Woodbay GreensIRON 3900 Installation and operating instructions

Rev. 3 –11/26/09
OPERATION, PARTS & SERVICE MANUAL
MANUFACTURED BY

1
PRESIDENT’S MESSAGE
On behalf of Wood Bay Turf Technologies and your local distributor,
we thank you for purchasing the high performance greensIRON
3900. You are rolling in the right direction for smooth and fast
greens!
Introducing a greensIRON into the turf maintenance program at your
course will provide many important benefits. In the development of
the greensIRON 3900, our engineers were thinking about the needs
of your course. We’ve met the many challenges and unconventional
requirements of turf managers by working with superintendents and
their staff. You can be assured the smoothest putting greens,
increased green speed, and decreased mowing frequency are all very
important benefits received when you iron your greens with Wood
Bay’s 3900. The greensIRON 3900 will improve the putting surface
after aeration and/or top dressing and allow an increase in mowing
heights to reduce turf stress. Meet your expectations with superior
equipment manufactured by Wood Bay Turf Technologies.
The greensIRON Turf Broom is a very popular attachment for
enhancing putting surfaces after top dressing. It will decrease your
labor costs and is one of numerous customer suggestions developed
into smart design solutions for greensIRON owners. The
greensIRON Turf Ventilator also lets you improve air and water
penetration in your greens without any player interruption. We are
manufacturers of eco-friendly products. The greensIRON light kit
allows staff to get that early start and we began offering an electric
start option for additional operator convenience.
We urge you to read this manual carefully. The instructions and recommendations for operating the
greensIRON 3900 will help assure the safe and enjoyable use of this equipment.
Thank you for choosing the greensIRON 3900.
D. Lyall Adams
President

2
INTRODUCTION
The purpose of this manual is to provide you with reference information and assistance in setting up,
maintaining and operating your greensIRON 3900 in a safe, effective and efficient manner. It is intended for
turf rollers powered with the Hydro-Gear hydrostatic transmission. We expect that this manual will answer
most of your questions, but Wood Bay encourages you to contact your local distributor or Wood Bay’s
Technical Service Center on our toll free line (available in North America at 1-800-661-4942) for further
assistance or clarification at any time.
The manual alerts you to safety and environmental considerations, special features of the greensIRON 3900,
operations, ironing techniques, adjustments, servicing, trouble shooting and replacement parts identification.
It also introduces you to the special attachments and accessories that you may obtain to increase the benefits
of turf rolling in maintaining and enhancing your greens, both in terms of turf health and putting performance
for your golfers. We strive for not only what could be, but what should be in your turf management program.
Please note that the information, illustrations and specifications contained in this manual are based on the
latest product information available at the time of printing this manual. Wood Bay Turf Technologies
reserves the right to make changes at any time, without notice, in specifications and models and also to
discontinue models. The right is also reserved to change any specifications or parts at any time without
incurring any obligation to install the same equipment on models manufactured prior to the date of such
change.
The illustrations used in this manual may not depict actual models or equipment and are intended as
representative views for reference only.

