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Greensmaster 3150

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2. BACKLAP HOUR METE KILL RELAY KI START SAFETY K2 JOYSTICK RELAY K3 MOW RELAY K4 LOWER RELAY K5 RAISE RELAY K6 OPTIONAL JI P3I PI P2 P3 P4 PS P6 PT GO 3 30 85974 87 86 IGNITION SWITCH 1 kB 1 2 3 1 2 3 4 5 12 34 5 12 34 5 123 4 5 1 5 12 3 5 iio e XY A BS S 1 5 50 9 DIEESE 5 3 08 a amp m 5 m a ur Q x 5 a 8 2 Z g 5 a 8 SEAT HARNESS z 5 BLUE BLACK P8 WHITE BLACK dd WHITE BLACK A VIOLET BLACK 8 SPI GRAY BLACK 2 VIOLET BLACK 3 M 100 2 m PINK BLACK amp JOYSTICK VIOLET Serial Number Under 230000801 S LOWER LOAD 1 5 5 6 BLUE RED 5 2 BLUE RED A T J5 TIME ORANGE BLACK gt ree DELAY 2 GREEN RED REELS 3 GREEN GRAY GREEN GRAY 2 3 n e GREEN BLACK di 5 E GREEN BLACK BLACK GREEN BLACK A zz JOYSTICK 3 shs WHITE BLUE 8 YELLOW RAISE GRAY BLACK c BLUE BLACK D PIS BLACK BLACK XC B
3. 1 did Y 4 0982 0091 3 gt cael acd 1S1SOHGAH 1 hd 4 110 T 1 1 21 7 Y 1 pu ze 2 J hc E MED m ae EMPRESA ISd 3NTV 1 lt j lt x 092 002 3NIVA 9NIH331S H3MOd sip dam ce 71 lisha Y Q JA INVA v 52 os taps AO s1334 2 t gt 71 is E uu ee Ld a Q p 87 0 INVA 401 WOLLOS B 225 lt 4 j 90 zs 4 2 gt SS gt 2 dcs ra q Y H3MO1 90 8 H 9s HOLON 133HM L J SIMA Y NOLLOVH LL dv1Mova TN Su3aNnao 141 WNOlLdO 5 5 an vn 6
4. 0 TIGNITION SWITCH 18 3 B P18 P15 RAISE ENGAGE D C SOLENOID 63 SOLENOID S1 il UD A P12 NEUTRAL SWITCH A B P9 DIODE 3 BD 9 J3 J B STARTER SOLENOID P29 SEAT SWITCH 1 2 P31 JOYSTICK LOWER SWITCH al P28 321 JOYSTICK RAISE SWITCH P26 INTERCONNECT 1 In 321 SEAT HARNESS P27 J10 INTERCONNECT 2 IGNITION SWITCH gs 4 5 I lt I oa n 1 1 CE 32 P6 LOWER as P3 RELAY 5 P7 RAISE RELAY K6 KILL RELAY K1 EE P24 ALARM TIME DELAY 3 e GR T es pmr o J4 00 7 LOAD1 J5 J14 J13 e 5 2 65 48 OPTIONAL LIGHT 2 4 400 time DeLay REELS 312 17 5567 1 2 1 21 gue 2 TEST LIGHT 4 2 eu SWITCH 3 iD ME HGFEDCBA b
5. fYYYY x 1 relays and solenoids GI ALARM are shown as de energized BU LEAK DETECTOR CLOSED WHEN THERE S oy 1 SEC DELAY ON HYDRAULIC OIL LEAK HR vot STARTER HR METER 4 deri TO THE LIGHTS R Ld 7S OPTIONAL 1 F2 10 4 zo R 1 1 em 5 w TO THE LIGHTS x ae LIGHT TEST SW 4 OPTIONAL 2 E amp FUSIBLE LINK R E 4 1 i 8k T PK BU PK BU pn rr Mo TE 1 i W BU i a dees ae gt B 87 P31 A NEUTRAL SWITCH oo we ES ae 3 STARTER SOLENOID 87 t 85 85 BK 1 8 OPTIONAL BACKLAP s 1 1 Y SWITCH BACKLAP RELAY K7 1 i fYYYY 01 GN R OFF RUN START BU BK 1736 1 1 51 x x 01 OR BK REEL ENGAGE n 3 10 A Y p S 4 MOW RELAY K4 ol 1 8 2 8 SEATSWTCH 2 PARKING BK P31 8 ON POSITION M 1 6 F4 10A GN BK A 9 GN BU 5 In t 2 A 01 0 JOYSTICK 4 OR BK oo BU BK 1 FRAME GND 2522 7977 LOWER MOW D ENGINE GND PK OW SWITCH gt GY BK Y Y po 3 JOYSTICK RELAY 3 01
6. ALARM Backlap Circuits Serial Number 230000801 To 250999999 Shown 1 Power Current Control Current r Bu T f GY l Indication Current D ici amp s GY DELAY ON HYDRAULIC FLUID LEAK STARTER 66 2950 A HOURMETER i 2 1 R F120A F210A OPTIONAL Eum 5 ve E M 1 T 6 Ww gt LIGHTS 2 BK LIGHT TEST SWITCH y OPTIONAL 1 FUSIBLE RERQ 9ee 9 5 9 5 5 9 deS dO RS TROP IS S UN 3 1 7 BU 99 7430 1 28 4210 jy BACKLAP RELAY K7 BK T PK BU PK BU 5 87 evened 1 Mi un m TA mt d T FORM BU UM Pei onk NT P31 A uU STARTER SWITCH START SAFETY K2 BACKLAP 30 SOLENOID IGNITION SWITCH Y BACKLAP 1 D1 A d 997430 ST OFF RUN START OPTIONAL suek 7 e ER 1 7 4 5 ones MOW RELAY K4 eee SEAT BK SWITCH s 1 4 BE E E D1 D JOYSTICK 7 i 4 OR BK
7. 80 9330 695 ALARM Lower Reels 6 seconds Circuits w Serial Number 230000801 To 250999999 Shown Power Current r Bu po ay 83 2280 Control Current LEAK DETECTOR 1SECOND Indication Current CLOSED DURING DELAY ON HYDRAULIC FLUID LEAK STARTER 66 2950 HOURMETER 2 ES LIGHTS R 1 20 2 10 rs OPTIONAL paa 5 gota M R 1 T EB 5 LIGHTS 2 BK LIGHT TEST SWITCH OPTIONAL 1 FUSIBLE LINK MEN NES Els Gee euis E eS mc cecus uuu KM dd Bu EL 284210 BACKLAP RELAY K7 BK T PK BU PK BU 5 87 1 en TE E OTT ra m 35 T Pa N 1s NEUTRAL T T gt P31 A 89174801 IGNITION SWITCH SWITCH H a BACKLAP MK 874 PK SOLENOID PK Y BG SWITCH 99 7430 fm OFF RUN START 1 D1 A S OPTIONAL see e eire GN R 1 2 2 i ME AG 4d vs W gt 2525 y MOW RELAY K4 ENGAGE SWITCH PARKING 1 x ON POSITION 4j 99 7430 os Lap ei D1 D 7 BU BK Wd LOWER _ i B 4 MOW SWITCH D STOP NONE
8. JO YIH 1HOd se UMOUS PHYO uonisod pezifreue ui UMOUS SI TS spiousgjos D 3 ana tiya Y IVNOLLdO 3 gt 431009 1 1 110 LA 1 1 ld ig d a 4 lt ANWA ONIH331S H3MOd ww 1S 1d Id Y INVA MERE 189 7084LNO9 gt lt Is vel agl 1 50 4 p 4 1 x an 50 Y es i d es n 5 3914140 90 91 95 x 2 88 SANTA l dv ova Su3aNnao 141 mm TWNOLLdO vs 30018 1 D NOJ lt PRU 1 INOS 4 4 UMOUS 666666092 01 108000062 JequunN MON 0612 Je1seuisueaJc SHOLON T33H lt gt WO LLOS YOLOW T33HM NOILOVH L WNOILLdO ANIWA dOL WOLLOG 1441 E WOLLOS SHOLOW 133HM NOILOVH L Greensmaster 3150 Page
9. SOLENOID n Lower Reels 6 seconds Circuits B Ua eB 55 Serial Number Above 270000000 Shown ENERGIZED ALARM Power Current w Control Current Indication Current poo Bee BU Gy LEAK DETECTOR CLOSED WHEN THERE IS SEC DELAY ON A HYDRAULIC OIL LEAK HR METER G9 1 2 TO THE LIGHTS STARTER BU 53 OPTIONAL 1 F2 10A R T 1 1 w TO THE LIGHTS lt BK LIGHT TEST SW OPTIONAL 2 0 FUSIBLE LINK gl PK BU E w NEUTRAL SWITCH STARTER SOLENOID H START SAFETY K2 30 UUU BK IGN SWITCH NOT IN NEUTRAL BG PACA 87 85 WW 86 RE Em TOFFRUNSTAHT D1 A lt BACKLAP RELAY K7 Lao 87 GNIR i o 97 26 A i 26 BF3 10A 36 B 36 C 01 OR BK REEL ENGAGE MOW RELAY K4 SEAT SWITCH PARKING BRAKE EN 26 C F4 10 OCCUPIED OFF POSITION BU BK ri GN B E iX Y 87 bip 1 gt 2 JOYSTICK 36 E pe OR BK BU BK d FRAMEGND LOWER 85 WY 86 MOW SWITCH D E E N F 36 177 eg JOYSTICK RELAY Z is NN ENERGIZED ol Sa Y D1 C 4 28 STOP NONE A SSS Soe gt d o RUN B H4A X4Y Yl 36 D RAI ne
10. HG egi ete SS zT jl Greensmaster 3150 S5 80 9330 H P ALARM Mow Circuits w Serial Number 230000801 To 250999999 Shown Power Current Control Current BU f GY LJ UN Indication Current LEAK DETECTOR CLOSED DURING GY DELAY ON HYDRAULIC FLUID LEAK STARTER 66 2950 HOURMETER d 2 ve i R F1 20A 210 OPTIONAL 5 ve E N 7 E gt LIGHTS 2 LIGHT TEST SWITCH OPTIONAL FUSIBLE LINK NET PETRO EHE ENT 5 Net Ne 1 jM 554 BU 99 7430 672218 ar at BACKLAP RELAY K7 BK PK BU PK BU carl J11 1 9 1 VIO 85 UU 86 BK 4 e w 1 A 27 wiBu SM Bata 99 7430 22 222 NEUTRAL START SAFETY ko 0 OR BK 39 DE EM 4 STARTER SWITCH T K2 BACKLAP sa lt 5011786 SOLENOID pk IGNITION SWITCH y des d EI OFF RUN START K OPTIONAL 7 EE GN R Sd LI Dt B NE REEL 2 2 OR BK ENGAGE v RELAY SEAT BK 3 SWITCH P BAKE GN BK BK oNPOSITION I KZ MES i JOYSTICK
11. P3 Ji LOAD 6 3 15 2 TIME DELAY REELS PARKING OPTIONAL a AL 21 LIGHT P29 SEAT SWITCH B Sold gt OPTIONAL LIGHT 55 JOYSTICK ooo pz T 23 RAISE P31 LOWER IGNITION SWITCH P30 2 3 RD P17 PAL P12 RAISE LOW ER MOW NEUTRAL 216 52 P19 PT SW ITCH SWITCH LOWER SOLENOID S6 RAISE ORIFICE RELAY LOWER RELAY KS p21 eA TEST LIGHT Gare tach fe ri 237 SWITCH p2 MU A KILL T 5 P18 SN B ee B 5 BACK RELAY Kf INTERCONNECT 3 RAISE 53 1 2 OPTIONAL RN CRE LIGHT 2 pts 2 LT E z m H E P35 FA mE CHARGE T CIRCUIT KB 1 P36 m INTERCONNECT rite BACKLAP 2 7 DEAE OPTIONAL m HOUR METER ALARM 2 P10 0100 PACK 1 Ph JOYSTICK RELAY NP LEAK DETECTOR Lug LEAK DETECTOR SOL P31 E BACKLAP OPTIONAL P26 INTERCONNECT Greensmaster 3150 Electric
12. E 4 zl Page 11 7 LEAK DETECTOR SOLENOID WY LS RE Greensmaster 3150 EE es Run Circuits AEREN Serial Number 230000801 To 250999999 Shown w Power Current Control Current r Bu o Gy 83 2280 Indication Current LEAK DETECTOR 1 SECOND m CLOSED DURING GY DELAY ON HYDRAULIC FLUID LEAK i STARTER HOURMETER n 49 BU a LIGHTS 1 al F120A 2 10 2 OPTIONAL 5 09 N 7 i N 1 7 6 LIGHTS 2 BK LIGHT TEST SWITCH y OPTIONAL L FUSIBLE LINK Ss a a ee i a M Uo 1 11 UA a BU 99 7430 1 28 4210 ae Lus Qu jy BACKLAP RELAY K7 il Ha Pu E Am 85 i 5 2 N 0007 ER E GET 2 7 v o ORIBK s P31 A oe KE NEUTRAL
13. Lay 7 p z 3 ue ST 1809 14 aaziou3N3 N 5 1 lr zi i aazioH3Na LON 1018 Es T aR lt ha Le T i 1 o Za NI 7 M LON AOM zilel sso 7 Noa Greensmaster 3150 Page 4 14 Hydraulic System Rev E Raise and Lower Cutting Units Serial Number Above 270000000 The gear pump P2 is directly coupled to the hydrostat through gear pump P1 It supplies hydraulic pressure for raising and lowering the cutting units for the steering circuit and for maintaining 100 to 150 PSI 6 9 to 10 0 bar to the low pressure side of the traction circuit charge pressure The gear pump P2 takes its suction from the hydraulic reservoir Maximum circuit pressure is limited by relief valve R5 which is located in the steering control valve During cutting unit hold not raising or lowering condi tions flow from the gear pump P2 is by passed through the steering control valve and de energized so lenoid valve S2 directly to the hydrostat and the charge relief valve R4 Flow then returns to the hydraulic res ervoir Raise Cutting Units
14. Hydraulic Hoses Hydraulic Hose and Tube Installation O Ring Face Seal Fitting Hydraulic Fitting Installation SAE Straight Thread O Ring Fitting into Component Port HYDRAULIC SCHEMATICS Serial Number Under 230000801 Serial Number 230000801 To 260999999 Serial Number 270000001 amp Up HYDRAULIC FLOW DIAGRAMS Traction Forward and Reverse Raise and Lower Cutting Units Serial Number Under 260999999 Raise and Lower Cutting Units Serial Number Above 270000000 Mow and Backlap Serial Number Under 260999999 Mow and Backlap Serial Number Above 270000000 Right and Left SPECIAL TOOLS Y TROUBLESHOOTING TESTING IMEEM Precautions for Hydraulic Testing Traction Drive Hydrostat P3 Flow Test Wheel Motor Efficiency Test Charge Relief Valve R4 Pressure Test Gear Pump P2 Flow and Implement Relief Valve R5 Pressure Tests Lower Cutting Units Relief Valve R2 Pressure Test sae bem p bet Gear Pump P1 Flow Test Mow Circuit Relief Valve R1 Pressure Test R
15. 20 Wire Harness Diagram Serial Number Under 260000000 21 Wire Harness Drawing Serial Number 260000001 To 260999999 22 Wire Harness Diagram Serial Number 260000001 To 260999999 23 Wire Harness Drawing Serial Number Above 270000000 24 Wire Harness Diagram Serial Number Above 270000000 25 t 6 L4 9 6 Greensmaster 3150 Pagell 1 Rev Electrical Diagrams This page is intentionally blank Electrical Diagrams Page 11 2 Greensmaster 3150 LEAK DETECTOR SOLENOID Greensmaster 3150 fYm 52 Electrical Schematic ALARM Serial Number Under 230000801 w All relays and solenoids are shown as de energized BU 0 GY 83 2280 LEAK DETECTOR 1 SECOND CLOSED DURING GY DELAY ON HYDRAULIC FLUID LEAK STARTER 1 HOURMETER 2 BU LIGHTS 1 F1 20A F2 10A OPTIONAL 5 40 5 A re T 0 6 SP Ww gt LIGHTS 2 BK LI
16. EUELSOLENOID y y og W BK frr ENGINE 34 A 30 54 87 REELS LOWER LOWER RELAY K5 DS D3 VIO BK 52 RAISE LOWER BK p au S3 3o 87a REELS RAISE EM 87 BU R frm SSS BK RAISE RELAY BK Page 11 6 Rev E LEAK DETECTOR SOLENOID Greensmaster 3150 fm BK 2 2 S5 adeeb Crank Circuits 9 ALARM Serial Number 230000801 To 250999999 Shown Ww Power Current Control Current 27 2 83 2280 Indication Current LEAK DETECTOR T Spare CLOSED DURING ee ees HYDRAULIC FLUID LEAK STARTER i 1 HOURMETER n n BU eas LIGHTS 1 F120A 2 10 OPTIONAL T 5 m A 75 w gt LIGHTS 2 BK LIGHT TEST SWITCH OPTIONAL FUSIBLE LINK K 7 BU 99 7430 28 4210 1 qui BACKLAP RELAY K7 BK 7 PKBU b ves 1 C 6 EN DECRE 85 86 i Tm 00 S mile m mL LE l STARTER ii START
17. Ks 009 SESS _ Im gt ud muc 1S1SOHQAH 1 E m 1 552 T L EE Pers 1 71 J gt gt D 1 a Sd E T 55 Ca cc p 7 aon 7 042 002 aana SAWA ONIH3H LS gt a A ee 7 zal 15 3 Id INVA E Pues Lo Z NE S133H L lt IS ve 8n 7 z 90 1 E WOLLOG dOL 5 1 50 p ina x Ld es ISd 3sivH amp A Bg vel E om Y H H so 91 ER Y 95 133HM S3ATV NOILOVH L dv Ova rau 8 14 L TWNOILdO 1 V gt VN 30018 G102INVIA ANOHH 9 woiiog CX LO Jo umay us L eunssejqg lt lt eunssejg SIN 1331 WOLLOG pezifueue 3p Se UMOUS SPIOUZIOS SHOLOW 133HM UMO H 1HOd US 66666609c INO 7 01 L0800008c Jequunw 5 004 en 0912 SYOLOW Greensmaster 3150 Page 4 10 Hydraulic System Rev E Traction Forward and Reverse Forward The hydrostat is driven directly by the engine The trac tion circuit
18. Figure 33 Bearing lock nut 2 Seal CO ENE 0 22 Figure 34 3 Assembly spacer Dual Point Adjust Cutting Units This page is intentionally blank Dual Point Adjust Cutting Units Page 10 26 Rev Greensmaster 3150 TORO Table of Contents SPECIFICATIONS GENERAL INFORMATION Transport Mode TROUBLESHOOTING Factors Affecting Grooming Groomer Reel Mechanical Problems ADJUSTMENTS Height Depth of Groomer Adjustment Greensmaster 3150 Chapter 10 1 Groomer DPA Cutting Unit eio 2 SERVICE AND REPAIRS 7 TL 3 Groomer Belt Replacement 7 peces 3 Groomer Reel 8 4 Groomer Reel Service 11 RUPEE RR 4 Groomer Reel Bearing Replacement 12 DNE 5 Idler Assembly 14 6 Lift Arm Assembly 15 Lb peu 6 Groomer Brush 16 Page 10 1 1 Groomer DPA Cutting Unit Rev A E 5 amp Specifications MOUNTING The groomer is mounted to the Dual Point Adjust DPA cutting reel bearing housings and frame REEL CONSTRUCTION 2 375 inch 6 cm diameter 41 steel blades with 1 2 inch blade spacing Blade spac ing can be adjusted to 1 4 in
19. KILL RELAY 1 js WLU 86 FUEL SOLENOID ENERGIZED Y W BK ii ENGINE SUA 87a REELS LOWER LOWER RELAY 5 D2 D3 VIO BK gars 2 RAISE LOWER BK s 87a REELS RAISE Y s BU R GN GY 85 86 BK RAISE RELAY K6 Page 11 17 Rev E Greensmaster 3150 LEAK DETECTOR Bac klap Circuits SOLENOID Serial Number Above 270000000 Shown SS l Power Current 5 ALARM Control Current ENERGIZED Indication Current w BUs BU GY LEAK DETECTOR CLOSED WHEN THERE IS TSEC DELAY ON A HYDRAULIC OIL LEAK HR METER 1 220 TO THE LIGHTS 1 STARTER n BU OPTIONAL 41 pm F2 10A 24 R 5 e T yj 3 w TO THE LIGHTS LIGHT TEST SW OPTIONAL 2 EUSIBLE LIC m Srey ere ACC ee A area PK BU o 87 pem exce ud E ee uf T NEUTRAL swiTcH iis so MEUM STARTER SOLENOID START SAFETY K2 30 77 m edd e IN NEUTRAL 1 BACKLAP 87a 85 86 IGN SWITCH v ENERGIZED 1 SWITCH es 2058 Y
20. WHITE BLACK VIOLET BLACK VIOLET BLACK VIOLET 5 4 VIOLET BLUE RED E PINK BLACK BLACK BLUE RED sut BLUE RED WHITE BLACK 5 ORANGE BLACK SN BLACK GREEN RED BLACK BLACK BLACK 1 5 14 5 8 BLACK ns BLACK B BLACK WHITE BLUE 5 5 GREEN GRAY E PIG 8 BLACK PINK BLUE BLACK SP13 AN BLACK WHITE PIT BLACK 8 BLACK m BLACK BLACK 3 a FUSIBLE UNK x SPI 3 X a a 2 t BLACK YELLOW WHITE BLUE i E BLUE RED BLACK VIOLET rib RED 2 PINK WHITE AS PINK ORANGE BLACK 5 ORANGE 5 YELLOW SP7 1 GREEN BLUE BLUE BLACK 8 WHITE V BLUE P YELLOW GRAY GRAY WHITE WHITE 2 u 81318 5 a m a gt gt E amp m pe cot Yrer ttf Rm P34 JM P21 28 Ji P26 P36 Pee P23 Pea P25 INTERCONNECT 3 OPTIONAL LIGHT 2 TEST LIGHT SWITCH OPTIONAL LIGHT INTERCONNECT 1 INTERCONNECT 2 LEAK DETECTOR SOL ALARM TIME DELAY ALARM LEAK DETECTOR DIODE PACK 2 P37 DIODE PACK 1 Plo JA START SOLENOID 43 NEUTRAL SWITCH PARKING BRAKE ORANGE IGNITION SWITCH P30 X YA BS PINK INTERCONNECT 1 Pla MOW SWITCH GREEN SEAT HARNESS LOWER GRAY BLACK JOYSTICK GREEN BLACK BLUE RAISE GREEN GRAY GREEN BLAC P28
21. TP sovsriog l D1 Y GROUND GROUND ja RUN e START B l S EPE ea a mana e a 2 D E E H avek EN 92 2538 BK GN GY Y 2 4 RELAY 1 1 L a ese _ TTE ENGINE 2 MAGNETO E ALTERNATOR BOA eae 1 j 1 L 99 7430 puce 1 ype MliMiIiM i i i i SSS ee MENOR PES E RM Sa occ ERE 1 E r a jr at 87d 4 REELS LOWER LOWER RELAY K5 VA 4 RAISE LOWER D3 BUR i EZ ORIFICE PE Sr id yt sum S3 REELS RAISE RAISE RELAY K6 L L LEAK DETECTOR SOLENOID
22. cresce SWITCH START SAFETY RA sra BK l SOLENOID pk IGNITION SWITCH M EAE SITE D1 A 99 7430 ict GN R T OFF RUN START OPTIONAL Bud 130 51 Be A D1 B id gral REEL 1 i i Ws o v MOW RELAY K4 PARKING BK P31 B BK 1 SWITCH BRAKE A ON POSITION 2 30 474 D1 D LL JOYSTICK s BU BK LOWER ims 2 F 85 mMm ag l MOW SWITCH D E y eae oe e al F JOYSTICK 5 x 3 ENGINE GN BK RELAY K3 Y GROUND GROUND 8 A START BAGS 1 ab n x RAISE GY BK GN BK 92 2538 s GN GY Y OR BK Em i KILL RELAY K1 3 e REFS FOS M rae ee te rake pete Mee ow Hae AN E T MAGNETO w FUSIBLE LNK ____ 99 7430 Ec BK t SP J 854746 me m ms m L W BK l X T rune id S4 iene gei REELS LOWER LOWER RELAY 5 ciiin 228 VIO BK tm 52 RAISE LOWER E 1 A 2 BUR 99 7430 m ao 2574 Es YT S3 __ asm REELS RAISE
23. 8 1 ae 8 BU 1 2 0 t 8 RAISE GY BK 1 105 GN BK mg io O OR BK REGULATOR BK GN GY Y 3 KILL RELAY K1 BK 1 41 K RS UMS 59 A ip 6 SEC DELAY OFF ENGINE GND 4 MAGNETO 87 10 55 4 PK BK 87 ENGINE Besos cere gt gt a 85 UL 86 BK 4 FUEL SOLENOID i i Y 1 oa W BK Y 1 30 0 5 02 8741 REELS LOWER LOWER RELAY K5 4 x 4 H 7 02 5 gt 02 FETI gt 52 RAISE LOWER F 5 02 0 ji BU R p BU R 56 ORIFICE Y 30 gt i t 0 87 BU R CTE 1 53 GN CY 85 7771 REELS RAISE RELAY 11 5 Rev E LEAK DETECTOR Greensmaster 3150 SOLENOID Electrical Schematic BU EE BK 3 Serial Number Above 270000000 ALARM 4 relays and solenoids are shown as de energized BU BU Gy LEAK DETECTOR CLOSED WHEN THERE 15 Gy VS
24. L1B Ha n L2B 2 lt lt OIL L2A FILTER _ STEERING CONTROL VALVE TRACTION CHARGE CIRCUIT OOLER OIL C OPTIONAL TESTER FROM gt GEAR PUMP HYDROSTAT Serial Number 230000801 To 260999999 Shown High Pressure Low Pressure Return or Suction gt Flow Hydraulic System Rev E Page 4 38 Greensmaster 3150 Procedure for Lower Cutting Units Relief Valve R2 Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered Make sure engine is off and the parking brake is engaged Make sure the hydraulic tank is full A CAUTION Before continuing further read and become fa miliar with Precautions for Hydraulic Testing 3 Measure and record charge relief valve R4 pres sure see Charge Relief Valve R4 Pressure Test in this section 4 Use same tester connections as described in the Gear Pump P2 Flow and Implement Relief Valve R5 Pressure Test in this section
25. is fol GN BK 1X Y 2 36 E 87a 980 9 5 01 0 1 JOYSTICK 2 87 OR BK BU BK K E pond LOWER MOW SWITCH gt GY BK 85 86 F3 L CY V T 1 36 F JOYSTICK RELAY K3 203 GN BK h5 D1 C 3 36 STOP NONE 1 SN RUN X Y 5 Y 36 D ace Be START BH4S GY BK 4 58 5 GN GY Y OR BK 2 lt 7 5 5 gt a Se 1 I L 86 85 26 0 6 SEC DELAY OFF BK EROR Fy ES Uem w pg PK BK petas 55 LT iUe i g WIBK A 30 Fo REELS cower LOWER RELAY K5 D2 D3 VIO BK 52 RAISELOWER 2 87a REELS Y 30 gr frm GN GY 85 vvv 86 BK 11 13 Rev E STARTER 20A F 1 FUSIBLE LINK LEAK DETECTOR SOLENOID 55 ENERGIZED w BU GY LEAK DETECTOR 9 CLOSED WHEN THERE IS ev AHYDRAULIC OIL LEAK HR METER 2 1 BU 3 ola F2 10A 24 5 av 1 w ALARM 1 SEC DELAY ON TO THE LIGHTS OPTIONAL 1 LIGHT TEST SW BK TO THE LIGHTS OPTIONAL 2 Greensmaster 3150 Run Circuits Seria
26. YELLOW INTERCONNECT 2 WHITE Greensmaster 3150 Wiring Diagram Serial Number 260000001 To 260999999 Pes SEAT SWITCH Page 11 23 Rev E 2 1 P29 SEAT SWITCH 12 OPTIONAL LIGHT 9 OPTIONAL LIGHT SEAT HARNESS LEE onal 123 RAISE P31 any P26 INTERCONNECT 2 IGNITION SWITCH P36 P30 INTERCONNECT 1 2 3 JO P12 NEUTRAL SWITCH Piu SWITCH P35 CHARGE RAISE P6 RELAY K6 LOWER CIRCUIT RELAY KS P3 P39 START P2 BACKLAP P21 SAFETY K2 eva th SW ITCH vi TEST LIGHT SWITCH ere 99 P34 RAISE S3 LIGHT 2 12 INTERCONNECT 3 is 15 FUSE BLOCK ENGAGE 7 D A 7 18 P17 RAISE LOW ER 52 MOW RELAY K4 x P16 A LOWER LOAD 2 ES 2 P1 TIME eb D P38 SS SS HOUR METER TIME DELAY REELS i S 8H P23 4 PL ALARM ui JOYSTIC
27. a 36H1NGS Lo 92 vu S133H amp 4 t gels 4 is DK F vel 1 1 10 57 WOLLO dol amp 1 Hu 50 is gt lt 5 t 3sivu Sd ids vel m om X 4 H H 8e 90 95 ad H NOLLOVH L dv ova Tum 1VNOILdO SH3QNIT1AO L47 TVNOILdO vs VN 30018 aan wo lt 1HOd QHvMHOJ uonong 40 uunjeH AAT woog ainsseig ts 1HOd uim e peuonisod a 3 SI 5 SIN pezi amp uaua op se 13431 WOlLOS UMOUS spioug Jos 2 SHOLOMW T33HM NOLLOVH L UMOUS 66666609c FN 1HOd 1NOHd 01 1080000 1 ees uunj Cy En 0612 Je1seuisueeJc SHOLOW eee Greensmaster 3150 Page 4 20 Hydraulic System Rev E Right and Left Turn The gear pump P2 is directly coupled to the hydrostat through gear pump P1 It supplies hydraulic pressure to the power steering valve for turning the rear wheel for raising and lowering the cutting units and for maintain ing 100 to 150 PSI 6 9 to 10 0 Bar to the low pressure side of the traction circuit charge pressure The gear pump P2 takes its suction from the hydraulic reserv
28. lt lt 77 10 24 25 26 27 28 29 30 31 32 33 34 e 20 to 26 ft Ib 28 to 35 Nm Serial Number Above 280000000 2 O ring Panel nut 6 used Steering valve cover Cap screw 2 used Flat washer 2 used Spacer 2 used Knob Lock nut 2 used Hair pin Steering valve below 270999999 Steering valve above 280000000 Greensmaster 3150 Removal Fig 62 1 Before removing any parts from the hydraulic sys tem park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components 2 Remove screw 10 and steering wheel cover 11 from the steering wheel 8 3 Remove steering wheel nut 9 and steering wheel from the steering column assembly 4 Remove screws 14 and remove the steering valve cover 26 5 Removecap screws 12 Remove steering column 15 if equipped and steering control valve 33 or 34 6 Cut and remove any cable ties from the hose as semblies Label all hydraulic connections for reassemb ly 7 Disconnect hose assemblies 22 and remove O rings 21 and 24 from hydraulic fittings 19 and 23 Al low hoses to drain into a suitable container Note Disconnect hydraulic hose assemblies 22 at the manifold block P2 or ST ports at the steering cylin
29. Figure 23 2 Saddle clamp 1 Rear roller 10 Install the front roller see Front Roller Installation in this chapter 11 Adjust the cutting unit See the Cutting Unit Opera tor s Manual for adjustment procedures Note The parallel position of the rear roller to the reel is controlled by the precision machined components of the assembled cutting unit Only a limited amount of ad justment is possible if necessary due to tapered reel wear To adjust A Place the assembled cutting unit on a surface plate B Loosen each bedbar adjuster assembly both cap screws 24 and all four shoulder bolts 7 C Adjust the cutting unit and tighten the shoulder bolts 7 to a torque of 17 to 20 ft lbs 23 to 27 Nm D Tighten the cap screws 24 E Tighten each bedbar adjuster assembly until the adjuster spring is fully compressed then loosen lock nut 1 2 turn Note For severely tapered reels a 010 in 254 mm shim Toro Part No 106 6923 is available for the rear roller mount Greensmaster 3150 Preparing Reel for Grinding Note Check to make sure the reel bearings are in good condition before grinding a reel 1 Remove bedbar assembly see Bedbar Removal and Installation 2 Remove parts as necessary to mount cutting unit into grinder e g front roller front roller brackets Note Thecutting unit must be aligned so the grinding wheel will travel parallel to the reel shaft This will result in th
30. See Troubleshooting in Chapter 5 Hydraulic System Install Variable Speed Traction Kit if necessary to con trol traction speed in varying conditions or with dif ferent attachments Will allow change in traction speed while maintaining full engine rpm and reel motor rpm Center cutting unit must drop after front cutting unit 17 Cutting drop speed and sequence See Troubleshooting in Chapter 5 Hydraulic System Greensmaster 3150 Page9 7 Troubleshooting Factors Affecting Grooming There are a number of factors that can affect the perfor mance of grooming These factors vary for different golf courses and from green to green on the same golf course It is important to inspect the turf frequently and vary the grooming practice with the need Itisimportantto rememberthat Factors Affecting Quality of Cut also affect grooming performance IMPORTANT Improper or over aggressive use of the groomer reel i e too deep or too frequent groom ing may cause unnecessary stress on the turf lead ing to severe turf damage Use the groomer cautiously READ AND UNDERSTAND THE OPERATOR S MANUAL BEFORE OPERATING OR TESTING GROOMER PERFORMANCE Variables That Affect The Use and Performance of Grooming Reels 1 Time or year 1 growing season and weather patterns 2 General turf conditions 3 Frequency of grooming cutting how many cuttings per week and how many passes per cutting 4 Groomin
31. l Before removing any parts from the hydraulic sys tem park machine on a level surface set brake lower cutting units and stop engine Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components 2 Label all hose connections for reassembly pur poses 3 Remove hose assemblies and O rings from hy draulic fittings at the cylinder Allow hoses to drain into a suitable container 4 Remove lock nutand flatwasher from barrel mount ing stud Remove steering cylinder from barrel stud 5 Remove cotter pin slotted hex nut and and spacer from rod end at rear wheel castor fork 6 Remove steering cylinder from traction unit 7 If rod end 13 is to be removed from cylinder rod fully retractcylinderrod and measure distance from cen ter of rod end to end of cylinder for assembly purposes Fig 72 Record measured distance Loosen jam nut and then remove rod end and jam nut cylinder rod Greensmaster 3150 Page 4 97 Rev Installation Fig 71 1 If rod end 13 was removed from cylinder rod fully retract cylinder shaft and thread rod end onto shaft so that distance is as measured during removal process Fig 72 Tighten jam nut to retain rod end 2 Secure cylinder rod end to the castor fork with spacer slotted hex nut and cotter pin to rear wheel cas tor fork 3 Install hydraulic fittings and O rings to the steering cyli
32. 1 Remove rear roller assembly 2 Remove capscrew and nut anchoring the rear roller height of cut bracket to the side plate on both ends of the cutting unit Fig 23 3 Loosen allen set screws securing the roller shaft Fig 23 4 Remove the rear roller height of cut brackets from both side plates 5 Remove the bedbar mounting bolts from each end of the cutting unit Fig 23 Then loosen the bedknife adjusting screws at each end of the cutting unit Fig 23 The bedknife assembly can then be removed by rotating it away from the reel IMPORTANT When installing the bedbar assembly be sure to position the center portion of the grass shield over the rear edge of the bedbar Fig 24 Securely seat the 2 bedbar pivot bolts to a maxi mum torque of 40 ft Ibs Always check reel bearing adjustment after installing bedbar NOTE For proper grinding of bedknife follow proce dures in the Toro publication Sharpening Reel amp Rotary Mowers Form No 80 300 PT 6 Reverse steps 1 5 to install the bedbar Greensmaster 3150 Page 7 17 Figure 23 1 Rear roller height of cut bracket 2 Allen set screw 3 Bedbar mounting bolts 4 Bedknife adjusting screws 5 Height of cut rod locknuts 6 Roller shaft clamp bolts 7 Height of cut adjustment knob Figure 24 Bedbar under lip of shield Repairs Bedknife Replacement 1 Remove bedbar 2 Remove bedknife screws and remove bedknife 3 Remove
