Toro 3100 User Manual

Greensmaster ® 3100/3050

Preface

This publication provides the service technician with information for troubleshooting, testing, and repair of major systems and components on the Greensmaster 3100 and 3050.

REFER TO THE TRACTION UNIT, CUTTING UNIT AND ACCESSORY OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided at the end of Chapter 2 in this publication to insert the Operator’s Manuals and Parts Catalogs for your machine. Replacement Operator’s Manuals are available by sending complete Model and Serial Number of traction unit and cutting unit to:

The Toro Company 8111 Lyndale Avenue South Minneapolis, MN 55420

The Toro Company reserves the right to change product specifications or this publication without notice.

Part No. 92784SL, Rev. E

Service Manual

This safety symbol means DANGER, WARNING, or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions may result in personal injury.

NOTE: A NOTE will give general information about the correct operation, maintenance, service, testing or repair of the machine.

IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the machine.

This page is intentionally blank.

Table Of Contents

Chapter 1 - Safety

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

Chapter 2 - Product Records and Manuals

Product Records. . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1

Equivalents and Conversions. . . . . . . . . . . . . . . . 2 - 2

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . 2 - 3

Maintenance Interval Charts. . . . . . . . . . . . . . . . . 2 - 4

Equipment Operational and Service Historical Report Record

Chapter 3 - Engine

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5

BRIGGS & STRATTON VANGUARD V-TWIN OHV SERVICE & REPAIR INSTRUCTIONS

Chapter 4 - Hydraulic System

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2

General Information . . . . . . . . . . . . . . . . . . . . . . . 4 - 3

Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . 4 - 5

Hydraulic Schematic. . . . . . . . . . . . . . . . . . . . . . 4 - 12

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 36

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 39

Chapter 5 - Electrical System

Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2

Turf Guardian Leak Detection System . . . . . . . . . 5 - 3

Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 13

Chapter 6 - Wheels, Steering and Brakes

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4

Chapter 7 - 4 Bolt Adjust Cutting Units

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2

Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5

Set Up and Adjustments . . . . . . . . . . . . . . . . . . . . 7 - 7

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 15

Chapter 8 - Single Point Adjust Cutting Units

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 3

Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 4

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 6

Set Up and Adjustments . . . . . . . . . . . . . . . . . . . . 8 - 6

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19

Chapter 9 - Grooming Reel Cutting Units

Greensmaster

3100

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 3

Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 4

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 6

Set Up and Adjustments . . . . . . . . . . . . . . . . . . . 9 - 10

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 21

Chapter 10 - Dual Point Adjust Cutting Units

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 3

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 5

Setup and Adjustments . . . . . . . . . . . . . . . . . . . .10 - 7

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 8

Rev. D

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Table of Contents

Chapter 1

Safety

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 1

Before Operating. . . . . . . . . . . . . . . . . . . . . . . . . 1

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. of ballast is added to rear wheel. Hazard control and accident prevention are dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine. Improper use or maintenance of the machine can result in personal injury or death. To reduce the potential for injury or death, comply with the following safety instructions.

Before Operating

While Doing Maintenance, Troubleshooting,

Testing, Adjustments or Repairs . . . . . . . . . . . . . 3

CAUTION

Obey the following safety instructions. Read and understand these instructions before operating the Greensmaster 3100 or doing maintenance, troubleshooting, testing, adjustments or repairs. Failure to comply with the safety instructions may result in personal injury.

1. Read and understand the Operator’s Manual before starting, operating, maintaining or repairing the machine. Replacement Operator’s Manuals are available by sending complete Model and Serial Number of traction unit and cutting units to:

The Toro Company 8111 Lyndale Avenue South Minneapolis, MN 55420

Use the Model and Serial Number when referring to your machine. If you have questions about this Service Information, please contact:

The Toro Company Commercial Service Department 8111 Lyndale Avenue South Minneapolis, MN 55420

2. Never allow children to operate the machine or adults to operate it without proper instruction.

Greensmaster®3100 Page 1 - 1 Safety Instructions

3. Become familiar with the controls and know how to stop the machine and engine quickly.

4. Keep all shields, safety devices and decals in place. If a shield, safety device or decal is defective or damaged, repair or replace it before operating the machine.

5. Always wear substantial shoes. Do not operate machine wearing sandals, tennis shoes, sneakers or when barefoot. Do not wear loose fitting clothing that could get caught in moving parts and possibly cause personal injury.

6. Wearing safety glasses, safety shoes, long pants and a helmet is advisable and required by some local ordinances and insurance regulations.

7. Make sure the work area is clear of objects which might be picked up and thrown by the reels.

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

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.

10. Do not run engine in a confined area without adequate ventilation. Exhaust is hazardous and could be deadly.

11. Sit on the seat when starting and operating the machine.

12. Check interlock switches daily for proper operation. If a switch fails, replace it before operating the machine. The interlock system is for your protection, so do not bypass it. Replace all interlock switches every two years.

13. To start the engine:

A. Sit on the seat, depress lift pedal and release it to disengage cutting units. B. Verify that traction system is in neutral. C. Verify that parking brake is set. D. Proceed to start the engine.

14. Using the machine demands attention. To prevent loss of control:

A. Mow only in daylight or when there is good artificial light. B. Watch for holes or other hidden hazards. C. Be extremely careful when operating close to sand traps, ditches, creeks, steep hillsides or other hazards. D. Reduce speed when making sharp turns. Avoid sudden stops and starts. E. Look to the rear to assure no one is behind the machine before backing up. F. Watch for traffic when near or crossing roads. Always yield the right-of-way. G. Apply the service brakes when going down hill to keep forward speed slow and to maintain control of the machine.

15. Keep hands, feet and clothing away from moving parts and the reels. The grass baskets must be in place during operation of the reels or thatchers for maximum safety. Shut the engine off before emptying the baskets.

16. Raise cutting units when driving from one work area to another.

17. Do not touch engine, muffler or exhaust pipe while engine is running or soon after it is stopped. These areas could be hot enough to cause burns.

18. Stay clear of rotating screen at side of engine to prevent direct contact with body or clothing.

19. If cutting unit strikes a solid object or vibrates abnormally, stop immediately, turn engine off, set parking brake and wait for all motion to stop. Inspect for damage. If reel or bedknife is damaged, repair or replace it before operating.

20. Before getting off the seat:

A. Move shift selector to N (neutral). B. Depress the lift pedal to raise the cutting units, wait for the reels to stop spinning and release lift pedal. C. Set the parking brake. E. Stop engine and remove key from switch.

21. Traverse slopes carefully. Do not start or stop suddenly when traveling uphill or downhill.

22. Operator must be skilled and trained in how to drive on hillsides. Failure to use caution on slopes or hills may cause loss of control and vehicle to tip or roll, possibly resulting in personal injury or death.

23. If engine stalls or loses headway and cannot make it to the top of a slope, do not turn machine around. Always back slowly straight down the slope.

24. DO NOT TAKE AN INJURY RISK! When a person or pet appears unexpectedly in or near the mowing area, STOP MOWING. Careless operation, combined with terrain angles, ricochets, or improperly positioned guards can lead to thrown object injuries. Do not resume mowing until area is cleared.

25. Whenever machine is left unattended, make sure cutting units are fully raised and reels are not spinning, key is removed from ignition switch and parking brake is set.

Safety Instructions Page 1 - 2 Greensmaster

3100

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. Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system.

29. Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. Use cardboard or paper to find hydraulic leaks. Hydraulic fluid escaping under pressure can penetrate the skin and cause injury. Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor or gangrene may occur.

30. Before disconnecting or performing any work on the hydraulic system, all pressure in system must be relieved by stopping engine and lowering cutting units and attachments to the ground.

31. To reduce potential fire hazard, keep engine area free of excessive grease, grass, leaves and dirt. Do not use flammable solvents for cleaning parts. Do not use diesel fuel, kerosene or gasoline.

32. If the engine must be running to perform an inspection or procedure, use extreme caution. Always use two people, with the operator at the controls able to see the person doing the inspection or procedure. Keep hands, feet, clothing, and body away from cutting units and other moving parts.

33. Do not overspeed the engine by changing governor settings. Maximum governed engine speed should be 2850 rpm.

34. Shut engine off before checking or adding oil to the engine crankcase.

35. Be sure you understand a service procedure before working on the machine. Unauthorized modifications to the machine may impair the function, safety and life of the machine. If major repairs are ever needed, or assistance 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.

37. When changing attachments or performing other service, use the correct blocks and hoists. Always use jackstands to safely support the machine when it is raised by a jack or hoist.

38. Do not use your hand to prevent cutting unit reel from turning while servicing; this can result in personal injury. Use a 1/2 in. thick x 3 in. wide x 8 in. long piece of hardwood inserted into front of cutting unit between reel blades.

39. For optimum performance and safety, use genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous and my void the product warranty of The Toro Company.

Greensmaster

3100 Page 1 - 3 Safety Instructions

Safety Instructions Page 1 - 4 Greensmaster®3100

Table of Contents

Rev. D

Chapter 2

Product Records and Manuals

PRODUCT RECORD FORM . . . . . . . . . . . . . . . . . . 1

EQUIVALENTS AND CONVERSIONS . . . . . . . . . . 2

Decimal and Millimeter Equivalents . . . . . . . . . . 2

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 Instructions, Operator's Manuals and Parts Catalogs for any accessories that have been installed on your Greensmaster 3100 or 3050 at the end of this section.

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . 3

Capscrew Markings and Torque Values - U.S. . . 3 Capscrew Markings and Torque Values - Metric . 3

Greensmaster®3100 Page 2 - 1 Product Records

Rev. B

Equivalents and Conversions

Decimal and Millimeter Equivalents

_________________________________________________________ __________________________________________

Fractions Decimals mm Fractions Decimals mm

_________________________________________________________ __________________________________________

1/64 0.015625 — 0.397 33/64 0.515625 — 13.097

1/32 ––––– 0.03125 — 0.794 17/32 –––– 0.53125 — 13.494

3/64 0.046875 — 1.191 35/64 0.546875 — 13.891

1/16 –––––––––––– 0.0625 — 1.588 9/16 –––––––––––– 0.5625 — 14.288

5/64 0.078125 — 1.984 37/64 0.578125 — 14.684

3/32 ––––– 0.9375 — 2.381 19/32 –––– 0.59375 — 15.081

7/64 0.109275 — 2.778 39/64 0.609375 — 15.478

1/8 ––––––––––––– 0.1250 — 3.175 5/8 ––––––––––––– 0.6250 — 15.875

9/64 0.140625 — 3.572 41/64 0.640625 — 16.272

5/32 ––––– 0.15625 — 3.969 21/32 –––– 0.65625 — 16.669

11/64 0.171875 — 4.366 43/64 0.671875 — 17.066

3/16 –––––––––––– 0.1875 — 4.762 11/16 ––––––––––– 0.6875 — 17.462

13/64 0.203125 — 5.159 45/64 0.703125 — 17.859

7/32 ––––– 0.21875 — 5.556 23/32 –––– 0.71875 — 18.256

15/64 0.234375 — 5.953 47/64 0.734375 — 18.653

1/4 ––––––––––––– 0.2500 — 6.350 3/4 ––––––––––––– 0.7500 — 19.050

17/64 0.265625 — 6.747 49/64 0.765625 — 19.447

9/32 ––––– 0.28125 — 7.144 25/32 –––– 0.78125 — 19.844

19/64 0.296875 — 7.541 51/64 0.796875 — 20.241

5/16 –––––––––––– 0.3125 — 7.541 13/16 ––––––––––– 0.8125 — 20.638

21/64 0.328125 — 8.334 53/64 0.828125 — 21.034

11/32 –––– 0.34375 — 8.731 27/32 –––– 0.84375 — 21.431

23/64 0.359375 — 9.128 55/64 0.859375 — 21.828

3/8 ––––––––––––– 0.3750 — 9.525 7/8 ––––––––––––– 0.8750 — 22.225

25/64 0.390625 — 9.922 57/64 0.890625 — 22.622

13/32 –––– 0.40625 — 10.319 29/32 –––– 0.90625 — 23.019

27/64 0.421875 — 10.716 59/64 0.921875 — 23.416

7/16 –––––––––––– 0.4375 — 11.112 15/16 ––––––––––– 0.9375 — 23.812

29/64 0.453125 — 11.509 61/64 0.953125 — 24.209

15/32 –––– 0.46875 — 11.906 31/32 –––– 0.96875 — 24.606

31/64 0.484375 — 12.303 63/64 0.984375 — 25.003

1/2 ––––––––––––– 0.5000 — 12.700 1 –––––––––––––– 1.000 — 25.400

1 mm = 0.03937 in. 0.001 in. = 0.0254 mm

_________________________________________________________ __________________________________________

U.S to Metric Conversions

_________________________________________________________ __________________________________________

Linear Miles Kilometers 1.609 Measurement Yards Meters 0.9144

_________________________________________________________ __________________________________________

Area Square Miles Square Kilometers 2.59

_________________________________________________________ __________________________________________

Volume Cubic Yards Cubic Meters 0.7646

_________________________________________________________ __________________________________________

Weight Tons (Short) Metric Tons 0.9078

_________________________________________________________ __________________________________________

Pressure Pounds/Sq. In. Kilopascal 6.895

_________________________________________________________ __________________________________________

Work Foot-pounds Newton-Meters 1.356

_________________________________________________________ __________________________________________

Liquid Volume Quarts Liters 0.9463

_________________________________________________________ __________________________________________

Liquid Flow Gallons/Minute Liters/Minute 3.785

_________________________________________________________ __________________________________________

Temperature Fahrenheit Celsius 1. Subract 32

_________________________________________________________ __________________________________________

To Convert Into Multiply By

Feet Meters 0.3048 Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4

Square Feet Square Meters 0.0929 Square Inches Square Centimeters 6.452 Acre Hectare 0.4047

