Toro greensmaster 3100, 4356 Operator's Manual

FORM NO. 3324-858
© The Toro Company—2000
To understand this product, and for safety and optimum performance, read this manual before starting operation. Pay special attention to SAFETY INSTRUCTIONS highlighted by this symbol.
The safety alert symbol means CAUTION, WARNING or DANGER—personal safety instruction. Failure to comply with the instruction may result in personal injury.
MODEL NO. 04356—200000001 AND UP
GREENSMASTER
OPERATOR’S
MANUAL
®
3100
Forward
Table of Contents
2
Forward 2
Table of Contents 2
Safety 3
Sound & Vibration Levels 5
Symbol Glossary 6
Specifications 9
Set-Up 10
Install the Cutting Units 10 Installing Cutting Units 11 Rear Ballast 12
Before Operating 13
Check the Engine Oil 13 Fill the Gas Tank 13 Check the Hydraulic System 14 Tire Pressure 15 Check Wheel Nut Torque 15
Controls 16
Operating Instructions 18
Break-In Period 18 Starting Instructions 18 Check the Interlock System Operation 18 Check the Leak Detector Operation 20 Preparing the Machine for Mowing 21 Training Period 21 Before Mowing 21 Mowing Procedures 21 Leak Detector Operation 22 Transport Operation 23 Inspection and Clean-Up After Mowing 23
Maintenance 24
Maintenance Schedule 24 Lubrication 26 Changing the Engine Oil and Filter 28 Servicing the Air Cleaner 28 Adjusting the Throttle Control 29 Adjusting the Choke Control 29 Adjusting Carburetor and Speed Control 29 Replacing Spark Plugs 30 Fuel Filter Replacement 30 Changing the Hydraulic Oil and Filter 31 Checking Hydraulic Hoses and Lines 31 Brake Adjustment 32 Rear Camshaft Adjustment 32 Adjusting the Lift and Mow Pedal Height 33 Leveling the Lift and Mow Pedals 33 Adjusting the Traction Pedal 33 Adjusting the Cutting Unit Lift/Drop 34 Adjusting the Lift Cylinders 35 Seat Switch Maintenance 35 Traction Switch Maintenance 35 Mow/Lift Switch Maintenance 36 Adjusting the Traction Return Linkage 36 Battery Care 36 Troubleshooting 38 Storage 44 Identification and Ordering 44
The Greensmaster 3100 was developed to provide an efficient, trouble-free and time-saving method of mowing high-quality turf on the finest greens. The latest concepts in engineering, design and safety have been incorporated into this machine, along with the highest quality parts and workmanship. This product will provide excellent service if you follow proper operation and maintenance practices.
We know, because you have purchased the industry leader in mowing excellence, that future performance and dependability are of prime importance. Therefore, this manual should be read by you and all others involved with the Greensmaster 3100 to make sure that safety, operation and maintenance procedures are followed.
Safety
Training
1. Read the instructions carefully. Be familiar with
the controls and the proper use of the equipment.
2. Never allow children or people unfamiliar with
these instructions to use the lawn mower. Local regulations may restrict the age of the operator.
3. Never mow while people, especially children, or
pets are nearby.
4. Keep in mind that the operator or user is
responsible for accidents or hazards occurring to other people or their property.
5. Do not carry passengers.
6. All drivers should seek and obtain professional
and practical instruction. Such instruction should emphasize:
the need for care and concentration when working with ride-on machines;
control of a ride-on machine sliding on a slope will not be regained by the application of the brake. The main reasons for loss of control are:
insufficient wheel grip;
being driven too fast;
inadequate braking;
the type of machine is unsuitable for its
task;
lack of awareness of the effects of
ground conditions, especially slopes;
incorrect hitching and load distribution.
Preparation
1. While mowing, always wear substantial footwear
and long trousers. Do not operate the equipment when barefoot or wearing open sandals.
2. Thoroughly inspect the area where the equipment
is to be used and remove all objects which may be thrown by the machine.
3. WARNING—Petrol is highly flammable.
Store fuel in containers specifically designed for this purpose.
Refuel outdoors only and do not smoke while refueling.
