Toro 3100 - Manual

8. Do not carry passengers on the machine. Keepeveryone, especially children and pets, away from theareas of operation. 9. Since gasoline is highly flammable, handle itcarefully: A. Use an approved fuel container. B. Do not remove fuel tank cap while engine is hotor running.C. Do not smoke while han...

Chapter 2 Product Records and Manuals Table of Contents PRODUCT RECORD FORM . . . . . . . . . . . . . . . . . . 1EQUIVALENTS AND CONVERSIONS . . . . . . . . . . 2 Decimal and Millimeter Equivalents . . . . . . . . . . 2U.S. to Metric Conversions . . . . . . . . . . . . . . . . . 2 TORQUE SPECIFICATI...

Equivalents and Conversions Decimal and Millimeter Equivalents U.S to Metric Conversions ___________________________________________________________________________________________________ Fractions Decimals mm Fractions Decimals mm ___________________________________________________________________...

Torque Specifications Use these torque values when specific torque valuesare not given. DO NOT use these values in place ofspecified values. The torque values listed below are for lubricatedthreads. Plated threads are considered to be lubricated. Capscrew Markings and Torque Values - U.S. Customary ...

Chapter 3 Engine Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Throttle Control Adjustment . . . . . . . . . . . . . . . . . 2Choke Control Adjustment . . . . . . . . . . . . . . . . . 2Gove...

Adjustments Throttle Control Adjustment (Fig. 1) Before adjusting carburetor, make sure throttle controlis operating properly. 1. Loosen cable clamp screw securing cable to engine. 2. Move remote throttle control lever forward to FASTposition. 3. Pull firmly on throttle cable until back of swivel co...

Governor Adjustment (Before starting engine) IMPORTANT: If carburetor has been removed orgovernor linkage disassembled, the governor lever,throttle restrictor and secondary governor springmust be adjusted before the engine is started. Governor Lever Adjustment (Fig. 2) All linkage must be installed ...

Carburetor and Speed Control Adjustment (Fig. 5, 6) IMPORTANT: Before carburetor and speed controlare adjusted, the throttle and choke controls mustbe adjusted properly. Engine must be running during adjustment ofcarburetor and speed control. To guardagainst possible personal injury, shift intoneutr...

Engine Removal and Installation Removing the Engine 1. Disconnect the negative (–) and positive (+) batterycables from the battery. 2. Close the fuel shut-off valve and disconnect the fuelline. Gasoline is highly flammable. Use cautionwhile handling it. Do not smoke cigarettes,cigars or pipes. Dispo...

Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . 3Hydraulic Fitting Installation . . . . . . . . . . . . . . ....

Specifications Item Description __________________________________________________________________________________________ Hydraulic Pump External gear type 5 section (Greensmaster 3100)4 section (Greensmaster 3050) Steering relief pressure (Greensmaster 3100) 850 psi _______________________________...

General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions suchas, pressure differentials during operation and exposureto weather, sun, chemicals, very warm storage condi-tions or mishandling during operation or maintenance.These conditions can cause damage or premature de...

Hydraulic Flow Diagrams Traction, No. 1 Position When engine is started, pump draws oil from reservoirthrough two suction lines. Oil from one section of pumppasses through fitting in No. 4 spool valve into valve.Traction lever, when located in No. 1, positions spool sooil is directed to flow into th...

Traction, Reverse Position Traction lever is positioned in No. 1 or No. 2. Whentraction pedal is pushed rearward, flow from one pumpsection goes through No. 4 selector valve section into No. 5 metering section and out the lines at the front ofthe valve to the traction motors, which drive the tractio...

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 throughleft end cover and out line leading to left front cutting unitdrive motor. Flow causes motor to turn, driving...

Reel Drive, Lower Cutting Units The MOW pedal is depressed to start reel drive opera-tion, flow from one pump section passes through No. 3spool section and out three lines, each leading to a liftcylinder. This actuates the lift cylinders and lowers thecutting units. Oil is returned to a three-way fi...