Cubic Feet Cubic Meters 0.02832 Cubic Inches Cubic Centimeters 16.39

Pounds Kilograms 0.4536 Ounces (Avdp.) Grams 28.3495

Foot-pounds Kilogram-Meters 0.1383 Inch-pounds Kilogram-Centimeters 1.152144

Gallons Liters 3.785

2. Multiply by 5/9

Equivalents and Conversions Page 2 - 2 Greensmaster®3100

Torque Specifications

Use these torque values when specific torque values are not given. DO NOT use these values in place of

The torque values listed below are for lubricated threads. Plated threads are considered to be lubricated.

specified values.

Capscrew Markings and Torque Values - U.S. Customary

SAE Grade Number 5 8

_______________________________________________________ _________________________________________________________________________________________________

Capscrew Head Markings

_______________________________________________________ _________________________________________________________________________________________________

Capscrew Body Size Cast Iron Aluminum Cast Iron Aluminum

_______________________________________________________ _________________________________________________________________________________________________

1/4-20 79681115912

_______________________________________________________ _________________________________________________________________________________________________

-28 9 12 7 9 13 18 10 14

5/16-18 1520121622301824

-24 1723141924331925

3/8-16 3040202540553040

-24 3040253545603545

7/16-14 4560354565905065

-20 5065405570955575

1/2-13 709555759513075100

-20 75 100 60 80 110 150 90 120

9/16-12 100 135 80 110 140 190 110 150

-18 110 150 85 115 155 210 125 170

5/8-11 135 180 110 150 190 255 150 205

-18 155 210 120 160 215 290 170 230

3/4-10 240 325 190 255 340 460 270 365

-16 270 365 210 285 380 515 300 410

7/8-9 360 490 280 380 550 745 440 600

_______________________________________________________ _________________________________________________________________________________________________

-14 390 530 310 420 610 825 490 660

1-8 530 720 420 570 820 1100 660 890

-14 590 800 480 650 890 1200 710 960

Capscrew Torque - Grade 5 Capscrew Torque - Grade 8

ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm

Capscrew Markings and Torque Values – Metric

Commercial Steel Class 8.8 10.9 12.9

_______________________________________________________ _________________________________________________________________________________________________

Capscrew Head Markings

_______________________________________________________ _________________________________________________________________________________________________

Thread Capscrew Torque - Class 8.8 Capscrew Torque - Class 10.9 Capscrew Torque - Class 12.9

Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum

mm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm

_______________________________________________________ _________________________________________________________________________________________________

Greensmaster®3100 Page 2 - 3 Torque Specifications

65947914711914711

7 914 7111418 111418231418

8182514182332182527362128

10 30 40 25 30 45 60 35 45 50 70 40 55

12 55 70 40 55 75 105 60 80 95 125 75 100

14 85 115 65 90 120 160 95 125 145 195 110 150

16 130 180 100 140 175 240 135 190 210 290 165 220

18 170 230 135 180 240 320 185 250 290 400 230 310

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Table of Contents

Rev. D

Chapter 3

Engine

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1

ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Throttle Control Adjustment. . . . . . . . . . . . . . . . . 2

Choke Control Adjustment . . . . . . . . . . . . . . . . . 2

Governor Adjustment. . . . . . . . . . . . . . . . . . . . . . 3

ENGINE REMOVAL AND INSTALLATION . . . . . . . . 5

Removing the Engine . . . . . . . . . . . . . . . . . . . . . 5

Installing the Engine . . . . . . . . . . . . . . . . . . . . . . 5

BRIGGS & STRATTON VANGUARD V-TWIN OHV

SERVICE & REPAIR INSTRUCTIONS

Carburetor and Speed Control Adjustment . . . . . 4

Specifications

Item Specification

___________________________________________________________________________________________

Make/Designation Briggs & Stratton Vanguard ® V-Twin OHV,

_______________________________________________________ _________________________________________________________________________________________________

Crankcase Oil Capacity See Operator's Manual

_______________________________________________________ _________________________________________________________________________________________________

Oil See Operator's Manual

_______________________________________________________ _________________________________________________________________________________________________

Fuel Unleaded Regular Gasoline

_______________________________________________________ _________________________________________________________________________________________________

High Idle Speed (no load) 2800

_______________________________________________________ _________________________________________________________________________________________________

Low Idle Speed (no load) 1400 ± 50 RPM

air cooled, gas engine with cast iron cylinder sleeves

+50

RPM

–100

Greensmaster®3100 Page 3 - 1 Specifications

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 contacts stop.

4. Tighten cable clamp screw.

Figure 1

1. Throttle casing clamp screw

2. Throttle cable

3. Swivel

4. Stop

5. Choke casing clamp screw

6. Choke cable

7. Choke butterfly

Choke Control Adjustment (Fig. 1)

1. Loosen cable clamp screw securing cable to engine.

2. Move remote choke control lever forward to CLOSED position.

3. Pull firmly on choke cable until choke butterfly is completely closed, then tighten cable clamp screw.

Adjustments Page 3 - 2 Greensmaster®3100

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. Hold lever in this position and rotate governor shaft counterclockwise as far as it will go. Hold lever and shaft in position and torque governor lever bolt and nut to 70 in-lb.

Throttle Restrictor Adjustment (Fig. 3)

Move throttle control lever to SLOW position. Hold governor lever so that throttle lever touches idle speed adjustment screw. Use tang bender (Briggs & Stratton Tool #19352) and bend throttle restrictor tang so throttle opening is limited to 1/4 in. travel when governor lever is released.

Figure 2

Secondary Spring Adjustments (Fig. 4)

With throttle control lever in SLOW position, install adjustment gauge (Brigss & Stratton Tool #19385) over end of governor lever as shown. Holding gauge in position, bend tab so that all slack is removed from secondary governor spring between its two anchor points. DO NOT STRETCH SPRING. Remove adjustment gauge.

Figure 3

Figure 4

Greensmaster®3100 Page 3 - 3 Adjustments

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. Start engine and let it run at half throttle for approximately five (5) minutes to warm up.

2. Move throttle control to SLOW position. Hold governor lever so throttle lever is in the idle position (against idle stop screw) and turn idle stop screw in or out to get 1400 ± 50 RPM. Check speed with a tachometer.

Figure 5

3. Adjust idle mixture screw:

A. Turn idle mixture screw slowly clockwise (lean mixture) until engine speed just starts to decrease. Note position of screw.

B. Now turn idle mixture screw slowly counterclockwise (rich mixture) until engine speed just starts to decrease. Note position of screw.

C. Set the idle mixture screw half way between the rich and lean settings.

4. After idle mixture has been adjusted, hold governor lever so throttle lever is in idle position (against idle stop screw) and adjust idle stop screw to bring engine speed to 1200 ± RPM.

5. With governor control lever in governed idle position (no tension on high speed spring) bend governed idle spring anchor tang to get a governed idle speed of 1400 ± RPM (Fig. 5).

6. Move throttle control to FAST position. Bend high speed spring anchor tang to bring engine speed to 2800 +50/–100 RPM (Fig. 6).

Figure 6

Adjustments Page 3 - 4 Greensmaster®3100

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. Dispose of the gasoline in a safe place immediately after draining.

Installing the Engine

1. Support the engine, align it with the engine mounts, and instal the pump hub over the engine shaft and key. Be sure that the key is properly positioned and aligned with the keyway.

2. Install the engine mount bolts, washers and nuts.

3. Remove the starter cable, throttle and choke cable and ground wire from engine.

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. DO NOT disconnect the hydraulic hoses from the pump.

6. Support the engine and remove the engine mount bolts, nuts and washers to remove the engine.

4. Re-connect the fuel line, wire connectors and the cables to the engine and battery.

5. Make sure the crankcase is filled the correct oil. Open the fuel shut-off valve. Fill the fuel tank. Start the engine and check for proper operation.

3. Mount the pump to the pump housing and tighten the set screws to secure the hub to the shaft.

Greensmaster®3100 Page 3 - 5 Engine Removal and Installation

Engine Removal and Installation Page 3 - 6 Greensmaster®3100

Table of Contents

Chapter 4

Hydraulic System

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 . . . . . . . . . . . . . . . . . . . . 6

Traction, Reverse Position . . . . . . . . . . . . . . . . . 7

Reel Drive, Mowing Operation . . . . . . . . . . . . . . 8

Reel Drive, Lower Cutting Units . . . . . . . . . . . . . 9

Reel Drive, Raising Cutting Units . . . . . . . . . . . 10

Power Steering, R.H. Turn . . . . . . . . . . . . . . . . . 11

HYDRAULIC SCHEMATIC. . . . . . . . . . . . . . . . . . . 12

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 13

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 16

Slow Groundspeed in All Traction Selections . . 17

Slow or No Ground Speed in No. 1

and Reverse, No. 2 Appears Normal . . . . . . . . 18

No Increase in Speed From No. 1 to No. 2 . . . . 19

One or More Cutting Units Slow

or No Reel Drive Action. . . . . . . . . . . . . . . . . . . 20

All Reels Slow or Will Not Turn . . . . . . . . . . . . . 21

Mow Pedal Won’t Stay Engaged -

Reels Slow Down or Stop . . . . . . . . . . . . . . . . . 22

Cutting Unit(s) Drop During Transport. . . . . . . . 23

Cutting Units Lift Too Slowly or Not At All . . . . . 24

Lift Pedal Binding . . . . . . . . . . . . . . . . . . . . . . . 25

Center (#1) Cutting Unit

Operates In Raised Position . . . . . . . . . . . . . . . 25

Center (#1) Cutting Unit Drops Before

Front Cutting Units or Drops Too Fast. . . . . . . . 25

Steering Loss, Steering Wander or Free Play. . 26

TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Test Hook Up No. 1, Traction Pump

Flow and Traction Relief Setting . . . . . . . . . . . . 28

Test Hook Up No. 2, Traction Motors Mechanical Drag, Valve

Bank Leakage,Traction Motors Efficiency . . . . . 28

Test Hook Up No. 3,

Reel Drive Pump Efficiency . . . . . . . . . . . . . . . . 32

Test Hook Up No. 4, Reel Drive Motor Flow, Reel Drive Relief Setting, Reel Motor Efficiency 33 Test Hook Up No. 5, Steering Pump

Flow and Steering Pump Relief Setting. . . . . . . 35

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Lift and Mow Pedal Height Adjustment . . . . . . . 36