Add fuel before starting the engine. Never remove the cap of the fuel tank or add petrol while the engine is running or when the engine is hot.
If petrol is spilled, do not attempt to start the engine but move the machine away from the are of spillage and avoid creating any source of ignition until petrol vapors have dissipated.
Replace all fuel tanks and container caps securely.
4. Replace faulty silencers.
Operation
1. Do not operate the engine in a confined space
where dangerous carbon monoxide fumes can collect.
2. Mow only in daylight or in good artificial light.
3. Before attempting to start the engine, disengage
all blade attachment clutches and shift into neutral.
4. Do not use on slopes of more than:
Never mow side hills over 5°
Never mow uphill over 10°
Never mow downhill over 15°
5. Remember there is no such thing as a “safe”
slope. Travel on grass slopes requires particular care. To guard against overturning:
do not stop or start suddenly when going up or downhill;
engage the clutch slowly, and always keep the machine in gear, especially when travailing downhill;
machine speeds should be kept low on slopes and during tight turns;
3
4
stay alert for bumps and hollows and other hidden hazards;
never mow across the face of the slope, unless the lawn mower is designed for this purpose.
6. Use care when pulling loads or using heavy
equipment.
Use only approved drawbar hitch points.
Limit loads to those you can safely control.
Do not turn sharply. Use care when reversing.
Use counterweight(s) or wheel weights when suggested in the instruction handbook.
7. Watch out for traffic when crossing or near
roadways.
8. Stop the blades rotating before crossing surfaces
other than grass.
9. When using any attachments, never direct
discharge of material toward bystanders nor allow anyone near the machine while in operation .
10. Never operate the lawn mower with defective
guards, shields or without safety protective devices in place.
11. Do not change the engine governor settings or
overspeed the engine. Operating the engine at excessive speeds may increase the hazard of personal injury.
12. Before leaving the operator’s position:
Disengage the power take-off and lower the attachments;
Change into neutral and set the parking brake;
Stop the engine and remove the key.
13. Disengage the drive to attachments when
transporting or not in use.
14. Stop the engine and disengage the drive to the
attachment
Before refueling;
Before removing the grass catcher;
Before making height adjustments unless the adjustment can be made from the operator’s position.
Before clearing blockages;
Before checking, cleaning or working on the lawnmower;
After striking a foreign object. Inspect the lawnmower for damage and make repairs before restarting and operating the equipment.
15. Reduce the throttle setting during engine runout
and, if the engine is provided with a shutoff valve, turn the fuel off at the conclusion of mowing.
Maintenance and Storage
1. Keep all nuts, bolts and screws tight to be sure
the equipment is in safe working condition.
2. Never store the equipment with petrol in the tank
inside a building where fumes may reach an open flame or spark.
3. Allow the engine to cool before storing in any
enclosure.
4. To reduce the fire hazard, keep the engine,
silencer, battery compartment and petrol storage area free of grass, leaves, or excessive grease.
5. Check the grass catcher frequently for wear or
deterioration.
6. Replace worn or damaged parts for safety.
7. If the fuel tank has to be drained, this should be
done outdoors.
8. Be careful during adjustment of the machine to
prevent entrapment of the fingers between moving blades and fixed parts of the machine.
9. On multi-bladed machines, take care as rotating
one blade can cause other blades to rotate.
10. When the machine is to be parked, stored or left
unattended, lower the cutting means unless a positive mechanical lock is used.
Sound & Vibration Levels
Sound Levels
This unit has an equivalent continuous A-weighted sound pressure at the operator ear of: 86 dB(A), based on measurements of identical machines per 84/538/EEC.
This unit has a sound power level of 100 dB(A)/1pW, based on measurements of identical machines per procedures outlined in Directive 79/113/EEC and amendments.
Vibration Levels
This unit has a vibration level of 2.5 m/s2at the posterior, based on measurements of identical machines per ISO 2631 procedures.
This unit does not exceed a vibration level of 0.5 m/s
2
at the posterior based on measurements of identical machines per ISO 2631 procedures.