3
TABLE OF CONTENTS
PRESIDENT’S MESSAGE .............................................................................................................................1
INTRODUCTION............................................................................................................................................2
TABLE OF CONTENTS.................................................................................................................................3
SECTION 1........................................................................................................................................................4
WARNINGS-SAFETY CONSIDERATIONS...................................................................................... 4
SECTION 2........................................................................................................................................................5
MAJOR COMPONENT DESCRIPTIONS.......................................................................................... 5
FRONT VIEW............................................................................................................................. 5
SIDE VIEW ................................................................................................................................. 5
TOP VIEW .................................................................................................................................. 5
SECTION 3........................................................................................................................................................6
FEATURES............................................................................................................................................. 6
SECTION 4........................................................................................................................................................7
ASSEMBLY AND SET UP.................................................................................................................... 7
ASSEMBLY INSTRUCTIONS.................................................................................................. 7
SET UP PROCEDURES............................................................................................................. 8
SECTION 5......................................................................................................................................................10
OPERATION.........................................................................................................................................10
BEFORE STARTING YOUR greensIRON 3900 TURF ROLLER.......................................10
STARTING HONDA MOTOR.................................................................................................10
OPERATOR FAMILIARITY WITH MACHINE..................................................................11
PEDAL CONTROL...................................................................................................................11
STEERING.................................................................................................................................12
LOADING AND UNLOADING ...............................................................................................12
IRONING TECHNIQUES AND PRACTICES.......................................................................13
SECTION 6......................................................................................................................................................14
SERVICING AND MAINTENANCE..................................................................................................14
HYDROSTATIC TRANSMISSION and HYDRAULIC MOTOR .......................................14
MONITORING THE HYDROSTATIC TRANSMISSION PERFORMANCE ..................14
CARE OF THE DRIVE CHAIN...............................................................................................15
CLEANING OF STEERING ROLLERS AND TRAILER....................................................15
DRIVE ROLLER.......................................................................................................................15
STEERING ROLLERS AND HANDLE BARS......................................................................15
TRAILER....................................................................................................................................15
SEAT ...........................................................................................................................................16
PAINTED SURFACES..............................................................................................................16
HYDRO-GEAR TRANSMISSION ..........................................................................................16
FIRST 20 HOURS......................................................................................................................16
ENGINE MAINTENANCE.......................................................................................................17
SECTION 7......................................................................................................................................................18
TROUBLE SHOOTING.......................................................................................................................18
SECTION 8......................................................................................................................................................21
PARTS LIST AND ILLUSTRATIONS...............................................................................................21
SECTION 9 .....................................................................................................................................................39
WARRANTY .........................................................................................................................................40
FOR LOCAL SALES.................................................................................................................47

4
SECTION 1
WARNINGS-SAFETY CONSIDERATIONS
PLEASE OBSERVE ALL WARNING STICKERS LOCATED ON THE EQUIPMENT.
WARNING INDICATES A STRONG POSSIBILITY THAT EQUIPMENT DAMAGE OR
PERSONAL INJURY COULD OCCUR WITH IMPROPER USE. REMEMBER SAFETY FIRST!
*
WARNING
Ensure that the trailer is attached to the transport vehicle before unloading or
loading the greensIRON.
*
WARNING
Keep all person(s) clear when towing unit because the TRAILER MAY BE
WIDER THAN TOW VEHICLE.
*
WARNING
Learn how to stop the Honda motor quickly, and understand the operation of all
controls. Never permit anyone to operate the greensIRON without proper
instructions and initial training at slow speeds.
*
WARNING
Do not over fill the fuel tank. There should be no fuel in the filler neck. If any
fuel is spilled, clean it up completely and allow petroleum vapor to dissipate
before starting the motor. Refuel in a well-ventilated area with the motor
stopped; do not smoke or allow flame or sparks in the area. Gasoline is highly
flammable and explosive under certain conditions. Close the filler cap securely.
*
WARNING
The exhaust muffler becomes hot during operation and remains hot for a period
of time after stopping the engine. Be careful not to touch the exhaust muffler
while it is hot.
*
WARNING
Children or passengers must not be allowed to ride on the greensIRON or
trailer.
*
WARNING
Be aware of and avoid severe grades and unusual undulations, as well as
adjacent sand traps and water features (this also applies to loading and
unloading). Ensure paths, gates and bridges can accommodate width of trailer.
*
WARNING
Start and stop the motor from a seated position when possible, and ensure
pedals are in the neutral position to avoid any unexpected movement.
*
WARNING
Be aware of the local conditions that you are operating under. The greensIRON
may have less traction on wet turf, and on higher cut turf.
*
WARNING
Ensure that the motor is shut off prior to servicing any component under the
safety guards, deck, transmission, motor coupling, or the motor itself.
*
WARNING
Wear suitable protective clothing and sunscreen so as to prevent eye damage,
hearing impairment and sunburn.
*
WARNING
Sudden release of the forward clutch pedal will result in the gradual slowing
down/ stopping of the greensIRON. Engaging the opposite clutch pedal while
the greensIRON is in motion will result in the sudden or immediate stop of the
drive roller and could cause personal injury and possible bruising of the turf.
Always train on the equipment at slow speeds.
TO VALIDATE THE greensIRON 3900 WARRANTY, COMPLETE THE SAFETY
ACKNOWLEDGEMENT AND WARRANTY FORMS PROVIDED AND RETURN TO WOOD
BAY TURF TECHNOLOGIES (see Pages 42 and 44).