33. 2 Slide seal removal over roller end of roller shaft 3 Usethe tool as a template to locate mark and drill two 7 64 in diameter holes the outer face of the seal Y gt 1 4 20 UNC 2 4 Thread two No 8 x 3 4 in long 164 in diameter self tapping screws through the seal removal tool and into the drilled holes in the seal 5 Thread two 1 4 20 x 1 in long cap screws into the Figure 27 seal removal tool 6 Alternately tighten the cap screws to pull the seal from the roller body Note Seals will be destroyed during removal Do not re use seals that have been removed from the roller Seal Installation 1 Apply athin film of clean oil to the inner lip of the seal and slide the seal over the end of the roller shaft 2 Press the seal squarely into the roller body The seal face should be flush with the end of the roller body when correctly installed Dual Point Adjust Cutting Units Page 10 22 Rev A Greensmaster 3150 Bearing Removal Note Replace both roller bearings as a set after a bearing failure 1 Remove the roller seals see Roller Seal Removal in this chapter of this manual 2 Remove both spiral retaining rings from the roller shaft Note Roller bearings have a press fit into the roller body and a slip fit on the roller shaft 3 Loosely secure roller body in a vise Lightly tap one end of the roller shaft with a plastic hammer to drive the shaft and one of the
34. Electrical Diagrams This page is intentionally blank Greensmaster 3150 Chapter 1 S afety TORO Table of Contents SAFETY INSTRUCTIONS 2 Maintenance and Service 4 Before Operating 2 SAFETY AND INSTRUCTION DECALS 4 While Operating 3 Greensmaster 3150 Pagel 1 Safety Safety Instructions The GREENSMASTER 3150 was tested and certified by Toro for compliance with national and international standards as specified in the Operator s Manual Al though hazard control and accident prevention partially are dependent upon the design and configuration of the machine these factors are also dependent upon the awareness concern and proper training of the person nel involved in the operation transport maintenance and storage of the machine Improper use or mainte nance of the machine can result in injury or death Before Operating 1 Read and understand the contents of the Opera tor s Manual before starting and operating the machine Become familiar with all controls and know how to stop quickly Copies of the Operator s Manual are available on the internet at www Toro com 2 Neverallow children to operate the machine Never allow adults to operate it without proper instructions 3 Become familiar with the controls and know how to stop the engine quickly 4 Keep all shields safety devices and decals
35. or attempting to cut off too much grass height may not always be overcome by adjusting the machine It is important to remember that the lower the height of cut the more critical these factors are See the Adjustments and Repairs sections for detailed adjust ment and repair information Factors Affecting Quality of Cut 1 Tire pressure 2 Engine governed speed 3 Reel bearing condition adjustment 4 Reel and bedknife sharpness 5 Bedknife to reel contact 6 Bedknife attitude 7 Rear roller parallel to reel 8 Height of cut 9 Proper bedknife for height of cut 10 Front roller scraper and comb Adjustment Greensmaster 3150 Page7 5 Possible Problem Correction Check tire pressure adjust to specification if necessary Must be equal in two front tires Check maximum governed engine speed Adjust to specification if necessary affects reel speed Check and adjust to specification Replace bearings if worn or damaged Bearing cones must be installed square to bearing housing make sure there is no flash paint or other foreign material in housing before installing new bearing cone Reel and or bedknife that has rounded edge cannot be corrected by tightening bedknife to reel contact Grind reel to remove taper cone shape and or rifling grooved or ribbed appearance Grind bedknife to sharpen and or remove rifling Most common cause of rifling is bedknife to reel contact that is t
36. 20 UNC 48 7 599 79 100 10 1125 100 140 15 1580 170 1 4 28 53 7 65 10 734 113 115 10 1300 100 160 15 1800 170 5 16 18 UNC 115 15 105 17 1186 169 200 25 2250 280 300 30 3390 340 5 16 24 UNF 138 17 128 17 1446 192 225 25 2540 280 325 30 3670 340 E a o a lo N N a X A a lo o ala o a olo o o 1 2 13 UNC 30 3 102 11 105 10 142 14 1 2 20 UNF 32 3 72 9 8 115 11 120 10 163 14 5 8 11 65 10 88 12 119 16 150 15 203 20 210 20 285 27 5 8 18 UNF 75 10 95 15 129 20 170 15 230 20 240 20 325 27 3 4 10 UNC 93 12 140 20 190 27 265 25 359 34 375 35 508 47 3 4 16 UNF 115 15 165 25 224 34 300 25 407 34 420 35 569 47 7 8 9 140 20 225 25 305 34 430 45 583 61 600 60 813 81 7 8 14 UNF 155 25 260 30 353 41 475 45 644 61 660 60 895 81 Note Reduce torque values listed in the table above on the fastener size the aluminum or base material by 25 for lubricated fasteners Lubricated fasteners strength length of thread engagement etc are defined as threads coated with a lubricant such as gr
37. 22 55 gt Hydrostatic Transmission Pump inlet hose Gear pump 90 hydraulic fitting 90 hydraulic fitting O ring O ring Hose clamp O ring O ring Hose assembly O ring Hydrostat Socket head screw Flat washer Hose assembly O ring e e a OURWNEO Hydraulic System Rev E Antiseize 27 to 31 ft lb Lubricant 37 to 42 Nm Figure 30 90 hydraulic fitting O ring Hose assembly Hose assembly Key Lock nut Square head set screw Pump hub Coupling spacer Drive coupling Flat washer Cap screw Lock nut Engine hub Flat washer Cap screw Page 4 54 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 19 90 to 110 in Ib 10 2 to 12 4 Nm __ 18 Flat washer Lock washer Cap screw O ring Support clamp Cap screw Flat washer Tube assembly O ring 90 hydraulic fitting O ring Hose assembly O ring 45 hydraulic fitting O ring Greensmaster 3150 Removal Fig 30 1 Before removing any parts from the hydraulic sys tem park machine on a level surface engage parking brake lower cutting units and stop engine Usecaution when removing the lock nutfrom the pin The extension spring is under tension and may cause personal injury during removal Figure 31 1 Extension spring 4 Adapter plate Note The neutral system assembly can be removed 2 Dampener hos
38. 7 Shut off engine 8 If specification is not met remove hydrostat back plate assembly that contains the charge relief valve see Piston Pump Service in the Service and Repairs section of this chapter Repair or replace relief valve compo nents as necessary 9 Adynamic charge pressure test can be performed as follows A With tester still connected sit in the operator seat and press the traction pedal to forward B While machine is moving monitor the charge pressure reading on the pressure gauge C The charge pressure should drop no more than 1596 from initial test reading Step 6 above A pres sure drop of more than 15926 indicates a traction cir cuit leak e g a worn or damaged hydrostat and or wheel motor Further testing of the traction circuit should be completed see Traction Drive Hydrostat P3 Flow and Wheel Motor Efficiency Tests in this section 10 When testing is complete disconnect pressure gauge and T fitting from the pump fitting and hose Re connect hose to the pump fitting Hydraulic System Rev E 2 3 5 52 gt Gear Pump P2 Flow and Implement Relief Valve R5 Pressure Tests Using Tester with Flowmeter and Pressure Gauge WW NW Y gt g m Ai ww TO REEL MOTOR CIRCUIT TO STEERING AND POWER STEERING
39. If bearing drag does not meet above specification adjust the reel bearings NOTE If you do not have an inch pound torque wrench do steps 1 3 under Reel Bearing Adjustment below Reel Bearing Adjustment 1 Remove the mounting nuts from the counterbalance end cap and remove end cap from the mounting studs Fig 6 2 Remove bolt mounted on the end of reel shaft This will make it possible for a large socket wrench to be mounted on the reel bearing adjusting nut inside the side plate CAUTION Do not use your hand to prevent reel from turning while servicing this can result in per sonal 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 NOTE If reel bearings will not hold adjustment during operation loosen adjustment nut tighten reel shaft spline nut on right hand end of reel shaft to a torque of 40 to 60 ft Ib then adjust reel bearings 3 Loosen large reel bearing adjustment nut Fig 7 Figure 6 Tighten nut until all reel shaft end play is removed then tighten an additional 1 16 to 1 8 turn Be certain to remove all end play but do not overtighten 1 Counterbalance end cap NOTE Adjustment nut must have enough resistance against reel shaft threads to retain bearing adjustment Replace adjustment nut if necessary 4 Install bolt into end of reel shaft and check rolling torque with an inch pound torque wrench Fig 7
40. Reel bearing condition Reel and bedknife sharpness Greensmaster 3150 Page 10 5 Check pressure of all tires Pressure must be equal on both front tires Adjust pressure as necessary See Chapter 6 Wheels and Brakes Check maximum governed engine speed Adjust engine to specifications if necessary See Maintenance section in the Traction Unit Operator s Manual and or the Briggs amp Stratton Repair Manual for 4 cycle V Twin Cylinder OHV Head Engines All reels must rotate at the same speed within 100 rpm All cutting units must have equal bedknife to reel and height of cut adjustments Check reel speed setting if an optional backlap variable reel speed kit is installed See Troubleshooting in Chapter 4 Hydraulic System in this manual Check bearings for wear and replace if necessary See Reel and Bearing Removal and Installation in this chapter of this manual A reel and or bedknife that has rounded cutting edges or rifling grooved or wavy appearance cannot be corrected by tightening the bedknife to reel contact Grind reel to remove taper and or rifling Grind bedknife to sharpen and or remove rifling The most common cause of rifling is bedknife to reel contact that is too tight A new bedknife must be ground or backlapped after installation to the bedbar Dual Point Adjust Cutting Units Bedknife to reel adjustment Check bedknife to reel contact daily The bedknife must have light conta
41. Removal Fig 70 1 Before removing any parts from the hydraulic sys tem park machine on a level surface set brake lower cutting units and stop engine Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components 2 Place a clean container large enough to collect 2 gallons 7 6 liters underthe hydrostatto collect hydrau lic oil 3 Clamppumpinlethoseto control drainage Remove pump inlet hose from hydrostat Release clamp from hose and drain about 2 gallons 7 6 liters from the hy draulic tank Fig 71 4 Clamppumpinlethoseto prevent draining addition al hydraulic oil 5 Remove cap screw 31 and flat washer 30 secur ing the tether 29 to the auxiliary tank 6 Unplug leak detector harness from the main tractor harness 7 Remove four cap screws 6 and 9 flat washers 4 neoprene washers 3 and spacers 3 and 10 8 Loosen either hose clamp 26 and disconnect over flow hose 27 9 Lift auxiliary tank slightly loosen hose clamp 13 and disconnect valve hose 32 at valve fitting Remove auxiliary tank assembly 10 If valve removal is necessary loosen hose clamp 13 and disconnect tank hose 23 at hydraulic tank fit ting 14 Remove two cap screws 25 andlock washers 24 securing the valve assembly to the hydraulic tank and remove the valve assembly Disassembly and Inspection Fig 70 1 The leak de
42. fae a 4 BK LEAK DETECTOR SOLENOID T 05990 Raise Reels Circuits cd Serial Number 230000801 To 250999999 Shown ow Power Current Control Current i GY 83 2280 Indication Curren Bu 7 Indication Current LEAK DETECTOR 1 SECOND TEASE STARTER 66 2950 HOURMETER i LIGHTS 1 R 120 F210A os OPTIONAL 5 1 M pt 1 75 6 gt LIGHTS 2 BK LIGHT TEST SWITCH OPTIONAL FUSIBLE LINK Jerem ete Ru evel d tlc St iE iu iat C E Aa 1 VIO ru 2997490 PK BU PK BU Jn ma m d ud s b Is EC ye a eu pm v E w NEUTRAL T WBU erit 1 gt P31 A NIE UN STARTER SWITCH SART SARETY KAN BACKLAP as ee BK SOLENOID pk IGNITION SWITCH Y THAO poe D1 A OPTIONAL 99 7430 i o GN R YY OFF RUN START BU BK 871 1 Y 3U meu 51 D1 B 874 REEL 4 4 C S V Mow RELAY ka ENGAGE SEAT PARKING BK qe
43. mae fo BU BK LOWER 2F dg adl MOW SWITCH D E r ye 2 1 STOP NONE Es deve D1 C ENGINE FUN S Belt And RELAY GROUND GROUND 8 START BIS L PENN ax 1 S Y La xcd E 2 2 D Gane L 4 4 ew herr et ETARE RENEE E J x 5 N 92 2538 GN GY Y L ons gt 4 KILL RELAY K1 PD i Ob A SS SS L oso ee 1 41 ENGINE i PAINT q Tle 2 6 6 1 MAGNETO W i gu DELAY OFF ALTERNATOR te STD J E Bo o 88 UW 86 BK ELEM FUEL SOLENOID l YY qoe ee a pete DTE 25 UND m e oh EA REELS LOWER LOWER RELAY K5 Er Mee VIO BK frm ST WER 5 Sm Ad BU R mm 4 UA 2 8 S6 us ORIFICE Y MT er BU R m 129 S3 l __ REELS RAISE LEAK DETECTOR SOLENOID pole 7 4 Greensmaster 3150 80 9330
44. 1 Liftarm 2 Lock screw grooming 2 5 amp Greensmaster 3150 Page 10 1 3 Groomer DPA Cutting Unit Rev A Troubleshooting Factors Affecting Grooming There are a number of factors that can affect the perfor mance of grooming These factors vary for different golf courses and from green to green It is important to in spectthe turf frequently and vary the grooming practice with turf needs It is important to remember that factors affecting quality of cut also affect grooming performance IMPORTANT Improper or overaggressive use of the groomer reel such as too deep or frequent grooming may cause unnecessary stress on the turf leading to severe turf damage Use the groomer carefully READ AND UNDERSTAND THE OPERA TION INSTRUCTIONS BEFORE OPERATING OR TESTING GROOMER PERFORMANCE Variables That Affect the Use and Performance of Grooming Reels 1 The growing season and weather conditions 2 General turf conditions 3 The frequency of grooming cutting number of cut tings per week and how many passes per cutting 4 The blade spacing on the groomer reel 5 height of cut 6 The grooming depth 7 The type of grass on the green 8 The amount of time that a groomer reel has been in use on a particular turf area 9 The amount of traffic on the turf 10 The overall turf management program irrigation fertilizing weed control coring overseeding sand dressing and disease and pest
45. 5 Clutch adapter shaft Figure 49 1 Clutch adapter shaft 2 Reel shaft Greensmaster 3150 Installation and Assembly Disassembled Clutch 1 Pack bearings and area inside clutch body with No 2 multi purpose lithium base grease IMPORTANT When assembling clutch make sure belleville washers are installed correctly Fig 50 2 Apply thick coating of grease to special screw do not get on threads and cam surface of clutch release disk Apply Loctite 271 or equivalent to threads of special screw before assembling to clutch pin Assemble so clutch pin is 0 240 0 260 in out fromface of clutch body when pin is in fully extended position 3 Install clutch adapter to reel shaft Fig 49 Tighten clutch adapter to a torque of 170 210 in Ib 4 Hold belt on drive pulley of clutch and slide clutch on clutch adapter while sliding belt on driven pulley Install washer and nut on clutch adapter shaft and tighten nut to a torque of 7 10 ft Ib 5 Adjust belt tension Install groomer reel housing cover Fig 39 Install clutch knob and tighten two 2 set screws against flats of clutch release disk N lt PPP LL Al WY apn WV Figure 50 1 Clutch body drive pulley 2 Belleville washer 2 3 Nut and washer 4 Clutch engage disengage knob 5 Clutch adapter 6 0 250 in 0 10 pin extended Figure 51 1 Set screw 2 Felt seal 3 Clutch adapter 4 Needle bearing 5 Clut
46. 7 Grind the reel to remove any taper and renew cutting edges See Preparing Cutting Unit for Reel Grinding in this section of the book 8 Check size of hole bedbar end bushings every time bedbar is removed Insert flange bushing into rubber bushing Fig 28 Insert clean shoulder bolt into flange bushing rubber bushing assembly If bolt slides easily into bushing replace all four bedbar bushings See Bedbar Bushing Replacement in this section of the book 1 Rubber bushing 3 Shoulder pivot bolt 2 Flange bushing Figure 28 Repairs Page 9 22 Greensmaster 3150 9 With frame on level surface and pivot set screws installed measure from flat surface up to end of each setscrew Fig 29 If not within 1 16 in of each other carefully bend frame supports toline up screws Remove pivot set screws Measure distance between frame pivot supports Fig 29 If dimension is not between 1 9 16 in and 1 5 8 in carefully bend supports until correct Equal distance S within 1 16 in 10 To install bedbar slide it into position between side CES plates making sure each end of bedbar is under shield 6 Fig 30 in c 5 8 1 9 1 1 IMPORTANT Always use McLUBE Part 505 35 on bedbar pivot and pivot bolts Figure 29 11 Install jam nut on eccentric pivot bolt Put plastic washer between left side of bedbar and side plate Thread pivot bolt into side frame until distance fro
47. 7 Lower Reels Time Delay 15 ELECTRICAL SYSTEM QUICK CHECKS 8 Leak Detector Alarm and Delay Timer 15 Battery Test Open Circuit 8 Leak Detector Float Switch 16 Charging System Test 8 Leak Detector Solenoid Valve 16 COMPONENT TESTING 9 Diodes zur Peis Moa es 17 Ignition Switch 9 SERVICE AND REPAIRS 18 Hour Meter 9 Verify Interlock System Operation 18 Helays Rep ea 10 Battery Service 19 Greensmaster 3150 Page5 1 Rev D Electrical System Electrical Schematics The electrical schematics and other electrical drawings for the Greensmaster 3150 are located in Chapter 11 Electrical Diagrams Electrical System Page 5 2 Greensmaster 3150 Special Tools Order special tools from your Toro Distributor Some tools may also be available from a local supplier Multimeter The meter can test electrical components and circuits for current resistance or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circui
48. Fully open control valve on the tester 5 Start engine and move throttle to full speed 2850 50 RPM Make sure that cutting units are fully lowered and engage the cutting units Note The LOWER function is electrically timed and automatically turns off after approximately six 6 sec onds 6 Watch pressure gauge carefully while moving the Raise Lower Mow Control lever to LOWER and note pressure that relief valve opens Shut off engine and re cord test results Note While performing this hydraulic test if relief pressure cannot be determined within the LOWER func tion six 6 second timeframe repeat this test proce dure Note The lower cutting units relief valve R2 is se ries with charge relief valve R4 R4 pressure will af fect R2 pressure 7 The lower cutting units relief pressure R2 should be 300 PSI 21 0 bar higher than charge relief R4 pressure e g if charge relief valve pressure is 100 PSI the lower relief valve R2 pressure should be 400 PSI Greensmaster 3150 Page 4 39 8 Ifrelief valve R2 pressure is incorrect adjust relief valve R2 Fig 20 or 21 see Adjust Manifold Relief Valves in the Adjustments section of this Chapter Re test relief valve pressure after adjustment is performed 9 If testing is complete disconnect test gauge from gear pump and hose Reconnect hose to hydraulic fit ting on pump RELIEF lt 2 VALVE R2 m i 7 lt MA
49. If relief valve R5 pressure is incorrect inspect re lief valve R5 located in the steering control valve see Steering Control Valve Service in the Service and Re pairs section of this Chapter Clean relief valve or ser vice steering control valve as needed IMPORTANT Hold steering wheel at full lock only long enough to get a system pressure reading 8 Relief Valve R5 is also activated by the steering system With tester still connected to gear pump P2 start engine and watch the pressure gauge Turn the steering wheel completely in one direction and hold Re lief valve R5 should open just after rear wheel gets to the full lock position Relief pressure measured with the steering system should be similar to results in step 5 Note Lower Cutting Units Relief Valve R2 Pressure can be measured with tester positioned as described in this check see Lower Cutting Units Relief Valve R2 Pressure Test in this section 9 If testing is complete disconnect tester from the pump and hose Reconnect hose to the pump Hydraulic System Rev E lt a D Lower Cutting Units Relief Valve R2 Pressure Test TO AND FROM REEL MOTORS 4 MANIFOLD BLOCK OPTIONAL BACKLAP S6 ORIFICE LIFT CYLINDERS 3 t LOWER L3A RAISE
50. Lower Reels Time Delay This is a solid state timer used to energize solenoid valve S4 long enough to fully retract the cutting unit lift cylinders making sure the cutting units are fully lower INPUT VOLTAGE ed Upon the application of power the load is energized and the time delay is started After 6 seconds the load is de energized 1 Connect voltmeter across test load and test load to timer Connect 12VDC source to timer and load Make sure to observe polarity After 6 seconds there should be no voltage across the load 2 Disconnecttimer from 12VDC source and test load TIMING RESISTOR Figure 21 Figure 20 Leak Detector Alarm and Delay Timer To preventthe leak detector system from sounding false alarms during normal operation the alarm circuit in cludes a one second delay timer 1 Turn ignition switch to On do not start the engine then move leak detector test switch rearward and hold After a one second time delay the alarm should sound Figure 22 1 Alarm 2 Delay timer Greensmaster 3150 Page 5 15 Electrical System Leak Detector Float Switch The leak detector float switch closely monitors the hy draulic fluid level in the main hydraulic tank The switch contacts are open when the float is inthe raised position and closed when the float is in the lowered position 1 Ifthe float switch is connected to the main harness remove hydraulic tank cap
51. ON POSITION Sess 99 7430 2E m NU D1 D RR JOVSTICK mir ORBk s BU BK d ove 27 eser MOW SWITCH D E x JOYSTICK E um EUN T START 5 Is UE seeds 5 Y 2571 2 4 BK ox RAISE GY BK GN BK l GN GY Y OR BK 44514 J KILL RELAY K1 3 E eM 9 SUE 4 foc 6 SECOND 1 ENGINE M AME DELAY OFF MAGNETO FUSIBLE LNK _____ 99 7430 w ee 3p BUUS 4 ue hr m ae W BK pus E Iur REELS LOWER LOWER RELAY 5 xs pie 6 ORIFICE Lacer i p i aL L m 24 Ellccecc zo ue EMEL __ _ REELS RAISE poer t RES J RAISE RELAY K6 pisa d a cec Duet dull llc uncias e ue E LL E lorc lute eal Greensmaster 3150 LEAK DETECTOR SOLENOID mmm ee Greensmaster 3150
52. OPTIONAL REAR WHEEL 3WD MOTOR VALVE R4 DUM xit Ld pou BLEED 200 250 PSI Hydraulic System Rev E HYDROSTAT FROM LIFT CIRCUIT PRESSURE GAUGE Page 4 34 PUMP P3 CHARGE PORT TO REEL MOTOR CIRCUIT TO STEERING AND LIFT CIRCUITS e ENGINE High Pressure Low Pressure Return or Suction Flow Greensmaster 3150 Procedure for Charge Relief Valve R4 Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered Make sure engine is off and the parking brake is engaged Make sure the hydraulic tank is full A CAUTION Before continuing further read and become fa miliar with Precautions for Hydraulic Testing 3 Disconnect hydraulic hose from the fitting in the charge port of piston pump P3 traction pump section Connect T fitting and pressure gauge to the fitting and hose connection 4 Make sure that traction pedal and lift control are in neutral and the parking brake is engaged 5 Start engine and operate at full speed 2850 50 RPM 6 Pressure gauge should read approximately 100 to 150 PSI 6 9 to 10 4 bar Record test results Greensmaster 3150 Page 4 35
53. Reel bearing rolling torque should not exceed 7 in Ib Repeat setps 2 and 3 if necessary 5 If bearings require replacement see Reel Removal and Bearing Replacement in the Repairs section of this chapter Figure 7 1 Reel bearing adjustment nut Set Up and Adjustments 7 8 Greensmaster 3150 n nnn Bedknife To Reel Adjustment IMPORTANT For adjusting bedknife to reel use a 3 8 in open end wrench that is 3 to 6 in in length A longer wrench will provide too much leverage and may cause distortion of the adjustment screw mounting plate or bedbar breakage 3 1 To move bedbar closer to reel blades loosen bottom screw on each side of cutting unit Fig 8 then tighten top adjustment screw on each side of cutting unit Fig 9 To move bedknife away from reel blades loosen top screw on each side of cutting unit Fig 8 then tighten bottom adjustment screw on each side of cutting unit Fig 9 2 After adjusting bedknife to reel make sure that both the top and the bottom adjustment screws are secured at both ends of cutting unit Fig 8 9 Figure 9 3 After adjustment check to see if reel can pinch paper when inserted from the front and cut paper when in 1 Bedknife closer to reel 4 3 8 inch wrench serted at a right angle Fig 10 should be possible to 2 Bedknife further from reel 5 Bedknife cut paper with minimum
54. Secure flangettes with bearing loosely to the inside of the castor fork with cap screws 12 bearing tab 7 and lock nuts 8 A Position grease fitting on flangette downward B Torque socket head screws 16 to 85 ft Ib 115 Nm C Torque cap screws 12 to 30 ft Ib 41 Nm 8 Apply loctite to both set screws 27 Torque set screws from 80 to 100 in Ib 9 0 to 11 3 Nm 9 Install both hose assemblies 4 and new O rings 23 to the hydraulic fittings at the hydraulic motor and hub assembly Hydraulic System Rev E 2g 3 SE 52 gt Wheel Motor Service Note 0 Parts not listed in partlist are not serviced separately 25 19 20 21 26 15 16 23 27 1 4 5 6 7 15 28 2 3 8 9 10 Dirt seal Bearing Housing Back up washer Seal rings Back up washer Inner seal Thrust washer Thrust bearing Bearing Figure 38 Coupling shaft Thrust bearing Drive link Cap screw Commutator seal Commutator Woodruff key Wear plate Rotor For repair of the wheel motors see the Ross Torqmotor MG MF MP ME and MJ Series Ser vice Procedure Service Manual 2704 003 at the end of this chapter Hydraulic System Rev E Page 4 64 Vane Stator Manifold Commutator ring End cover Rotor set Commutator assembly Seal kit Housing assembly Greensmaster 3150 Flush Hydraulic System IMPORTANT Flush the hydrauli
55. Stack shims to the thickness of the crush ring 3 Insertshims into the cover plate in the same location that the crush ring was removed from 4 Assemble housing sub assembly consisting of the housing camplate bearing cone bearing cup and cov er plate see Eaton Medium Duty Piston Pump Repair Information Model 70160 Variable Displacement Piston Pump atthe end of this chapter Greensmaster 3150 Page4 59 Rev F 5 Install washers and cap screws to the cover plate and housing Torque cap screws to 29 ft Ibs 39 Nm 6 Check torque required to rotate control shaft Torque should be 5 to 15 in Ibs 0 6 to 1 7 Nm A Iftorque is too low add additional shims and re peat steps 3 through 6 until the specified torque is achieved B If torque is too high remove shims and repeat steps 3 through 6 until the specified torque is achieved 7 Complete assembly ofthe pump see pump service manual atthe end of this chapter Hydraulic System Rev E Sg a gt Front Wheel Motors P 4 N i 70 to 90 ft Ib 95 to122 Nm N RIGHT FRONT Pd Lug nut Tire Rim Valve stem Brake drum Wheel hub Drive stud Backing plate Brake 10 Retaining ring 11 Return spring Hydraulic System Rev E 250 to 400 ft Ib 3 Pr i 339 to 542 Nm 24 Figure 36 12 Brake shoe 13 Woodruff key 14 Brake bracket 15 Hydraulic hose 16 Hydraulic hos