Traction Pedal Adjustment. . . . . . . . . . . . . . . . . 37

Rear Camshaft Adjustment . . . . . . . . . . . . . . . . 38

REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Reel Motor Removal and Installation. . . . . . . . . 39

Reel Motor Shaft Seal Replacement . . . . . . . . . 39

Reel Motor Repair . . . . . . . . . . . . . . . . . . . . . . . 40

Pump Removal and Installation. . . . . . . . . . . . . 42

Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Control Valve Removal and Installation. . . . . . . 44

Relief Valve Removal and Installation . . . . . . . . 45

Control Valve Spool Seal Replacement. . . . . . . 46

Control Valve Internal Seal Replacement . . . . . 47

Control Valve No. 1 Spool Detent Replacement 48 Control Valve No. 4 Spool Detent Replacement 49

Lift Cylinder Removal and Installation . . . . . . . . 50

Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . 52

Wheel Motor Removal and Installation . . . . . . . 54

Wheel Motor Repair. . . . . . . . . . . . . . . . . . . . . . 55

Steering Cylinder Removal and Installation. . . . 58

Steering Cylinder Repair . . . . . . . . . . . . . . . . . . 59

Steering Control Unit Removal and Installation. 60

Steering Control Unit Repair . . . . . . . . . . . . . . . 61

Greensmaster®3100 Page 4 - 1 Table of Contents

Specifications

Item Description

__________________________________________________________________________________________

Hydraulic Pump External gear type

Steering relief pressure (Greensmaster 3100) 850 psi

_________________________________________________________________ _______________________________________________________________________________________

Wheel Motor (2) Orbit rotor type

_________________________________________________________________ _______________________________________________________________________________________

Reel Motor (3) External gear type

_________________________________________________________________ _______________________________________________________________________________________

Control Valve 5 section spool type Main and No. 1 section port relief pressure 2000 psi No. 2 and 3 section port relief pressure 2000 psi No. 4 (traction) section port relief pressure 1850 psi

_________________________________________________________________ _______________________________________________________________________________________

Power Steering Control Gerotor type steering control unit

_________________________________________________________________ _______________________________________________________________________________________

Hydraulic Oil See Operator's Manual

_________________________________________________________________ _______________________________________________________________________________________

Reservoir Capacity See Operator's Manual

_________________________________________________________________ _______________________________________________________________________________________

Oil filter Screw-on cartridge type, 10 micron

5 section (Greensmaster 3100) 4 section (Greensmaster 3050)

Specifications Page 4 - 2

Figure 1a

(Greensmaster 3050)

1. Hydraulic reservoir 2. Screen

Rev. D

Greensmaster

3100

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. To prevent possible problems it is recommended that hoses are replaced periodically, regardless of condition.

When replacing a hydraulic hose, be sure that the hose is straight (not twisted) before tightening the fittings. This can be done by observing the imprint on the hose. Use two wrenches; one to hold the hose straight and one to tighten the hose swivel nut onto the fitting.

WARNING

Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved by stopping the engine and lowering the cutting units to the ground.

Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and do serious damage. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result.

Hydraulic Fitting Installation

O-Ring Face Seal (Fig. 1, 2)

1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material.

2. Make sure the O-ring is installed and properly seated in the groove. It is recommended that the O-ring be replaced any time the connection is opened.

3. Lubricate the O-ring with a light coating of oil.

4. Put the tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight.

5. Mark the nut and fitting body. Hold the body with a wrench. Use another wrench to tighten the nut to the correct flats from finger tight (F.F.F.T.). The markings on the nut and fitting body will verify that the connection has been tightened.

Size F.F.F.T.

4 (1/4 in. nominal hose or tubing) .75 ± .25

6 (3/8 in.) .75 ± .25

8 (1/2 in.) .75 ± .25

10 (5/8 in.) 1.00 ± .25

12 (3/4 in.) .75 ± .25

16 (1 in.) .75 ± .25

Nut

Sleeve

Seal

Body

Figure 1

Mark Nut and Body

Finger Tight After Proper Tightening

Final Position

Extend Line

Initial Position

Figure 2

Greensmaster®3100 Page 4 - 3 General Information

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. 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 F.F.F.T.

4 (1/4 in. nominal hose or tubing) 1.00 ± .25 6 (3/8 in.) 1.50 ± .25 8 (1/2 in.) 1.50 ± .25 10 (5/8 in.) 1.50 ± .25 12 (3/4 in.) 1.50 ± .25 16 (1 in.) 1.50 ± .25

O-Ring

Figure 3

SAE Straight Thread O-Ring Port (Adjustable) (Fig. 4, 5)

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. Lubricate the O-ring with a light coating of oil.

4. Turn back the jam nut as far as possible. Make sure the back up washer is not loose and is pushed up as far as possible (Step 1).

5. Install the fitting into the port and tighten finger tight until the washer contacts the face of the port (Step 2).

6. To put the fitting in the desired position, unscrew it by the required amount, but no more than one full turn (Step 3).

7. Hold the fitting in the desired position with a wrench and turn the jam nut with another wrench to the correct flats from finger tight (F.F.F.T.) (Step 4)

Step 1

Lock Nut

Back-Up Washer

O-Ring

Figure 4

Step 3

Size F.F.F.T.

4 (1/4 in. nominal hose or tubing) 1.00 ± .25 6 (3/8 in.) 1.50 ± .25 8 (1/2 in.) 1.50 ± .25 10 (5/8 in.) 1.50 ± .25 12 (3/4 in.) 1.50 ± .25 16 (1 in.) 1.50 ± .25

Step 2

Step 4

Figure 5

General Information Page 4 - 4 Greensmaster®3100

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

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. Low pressure oil returns to valve through valve and main return line, through filter to reservoir.

Greensmaster®3100 Page 4 - 5 Hydraulic Flow Diagrams

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

from two other pump sections. The additional flow increases the RPM of the wheel motors to increase ground speed.

Hydraulic Flow Diagrams Page 4 - 6 Greensmaster®3100

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

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.

Greensmaster®3100 Page 4 - 7 Hydraulic Flow Diagrams

Reel Drive, Mowing Operation

GR3100 WITH DANFOSS PUMP SHOWN.

MACHINES WITH PARKER PUMP USE

CENTER 3 PUMP SECTIONS FOR REEL

DRIVE CIRCUITS.

Rev. E

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 lead ing 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. Return oil from two front cutting units joins together and returns to right end of valve section, where

is passes into the main return line and flows back to reservoir.

Flow from another separate pump section passes through No. 3 spool section and out through a line to the rear cutting unit drive motor. Return oil from the motor passes through a line leading to the right hand end of the valve bank, where it also joins with the main return line back to the reservoir.

Hydraulic Flow Diagram s Page 4 - 8 Greensmaster® 3100

Reel Drive, Lower Cutting Units

GR3100 WITH DANFOSS PUMP SHOWN.

MACHINES WITH PARKER PUMP USE

CENTER 3 PUMP SECTIONS FOR REEL

DRIVE CIRCUITS.

Rev. E

The MOW pedal is depressed to start reel drive operation, flow from one pump section passes throu gh 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 fit ting 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. When the cylinders complete their travel, oil flow from the No. 3 spool section is then directed to the rear cut ting unit drive motor.

Greensmaster® 3100 Page 4 - 9 Hydraulic Flow Diagrams

Reel Drive, Raising Cutting Units

GR3100 WITH DANFOSS PUMP SHOWN.

MACHINES WITH PARKER PUMP USE

FOURTH PUMP SECTION FOR LIFT.

Rev. E

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 c ylinders travels through lines leading to No. 3 spool section, th rough the valve bank and back to reservoir through main return line.

Hydraulic Flow Diagrams Page 4 - 10 Greensmaster® 3100

Power Steering, R.H. Turn (Greensmaster 3100)

GR3100 WITH DANFOSS PUMP SHOWN.

MACHINES WITH PARKER PUMP USE

LAST PUMP SECTION FOR STEERING

CIRCUIT.

Rev. E

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 se ction 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. Oil displaced by the other end of the

steering cylinder returns to the steering valve through port “L” which directs it out port “T” back to reservoir.

When the steering wheel stops turning , th e cont rol s ection within the steering valve shifts back to neutral allowing all oil from the pump to flow through the s teering valve out port “T” back to reservoir. Oil in the rest of the steering circuit is then trapped.

Greensmaster® 3100 Page 4 - 11 Hydraulic Flow Diagrams

Hydraulic Schematic

(Greensmaster 3100 2WD Serial Number Below 230000000)

LEVEL

SENSOR

HYDRAULIC

TANK

40 MICRON

TANK BREATHER

AUXILIARY

HYDRAULIC

TANK

NORMALLY OPEN

SOLENOID VALVE

.33 IN /REV

(5.4 CU CM/REV)

2850 RPM MAX

PUMP (DANFOSS)

10.3 CU. IN/REV.

(169 CU. CM/REV)

WHEEL DRIVE MOTORS

OIL FILTER

10 MICRON

FWD

2ND

1ST

SAFETY

INTERLOCK

SWITCH

VALVE BANK

REV

SWITCH

SAFETY INTERLOCK

1850 PSI

(130 KG/SQ CM)

2000 PSI

.18 IN /REV

850 PSI

(60 KG/SQ CM)

.33 IN /REV

.58 IN /REV

2000 PSI

(141 KG/SQ CM)

(2.9 CU CM/REV)

(5.4 CU CM/REV)

(9.5 CU CM/REV)

REEL MOTORS

.43 CU. IN/REV.

(7 CU. CM/REV.)

Hydraulic Schematics

CENTER

Page 4 – 12

LIFT CYLINDERS

Rev. E

(141 KG/SQ CM)

2000 PSI

(141 KG/SQ CM)

STEERING CYLINDER

STEERING CONTROL VALVE

4.5 CU. IN/REV.

(75 CU. CM/REV)

Greensmaster 3100

Hydraulic Schematic

(Greensmaster 3100 2WD Serial Number Above 230000000)

LEVEL

SENSOR

HYDRAULIC

TANK

40 MICRON

TANK BREATHER

AUXILIARY

HYDRAULIC

TANK

NORMALLY OPEN

SOLENOID VALVE

.18 IN /REV

(2.9 CU CM/REV)

PUMP (PARKER)

2850 RPM MAX

10.3 CU. IN/REV.

(169 CU. CM/REV)

WHEEL DRIVE MOTORS

OIL FILTER

10 MICRON

FWD

2ND

1ST

SAFETY

INTERLOCK

SWITCH

VALVE BANK

REV

SWITCH

SAFETY INTERLOCK

1850 PSI

(130 KG/SQ CM)

2000 PSI

850 PSI

(60 KG/SQ CM)

.32 IN /REV

.57 IN /REV

2000 PSI

(141 KG/SQ CM)

(5.2 CU CM/REV)

(9.3 CU CM/REV)

REEL MOTORS

CENTER

.43 CU. IN/REV.

(7 CU. CM/REV.)