Reel Drive, Raising Cutting Units When the LIFT pedal is depressed, No. 1, 2 and 3 spoolsare pushed inward. When spools pass neutral, cuttingunits stop operation. Holding pedal depressed keepsspools fully in. This directs flow from one pump sectionto pass through end cover and No. 1 spool valve, out...

Greensmaster 3100 Page 4 – 12 Hydraulic Schematics Rev. E Hydraulic Schematic (Greensmaster 3100 2WD Serial Number Below 230000000) REEL MOT ORS LH RH CENTER LIFT CYLINDERS LH RH CENTER T P STEERING CYLINDER LR PUMP (DANFOSS) LH RH WHEEL DRIVE MOT ORS 10.3 CU. IN/REV . (169 CU. CM/REV) STEERING CONT...

Special Tools NOTE: Order special tools from the T O R O S P E C I A L T O O L S A N D A P P L I C AT I O N S G U I D E ( C O M M E R C I A LP R O D U C T S ) . S o m e t o o l s m a y b e l i s t e d i n t h e Greensmaster 3100 Parts Catalog. Some tools mayalso be available from a local supplier. H...

Troubleshooting The cause of an improperly functioning hydraulic sys-tem is best diagnosed with the use of proper testingequipment and a thorough understanding of the com-plete hydraulic system. A hydraulic system with an excessive increase in heator noise is a potential failure. Should either of th...

Slow Groundspeed in All Traction Selections Low Misadjusted or damaged Drag Drag * Check engine RPM Improper OK Adjust – use tachometer Fill to proper level * Check hydraulic oil level Check hydraulic oil filter Replace filter * Check shift lever bracket and rear camshaft Check brakes and brake link...

Slow or No Ground Speed in No. 1 and Reverse No. 2 Appears Normal Low Defective OK OK Misadjusted or damaged Adjust or repair Check traction pump flow. Test hook up No. 1 Test A Remove valve bank and replace disk seal Repair or replace traction pump Check for internal valve bank leakage. Test hook u...

All Reels Slow or Will Not Turn Clogged Low Low OK Adjust – use tachometer Check engine RPM Fill to proper level Check reel pump flow. Test hook up No. 3 Test A Check hydraulic oil filter Replace filter Check hydraulic oil level Check linkage and roll pin on end of mow pedal shaft Repair linkage OK ...

Cutting Units Lift Too Slowly or Not At All Restricted Insufficient Binding OK Loosen and lubricate liftassemblies Check for binding lift assemblies Adjust rear camshaft Check lift section of pump. Test hook up No. 3 Test A Check for restriction in lines to or from cylinders Replace restricted line ...

Steering Loss, Steering Wander or Free Play Loose Restriction Replace restricted line or fitting Defective OK OK OK OK Binding Check for dam- aged steering wheel or shaft Repair and lubricate castor fork and bushings Check steering cyl- inder for internal leakage Replace ball joint(s) Repair or repl...

Testing The most effective method for isolating troubles in thehydraulic system is by using hydraulic test equipmentsuch as pressure gauges and flow meters in the circuitsduring various operational checks. (See the SpecialTools section in this Chapter.) Hydraulic testers may vary significantly in si...

TEST HOOK UP NO. 4 ( c o n tin u e d ) 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 crosstube to prevent reel from turning. Engine RPM 2800. Hydraulic oil at operating temperature. Engage mow ...

Traction Pedal Adjustment (Fig. 14) To check forward and reverse operation of traction pedaluse the following procedure: Reverse 1. Push down on rear of traction pedal (reverse) untilNo. 5 section spool valve is completely pushed in. 2. Check distance between bottom of pedal and foot-rest. Distance ...

Rear Camshaft Adjustment (Fig. 15) A camshaft misaligned with the valve bank may causethe 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. Slow lift of the cutting units. D. Slow or no drive to...

Repairs Reel Motor Removal and Installation (Fig. 16) 1. Disconnect hydraulic lines. Put caps or plugs onfittings 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 studsand pull motor out. 4. R...