5
SECTION 2
MAJOR COMPONENT DESCRIPTIONS
FRONT VIEW
1Soft Hand Grips (each side)
2Handle Bar Adjustment Lever (Not Shown)
3Honda GX160 K1QX 5.5 hp Motor
4Manual Recoil Starter and Hour/RPM Meter
5Engine Switch (ON/OFF) & Oil Alert Light
6Steering Rollers (Galvanized Tapered/Non-
Ridging)
7Drive Roller (Super Turf Trac Coating)
8Optional Electric Start (Battery Not Shown)
SIDE VIEW
9High Back Seat c/w Drain Hole
10 Steering Column Cowling and Cover
11 Transmission Cover
12 Drive Chain and Sprocket
13 Drive Roller Bearings
14 Super Turf Trac covering (Disperses Water and
Provides Positive Traction)
15 Drive Roller Tapered (Non-Ridging)
TOP VIEW
16 greensIRON - Trailer Locking Latch Bar
17 Non-Slip Deck Surface
18 Direction Pedal - Right
19 Direction Pedal - Left
20 Seat Forward/Reverse Adjustment Lever
21 Optional Turf Broom Attachment
22 Optional Turf Ventilator Attachment
23 Optional Lights
24 Bumper Pads
25 Accessories Attachment Bracket (Not Shown)
18
19
17 16
3 20
24 24
15
13
15
13
14
12
23
9
10

greensIRON
11
24 25
25
6 7
5
19
21
22
1
2
3
4

6
SECTION 3
FEATURES
UNMATMATCHED QUALITY AND COMMITMENT: PERFORMANCE EVERY DAY
Precision engineered components in each greensIRON produce amazing operator satisfaction from start
to finish.
Unique and dynamic steering system for straight tracking over flat to undulating greens.
High back padded seat with slide adjustment for maximum operator comfort and support.
Minimal day to day maintenance requirements combined with the new low torque powerful Hydro-Gear
hydrostatic transmission and hydraulic motor. Customers can expect longer life with less maintenance.
Machined and tapered galvanized steel steering rollers give both maximum durability and aesthetic
appeal.
Minimal vibration levels and comfortable seat improves productivity and significantly reduces operator
fatigue.
The Super Turf Trac drive roller covering provides increased high performance traction when you need
it in severe undulating conditions. Produces a soft touch effect for putting. Reduced scuffing on
collars.
Industrial bearings, with convenient access to grease ports.
Powerful and economical to operate Honda GX160 UTQX26 5.5 hp engine.
Multi-purpose transport trailer complete with extra long tailgate ramp is designed for fast, trouble–free
loading and unloading. Highest quality rust protection liner throughout trailer.
Convenient and easy to locate main drive components including: hydrostatic pump oil reservoir, drive
sprockets, drive coupler, hydrostatic transmission, hydraulic motor, Honda motor and drive chain
adjustments.
Factory installed oil drain hose and tap for easy and efficient servicing of Honda motor.
Optional 25-watt magneto lighting system for “night time” illumination.
Optional Turf Broom attachment will create a perfect finish to greens following top dressing.
Optional Turf Ventilator available when fast and efficient aeration is required on greens and tees.
Optional, side-loading trailer (special order) for courses with narrow pathways, gates and bridges.
Optional electric Honda motor start for extra convenience.
Limited one year warranty on parts and labor.
Owning a greensIRON 3900 is rolling in the right direction!