CENTER

LIFT CYLINDERS

Greensmaster 3100 Page 4 – 12.1 Hydraulic SchematicsRev. E

(141 KG/SQ CM)

2000 PSI

(141 KG/SQ CM)

STEERING CYLINDER

STEERING CONTROL VALVE

4.5 CU. IN/REV.

(75 CU. CM/REV)

Hydraulic Schematic (Greensmaster 3100 3WD)

TANK

AUXILIARY

40 MICRON

TANK BREATHER

WHEEL DRIVE MOTOR

20 CU IN/REV

(328 CU CM/REV)

HYDRAULIC

OIL FILTER

10 MICRON

LEVEL

SENSOR

TANK

HYDRAULIC

VALVE

BANK

.33 IN /REV

(5.4 CU CM/REV)

2850 RPM MAX.

PUMP (DANFOSS)

.18 IN /REV

(2.9 CU CM/REV)

10.3 CU IN/REV (169 CU CM/REV)

WHEEL DRIVE MOTORS

REAR

SAFETY

SWITCH

INTERLOCK

FWD

2ND

1ST

REV

SAFETY

SWITCH

INTERLOCK

1850 PSI

(130 KG/SQ.CM)

.58 IN /REV

2000 PSI

(141 KG/SQ CM)

2000 PSI

(141 KG/SQ CM)

850 PSI

.33 IN /REV

(9.5 CU CM/REV)

(60 KG/SQ. CM)

(5.4 CU CM/REV)

4.5 CU IN/REV

(75 CU CM/REV)

STEERING CONTROL VALVE

.43 CU IN/REV

(7 CU CM/REV)

REEL MOTORS

CENTER

2000 PSI

(141 KG/SQ CM)

LIFT CYLINDERS

STEERING CYLINDER

Greensmaster 3100Page 4 – 12.2Hydraulic Schematics Rev. E

Hydraulic Schematic (Greensmaster 3050)

HYDRAULIC

OIL FILTER

10.3 CU. IN/REV. (169 CU. CM/REV)

WHEEL DRIVE MOTORS

LH RH

TANK

VALVE BANK

.33 IN /REV

(5.4 CU CM/REV)

PUMP

2850 RPM MAX

SAFETY

INTERLOCK

SWITCH

2ND

FWD

1ST

REV

SWITCH

SAFETY INTERLOCK

1850 PSI

(130 KG/SQ CM)

2000 PSI

(141 KG/SQ CM)

2000 PSI

(141 KG/SQ CM)

.33 IN /REV

(5.4 CU CM/REV)

.58 IN /REV

(9.5 CU CM/REV)

REEL MOTORS

CENTER

.43 CU. IN/REV.

(7 CU. CM/REV.)

CENTER

LIFT CYLINDERS

Greensmaster 3100 Page 4 – 12.3 Hydraulic SchematicsRev. E

2000 PSI

(141 KG/SQ CM)

This page is blank.

Greensmaster 3100Page 4 – 12.4Hydraulic Schematics Rev. E

Special Tools

NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be listed in the

Greensmaster 3100 Parts Catalog. Some tools may also be available from a local supplier.

Hydraulic Tester (Fig. 6)

Low Pressure Gauge

Load Valve

Outlet Hose

Gauge Protector Valve

Inlet Hose

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.

2. LOAD VALVE: If required, upon turning the valve to restrict flow, a simulated working load is created in the circuit.

3. LOW PRESSURE GAUGE: Low range gauge to provide accurate reading at low pressure, 0 - 1000 psi (0 - 6895 kPa).

Flow Meter

High Pressure Gauge

Figure 6

4. HIGH PRESSURE GAUGE: High range gauge to accommodate pressure beyond the capacity of the low pressure gauge, 0 - 5000 (0 - 34475 kPa).

5. FLOW METER: This meter measures actual oil flow in the operation circuit. The reading is given in gallons per minute (GPM) and liters per minute (LPM) with a gauge rated at 15 GPM (57 LPM).

6. OUTLET HOSE: Hose from the outlet side of the hydraulic tester to be connected to the hydraulic system circuit.

This gauge has a protector valve which cuts out when pressure is about to exceed the normal range for the gauge. The cutout pressure is adjustable.

Greensmaster®3100 Page 4 - 13 Special Tools

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.

Detent Installation Tool (Fig. 8)

Use this tool with a 3/8 in. drive torque wrench to tighten the detent stud in the No. 1 spool of the control valve. Apply Loctite 222 or equivalent to the threads of the detent stud. Tighten the stud to a torque of 10 - 14 ft-lb.

Figure 7

Figure 8

Special Tools Page 4 - 14 Greensmaster®3100

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.

Assembly Studs (Fig. 10)

Use for proper alignment of internal parts during disassembly and repair of the TRW Torqmotor hydraulic wheel motor.

Figure 9

IMPORTANT: The wheel motor geroters are indexed and must be kept in their original position.

Control Valve Spool Seal Installation Tools (Fig. 11)

This tool can be made to the dimensions shown.

Soak new seal in clean hydraulic fluid before installing. Install seal into end of large diameter tool with open side of seal facing out. Install small diameter tool into large diameter tool against flat (closed) side of seal. Carefully install seal and tools over valve spool, hold large tool against valve body and push seal into bore with small diameter tool.

Figure 10

0.75 DIA

2.5

NOTE: REMOVE SHARP EDGES.

0.991/

0.994 DIA

0.997/

1.000 DIA

1.5

Dimensions shown in inches.

1.25 DIA

Figure 11

Greensmaster®3100 Page 4 - 15 Special Tools

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. Continued use of an improperly functioning hydraulic system could lead to extensive internal component damage.

The charts that follow contain detailed information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. All causes should be checked in the order in which they are listed on the charts; do not deviate from this procedure.

Refer to the Testing section of this Chapter for precautions and specific test procedures.

Troubleshooting Page 4 - 16 Greensmaster

3100

Slow Groundspeed in All Traction Selections

* Check

engine

RPM

* Check

hydraulic

oil level

Check

hydraulic

oil filter

* Check shift lever bracket

and rear

camshaft

Improper

Clogged

Misadjusted

or damaged

Adjust –

use

tachometer

* Reels also affected.

Fill to

proper

level

Replace

filter

Adjust

Check brakes and

brake linkage

for binding

Check traction

pump flow.

Test hook up

No. 1 Test A

Check traction

relief. Test

hook up

No. 1 Test B

Check traction mo-

tors for mech.

drag. Test hook up

No. 2 Test A

Binding

Low

Defective

Drag

Free linkage

and adjust

brakes

Check for

restriction in

pump intake line

Repair

or replace

traction relief

valve

Remove brake

drum and

repeat test

Drag

Repair

or replace

pump

Repair or

replace

defective motor

Check traction mo-

tor efficiency.

Test hook up

No. 2 Test C

Inefficient

Repair or

replace

defective motor

Greensmaster®3100 Page 4 - 17 Troubleshooting

Slow or No Ground Speed in No. 1 and Reverse

No. 2 Appears Normal

Check control

linkage

Check traction

pump flow.

Test hook up

No. 1 Test A

Check for internal

valve bank leakage.

Test hook up

No. 2 Test B

Misadjusted

or damaged

Low

Leaking

Adjust

repair

Check for

restriction in

pump intake line

Check disk seal

between #3 and

#4 valve sections

Defective

Repair or

replace

traction pump

Remove valve bank

and replace

disk seal

Troubleshooting Page 4 - 18 Greensmaster®3100

No Increase in Speed from No. 1 to No. 2

Check

hydraulic

oil level

Check traction

lever

Check rear

camshaft

Check #2 and #3

pump section flow.

Test hook up No. 3

Test A

Low

Misadjuste

or damaged

Misadjusted

or damaged

Fill to

proper

level

Adjust or

repair

Adjust or

repair

Check for

restriction in

pump intake line

OKLow

Repair or

replace

pump

Check #2 and #3

valve section re-

liefs. Test hook up

No. 4 Test B

Defective

Repair or

replace

relief valve

Greensmaster®3100 Page 4 - 19 Troubleshooting

One or More Cutting Units Slow or

No Reel Drive Action

Check

Pedal

Linkage

Check rear-

ward valve spool trave

Check

bedknife

adjustment

Check for

tight

reel bearings

Misadjusted

or Damaged

Insufficient

Tight

Adjust or repair

and

lubricate

Adjust or repair

rear camshaft

Adjust

bedknife

Adjust

bearings. Replace

if necessary.

Check reel pump

flow. Test hook up

No. 3 Test A

Check reel motor

flow. Test hook up

No. 4 Test A

Check reel drive

relief. Test hook

up No. 4 Test B

Check reel motor

efficiency. Test

hook up No. 4

Test B

Low

Defective

Check for

restriction in pump

intake line(s).

Check for flow re-

striction.

Repair or replace

reel drive

relief valve

Repair or replace

reel drive motor

Repair or

replace pump

Troubleshooting Page 4 - 20 Greensmaster®3100

All Reels Slow or Will Not Turn

Check

engine

RPM

Check

hydraulic

oil level

Check

hydraulic

oil filter

Check linkage

and roll pin

on end of mow

pedal shaft

Low

Clogged

Worn or

broken

Adjust –

use tachometer

Fill to proper

level

Replace

filter

Repair

linkage

Check reel pump

flow. Test hook up

No. 3 Test A

Low

Repair or

replace pump

Greensmaster®3100 Page 4 - 21 Troubleshooting

Mow Pedal Won’t Stay Engaged –

Reels Slow Down or Stop

Check linkage

from pedal

to valve bank

Check roll pin in

end of mow pedal

shaft

Check rearward

valve spool

travel

Check the

spool detent

Misadjusted

or damaged

Worn

or broken

Insufficient

Defective

Adjust, repair and

lubricate linkage

Replace

Adjust rear

camshaft

Lubricate or

repair valve spool

detent

Troubleshooting Page 4 - 22 Greensmaster®3100

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

Binding

Leaking

Binding

Lubricate and

adjust camshaft

Repair or replace

cylinder(s)

Replace

o-ring

Lubricate or repair valve spool detent

Greensmaster®3100 Page 4 - 23 Troubleshooting

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

Binding

Insufficient

Restricted

Leaking

Loosen and

lubricate lift assemblies

Adjust rear

camshaft

Replace restricted

line or fitting

Repair or

replace cylinder

Check lift section

of pump. Test hook up No. 3

Test A

Defective

Repair or replace

pump

Troubleshooting Page 4 - 24 Greensmaster®3100

Lift Pedal Binding

Check pedal

linkage

Check valve spool

detent assembly

Misadjusted

or Damaged

Binding or

Damaged

Adjust or repair link-

age and lubricate

Lubricate and repair

detent

Center (#1) Cutting Unit Operates in Raised Position

shaft for #3 spool

too far out of body

Check for restric-

tion in brazed tube

assembly on #3

valve section

Misadjusted

Restricted

Adjust camshaftCheck rear cam-

Remove

restriction

Check for restriction

in valve return port

between #3 section

and R.H. cover

Defective

Remove valve bank

and disassemle to

remove restriction

Center (#1) Cutting Unit Drops

Before Front Cutting Units or Drops Too Fast

Check for missing

orifce reducer in cylin-

der line attached to

center fitting on crows-

foot

Check for

incorrect crows

foot fitting

Missing

Incorrect

Install orifice re-

ducer in cylinder line

Replace crows foot

fitting with correct fit-

ting

Greensmaster®3100 Page 4 - 25 Troubleshooting

Steering Loss, Steering Wander or Free Play

Check steering cyl-

inder

ball joints

Disconnect cylin-

der and check cas-

tor fork movement

Check steering cyl-

inder for

internal leakage

Check for

restriction in hy-

draulic hose or fit-

ting

Loose

Binding

Leakage

Restriction

Tighten castle nuts

and jam nut

Repair and

lubricate castor fork

and bushings

Repair or replace

steering cylinder

Replace restricted

line or fitting

Replace ball

joint(s)

Check steering

pump flow. Test

hook up No. 5

Test A

Check for dam-

aged steering

wheel or shaft

Worn or damaged

steering control

unit. *Thermal

shock

Defective OK

Defective

Check for

restriction in pump

intake line

Replace steering

wheel or shaft

Repair or replace

steering

control unit

Repair or replace

pump

* Thermal shock - A condition caused when the hydraulic system is operated for some time without turning the steering wheel so that fluid in the reservoir and system is hot and the steering control unit is relatively cool (more than 50

F temperature differential). This can also happen when washing the machine. When the steering wheel is turned quickly the result is temporary seizure and possible damage to internal parts of the steering control unit. The temporary seizure may be followed by total free wheeling.

Troubleshooting Page 4 - 26 Greensmaster

3100

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.

All obvious areas such as oil supply, filter, binding linkage, loose fasteners, or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem being experienced.

WARNING

Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved by stopping the engine and lowering the implement to the ground.

Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and do serious damage. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result.

Before Performing Hydraulic Tests

2. Put caps or plugs on any hydraulic lines left open or exposed during testing or removal of components.

3. The engine must be in good operating condition. ALWAYS use a tachometer when making a hydraulic test. Engine speed will affect the accuracy of the tester readings.