56. Suction fitting 6 Frontidler gear 13 Adapter plate 20 Washer 7 Back idler gear 14 Key 21 Shaft seal Note For repair of the gear pump see Eaton Gear Pumps Repair Information Series 26 Model 26000 Multiple Gear Pumps at the end of this chapter Hydraulic System Rev E Page 4 52 Greensmaster 3150 Hydraulic System Start up Note Wheninitially starting the hydraulic system with new or rebuilt components such as motors pumps or lift cylinders it is important that this start up procedure be used This procedure reduces the chance of damag ing the system or its components from not purging the system of air 1 After the hydraulic system components have been properly installed and if the traction pump was rebuilt or replaced make sure traction pump housing is at least half full of clean hydraulic oil 2 Make sure all hydraulic connections and lines are secured tightly 3 Make sure hydraulic reservoir is full Add correct oil ifnecessary see Check Hydraulic System Fluid Drain flush and refill hydraulic system reservoir and change oil filter if component failure was severe or system is contaminated 4 After repairs check control linkage for proper ad justment binding or broken parts 5 Make sure traction pedal is in neutral and the cut ting unit switch is off 6 Disconnect both spark plug wires from spark plugs to prevent the engine from starting 7 Turn ignition key switch and engage starter for
57. Watch pressure gauge carefully while slowly clos ing the flow control valve on the tester to fully closed 9 Onmachines with serial number under 260999999 system pressure should be from 2160 to 2640 PSI 149 to 182 2 bar Note If a dethatching kit is installed sys tem pressure should be from 2700 to 3300 PSI 186 3 to 227 7 bar Record test results A If this specification is met go to step 11 B If specification is not met open control valve on tester shut off engine and adjust relief valve R1 Fig 22 see Adjust Manifold Relief Valves in the Adjustments section of this Chapter After adjust ment retest relief valve R1 pressure Greensmaster 3150 Page 4 43 10 On machines with serial number above 270000000 system pressure should be from 2700 to 3300 PSI 186 3 to 227 7 bar Record test results A If this specification is met go to step 11 B If specification is not met open control valve on tester shut off engine and remove solenoid relief valve S1R1 on manifold Fig 23 Clean or replace valve see Hydraulic Manifold Service Serial Num ber Above 270000000 in the Service and Repairs section of this chapter Retest relief valve R1 pressure 11 Disengage cutting units Open control valve on test er and shut off engine 12 Disconnect tester from manifold and hose Recon nect hose to the bulkhead connection 13 Correctly readjust bedknife on all cutting units Figure 22 1
58. and head assembly into the barrel being careful not to damage the seals 6 Secure head in barrel by installing retaining ring Align retaining ring hole in the head with the access slot in the barrel Insert the retaining ring hook into the hole and rotate head clockwise until the retaining ring is com pletely pulled into the barrel and the ring ends are cover ed Hydraulic System Rev E 2g 5 gt gt N Hydraulic Manifold Hydraulic manifold assembly Flow control valve Straight swivel hydraulic fitting O ring O ring 90 hydraulic fitting Hose assembly Tee hydraulic fitting Hose assembly 10 Straight hydraulic fitting 1l Hose assembly 12 Hose assembly 13 45 hydraulic fitting Figure 53 Hose assembly 900 hydraulic fitting O ring O ring Tube assembly 90 hydraulic fitting O ring O ring Hose assembly Straight hydraulic fitting Hose assembly Hose assembly Serial Number 230000801 To 260999999 Shown Cap screw Straight hydraulic fitting O ring O ring Hose assembly Straight hydraulic fitting O ring O ring Hose assembly 45 hydraulic fitting Tube assembly Tube assembly Note The ports on the manifold are marked for easy identification of components Example R1 is the reel circuit relief valve and P1 is the gear pump connection port see Hydraulic Schematic to identify the functio
59. der or at the hydraulic pump Fig 63 if necessary 8 Ifnecessary remove hydraulic fittings and O rings from steering control valve Greensmaster 3150 Page 4 91 UUs WAAL mtm Z S Figure 63 Installation Fig 62 1 Ifremoved install hydraulic fittings 19 and 23 and O rings 20 to the steering control valve 33 or 34 2 Install hose assemblies 22 and O rings 21 and 24 Note Connect any hydraulic hose assemblies 22 that may have been disconnected at the manifold block P2 or ST ports at the steering cylinder or at hydrau lic pump Fig 63 if necessary 3 Install any cable ties removed from the hose assem blies 4 Install steering column assembly if equipped and steering control valve 33 or 34 to steering mount with cap screws 12 5 Install steering valve cover 26 with cap screws 14 6 Install steering wheel 8 and nut 9 Torque nut from 20 to 26 ft Ib 28 to 35 Nm 7 Secure steering wheel cover 11 with screw 10 Hydraulic System Rev E 2 E i gt I gt gt wn Steering Control Valve Service Serial Number Below 270999999 140 to 160 in Ib 16 to 18 Nm Figure 64 1 Steering valve housing 10 End cap 18 Wear plate 2 Dustseal 11 O ring 19 Bearing race 3 O ring 12 Seal ring 20 Thrust bearing 4 Spool 13 O ring 21 Plug 5 Spring retaining ring 14 Geroter 2
60. gt FUSE BLOCK P10 MOW RELAY K4 Bos P1 DIODE PACK P4 HOURMETER JOYSTICK RELAY K3 ALARM P22 LEAK DETECTOR eu SOLENOID B 25 LEAK DETECTOR Page 11 20 Rev E P13 PARKING BRAKE J9 im J12 OPTIONAL AE EB OPTIONAL LIGHT 1 T LIGHT 1 P31 OPTIONAL BACKLAP P14 MOW SWITCH J11 P26 OPTIONAL INTERCONNECT 1 AT B m BACKLAP a lt a C A a 49 P8 B DIODE 2 P27 INTERCONNECT 2 A B P17 P19 RAISE LOWER ORIFICE SOLENOID S2 SOLENOID S6 Serial Number 230000801 To 250999999 A Q i B P16 LOWER SOLENOID S4 Greensmaster 3150 Electrical Harness Drawing Serial Number Under 260000000
61. in assembly but allow bracket to slide freely on side plate Set Up and Adjustments Page 8 12 Figure 10 1 Rear height of cut bracket 3 Bottom nut 2 Top capscrew and nut Figure 11 1 Right rear roller bracket capscrews Greensmaster 3150 6 Position 1 4 inch or thicker plate under the reel blades and against the front face of the bed knife Fig 12 NOTE Make sure plate covers full length of reel blades and 3 blades contact plate 8 blade reel 7 While holding reel securely on plate level roller by rotating lower left roller pivot bolt The pivot bolt has an offset thread which when rotated acts as a cam to raise orlowerthe roller On the bolt head there is an identifica tion dot Fig 13 which denotes the offset ofthe bolt Dot indicates in which direction left end of roller moves when bolt is turned 8 To verify if roller is level try inserting a piece of paper under each end of roller 9 When roller is level tighten left capscrew and pivot Figure 12 bolt securely Hold the eccentric pivot bolt while tighten ing the nut to keep the proper roller position 1 1 4 plate 2 Bedknife Figure 13 1 Pivot bolt Greensmaster 3150 Page 8 13 Set Up and Adjustments Height of Cut Height of cut as measured in the turf and on the cutting unit is different The grass prevents the cutting unit from settling all the way to the ground line as the machine
62. through the carbon cannister Note Ifthere is restriction in the fresh air filter the car bon cannister or the fuel vent valve the fuel tank may distortdue to venting issues If the fuel tank returns to it s normal shape when the fuel cap is removed restriction in the evaporative control system is likely Greensmaster 3150 machines have used two 2 loca tions for the carbon canister Components used in the evaporative control system on these systems have some differences besides the canister location Figure 7 illustrates the components used in the evaporative control system Machines with a frame mounted carbon canister include a Single engine connection atthe engine intake manifold thatis used to connect evaporative system to the en gine These machines use an inline check valve be tween the carbon cannister and the engine intake manifold fitting Evaporative control system compon ents for these machines are shown in Figure 8 Machines with a carbon canister mounted to the top of the leak detector tank include two 2 connections to the engine one to the intake manifold and the second to the air cleaner base Venting hose assemblies purge hose assembly and t hose assembly include check valves in two 2 locations Evaporative control system compon ents for these machines are shown in Figure 9 Note machines with the canister mounted to the leak detector tank the purge hose assembly item 5 in Fig 9 and tee
63. 10 Dust seal 11 Lug nut 12 Wheel assembly 13 Valve stem Greensmaster 3150 3 TI 00 3 7 70 to 90 ft Ib 95 to 122 Nm 00 ee 33 32 14 15 16 17 Hub assembly 18 Seal 19 Bearing cone 20 Bearing cup 21 Hub 22 Grease fitting 23 Drive stud 24 Castor fork 25 Cap screw Page 6 3 26 27 28 29 30 31 32 33 34 35 36 37 Lock nut Cotter pin Slotted hex nut Spacer Adapter plate Lock nut Lock nut Motor adapter plate Castor bolt Cap screw Lock nut Washer Wheels and Brakes Removal Fig 2 1 Park machine on alevel surface Make sure engine is off Set brake and block front wheels 2 Jack up and secure the rear wheel off the ground Note The wheel assembly consists of the tire 14 rim 15 and valve stem 13 with cap The hub assem bly consists of the wheel hub 21 oil seals 18 bearing cones 19 bearing cups 20 grease fitting 22 and drive studs 23 3 Remove lock nut 26 from the castor bolt 34 Sup port the rear wheel assembly and pull the castor bolt from both adapter plates 30 and 33 4 Remove the spacers 16 and the wheel and hub assemblies from the castor fork 24 5 If damage to the castor fork bearings is suspected remove the castor fork 24 from the frame as follows A Remove cotter pin 27 and slott
64. 14 Retaining ring later production 5 Jam nut early production 10 Washer Removal Fig 14 1 Remove bedbar see Bedbar Removal in this sec tion of this manual 2 Remove lock nut 12 spring 11 and washer 10 from adjuster screw 3 Unscrew adjuster screw 6 from adjuster shaft 4 Remove adjuster shaft from cutting unit frame A On early production cutting units remove jam nut 5 and wave washer 4 from adjuster shaft 1 Slide adjuster shaft from frame B On later production cutting units remove retain ing ring 14 and wave washer 4 from adjuster shaft 13 Slide adjuster shaft from frame 5 Inspectflange bushings 2 and remove from cutting unit frame if necessary 6 Ifthe detent 7 is damaged remove it from the cut ting unit frame by removing the cap screw 9 and lock washer 8 Installation Fig 14 1 Ifthe detent 7 was removed secure detent to the cutting unit frame with cap screw and lock washer Dual Point Adjust Cutting Units 10 12 Rev 2 If flange bushings 2 were removed align key on bushing to slot in frame and install bushings 3 Slide adjuster shaft 1 or 13 into flange bushings in cutting unit frame 4 Install wave washer 4 onto adjuster shaft 5 Secure adjuster shaft to cutting unit frame A On early production cutting units apply Loctite 242 or equivalent to the threads of the jam nut 5 Install jam nut onto adjuster shaft and to
65. 23 27 ft Ib Install two 2 flange locknuts reel motor mounting nuts Fig 42 14 Install grooming reel adjustment knob assembly to right side groomer plate assembly Fig 42 Install groomer reel shaft to right side groomer plate assembly and install locknut on right end of groomer shaft 15 Install left side groomer housing and bearing adapter Fig 41 Install two 2 flat head socket screws and tighten to 17 21 ft lb Make sure a spacer is installed over each flat head socket screw between groomer bearing adapter and reel bearing housing Install two 2 locknuts and tighten to 23 27 ft lb 16 Install groomer reel driven pulley to groomer reel shaft left hand thread and tighten to 29 35 ft lb Fig 40 17 Install clutch adapter on reel shaft and tighten to 170 210 Fig 49 Hold belt on drive pulley and slide clutch assembly on clutch adapter while sliding belt onto driven pulley Fig 40 Install washer and nut removed in step 4 on clutch adapter shaft Use a block of wood to keep reel from rotating and tighten nut to a torque of 7 10 ft Ib 18 Install grooming reel adjustment knob assembly to left side groomer housing Fig 40 19 Adjust belt tension See Groomer Reel Drive Belt Adjustment in the Adjustments section of this book Install groomer reel housing cover Fig 39 Install clutch knob and tighten two 2 set screws against flats of clutch release disk 20 Do steps 5 16 un
66. 3 Read Precautions for Hydraulic Testing 4 Make sure the transmission is adjusted to the neu tral position see the Traction Unit Operator s Manual 5 Attach a heavy chain to the rear of the machine frame and an immovable object to prevent the machine from moving during testing 6 If machine has 3 wheel drive block up the rear wheel offthe ground to allow flow through the rear wheel motor 7 Chock front wheel being tested to prevent rotation of the wheel Make sure parking brake is on 8 Disconnect hydraulic lines from front wheel motor that is not being tested Cap the disconnected hydraulic lines and plug ports in wheel motor see Special Tools 9 Disconnect hydraulic hose from the hydraulic tube that connects to the upper hydraulic fitting on the front side of the hydrostat 10 Install flow tester in series with the pump and the disconnected hose same tester connections as Trac tion Drive Hydrostat P3 Flow Test Make sure the tester flow control valve is fully open Use extreme caution when performing test The wheel being tested will be trying to move the ma chine 11 Start engine and move throttle to full speed 2850 50 RPM Greensmaster 3150 Page 4 33 12 Slowly push traction pedal in forward direction until 1000 PSI 69 bar is displayed on the tester pressure gauge 13 Wheel motor internal leakage will be shown on flow meter in GPM Flow should be less than 1 5 GPM for the tested
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68. 3150 UO om gt N This page is intentionally blank Greensmaster 3150 Page 4 71 Hydraulic System Rev E Lift C ylinders RIGHT LIFT CYLINDER LEFT LIFT CYLINDER Figure 47 1 Frame 6 Capscrew 11 Lift arm 2 Straight hydraulic fitting 7 Washer 12 Spacer 3 O ring 8 Pivotpin 13 Spacer 4 O ring 9 Cotter pin 14 Hydraulic cylinder 5 Hose assembly 10 Clevis pin Front Cylinder Removal Fig 47 1 Before removing any parts from the hydraulic sys tem park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components 2 Label all hydraulic connections for reassembly 3 Disconnect hose assemblies and O rings from the hydraulic fittings at the lift cylinder Allow hoses to drain into a suitable container 4 Remove cotter pin and clevis pin from the cylinder clevis Hydraulic System Rev E Page 4 72 5 Support hydraulic cylinder to prevent it from drop ping A Remove cap screw and washer from the pivot pin B Pull pivot pin from the frame spacers and hy draulic cylinder C Remove hydraulic cylinder from the frame Front Cylinder Installation 1 Position hydraulic cylinder to the frame Insert pivot pin through the frame bracket spacers and cylinder Secure pin w
69. 3150 Battery Service The battery is the heart of the electrical system With regular and proper service battery life can be extended Additionally battery and electrical component failure can be prevented When working with batteries use extreme cau tion to avoid splashing or spilling electrolyte Electrolyte can destroy clothing and burn skin or eyes Always wear safety goggles and a face shield when working with batteries Electrolyte Specific Gravity Fully charged 1 265 corrected to 809F 26 79C Discharged less than 1 240 Battery Specifications BCI Group Size U1 300 Amp Cranking Performance at 0 F 17 89 C 28 Minute Reserve Capacity at 809F 26 79C Removal Fig 28 and 29 IMPORTANT Be careful not to damage terminal posts or cable connectors when removing the bat tery cables 1 Remove wing nuts and battery retainer 2 Disconnect the ground cable first to prevent short circuiting the battery other components or the op erators hands Disconnect the positive cable 3 Make sure that the filler caps are on tightly 4 Remove battery from the battery compartment to a service area This will minimize possible battery dam age and allow better access for inspection and service Inspection Maintenance and Testing 1 Perform following inspections and maintenance A Check for cracks caused by overly tight or loose hold down clamp Replace battery if cracked and leaking B Check batter
70. 39018 lt 1HOd uoljons 40 Lo INO woog e nss ld YH gt 1 se g v UMOUS UO SN uonisod pezibueue 1581 norog umoys ES pue 25 5 2 SHOLOW 133HM NOLLOWHL UMOUS 666666092 oa P RES 01 L0800008c 1Jequunw ejes Cy suun ew 5 0916 19 9 SHOLOW Greensmaster 3150 Page 4 12 Hydraulic System Rev E Raise and Lower Cutting Units Serial Number Under 260999999 The gear pump P2 is directly coupled to the hydrostat through gear pump P1 It supplies hydraulic pressure for raising and lowering the cutting units for the steering circuit and for maintaining 100 to 150 PSI 6 9 to 10 0 bar to the low pressure side of the traction circuit charge pressure The gear pump P2 takes its suction from the hydraulic reservoir Maximum circuit pressure is limited by relief valve R5 which is located in the steering control valve During cutting unit hold not raising or lowering condi tions flow fromthe gear pump is by passed through the steering control valve and solenoid valve S2 directly to the hydrostat and the charge relief valve R4 Flow then returns to the hydraulic reservoir Raise Cutting Units When the cutting
71. 3hrs 15 hrs 3 amps 3 amps 3 amps 3 amps 81 to 125 5 3hrs 10 5 hrs 15 8hrs 21 hrs 4amps 4amps 4 amps 4 amps Battery Charge Level Percent of Fully Charged 126 to 5 5 hrs 11 hrs 16 5hrs 22 hrs 170 5 amps 5 amps 5 amps 5 amps 171 to 5 8hrs 11 5 hrs 17 3 hrs 23 hrs 250 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 250 10 amps 10 amps 10 amps 10 amps Greensmaster 3150 Page 5 21 Do notcharge a frozen battery because itcan ex plode and cause injury Let the battery warm to 60 F 15 5 C before connecting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are explosive keep open flame and elec trical spark away from the battery Do notsmoke Nausea may result if the gases are inhaled Un plug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts 3 Following the manufacturer s instructions con nectthe charger cables to the battery Make sure a good connection is made 4 Charge the battery following the manufacturer s instructions 5 Occasionally check the temperature of the battery electrolyte If the temperature exceeds 125 F 51 69 or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 6 Three hours prior to t
72. 4 16 Hydraulic System Rev E Mow and Backlap Serial Number Under 260999999 The gear pump P1 is directly coupled to the hydrostat which is driven directly by the engine Taking its suction directly from the hydraulic reservoir the gear pump P1 supplies oil flow to the hydraulic manifold block and to the cutting reel motors Maximum circuit pressure is lim ited by relief valve R1 which is located in the hydraulic manifold With the engine running and the Functional Control and Raise Lower Mow levers positioned so the reels will notturn see Operator s Manual solenoid valve S1 is de energized 51 by passes flow from the gear pump P1 directly to the hydraulic reservoir Mow With the engine running and the Functional Control and Raise Lower Mow levers positioned so the reels will turn see Operator s Manual solenoid valve S1 is en ergized Gear pump P1 flow is routed out manifold port MA and to the reel motors that are connected in se ries Oil flows through the left M2 right M3 and then rear reel motor M1 as it turns the motors in the mow direction The oil then returns through the manifold block oil filter and then to the reservoir Note On traction units with serial number from 230000801 to 260999999 solenoid valve S6 is ener gized when the cutting units are raised This forces the return flow from the reel motors through the 125 orifice putting back pressure on the reel circuit and s
73. 4 Remove the front bracket and slide the roller and shaft from the cutting unit Remove the remaining front roller bracket if necessary Installation Fig 25 1 Place cutting unit on a level working surface 2 If both front roller brackets were removed A Insert carriage screw through the cutting unit side plate and front bracket Secure carriage screw and roller bracket with tab washer and lock nut Dual Point Adjust Cutting Units Page 10 20 Figure 25 1 screw 4 Carriage screw 2 Roller assembly 5 Locknut 3 Front roller bracket 6 Tab washer 3 Slide roller shaft into the front bracket attached to the cutting unit Slide second front bracket on the other end of roller Secure bracket with carriage screw tab washer and lock nut 4 Apply Loctite 242 or equivalent to the cap screw threads Center roller in the front brackets and secure into place with the cap screws 5 Adjust cutting unit height of cut see Cutting Unit Operator s Manual Greensmaster 3150 This page is intentionally blank Greensmaster 3150 10 21 Rev Dual Point Adjust Cutting Units Roller Service Roller Shaft with Circlip Figure 26 1 Roller seal 3 Roller bearing 5 Roller shaft 2 Spiral retaining ring 4 Rearroller body 6 Frontroller body Seal Removal SEM 188 in dia 2 1 Make a seal removal tool from a 1 4 x3 x 3 in 63 x 625 in di 7 6 x 7 6 cm piece of steel as shown Fig 27
74. 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 sur faces 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 10 Position the motor with rear cover downwards Care fully slide the front flange onto the assembly using mark er or scribe mark for proper location 11 Install the four 4 cap screws and hand tighten IMPORTANT Avoid using excessive clamping pressureon the motor housing to preventdistorting the housing 12 Place motor front flange in a vise and alternately torque the cap screws from 215 to 280 in Ib 24 to 32 Nm 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 Greensmaster
75. 8 Install bedbar Install front and rear roller assembly side plate to remove housing Greensmaster 3150 Page 7 19 Repairs i 1 1 1 Lift Bail Replacement 4 S N N N N N N N N b Figure 30 1 Use a saw to cut the lift bail off ofthe cutting unit Make 4 Support the lift bail so the bottom radius is 4 546 inches the cut 1 inch from the horizontal frame tube Fig 30 from the top of the horizontal frame tube Make sure the lift bail is square to the side frame 2 Use a grinder to remove burrs from the stubs of the lift bail remaining on the cutting unit 5 Weld all around the bottom of the repair lift bail with mild steel rod both sides 3 Install the repair lift bail Part No 71 1600 Repairs Page 7 20 Greensmaster 3150 TORO Table of Contents SPECIFICATIONS 3 5 4 6 SETUP AND 5 8 Adjustment Summary and Check List 8 Bedknife to Reel Contact 9 Reel Bearing Service and Adjustment 10 Parallel Bedknife to 11 Leveling Rear Roller to Reel 12 Height 14 Front Roller Scraper Adjustment 16 Comb Adjustment 16 Shield Height A
76. A With the joystick in the rest position continuity should only exist between the common and NC ter minals open terminal and green black wires B With the joystick in the lower position continuity should only exist between the common and NO ter minals green black and gray black wires 4 Aftertesting connectthe harness connectors to the joystick switches and reinstall the plastic cover Backlap Switch If Equipped The backlap switch is located on the hydraulic manifold when the Backlap Kit is installed It is normally open and closes when the backlap knob is turned to the back lap position 1 With the engine off disconnect electrical connector 2 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals 3 Turn the backlap knob clockwise to the backlap position while watching the multimeter Continuity should be made as the switch closes 4 Turnthe backlap knob counterclockwise to the mow position while watching the multimeter Continuity should be broken as the switch opens 5 Reconnect the electrical connector Electrical System Page5 14 Rev E Figure 17 J oystick assembly 3 Raise switch Lower switch Figure 18 3 NC terminal 4 Switch lever Common terminal NO terminal Ne Serial Number 230000801 To 260999999 Shown Figure 19 1 Connector 3 Backlap knob 2 Backlap switch Greensmaster 3150
77. Always fill fuel tank out side and wipe up any spilled fuel before starting the engine Store fuel in a clean safety ap proved container and keep the cap in place Use gasoline for the engine only not for any other purpose 3 Close shut off valve on fuel tank Disconnect fuel supply hose atthe fuel pump Drain any fuel trapped in the fuel filter and fuel hose into a suitable container 4 f machine is equipped with a fuel evaporative con trol system disconnect system hose s from engine see Fuel Evaporative Control S ystem Serial Number Above 310000365 in this section 5 Disconnectengine wiring harness 29 choke con trol cable throttle control cable and ground wires 11 atthe engine 6 Loosenthe two setscrews 38 securing the engine hub 40 to the engine shaft 7 Supportthe hydraulic pump assembly and remove the two cap screws 43 lock washers 42 and hard ened washers 32 securing the pump to the pump adapter 19 Do Notdisconnectthe hydraulic hoses or neutral control linkage from the pump 8 Supportthe engine assembly and remove the three engine mountflange nuts 7 cap screws 1 flat wash ers 2 and spacers 3 9 Carefully move the engine away from the hydrostat until the crankshaft clears the engine hub Remove the engine from the machine Locate and retrieve key from crankshaft Greensmaster 3150 Page3 7 Rev F Engine Installation Fig 6 1 Apply antiseize lubricant to bore
78. B If valve sealing surfaces appear pitted or dam aged the hydraulic system may be overheating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air Greensmaster 3150 Page 4 83 5 Cleaning cartridge valves A For non solenoid operated valves Submerge valve in clean mineral spirits to flush out contamination If valve design allows use a probe to push the internal spool in and out 20 to 30 times to flush out contamination Particles as fine as talcum powder can affect the operation of high pressure hy draulic valves Clean and dry cartridge with com pressed air B For solenoid operated valves Temporarily install solenoid on cartridge valve and connect a 12 volt power source to the solenoid While energized flush out any contamination with a non flammable aerosol brake cleaner De energize the solenoid Repeat the flush while energized proce dure 5 or 6 times Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves Remove solenoid from cartridge 6 Reinstall the cartridge valve into the manifold A Lubricate new O rings and backup rings of seal kit with clean hydraulic oil and install on cartridge The O rings and backup rings must be arranged properly on the cartridge valve for proper operation and sealing IMPORTANT Use care when installing the car tridge valve Slight bending or distortion of the stem tube