Greensmaster 3100 Page 4 – 41.3 Repairs Rev. D Reel Motor 105–9770 Repair (Fig. 18b) 1. Rear cover 2. Drive gear 3. Seal4. Tab washer 5. Pressure seal 6. Back–up ring 7. O–ring8. Body 9. Idler gear 10. Cap screw11. Front flange Figure 18b 7 4 3 1 2 5 6 9 10 11 (45 to 55 Nm) 33 to 40 ft–lb 8 5 6 7 Di...

Greensmaster 3100 Page 4–41.4 Repairs Rev. D IMPORTANT: Avoid using excessive clampingpressure on the motor flange to prevent distortingthe casting. 3. Clamp mounting flange of motor in a vise with theshaft end down. 4. Loosen cap screws on the rear cover. 5. Take motor from the vise and remove cap ...

Greensmaster 3100 Page 4 – 41.5 Repairs Rev. D 3. Inspect drive gear, idler gear and bearing blocks(Fig. 18f) for the following: A. Gear shafts should be free of rough surfaces andexcessive wear at bushing points and sealing areas.Scoring, rough surfaces, or wear on gear shafts indi-cates need for r...

Hydraulic Pump Removal and Installation - Greensmaster 3100 shown (Fig. 19) Figure 19 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. IMPORTANT: When disassembling hydraulic linesmake sure hyd...

Pump Repair - Greensmaster 3100 shown (Fig. 22) Figure 22 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 reliefvalve bore and seat in bearing plate (...

Control Valve Spool Seal Replacement IMPORTANT: To prevent leakage, make sure youkeep foreign material such as dirt, sand or paintchips 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 removedfrom the machine to replace sp...

Control Valve No. 4 Spool Detent Replacement (Fig. 30) NOTE: The control valve assembly must be removed toreplace this assembly. (See Control Valve Removal andInstallation in this section of the book.) 1. Be sure No. 4 spool is in neutral and remove thebonnet, large spring, and stop collar. 2. Hold ...

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...

9. Place rotor set on a flat surface and center rotor(Item 19) in stator (Item 21) such that two rotor lobesare 180 ° apart and a roller vane (Item 20) centerline are on the same stator centerline. Check the rotor lobe toroller vane clearance with a feeler gage at this commoncenterline. If there is ...

Steering Cylinder Removal and Installation - Greensmaster 3100 (Fig. 39) Figure 39 1. Disconnect the hydraulic hoses (Item 28, 29) fromsteering cylinder (Item 33). Put caps or plugs on all thefittings and hoses to prevent contamination. NOTE: To ease reassembly, tag each of the hoses toshow their co...

Steering Cylinder Repair - Greensmaster 3100 (Fig. 40) Figure 40 IMPORTANT: To prevent damage when clamping thecylinder barrel in a vise, clamp only on the pivot end.Do not clamp the vise jaws against the smooth shaftsurface. Protect the shaft surface before mountingin the vise. 1. After removing th...

Steering Control Unit Removal and Installation - Greensmaster 3100 (Fig. 41) Figure 41 1. Remove six (6) capscrews (Item 21) and remove thesteering cover (Item 25). 2. Clean the outside of the steering valve and the areaaround the hydraulic fittings. Disconnect the hydraulichoses from the steering v...

Steering Control Unit Repair - Greensmaster 3100 (Fig. 42) Figure 42 1. Dust seal 10. Housing 19. Capscrew 2. Retaining ring 11. Control sleeve 20. Centering pin kit 3. Gland bushing seal 12. Control spool centering springs 21. Check ball retainer 4. O-ring 13. Control spool 22. Check ball 5. Backup...

7. Remove drive. 8. Remove spacer plate. 9. Remove seal from housing. Control End Disassembly 10. Remove housing from vise. Place housing on aclean soft cloth to protect surface finish. Use a thin bladescrewdriver to pry retaining ring from housing. 11. Rotate spool and sleeve until pin is horizonta...

Chapter 5 Electrical System Table of Contents WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . 2TURF GUARDIAN TM LEAK DETECTION SYSTEM . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 6 Verify Interlo...