5
6
Symbol Glossary
Caustic liquids, chemical burns to fingers or hand
Crushing of whole body, applied from above
Cutting or entanglement of foot, rotating auger
Poisonous fumes or toxic gases, asphyxiation
Crushing of torso, force applied from side
Severing of foot, rotating knives
Electrical shock, electrocution
Crushing of fingers or hand/, force applied from side
Severing of fingers or hand, impeller blade
High pressure fluid, injection into body
force applied from side
Wait until all machine components have completely stopped before touching them
High pressure spray, erosion of flesh
Crushing of whole body
Severing of fingers or hand, engine fan
High pressure spray, erosion of flesh
Crushing of head, torso and arms
Whole body entanglement, implement input drive line
Crushing of fingers
or hand,
force
applied from
above
Cutting of fingers or hand
Crushing of toes or foot, force applied from above
Cutting of footCrushing of leg,
Fingers or hand entangle­ment, chain drive
Hand & arm entanglement, belt drive
Explosion Fire or open
Shut off engine & remove key before performing mainten­ance or repair work
Thrown or fly­ing objects, whole body exposure
flame
Riding on this machine is allowed only on a passen­ger seat & only if the driver’s view is not hindered
Thrown or flying objects, face exposure
Secure lifting cylinder with locking device before getting in hazardous area
Consult technical manual for proper service procedures
Runover/back­over, (relevant machine to appear in dashed box)
Stay a safe distance from the machine
Fasten seat belts Safety alert
Machine tipping, riding mower
Stay clear of articulation area while engine is running
Machine rollover, ROPS (relevant machine to appear in dashed box)
Stored energy hazard, kickback or upward motion
Do not open or remove safety shields while engine is running
triangle
Do not step on loading platform if PTO is connected to tractor & engine is running
outline safety alert symbol
Hot surfaces, burns to fingers or hands
Do not step
Read operator’s manual
7
Symbol Glossary
8
Reel 3
Engine coolant pressure
Engine coolant f ilter
n/min
Engine failure/ malfunction
Transmission failure/malfunction
Engine rotational speed/frequency
Clutch Neutral High Low Forward Reverse Park
231
First gear Second gear
Engine lubricating oil pressure
Choke Primer (start aid) Electrical preheat
Engine intake/ combustion air
Engine intake/ combustion air pressure
(low temperature start aid)
Engine intake/ air filter
Transmission oil Transmission oil
Engine start Engine stop
pressure
Transmission oil temperature
NHLFRP
Third gear (other #'s may be used until the maximum # of for­ward gears is reached.)
Hydraulic oil Hydraulic oil
Hydraulic oil pressure
Hydraulic oil level Hydraulic oil filter
temperature
Hydraulic oil failure/malfunction
Headlights Lock Unlock Differential lock 4-Wheel drive Pow er Take-Off Power Take-Off,
Reel cutting element, height adjustment
Parking brake Fuel
Traction Above working
temperature range
0430 weight Do not dispose
Fuel level Fuel filter Fuel system
Drilling Manual metal arc
welding
in the garbage
failure/malfunction
Manual 0356 Water pump
CE logo
Diesel fuel Unleaded fuel
rotational speed
Reel cutting element
0626 Keep dry
9
Configuration: Tricycle vehicle with the front two wheels providing drive and the rear wheel providing steering. The operator sits in the center over the No. 1 cutting unit with the No. 2 & 3 cutting units in front of the vehicle.
Power: 4-cycle gasoline engine, electric start, with output of 13.4 kW @3,600 rpm. Maximum no-load governed engine speed is 2,900 rpm.
Traction: All-hydraulic drive, consisting of multiple stack pump valve, valve, and two orbital gear motors to drive the front wheels.
Cutting Units: All-hydraulic drive, consisting of three gear pump sections, three valve sections and three gear motors that drive the reels.
Hydraulic Valve: Five spool sections: the first 3 spool sections control the lowering, mowing and lift functions of the cutting units. The spools moved out provide lowering and MOW operation; moved in they provide LIFT operation. The number 4 spool section controls the traction functions, N (Neutral), 1 (Mow), and 2 (transport). The number 5 spool section controls forward and reverse traction.
Tire Pressure :
• 55–83 kPa—front
• 55–103 kPa—rear
Brakes: 15 cm drum-type mechanical with rack and pawl lock for parking.