7
SECTION 4
ASSEMBLYAND SET UP
ASSEMBLY INSTRUCTIONS
1. Remove all packaging and crating materials except the bottom pallet.
2. Remove and unpack fenders (2), wheel hub and axle assemblies (2), tow bar for trailer (1), and seat for
the greensIRON 3900 turf roller.
3. If the optional Turf Broom and/or Turf Ventilator attachment kits are included in your order (see
packing slip and notations on crate), remove, and assemble them separately. The Turf Ventilator is
assembled, and the Turf Broom has been assembled in part, at the manufacturing plant prior to
shipping. The hardware package and instructions are enclosed. The right and left support brackets can
stay permanently bolted to the side of the greensIRON.
4. Located under the transmission cover is the hardware (bolt package) and operations manuals (including
the greensIRON 3900, Honda engine, Hydro-Gear hydrostatic transmission and hydraulic motor) with
their warranty registration forms.
5. Remove the two locking pins and lower tailgate down to the floor surface. Place cardboard or packing
material between the floor and tail gate to prevent scratching/paint damage.
6. Lift the roller-locking pin at the front of the trailer, releasing the greensIRON 3900, and insert it back in
the holder slot. Slowly roll the greensIRON out of the trailer box and down the ramp. Remove the
pallet from under the trailer.
7. Raise the tail gate and insert both locking pins. Tip the trailer box to rest on the tail gate for the next
part of the assembly. Install the trailer fenders with eight (8) 3/8” x 1” bolts, nuts and washers prior to
installing axels and wheels.
8. Insert the axle tube assemblies (2) into the sides of the trailer box. Ensure that hub is positioned
above the axle tube to maintain a low trailer elevation. Attach securely with four (4) of the 1/2” x 2
3/4” bolts, washers and nuts (nuts facing the rear). If it is difficult to push the bolts through the holes,
try switching the axle tubes from one side to the other.
9. Mount wheels to the hubs with wheel lugs provided. The bearings have been serviced and packed, and
are ready for operation. Check the tire pressure. Since the trailer has no springs, eight to ten (8-10) psi
is recommended for most conditions.
10. Secure the trailer tow bar to the trailer box, using two (2) of the 1/2” x 2 3/4” bolts, washers and nuts.
Ensure that when installed the tow bar curves upwards at the towing machine. Tip the trailer
back down on its wheels. The trailer is now ready for use. Note: the tow bar should always be firmly
connected to a towing machine before attempting to reload the greensIRON 3900 turf roller. When
connected to the towing unit, the bar and trailer box should be parallel with the ground.

8
SECTION 4 (con’t)
11. Loosen the handle bar clamp; turn the handle bars up so the hand grips are in a vertical position.
Tighten adjustment lever. Note: The position of the handle bars may be adjusted to meet operator
preference using the handle bar lever; caution: do not wear the knarling on the handle bar clamp.
12. Install the seat with its slide frame onto the turf roller seat brackets, and secure with the four (4) 5/16”
nuts and lock washers provided. Tilt the seat forward prior to opening transmission cover.
NOTE: greensIRON 3900 is shipped without motor and transmission lubricants, or fuel.
13. Refer to the enclosed Honda motor owner’s manual; fill the motor to the correct level with the
recommended lubricant. Use high detergent, premium quality oil for the motor. The Honda manual
recommends SAE 10W 30 for general, all temperature use.
14. Fill the fuel tank with unleaded fuel. Do not overfill.
15. Pour approximately three (3) liters of Mobil 1 5W40/50 synthetic oil into the Hydro-Gear transmission
tank. Do not fill over/above the sight glass.
16. Lubricate the drive chain as required –see Maintenance Schedule.
17. Grease as required the steering roller pivot (1) and drive roller bearings (2).
Now that your greensIRON 3900 is completely assembled, refer to the “Set Up Procedures” before
moving onto the green.
SET UP PROCEDURES
1. Your greensIRON 3900 does not have a throttle cable. Prior to normal operations, set the Honda motor
throttle lever for preferred RPMs. Initially, RPMs should be set low until the operator is familiar with
the operations of the machine. Once training and familiarization with the equipment is complete,
RPM’s may be increased (maximum 3650) for faster greensIRON speeds. See RPM digital tach
located on motor.
2. The drive chain tension has been preset at the factory. During assembly the greensIRON 3900 may
require minor adjustment. To make an adjustment, loosen the ½ inch nut on the idler sprocket and
slide the sprocket in the direction required to ensure a ¼ inch deflection at the center of the chain. It
will feel quite tight. Ensure that the chain is lubricated regularly.
3. All steering end roller bearings come pre-packed with grease. After one months operation apply
additional grease sparingly.
Recheck all nuts, screws and set screws to ensure that none have loosened during transport.
Your greensIRON 3900 is now ready to operate.