4. To prevent damage to the tester or components, the inlet and the outlet hoses must be properly connected, and not reversed (tester with pressure and flow capabilities).

5. To minimize the possibility of damaging the components, completely open the load valve by turning it counterclockwise (tester with pressure and flow capabilities).

IMPORTANT: The pump used on the Greensmaster 3100 is a positive displacement type. If its output flow is completely restricted or stopped, damage to the pump or other components could occur.

6. Install fittings finger tight, far enough to insure that they are not cross-threaded, before tightening with a wrench.

7. Position the tester hoses so that rotating machine parts will not make contact with them and result in hose or tester damage.

8. Check the oil level in the reservoir.

9. Check the control linkage for improper adjustment, binding or broken parts.

10. All hydraulic tests should be made with the hydraulic oil at normal operating temperature (hoses warm to the touch).

1. Thorough clean the machine before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment.

Greensmaster®3100 Page 4 - 27 Testing

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.

Hydraulic oil at operating temperature.

While watching flow and pressure gauges, slowly close flow control valve until 1000 PSI is obtained.

TESTER READINGS

Flow not lower than 5 GPM at 1000 PSI.

Record pressure and flow readings.

If flow is lower than 5 GPM or a pressure of 1000 PSI cannot be obtained, check for restriction in pump intake line. If not restricted, remove pump and repair as necessary.

Testing Page 4 - 28 Greensmaster

3100

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.

Greensmaster

3100 Page 4 - 29 Testing

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. 5 and hydraulic tube leading to front wheel motors, remove “U” tube and install tester in series between the two exposed fittings.

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.

CAP (TEST B AND C)

(TEST B AND C)

CAP

2345

TESTER

TEST A: TRACTION MOTORS MECHANICAL DRAG

PROCEDURE

Block up the machine so traction wheels are off floor. If machine is equipped with 3WD, rear wheel needs to be off floor as well.

Disconnect brake control rod on wheel being tested.

Apply brake 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. Front wheel that is NOT locked by brake should rotate.

Greensmaster 3100 Page 4 – 30

Rev. E

Testing

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 B:

PROCEDURE

TESTER READINGS

TEST C:

PROCEDURE

TESTER READINGS

Testing

VALVE BANK LEAKAGE

Disconnect both hydraulic hoses that lead to left front wheel motor from hydraulic tubes on left side of machine. Cap open ends of tubes and hoses.

Block up the machine so traction wheels are off floor. If machine is equipped with 3WD, rear wheel needs to be off floor as well.

Disconnect brake control rod on front right wheel.

Engine RPM 2800.

Hydraulic oil at normal operating temperature.

Engage transmission lever to No. 1 position.

Push traction pedal to forward position. Front right wheel should rotate.

While watching flow and pressure gauges, slowly close flow control valve until 1000 PSI is obtained.

Flow not less than 5 GPM at minimum 1000 PSI.

If flow is lower than 5 GPM or pressure of 1000 PSI cannot be obtained, there is internal valve bank leakage. Check:

1. Relief valve

2. No. 4 spool position

3. Disc seal between No. 3 and No. 4 valve bank sections

TRACTION MOTOR EFFICIENCY

Tester Flow Control Valve Open.

Disconnect hydraulic hoses (pressure and return) that lead to front left motor. Install caps to open ends of tubes and hoses.

Block up the machine so traction wheels are off floor. If machine is equipped with 3WD, rear wheel needs to be off floor as well.

Apply brake 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.

Flow not more than 1.5 GPM at a pressure of 1850 to 1950 PSI.

If flow is higher than 1.5 GPM, remove right wheel motor and repair as necessary.

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.

Page 4 – 31

Rev. E

Greensmaster 3100

TEST HOOK UP NO. 3

GR3100 WITH DANFOSS PUMP SHOWN.

MACHINES WITH PARKER PUMP USE

CENTER 3 PUMP SECTIONS FOR REEL

DRIVE CIRCUITS.

Rev. E

Reel Drive Pump Efficiency

TESTER CONNECTION:

T e ster in series between reel pump outlet hose on susp ected 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 saf ety interlock will stop the

engine when the mow pedal is engaged.

TESTER

TEST A: REEL DRIVE PUMP EFFICIENCY PROCEDURE

Traction lever in neutral position. Engine RPM 2800. Hydraulic oil at operating temperature. While watching pressure gauges, slowly close flow control valve until 1000 PSI is

obtained. Read flow gauge.

TESTER READINGS

Flow not less than 2.5 GPM at 1000 PSI. If unable to get 1000 PSI or flow is be low 2.5 GPM, check for restrictio n in inta ke line to

reel drive pump. If not restricted, remove pump and repair as necessary.

Testing Page 4 - 32 Greensmaster

3100

TEST HOOK UP NO. 4

MACHINES WITH PARKER PUMP USE

CENTER 3 PUMP SECTIONS FOR REEL

DRIVE CIRCUITS.

GR3100 WITH DANFOSS PUMP SHOWN.

Rev. E

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 saf ety interlock will stop the

engine when the mow pedal is engaged.

TESTER

TEST A: REEL DRIVE MOTOR FLOW PROCEDURE

Engine RPM 2800. Mow pedal engaged. While watching pressure gauges, slowly close flow control valve until 1000 PSI is

obtained. Read flow gauge.

TESTER READINGS

Flow not less than 2.5 GPM at 1000 PSI. If unable to get 1000 PSI or flow is below 2.5 GPM, check rearward sp ool travel. If spool

position is good, remove relief cartridge and examine for contamination or wear.

Greensmaster

3100 Page 4 - 33 Testing

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.

If pressure is is not in listed range, remove relief valve controlling reel being checked and examine for wear or contamination.

Testing Page 4 - 34 Greensmaster

3100

TEST HOOK UP NO. 5 (Greensmaster 3100)

GR3100 WITH DANFOSS PUMP SHOWN.

MACHINES WITH PARKER PUMP USE

LAST PUMP SECTION FOR STEERING

Rev. E

CIRCUIT.

Steering Pump Flow and Relief Pressure

TESTER CONNECTION:

Tester in series between steering pu mp outlet line and fitting on P (pressu re) 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

TEST A: STEERING PUMP FLOW PROCEDURE

Traction Lever in neutral. Engine RPM 2800. Hydraulic oil at operating temperature. While watching flow and pressure gauges, slowly close flow co ntrol v alve until 600 PSI

is obtained.

TESTER READINGS

Flow not lower than 1.5 GPM at 750 to 850 PSI If flow is less than 1.5 GPM, check for restriction in pump intake line. If not restricted,

remove pump and repair as necessary. If pressure not within listed range, remove steering relief cartridge and examine for

contamination or damage. Adjust steering relief valve if necessary.

Greensmaster

3100 Page 4 - 35 Testing

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.

2. Loosen jam nut securing yoke on front of long control rod, remove cotter pin and clevis pin.

3. Move adjustment lever by hand to level the mow and lift pedals and adjust yoke on control rod until hole in yoke lines up with the adjustment lever hole.

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.

Figure 13

1. Jam nut

2. Yoke

3. Control rod

4. Adjustment lever

Adjustments Page 4 - 36 Greensmaster®3100

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. Remove jamnut and balljoint securing control rod to traction shaft pivot.

4. Loosen jamnuts securing balljoints to control rod and adjust balljoints and control rod to get 3/16 in..

Forward

1. Push the traction pedal fully forward until No. 5 section valve spool is completely pulled out.

2. Pedal should contact pedal stop. If pedal contacts stop before spool is completely out, or if pedal does not make contact with stop, an adjustment to the stop is necessary.

Figure 14

1. Fully forward 3. Reverse

2. Pedal stop 4. Control rod

3. Loosen hex nut securing threaded rod to frame. Turn flange nut on rod to raise or lower stop (rod), while checking pedal.

4. When completed, retighten nut.

Traction Return Linkage (Fig. 14a)

If shift selector does not return to Neutral or No. 1 position from No. 2 position when mow pedal is engaged, an adjustment to the traction return linkage is required.

1. Loosen front jam nut securing cable assembly to mow/lift control rod bracket.

2. Move shift lever to No. 1 position.

3. While holding mow/lift control rod in rear position, tighten rear locknut to remove almost all slack from cable assembly. Do not over-tension cable.

4. Tighten front jam nut ot lock adjustment.

Figure 14a

5. Check operation and adjust again as necessary.

Greensmaster®3100 Page 4 - 37 Adjustments

1. Cable assembly 3. Mow/lift control rod

2. Mow/lift control rod bracket

Rev. B

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. 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.

Retighten the capscrews.

CAUTION

You must readjust the mow-lift switch when the camshaft adjustment is completed. (See Mow-Lift Switch Adjustment in the Adjustments section of Chapter 5 - Electrical System). The lift and mow pedal height must also be adjusted. (See Lift and Mow Pedal Height Adjustment in this section.)

Figure 15

1. Mounting capscrews

Adjustments Page 4 - 38 Greensmaster®3100

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.

4. Reverse steps 1 - 3 to reinstall motor.

Reel Motor Shaft Seal Replacement (Fig. 17)

1. Disconnect and reverse hydraulic lines on affected motor (connect pressure line to outlet fitting on motor and return line to inlet fitting on motor).

IMPORTANT: Make sure hydraulic lines are connected properly after shaft seal is replaced.

2. Loosen motor mount nuts.

3. Rotate motor clockwise so motor flanges clear studs and pull motor out.

Figure 16

1. Motor mount nuts 2. Motor

10. Apply “Loctite 515 Gasket Eliminator” or equivalent to outside diameter of new seal.

11. Apply generous amount grease to inside diameter of new shaft seal.

12. Use seal installation tool to install new shaft seal. Make sure seal is installed square with the seal bore.

4. Remove snap ring from motor.

5. Start the engine. DO NOT engage the mow pedal. Back pressure in the hydraulic system will push shaft seal out of motor. Stop the engine.

NOTE: Seal may also be removed by punching two holes in face of seal 180 and pulling seal out by grasping the screws.

6. Disconnect hydraulic lines from motor.

7. Remove and discard shaft seal and spacer.

8. Install a new spacer on motor shaft.

9. Put seal protector on motor shaft or apply tape on the shaft. Be careful to prevent the shaft spline from damaging the new seal.

Greensmaster®3100 Page 4 - 39 Repairs

apart, installing metal screws

Figure 17

1. Seal protector

2. Seal installation tool

Reel Motor 70-9800 Repair (Fig. 18)

13 16

1415

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. Put your hand on the cover assembly and gently tap the drive shaft with a soft face hammer to separate the body from the cover. Be careful not to drop parts or disengage gear mesh.

5. Before removing gear set, apply marking dye to mating teeth to retain “timing” when reassembling.

6. Be careful when disassembling. The needle bearings 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 cover and body.

7. Remove and discard the bridging insert, gasket insert, anti-extrusion block, snap ring, shaft seal, spacer, seal assembly, wear plate and o-ring, (Items 5, 6, 8-11, 14, 15 and 17). These items are available in a repair kit.

8. Clean all parts and check for burrs, scoring, nicks, etc.

9. Rub mating surfaces of body and cover with 400 grit or finer sandpaper to remove any Loctite residue. Wash body and cover to remove abrasive material.

10. Apply grease to bridging insert and put in cover, tab side down.

11. Apply grease to gasket insert and put in place over bridging insert.

12. Stone gears if wear plate appears scored. Replace as set if necessary. Oil the inside of cover and insert the gear set, maintaining the original timing and locations.

13. Apply grease to wear plate and slip over shafts with wider cross section next to bridging insert. If the wear plate is made of steel backed bronze, the bronze side must face gears.

Repairs Page 4 - 40

Rev. B

Greensmaster

3100

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).

18. Before tightening the capscrews, rotate the drive shaft in the direction of normal rotation (counterclockwise) to check for binding. You may not be able to rotate the drive shaft by hand. Protect the shaft if using a pliers.

19. Tighten the capscrews evenly in a crossing pattern to a torque of 190-210 in-lb.

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. Spread a thin, even coating of “Loctite 515 Gasket Eliminator” or equivalent on one surface.

17. Assemble the body to the cover, making sure that none of the parts become displaced. Insert the capscrews and washers and hand tighten.