Hydraulic Filter: 10-micron, cartridge type.
Hydraulic Oil Reservoir: 32.2 liter capacity with
internal baffle. Type fluid: Mobil 15M. Red dye is added at the factory.
Gas Tank: 28.4 liter capacity.
Fuel Filter: In-line type.
Fuel Pump: Vacuum pulse type.
Seat Adjustment: 17.8 cm (forward and rearward).
Wheel Bearings:
Drive Wheels: Needle provided in wheel motors. Rear Caster Wheels: Timken tapered roller
Electrical & Instrumentation: The engine contains a 18-amp alternator; the circuit is fused at 20 amps. Instruments include ammeter and hour meter. An accessory terminal is available at the leak detector test switch if attachment of headlights is desired.
Battery: 12-Volt, lead acid, 32-amp. hour. Size: Length—18.4cm, Width—12.4cm, height—15.2cm.
General Specifications:
Width of Cut: 149.9 cm Wheel Tread: 123.3 cm Wheel Base: 119 cm Overall Length: 229 cm Overall Width: 177 cm Overall Height: 123 cm Net Weight (Wet): 381 kg Shipping Weight (In carton): 471 kg
Speeds:
1st —6.1 kmh 2nd—13 kmh Rev.—3.1 kmh
Reels: 1,975 rpm (approximately)
Clip:
0.46 cm (11-Blade Cutting Unit)
0.64 cm (8-Blade Cutting Unit)
1.0 cm (5-Blade Cutting Unit)
Specifications and design subject to change without notice
.
Specifications
10
Install the Cutting Units
For Cutting Unit Models 04404, 04406, 04408 04450 and 04468.
Note: When sharpening, setting height of cut, or performing other maintenance procedures on the cutting units, store the cutting unit reel motors in support tubes on the front of the frame to prevent damage to the hoses.
1. Remove the cutting units from their cartons.
Assemble and adjust according to the operator’s manual for the cutting units. Use the height gauge bar from the loose parts kit to adjust height of cut.
2. Slide the cutting units under the pull frames and
position the hoop on the top of cutting units over the lift arms (Fig. 1).
Figure 1
1. Hoop
2. Lift arm
3. Pull frame
4. Pull arm
3. Assemble the mount nuts for the reel drive motor
to each cutting unit. Leave approximately 1.2cm of threads exposed on each mount stud (Fig. 2).
Figure 2
1. Motor mount nuts
2. Coat with grease
4. Remove the protective covers from the cutting
units and the reel drive motor shafts. Coat the spline shaft of the motor with clean grease and install the motor by turning the motor clockwise so the motor flanges clear the studs. Rotate the motor counterclockwise until the flanges encircle the studs, then tighten the mounting nuts (Fig. 2).
Note: Retain the protective covers for the cutting units. Install them whenever the reel drive motors are removed to protect the cutting unit bearings from contamination.
5. Slide the sleeve back on the ball joint and rotate
the pull arm down so the socket fits over the ball stud. Release the sleeve so it slides over the stud and locks the assemblies together (Fig. 4).
6. Mount the baskets on the pull frames, loosen the
jam nuts on the pull arms and adjust the ball sockets until there is 6–11mm clearance between the lip of the basket and the reel blades (Fig. 3).
Note: This prevents the basket from tipping the cutting unit forward, causing the hoop to come off the lift arm while mowing.
Be sure the basket lips are equidistant from the reel blades all across each reel. If the basket is too close to the reel, it is possible for the reel to contact the basket when the cutting unit is raised off the ground.
Set-Up
11
Figure 3
1. Jam nut
2. Pull arm
3. Ball joint-adjust for clearance
4. 6–11mm clearance
7. Align the sockets in the ball joints so the open
side of the socket is centered toward the ball stud. Tighten the jam nuts to secure the sockets in position (Fig. 3).
Figure 4
1. Slide back to mount
2. Ball stud
Installing Cutting Units
For Cutting Unit Models 04480, 04481, 04482, and
04483.
Note: When sharpening, setting height of cut or
performing other maintenance procedures on the cutting units, store the cutting unit reel motors in support tubes on the front of the frame to prevent damage to the hoses.