79. CAUTION Be careful when lapping the reel because con tact with the reel or other moving parts can result in personal injury NOTE For a better cutting edge run a file across front face of bedknife when lapping operation is completed This will remove any burrs or rough edges that may have built up on the cutting edge Bedbar Removal and Installation 1 Loosen pivot screws securing bedknife pivot assemb ly to reel frame supports Fig 27 2 Rotate adjustment knob and pivot assembly clock wise left hand thread until it is unthreaded from bedbar pivot Fig 27 3 Loosen jam nuts retaining right and left bedbar pivot bolts Remove pivot bolts Fig 27 IMPORTANT Note position of plastic washer and steel washer on right end of bedbar and plastic washer on left end of bedbar for reinstallation 4 Slide bedbar down and out from under cutting unit Figure 27 Do not misplace washers 1 Pivot screw 7 Left bedbar pivot bolt 5 Replace and or grind bedknifeto renew cutting edges 2 Bedknife pivotass y 8 Right bedbar pivot bolt 3 Frame supports 9 Steel washer 20 NOTE For proper grinding of bedknife follow proce x 2 bs Mie ing dures in the Toro publication Sharpening Reel and 6 Jam rite 12 Compression spring Rotary Mowers Form No 80 300 PT 6 Adjust the reel bearings See Reel Bearing Service and Adjustment in the Adjustments section of this chap ter
80. D1 A s IN BACKLAP BACKLAP RELAY 27 ONR i 2e BF3 10 36 B 36 C ______ 87 REEL ENGAGE Y 01 OR BK Y MOW RELAY K4 ENERGIZED SEAT SWITCH PARKING BRAKE ENERGIZED 26 C F4 10A UNOCCUPIED ON POSITION 1 BU BK BI VIO GN BK mp ke SN 5 i 01 0 JOYSTICK 36 E m T OR BK BU BK 5 LOWER MOW SWITCH 85 86 ENGINE GND muc a ILLI We 2 ee OFF POSITION F El de GN BK JOYSTICK RELAY K3 he DM ENERGIZED _ 52 D1 C 128 STOP NONE A d 7 2 o RUN B H A X 51 Y ws L START BHS umm eiue 5 14 D GNK ae gu re REGULATOR L FUSIBLE LINK 71 E ur 2 4 2 04 SP w ag P 85 1 i _ 4 MAGNETO w 87 ENGINE GND 30 34 SES Xt E KILL Rer K1 85 1 86 BK EVEL SOLENOID ENERGIZED AA pA Mem Y x W BK ENGINE 34 A 54 87a REELS LOWER LOWER RELAY 5 E D3 VIO BK 92 RAISE LOWER BK 8574 REELS RAISE Y 87 BU R i S288 RAISE RELAY K6 Page 11 18 Rev E This page is intentionally blank Page 11 19 Rev E
81. E Remove the spare length of fuel hose from the fuel shut off valve If machine is equipped with a fuel evaporative con trol system disconnect vent hose from fuel vent valve Fig 5 4 4 Remove four cap screws 9 flat washers 7 and rommets 6 securing the fuel tank to the vehicle frame 12 Remove the fuel tank from the vehicle frame Greensmaster 3150 Fuel Tank installation Fig 4 1 2 Position fuel tank 5 on the vehicle frame 12 A Apply antiseize lubricant to the threads of the four cap screws 9 B Secure the fuel tank to the vehicle frame with four grommets 6 flat washers 7 and cap screws 9 Make sure the fuel hose support clamps 8 are positioned correctly C Torque cap screws from 20 to 25 ft Ib 27 to 34 Nm Connectfuel hose 14 to the fuel shut off valve 15 with hose clamp 2 3 If machine is equipped with a fuel evaporative con trol system connectventhose to fuel vent valve Fig 5 4 Open fuel shut off valve 15 and fill fuel tank with fuel See Filling Fuel Tank in the Traction Unit Operator s Manual Check all fuel hoses and tank for leaks Page3 5 Rev F Figure 5 1 Fuel tank 4 Hose clamp 2 Fuel cap 5 Vent hose 3 Fuel vent valve 6 Grommet Engine Engine Loctite 242 38 90 to 110 in Ib gt 10 2 to 12 4 Nm Cap screw 3 used Flat washer 3 used Spacer 3 used Exhaust manifold Regulat
82. F F T Step 4 If port material is aluminum tighten fitting to 6096 of listed F F F T Size F F F T 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 6 8 in 1 50 0 25 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 Hydraulic System Rev E 4 6 Greensmaster 3150 Hydraulic Schematics ana TWNOILdO a me gt u31009 1SISOHGAH 1 OO t bas y E Zd ld d SH I M SATA d 09 002 aang 9NIH331S H3MOd mE ISd Sz INVA AN 05 30018 G102INVIA 1S 1d ld a MO
83. GREEN BLACI YELLOW WHITE PIO DIODE PACK 1 P26 P36 P29 INTERCONNECT 1 INTERCONNECT 2 SEAT SWITCH JA 2 START SOLENOID PI2 NEUTRAL SWITCH PARKING BRAKE 4 SWITCH Greensmaster 3150 Wiring Diagram Serial Number Above 270000000 Page 11 25 Rev E This page is intentionally blank Page 11 26 Rev E
84. Hydraulic manifold serial number under 260999999 2 Relief valve R1 Figure 23 1 Hydraulic manifold serial number above 270000000 2 Solenoid relief valve S1R1 Hydraulic System Rev E gt I Reel Motor Case Drain Flow Test Using Tester with Flowmeter and Pressure Gauge _ 1 ANAL BW Y 1 5 I ot HH HH gt gt 7 i LEFT MOTOR VOD CASE DRAIN gt SS RIGHT MOTOR CASE DRAIN 8 REAR MOTOR RETURN High Pressure Y FROM MANIFOLD Low Pressure PORTMA TO HYDRAULIC TO MANIFOLD RESERVOIR PORTMB lt ma Return or Suction Flow 3 Hydraulic System Rev E Page 4 44 Greensmaster 3150 Procedure for Reel Motor Case Drain Flow Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered Make sure engine is off and the parking brake is engaged A CAUTION Before continuing further read and become fa miliar with Precautions for Hydraulic Testing 3 Forthe suspected bad reel motor disconnect return hose from motor 4 Installtesterin series with the reel motor and the dis connected return hose Make sure the flow contr
85. Idler gear Greensmaster 3150 Page 4 69 Hydraulic System Rev E 3 Inspect drive gear idler gear and bearing blocks Fig 46 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 indi cates 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 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 gas kets and seal grooves with a thin coat of petroleum jelly Lubricate all other internal parts freely with clean hy draulic 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 plac ing the back up rings into the grooves 4 Install new O rings to the body Hydraulic System Rev E Page 4 70
86. Itis best to make the reel to bedknife adjustment in the morning immediately before each day of mowing Weekly Checks 1 Check reel bearing adjustment and bearing condition 2 Make sure bed bar bolt plastic washers are SNUG against the bedbar 3 Make sure bedknife adjustment knob pivot assembly is held FIRMLY in place between frame supports 4 Use a gauge bar to check height of cut setting 5 Use a gauge bar to check groomer depth setting Set Up and Adjustments Page 9 10 Monthly Adjustments NOTE Remove cutting unit from traction unit 1 Parallel bedknife to reel Use newspaper as a feeler gauge Dot on eccentric bolt must face rear of mower Turn bedknife adjustment knob to hold paper on right hand end of bedknife Turn eccentric left bedbar bolt to hold paper on left hand end of bedknife Hold eccentric bedbar bolt while securing locknut 2 Adjust rear roller parallel to reel eccentric bolt faces to rear 3 Check grass shield adjustment 4 3 4 in from crossbar normal Dry grass lower shield Wet grass raise shield 4 Set top bar cut off bar adjustment 0 060 in from reel normal 5 Set cutting unit on ground setting on both rollers and remove reel motor Adjust bedknife to reel contact 6 Use a gauge bar to check height of cut and adjust as necessary 7 Use a gauge bare to check groomer depth and adjust as necessary Special Notes 1 Rep
87. Lift Cylinder Flow Control Valve Serial Number Under 260999999 89 Steering Control Valve 90 Steering Control Valve Service Serial Number Under 270999999 92 Steering Control Valve Service Serial Number Above 280000000 94 Steering Cylinder 96 Steering Cylinder Service 98 Leak Detector 100 Hydraulic Reservoir 102 EATON GEAR PUMPS REPAIR INFORMATION SE RIES 26 MODEL 26000 MULTIPLE GEAR PUMPS EATON MEDIUM DUTY PISTON PUMP REPAIR INFORMATION MODEL 70160 VARIABLE DIS PLACEMENT PISTON PUMP ROSS TORQMOTOR MG MF MP MB ME AND MJ SERIES SERVICE PROCEDURE SERVICE MANUAL 2704 003 SAUER DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Page4 1 Hydraulic System Rev E 2g 3 SE 52 gt Specifications Item Description Hydrostatic Transmission P3 Maximum Flow Charge Pressure R4 Variable displacement piston pump 14 8 GPM 55 8 LPM 2800 RPM and 98 Efficiency 100 to 150 PSI 6 9 to 10 4 bar Gear Pump Front Section to Reel Circuit P1 Maximum Flow Rear Section to Steering and Lift Circuits P2 Maximum Flow 2 stage positive displacement gear type pump 6 9 GPM 26 1 LPM 2800 RPM and 98 Efficiency 3 7 GPM 13 9 LPM 9 2800 RPM and 98 Efficiency Wheel Motors Front Orbital
88. Make sure flow control valve on the tester is fully open 7 Make sure functional lever is in the transport posi tion 8 Startengine and move throttle to full speed 2850 50 RPM position The drive wheels will be off the ground and rotat ing during this test Make sure machine is well supported so it will not move and accidentally fall to prevent injuring anyone near the machine 9 Slowly push traction pedal into fully forward posi tion Greensmaster 3150 Page 4 31 Rev F Note Makesuretransportspeedis properly adjusted See Adjusting the Transport S peed in the traction unit Operator s Manual for additional information 10 Slowly close flow control valve until pressure gauge reads 1000 PSI 69 bar 11 Observe flow gauge TESTER READING should be a minimum flow of 12 5 GPM Record test results 12 Release traction pedal open control valve on tester and turn off engine 13 If specifications are not met consider the following A The traction pedal and or traction speed may need adjustment see the Traction Unit Operator s Manual B The hydrostat needs to be repaired or replaced as necessary C Make necessary repairs before performing addi tional tests 14 If specifications are met check wheel motor effi ciency see Wheel Motor Efficiency Testin this chapter 15 If testing is complete disconnect tester from hy draulic tube and hose Reconnect hose to tube Figure 23 1 Hydrost
89. Manifold body Solenoid coil Flow control orifice 060 Orifice plug 055 2 used Flow control orifice 013 Plug Zero Leak 4 12 used Plug Zero Leak 6 5 used Plug Zero Leak 8 3 used Plug SAE 4 2 used 10 Rotary cartridge valve FC1 11 Rotary handle assembly WENDT RUNH Hydraulic System Rev E 60 in Ib 6 7 N m 12 13 14 15 16 Solenoid cartridge valve S4 18 19 20 21 5 x 15 ft Ib 20 N m Figure 55 Pilot piston Relief cartridge valve PRV Solenoid cartridge valve S2 Solenoid relief cartridge valve 512 1 Solenoid cartridge valve S3 Relief cartridge valve R2 Logic control cartridge valve OR1 Ball Solenoid coil 4 82 40 ft lb 54 N m 198 in Ib 22 N m VIEW FROM 120 in Ib 13 5 N m Dowel pin Ball switch N O O ring Flow control cartridge valve FC2 Nut Flow control orifice 025 Hydraulic fitting Nut O ring O ring Greensmaster 3150 NOTE The ports onthe hydraulic manifold are marked for easy identification of components Example FC1 is the flow control valve and P1 is the gear pump connec tion port see Hydraulic Schematics to identify the func tion of the hydraulic lines and cartridge valves at each port location NOTE Thehydraulic manifold shown in Figure 55 uses several zero leak plugs These plugs have a tapered sealing surface on the plug head that
90. REEL MOTOR CENTER REEL MOTOR Figure 41 O ring O ring Straight hydraulic fitting O ring O ring Hose assembly Hose assembly Hose assembly Hose assembly Hose assembly Page 4 66 22 23 24 25 26 27 28 29 30 31 RIGHT REEL MOTOR Hose assembly 90 hydraulic fitting O ring Washer Spacer Grommet Bulkhead nut Tee hydraulic fitting O ring Bulkhead nut Greensmaster 3150 Removal Fig 41 1 Before removing any parts from the hydraulic sys tem park machine on a level surface engage parking brake lower cutting units and stop engine Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components 2 Remove reel motor from the cutting unit see Cut ting Unit Removal and Installation in Chapter 7 8 9 or 10 Cutting Units Note The position of hydraulic fittings on the reel mo tor is critical to properly reconnecting hydraulic hoses 3 Label all hose connections for reassembly pur poses Matchmark reel motor and all hydraulic fittings for reassembly purposes 4 Remove hose connections from the hydraulic fit tings on the reel motor Allow hydraulic oil to drain from hoses into a suitable container Put caps or plugs on ends of hoses to prevent contamination 5 Remove hydraulic fittings and O rings from the reel motor Put caps or plugs in motor openings to prevent contaminat
91. Reel Bearing Replacement NS Seal lip toward center of cutting unit toward center of cutting unit Seal lip toward center of cutting unit Figure 13 1 Drive side plate LH shown 2 Oil seal 3 Groomer reel bearing 5 Bushing Note The groomer reel drive is located on the oppo site side ofthe cutting unit from the cutting reel hydraulic motor Figure 13 shows the groomer reel drive from the left side of the cutting unit Bearing Removal 1 Remove front roller drive side groomer side plate and groomer reel from cutting unit see Groomer Reel Removal in this section 2 Remove non drive groomer side plate from cutting unit A Remove hydraulic reel motor from cutting unit see Hydraulic Reel Motor Removal in the Service and Repairs section of Chapter 10 DPA Cutting Units Groomer DPA Cutting Unit Rev A 4 Grease fitting Page 10 1 12 6 Side plate bushing 7 Non drive side plate RH shown B Remove two 2 socket head screws and lock nuts that secure motor mountto cutting unit Fig 14 Remove motor mount from cutting unit C Remove lock nut and spring washer that secure groomer arm lift rod to non drive groomer side plate Fig 15 Remove non drive groomer side plate from mower 3 Remove bearings in both side plate assemblies Fig 13 A Remove seals from groomer side plates Discard seals B Push bearings out of side plate housings Bear ings in drive si
92. Remove lug nuts 1 tire 2 and rim 3 Loosen but do not remove lock nut 24 from hydraulic wheel motor shaft IMPORTANT DO NOT hit wheel hub 6 with a ham mer during removal or installation Hammering may cause damage to the hydraulic wheel motor 4 Use wheel hub puller see Special Tools to free wheel hub 6 and brake drum 5 assembly from motor shaft Remove lock nut 24 wheel hub and brake drum assembly and key 13 from the hydraulic wheel motor shaft 5 Remove return springs 11 from brake shoes 12 Remove brake shoes from backing plate 8 6 Remove retaining ring 10 and brake cam 9 from the brake lever 23 and backing plate 8 7 Remove four cap screws 26 lock nuts 29 and backing plate 8 from the brake bracket 14 8 Parts should be clean and free of rust Inspect brake shoe 12 and brake drum 5 contact surfaces for ex cessive wear Replace any worn or damaged parts Installation Fig 7 and 8 1 Secure backing plate 8 to the brake bracket 14 with the four hex head screws 26 and lock nuts 29 2 Position both brake shoes 12 on the backing plate 8 Insert return springs 11 into the holes of both brake shoes 12 Wheels and Brakes 6 10 Rev Figure 8 3 4 Backing plate 1l Return spring 2 Brake shoe 3 Install brake cam 9 into the backing plate 8 and brake lever 23 Secure cam to the lever with the
93. Seal kit 8 2400 PSI relief cartridge Port R1 17 Plug SAE 10 26 Seal kit 9 N C cartridge Port S4 18 Cavity plug Port RD1 27 Orifice 125 Note The ports on the manifold are marked for easy identification of components Example R1 is the reel circuit relief valve and P1 is the gear pump connection port see Hydraulic Schematic to identify the function of the hydraulic lines and cartridge valves at each port location Hydraulic System Rev E Page 4 80 Greensmaster 3150 Solenoid Operated Cartridge Valves Fig 54 1 Make sure the manifold is clean before removing the valve s 2 Remove nut securing solenoid to the cartridge valve Slide solenoid and both O rings off the valve Note Use care when handling the cartridge valve Slight bending or distortion of the stem tube can cause binding and malfunction 3 Removecartridge valve with a deep socket wrench Remove seal kit 4 Visually inspect the port in the manifold for damage tothe sealing surfaces damaged threads and contami nation 5 Visually inspect cartridge valve for damaged seal ing surfaces and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in small valve orifices or seal areas causing malfunc tion B If spool valve 8 sealing surfaces appear pitted or damaged the hydraulic system may be overheat ing or there may be water in the system A CAUTION Use eye protection such
94. Table of Contents SPECIFICATIONS interi ek rte nis SPECIAL TOOLS TROUBLESHOOTING Factors Affecting Quality of Cut SET UP AND ADJUSTMENTS Characteristics SERVICE AND REPAIRS Hydraulic Reel Motor Removal Inspection and Installation Backlapping Units without Optional Backlap Variable Reel Speed Kit Backlapping Units with Optional Backlap Variable Reel Speed Kit Greensmaster 3150 Page 10 1 Rev Chapter 10 Dual Point Adjust Cutting Units Bedbar Assembly 10 Bedbar Removal and Installation 11 Bedbar Adjuster Service 12 Bedknife Replacement and Grinding 13 Reel Assembly 14 Reel Removal 15 Left Side Plate Service 16 Right Side Plate Service 16 Reel Service 17 Reel Installation 18 Preparing a Reel for Grinding 19 Front Roller Removal and Installation 20 Roller Service Roller Shaft with Circlip 22 Roller Service Threaded Roller Shaft 24 Dual Point Adjust Cutting Units Specifications DUAL POINT ADJUST UNIT Figure 1 H
95. VA BK 8 1 Y 30 uS i 3 mm i i S3 86 REELS EISE RAISE RELAY K6 BK BK Page 11 3 LEAK DETECTOR SOLENOID d Greensmaster 3150 BK 2 S5 PERT Electrical Schematic 94 ALARM Serial Number 230000801 To 250999999 w All relays and solenoids are shown as de energized BU 0 GY 83 2280 LEAK DETECTOR 1 SECOND CLOSED DURING GY DELAY ON HYDRAULIC FLUID LEAK STARTER 00 1 HOURMETER 2 BU 8 LIGHTS 1 1 F120A 2 10 OPTIONAL 5 ko A re R T 6 SP LIGHTS 2 BK LIGHT TEST SWITCH y OPTIONAL FUSIBLE LINK Moe R I BU 99 7430 28 4210 E i 5878 BACKLAP RELAY 7 BK PK BU PK BU E J11 o 85 UW BK w 1 W BU smes MEE 99 7430 STARTE a me mE n uU TARTER SWITCH SOLENOID IGNITION SWITCH 87 RBS PK Y B SWITCH D1 A 99 7430 19 GN R frm OFF RUN START E N OPTIONAL BU BK 87 D1 B 130 Si F3 10A 2B oio OR
96. VALVE LIFT CIRCUITS P Nip oe ERES CHER 51 TO TRACTION CHARGE CIRCUIT atr L TO LIFT CIRCUIT pa 1 p L L K a anai JJ FROM HYDROSTAT High Pressure Low Pressure Return or Suction Flow Hydraulic System Rev E Page 4 36 Greensmaster 3150 Procedure for Gear Pump P2 Flow Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered Make sure engine is off and the parking brake is engaged Make sure the hydraulic tank is full A CAUTION Before continuing further read and become fa miliar with Precautions for Hydraulic Testing 3 Disconnecthydraulic hose from the discharge fitting of gear pump P 2 end pump section 4 Install tester in series with the gear pump and the disconnected hose Make sure that tester flow arrow points from the pump discharge and toward the discon nected hose Make sure flow control valve on the tester is fully open 5 Make sure that traction pedal and lift control are in neutral and the parking brake is engaged 6 Operate engine at full speed 2850 50 RPM 7 Watch flow and pressure gauge carefully while slowly closing the flow control valve on the tester until the pressure gauge reads 800 PSI 55 2 bar 8 Minimum f
97. accessories it is recommended that you change only one cutting unit and keep the other two existing cutting units on the machine 1 Set the new cutting unit to a height of cut approximately 1 16 0 06 in higher than the old cutting unit 2 Do a mowing test and compare results between the new cutting unit and old cutting units 3 Adjust the new cutting unit to match the cut of the old cutting units 4 The other two cutting units can now be replaced Adjust these two new cutting units so they are the same as the other new cutting unit that was tested Figure 13 1 Helght of cut knob locknut 4 Height of cut knob 2 Gauge bar 1 8789 5 Roller shaft clamp bolt 3 Gauge bar screwhead 6 Comb assembly Set Up and Adjustments Front Roller Scraper Adjustment The front roller scraper should be adjusted so there is a clearance of approximately 1 32 of an inch between the scraper and roller Fig 14 Figure 14 Comb Adjustment 1 Make sure rear roller is in the desired height of cut position Loosen the bolts anchoring the front roller shaft Fig 15 Rotate the shaft 2 adjust the aggressiveness of the comb teeth Fig 15 proceed as follows Teeth touching the adjusting gauge bar gives aggressive setting B Adjustment of the comb assembly so it is midwa
98. also influence effective height of cut Changing the machine such as adding a wiehle roller will increase penetration into the turf and lower the effective height of cut Changing from a heavier single point adjust cutting unit to a lighter 4 bolt adjust cutting unit will reduce penetration into the turf and raise the effective height of cut Height of Cut Adjustment IMPORTANT Lower heights of cut are limited by thickness of bedknife Select proper bedknife for desired height of cut If bedknife is too thick for height of cut poor quality of cut will result and excessive pressure from turf on bottom of bedknife can cause rifling of bedknife and reel 1 To adjust height of cut cutting unit should be turned over and the locknuts on each end of the cutting unit securing the height of cut adjusting knob loosened Fig 13 2 On gauge bar Part No 1 8789 set head of screw to desired height of cut This measurement is from bar face to underside of screw head 3 Put the bar across the front and rear rollers and adjust the height of cut knob until the underside of the screw head engages the bedknife cutting edge Fig 10 IMPORTANT Do step 3 on each end of the bedknife Tighten height of cut adjustment locknuts on both ends Greensmaster 3150 Page 7 11 Changing To A Different Type of Cutting Unit or Adding Cutting Unit Accessories When changing to a different type of cutting unit or adding cutting unit
99. an inch between the scraper and roller Fig 16 Figure 16 Comb Adjustment 1 Make sure rear roller is in the desired height of cut position Loosen the bolts anchoring the front roller shaft Fig 17 Rotate the shaft 2 To adjust the aggressiveness of the comb teeth Fig 17 proceed as follows Teeth touching the adjusting gauge bar give an aggressive setting B Teeth midway between the adjusting gauge bar and the cutting edge of the bedknife give a medium setting C Teeth even with the cutting edge of the bedknife Figure 17 give a light setting 1 Roller shaft clamp boit 2 Comb teeth NOTE Securing one end ofthe comb assembly ata time simplifies the above procedure 3 Tighten the roller shaft bolts Set Up and Adjustments Page 8 16 Greensmaster 3150 Shield Height Adjustment Adjust shield to get proper grass clipping discharge into basket 1 Set cutting unit in normal cutting position and measure distance from top of front crossbar to shield at each end of cutting unit Fig 18 2 Height of shield from crossbar for normal cutting conditions should be 4 3 4 inches Loosen capscrews and nuts securing shield to each side plate adjust shield to correct height and tighten fasteners Fig 18 3 Repeat adjustment on remaining cutting units and adjust top bar See Adjusting Top Bar in this section of the book NOTE Shield can be lowe
100. and screen from filler neck of hydraulic tank Turn ignition switch to On do not start the engine Insert a clean rod or screw driver into filler neck and gently push down on switch float Alarm should sound after a one second time delay 2 Ifthe float switch is removed or disconnected from the main harness connect a continuity tester across the float switch wire terminals Current should flow across the terminals only when the float is pushed down There should be no current flow across the terminals when the float is in the raised position Leak Detector Solenoid Valve The leak detector solenoid valve is a normally open valve that allows hydraulic fluid to flow from the auxiliary tank to the main hydraulic tank while the ignition is Off This feature fills the main hydraulic tank with fluid from the auxiliary tank prior to starting the unit The valve closes when the ignition is On and during unit operation 1 Disconnect the wiring connector at the valve sole noid 2 Connect 12 vdc power across the solenoid termi nals The valve spool should retract completely 3 Ifvalve does not retract smoothly or does not retract completely replace or rebuild the valve see Solenoid Operated Cartridge Valves in this chapter of this manu al 4 To check the valve supply power set the ignition switch to On do not start the engine Connect a DC voltmeter across the main harness leads for the sole Figure 23 1 Main hydra
101. as goggles when using compressed air 6 Clean cartridge valve using clean mineral spirits Submerge valve in clean mineral spirits to flush out con tamination Use a probe to push the internal spool in and out 20 to 30 times to flush out contamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves Use compressed air for cleaning 7 Reinstall the cartridge valve A Lubricate new O rings and backup rings of seal kit with clean hydraulic oil and install The O ring and backup ring must be arranged properly on the cartridge valve for proper operation and sealing B Thread spool valve carefully into port The valve should go in easily without binding Note Use care when handling the cartridge valve Slight bending or distortion of the stem tube can cause binding and malfunction Greensmaster 3150 4 81 Torque cartridge valve using a deep socket to 35 ft Ib 47 Nm D Make sure a new O ringis at each end ofthe so lenoid coil Install solenoid coil to the cartridge valve Apply Loctite 242 or equivalent to the threads of the valve Torque nut to 15 in Ib 1 7 Nm E If problems still exist remove valve and clean again or replace valve Cartridge Relief Valves Fig 54 1 Make sure the manifold is clean before removing the cartridge valve and seal kit 2 Remove cartridge relief valve 3 Visually inspect port in the manifold for damage to the se
102. bedknife to bedbar Check and adjust as necessary Check before operating with cutting unit on ground Rotate the reel backwards by hand Turn adjusting kn ne 1 click at a time until first contact between reel an knife is felt or heard then tighten one 1 more click to get light contact No contact will dull the cutting edges Excessive contact accelerates wear Set to recommendations in chart on Page 10 14 Check and adjust as necessary All cutting units set at same height of cut Set with front roller must be equal at both ends of roller Bench set height of nd actual effective height of cut are dif ferent Effective height of cut depends on cutting unit weight cutting unit accessories and turf conditions 9 6 If bedknife is too thick for effective height of cut poor quality of cut will result Greensmaster 3150 Possible Problem Correction Make sure bedbar bolt plastic washers are snug against bedbar Bedbar must pivot without binding 11 Stability and position of bedbar Check bedbar end bushings and pivot bushings for wear or damage and replace if necessary Make sure proper bushings are installed in each location bedbar end bushings are different from pivot bushings Check adjustment knob to make sure detent holds ad justment Repair if necessary With adj knob pivot assembly removed pivot screws installed and frame on level surface