9
SECTION 4 (con’t)
Comment
We trust that these instructions have enabled you to assemble and get to know your greensIRON 3900 turf
roller. If you have suggestions, questions, or wish to comment on the instructions, please let us know; in
North America telephone [phone] or 780-468-4378, e-mail at [e-mail] or fax
comments to 780-468-0059. We appreciate your assistance and thank you for choosing one of Wood Bay’s
innovative products, the greensIRON 3900.
For further information contact your local distributor
or the manufacturer Wood Bay Turf Technologies, 1-800-661-4942.
www.woodbayturftech.com

10
SECTION 5
OPERATION
BEFORE STARTING YOUR greensIRON 3900 TURF ROLLER
Refer to your Honda motor, Hydro-Gear hydrostatic transmission, and the hydraulic motor owner’s
manuals for start up and break-in recommendations.
Check oil levels in both Honda motor and Hydro-Gear oil reservoir.
Check fuel level (unleaded fuel is recommended).
Check drive chain adjustment. Chain may require tightening after initial operation on golf course.
Lubricate chain frequently.
Check on both sides of the greensIRON prior to operation to ensure there are no obstructions that could
tear the Super Turf Trac drive roller covering.
STARTING HONDA MOTOR
Turn the fuel switch to the ON position.
Turn the motor switch to the ON position.
Engage the choke switch if required.
Pull the starter recoil handle (it is recommended that the operator start the engine while seated on the
greensIRON). Ensure both foot pedals are in the neutral position.
Once the motor is running, shut off the choke switch and adjust throttle speed.
Set the throttle speed manually with engine throttle lever.
To stop motor, turn ON/OFF switch to the OFF position,
and close OFF fuel switch.
1Fuel switch
2Choke
3Manual throttle lever
4Engine switch
5Pull start handle
6Hour/RPM meter (not shown)

11
SECTION 5 (con’t)
OPERATOR FAMILIARITY WITH MACHINE
When initially operating a greensIRON with the Hydro-Gear hydrostatic transmission, it is important to
get comfortable with the controls and the "feel" of the smooth operation of this turf roller. Operator
training should be conducted at a relatively low-speed on large level greens. Since the speed of the
motor determines the amount of torque delivered through the hydrostatic transmission, Wood Bay
recommends that all operators set the engine speed to less than one-half throttle until they are very
comfortable with both the steering handle bars and the left and right directional foot pedals. A low
throttle setting will limit the maximum speed at which the turf roller will travel in a given direction when
the pedal is fully depressed. When the operator has become accomplished with the greensIRON
controls, the throttle can be set fully open to both increase speed, and efficiency in “ironing” your greens.
WARNING: Do not jam your foot down hard on a directional pedal to start the greensIRON moving.
This action could suddenly engage the drive roller causing it to spin and potentially bruise the turf.
Smooth, steady starts and stops of the greensIRON, effected through even foot pedal pressure, will
produce the best turf ironing results for the golf course.
PEDAL CONTROL
DO NOT DEPRESS BOTH PEDALS AT THE SAME TIME, as clutch linkage damage will occur.
Depress the pedal smoothly and steadily for the desired direction of travel; left pedal for left travel; right
pedal for right travel (reference to left and right side of the greensIRON is determined while seated on
the unit looking forward). To increase ground speed, press the pedal down further.
When slowing or stopping the greensIRON 3900, ease back on the foot pedal.
For an EMERGENCY stop, release the direction-controlling foot pedal and apply light pressure to the
opposite foot pedal. If the engine does not stop, turn the engine switch to “Off”. DO NOT DRAG
YOUR FEET ON THE GROUND AS A BRAKING DEVICE.
ABRUPT EMERGENCY STOPS MAY RESULT IN BRUISING OF THE TURF.
The greensIRON will remain in a stationary position when
pedals are in the neutral position.
1Left drive direction control pedal
2Right drive direction control pedal
3Aluminum checkered traction plate
4Engine switch (ON/OFF) and oil alert
5Pull starter handle
6Fuel switch and choke lever
7Roller-trailer locking latch bar
1
Right Roll
(loading)
Direction
Left Roll
(unload)
Direction
4
2
3
5
6
7