1. Remove the cutting units from their cartons.
Assemble and adjust according to the operator’s manual for the cutting units. Use the height gauge bar from the loose parts kit to adjust height
of cut.
2. Mount a washer and ball stud to each end of the
front roller on the cutting units (Fig. 5).
3. Slide the cutting unit under the pull frame while
hooking the lift roller onto the lift arm (Fig. 5).
Figure 5
1. Pull frame
2. Lift roller
3. Lift arm
4. Pull arm
5. Ball stud
4. Slide the sleeve back on the ball joint and rotate
the pull arm down so the socket fits over the ball stud. Release the sleeve so that it slides over the stud and locks the assemblies together (Fig. 6).
5. Mount the baskets on the pull frames, loosen the
jam nuts on the pull arms and adjust the ball sockets until there is 6–11mm clearance between the lip of the basket and the reel blades or front shield.
Note: This prevents the basket from tipping the cutting unit forward causing the lift roller to come off the lift arm while mowing.
Be sure the basket lips are equidistant from the reel blades all across each reel. If the basket is too close to the reel, it’s possible for the reel to contact the basket when the cutting unit is raised off the ground.
12
Figure 6
1. Ball joint
2. Pull arm
3. Jam nut
6. Align the sockets in the ball joints so the open
side of the socket is centered toward the ball stud. Tighten the jam nuts to secure the sockets in position (Fig. 6).
7. Assemble the mounting capscrews for the reel
drive motor to each cutting unit. Leave approximately 1.2cm of thread exposed on each mounting capscrew (Fig. 7).
Figure 7
1. Capscrews
2. Drive motor
8. Remove the protective covers from the cutting
units and the reel drive motor shafts.
Note: Retain the protective covers for the cutting units. Install them whenever the reel drive motors are removed to protect the cutting unit bearings from contamination.
9. Using a hand pump grease gun, fill the cavity at
the end of the cutting unit with #2 general purpose grease.
10. Coat the spline shaft of the motor with clean
grease and install the motor by rotating the motor clockwise so that the motor flanges clear the studs. Rotate the motor counterclockwise until the flanges encircle the studs, then tighten the mounting capscrews (Fig. 7).
Rear Ballast
This unit complies with the ANSI B71.4-1999 Standard when 40 lbs. of calcium chloride ballast is added to the rear wheel.
If a puncture occurs in a tire with calcium chloride, remove the unit from the turf area as quickly as possible. To prevent possible damage to turf, immediately soak the affected area with water.
Important
13
Check the Engine Oil
The engine is shipped with 1.7 liter (with filter) of oil in the crankcase; however, the level of oil must be checked before and after you first start the engine.
1. Position the machine on a level surface.
2. Unscrew the dipstick and wipe it with a clean
cloth. Screw the dipstick into the tube and make sure it is seated fully. Unscrew the dipstick and check the oil level. If it is low, remove the filler cap from the valve cover and add enough oil to raise the level to the FULL mark on the dipstick.
Figure 8
1. Dipstick
2. Fill Cap
3. The engine uses any high-quality detergent oil
having the American Petroleum Institute — API—service classification SC, SD, SE, SF or SG. Recommended viscosity (weight) is SAE
30.
4. Pour the oil into the opening in the valve cover
until the oil level is up to the FULL mark on the dipstick. Add the oil slowly and check the level often during this process. DO NOT OVERFILL.
Check the oil level every 8 operating hours or daily. Initially change the oil and filter after the first 8 hours of operation; after that—under normal conditions—change the oil after every 50 hours and the filter after every 100 hours. However, change the oil more often when you operate the engine in extremely dusty or dirty conditions.
5. Install the dipstick firmly in place.
Fill the Gas Tank
THE TORO COMPANY STRONGLY RECOMMENDS THE USE OF CLEAN, FRESH UNLEADED REGULAR GASOLINE IN TORO GASOLINE-POWERED PRODUCTS. UNLEADED GASOLINE BURNS CLEANER, EXTENDS ENGINE LIFE, AND PROMOTES GOOD STARTING BY REDUCING THE BUILD-UP OF COMBUSTION CHAMBER DEPOSITS. LEADED GASOLINE CAN BE USED IF UNLEADED IS NOT AVAILABLE.