20. 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).

21. Allow 60 minutes for liquid gasket material to harden before operating motor.

Greensmaster

3100 Page 4 - 41 Repairs

Reel Motor 94–3506 Repair (Fig. 18a)

Figure 18a

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 (1) and washers (2).

4. Put your hand on the cover assembly (4) and gently tap the drive shaft with a soft face hammer to separate the body (10) from the cover. Be careful not to drop parts or disengage gear mesh.

5. Before removing gear set, apply marking dye to mating teeth to retain “timing” when reassembling. Motor efficiency may be affected if the teeth are not installed in the same position during reassembly.

IMPORTANT: To prevent damage to load plate or cover during motor operation, do not mark gears with a punch or scribe.

6. Be careful when disassembling. The needle bearings (5) may be of the loose grease retained type. Pack these

with general purpose grease to retain them for re– asembly. It is recommended NOT to remove the bearing races from the cover and body.

7. Remove the load plate assembly (9).

8. Remove and discard the seal ring (8), snap ring (13), shaft seal (12), and spacer (11). These items are available in a repair kit.

9. Clean and air dry all parts. Check for burrs, scoring, nicks, etc.

10. Replace gears as set if excessively scored or worn. Replace load plate if worn or scored.

11. Apply grease or petroleum jelly to load plate assembly (9) and install in body.

12. Dip gears in oil and install in body, maintaining original timing and locations.

13. Apply grease or petroleum jelly to ring seal (8) and install in body.

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.

Repairs

Page 4 – 41.1

Rev. B

Greensmaster 3100

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.

16. Tighten the capscrews evenly in a crossing pattern to a torque of 17 ft–lb.

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).

Greensmaster 3100 Page 4–41.2 RepairsRev. B

Reel Motor 105–9770 Repair (Fig. 18b)

33 to 40 ft–lb

(45 to 55 Nm)

Figure 18b

1. Rear cover

2. Drive gear

3. Seal

4. Tab washer

5. Pressure seal

6. Back–up ring

7. O–ring

8. Body

Disassembly

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. Use a marker or scribe to make a diagonal mark across the front flange, body, and rear cover for reassembly purposes (Fig.18c).

9. Idler gear

10. Cap screw

11. Front flange

DIAGONAL MARK

Repairs

Page 4 – 41.3

Rev. D

Figure 18c

Greensmaster 3100

IMPORTANT: Avoid using excessive clamping pressure on the motor flange to prevent distorting the casting.

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.

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. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish.

7. Place the motor on its side and push on the rear bearing block to remove the bearing block and gear set (Fig. 18d).

8. Carefully remove and discard o–rings, pressure seals, and back–up rings (Fig. 18e) from motor. Do not cause any damage to the machined grooves during the removal process.

Figure 18d

1. Motor body 2. Bearing block & gear set

IMPORTANT: Make sure not to damage the counter bore when removing the shaft seal from the front plate.

9. Position front flange with seal side up. Remove shaft seal.

Inspection

1. Remove any nicks and burrs from all motor components with emery cloth.

CAUTION

Use eye protection such as goggles when using compressed air.

2. Clean all motor components with solvent. Dry all parts with compressed air.

Figure 18e

1. Drive gear

2. Idler gear

Greensmaster 3100 Page 4–41.4 RepairsRev. D

Figure 18f

3. Bearing block

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. Bearing areas of bearing blocks should not have excessive wear or scoring.

E. Face of bearing blocks that are in contact with gears should be free of wear, roughness or scoring.

5. Lubricate gear faces and bearing surfaces of drive gear, idler gear, and bearing blocks. Carefully assemble bearing blocks and gears noting identification marks made during disassembly.

6. Position the motor body on its side. Carefully slide bearing block and gear assembly into the body cavity using identification marks made during disassembly.

7. Remove any excess lubrication from mating surfaces of body, rear cover, and front flange. Make sure that these surfaces are clean and dry.

8. Install dowel pins in body.

IMPORTANT: Do not dislodge o–rings, pressure seals, or back–up rings during final assembly.

9. Gently slide the rear cover onto the assembly using marker or scribe mark for proper location. Firm hand pressure should be sufficient to engage the dowel pins.

4. Inspect front flange and rear cover for damage or wear.

Reassembly

NOTE: When reassembling the motor, check the identi-

fication marks made during disassembly to make sure the parts are properly aligned during reassembly.

1. Lubricate o–rings, pressure seals, back–up gaskets, and seal grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic oil.

2. Install new shaft seal into front flange.

3. Install lubricated pressure seals into the grooves in the front flange and rear cover. Follow by carefully placing the back–up rings into the grooves.

4. Install new o–rings to the body.

10.Position the motor with rear cover downwards. Carefully slide the front flange onto the assembly using marker or scribe mark for proper location.

11. Install the four cap screws and hand tighten.

IMPORTANT: Avoid using excessive clamping pressure on the motor housing to prevent distorting the housing.

12.Place motor front flange in a vise and alternately torque the cap screws from 33 to 40 ft–lb (45 to 55 N–m).

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.

Repairs

Page 4 – 41.5

Rev. D

Greensmaster 3100

This page is intentionally blank.

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 lines make sure hydraulic plugs are placed in the open end of the hydraulic line to prevent debris from contaminating hydraulic fluid. It is also a good idea to tag hydraulic lines when disassembling so that they can be properly reassembled. Keep all hydraulic and suction lines clean and free from debris. During replacement avoid overtightening fittings (see the Hydraulic Hose and Fitting Information section of this chapter). Check hydraulic lines for breaks or cracks. Check the hydraulic reservoir for proper fluid level after replacement of any large component.

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.

Reassembly

1. Fill pump with clean hydraulic fluid and cap fittings.

2. Assemble the pump to the engine in reverse of the disassembly procedures. Check all lines for clearance from the frame and other components.

3. Start machine and check for proper performance.

Repairs Page 4 - 42 Greensmaster®3100

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 relief valve bore and seat in bearing plate (Item 28).

4. Inspect spring for damage.

5. Clean and dry all parts. Apply hydraulic oil to parts. Install ball, spring and valve adjuster.

6. Install new o-ring on cap and install cap.

7. Before operating the machine, check steering relief pressure and adjust to 800 psi. To adjust, remove cap, turn adjuster clockwise to increase pressure and counterclockwise decrease pressure. (See Test Hook Up No. 5, Steering Pump Flow and Steering Pump Relief Setting in the Testing section of this chapter.)

Pump Service

1. Plug ports and wash exterior of pump with mineral spirits or solvent. Make sure parts and work area are clean.

2. Draw a line across the seam areas on the pump case with a scribe or marker to ensure proper reassembly.

IMPORTANT: Use caution when using a vise to avoid distorting any parts.

3. Secure the flange end of the pump (Item 15) in a vise with the drive shaft (Item 20) pointing down.

4. Remove the four locknuts (Item 1) and lockwashers (Item 2).

5. Put your hand on the pump case and gently tap the pump case with a soft face hammer to loosen the pump sections. Be careful not to drop parts or disengage gear mesh.

6. Before removing each gear set, apply marking dye to mating teeth to retain “timing” when reassembling.

Greensmaster®3100 Page 4 - 43 Repairs

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.

11. Assemble pump sections starting at the body assembly (Item 15). Install woodruff keys (Item 19) and align keyways in gears as they are installed over the shafts. Apply grease to new seal rings (Item 23) before installing.

12. After pump has been assembled, tighten locknuts by hand. Rotate the drive shaft to check for binding. Protect the shaft if using a pliers.

9. Clean all parts. All parts must be check for burrs, scoring, nicks, etc. Check the bushings in the plate assemblies (Items 22, 26 and 28) and cover assembly (Item 31) for excessive wear or scoring. Replace the assemblies as necessary. The bushings are not serviceable.

10. Stone gears if plate surfaces appear scored. Replace gears as sets if necessary. Oil the inside of gear plates (Items 14, 25 and 30) and insert gear sets, maintaining the original timing and locations.

13. Tighten the locknuts evenly in a crossing pattern to a torque of 17 to 19 ft-lb.

14. Before installing oil seal (Item 17) put seal protector on pump shaft or apply tape on the shaft.

15. Before installing fill volume between lips of new seal with Master Lubricant Co. “Lubrico M-6”, Lubriplate “Aero Lube” or equivalent. Apply grease to inside diameter of new oil seal. Carefully install a new oil seal. Assemble spring loaded lip of seal toward bearing.

Repairs Page 4 - 44 Greensmaster

3100

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. Loosen the capscrews securing the valve bank to the frame and remove the valve bank.

NOTE: Shims may be installed between the bank and frame. Note the quantity and mounting location and install in proper location upon reassembly.

6. Reverse steps 1 - 5 to install the valve bank. Do not over-tighten fittings. Use two wrenches to secure flexible line connectors, one wrench to prevent the Line from twisting, the other to tighten the connection. (See the Hydraulic Lines and Fittings section of this chapter.)

7. Check to be sure all lines are routed correctly and are not in contact with one another or other components. It should be possible to slip a strip of paper between any lines and other components in close relationship. Relocate if necessary.

8. Adjust the traction linkage, switches and reel drive camshaft as necessary.

Relief Valve Removal and Installation (Fig. 24)

Figure 23

1. Be careful not to interchange parts, such as springs or shims, between relief valves. The same number and thickness of shims must be installed when reassembling the relief valve.

2. Clean and inspect relief valve parts and the valve section housing. Replace parts as necessary. Install new seals and back-up rings. Apply hydraulic oil to parts before installing.

3. Before operating the machine, check the relief pressure for the affected relief valve. (See the Testing section of this chapter.) Adjust relief valve by adding or removing shims between the spring and poppet.

Figure 24

1. Main & No. 1 section relief 3. No. 3 section port relief

2. No. 2 section port relief 4. No. 4 (traction) relief

Greensmaster®3100 Page 4 - 45 Repairs

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. Clean the seal groove.

Figure 25

3. Soak the new seal in clean hydraulic fluid. INSTALL THE SEAL WITH THE OPEN (LIP) SIDE FACING IN TOWARDS THE VALVE BODY. Install the back-up washer and seal retainer

4. Install the breather washer, boot and chain link. Start the engine and check for leaks.

Rear (Bonnet) Side (Fig. 26)

1. Remove the bonnet.

NOTE: The valve bank must be removed in order to replace the spool seal under the bonnet on No. 4 spool.

2. Disassemble the components attached to the rear of the spool. (See Control Valve No. 1 Spool Detent Replacement and Control Valve No. 4 Spool Detent Replacement in this section of the book.)

NOTE: The assemblies under each spool bonnet are different from one another. Pay close attention to how they are disassembled so they will be reassembled correctly.

1. Boot 4. Back-up washer

2. Breather washer 5. Lip seal

3. Seal retainer

Figure 26

1. Seal retainer

2. Back-up washer

3. Lip seal

3. Remove the seal retainer, back-up washer, and lip seal from the valve body and clean the seal groove.

4. Soak the new seal in clean hydraulic fluid. INSTALL THE SEAL WITH THE OPEN (LIP) SIDE FACING IN TOWARDS THE VALVE BODY. Install the back-up washer, seal retainer and remaining components.

IMPORTANT: Make sure the switch is correctly positioned and adjusted when bonnet is installed on No. 2 or No. 4 spool. (See Mow/Lift Switch Replacement and Adjustment or Traction Switch Replacement and Adjustment in Chapter 6 - Electrical System.)

Repairs Page 4 - 46 Greensmaster®3100

Control Valve Internal Seal Replacement (Fig. 27)

2.5 in. traction spring

1.5 in. spring

These components changed locations after serial no. 210000701

Figure 27

1. Internal seals (4 between ea. sect.) 3. No. 2 section relief valve 5. No. 4 (traction) section relief valve

2. Main & No. 1 section relief valve 4. No. 3 section relief valve

NOTE: Replace all internal seals whenever valve sections are disassembled. Original seals may not seal

for any imperfections or contaminants which could cause leakage to occur.

after the valve assembly is installed on the machine.