103. brake and move Functional Control Lever to NEUTRAL Try to depress traction pedal If the pedal does not depress the inter lock system is operating correctly Correct problem if not operating properly 2 Siton the seat engage parking brake keep traction pedal in neutral and place Functional Control Lever in MOW or TRANSPORT Try to startthe engine If the en gine does not crank the interlock system is operating correctly Correct problem if not operating properly 3 Siton the seat and start engine Move Functional Control Lever to MOW Raise off the seat If the engine stops the interlock system is operating correctly Cor rect problem if not operating properly 4 Siton the seat and start engine Move Functional Control Lever to TRANSPORT Raise off the seat If the engine stops the interlock system is operating correctly Correct problem if not operating properly 5 Sitonthe seat engage parking brake keep traction pedal in neutral and place Functional Control Lever in NEUTRAL Start the engine Move Raise Lower Mow Control Lever forward to lower the cutting units If the units do not start rotating the interlock system is operat ing correctly Correct problem if not operating properly 6 Sitonthe seat and set the parking brake Start the engine and move the functional control lever to MOW Ifthe engine stops the interlock system is operating cor rectly Correct problem if not operating properly Greensmaster
104. can cause binding and malfunction Make sure that deep well socket fully engages the valve base B Lubricate threads on cartridge valve with clean hydraulic oil Thread cartridge valve carefully into correct manifold port The valve should go in easily without binding C Torque cartridge valve using a deep well socket to specification shown in Figure 55 7 For solenoid valve slide solenoid coil onto the car tridge valve Install and torque nut to 60in Ib 6 7 N m 8 If problems still exist remove valve and clean again or replace valve Hydraulic System Rev E 2g SE 52 gt Rotary Cartridge Valves 1 Remove rotary handle from valve Fig 56 A Loosen two 2 set screws that secure handle cap B Remove screw and then lift handle cap from valve C Locate and retrieve detent pin compression spring bushing and lip seal The sleeve bearing should stay in the cap D Loosen two 2 set screws that secure handle base to flow control valve and remove base IMPORTANT Use care when removing the rotary cartridge valve Slight bending or distortion of the stem tube can cause binding and malfunction Make sure that deep well socket fully engages the valve base 2 Make sure manifold is clean before removing the rotary cartridge valve Remove cartridge valve from manifold with a deep well socket Note location of O rings and backup rings on valve Remove and discard removed seal kit 3 Visually i
105. control 11 Stress periods for turf high temperatures high hu midity unusually high traffic Groomer DPA Cutting Unit Rev A Page 10 1 4 Greensmaster 3150 Groomer Reel Mechanical Problems The groomer reel rotates when it is in the raised transport position No rotation of the groomer reel The turf is damaged or has uneven grooming Greensmaster 3150 The groomer reel should rotate whenever the cutting reel is en gaged Seized groomer reel or idler bear ing s in groomer side plate s Broken or damaged idler spring The groomer belt is worn broken or damaged The groomer reel blades are bent damaged or missing The groomer reel shaft is bent or damaged Grooming depth is not equal on both ends of groomer reel Page 10 1 5 Normal operation Identify and replace faulty bear ing s Replace spring If the belt slips it probably is worn and must be replaced Repair or replace belt if necessary A broken or worn belt could be the result of improper belt routing or seized bearings in groomer assem bly Repair or replace blades if neces sary Replace groomer reel shaft Adjust depth if necessary Check and adjust cutting unit set up level bedknife to reel level rear roller to reel set height of cut etc Groomer DPA Cutting Unit Rev A 5 D amp Adjustments Never work on the cutting unit with the engine running A
106. discharge area The grass baskets must be in place during operation of the reels or thatch ers for maximum safety Shutthe engine off before emp tying the baskets Greensmaster 3150 1 3 Rev 16 The GREENSMASTER 3150 has a maximum sound pressure level of 84 dB A at the operator s ear Ear protectors are recommended for prolonged expo sure to reduce the potential of permanent hearing dam age 17 Raise the cutting units when driving from one work area to another 18 Do not touch engine muffler or exhaust pipe while engine is running or soon after it is stopped because these areas could be hot enough to cause burns 19 If a cutting unit strikes a solid object or vibrates ab normally stop immediately turn engine off wait for all motion to stop and inspect for damage A damaged reel or bedknife must be repaired or replaced before opera tion is continued 20 Before getting off the seat A Make sure cutting units are disengaged B Verify that functional control lever is in neutral C Set the parking brake D Stop the engine and remove key from ignition switch 21 Traverse slopes carefully Do not start or stop sud denly when traveling uphill or downhill 22 Operator must be skilled and trained in how to drive on hillsides Avoid wet slopes 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 engi
107. each of the three 3 cutting units track straight with the traction unit A On a smooth level surface draw a straight line on the floor Fig 18b Push traction unit forward removing slack from pull arms so center of each front wheel is on top of the line Use a plumb bob or square to make sure each wheel is centered on the line B Measure from each end of cutting unit front roller to chalk line Distance from each end of roller to line must be equal within 3 16 0 187 in C Loosen jam nuts on pull arms and adjust ball sockets so distance from each end of roller to line is within 3 16 0 187 in NOTE If a cutting unit cannot be adjusted to track correctly with the traction unit the pull frame or lift arm is damaged and or the lift arm and pull frame bushings are worn and must be replaced 1 Jam nut 2 Pull arm Draw line on floor and center wheels over line Set Up and Adjustments Page 7 14 Figure 18a 3 Ball joint adjust for clearance 4 1 4 1 2 in 6 13 mm clearance Figure 18b Measure from each end of cutting unit front roller to line on floor Must be equal within 3 16 0 1867 in Greensmaster 3150 Repairs Cutting Unit Removal and Installation Remove cutting unit from traction unit before doing adjustments or repairs 1 Remove basket from pull frame 2 Loosen reel motor mounting nuts Fig 19 Rotate the motor clockwise so motor flanges clear studs and pull moto
108. if worn or damaged Bearing cones must be installed square to bearing housing make sure there is no flash paint or other foreign material in housing before installing new bearing cone Reel and or bedknife that has rounded edge cannot be corrected by tightening bedknife to reel contact Grind reel to remove taper cone shape and or rifling grooved ribbed appearance Grind bedknife to sharpen and or remove rifling Most common cause of rifling is bedknife to reel contact that is too tight NOTE New bedknife must be ground after installing on bedbar to match bedknife to bedbar Check and adjust as necessary Check before operating with cutting unit on ground Remove reel motor and rotate reel by hand Turn ad justing kn ne 1 cli time until first contact be tween reel and bedknife is felt or heard then tighten one 1 more click to get light contact No contact dulls cutting edges Excessive contact increases wear 7 Bedknife attitude rear roller bracket hole position 8 Rear roller parallel to reel 9 Height of cut Check and adjust as necessary Set to recommendations in chart on Page 9 12 All cutting units set at same height of cut Set with front roller must be equal at both ends of roller Bench set height of nd actual effective height of re dif ferent Effective height of cut depends on cutting unit 10 Proper bedknife for height of cu
109. in Figure 23b 3 Ball joint adjust for clearance 4 1 4 1 2 in clearance Greensmaster 3150 Repairs Cutting Unit Removal and Installation Remove cutting unit from traction unit before doing adjustments or repairs 1 Remove basket from pull frame 2 Loosen reel motor mounting nuts Fig 24 Rotate the motor clockwise so motor flanges clear studs and pull motor off of cutting unit Figure 24 1 Motor mount nuts 2 Motor shaft 3 Slide the sleeve back on the ball joint and disconnect the pull arm from each side of the cutting unit Fig 25 Figure 25 1 Slide back to mount 2 Ball stud 3 Swing up to remove down to install 4 Slide cutting unit out from under pull frame disengag ing the lift arm from the lift bail Fig 26 5 Reverse steps 1 4 to install the cutting unit Figure 26 1 Lift bail 3 Pull frame 2 Lift arm 4 Pull arm Greensmaster 3150 Page 9 21 Repairs Reel Lapping Check reel bearing adjustment and correct if necessary before backlapping Make sure bedknife is parallel to reel On groomer equipped cutting units backlap by using a length of 3 8 in square stock inserted into the center hole in the reel shaft on the reel drive motor end of the cutting unit Attach a socket extension and back lapping machine Backlap according to procedures in the Toro publication Sharpening Reel amp Rotary Mowers Form No 80 300 PT A
110. in place If a shield safety device or decal is defective il legible or damaged repair or replace it before operating the machine 5 Always wear substantial shoes Do not operate ma chine while wearing sandals tennis shoes or sneakers Do not wear loose fitting clothing which could get caught in moving parts and cause personal injury 6 Wearing safety glasses safety shoes long pants and a helmet is advisable and required by some local safety and insurance regulations 7 sure work area is clear of objects which might be picked up and thrown by the reels Safety Pagel 2 Rev WARNING reduce the potential for injury or death comply with the following safety instructions 8 Donotcarry passengers on the machine Keep ev eryone especially children and pets away from the areas of operation 9 Gasoline fuel is highly flammable handle it care fully A Store fuel in containers specifically designed for this purpose B Add fuel before starting the engine Never re move the cap of the fuel tank or add fuel while the engine is running or when the engine is hot C Refuel outdoors only and do not smoke while refuelling D Fill fuel tank to a level no higher than to the bot tom of fuel tank filler neck Do not overfill E Replace all fuel tanks and container caps se curely F Iffuelis spilled do not attempt start the engine but move the machine away from the area of spi
111. in the direction of travel 10 Use a soft face hammer to rotate each bearing housing slightly Install bolts from outside of housings and turn bolts alternately against side plate to remove bearing housings Fig 43 Bearing housings will slip out of side plates Reel can be removed as soon as bearing housings are disassembled from side plates Figure 41 1 Left side groomer housing 4 Flat head screws 2 Bearing adapter 5 Spacer 3 Reel bearing adjustment nut Repairs Page 9 26 Greensmaster 3150 11 If necessary install new bearings and seals A Remove bearing cup bearing cone and inner seal B Bearing housing must be completely free of paint and foreign material before installing bearing cup If necessary remove any flash from bearing housing that may interfere with accurate seating of bearing Install inner seal Install bearing cup C Install bearing housing to frame Pack bearing cone with grease and install over reel shaft into bear ng cup 12 After installing reel tighten spline nut to 40 60 ft Ib then adjust bearings See Reel Bearing Service and Adjustment in the Adjustments section of this chapter 13 Install right side groomer plate assembly and bearing adapter Use a stud installation 100 or double nuts to tighten two 2 special studs to 17 21 ft lb Make sure a spacer is installed over each stud between groomer bearing adapter and reel bearing housing Tighten two 2 inside locknuts to
112. injury or gangrene may result 30 Before disconnecting or performing any work on the hydraulic system all pressure in system must be re lieved by stopping engine and lowering cutting units and attachments to the ground 31 To reduce potential fire hazard keep the engine area free of excessive grease grass leaves and accu mulation of dirt Never wash a warm engine or electrical connections with water 32 Check all fuel lines for tightness and wear on a regu lar basis and tighten or repair as needed 33 If the engine must be running to perform a mainte nance adjustment keep hands feet clothing and any Safety and Instruction Decals Numerous safety and instruction decals are affixed to the traction unit and the cutting units of the Greensmas ter 3150 If any decal becomes illegible or damaged in Safety Pagel 4 other parts of the body away from the cutting units at tachments and any moving parts Keep everyone away 34 Do not overspeed the engine by changing governor settings To assure safety and accuracy have an Autho rized Toro Distributor check maximum engine speed with a tachometer Maximum governed engine speed should be 2850 50 RPM 35 Engine must be shut off before checking oil or ad ding oil to the crankcase 36 If major repairs are ever needed or if assistance is desired contact an Authorized Toro Distributor 37 Atthe time of manufacture the GREENSMASTER 3150 conformed to safety st
113. is against the bottom of the bore 7 Packthe cavity of the inner seal 13 with Mobil High Temperature HP or equivalent grease 8 Using inner grease seal installation washer Toro Part Number 104 0532 press the inner seal 13 into the side plate until the washer is flush with the outer edge of the side plate bore Remove the washer When properly installed the seal should be positioned 104 in 2 6 mm below the inner edge of the side plate bore 9 Press the outer seal 9 into the side plate until it is flush with the the outer edge of the side plate bore IMPORTANT The outer grease seal 9 should be installed so the lip is facing out This helps keep contamination from entering and allows grease to vent or purge out if necessary Fig 22 10 Fill remaining voids behind inner grease seal 13 and outer grease seal 9 lips with Mobil High Tempera ture HP or equivalent grease Greensmaster 3150 Reel Service Fig 18 Note Install new reel components on each end of the reel shaft that mates with newly serviced side plate com ponents 1 Remove the retaining ring 5 and the drive coupler 4 from the end of the reel shaft 2 Remove the V ring 3 from the reel shaft 3 Using a flat blade screw driver or similar tool re move the speedi sleeve 2 from the reel shaft Note Replacement Seal Kit Toro Part No 106 6937 is available for reel service of dual point adjust cutting units 4 Inspect the r
114. is in the raised position Raisethe groomer reel by rotating the right and left quick up levers so they face to the rear Fig 6 4 Make sure the groomer reel is disengaged Push the clutch snubber down and turn the clutch knob clockwise to disengage the clutch Fig 6 IMPORTANT When engaging or disengaging the clutch be sure to turn the knob all the way it will come to a firm stop Failure to do so could cause damage to the clutch 5 On each cutting unit loosen 2 flange nuts securing reel motor to cutting unit Twist motor clockwise to disengage from cutting unit and remove motor 6 Slowly rotate reel listening for reel to bedknife con tact If no contact is evident TURN BEDKNIFE ADJUST ING KNOB CLOCKWISE ONE 1 CLICK AT A TIME UNTIL FIRST CONTACT IS FELT AND HEARD THEN TIGHTEN ONE 1 MORE CLICK TO GET LIGHT CON TACT Fig 7 7 If contact is felt turn bedknife adjusting knob counterclockwise one 1 click at a time until no contact is evident Turn bedknife adjusting knob one 1 click at atime clockwise until first contact is felt and heard then tighten one 1 more click to get light contact 8 Install hydraulic motor to cutting unit IMPORTANT LIGHT CONTACT MUST BE MAIN TAINED AT ALL TIMES If light contact is not main tained bedknife and reel edges will not self sharpen sufficiently This will result in dull cutting edges after Greensmaster 3150 Page 9 11 a period of operation If ex
115. knob 17 counterclockwise so the arrow is 90 with the back of the manifold 27 Simultaneously tighten upper jam nut 18 and turn knob so itis tight and the arrow is pointing 45 to the right in line with the indicator plate 6 J On flow control cartridge valve 13 turn knob 17 counterclockwise until the arrow points at the number 5 Simultaneously tighten upper jam nut 18 andturn knob so 15 tight and the arrowis point ing at the number 1 on the locating plate 19 Hydraulic System Rev E 2g 3 5 52 gt Optional Backlap Kit Logic Cartridge Valves Fig 58 Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components 1 Remove logic cartridge valve 10 and seal kit 9 2 Visually inspect the port in the manifold 27 for damage to the sealing surfaces damaged threads and contamination 3 Visually inspect logic cartridge valve 10 for dam aged sealing surfaces and contamination A Contamination may cause valves to stick or hang up it can become lodged in small valve ori fices or seal areas causing malfunction B If sealing surfaces appear pitted or damaged the hydraulic system may be overheating or there may be water in the system Hydraulic System Rev E Page 4 88 A CAUTION Use eye protection such as goggles when using compressed air 4 Clean logic cartridge valve 10 usin
116. knob 2 Ballswitch 4 Hydraulic manifold 9 To make an adjustment to the cutting units while backlapping turn reels OFF by moving the RAISE LOWER MOW control to the RAISE position Shut off engine After the adjustments have been completed re peat steps 4 through 6 10 When the backlap operation is completed shut off engine and rotate directional valve knob counter clock wise fully 90 from the backlap position to forward posi tion Also rotate flow control valve knob to position 13 for height of cut settings of a 1 4 inch or below Note For additional settings refer to the instructions on the decal that is located on the underside of the seat support 11 Wash all lapping compound off the cutting units 12 For a better cutting edge run a file across the front face of the bedknife when the lapping operation is com pleted This will remove any burrs or rough edges that may have built up on the cutting edge Note Additional instructions and procedures on backlapping are available in the Toro General Service Training Book Reel Mower Basics part 09168501 Dual Point Adjust Cutting Units Bedbar Assembly 190 to 240 in Ibs A 211027 Nm Antiseize Lubricant Figure 12 1 Side plate 7T Bedbar pivot bolt 13 Cap screw 2 Rubber bushing 8 Flange nut 14 Rear roller assembly 3 Flange bushing 9 Flange nut 15 Lock nut 4 Washer plastic 10 Shim 16 Bedknife 5 Washer metal 11 Spacer 1
117. knob counterclockwise one 1 click at a time until no contact is evident Turn bedknife adjusting knob one 1 click at atime clockwise until first contact is felt and heard then tighten one 1 more click to get light contact 6 Install hydraulic motor to cutting unit IMPORTANT LIGHT CONTACT MUST BE MAIN TAINED AT ALL TIMES If light contact is not main tained bedknife and reel edges will not self sharpen sufficiently This will result in dull cutting edges after a period of operation If excessive contact is main tained bedknife reel wear will be accelerated Un even wear can result and quality of cut may be adversely affected NOTE As the reel blades continue to run against the bedknife a slight burr will appear on the front cutting Greensmaster 3150 Page 8 9 edge surface the full length of the bedknife If a file is occasionally run across the front edge to remove this burr improved cutting performance can be obtained NOTE After extended running notches will eventually develop at both ends of the bedknife These notches must be rounded off or filed flush with cutting edge of bedknife to assure smooth operation Figure 6a Tool adjustable knob 1 Bedknife adjusting knob 3 Pivot bar 2 Compression spring Figure 6b Hand adjustable knob 1 Bedknife adjusting knob 2 Compression spring Set Up and Adjustments 3 Locknut left hand thread Reel Bearing Service and Adjustment 1 First mak
118. mounting shim accordingly 3 Adjust the height of cut 4 Adjust the cut off bar See Cutting Unit Operator s Manual for adjustment pro cedures for the cutting units on the Greensmaster 3150 Greensmaster 3150 Page 10 7 Dual Point Adjust Cutting Units Service and Repairs Hydraulic Reel Motor IMPORTANT When performing maintenance pro cedures on the cutting units store the cutting unit reel motors in supporttubes on the frame to prevent damage to the hoses Do not raise suspension to transport position when the reel motors are in the holders in the traction unit frame Damage to the motors or hoses could result Removal 1 Park machine on a clean and level surface lower cutting units completely to the ground stop engine en gage parking brake and remove key from the ignition Switch 2 Remove basket from carrier frame 3 Loosen flange head screws that secure the hydrau lic motor to the motor adapter plate Rotate motor clock wise and remove motor 4 Place protective plastic cap see Special Tools into the hole in the motor adapter plate Inspection 1 Check reel drive coupler splines for wear Replace if necessary see Reel Removal and Installation in this chapter of this manual Installation 1 Coatspline shaft ofthe motor with clean No 2 multi purpose lithium base grease 2 Install the flange head screws for the reel drive mo tor into the motor adapter plate and leave approximately 1 2
119. of the hydraulic system acts essentially as a closed loop Taking its suction directly from the return side of the wheel motors of the traction circuit the hy drostat supplies oil flow to the wheel motors through the supply side of the traction circuit With the engine running and traction pedal in the neutral position the hydrostat supplies no flow to the wheel mo tors When the traction pedal is pressed to the forward position the linkage from the pedal positions the swash plate in the hydrostat so oil flows out the top port of the pump Oil flow out of the top port goes to the wheel mo tors and turns them in the forward direction Oil flowing out ofthe wheel motors returns to the bottom port ofthe hydrostat and is continuously pumped outthe top port Hydraulic oil is supplied to the traction circuit from the gear pump P2 though the steering control valve and backthrough the charge circuit check valves This oil re places oil losses from flow through the internal case drain internal bleed valve and small amounts of leak age Charge circuit pressure is maintained by the charge relief valve R4 that is attached to the hydrostat back plate Greensmaster 3150 Page 4 11 Reverse The traction circuit operates essentially the same in re verse as it does in the forward direction However the flow through the circuit is reversed With the engine running and traction pedal in the neutral position the hydrostat supplies n
120. ohm 5 Solenoid S6 8 1 ohm 3 Solenoid 53 7 2 ohm Serial Number Above 270000000 Shown Figure 11 1 Solenoid S1R1 7 1 ohm 3 Solenoid 53 7 1 ohm 2 Solenoid S2 8 6 ohm 4 Solenoid S4 8 6 ohm Greensmaster 3150 Seat Switch The seat switch is normally open and closes when the operator is on the seat If the Functional Control Lever is moved out of neutral neutral switch opens and the operator raises out of the seat the engine magneto will ground and the engine will stop The switch and its elec trical connector are located directly under the seat 1 sure the engine and ignition switch is Off Re move seat from the support assembly by removing four lock nuts from the seat bolts 2 Disconnect electrical connector from the seat switch 3 Check the continuity of the switch by connecting multimeter ohms setting across the connector termi nals 4 With nooperator in the seat there should be no con tinuity between the terminals 5 Press directly onto the seat switch through the seat cushion There should be continuity as the seat cushion approaches the bottom of its travel 6 Connectswitch electrical connector Reinstall seat Fuse Block Fuses can be removed to check continuity The test me ter should read less than 1 ohm Fuses supply power to the following Fig 13 1 The 20 amp fuse F1 supplies power to the run and mow relays 2 The 10 amp fuse F2 supplies power
121. pull frames and lift arms for damage binding or bushing wear Repair if necessary Roller condition Make sure rollers rotate freely Repair bearings as necessary See Roller Bearing Replacement in the Service and Repairs section in this chapter of this manual Cutting Unit drop speed and sequence Rear cutting unit must drop after front cutting units See Rear Lift Cylinder Flow Control Valve in Chapter 4 Hydraulic System in this manual Dual Point Adjust Cutting Units Page 10 6 Greensmaster 3150 Set and Adjustments Characteristics Never install or work on the cutting units or lift arms with the engine running Always stop en gine and remove key first The dual knob bedknife to reel adjustment system in corporated in this cutting unit simplifies the adjustment procedure needed to deliver optimum mowing perfor mance The precise adjustment possible with this de sign gives the necessary control to provide a continual self sharpening action This feature maintains sharp cutting edges assures good quality of cut and greatly reduces the need for routine backlapping In addition the rear roller positioning system allows for two height of cut ranges If a cutting unit is determined to be out of adjustment complete the following procedures in the specified order to adjust the cutting unit properly 1 Adjust the bedknife parallel to the reel 2 Determine desired height of cut range and install rear roller
