear items Normal wear and tear includes but is not limited to damage to seats due to wear or abrasion worn painted surfaces scratched decals or windows etc Parts Parts scheduled for replacement as required maintenance are warranted for the period of time up to the ...

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Toro GREENSMASTER 3100, Operator'S Manual

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Summary of Contents for GREENSMASTER 3100

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