Greensmaster 3100 Page 5 – 2 Wiring Schematics Rev. D Wiring Schematic (Greensmaster 3100, S/N Below 80000) – + K E Y SWITCH AMMETER TEST/LIGHT SWITCH ALARM HOUR METER ENGINE ST AR TER GROUND ST AR TER SOLENOID TRACTION SWITCH SEA T SWITCH BA TTER Y LEVEL SWITCH SOLENOID VA LV E S B A G M L RED BLAC...

Greensmaster 3100/3050 Page 5 – 2.7 Wiring Schematics Rev. D Wiring Harness (Greensmaster 3100/3050, S/N 80001 – 200999999) P 2 Mow Switch P 3 T raction Switch P 4 Seat Switch J 10 Harness ground P 7 Kill Relay P 5 Leak Detector J 1 Key Switch P 1 Key Switch P 6 Fuse Holder P 8 V olt meter J 4 Light...

Turf Guardian TM Leak Detection System Before Start-Up (Cold Oil) With ignition switch off, solenoid valve is open. Beforestart-up, hydraulic fluid is at level mark of sight gauge(oil cold). Float is in raised position, keeping alarm circuitopen. To check alarm and delay timer, turn ignition switch ...

Troubleshooting Remove all jewelry, especially rings andwatches, before doing any electrical trou-bleshooting. Disconnect battery cables un-less the test requires battery voltage. For effective troubleshooting and repairs, you musthave a good understanding of the electrical circuits andcomponents us...

Problem Cause Correction 11. Engine does not stop when ig-nition key is rotated to OFF posi-tion. Loose wire(s) in electrical system. Ignition switch is malfunctioning. Engine timing or carburetor out ofadjustment. Check all connections and repairas necessary. Replace ignition switch. Adjust carbure...

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 batteryshould be charged. Hourmeter Test the hourmeter by disconnecting the wires andapplying 12 V.D.C. between the terminals. Turf Guardian TM...

Repairs General Safety Interlock Switch Service The following procedures should be followed whenevera switch requires adjustment or replacement: 1. Be sure rubber boot is reinstalled in both switchgrooves on the button end of seat switch after it isproperly adjusted. IMPORTANT: Rubber boot on button...

Mow/Lift Switch Replacement and Adjustment (Fig. 17) IMPORTANT: Spool travel for 1, 2 and 3 spools mustbe correct before Mow/Lift switch can be adjusted.(See Rear Camshaft Adjustment in the Adjustmentssection of Chapter 4 - Hydraulic System.) 1. Pull connector off switch terminals from end ofmow/lif...

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 electricalcomponents, do not operate the engine with thebattery cables disconnected. Ke...

Chapter 6 Wheels, Steering and Brakes Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 3 REPAIRS . . . . . . . . . . . . . . . ....

Repairs Brake Service (Fig. 2) Figure 2 Brake Disassembly 1 Place blocks on each side of opposite wheel, jackmachine up and place blocks beneath frame underwheel motor. 2. Remove wheel nuts (Item 29) and remove wheel.Remove large nut (Item 4) securing wheel hub (Item 5)to motor shaft. IMPORTANT: To ...

Greensmaster 3100 Page 6 – 5 Repairs Rev. B Steering Arm (Greensmaster 3050) 1. Remove 1/2–13 x 3/4 capscrew and .53 I.D. wash- er mounted to outside steering arm frame bracket. 2. Pivot steering arm upward aligning mounting holes in arm with holes in frame bracket. 3. Select desired mounting hole f...

Chapter 7 4 Bolt Adjust Cutting Units Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 5 Factors Affecting Quality of Cut . . . . . ...

Chapter 8 Single Point Adjust Cutting Units Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 6SET UP AND ADJUSTMENTS . . . . . . . ....

Chapter 9 Grooming Reel Cutting Units Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 6 Factors Affecting Quality of Cut . . . . . ...

Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 1 Chapter 10 Dual Point Adjust Cutting Units Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 5 . . . . . ...

Greensmaster 31 0 0 Dual Point Adjust Cutting Units Page 10 - 2 Specifications Figure 1 DUAL POINT ADJUST UNIT Height–of–Cut (HOC): Cutting height is adjusted on the front roller by two vertical screws and held by twolocking capscrews. Standard bench height of cut rangeis .062 inch (1.6 mm) to .375 ...

Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 3 Special Tools OTC (Owatonna Tool Company) supplies special toolsfor servicing Toro Commercial Products. The TORO SPECIAL TOOLS AND APPLICATIONS GUIDE shows service tool applications. Some tools may have been supplied with your mower ora...

Greensmaster 31 0 0 Dual Point Adjust Cutting Units Page 10 - 4 Inner Grease Seal Installation Washer inner grease seal installation washer Toro Part Number104-0532 This washer is used when replacing the reel bearing in-ner grease seal. It enables pressing the grease seal toa depth of .104 in. (2.64...

Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 5 Troubleshooting There are a number of factors that can contribute to un-satisfactory quality of cut, some of which may be turfconditions. Turf conditions such as excessive thatch,“sponginess” or attempting to cut off too much grassheigh...

Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 7 Set Up and Adjustments Characteristics CAUTION Never install or work on the cutting units or liftarms with the engine running. Always stop en-gine and remove key first. The dual knob bedknife–to–reel adjustment system in-corporated in t...

Greensmaster 31 0 0 Dual Point Adjust Cutting Units Page 10 - 8 Repairs Hydraulic Reel Motor IMPORTANT: When performing maintenance pro-cedures on the cutting units, store the cutting unitreel motors in support tubes on the frame to preventdamage to the hoses. Do not raise suspension totransport pos...

Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 9 Backlapping (Units with Optional Backlap/Variable Reel Speed Kit) DANGER 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....

Greensmaster 31 0 0 Dual Point Adjust Cutting Units Page 10 - 10 Bedbar Assembly 1. Side plate 2. Rubber bushing 3. Flange bushing 4. Washer (plastic) 5. Washer (metal) 6. Bedbar 7. Bedbar pivot bolt8. Flange nut 9. Flange nut 10. Shim11. Spacer12. Retainer 13. Cap screw14. Rear roller assembly15. L...

Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 11 Bedbar Removal and Installation Removal (Fig. 10) 1. Position machine on a clean and level surface, low- er cutting units, stop engine, engage parking brake, andremove key from the ignition switch. 2. Remove the basket from the cutting...

Greensmaster 31 0 0 Dual Point Adjust Cutting Units Page 10 - 12 Bedbar Adjuster Service Figure 12 1. Adjuster shaft 2. Flange bushing 3. Cutting unit frame4. Wave washer 5. Jam nut 6. Adjuster screw 7. Detent8. Lock washer 9. Cap screw 10. Washer11. Spring12. Lock nut 8 7 3 2 4 5 6 10 11 12 1 9 2 R...

Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 13 Bedknife Replacement and Grinding Removal 1. Remove bedbar from frame (see Bedbar Removal). 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special Tools). Discardscrews. Remove bedknife from the bedbar ...

Greensmaster 31 0 0 Dual Point Adjust Cutting Units Page 10 - 14 Reel Assembly 1. Reel2. Speedi sleeve 3. V–ring4. Drive coupler 5. Retaining ring 6. Left side plate assembly7. Shoulder bolt 8. Bearing lock nut9. Outer grease seal 10. Right side plate assembly11. O–ring12. Bearing13. Inner grease se...

Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 19 Preparing a Reel for Grinding Note: Check to make sure the reel bearings are in good condition before grinding a reel. 1. Remove bedbar assembly (see Bedbar Removal and Installation). 2. Remove parts as necessary to mount cutting unit ...

Greensmaster 31 0 0 Dual Point Adjust Cutting Units Page 10 - 20 Front Roller Removal and Installation Removal (Fig. 23) 1. Position machine on a clean and level surface, low- er cutting units, stop engine, engage parking brake, andremove key from the ignition switch. Note: The front roller can be r...

Greensmaster 31 0 0 Dual Point Adjust Cutting units Page 10 - 21 Front and Rear Roller Service 1. Roller seal 2. Spiral retaining ring 3. Roller bearing 4. Rear roller body 5. Roller shaft 6. Front roller body Figure 24 v 1 2 3 4 6 5 Seal Removal 1. Make a seal removal tool from a 1/4 x3 x 3 in (.63...