12
SECTION 5 (con’t)
STEERING
Pushing the left handle bar away from the operator will pivot the
front of the steering rollers out. This will cause the greensIRON to
commence a turn to the right when rolling in that direction, or to the
left when rolling in that direction.
Pushing the right handle bar away from the operator will pivot the
back of the steering rollers out. This will cause the greensIRON to
commence a turn to the left when rolling to the right, or to the right
when rolling to the left.
Avoid over steering to prevent the possibility of turf damage.
This is especially true when the greensIRON is in a stationary
position.
LOADING AND UNLOADING
Ensure the transport trailer is securely attached to the
transport vehicle and the greensIRON locking latch is
engaged before transporting equipment to the green.
Transport the greensIRON to the green to be ironed.
Back the trailer unit towards the green so that when the
tail gate is lowered it will rest evenly on the edge of
the collar. DO NOT BACK THE TRAILER ON TO
THE GREEN.
For side-loading units, transport the greensIRON to the
collar of the green to be ironed, and stop at a distance
where the gate can be lowered to rest evenly at the
collar edge. DO NOT DRIVE TRAILER ON TO THE GREEN.
Start the motor, release the greensIRON locking latch, depress the left pedal and drive the unit down the
ramp on to the green. FOR SAFETY REASONS DO NOT OVER ACCELERATE WHEN
LOADING OR UNLOADING.
To reload the unit, reverse the above procedures aligning loading markings on the greensIRON with
centerline on the tail gate. The greensIRON can only be loaded and secured to the trailer from the
operator’s right hand side. The non-slip coating on the tail gate ramp and trailer deck provides excellent
traction when loading. Line up the greensIRON with the trailer and drive up the tail gate. Do not over
accelerate, and stop gently. Once the greensIRON is in place on the trailer, insert the locking pin to
prevent roller movement during transport. Shut off the motor and fuel switches, and latch both sides of
the tail gate.

13
SECTION 5 (con’t)
IRONING TECHNIQUES AND PRACTICES
DO NOT REFUEL greensIRON WHILE ON THE GREEN.
DO NOT DRIVE TRAILER ON GREENS OR TEES.
Ensure transport trailer is always securely attached to the
transport vehicle during loading and unloading.
DO NOT LEAVE greensIRON SITTING ON THE GREEN
SURFACE FOR LENGTHY PERIODS OF TIME.
Always have the greensIRON in motion when turning sharply.
The most efficient ironing pattern likely will be to travel across a
steep sloping green at a slight angle. The ironing pattern should
allow the operator to face oncoming play from down the fairway.
Maximum ironing performance is gained by keeping the left side
of the greensIRON on the downhill side of a slope.
Prevent creasing, marking or ridging. Adjust the ironing pattern
to accommodate any sharp undulations in green surface. Steer
the roller into a steep slope along the periphery of a green,
minimizing the chance of creasing on the low side of the greensIRON.
Be aware of bunkers, steep drops or water features adjacent to greens.
The preferred ironing effect for putting is obtained at a travel speed of 1000 sq. ft. per min. (5-7 mph).
Iron green in the direction that allows the Turf Broom to contact top dressing before the rollers.
For superior results, drive greensIRON with the Turf Ventilator in the forward position.
For new operators, driving the greensIRON toward the direction of the sun will help travelling in straight
lines and increase efficiency.
On large rectangular greens, ironing the green over the longest direction will increase efficiency.
For TV golf events and other important tournaments make two passes around the periphery of the green.
Start turning the greensIRON early when both going down a slope and turning at the same time.
Should a crease(s) occur when operating in low, wet areas of a green, iron the green while travelling in
the opposite direction and this will remove strip marks.