5. Soak the replacement o-rings in clean hydraulic fluid

1. Remove the valve bank. (See Control Valve Removal and Installation in this section of the book.)

2. Put the valve bank in a vertical position in a bench vise, and remove the locknuts from the three (3) bolts

and install them into the ring grooves as you stack each section on top of another.

6. Install the locknuts onto the studs and torque them to 15-20 ft-lb (20.4-27.2 Nm).

securing the sections together (Fig. 27).

IMPORTANT: Do not overtorque. This will distort the

3. Slide each section off the studs. Identify them so they

valve bodies and cause binding of the spools.

will not be reassembled in the wrong location.

7. Install the valve bank onto the machine.

4. Remove all original o-ring seals, clean the o-ring grooves and check the mating surfaces of each section

Greensmaster®3100 Page 4 - 47 Repairs

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. The spring (Item 6) needs to be compressed to get detent stud started. Anchor the slotted end of the spool and apply 10-14 ft-lb (13.6-19 Nm) torque to detent stud (Item 9).

3. Slip bonnet (Item 1) over the entire assembly and secure it to the valve body with the two capscrews. Be sure slot in mounting face of bonnet is at bottom before installation.

4. Install the thrust plate (Item 5) into the bonnet (Item 1) so it bottoms out. Apply approximately 1/4 in. (6 mm) of #2 multi-purpose Lithium-base grease on top of thick washer (Item 5).

1. Bonnet 6. Spring

2. Spring 7. Capscrew

3. Race 8. Stop collars

4. Ball 9. Detent stud

5. Thrust plate 10. Adjustment cap

Figure 28

5. Install twelve balls (Item 4) into thrust plate (Item 5).

IMPORTANT: If the detent bonnet contains a vent pocket, do not let the balls fall into the vent.

6. Insert race (Item 3) on top of balls with ramp of race facing inward as shown. Rotate race (Item 3) until you are sure all balls are resting properly against the surfaces of the race and thrust plate (Items 3 and 5).

7. Insert spring (Item 2) into bonnet (Item 1).

8. Apply Locktite 222 or equivalent to the threads of adjustment cap (Item 10) and thread into bonnet. Turn adjustment cap in to compress the spring (Item 2). Actuate the spool assembly, then turn the adjustment cap until the desired detent action is obtained. This will usually be within three turns from bottoming out the adjustment cap..

NOTE: Each turn of adjustment cap (Item 10) changes the “Feel” of the detent action about 20%.

Figure 29

Repairs Page 4 - 48 Greensmaster®3100

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. Push the front of the spool in carefully until the holes in the detent adapter are just past the edge of the detent sleeve.

IMPORTANT: Do not push the spool too far or the rear spool seal may be cut by the spool.

Figure 30

4. Hold the front of the spool from turning, insert a drift punch through the holes in the adapter and rotate the adapter counter-clockwise to remove it from the spool.

5. Remove the detent sleeve.

Reassemble With the Following Procedures:

1. Mount the detent sleeve and the detent adapter. Lock the adapter securely to the spool.

2. Apply a light coat of grease to the adapter holes, insert the small spring, the four balls, and the ball follower.

3. Stand the valve bank assembly up so the front (clevis end) of No. 4 spool is facing downward.

4. Slide the detent sleeve up to the four balls. Apply light pressure against the balls with the sleeve. Push against the center of the ball follower with a drift punch to allow the balls to slip into the adapter holes and the sleeve to slide over the assembly.

IMPORTANT: Do not push spool too far or the rear spool seal may be cut by the spool.

1. Bonnet 5. Balls (4)

2. Spring 6. Detent adapter

3. Stop collar 7. Spring

4. Detent sleeve 8. Ball follower

5. Assemble the stop collar, large spring and bonnet to the valve body. Check the spool for proper detent operation and mount the valve bank onto the machine.

6. Adjust the traction switch. (See Traction Switch Removal, Installation and Adjustment in the Repairs section of Chapter 5 - Electrical System.)

Greensmaster®3100 Page 4 - 49 Repairs

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).

6. Reverse steps 2 - 5 to install the cylinder. Coat cylinder pivot on lift arm (Item 21) with Never-Seez or grease to achieve free pivot action of lift arm in cylinder clevis before reinstalling.

IMPORTANT: When disassembling hydraulic lines make sure hydraulic plugs are placed in the open end of the hydraulic line to prevent foreign debris from contaminating hydraulic oil. It is also a good idea to tag the hydraulic lines when disassembling so they can be properly reassembled. Keep all hydraulic lines clean and free from foreign debris. During replacement of lift cylinder, avoid overtightening fittings. Check hydraulic lines for cracks or breaks. If a hydraulic leak should appear after replacement of lift cylinder, replace the fitting or line that is leaking. Check hydraulic reservoir for level of hydraulic fluid after replacement of lift cylinder.

Repairs Page 4 - 50 Greensmaster®3100

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.

5. Reverse steps 2 - 5 to install the lift cylinder. Coat the hinge pin with Never-Seez or grease to achieve free pivot action of the cylinder before reassembling.

Greensmaster®3100 Page 4 - 51 Repairs

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. Mount the cylinder in a vise so the shaft end of the cylinder is tilted up slightly. Do not close the vise so firmly that the barrel could become distorted.

4. Remove the retaining ring (Item 10). Grasp clevis end of shaft (Item 11) and use a twisting and pulling motion to carefully extract piston (Item 4), shaft (Item 11), and head (Item 8) from the barrel (Item 1).

5. Securely mount the shaft (Item 11) in a vise and remove the lock nut (Item 2) from the piston end of the shaft. Remove the piston (Item 4). Slide the head (Item 8) off of the shaft.

6. Remove and discard all seals and back-up rings (Items 3, 5, 6, 7, 9).

7. Wash the parts in a safe solvent. Dry the parts with compressed air. DO NOT wipe them dry with a cloth or paper as lint and dirt may remain.

8. Inspect the internal surface of the barrel (Item 1) for damage (deep scratches, out-of-round, etc.). Inspect the head (Item 8), shaft (Item 11) and piston (Item 4) for evidence of excessive scoring, pitting, or wear. Replace any defective parts.

9. Put a light coating of hydraulic oil on all new seals and back-up washers. Install the new seals and back-up washers (Items 3, 5, 6, 7, 9). Install the head (Item 8) onto the shaft (Item 11). Install the piston (Item 4) onto the shaft and tighten the lock nut (Item 2).

10. Put a light coating of hydraulic oil on all cylinder parts to ease assembly. Slide the shaft assembly and head into the barrel. Install the retaining ring (Item 10) to secure the assembly in the barrel.

Repairs Page 4 - 52 Greensmaster®3100

Lift Cylinder Repair – No. 2 and 3 (Left and Right) (Fig. 35)

Figure 35

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. Mount the cylinder in a vise so the shaft end of the cylinder is tilted up slightly. Do not close the vise so firmly that the barrel could become distorted.

4. Remove the retaining ring (Item 10). Grasp clevis (Item 13) at end of shaft and use a twisting and pulling motion to carefully extract piston (Item 3), shaft (Item 6), and head (Item 9) from the barrel (Item 1).

5. Securely mount the shaft (Item 6) in a vise and remove the lock nut (Item 2) from the piston end of the shaft. Remove the piston (Item 3). Slide the head (Item 9) off of the shaft.

6. Remove and discard all seals and back-up rings (Items 4, 5, 12, 7, 8, 11).

7. Wash the parts in a safe solvent. Dry the parts with compressed air. DO NOT wipe them dry with a cloth or paper as lint and dirt may remain.

8. Inspect the internal surface of the barrel for damage (deep scratches, out-of-round, etc.). Inspect the head, shaft and piston for evidence of excessive scoring, pitting, or wear. Replace any defective parts.

9. Put a light coating of hydraulic oil on all new seals and back-up washers. Install the new seals and back-up washers (Items 4, 5, 12, 7, 8, 11). Install the head (Item 9) onto the shaft (Item 6). Install the piston (Item 3) onto the shaft and tighten the lock nut (Item 2).

10. Put a light coating of hydraulic oil on all cylinder parts to ease assembly. Slide the piston, shaft and head into the barrel. Install the retaining ring (Item 10) to secure the assembly in the barrel.

Greensmaster®3100 Page 4 - 53 Repairs

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.

2. Remove wheel nuts (Item 29) and remove wheel (Item 3). Remove large nut (Item 4) from wheel hub (Item 5).

IMPORTANT: To prevent damage to wheel motor, DO NOT hit wheel hub with a hammer during removal or installation.

3. Mount a wheel puller to wheel mount studs and remove wheel hub (Item 5) and brake drum (Item 6). Remove key (Item 11) from wheel motor shaft.

4. Disconnect hydraulic lines from fittings on wheel motor (Item 22). Put caps on open lines and fittings to prevent contamination.

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.

6. Reverse steps 1 - 6 to install the wheel motor. Tighten nut (Item 4) to a torque of 250 - 400 ft-lb.

IMPORTANT: When disassembling hydraulic lines make sure hydraulic plugs are placed in the open end of the hydraulic line to prevent foreign debris from contaminating hydraulic oil. It is also a good idea to tag the hydraulic lines when disassembling so they can be properly reassembled. Keep all hydraulic lines clean and free from foreign debris. During replacement of wheel motor, avoid overtightening fittings. Check hydraulic lines for cracks or breaks. If a hydraulic leak should appear after replacement of lift cylinder, replace the fitting or line that is leaking. Check hydraulic reservoir for level of hydraulic fluid after replacement of lift cylinder.

Repairs Page 4 - 54 Greensmaster®3100

Wheel Motor Repair (Fig. 37, 38)

Figure 37

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.

2. Remove the seven (7) special bolts (Item 14) using a 9/16 inch thin wall socket. Inspect bolts for damaged threads, or sealing ring under bolt head. Replace damaged bolts.

3. Remove end cover assembly (Item 24) and seal ring (Item 5).

4. Thoroughly wash cover in solvent and blow dry. Make sure cover valve apertures, including internal orifice plug, are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace cover as necessary.

5. Remove commutator ring (Item 23), commutator (Item 16), and manifold (Item 22).

6. Remove commutator seal (Item 15) from commutator (Item 16), using an air hose to blow air into ring groove until seal ring is lifted out and discard seal. Inspect commutator and commutator ring for cracks or burrs. Inspect commutator for wear, scoring, spalling or brinelling. If any of these conditions exist, replace commutator and commutator ring as a matched set.

7. Remove manifold (Item 22). Inspect manifold for cracks, surface scoring, brinelling or spalling. Replace manifold that shows any of these conditions. A polished pattern on the ground surfaces from commutator or rotor rotation is normal.

8. Remove rotor set (Item 19, 20, 21) and wear plate (Item 18). Retain rotor set in its assembled form to maintain the same rotor vane to stator contact surfaces. Inspect rotor set in its assembled form for nicks, scoring, or spalling, on any surface and broken or worn rotor splines. If any rotor set component requires replacement, the complete rotor set must be replaced as it is a matched set. Inspect the wear plate for cracks, brinelling, or scoring.

Greensmaster®3100 Page 4 - 55 Repairs

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. Inspect drive link for cracks and for worn or damaged splines. There should be no lash (play) between mating spline parts.

Before Assembling Motor

Replace all seals and seal rings with new ones. Lubricate all seals and seal rings with hydraulic oil or clean grease before assembly.

NOTE: Unless otherwise indicated, do not oil or grease parts before assembly.

Wash all parts in clean petroleum-based solvents before assembly. Blow them dry with compressed air. Remove any paint chips from mating surfaces of the end cover, sleeve, and housing and from port and sealing areas.

11. Remove thrust bearing (Item 12) and inspect for wear, brinelling, corrosion, and a complete set of rollers retained in position.

12. Remove coupling shaft (Item 11) by pushing on the output end of shaft. Inspect coupling shaft bearing and seal surfaces for spalling, nicks, grooves, severe wear or corrosion and discoloration. Inspect for damaged or worn keyway. Replace coupling shaft if any of these conditions exist.

NOTE: Minor shaft wear in seal area is permissible. If wear exceeds .020 inches (0.51 mm) diametrically, replace coupling shaft.

