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