14
SECTION 6
SERVICINGAND MAINTENANCE
PRIOR TO UNDERTAKING MAINTENANCE WORK ON YOUR
greensIRON 3900, SHUT OFF MOTOR.
CAUTION: GASOLINE AND/OR OIL SPILLED OR TRACKED ON TO TURF MAY
CAUSE SEVERE DAMAGE.
HYDROSTATIC TRANSMISSION and HYDRAULIC MOTOR
Refer to your Hydro-Gear hydrostatic and hydraulic motor transmission owner’s manuals.
The Hydro-Gear hydrostatic transmission provides a smooth, powerful and quiet operation. It has been
checked and adjusted at the factory to ensure it performs effectively, and that the clutch pedals return to
their neutral (i.e., full stop) position when released. Add approximately three (3) liters of Mobil 1
5W40/50 synthetic oil to the reservoir. Change oil and filter after 100 hours and every 400 hours
or annually thereafter.
MONITORING THE HYDROSTATIC TRANSMISSION PERFORMANCE
Monitor closely the cleanliness of the fan and cooling fins. The transmission may be cleaned with a
pressure washer, but the input and output shaft seals are never to be sprayed directly.
Direct pressure wash spraying can damage the seals. Such damage will not be covered under warranty.
Check temperature and oil levels on reservoir site gauge.
Performing regularly scheduled maintenance will keep your greensIRON running in top
condition.

15
SECTION 6 (con’t)
CARE OF THE DRIVE CHAIN
The drive chain should be re-tensioned and lubricated regularly. Lubricate chain before or after every
operation with a spray-on chain lube - lubricating chain regularly will extend life of the chain.
The chain should have a 3/8” to 1/2” deflection on the side opposite to idler sprocket, under normal
operating conditions.
Should the chain become too loose or too tight, loosen the axle bolt on the idler sprocket and then adjust
the idler sprocket as needed to increase or reduce the chain tension. Tighten axle bolts.
If it is no longer possible to tighten the chain as needed by adjusting the idler sprocket, remove a half
link or a full link to shorten the chain. The chain should then be adjusted to the preferred tension.
Regular applications of a spray-on chain lube will ensure the chain does not become dry and will avoid
the possibility of oil or grease contamination on the turf.
If the chain is allowed to become dry, it will cause the chain to wear and/or break prematurely.
CLEANING OF STEERING ROLLERS AND TRAILER
Tilt the greensIRON down on the drive roller side and remove sand, thatch and other debris on the
steering rollers and undercarriage with a pressure hose. Wash the sand and grass material from the trailer
while empty. Keeping the trailer clean will help extend the life of the traction surface on the drive roller
and enhance the appearance and longevity from the tough abrasion. The liners are great looking with a
fine textured finish.
DRIVE ROLLER
Inspect the drive roller for any dirt or grass clippings and clean thoroughly prior to going on green.
Clean with a high powered hose.
Using a lithium II or non high-temp grease, lubricate both bearings every 20 hours of operation.
STEERING ROLLERS AND HANDLE BARS
Inspect the rollers for any dirt or grass clippings and clean them prior to traveling on the green.
Using a lithium II or non high-temp grease, lubricate bearings every 50 hours of use.
Check periodically for correct steering roller/handle bar alignment.
Steering rollers must be aligned parallel with the right deck edge. The handle bar in driving position
must be at right angles (90) to the steering rollers. The handle bar alignment can be adjusted by
increasing or decreasing the length of the steering rod arm connector assembly, located under the deck.
To make an adjustment in the handle bar alignment requires disconnecting at least one rod end, releasing
the jam nut, and turning the rod end toward or away from the other rod end on the connector assembly.
TRAILER
Using lithium II or non-high temperature grease, lubricate the two wheel bearings annually.
Check tire pressure prior to use. Tire pressure should be kept between 8 - 10 psi.

16
SECTION 6 (con’t)
SEAT
Use soap and water to keep the seat clean as needed and apply a vinyl protector only, prior to seasonal
storage.
PAINTED SURFACES
Wash with soapy water and a soft cloth. Pressure washing is not recommended. For further protection, an
application of wax every month is recommended to maintain an attractive finish.
HYDRO-GEAR TRANSMISSION
It is important to keep the veins (vents) of the transmission clear of dust and debris to ensure adequate
cooling.
FIRST 20 HOURS
After the first 20 hours of operation, check and tighten, as needed, the linkage of the foot pedals, drive
chain, wheel bolts and motor mounts. Also check and tighten as needed all key ways and set screws. This
procedure should be conducted every 50 hours thereafter. Check and ensure the steering handle bar
clamp bolts remain tight to ensure the gnarling is not damaged.
KEEP AN UPDATED RECORD OF THE MAINTENANCE ON YOUR
greensIRON 3900.