A slight “polish” is permissible in the shaft bearing area. Anything more would require coupling shaft replacement.

13. Remove inner seal (Item 7), back-up washer (Item 6) and back-up washer (Item 4). Discard seal and back up rings.

14. Remove housing (Item 3) from vise, turn over and re-clamp in vise with dirt seal (Item 1) end pointed up.

15. Remove dirt seal (Item 1) and discard.

16. Inspect housing (Item 3) assembly for cracks, the machined surfaces for nicks, burrs, brinelling or corrosion. Remove burrs that can be removed without changing dimensional characteristics. Inspect tapped holes for thread damage.

17. Inspect the bearings (Item 2, 9, 10) and thrust washers (Item 8). The bearing rollers must be firmly retained in the bearing cages, but must rotate and orbit freely. All rollers and the thrust washers must be free of brinelling and corrosion.

Assembly of Motor (Fig. 37, 38)

1. Place housing (Item 3) in a vise and clamp down on housing port bosses with large bore end pointed up. Apply clean grease to new seal (Item ) and assemble into housing with seal lip pointed inward.

2. Install back-up washer (Item 4) into housing. Install back-up washer (Item 6) into housing with beveled side facing out so it will mate to inner seal (Item 7).

3. Apply a small amount of clean grease to back side of new inner seal (Item 7) and assemble into housing.

4. Lubricate and assemble coupling shaft (Item 11), firmly seating it against thrust washer (Item 8).

5. Assemble thrust bearing (Item 12) onto end of coupling shaft (Item 11).

6. Assemble drive link (Item 13) into coupling shaft (Item 11) with their splines in mesh. Align hole in drive link with hole in coupling shaft.

NOTE: Two alignment studs screwed finger tight into housing (Item ) bolt holes, approximately 180° apart, will facilitate the assembly and alignment of components as required in the following procedures.

NOTE: Make sure new seal rings (Item 5) are installed between each section of motor as it is assembled.

7. Assemble wear plate (Item 18) over drive link and studs onto housing.

8. Install assembled rotor set (Item 21) with counterbore in rotor (Item 19) down, if applicable, and splines in mesh with drive link splines.

NOTE: If necessary, go to “Rotor, Stator, Vane Assembly” procedures on next page.

Repairs Page 4 - 56 Greensmaster

3100

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)

1. Place stator (Item 21) onto wear plate (Item 18) after doing motor assembly procedures 1 through 7.

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.

11. Install end cover (Item 24). Assemble special bolts (Item 14) and screw in finger tight. Removal of the two alignment studs should be made after at least two bolts have been assembled. Alternately and progressively tighten the bolts to pull end cover assembly into place with final torque of 50 ± 5 ft.lbs. (68 ± 8 Nm).

12. Invert housing in vise so the coupling shaft (Item 11) is pointing up and install dust seal (Item 1). Seal should be pressing in flush to 0.02 inch below face.

NOTE: Torque required to rotate coupling shaft should not be more than 50 ft-lb (68 Nm).

19,20,21

2. If assembly alignment studs are not being used, align stator bolt holes with wear plate bolt holes and turn two (2) bolts (Item 14) finger tight into bolt holes 180° apart to keep stator and wear plate stationary.

3. Assemble six vanes (Item 20) into the stator vane pockets.

4. Assemble rotor (Item 19), counterbore down, if applicable, into stator (Item 21) and onto wear plate (Item 18) with rotor splines in mesh with drive link splines.

5. Grasp output end of coupling shaft (Item 11) and rotate coupling shaft, drive link and rotor to seat the rotor and assembled vanes into stator, creating necessary clearance to assemble seventh (7th) vane. Assemble the seven (7) vanes using minimum force.

6. Remove the two assembled bolts if used to retain stator and wear plate.

Press seal in flush to 0.020 inch below face

Figure 38

Greensmaster®3100 Page 4 - 57 Repairs

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.

NOTE: To ease reassembly, tag each of the hoses to show their correct position on the steering cylinder.

2. Remove jam nuts (Item 21) securing cylinder end to castor fork (Item 19).

3. Remove locknut (Item 26) and washer (Item 27) to remove cylinder from frame.

IMPORTANT: Before installing the cylinder make sure the distance between ball joint centers is

14.4 in. with cylinder rod completely retracted. Loosen jam nut and adjust ball joint if necessary, then tighten jam nut.

4. Reverse steps 1 - 3 to install the steering cylinder.

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.

IMPORTANT: When disassembling hydraulic lines make sure hydraulic plugs are placed in the open end of the hydraulic line to prevent foreign debris from contaminating hydraulic oil. It is also a good idea to tag the hydraulic lines when disassembling so they can be properly reassembled. Keep all hydraulic lines clean and free from foreign debris. During replacement of steering cylinder, avoid overtightening fittings. Check hydraulic lines for cracks or breaks. If a hydraulic leak should appear after replacement of lift cylinder, replace the fitting or line that is leaking. Check hydraulic reservoir for level of hydraulic fluid after replacement of lift cylinder.

Repairs Page 4 - 58 Greensmaster®3100

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. Mount the cylinder in a vise by clamping vise on center mounting location of cylinder.

4. Loosen setscrews (Item 1) and remove threaded end caps (Item 2) from each end of barrel (Item 12).

5. Grasp flats on threaded end of rod and use a twisting and pulling motion to carefully remove rod assembly (Item 9) and head from the barrel. Remove head (Item 5) from other end of barrel.

6. Slide head off of rod assembly.

7. Remove and discard all seals and back-up rings.

8. Wash parts in solvent. Dry the parts with compressed air. DO NOT wipe them dry with a cloth or paper as lint and dirt may remain.

9. Inspect internal surface of barrel for damage (deep scratches, out-of-round, etc.). Inspect head and rod assembly for evidence of excessive scoring, pitting, or wear. Replace any damaged or worn parts.

10. Put a light coating of hydraulic oil on all new seals and back-up washers. Install the new seals and back-up washers.

11. Put a light coating of hydraulic oil on all cylinder parts to ease assembly. Slide rod assembly (Item 9) into barrel. Install head (Item 5) to each end of barrel.

12. Install threaded cap (Item 2) on each end of barrel and tighten setscrews (Item 1).

Greensmaster®3100 Page 4 - 59 Repairs

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. Remove the steering wheel cap (Item 9) from the steering wheel (Item 11). Remove the locknut (Item 10) that secures the steering wheel to the shaft. Pull the steering wheel off the shaft.

NOTE: It may be necessary to use a jaw-type puller to remove the steering wheel from the steering shaft.

IMPORTANT: DO NOT hit the steering shaft with a hammer. This could damage the steering valve components.

4. Remove four capscrews (Item 7) and lower the steering valve (Item 24) and steering column (Item 23) out of the steering arm.

5. Reverse steps 1 - 4 to install the steering valve. Tighten the steering wheel nut so the top surface of the nut is flush with the top of the steering column.

IMPORTANT: When disassembling hydraulic lines make sure hydraulic plugs are placed in the open end of the hydraulic line to prevent foreign debris from contaminating hydraulic oil. It is also a good idea to tag the hydraulic lines when disassembling so they can be properly reassembled. Keep all hydraulic lines clean and free from foreign debris. During replacement of steering valve, avoid overtightening fittings. Check hydraulic lines for cracks or breaks. If a hydraulic leak should appear after replacement of lift cylinder, replace the fitting or line that is leaking. Check hydraulic reservoir for level of hydraulic fluid after replacement of lift cylinder.

Repairs Page 4 - 60 Greensmaster®3100

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 ring 14. O-ring 23. O-ring

6. O-ring 15. Spacer plate 24. Check ball seat

7. Seal 16. Drive 25. O-ring

8. Bearing race 17. Gerotor 26. Setscrew

9. Needle thrust bearing 18. End cap

Disassembly

Cleanliness is extremely important when repairing a steering control unit. Work in a clean area. Before disconnecting lines, clean port area of unit thoroughly. Use a wire brush to remove foreign material and debris from around exterior joints of the unit.

Although not all drawings show the unit in a vise, it is recommended that you keep the unit in the vise during disassembly. Follow the clamping procedures explained in the instructions.

Greensmaster®3100 Page 4 - 61 Repairs

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.

2. Remove 5/16" cap screws.

3. Remove end cap.

4. Remove seal from end cap.

Figure 43

5. Remove meter. Be careful not to drop star.

6. Remove seal from meter.

Figure 44

Figure 45

Repairs Page 4 - 62 Greensmaster®3100

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.

Figure 46

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.

Figure 47

Figure 48

Greensmaster®3100 Page 4 - 63 Repairs

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.

Figure 49

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.

Figure 50

Figure 51

Repairs Page 4 - 64 Greensmaster®3100

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. 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.

Figure 52

22. Remove two (2) seals from check valve seat.

23. Tip housing to remove check ball and check ball retainer.

Figure 53

Greensmaster®3100 Page 4 - 65 Repairs

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.

Refer to parts listings covering your steering control unit when ordering replacement parts. A good service policy is to replace all old seals with new seals.

Control End Reassembly

1. Use a needle nose pliers to lower check ball retainer into check valve hole of housing. Make sure retainer is straight (not tilted on edge) in housing.

2 Install check ball in housing.

3 Lubricate 5/8" diameter seal and 7/16" diameter seal. Install seals on check ball seat as shown

4. Lubricate check ball seat and seals thoroughly before installing seat in housing. When installing seat do not twist or damage seals. Install check ball seat in housing, insert open end of seat first. Push check ball seat to shoulder of hole.

5. Install set screw. Use a 1/4" allen wrench to torque set screw to 100 inch pounds. To prevent interference, make sure top of set screw is slightly below housing mounting surface.

6. Assemble spool and sleeve carefully so that the spring slots line up at the same end. Rotate spool while sliding parts together. Some spool and sleeve sets have identification marks, align these marks as shown. Test for free rotation. Spool should rotate smoothly in sleeve with finger tip force applied at splined end.

Figure 54

Figure 55

Repairs Page 4 - 66 Greensmaster®3100

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. Compress extended end of centering spring set and push into spool sleeve assembly withdrawing installation tool at the same time.

9. Center the spring set in the parts so that they push down evenly and flush with the upper surface of the spool and sleeve.

10. Install pin through spool and sleeve assembly until pin becomes flush at both sides of sleeve.

11. Position the spool and sleeve assembly so that the splined end of the spool enters the 14 hole end of housing first.

Figure 56

IMPORTANT: Be extremely careful that the parts do not tilt out of position while inserting. Push parts gently into place with slight rotating action, keep pin nearly horizontal. Bring the spool assembly entirely within the housing bore until the parts are flush at the meter end or 14 hole end of housing. Do not pull the spool assembly beyond this point to prevent the cross pin from dropping into the discharge groove of the housing. With the spool assembly in this flush position, check for free rotation within the housing by turning with light finger tip force at the splined end.

12. Place housing on clean, lint free cloth. Install 2-1/8" diameter seal in housing.

13. Install two (2) bearing races and the needle thrust bearing in the order shown .

Figure 57

Figure 58

Greensmaster®3100 Page 4 - 67 Repairs

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.

17. Install retaining ring (see Fig. 59 - 60) in housing. After installing ring, tap on ring end or pry with screwdriver around entire circumference of ring to properly seat ring in groove.

Figure 59

Figure 60

Repairs Page 4 - 68 Greensmaster®3100

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.

19. Install 3" diameter seal in housing.

20. Install spacer plate. Align bolt holes in spacer plate with tapped holes in housing.

Figure 61

Figure 62

Greensmaster®3100 Page 4 - 69 Repairs

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.

22. Install 3" diameter seal in meter.

Figure 63

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. Align bolt holes without disengaging meter from drive.

Figure 64

Figure 65

Repairs Page 4 - 70 Greensmaster®3100

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.

Figure 66

Figure 67

Greensmaster®3100 Page 4 - 71 Repairs

Repairs Page 4 - 72 Greensmaster®3100

Toro 3100 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Specifications

Adjustments

Engine Removal and Installation

Specifications

Special Tools

Troubleshooting

Testing

Adjustments

Repairs