NOTE: Never use methanol, gasoline containing methanol, gasohol containing more than 10% ethanol, gasoline additives, premium gasoline, or white gas because the engine fuel system damage could result.
1. Fill the gasoline tank to the bottom of the filler
neck. DO NOT OVERFILL. Install the cap and tighten it securely in place.
Important
Before Operating
Because gasoline is flammable, use caution when storing or handling lt. Do not fill the fuel tank while the engine is running, or hot, or when the machine is in an enclosed area. Vapors may build up and be ignited by a spark or flame source many feet away. DO NOT SMOKE while filling the fuel tank to prevent the possibility of an explosion. Always fill the fuel tank outside and wipe up any spilled gasoline before starting the engine. Use a funnel or spout to prevent spilling gasoline before starting the engine and fill the tank to about 1 inch from the top of the tank, not the filler neck. Store gasoline in a clean safety-approved container and keep the cap in place on the container. Keep gasoline in a cool, well-ventilated place—never in an enclosed area such as a hot storage shed. To assure volatility, do not buy more than a 30-day supply of gasoline. Gasoline is a fuel for internal combustion engines; therefore, do not use it for any other purpose. Since many children like the smell of gas, keep it out of their reach because the fumes are explosive and dangerous to inhale.
DANGER
14
Figure 9
1. Fuel tank cap
Check the Hydraulic System
The hydraulic system is designed to operate on anti­wear hydraulic fluid. The machine’s reservoir is filled at the factory with 8.5 gallons (32.2 l) of Mobil 15M hydraulic fluid. Check the level of hydraulic fluid
before the engine is first started and daily thereafter.
Group 1 Hydraulic Fluid (Moderate climate— average duty)
Note: The fluids within this group are
interchangeable.
ISO VG 46/48 multi-viscosity anti-wear hydraulic fluid
Mobil DTE 15M Amoco Rycon Premium ISO 46 Castrol AWH 46 Conoco Hydroclear AW MV68 Gulf Harmony HVI 46 AW Kendall Hyken Golden MV SAE 5W-20 Pennzbell AWX MV46 Phillips Magnus A KV 5W-20 Shell Tellus T 46 Sunoco Sun Hyd. Oil 2105 Texaco Rando HDZ 46
Universal Tractor Hydraulic Fluid
Mobil Mobilfluid 424 Amoco 1000 Fluid Chevron Tractor Hydraulic Fluid Conoco Hydroclear Powertran Esso Hydraul
Gulf Universal Tractor Fluid Kendall Hyken 052 Marathon Marafluid Super HT Pennzoil Hydra-trans Phillips HG Fluid Shell Donax TD 76 Lubricants Hydraulic/Tractor Fluid Sunoco TH Fluid Texaco TDH
Group 2 Hydraulic Fluid (Hot Climate—Heavy Duty)
Note: The fluids within this group are
interchangeable.
ISO VG 68 anti-wear hydraulic fluid
Mobil DTE 26 Amoco Rykon AW No. 68 Castrol AWS 68 Chevron Hydraulic Oil AW ISO 68 Conoco Hydroclear AW 68 Exxon Nuto H 68 Gulf Harmony 68AW Kendall Four Seasons AW68 Marathon ISO 68 Pennzoil IAW Hydraulic Oil 68 Phillips Magnus A ISO 68 Shell Tellus 68 76 Lubricants AW 68 Sunoco SunVis 868 Texaco Rando HD 68
Group 1 fluids are recommended for use at typical ambient temperatures of 0°C to 41°C. The ISO type 46/68 fluid has been found to offer optimal performance in a wide range of temperature conditions for the average user. The Universal Tractor Fluids offer similar performance for those who prefer them, with perhaps some slight loss of efficiency at high ambient temperatures compared with the Type 46/48 fluids
Group 2 fluids are recommended for heavy-duty use in hot climates where ambient temperatures range from about 20°C to 49°C. Use at lower ambient temperatures may result in hard starting, increased engine laboring while cold, sluggish or non-operating spool valves while cold and high
Important
1
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