122. repair ofthe engine used in the Greensmaster 3150 Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the Briggs amp Stratton Repair Manual for 4 Cycle V Twin Cylinder OHV Head Engi nes The use of some specialized test equipment is ex Engine Page 3 2 plained However the costofthe testequipmentand the specialized nature of some repairs may dictate that the work be done at an engine repair facility Service and repair parts for Briggs amp Stratton Vanguard V Twin OHV engines are supplied through your local Briggs and Stratton dealer or distributor If no parts list is available be sure to provide your distributor with the Toro model and serial number Greensmaster 3150 Specifications Item Description Make Designation Briggs and Stratton Vanguard V Twin OHV air cooled gas engine with cast iron cylinder sleeves Model 350447 Fuel Unleaded Regular Gasoline 85 Pump Octane Minimum Low Idle no load 1650 100 RPM High Idle no load 2850 50 RPM Engine Oil SAE 30 SG SH or SJ Crankcase Oil Capacity qt liters 1 75 1 65 with filter Greensmaster 3150 3 3 Engine Service and Repairs Fuel Tank ANTISEIZE LUBRICANT 20 to 25 ft Ib 27 to 34 Nm Figure 4 1 Fuel filter 8 Hose support clamp 14 Fuel hose shut off valve to filter 2 Hose clamp 9 Capscrew 15 Fuel shut off
123. retain ing ring 10 4 Make sure that wheel hub bore and wheel motor shaft are thoroughly cleaned Install key 13 to the hy draulic wheel motor 20 shaft Slide hub over shaft and key 5 Secure wheel hub 6 to motor shaft with lock nut 24 Torque nut from 250 to 400 ft Ib 339 to 542 Nm 6 Install rim 3 onto the wheel hub 6 Secure rim with lug nuts 1 to the wheel hub 7 drive studs Tighten lug nuts evenly in a crossing pattern to a torque from 70 to 90 ft Ib 95 to 122 Nm 7 Checkand adjust brakes see Brake Adjustment in the traction unit Operator s Manual Greensmaster 3150 TORO Table of Contents SPECIFICATIONS 2 SPECIAL 3 5 Factors Affecting Quality of Cut 5 SETUP AND 7 Adjustment Summary and Check List 7 Reel Bearing Service and Adjustment 8 Bedknife To Reel Adjustment 9 Leveling Rear Roller to Reel 10 Height 11 Front Roller Scraper Adjustment 12 Comb Adjustment 12 Greensmaster 3150 Page 7 1 Chapter 7 4 Bolt Adjust Cutting Units Shield Height Adjustment 13 Top Bar Cut Off Bar Adjustment 13 Pull Frame Adjustment 14 REPAIRS
124. ten 10 seconds to the prime pump Return ignition switch to off and wait one minute to allow starter to cool Repeat step a second time 8 Reconnect spark plug wires to spark plugs 9 Make sure traction pedal is in neutral and the cut ting unit switch is off Start engine and run it at low idle The charge pump should pick up oil and fill the hydraulic system If there is no indication of fill in thirty 30 sec ondas stop the engine and determine the cause Greensmaster 3150 Page 4 53 Be careful when operating the cutting unit reels Contact with the reel or other moving parts can result in personal injury 10 Afterthe hydraulic system starts to show signs of fill accomplish the following A If a reel motor was replaced or rebuilt run the cutting units at the minimum speed setting under no load for ten 10 minutes in both directions B reel motor drive pump was replaced or re built run the cutting units at the minimum speed set ting under no load for ten 10 minutes C Ifatraction pump or a wheel motor was replaced or rebuilt run the traction unit so the wheels slowly turn for ten 10 minutes 11 Operate the traction unit and cutting unit by gradual ly increasing their work load to full over a ten 10 minute period 12 Stop the machine Check reservoir and fill if neces sary Check hydraulic components for leaks and tighten any loose connections Hydraulic System Rev E 2g 3
125. the battery Tighten bolts with two wrenches 5 Secure battery retainer to the battery with the two wing nuts Do not overtighten to prevent cracking or dis torting the battery case Fig 28 6 Applyalight coat of grease on all battery posts and cable connectors to reduce corrosion after connections are made 7 Connecta digital multimeter setto amps between the negative battery post and the negative ground cable connector The reading should be less than O 1 amp Ifthe reading is 0 1 amp or more the unit s electri cal system should be tested and repaired 8 Connect the negative ground cable connector to the negative battery post Greensmaster 3150 Charging To minimize possible damage to the battery and allow the battery to be fully charged the slow charging meth od is presented here This charging method can be ac complished with a constant current battery charger which is available in most shops Follow the manufacturer s instructions when us ing a battery charger Note Using specific gravity of the battery cells is the most accurate method of determining battery condition 1 Determine the battery charge level from either its open specific gravity or circuit voltage Specific Level Gravity Voltage 1120 2 Determine the charging time and rate using the manufacturer s battery charger instructions or the following table Battery Reserve Capacity Minutes 80 or less 3 8hrs 7 5 hrs 11
126. the suction port on the gear pump Fig 33 9 Install gear pump to the hydrostat see Hydraulic Gear Pump Installation 10 Remove clamp from pump inlet hose 1 11 Installthe neutral system cable support assembly to the hydrostat with cap screws 6 Fig 32 Torque screws from 27 to 31 ft Ib 37 to 42 Nm 12 Position pump lever assembly onto the hydrostat camplate shaft and install the cap screw 1 and pivot washer 2 securing the pump lever assembly Fig 32 13 Connect the extension spring 1 and damper 2 to the spring bracket and the neutral arm Fig 31 14 Check neutral position of the traction pedal If ad justment is required see Adjust Transmission for Neu tral in the Traction Unit Owners Manual Greensmaster 3150 UO om gt N This page is intentionally blank Greensmaster 3150 Page 4 57 Hydraulic System Rev E Hydrostat Service REAR OF TRACTION UNIT Parts not listed in partlist are not serviced separately Figure 38 1 Key 18 Check valve 34 Shaft seal 2 Drive shaft 19 Dump valve 35 Retaining ring 3 Bearing 20 O ring 36 Retaining ring 4 Cap screw 21 Cap screw 37 O ring 5 Cover plate 22 Cap screw 38 O ring 6 O ring 23 Coupler 39 Seal kit 7 Shim kit for crush ring replacement 24 Roll pin 40 O ring 5 Kd cone 25 Cover plate 41 Charge relief housing y 26 Camplate insert 42 Charge relief poppet
127. to the cutting unit frame and secure with two shoulder nuts item 8 Greensmaster 3150 Page 10 1 9 Groomer DPA Cutting Unit Rev A 6 Apply grease to drive pulley splines and pulley hub taking care notto get grease on belt surface Slide drive pulley onto the reel shaft 7 Apply anti seize lubricant to threads of flange head screw item 4 used to attach drive pulley to reel shaft Secure drive pulley to reel with washer item 5 and flange head screw 8 Place square key item 31 in groomer shaft slot and install driven pulley onto the groomer shaft Thread flange nut item 17 onto the shaft threads 9 Secure groomer reel by holding the flange nut item 17 on one end of the reel and tightening the flange nut on the other end of groomer shaft Torque flange nuts from 100 to 120 in Ib 11 3 to 13 6 N m 10 Apply Loctite 242 or equivalent to threads of cap plug item 21 Install cap plug into non drive side plate and torque cap plug from 60 to 80 ft Ib 81 to 108 N m Fig 8 11 Insert front roller into non drive side groomer arm 12 Position drive side groomer arm to front roller groomer drive side plate and cutting unit frame Secure groomer arm to cutting unit with carriage bolt tab wash er and flange nut Groomer DPA Cutting Unit Rev A Page 10 1 10 13 Apply antisieze lubricant to threads of lift arm assem bly stud on groomer arm Install spring washer item 24 and lock nut item 25 to s
128. to the light test switch and the optional light circuit 3 The 10 amp fuse F3 supplies power to the engine fuel solenoid and the seat and parking brake interlock switches 4 The 10ampfuse F4 supplies power to leak detec tor solenoid and the joystick raise and lower switches Figure 12 1 Seatbolts 3 Seatswitch 2 Electrical connector Figure 13 Greensmaster 3150 5 11 Electrical System Neutral and Mow Switches The neutral and mow switches are normally open reed switches They close when the actuator comes in close proximity to the switch These switches are used to sense the Functional Control Lever in either the NEU TRAL or MOW position 1 Make sure the engine and ignition switch is Off Dis connect electrical connectors to both switches and move the functional control lever to TRANSPORT Check continuity of both switches by connecting a multi meter ohms setting across the connector terminals There should be no continuity across either switch 2 Place the Functional Control Leverinthe NEUTRAL position The NEUTRAL reed switch should have conti nuity and the MOW switch should be open Fig 14 3 Place the Functional Control Lever in the MOW position The NEUTRAL reed switch should be open and the MOW switch should have continuity Fig 14 4 Ifthe neutral mow switches do not satisfy any of the tests described in steps 1 2 or 3 adjustthe switches as follows A The dista
129. top of bedbar is grea seable Reel Speed 1940 rpm engine speed 2800 rpm Bedknife Screw Torque 200 to 250 in Ib Reel Splined Drive Nut Torque 40 to 60 ft Ibs Reel Bearing Rolling Torque 7 max Front or Rear Roller Run Out 0 014 in max 1 Lift bail 4 Pull rod studs 2 Height of cut adjustment knob 3 Height of cut adjustment locknut 6 Reel Greensmaster 3150 5 Grass shield Page 8 3 7 Heignt of cut brackets 2 8 Bedknife adjusting knob Specifications Special Tools NOTE Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PRODUCTS Some tools may be listed in the Greensmaster 3000 or 3000 D Parts Catalog Some tools may also be available from a local supplier McLube Aerosol or liquid lubricant Apply to bedbar pivot and bedbar pivot bolts Figure 1 Roller Bearing Replacement Tool Puller is used to remove bearings from front and rear rollers Driving tubes are used to install bearings into rollers Refer to instructions supplied with tool Used on swaged full and wiehle rollers Figure 2 Special Tools Page 8 4 Greensmaster 3150 Plastic Plug Insert plug in cutting unit bearing housing in place of reel motor when sharpening or grinding the reel V Figure 3 Handle Assembly For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel assembly Figure 4 Bedknif
130. valve S3 which directs flow to the lift cylinders Hydraulic pressure against the cylinder pistons moves their shafts causing the cutting units to lower At the same time the pistons push the hydraulic fluid out of the lift cylinders to energized solenoid valve S4 Flow continues back through solenoid valves S3 to the hydrostat Lower speed for the front cutting units is controlled by the 055 orifice A 025 orifice and adjustable flow control valve forthe center cutting unit allows a slight delay in lowering that cutting unit To control pressure while lowering the cutting units the system is equipped with adjustable relief valve R2 in the hydraulic manifold When solenoid valves S2 and S4 de energize spring action returns the valves to their original position and by passes flow back to the hydrostat stopping lift cylinder movement Hydraulic System Rev E 2g 3 5 52 gt LSLSOYCAH H IH 0982 0091 ANYA 042 002 aana
131. valve 3 Fuel hose filter to engine 10 Cap screw 16 Hose clamp 4 Fuelcap 11 Hose support clamp 17 Fuel hose tank to shut off valve 5 Fuel Tank 12 Vehicle frame 18 Hose clamp 6 Grommet 13 Not used 19 Spacer 7 Flatwasher Engine Page3 4 Greensmaster 3150 1 uel Tank Removal Fig 4 Park machine on a level surface lower cutting units stop the engine engage parking brake and remove the key from the ignition switch 2 2 A CAUTION The muffler and exhaust manifold may be hot Avoid possible burns allow exhaust system to cool before working on the engine Gasoline is flammable Use caution when storing or handling it Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running or in an enclosed area Always fill fuel tank out side and wipe up any spilled fuel before starting the engine Store fuel in a clean safety ap proved container and keep the cap in place Use gasoline for the engine only not for any other purpose Drain fuel tank 5 as follows A Close fuel shut off valve 15 B Disconnect fuel hose 14 at the fuel shut off valve and drain any fuel trapped in the fuel filter and fuel hose into a suitable container C Install one end of a spare length of fuel hose to the fuel shut off valve and place the other end of the hose into a suitable container for draining the tank D Drain fuel tank completely by opening the fuel shut off valve
132. 0 0 25 O ring Figure 9 Fitting Fitting Port Side Installation Torque Into Dash Size Thread Size Steel Port 7 16 20 15 to 19 ft Ib 21 to 25 N m 1 2 20 18 to 22 ft Ib 25 to 29 N m 9 16 18 34 to 42 ft Ib 47 to 56 N m 3 4 16 58 to 72 ft lb 79 to 97 N m 7 8 14 99 to 121 ft Ib 135 to 164 N m 1 1 16 12 134 to 164 ft lb 182 to 222 N m 1 3 16 12 160 to 196 ft lb 217 to 265 N m 1 5 16 12 202 to 248 ft Ib 274 to 336 N m 15 8 12 247 to 303 ft Ib 335 to 410 N m Figure 10 Greensmaster 3150 Page4 5 Installation Torque Into Aluminum Port 9 to 11 ft lb 13 to 15 N m 11 to 15 ft lb 15 to 20 N m 20 to 26 ft Ib 28 to 35 N m 35 to 43 ft Ib 48 to 58 N m 60 to 74 ft Ib 82 to 100 N m 81 to 99 ft Ib 110 to 134 N m 96 to 118 ft Ib 1831 to 160 N m 121 to 149 ft Ib 165 to 202 N m 149 to 183 ft Ib 202 to 248 N m Hydraulic System Rev E Hydraulic System Adjustable Fitting Fig 11 1 Make sure all threads and sealing surfaces of fitting and component port are free of burrs nicks scratches or any foreign material 2 Asapreventative measure against leakage it is rec ommended that the O ring be replaced any time the connection is opened Lock Nut 3 Lightly lubricate the O ring with clean hydraulic oil Fitting threads should be clean with no lubricant applied 2 Back up Washer 4 Turn back the lock nut as far as possible Make sure SK the back up washe
133. 0000 20 to 24 ft Ib 27 to 33 N m Figure 66 1 Plug 11 Thrust washer 21 Inner gearwheel 2 Plug 12 Bearing 22 End cover 3 Spring 13 Cross pin 23 O ring 5 used 4 Relief valve 14 Ring 24 Cap screw 5 used 5 Dustseal 15 Sleeve 25 Spring set 6 T port 16 Spool 26 Ball stop 7 Housing 17 Cardan shaft 27 Ball 8 R port 18 O ring 28 P port 9 E port 19 Distribution plate 29 L port 10 Shaft seal 20 Outer gearwheel NOTE For service of the steering control valve shown in Figure 66 see the Sauer Danfoss Steering Unit Type OSPM Service Manual at the end of this chapter Hydraulic System Rev E Page 4 94 Greensmaster 3150 This page is intentionally blank Greensmaster 3150 Page 4 95 Hydraulic System Rev E Steering Cylinder Steering cylinder 90 hydraulic fitting O ring O ring Hose assembly Hose assembly Cotter pin Slotted hex nut Washer 10 Bearing cup 11 Bearing cone 12 J am nut 13 Rod end 14 Grease fitting PONT Hydraulic System Rev E Figure 67 Dust seal Slotted hex nut Spacer Cotter pin Lug nut Valve stem Tire Rim Spacer Seal Bearing cone Bearing cup Hub Page 4 96 Drive stud Grease fitting Castor fork Cap screw Lock nut Adapter plate Lock nut Lock nut Motor plate Castor bolt Cap screw Lock nut Flat washer Greensmaster 3150 Removal Fig 71
134. 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 2332 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 7 938 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 12 05000 12 700 1 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre
135. 17 Bracket 27 Set screw 7 Bearing tab 18 Flat washer 28 Wheel assembly 8 Lock nut 19 Hose assembly 29 Lock nut 9 Bearing flangette lube 20 Tube assembly 30 Lug nut 10 Bearing 21 Clamp 31 Grease fitting 11 Bearing flangette Hydraulic System Rev E Page 4 62 Greensmaster 3150 Rear Wheel Motor Optional 3WD Removal Fig 37 1 Before removing any parts from the hydraulic sys tem park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components 2 Chock both front wheels to prevent the machine from moving Lift rear wheel off the ground using a jack and place blocks beneath the frame Secure the rear wheel off the ground 3 Labelhoses for reassembly Remove both hose as semblies 4 and O rings 23 from the hydraulic fittings at the hydraulic motor and hub assembly 14 Allow hoses to drain into a suitable container Supportwheel and motor and hub assembly dur ing removal to prevent dropping and causing personal injury 4 Remove wheel 28 and hydraulic motor and hub assembly from the castor fork 6 as follows A Remove cap screws 12 and lock nuts 8 se curing flangettes 9 and 11 and bearing tab 8 B Remove both socket head screws 16 flat washers 18 and lock nuts 29 C Lower wheel and hydrauli
136. 2 O ring 6 Pin 15 O ring 23 Relief valve R5 7 Sleeve 16 Spacer 24 Quad seal 8 Centering springs spacers 17 Geroter drive 25 Ring 9 Cap screw Disassembly NOTE Cleanliness is extremely important when repairing hydraulic components Work in a clean area Before disassembly drain the oil then plug the ports and thoroughly clean the exterior During repairs always protect machined surfaces 1 Remove the seven cap screws from the steering valve assembly 2 Remove end cap geroter spacer geroter drive wear plate seal ring and O rings from housing Fig 64 3 Remove the plug and relief valve Hydraulic System Rev E Page 4 92 4 Slide the spool and sleeve assembly from the hous ing 5 Remove the thrust bearing and bearing races 2 6 Remove the quad seal 7 Use a small blade screwdriver to carefully pry the dust seal from the housing Be careful to not damage the dust seal seat in the housing 8 Remove the pin that holds the spool and sleeve to gether Greensmaster 3150 9 Carefully slide the spool out of the sleeve cen tering springs and spring retaining ring will stay with the spool as it is removed A CAUTION The centering springs are under tension Re move the retaining ring carefully 10 Remove the spring retaining ring and centering springs from the spool Reassembly Check all mating surfaces Replace any parts with scratches or burrs that could cause leaka
137. 25 O ring 5 Washer 16 Cap screw 26 O ring 6 Castor fork 17 Bracket 27 Set screw 7 Bearing tab 18 Flat washer 28 Wheel assembly 8 Lock nut 19 Hose assembly 29 Lock nut 9 Bearing flangette lube 20 Tube assembly 30 Lug nut 10 Bearing 21 Clamp 31 Grease fitting 11 Bearing flangette Wheels and Brakes Page6 6 Greensmaster 3150 Removal Fig 4 1 Park machine on a level surface Make sure engine is off Set brake and block front wheels 2 Jack up and secure the rear wheel off the ground Support wheel 28 and motor and hub assembly 14 to prevent dropping them and causing per sonal injury while removing cap screws 12 and socket head screws 16 3 Remove wheel 28 and hydraulic motor and hub assembly 14 from the castor fork 6 as follows A Remove cap screws 12 lock nuts 8 and 29 and flat washer 18 securing flangettes 9 and 11 and bearing tab 7 B Remove both socket head screws 16 and lock nuts 13 securing the hydraulic motor and hub as sembly to the castor fork C Lower wheel and hydraulic motor and hub as sembly from the castor fork 4 Loosen set screws 27 on bearing 10 Pull flan gettes 9 and 11 and bearing from the hydraulic motor shaft 5 Remove grease fitting 31 from the hydraulic motor and hub assembly 14 Remove four lug nuts 30 and wheel 28 from the hub drive studs 6 If damage to the castor fork bearings is suspected remove the castor
138. 3 This diode prevents currentflow to solenoid S3 when so lenoids S2 and S4 are energized through lower relay R6 Testing The diodes can be individually tested using a digital multimeter ohms setting and the table to the right DIODE CIRCUIT BOARD DIODE CIRCUIT BOARD D1 C ByCyOyeE Figure 25 PLUG IN DIODE 1 A 2 D1 A x D1 B D1 C D1 D b Greensmaster 3150 Page 5 17 Figure 26 Figure 27 Electrical System Service and Repairs Verify Interlock System Operation The interlock switches are for the operator s protection do not disconnect them Check the operation of the switches daily to assure the in terlock system is operating If a switch is defec tive replace it before operating the machine The purposes of the interlock switches are to A Preventthe engine from cranking or starting un less the Functional Control Lever is in NEUTRAL B Prevent operating the traction pedal with the Functional Control Lever in NEUTRAL C Shutoffthe engine ifthe operator leavesthe seat without the Functional Control Lever in NEUTRAL D Shut off the reels ifthe Functional Control Lever is moved to NEUTRAL or TRANSPORT Electrical System 5 18 Rev D 1 Sit on the seat engage parking
139. 3 y 4 OPTIONAL REAR WHEEL 3WD MOTOR a lt FROM GEAR PUMP P2 BLEED 200 250 VALVE PSI X 4 amp 4 High Pressure Low Pressure TO HYDRAULIC HYDROSTAT Return or Suction RESERVOIR Flow Hydraulic System Rev E Page 4 30 Greensmaster 3150 Procedure for Traction Drive Hydrostat P3 Flow Test This test measures hydrostat pump output flow Dur ing this test pump load is created atthe flowmeter using the adjustable load valve on the tester 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off Make sure the hydraulic tank is full A CAUTION Before continuing further read and become fa miliar with Precautions for Hydraulic Testing 3 Make sure the transmission is adjusted to the neu tral position see the Traction Unit Operator s manual 4 Block up front wheels off the ground also rear wheel if machine is equipped with 3WD to allow flow through the traction circuit 5 Disconnect hydraulic hose from the hydraulic tube that connects to the upper hydraulic fitting on the front side of the hydrostat F ig 23 6 Install tester in series with the pump and the discon nected hose
140. 33HM NOILOVHL 1VNOILdO 1806 OLOW 01108 FES OS NR SW 10d 1231 01108 5840104 133HM NO LIVYL MO lt uonongjo y einsseJg pezibueue ep se UMOUS SPIOUZ OS IUO Iv uonisod pezifeue ui UMOUS pue zs spiousjos 0000000 2 1equunwN eues MOIA 0612 Je1seuisueaur Qe maps 7 aaziou3N3 818 Sieh VI III Ie oss a aka 2 J gt 747 1 wwo 0 0 331003 u Greensmaster 3150 4 18 Hydraulic System Rev E Mow and Backlap Serial Number Above 270000000 The gear pump P1 is directly coupled to the hydrostat which is driven directly by the engine Taking its suction directly from the hydraulic reservoir the gear pump P1 supplies oil flow to the hydraulic manifold block and to the cutting reel motors Maximum circuit pressure is lim ited by solenoid relief valve S1R1 which is located in the hydraulic manifold With the engine running and the Functional Control and Raise Lower Mow levers positioned so the reels will not turn see Operator s Manual solenoid relief valve S1R1 in the hydraulic manifold is de energized The de energi
141. 4 9 ung 9 vel Lo 1 F 1 57 pou eol 1334 v ANIA dOL E WOLLO pid aNvHa3MOT 2 an ae H 30 H Aj gt 5 ISd 4 T ia Xx 58 H3MO1 Ss 50 81 HOLON 133HM S3ATVA NOLLOVH L SH3aNnao 131 dy ova Lau TIVNOLLdO _ vs VIN dv ova 21343 9696 ONY 0002 031V1021V 3LYY M01 1HOd 7 1 VIN 2 5 060 z CH lH9IH WOLLO8 E L 001 3 4 1HOd zn v 5 H 006 2 INOS x 99 0072 d E La n E an Ee val tH 1 SHOLOW 133HM NOILOVHL E 5 074 EL CW zy 070 Hn m IW 1HOd vss vu 12 INOUS sem Se UMOUS 5 5 93 L E s uH p L080000 z 1 jequinN Sava su LNINOAdWO 2 Jiva Moli 28055244 10 gt 5 380553844 ONY ILYA MON ININ3IVIdSIO SHOLON 13934 0912 Hydraulic System Rev E 4 7 Greensmaster 3150
142. 5 gt BLUE BLACK ORANGE BLACK WHITE BLACK VIOLET BLACK VIOLET SPs VIOLET PINK BLACK BLUE RED BLUE RED 16 L VIOLET BLACK 5 ORANGE BLACK GREEN RED BLACK x E BLACK gt x L GREEN BLACK 3 GREEN BLACK 59 zi WHITE BLUE E 1 GRAY BLACK c BLACK x BLUE BLACK 0 es 4 BLACK 8 a BLUE BLACK F BLACK WHITE BLUE WHITE BLUE 5 SP7 5 ay 16 A gt PINK BLUE 4 BLACK SP13 SP10 WHITE 8 A E sns BLACK 3 8 BLACK BLACK a BLACK 5 5 FUSIBLE LINK Se 42 9 SPI 5 a 20 a a PIs B BLACK YELLOW WHITE BLUE E VIOLET RED 2 PINK WHITE m ORANGE BLACK 5 ORANGE H YELLOW 6 YELLOW SHOP 1 GREEN 8 BLUE BLUE BLACK 8 WHITE Y BLUE YELLOW sis GRAY GRAY WHITE 5 Sams 5 w ha IH cm a m m a g 2 1 1 A B CD 1 2 7 P34 J9 P26 P36 Pee P23 P24 P25 INTERCONNECT 3 OPTIONAL LIGHT 2 TEST LIGHT SWITCH OPTIONAL LIGHT INTERCONNECT 1 INTERCONNECT 2 LEAK DETECTOR SOL ALARM TIME DELAY ALARM LEAK DETECTOR IGNITION SWITCH P30 d SEAT HARNESS 2 lt a o LOWER GRAY BLACK 2 3 PB DIODE 2 x 5 JOYSTICK a w DIODE 3 x 9 2 a ul BLUE RAISE 5 GREEN GRAY 2 3
143. 7 Bedknife screw 6 Bedbar 12 Retainer Dual Point Adjust Cutting Units Page 10 10 Greensmaster 3150 Bedbar Removal and Installation Removal Fig 12 1 Position machine on a clean and level surface low er cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove the basket from the cutting unit carrier frame 3 Disconnect the drive motor from the cutting unit 4 Disconnect the cutting unit from the pull link 5 Unhook the cutting unit from the lift arm and slide the cutting unit out from under the carrier frame 6 Loosen the two lock nuts 15 on the end of each bedbar adjuster assembly 7 Loosen the two flange nuts 8 on each bedbar pivot bolt 7 8 Remove the two bedbar pivot bolts 7 and each of the washers 4 and 5 from the outside of the cutting unit side plates 9 Remove the bedbar 6 and each of the washers 4 and 5 from the inside of the cutting unit side plates 10 Inspect flange bushings 3 and remove if necessa ry 11 Inspect rubber bushings 2 and remove if necessa ry Installation Fig 12 1 If either rubber bushing 2 was removed from the side plate install a new bushing The bushing should be installed flush with the inside of the side plate Fig 13 2 Install the flange bushings 3 with flange facing out ward 3 Thread the flange nuts 8 all the way up to the head of each bedbar pivot bolt 7 and apply antiseize
144. 7 to the cutting reel shaft Slide drive pulley from cutting reel 11 Remove two shoulder nuts item 8 that secure the groomer drive side plate item 10 to the cutting unit frame Remove the groomer drive side plate assembly 12 Remove the cap plug item 21 from non drive side plate Fig 8 18 Remove the flange nut that secures the groomer shaft to the non drive side plate Figure 8 14 Pull the groomer reel from the non drive side plate u 15 Inspect seals bushings and bearings in side plates for wear or damage Replace components as needed Installation 1 Park machine on a clean and level surface lower cutting units completely to the ground stop engine en gage parking brake and remove key from the ignition switch 2 Apply a light coating of grease to seal lips in RH and LH side plates Make sure that seals bushings and bearings are properly positioned in side plates 3 Carefully place groomer reel assembly into the non Figure 9 drive side plate bearings taking care notto damage seal 1 Drive side plate 3 Driven pulley in side plate Thread flange nut item 17 onto the shaft 2 Drive pulley threads but do not tighten 4 Make sure that groomer shim item 11 is installed on groomer drive side of cutting unit 5 D amp 5 Carefully place drive side plate onto groomer shaft taking care not to damage seals in side plate Position side plate