17
SECTION 6 (con’t)
ENGINE MAINTENANCE
Oil
Check oil level prior to each use.
Change oil after first 20 hours use and then every
100 hours thereafter.
Reduction Case Oil
Check oil level prior to each operation.
Change oil after first 20 hours of use and then
every 100 hours thereafter.
Air Filter
Check prior to each use.
Clean every 50 hours.
Replace every year or 300 hours.
Sediment Cup
Clean every 100 hours.
Spark Plug
Replace every year or 300 hours.
Fuel Tank and Filter
Clean every 100 hours.
Refer to separate Honda Engine Owner Manual for specific parts and any other inquiries.
MAINTENANCE SCHEDULE
The greensIRON 3900 has been equipped with a Tiny Tach hour meter to aid you in maintaining your unit in top
condition.
Each
Use
20
Hours
50
Hours
100
Hours
400
Hours
Annually
or Prior
to Storage
Chains –lubricate
√
√
Chains –check tension
√
Transmission Reservoir
√
Change
Hydrostatic Transmission Filter
Change
Change
Change
Rollers –wash/rinse
√
Drive Roller –grease bearings
√
Steering Roller –grease
√
Trailer –grease
√
Trailer –tire pressure
√
Check & tighten the linkage of the foot pedals,
fan belt, drive chain, wheel bolts and motor
mounts. Check & tighten as needed all keyways
and set screws.
√
√
Honda Motor
Oil
√
Change
Change
Change
Air filter
√
Clean
Replace
Reduction Oil Case
Change
Sediment Cup
Clean
Spark Plug
Replace
Fuel Tank and Filter
Clean

18
SECTION 7
TROUBLE SHOOTING
TROUBLE SHOOTING
SYMPTOM
PROBABLE CAUSE
SOLUTION
Honda motor runs rough.
Choke on.
Dirty air filter.
Intermittent spark.
Improper fuel mixture.
Switch off choke.
Clean or replace filter.
Clean or replace spark plug.
Readjust—see Honda motor manual.
Honda motor cuts out when
changing throttle speed.
Oil level low.
Fuel level low.
Fill to correct level—see Honda manual.
Fill fuel tank.
No movement left or right when
pedals are depressed.
Chain is broken.
Replace chain. Adjust tension until
desired movement is obtained.
Jerky motion or chain is jumping.
Not enough tension in chain.
Adjust chain tension as explained in
Section 5.
Pedal movement is either too free
or is difficult to depress.
Tension on nylock nuts for the
linkage arms may need adjustment.
Adjust tension on nylock nuts until a
comfortable pedal motion is obtained.
Rattling, grinding type of noise
from under deck when turf roller
is moving.
Chain may be loose.
A steering bearing may be failing.
Bolts may be loose on moving parts.
If chain is rubbing deck, ensure it is
tightened and properly aligned.
Lift unit and hand turn rollers to check for
noise; grease and/or replace bearings as
needed.
Check and tighten bolts as needed on:
Drive roller pillow blocks
Pedal linkages
Steering roller end bolts/housings
Stopper bolts on top of steering
frame
Roller continues traveling after
release of pedals to neutral
position.
The connection to rocker arm needs
adjustment to balance the return
distance for both sides.
See Section 5, adjusting for roller creep
Transmission may over heat and
feel sluggish, going both left and
right to operator.
Transmission oil and filter have not
been changed.
Change filter and oil.

19
SECTION 7 (con’t)
TROUBLE SHOOTING
SYMPTOM
PROBABLE CAUSE
SOLUTION
With pedal depressed and throttle
open, roller needs to be pushed to
start moving.
Low oil in reservoir
Failure of Hydrostatic motor or
pump
Fill to proper oil level
Change Hydrostatic pump or motor
Transmission is running extra hot,
shortly after starting it up.
Low oil
Filter needs to be changed due
to poor oil flow
Fill to proper oil level
Change filter
greensIRON Left Side View: Honda Motor and Hydro-Gear Pump