145. 9 BU BK K LOWER 2 F MOW SWITCH Se enl 9 ere STOP NONE T RS D1 C ENGINE S RUN and X Y me K3 c START 1 5 tes ees __ _ 2 8 Y 1 8 BU 22 52 DC L 4 4 ew ee 1 92 2538 GN GY Y L ons gt J J L KILL RELAY K1 J M 71 ES ES T LG MEE 2 9 1 6 SECOND 1 W wi DELAY OFF 30 FUSIBLEUNK 187a _____ 99 7430 C REM LN mou t 8510111786 t FUEL SOLENOID 1 f 1 TET UL P Y SIT UU Uti e RI pese Lazy EN Y ET WEK 54 Ta Ei a REELS LOWER LOWER RELAY 5 LC VIO BK frm RAISE LOWER D3 BU R frm 99 7430 56 EA ORIFICE 1 S cH BU R mm 1 S3 __ onov esr REELS RAISE BI FRAME GND K ENGINE GND REGULATOR pr FUSIBLE LINK SP w START
146. Adjustment Adjust shield to get proper grass clipping discharge into basket 1 Set cutting unit in normal cutting position and measure distance from top of front crossbar to shield at each end of cutting unit Fig 20 2 Height of shield from crossbar for normal cutting conditions should be 4 3 4 inches Loosen capscrews and nuts securing shield to each side plate adjust shield to correct height and tighten fasteners Fig 20 3 Repeat adjustment on remaining cutting units and adjust top bar See Adjusting Top Bar in this section of the book Figure 20 NOTE Shield can be lowered in dry grass conditions clippings fall over top of baskets or raised to allow for 1 Shield 3 4 3 4 inches heavy wet grass conditions clippings build up on rear 2 Front crossbar 4 Shield fasteners edge of baskets Set Up and Adjustments Page 9 18 Greensmaster 3150 Greensmaster 3150 Cut Bar Adjustment Adjust top bar to make sure clippings are cleanly dis _ charged from reel area 1 Loosen screws securing top bar Fig 21 Insert 0 060 inch feeler gauge between top of reel and bar and tighten screws Make sure bar and reel are equal distance apart across complete reel 2 Repeat settings on remaining cutting units NOTE Bar is adjustable to compensate for changes in turf conditions Bar should be adjusted closer to reel whenturf is extremely wet By contrast adjust bar further away from reel when tu
147. Adjustment Bedknife adjusts against reel with positive adjustment control knob lo cated at center of bedbar Adjustment knob contains detent with 001 in movement of bedknife for each in dexed position Groomer Reel Depth 0 18 in max below height of cut 7 ON Sey Rz Lift bail Height of cut adjustment knob 2 Height of cut adjustment locknut 2 Pull rod studs 2 Reel Greensmaster 3150 Grass shield Groomer micro adjust locknut 2 Bedknife adjusting knob 9 3 Groomer Reel Raised Height 5 16 0 312 in from grooming reel height depth adjustment Reel Speed 1940 rpm engine speed 2800 rpm Groomer Reel Speed 3200 rpm Bedknife Screw Torque 200 to 250 in Ib Reel Splined Drive Nut Torque 40 to 60 ft Ibs Reel Bearing Rolling Torque 7 max Front or Rear Roller Run Out 0 014 in max Groomer Reel Drive Belt Tension 1 4 in deflection when a force of 5 10 Ib is applied midway between drive pulley and driven pulley Clutch Adapter Torque 170 to 210 in Ib Clutch Assembly Locknut Torque 140 in Ib remov ing all end play 9 Groomer reel 10 Groomer clutch snubber 11 Clutch engage disengage knob 12 Groomer quick up down lever Specifications Special Tools NOTE Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PRODUCTS Some tools may be listed in the Greensmaster 3000 or 3000 D Parts Cata
148. BACKLAP RELAY K7 rU 26 BF3 10 36 B 36 C 01 OR BK 87a REEL ENGAGE MOW RELAY K4 SEAT SWITCH PARKING BRAKE BK 26 C F4 10A OCCUPIED OFF POSITION sae BK B Vic GN BK 36 E 87a gt 01 JOYSTICK OR BK BU BK E FRAME GND LOWER dun 85 86 MOW SWITCH 3e H 1 n GN BK JOYSTICK RELAY K3 Z 2428 C D1 C 5 128 STOP NONE B A Sieg EE SRM 2 o RUN XaY tS LY 36 D RAE 71 X ug START B l S SNEK GY BK 1 lt gu o BEGUPATOR Eu L E GNIGY Y OR BK ENT FUSIBLE LINK 11 1 1 ONES 1 emanal SE 86 85 9 6 SEC DELAY OFF BK 4 MAGNETO n 87 GE ENGINE GND A 25 878 30 4 Soe yee KILL RELAY K1 85 86 BK EYEL SOLENOID y ENERGIZED v Y 0 87 94 30 ENGINE 878 REELS LOWER BK LOWER RELAY K5 RAISE RELAY K6 ENERGIZED D2 D3 52 RAISE LOWER ENERGIZED 53 REELS RAISE ENERGIZED Page 11 15 Rev E LEAK DETECTOR Greensmaster 3150
149. BE 87al REEL B 2o pop 26 2 00 EOBBC Joe RR ENGAGE io s v MOW RELAY K4 caa ihe 1 B SEAT PARKING BK 1 BK 12 4c F410A SWITCH BRAKE GN BK oe GN ON POSITION L 1 y ER 99 7430 X Parda eaaa ee ee M 2 E 1146 p D1 D E 8 Ce me JOYSTICK TES Z gt BU BK 88 9830 LOWER 2 F MOW SWITCH D Y GYIBK m TE REER 1 JOYSTICK 4 TOP NONE 3 FRAME ENGINE Bl AE pis Sw GN BK RELAY K3 Y GROUND GROUND f 5 START 1 5 ii BU o lt 2 QR 5e This BK Y BK GN BK oY 92 2538 GN GY Y OR BK 42 3 KILL RELAY K1 UU 1 2 8 6 SECOND g ENGINE w 57 i PK BK DELAY OFF MAGNETO vi Lr D FUSIBLE LINK ____ ALTERNATOR 27 w 99 7430 299 7480 5 SP 850786 FUEL SOLENOID Y L4 W BK Y M Y 54 30 ONE eai REELS LOWER LOWER RELAY K5 1 A 2 VIO BK 2 RAISE LOWER D3 pi BU R MM 99 7430 1 A 2 B s6 ORIFICE 30 LE Y EAS 1 T BUR 53 anay EMM ee REELS RAISE 4 RAISE RELAY K6 BIS BK 11 4 Greensmaster 3150 Electrical Schematic LENK TEETAR Serial Number 260000001 To 260999999
150. DETAILED ADJUSTMENT INSTRUCTIONS FOLLOW THIS SUMMARY AND CHECK LIST Study this informa tion and refer to it often to get maximum life and perfor mance from the cutting units Daily Performance Checks NOTE It is not necessary to remove the cutting units from the traction unit to perform these daily checks It is recommended that mowers be washed after each use Always remove key from ignition switch when working on the machine 1 Purge all water and debris from all of the bearings by greasing them Use No 2 multi purpose lithium base grease 2 Visually check for sharp reel and bedknife Remove burrs nicks and rounded edges 3 Lower cutting units to ground setting on both rollers and remove reel motor Rotate the reel by hand TURN ADJUSTING KNOB ONE 1 CLICK AT A TIME UNTIL FIRST CONTACT BETWEEN REEL AND BEDKNIFE IS FELT AND HEARD THEN TIGHTEN ONE 1 MORE CLICK TO GET LIGHT CONTACT Nocontact will dull the cutting edges Excessive contact accelerates wear quality of cut may be adversely affected tis best to make the reel to bedknife adjustment in the morning immediately before each day of mowing Weekly Checks 1 Check reel bearing adjustment and bearing condition 2 Make sure bed bar bolt plastic washers are SNUG against the bedbar 3 Make sure bedknife adjustment knob pivot assembly is held FIRMLY in place between frame supports 4 Using a gauge bar verify the correct height of cut se
151. E LIGHTS LIGHT TEST SW BK OPTIONAL 2 EUSIBEE LNK aum d uu a aa a f awe cp 1 87 PK BU PKU 30 ar T 25 5 a m 55 se L SAA W BU Enn Bux cn NEUTRAL SWITCH M START SAFETY K2 30 STARTER SOLENOID GN NOT IN NEUTRAL H K2 87 55 UN ka Aere RUE D1 A S BACKLAP RELAY ONR 1 26 BF3 10 36 B 36 C 91 8 OR BK is 87a REEL Nae Setar ENERGIZED en a BK Y MOW RELAY K4 SEAT SWITCH PARKING BRAKE ENERGIZED F4 10A OCCUPIED BK 26 C OFF POSITION BU BK GN BK umen 1 i 87 i 471 D1 D JOYSTICK 36 E OR BK o a BU BK K FRAME GND ENGINE GND LOWER PU NA MOW SWITCH D E se OR 4 1 ON POSITION F D 1 193 GN BK JOYSTICK RELAY K3 he E ENERGIZED _ E ol 5 D1 C 8 39 MET Eee TERI PE M 1 oN RUN X Y S Y 36 D L BK m g START 5 EM 4155 iu 5 REGULATOR L P LA OR BK FUSIBLE LINK 71 pW Eugene 52028 86 4454 85 6 SEC DELAY OFF 4 MAGNETO S y 87 ENGINE GND 87 90 34 B
152. EGABELACON AHYDRAULIC OIL LEAK 4 HR METER a 2 ve TO THE LIGHTS STARTER BU z 3 OPTIONAL 1 F2 10A 124 2 8 Sec T 5 56 w TO THE LIGHTS LIGHT TEST SW BK OPTIONAL 42 ll FUSIBLE LINK R 1 9 h h 30 87a T ix He pm VIO TE 7 BK E 85 86 w ee W BU 85 rri 86 oul NEUTRAL SWITCH CAST ABE Gy STARTER SOLENOID H START SAFETY K2 BACKLAP 99 87a 85 86 pcm IGN SWITCH Y B a G SWITCH lea RR OFERUNSTAR pi A K BACKLAP RELAY K7 Heier GNR TT 26 A B 26 10 36 B 36 C DIB 87a REEL ENGAGE PK J Y o w Y MOW RELAY K4 mm SEAT SWITCH PARKING BRAKE un C F4 x 26 POSITION BU BK Ace BU 5 GN BK f oy 4 2 yi 36 87a SEE yle 971 D1 D JOYSTICK OR BK o BU BK K E FRAMEGND fm LOWER ENGINE GND Mm GY BK 85 MMN 86 MOW SWITCH 1 i Tes 36 F JOYSTICK RELAY Ks 08 GN BK Y poate C D1 C bm i vx 8 STOP NONE BU dere o RUN X Y m y 36 RAISE a GY BK BK m START B l S D GNIBK 1 Sr wo REGULATOR GN GY Y OR BK 2 ITI 77 5 BK i KILL RELAY K1 BK IE LINK 34 C p 4 1 i w Le SP 86 es 26 0 6 DELAY OFF BK 4 MAGNETO ud 87 1 BK 1 iin ENGINE GND c X m 87a 50 x TA riae crm 85 ULL 86
153. ER R ENERGIZED FUSIBLE LINK LEAK DETECTOR Greensmaster 3150 rei 22 ro 4 MAGNETO ENGINE GND FUEL SOLENOID Bete 34 RAISE RELAY K6 SOLENOID T Crank Circuits BU BK i s5 8 Serial Number Above 270000000 Shown Power Current w Control Current Indication Current BU BU Gy LEAK DETECTOR CLOSED WHEN THERE 15 _ ASEC DELAY ON A HYDRAULIC OIL LEAK HR METER 50 2 se TO THE LIGHTS BU z 3 OPTIONAL 1 F2 10A 24 a PRI i aan a w TO THE LIGHTS Bic LIGHT TEST SW BK OPTIONAL 42 87 _ 5784 age es PKBU PK BU bw 6 ea aM 85 86 i L n NEUTRAL SWITCH e START SAFETY w l BACKLAP SY Tao UMS IGN SWITCH V IN NEUTRAL 1 ENERGIZED 85 86 ON SNITCH P aua m4 OFFRUNSTAR 1 T orn Si i 26 BF3 10 36 36 C L 87a REEL ENGAGE nml w D1 B Y MOW RELAY SEAT SWITCH PARKING BRAKE L D 26 C F4 10A UNOCCUPIED ON POSITION BK BUI 1
154. GHT TEST SWITCH y OPTIONAL FUSIBLE LINK VIO Le th oh BU 99 7430 284210 2878 j4 BACKLAP RELAY K7 BK PK BU PK BU er wo J E 85 UW e C 9 P m Weu 85 86 m oo 99 7430 eb NEUTRAL 522 525 0 ORBE a 871 931 IGNITION SWITCH SWITCH H START SARETY K2 BACKLAP BK SOLENOID c Y V DIA B SWITCH 99 7430 OFF RUN START E N OPTIONAL BUK 30 51 Y F3 10A oa id DIB dm 87a 5 RBK ff TE ENGAGE 2 1 2274 vs v RELAY K4 1 SEAT PARKING BK 1 BK 2 ae F4 10A SWITCH BRAKE GN BK i GN 1 ON POSITION o VIO 99 7430 ae la ae 87 w 2 E 075 01 0 us JOYSTICK EX ORIBK BU BK d Tr MEE LOWER 2 F MOW SWITCH D 88 9830 GY BK 85rrrm a ii fia te Nd F 1 JOYSTICK STOP NONE 3 GN BK FRAME ENGINE RUN B l A and X Y RELAY D1 C zh GROUND GROUND START B l S NC BU Q Ix 2 D K RAISE GY BK GN BK 92 2538 GN GY Y OR BK 42 E KILL RELAY K1 rre rer cA 1 21 86 BK ENGINE MN 8 2G 6 SECOND w PK BK DELAY OFF 7 MAGNETO vio FUSIBLE LINK j 99 7430 ALTERNATOR 99 7430 mA M Tar E SP 85 UW ge BK FUEL SOLENOID Y W BK fm X Y 1 30 M S4 TANE D2 REELS LOWER RELAY K5 LOWER 1 A 2 B VIO BK MMM s2 R RAISE LOWER 80
155. Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance Page 2 2 Greensmaster 3150 Torque Specifications Recommended fastener torque values are listed in the following tables For critical applications as determined by Toro either the recommended torque or a torque that is unique to the application is clearly identified and spe cified in this Service Manual These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of a thread sealant Loctite degree of lubrication on the fastener presence of a prevailing torque feature hard ness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Identification 59 Grade 1 Grad
156. Insert 0 060 inch feeler gauge between top of reel and bar and tighten screws Fig 17 Make sure bar and reel are equal distance apart across complete reel 2 Repeat settings on remaining cutting units NOTE Bar is adjustable to compensate for changes in turf conditions Bar should be adjusted closer to reel when turf is extremely wet By contrast adjust bar further away from reel when turf conditions are dry Bar should be parallel to reel for optimum performance and should be adjusted whenever shield height is adjusted or when Figure 17 ever reel is sharpened on a reel grinder 1 Top bar 2 Bar mounting screws 3 Feeler gauge Greensmaster 3150 Page 7 13 Set Up and Adjustments Pull Frame Adjustment 1 Put the basket on the pull frame 2 Level baskets to cutting unit by loosening nut at one end of pull frame roller Loosen bolt and move roller shaft in slot as necessary Tighten bolt 3 Loosen the jam nuts on the pull arms and adjust the ball sockets until there is 1 4 in to 1 2 in 6 to 13 mm clearance between the lip of the basket and the reel blades Fig 18a This prevents grass clippings from dropping on the ground 4 Make sure the basket lips are the same distance from the reel blades at both ends of the reel If the basket is too close to the reel it is possible for the reel to contact the basket at the instant the cutting unit is raised off the ground 5 Make sure
157. K P36 INTERCONNECT BACKLAP 2 RELAY RELAY 2 P10 P26 DIODE INTERCONNEC T PACK 1 5 P25 LEAK DETECTOR P22 LEAK DETECTOR SOL Greensmaster 3150 Electrical Hamess Drawing Serial Number Above 270000000 Page 11 24 Rev E LOAD 1 TIME DELAY REELS 2 3 ENGAGE 1 LOWER S4 RAISE LOWER S2 RAISE S3 FUSE BLOCK BACKLAP BACKLAP RELAY HOUR METER KILL RELAY START SAFETY K2 JOYSTICK RELAY K3 MOW RELAY K4 CHARGE CIRCUIT K8 LOWER RELAY K5 RAISE RELAY K6 P P39 P38 P P3 P P5 P35 P6 PT 30 8587487 86 OP e 30 85 87 86 120345 3 123 45 12345 2 3 4 TTT s TE 45 x x 5 5 9 5 3 5 53 z B x ag m a a 5 21 9 g Q ais 9 Pa Q 3 m I ui GRAY 3 3 5 uz 2 3 5 a z
158. LACK BLUE BLACK 8 BLACK SPI4 BLACK ENGAGE 51 WHITEJBEUE SPT WHITE BLUE B COD ABCDEFG DIODE ACK P26 P27 P29 o PIG SEA i 93 INTERCONNECT 1 INTERCONNECT 2 SWITCH A 8 BLACK PINK BLUE LOWER 54 BLACK BLACK 2 BLACK SPIO n BLACK BLACK 7 START WHITE en x SOLENOID amp BLACK E 5 a BLACK Fi a BLACK B RAISE LOWER S2 FUSIBLE LINK PIS 2 SPI n 4 5 m d m 5 BLACK a 8 d o gt RAISE 3 g YELLOW 19 WHITE BLUE 8 _ BLUE RED NEUTRAL SWITCH BLUE x BLACK 9 ORIFICE S6 Serial Number 230000801 amp Up 8 lt VIOLET y RED 2 PINK WHITE 8 TAN E PARKING BRAKE 5 ORANGE SP4 6 YELLOW PN PH 1 GREEN A 8 BLUE WHITE BLUE FUSE BLOCK V MOW SWITCH P3 YELLOW GRAY GRAY WHITE WHITE ESEE m m Z Greensmaster 3150 A Boc D 1 1 Dn 1 1 A B D T E T 8 A B Lh x A B A B u P34 2 29 P26 PH 5 E is Wiring Diagram Serial Number Under 260000000 INTERCONNECT 83 OPTIONAL LIGHT 2 TEST LIGHT SWITCH OPTIONAL LIGHT INTERCONNECT 1 INTERCONNECT 2 LEAK DETECTOR SOL ALARM DETECTOR Page 11 21 Rev E FUSE BLOCK 65556555 252252 Page 11 22 Rev E P26 INTERCONNECT 42 P36 INTERCONNECT 1
159. MPORTANT To prevent damage when clamping cylinder barrel in a vise clamp only on pivotend Do not clamp the vise jaws against the shaft surface 1 Pump oil out of cylinder into a drain pan by slowly moving rod in and out of cylinder bore Plug ports and Clean outside of cylinder 2 Mountcylinder in a vise by clamping vise on center mounting location of cylinder Do notclose vise so firmly that cylinder barrel could become distorted 3 Remove the heads from the barrel A Forserial numbers below 260999999 Fig 73 loosen set screws and remove threaded cap from each end of the cylinder barrel B For serial numbers above 270000000 Fig 74 use a spanner wrench to rotate head clockwise until the edge of the retaining ring appears in the barrel opening Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the opening Rotate the head counter clockwise to remove retaining ring from barrel and head C Grasp end of rod and use a twisting and pulling motion to carefully extract rod assembly and head from cylinder barrel Remove head from other end of barrel 4 For serial numbers below 260999999 Fig 73 loosen set screws that secure piston to shaft and care fully remove piston Slide head and threaded cap from shaft Piston for serial numbers above 270000000 F ig 74 is not removable from shaft 5 Remove and discard all seals back up rings and O rings from both heads an
160. NIFOLD USED SERIAL NUMBER BELOW 260999999 Figure 20 MANIFOLD USED ON SERIAL NUMBER ABOVE 270000000 RELIEF VALVE R2 S1R1 Figure 21 Hydraulic System Rev E Hydraulic Gear Pump P1 Flow Test Using Tester with Flowmeter and Pressure Gauge PUMP P1 OUTLET TO HYDRAULIC MANIFOLD TO HYDRAULIC MANIFOLD TO STEERING AND LIFT CIRCUITS ENGINE RPM High Pressure FROMHYDROSTAT gt 4 Low Pressure Return or Suction Flow Hydraulic System Rev E Page 4 40 Greensmaster 3150 Procedure for Gear Pump P1 Flow Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered Make sure engine is off and the parking brake is engaged Make sure the hydraulic tank is full A CAUTION Before continuing further read and become fa miliar with Precautions for Hydraulic Testing 3 On gear pump P1 reel drive disconnect the hose that leads to port P1 on the hydraulic manifold 4 Install tester in series with gear pump P1 and the disconnected hose Make sure the flow control valve on the tester is fully open 5 machines with backlap capabilities make sure backlap knob on the manifold block is in the mow posi tion and reel speed is set to maximum 6 Make sure tester load valve is fu
161. O NOT hammer on pivot boss of bedbar Figure 32 without support You will break the casting 5 Press center pivot bushings into place Fig 33 DO NOT hammer on pivot boss of bedbar without support You will break the casting 6 Do steps 5 16 under Bedbar Removal and Installation in this section of the book Figure 33 Figure 30 1 Bedbar end bushing 2 3 Flange bushing 4 2 Bedbar pivot bushing 2 Repairs Page 8 22 Greensmaster 3150 Bedknife Replacement 1 1 4 under Bedbar Removal and Installa tion in this section of the book 2 Remove bedknife screws and remove bedknife 3 Remove all rust scale and corrosion from bedbar surface before installing the bedknife 4 Install new bedknife with new bedknife screws 57 4910 Apply clean SAE 30 oil to the screws before installing screws Tighten the screws to a torque of 200 to 250 in Ib working from the center toward each end of the bedbar Fig 34 5 Grind the new bedknife to match it to the bedbar Note For proper grinding of bedknife follow proce dures in the Toro publication Sharpening Reel and Rotary Mowers Form No 80 300 PT 6 Do steps 6 16 under Bedbar Removal and Installa tion in this section of the book Preparing Reel for Grinding IMPORTANT Adjust reel bearings before grinding reel See Reel Bearing Service and Adjustment in the Adjustments section of this chapter 1 Dosteps 1 4under Bedbar
162. Part No 0311351 Rev Service Manual Model 04357 Greensmaster 3150 Preface The purpose ofthis publication is to provide the service technician with information for troubleshooting testing and repair of major systems and components on the Greensmaster 3150 REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR S MANUALS FOR OPERATING MAINTENANCE AND ADJUSTMENT INSTRUC TIONS For reference insert a copy of the Operator s Manuals and Parts Catalogs for your machine into Chapter 2 of this service manual Additional copies of the Operator s Manuals and Parts Catalog are available on the internet at www Toro com The Toro Company reserves the rightto change product specifications or this publication without notice This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION 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 re pair of the machine IMPORTANT The IMPORTANT notice will give im portantinstructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 2003 2004 2005 2006 2007 2009 2012 This page is intentionally blank Greensmaster 3150 Table Of Contents Chapter 1 Safety Safety Instructions Safety and Instr
163. R4 10 Camplate 11 Rotating kit 27 Shaft seal 43 Charge relief spring 12 Gasket 28 Washer 44 Washer 13 Valve plate 29 Housing 45 Retaining ring 14 Bearing 30 Retaining ring 46 Bleed off valve poppet 15 Dowel pin 31 Bearing race 47 Bleed off spring 16 Back plate 32 Thrust bearing 48 O ring 17 O ring 33 Washer 49 Cartridge Note Forrepairofthe hydrostat see Eaton Medium IMPORTANT The shims 7 are used to replace a Duty Piston Pump Repair Information Model 70160 crush ring in the cover plate 25 If the camplate Variable Displacement Piston Pump at the end of this 10 cover plate 25 or housing 29 is replaced chapter during servicing the old crush ring must be re Hydraulic System Rev E placed using the procedure on the following page see Piston Pump Crush Ring Replacement in con junction with the piston pump service manual 4 58 Rev Greensmaster 3150 Hydrostat Crush Ring Replacement Figure 39 1 Crushring 5 Camplate control shaft 8 O ring 2 Shims 6 Bearing cone 9 Washers 3 Cover plate 7 Bearing cup 10 Cap screws 4 Housing Piston Pump Crush Ring Replacement Fig 39 Note The shims replace the crush ring in the cover plate Ifthe camplate cover plate or housing is replaced during servicing of the pump the old crush ring can not be used to make sure of proper preload 1 Remove crush ring from the cover plate Measure thickness of crush ring 2
164. RING L CIRCUIT High Pressure FROM GEAR PUMP P1 Low Pressure Serial Number 230000801 To Return or Suction 260999999 Shown Flow Hydraulic System Rev E Page 4 42 Greensmaster 3150 Procedure for Mow Circuit Relief Valve R1 Pres sure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered Make sure engine is off and the parking brake is engaged Make sure the hydraulic tank is full Before continuing further read and become fa miliar with Precautions for Hydraulic Testing 3 Thoroughly clean and then disconnect hose con nection on the bulkhead that leads to the left reel motor 4 Install tester in series with the disconnected hose and bulkhead connection Make sure the flow control valve on the tester is fully open 5 To prevent reel damage temporarily adjust bed knife on all cutting units to allow clearance between bed knife and reel no contact 6 machines with backlap capabilities make sure backlap knob on the hydraulic manifold is in the mow position Make sure reel speed knob FC1 is setto high est speed setting fully open Keep away from reels during testto prevent per sonal injury from the rotating reel blades 7 Start engine and move throttle to full speed 2850 50 RPM Engage the cutting units 8
165. RTANT 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 Figure 44 IMPORTANT Mark the relative positions of the gear 1 Motor body 2 Bearing block amp gear set teeth and the bearing blocks so they can be re assembled in the same position Do not touch the gear surfaces as residue on hands may be corrosive to gear finish 7 Place the motor onits side and push on the rear bear ing block to remove the bearing block and gear set Fig 44 8 Carefully remove and discard O rings pressure seals and back up rings Fig 45 from motor Do not cause any damage to the machined grooves during the removal process IMPORTANT Make sure not to damage the counter bore when removing the shaft seal from the front m plate Backup Ring 5 9 Position frontflange with seal side up Remove shaft seal Figure 45 Inspection 1 Remove any nicks and burrs from all motor compo nents with emery cloth A CAUTION Use eye protection such as goggles when using compressed air 2 Clean all motor components with solvent Dry all parts with compressed air K Figure 46 1 Drive gear 3 Bearing block 2
166. Removal and Installa tion in this section of the book Note Some reel grinders may require rear roller as sembly be mounted to the cutting unit for proper support in reel grinder Rear roller must be parallel to reel shaft to remove taper when grinding 2 Raise or remove front roller assembly A Loosen the locknuts securing height of cut ad justing rods at both ends of the cutting unit and the roller shaft clamp bolts Fig 35 B Turn height of cut adjustment knobs to raise roll er out of way or remove roller if necessary For proper grinding of reel follow procedures in the Toro publication Sharpening Reel and Rotary Mowers Form No 80 300 PT 3 Do steps 8 16 under Bedbar Removal and Installa tion in this section of the book After grinding assemble cutting unit check bearing adjustment and adjust top shield and bar Backlap if necessary to get desired fit be tween reel and bedknife Greensmaster 3150 Page 8 23 O01 BN Figure 34 Figure 35 Height of cut locknut Roller shaft clamp bolt Height of cut knob End cap mounting nuts Counterbalance end cap Reel bearing adjustment nut Repairs Reel Removal and Bearing Replacement 1 Do steps 1 4 under Bedbar Removal and Installation in this section of the book 2 Remove counterbalance end cap from left hand side of the cutting unit Fi
167. SAFETY K2 BACKLAP ME EUU BK 7 t SOLENOID pk IGNITION SWITCH i BG SWITCH 799 7430 GR NM l OFF RUN START N OPTIONAL BU BK N 1 10 2 2 uw OR BK eee on ENGAGE rake vs 202225 95 y MOW RELAY 1 B SEAT PARKING BK BK 1 pM ON POSITION PE GN CJ p oum l w 2 30 Ys m D1 D n 7 de 1 evel zmm EM corn F 1 n z STOP NONE A ue JOYSTICK n FRAME ENGINE A RUN 1 and X Y i cl GROUND GROUND START ke 2o x RAISE BK GY BK GN BK NOME HE GN GY Y OR BK 42 BK 5 L KILL RELAY K1 _ po mue 1 M D ee 2 6 6 SECOND ENGINE 1 M 1 PKIBK DELAY OFF 18 ALTERNATOR FUSIBLE LINK 9 3 99 7430 e Cee SP w 88U4JJ 86 _ ___ ___ _ __ _ E mm 1 i a es 54 l tea dy 87a D2 REELS LOWER LOWER RELAY K5 028 VIO BK frm RAISEILOWER ba ctw v BU R m S6 5 E ORIFICE 30 28 1 Yoo G m 53 GN GY 85 YyY 86 REELSRAISE pn RAISE RELAY K6
168. THIS SUMMARY AND CHECK LIST Study this informa tion and refer to it often to get maximum life and perfor mance from the cutting units Daily Performance Checks NOTE It is not necessary to remove the cutting units from the traction unit to perform these daily checks It is recommended that mowers be washed after each use Always remove key from ignition switch when working on the machine 1 Purge all water and debris from all of the bearings by greasing them Use No 2 multi purpose lithium base grease 2 Visually check for sharp reel and bedknife Remove burrs nicks and rounded edges 3 Lower cutting units to the ground setting on both rollers Remove reel motor and rotate the reel back wards by hand Light contact between the bedknife and reel should be felt and heard should be possible to pinch newspaper when inserted form the front and cut paper when inserted at a right angle along entire length of bedknife It should be possible to cut paper with minimum bedknife to reel contact Should excessive reel drag be evident you must back lap or grind the cutting unit Nocontact will dull the cutting edges Excessive contact accelerates wear and quality of cut may be adversely affected Weekly Checks 1 Check reel bearing adjustment and bearing condi tion 2 Make sure bed bar pivot bolts are securely seated maximum 40 ft Ib 3 Using a gauge bar verify correct height of cut setting and ad
169. When the cutting units are to be raised solenoid valve S2 is energized and blocks flow directly to the hydros tat Flow is directed to energized solenoid valve S3 which directs flow to de energized solenoid valve S4 and the lift cylinders Hydraulic pressure against the inder pistons moves their shafts causing the cutting units to raise At the same time the pistons push the hy draulic fluid out of the lift cylinders and back through en ergized solenoid valve S3 to the hydrostat Raise speed for the front cutting units is controlled by a 055 orifice A 025 orifice in the return line for the center cut ting unit allows a slight delay in raising that cutting unit When solenoid valves 52 and S3 de energize spring action returns the valves to their original position and by passes flow back to the hydrostat stopping lift cylinder movement The lift cylinder position is locked in place since there is no complete circuit of flow to and from the lift cylinders Greensmaster 3150 Page 4 15 Lower Cutting Units Circuit operation for lowering the lift cylinders is similar to raising them However the solenoid valve S3 re mains de energized and solenoid valve S4 is ener gized Flow is reversed to and from the lift cylinders lowering the cutting units When the cutting units are to be lowered solenoid valve S2 is energized and blocks flow directly to the hydros tat Flow is directed to de energized solenoid
170. X GY BK BK 9 T START 1 5 ET REGULATOR L IR E TRE GN GY Y L 2 3 FUSIBLE LINK 7 me mms quies mai m RE cm Zue iem e X zt 38 55 89 26 D 6 SEC DELAY OFF BK 4 MAGNETO 87 YT ENGINE GND A S 3 4 DATO EN zy kanavia s EVEL SOLENOID Late etl ENGINE Page 11 16 Rev E 34 A ENERGIZED LOWER RELAY K5 REELS LOWER ENERGIZED ENERGIZED S2 RAISE LOWER ENERGIZED 53 35 87a REELS RAISE X 82 BU R frm 85 86 GN GY frm BK RAISE RELAY K6 LEAK DETECTOR SOLENOID Greensmaster 3150 MY Circuits 55 Serial Number Above 270000000 Shown ENERGIZED ALARM Power Current Control Current ks BU Gy Indication Current LEAK DETECTOR CLOSED WHEN THERE IS USECsDELAYON A HYDRAULIC OIL LEAK HR METER 1 220 TO THE LIGHTS STARTER BU 5 29 OPTIONAL 41 F2 10A M m T 7 w TO TH
171. Y OFF BK 4 MAGNETO 87 TS ENGINE GND Ex 30 4 Ra E E ER EE mi j KILL RELAY K1 1 85 UU 86 BK EYEL SOLENOID ENERGIZED US bl c Tm E Mar W BK 30 87a REELS LOWER LOWER RELAY K5 Do D3 VIO BK frm 52 RAISE LOWER BK pe S3 87a REELS RAISE 30 2 EM BU R frm 85 86 GN GY frm BK Page 11 14 Rev E RAISE RELAY K6 LEAK DETECTOR Greensmaster 3150 SOLENOID E mE Raise Reels Circuits BU Oe i S5 O Serial Number Above 270000000 Shown ENERGIZED H ALARM Power Current Ww Control Current Indication Current r BU BU LEAK DETECTOR Ya CLOSED WHEN THERE 15 Gv TSEC DELAY ON AHYDRAULIC OIL LEAK HR METER 52 1 2 TO THE LIGHTS STARTER n BU 3 OPTIONAL 1 2 10 R T 1 m 1 w TO THE LIGHTS t E LIGHT TEST SW BK OPTIONAL 2 amp FUSIBLE LINK HE PK BU w W BU Peg ee i NEUTRAL SWITCH GY 87 START SAFETY K2 30 BK STARTER SOLENOID NOT IN NEUTRAL H S K2 87 85 UAV ka o D1 A Pe
172. ach end of the roller 4 Remove nut and black assembly washer from each end of the roller IMPORTANT Failure to grease bearing lock nut be fore seal installation may result in seal damage 5 Apply a coating of grease to the nut surface to pre vent seal damage during seal installation Fig 32 6 Carefully install seals onto bearing lock nuts Pack the back of the seal 75 to 90 full with 2 grease Fig 32 7 Install a nut with seal onto each end of the roller shaft Tighten nuts until they bottom against bearings Fig 33 Remove nuts from roller shaft 8 Position an assembly spacer and yellow assembly washer see Special Tools on each end of roller shaft Fig 34 Thread nut onto each end of shaft 9 Tighten each nut until the yellow assembly washers bottom out against the roller housing Remove nuts as sembly washers and assembly spacers from roller shaft Note original bearing lock nut s are being used apply Loctite 242 or equivalent to threads of lock nut s 10 Insert a V ring onto each bearing lock nut 11 Lubricate lips of installed seals with 42 grease 12 Install bearing lock nut with V ring onto each end of the roller shaft Torque lock nuts from 25 to 30 ft Ib 34 to 41 Nm Greensmaster 3150 Bearing lock nut 2 Seal 4 Pack with grease Bearing lock nut 2 Yellow assembly washer 4 Seal Page 10 25 Rev Figure 32 3 Grease nut surface 1543 277 2
173. ackets and lift cylinder Secure pin with cap screw lock nut and washer 3 Connect hose assemblies and O rings to the hy draulic fittings Tighten hose connections Hydraulic System Rev E Sa gt Lift Cylinder Service Serial Number Under 240000000 FRONT HYDRAULIC CYLINDER 24 to 30 ft Ib 33 to 41 Nm Figure 49 1 Sealkit 6 Back up ring 11 Head 2 T seal 7 Dustseal 12 Rod 3 O ring 8 Rodclevis 13 Piston 4 Rodseal 9 Jamnut 14 Lock nut 5 O ring 10 Internal collar 15 Barrel 24 to 30 ft Ib REAR HYDRAULIC CYLINDER 33 to 41 Nm Figure 50 1 Seal kit 6 Back up ring 11 Head 2 T seal 7 Dustseal 12 Rod 3 O ring 8 Notused 13 Piston 4 Rod seal 9 Notused 14 Lock nut 5 O ring 10 Internal collar 15 Barrel Hydraulic System Rev E Page 4 74 Greensmaster 3150 Disassembly Figs 49 and 50 1 Remove the oil from the cylinder by slowly pumping the cylinder shaft while holding the cylinder over a drain pan Plug both ports and clean the outside of the cylin der IMPORTANT Prevent damage when clamping the hydraulic cylinder into a vise clamp on the cap end only Do notclose vise enough to distort the barrel 2 Mount lift cylinder in a vice Remove internal collar with a spanner wrench 3 Extract shaft head and piston by carefully twisting and pulling on the shaft IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft su
174. ad C Install piston and nut onto the shaft Torque nut from 24 to 30 ft Ib 33 to 41 Nm D Remove shaft from the vise IMPORTANT Prevent damage when clamping the hydraulic cylinder into a vise clamp on the cap end only Do notclose vise enough to distort the barrel 4 Mount barrel in a vice 5 Coat all internal parts with a light coat of clean hy draulic oil Slide piston shaft and head assembly into the barrel being careful not to damage the seals 6 Clean threads of internal collar and threads in cylin der barrel Apply medium strength thread locking com pound e g Loctite 242 to threads of internal collar Secure head in the barrel with internal collar using a spanner wrench Tighten collar until snug and the outer end of the collar is flush with end of the barrel Hydraulic System Rev E 2 E gt I Lift Cylinder Service Serial Number Above 240000000 FRONT HYDRAULIC CYLINDER 60 to 75 ft Ib 82 to 101 Nm 12 11 Figure 51 1 Sealkit 7 12 Head 2 Wearring 8 Wiper 13 Retaining ring 3 Seal with loader 9 Jam nut 14 Piston 4 O ring 10 Rod clevis 15 Lock nut 5 Back upring 11 Rod 16 Barrel 6 O ring REAR HYDRAULIC CYLINDER 60 to 75 ft Ib 82 to 101 Nm Figure 52 1 Sealkit 6 O ring 11 Retaining ring 2 Wearring 7 Seal 12 Piston 3 Seal with loader 8 Wiper 13 Lock nut 4 O ring 9 Head 14 Barrel 5 Back upring 10 Rod Hydrauli
175. al Hamess Drawing Serial Number 260000001 To 260999999 LOAD 1 TIME DELAY REELS 2 3 ENGAGE 1 LOWER 54 RAISE LOWER 52 RAISE 53 SOLENOID 56 ORIFICE FUSE BLOCK J BACKLAP HOUR METER KILL RELAY KI START SAFETY K2 JOYSTICK RELAY K3 MOW RELAY K4 CHARGE CIRCUIT K8 LOWER RELAY K5 RAISE RELAY K6 OPTIONAL P3 P4 P5 P35 P6 PT 30 8587487 86 a A 8 1 3 iy 22 59 2 4 5 123 4 fet ake Ss 12345 2348 IEEE e e e ERR t 4 0 0 qe 1 5 5 5 9 z a E 5 5 44 3 z 8 E um m TT F 8 8 E 8 TED gu 3 2 2 us 2 a gt lt gt lt a BLUE BLACK
176. aling surfaces damagedthreads and contamina tion 4 Visually inspect cartridge relief valve for damaged sealing surfaces and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in small valve orifices or seal areas causing malfunc tion B If sealing surfaces appear pitted or damaged the hydraulic system may be overheating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air 5 Cleancartridge relief valve using clean mineral spir its Submerge valve in clean mineral spirits to flush out contamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves Use compressed air for cleaning 6 Reinstall the cartridge relief valve A Lubricate new O ring and backup ring of seal kit with clean hydraulic oil and install The O ring and backup ring must be arranged properly on the car tridge valve for proper operation and sealing B Thread cartridge relief valve carefully into the applicable port The valve should go in easily with out binding Torque valve to 35 ft lb 47 Nm Hydraulic System Rev E 2g 3 5 55 gt Hydraulic Manifold Service Serial Number Above 270000000 25 ft Ib 34 N m 20 ft Ib PLUG TORQUE SAE 4 165 in Ib 18 6 N m Zero Leak 4 120 in Ib 13 5 N m Zero Leak 6 198 in Ib 22 N m Zero Leak 8 41 ft lb 55 N m
177. all rust scale and corrosion from bedbar surface before installing the bedknife 4 Install new bedknife with new bedknife screws 57 4910 Apply clean SAE 30 oil to the screws before installing screws Tighten the screws to a torque of 200 to 250 in Ib working from the center toward each end of the bedbar Fig 25 5 Grind the new bedknife to match it to the bedbar Figure 25 Note For proper grinding of bedknife follow proce dures in the Toro publication Sharpening Reel and Rotary Mowers Form No 80 300 PT 6 Install the bedbar Preparing Reel for Grinding IMPORTANT Adjust reel bearings before grinding reel See Reel Bearing Service and Adjustment in the Adjustments section of this chapter 1 Remove bedbar Note Some reel grinders may require rear roller as sembly be mounted to the cutting unitfor proper support in reel grinder Rear roller must be parallel to reel shaft to remove taper when grinding 2 If necessary remove front roller assembly A Loosen the locknuts securing height of cut ad justing rods at both ends of the cutting unit and the roller shaft clamp bolts Fig 26 B Turn height of cut adjustment knobs until they Figure 26 are disconnected from the height of cut adjusting Rear roller height of cut bracket rods Fig 26 The roller assembly can then be re Allen Set Screw 5 Bedbar mounting bolts moved from the cutting unit by pulling evenly on Bedknife adjusting scre
178. ame assembly Page 10 14 17 to 20 ft lbs 23 to 27 Nm Flange nut Cap screw Lift hook Cap screw Grass shield Washer Cap screw Lock nut Greensmaster 3150 Reel Removal Fig 18 1 Remove reel motor from the cutting unit see Hy draulic Reel Motor Removal in this chapter 2 Remove the 2 capscrews securing the counter weight to the side plate Fig 19 Remove the counter weight 3 Remove the bedbar assembly see Bedbar Remov al in this chapter Note Depending on tools available it may be neces sary to remove the reel motor adapter plate before re moving the left end bearing lock nut 8 4 Remove the reel bearing lock 8 nut from each end of the reel shaft 5 Loosen the setscrews securing the front roller to the height of cut arms Fig 20 Do not remove the set Screws 6 Loosen the saddle strap screws and flange nuts se curing the rear roller to the the side plates Fig 20 Do not remove the screws and nuts 7 Remove the capscrew 24 washer 23 and lock nut 25 securing each end of the grass shield to the side plates These are the only capscrews that must to be re moved The grass shield and the lift hook do not need to be removed 8 Remove the 2 shoulder bolts 7 securing the right hand side plate to the cutting unit frame Remove the side plate from the reel shaft and roller shafts 9 Remove the 2 shoulder bolts 7 securing the left hand side plate to
179. and clutch pin Fig 51 IMPORTANT The special screw and clutch pin were assembled using Loctite 271 It will be necessary to apply heat to these parts before disassembly 7 Check condition of roller bearing and needle bearing Fig 51 Replace bearings if worn or damaged Installation and Assembly New Clutch Assembly 1 Loosen two 2 set screws and remove clutch knob from new clutch assembly Fig 48 Use a block of wood to keep the reel from rotating and remove nut and washer from clutch adapter shaft Fig 48 2 Pull clutch adapter out of new clutch assembly and install on reel shaft Tighten clutch adapter to a torque of 170 210 3 Hold belt on drive pulley of clutch and slide clutch on clutch adapter while sliding belt on driven pulley IMPORTANT If clutch has come apart since nut and washer were removed in step 1 make sure belleville washers are installed as shown in Figure 50 4 Install washer and nut removed in step 1 on clutch adapter shaft and tighten nut to a torque of 7 10 46 Repairs Page 9 30 5 Adjust belt tension See Groomer Reel Drive Belt Adjustment in the Adjustments section of this book Install groomer reel housing cover Fig 39 Install clutch knob and tighten two 2 set screws against flats of clutch release disk 7 Figure 48 1 Belt drive clutch assembly 2 Clutch engage disengage knob 3 Allen head set screw 2 4 Nut and washer
180. and 4 Bolt Adjust cutting units require dif ferent front roller extension plates Greensmaster 3150 Page 9 9 Troubleshooting Set Adjustments Adjustment Summary and Check List DETAILED ADJUSTMENT INSTRUCTIONS FOLLOW THIS SUMMARY AND CHECK LIST Study this informa tion and refer to it often for maximum life and perfor mance of cutting units Daily Performance Checks NOTE It is not necessary to remove the cutting units from the traction unit to perform these daily checks It is recommended that mowers be washed after each use Always remove key from ignition switch when working on the machine 1 Purge all water and debris from all bearings by greas ing them Use No 2 multi purpose lithium base grease 2 Visually check for sharp reel and bedknife Remove burrs nicks and rounded edges 3 Visually check groomer reel for wear and damage Straighten bent blades Replace worn blades or reverse groomer reel to put sharpest blade edge forward Make sure right and left shaft end nuts are tight 4 Lower cutting units to the ground setting on both rollers and remove reel motor Rotate the reel by hand TURN ADJUSTING KNOB ONE 1 CLICK AT A TIME UNTIL FIRST CONTACT BETWEEN REEL AND BEDKNIFE IS FELT AND HEARD THEN TIGHTEN ONE 1 MORE CLICK TO GET LIGHT CONTACT Nocontact will dull the cutting edges Excessive contact accelerates wear quality of cut may be adversely affected
181. and make continuity between terminals 30 and 87A as 12 VDC is applied and removed from terminal 85 Solenoid Valve Coils Note Prior to taking small resistance readings with a digital multimeter shortthe test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing 1 Make sure engine and ignition switch is Off Discon nect solenoid valve electrical connector from machine wire harness 2 Apply 12VDC source directly to the solenoid Listen for solenoid to switch on Remove voltage source from solenoid 3 Measure resistance between the two solenoid coil connector terminals The coil resistance for machines with serial numbers under 260999999 is identified in Figure 10 The coil resistance for machines with serial numbers above 270000000 is identified in Figure 11 4 Replace solenoid if necessary Reconnect solenoid valve electrical connector to machine wire harness Electrical System Page5 10 HRev D 5 Disconnect ground voltage and multimeter leads from relay terminals 860 87A 30 86 MEI 85 87 87 85O Figure 9 Serial Number 230000801 To 260999999 Shown Figure 10 1 Solenoid S1 7 2 ohm 4 Solenoid S4 7 2 ohm 2 Solenoid S2 7 2
182. andards in effect for riding mowers To make sure of optimum performance and continued safety certification of the machine use genu ine TORO replacement parts and accessories Re placement parts and accessories made by other manufacturers could be dangerous and such use could void the product warranty of The Toro Company 38 When changing attachments tires or performing other service use correct blocks hoists and jacks Make sure machine is parked on a solid level floor such as a concrete floor Prior to raising the machine remove any attachments that may interfere with the safe and proper raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the machine is not properly sup ported by blocks or jack stands the machine may move or fall which may result in personal injury stall a new decal Part numbers are listed in your Parts Catalog and Operator s Manual Order replacement de cals from your Authorized Toro Distributor Greensmaster 3150 TORO Table of Contents PRODUCT RECORDS EQUIVALENTS AND CONVERSIONS Decimal and Millimeter Equivalents U S to Metric Conversions TORQUE SPECIFICATIONS Fastener Identification Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Standard Torque for Dry Zinc Plated and Steel Fas
183. aphite or thread sealant such Loctite Note The nominal torque values listed above for Grade 5 8 fasteners are based on 75 of the mini Note Torque values may have to be reduced when mum proof load specified in SAE J429 The tolerance is installing fasteners into threaded aluminum or brass approximately 10 of the nominal torque value Thin The specific torque value should be determined based height nuts include jam nuts Product Records and Maintenance Page2 4 Greensmaster 3150 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Thread Size Regular Height Nuts Class 8 or Stronger Nuts 57 5 in lb M16 X 2 0 M20 X 2 5 Note Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite 96 9 in Ib 19 2 ft lb 38 4 ft Ib 66 7 ft lb 166 15 ft lb 325 33 ft lb Note Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based Greensmaster 3150 Class 8 8 Bolts Screws and Studs with Page2 5 Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 225 20 N m 229 22 ft lb 310 30 450 37 fizo 6104 50N m on the fastener size the aluminum or base material strength length of thread engag
184. arate lever from cam Note The brake assembly consists of return spring 11 brake cam 9 brake shoes 12 backing plate 8 and retaining ring 10 6 Remove brake assembly from the brake bracket 14 by removing four cap screws 26 and lock nuts 29 from the backing plate 8 and brake bracket Do not dis assemble 7 Labelall connections for reassembly purposes 8 Disconnectboth hose assemblies 15 or 16 and O rings 18 from the both hydraulic fittings 17 Allow hoses to drain into a suitable container 9 Remove hydraulic fittings 17 and O rings 19 from the hydraulic wheel motor 20 10 Remove four cap screws 30 and lock nuts 32 from brake bracket 14 and hydraulic wheel motor 20 Remove motor from the frame Greensmaster 3150 Page 4 61 Front Wheel Motor Installation Fig 36 1 Position hydraulic wheel motor 20 to the frame Make sure ports of motor face the rear of the machine Secure motor and brake bracket 14 to the frame with four cap screws 30 and lock nuts 32 2 Removecapsor plugs from the hydraulic wheel mo tor 20 Lubricate new O rings 19 with clean hydraulic fluid Install O rings and hydraulic fittings 17 to the mo tor and tighten 3 Lubricate new O rings 18 with clean hydraulic fluid Install O rings and hose assemblies 15 or 16 to the hydraulic fittings 17 Tighten hose connections Note The brake assembly consists of return spring 11 brake
185. arm from cutting unit 3 Disassemble lift arm using Figure 18 as a guide Note Right and left side HOC groomer arms item 1 and lift arm assemblies item 8 are different other com ponents shown in Figure 18 are the same on both sides of cutting unit Note Grooved pin item 3 is used to retain lock screw item 6 to lift arm assembly Greensmaster 3150 Page 10 1 15 1 Assemble lift arm using Figure 18 as a guide 2 Apply antisieze lubricant to threads of groomer lift rod item 5 and lift arm assembly stud item 8 3 Install onto cutting unit Secure with flange nut item 2 and lock nut item 16 with spring washer item 17 4 Secure groomer in raised or lowered position with lock screw item 6 5 Check and adjust groomer reel height and mower height of cut settings Groomer DPA Cutting Unit Rev A 5 D amp Groomer Brush 20 to 25 in Ib 2 3 to 2 8 N m Figure 19 1 Groomer brush shaft 3 J bolt 2 Locknut The groomer brush attaches to the groomer drive in place of the groomer reel Removal and installation of the groomer brush usesthe same procedure as removal and installation of the groomer reel see Groomer Reel in this section To remove the groomer brush fromthe shaft remove the lock nut and from both ends ofthe brush and slide the brush from the shaft When assembling the brush to the shaft secure the assembly with J bolts a
186. at 3 Hydraulic tube 2 Upper fitting 4 Hydraulic hose Hydraulic System Rev E CS a gt Wheel Motor Efficiency Test Using Tester with Flowmeter and Pressure Gauge m L 4 3 TUBE FROM PPER FITTING TRACTION WHEEL MOTORS CAP lt lt P OPTIONAL Lm REAR WHEEL 3WD MOTOR fw lt g FROM GEAR PUMP BLEED 200 250 VALVE PSI fies High Pressure HYDROSTAT Low Pressure TO HYDRAULIC RESERVOIR Return or Suction gt Flow Hydraulic System Rev E Page 4 32 Greensmaster 3150 Procedure for Wheel Motor Efficiency Test Note Over a period of time a wheel motor can wear internally Aworn motor may by pass oilto its case drain causing the motor to be less efficient Eventually enough oil loss will cause the wheel motor to stall under heavy load conditions Continued operation with a worn inefficient motor can generate excessive heat cause damage to seals and other components in the hydraulic system and affect overall machine performance 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged
187. bar is raised As bolt is turned clockwise and is lowered so is left end of bedbar Identification dot must be positioned within rear 180 position when adjusting 5 Rotate left hand eccentric pivot bolt to raise orlower bedbar as required 6 Check adjustments by repeating steps 2 and 3 7 After getting light contact on paper at each end of bedknife hold left hand pivot bolt in position and tighten jam nut Make sure pivot bolt did not get out of adjust ment when turning jam nut Adjust again if necessary NOTE If the reel has worn so you cannot get the bedknife parallel to the reel by turning the eccentric bolt the reel will require grinding to remove taper The reel normally wears faster on the lead in side which results in the described taper Figure 11 1 Bedknife adjusting knob Figure 12 Greensmaster 3150 Page 9 13 Set Up and Adjustments Leveling Rear Roller to Reel 1 Put cutting unit on a flat level surface 2 Assemble rear height of cut brackets to desired posi tion by loosening top capscrew and nut and removing bottom nut on right and left hand sides of cutting unit Fig 13 3 Slide bolts thru each bracket until brackets can be realigned with appropriate mounting hole See table for proper position on brackets NOTE The different rear roller bracket positioning holes B thru E are designed to optimize bedknife location for different heights of cut Rear Roll
188. bearings from the roller body 4 Use the roller shaft to remove the remaining bear ing 5 Clean roller bearing cavity and remove any rust or corrosion with an abrasive cloth 6 Inspect bearings roller shaft spiral retaining rings and roller body for wear or damage Replace compo nents as necessary Bearing Installation 1 Pressing against the outer race of the bearing only drive one bearing all the way into either end of the roller body Fig 28 2 Slide roller shaft through roller body and installed bearing 3 Install spiral retaining ring against installed bearing 4 Slide the remaining bearing onto the roller shaft Pressing against the outer race of the bearing only drive the remaining bearing all the way into the end of the roll er body Fig 28 5 Install remaining spiral retaining ring 6 Install new seals see Roller Seal Installation in this chapter of this manual 1 2 3 Roller shaft Roller body Seal Greensmaster 3150 Page 10 23 Rev A Figure 28 4 Bearing 5 Spiral retaining ring Dual Point Adjust Cutting Units Roller Service Threaded Roller Shaft Figure 29 1 Wiehle roller 4 Ball bearing 2 Smooth roller 5 Seal 3 Roller shaft Disassembly 1 To hold roller shaft for bearing lock nut removal install a 3 8 24 UNF 2B screw into threaded end of roller shaft and secure in place with jam nut While retaining shaft remove bearing lock nut from each end o
189. c An electrical problem exists see Chapter 5 Electrical System Relief valve R1 is stuck open see Mow Circuit Relief Valve R1 Pressure Test logic valve when Backlap Kit is installed is stuck open Gear pump P1 is damaged see Gear Pump P1 Flow Test Reel speed is erratic A cutting unit problem exists see Cutting Unit chapter Hydraulic manifold reel circuit cartridge is leaking or damaged Hydraulic manifold orifice is plugged Reel speed is low A cutting unit problem exists see Cutting Unit chapter Hydraulic manifold reel circuit cartridge is leaking or damaged Excessive internal wear in reel motor exists see Reel Motor Case Drain Flow Test Greensmaster 3150 Page 4 25 Hydraulic System Rev E Cutting units will not lift or lift slowly Engine speed is too low Reservoir oil level is low Lift cylinder linkage is binding or broken Lift cylinder bushings bind Charge circuit pressure is low see Charge Relief Valve R4 Pres sure Test Implement relief valve R5 is leaking or damaged see Implement Relief Valve R5 Pressure Test Solenoid valve S2 is leaking or damaged not shifting to its ener gized position Relief valve R2 is leaking or damaged see Lower Cutting Units Relief Valve R2 Pressure Test Lift cylinders leak internally Spool in steering control valve is hung up see Steering Control Valve Test Gear pump P2 is worn or damaged see Gear Pump P2 F
190. c System Rev E Page 4 76 Greensmaster 3150 Disassembly Figs 51 and 52 1 Removethe oil from the cylinder by slowly pumping the cylinder shaft while holding the cylinder over a drain pan Plug both ports and clean the outside of the cylin der IMPORTANT Prevent damage when clamping the hydraulic cylinder into a vise clamp on the cap end only Do notclose vise enough to distort the barrel 2 Mount lift cylinder in a vice Use of a vise with soft jaws is recommended 3 Usingaspanner wrench rotate head clockwise until the edge ofthe retaining ring appears in the barrel open ing Insert a screwdriver under the beveled edge of the retaining ring to startthe retaining ring through the open ing Rotate the head counter clockwise to remove re taining ring from barrel and head 4 Extract shaft head and piston by carefully twisting and pulling on the shaft IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surface before mount ing in a vice 5 Mount shaft securely in a vise by clamping on the clevis or eye of the shaft Remove lock nut and piston from the shaft Slide head off the shaft 6 Remove wear ring and seal with loader from the pis ton Remove O ring back up ring seal and wiper from the head Remove O ring from rod A CAUTION Use eye protection such as goggles when using compressed air to dry cylinder parts 7 Wash parts in clean solvent Dry parts with com pressed ai
191. c motor and hub as sembly from the castor fork 5 Loosen both set screws 27 on bearing 10 Slide flangettes and bearing off the motor shaft 6 Remove grease fitting 31 from the hydraulic motor and hub assembly Remove four lug nuts 30 and wheel assembly from the hub drive studs Note For disassembly of the hub from the rear wheel motor see Rear Wheel Optional 3WD Disassembly in structions in Chapter 6 Wheels and Brakes Greensmaster 3150 Page 4 63 Rear Wheel Motor Optional 3WD Installation Fig 37 Note Forassembly ofthe hubtothe rear wheel motor see Rear Wheel Optional 3WD Assembly instructions in Chapter 6 Wheels and Brakes 1 Make sure grease fitting 31 is removed from the hydraulic motor and hub assembly 14 2 Secure wheel assembly 28 to the four drive studs of the hydraulic motor and hub assembly with four lug nuts 30 Torque nuts from 70 to 90 ft Ib 95 to 122 Nm 3 Reinstall grease fitting 31 onto hydraulic motor and hub assembly so it points away from the wheel 4 Slide flangette 11 bearing 10 and relube flan gette 9 onto the motor shaft 5 Position hydraulic motor and hub assembly flan gettes with bearing and wheel into the castor fork 6 Make sure hose fittings on the motor face rearward 6 Secure hydraulic motor and hub assembly loosely to the inside of the castor fork with both socket head screws 16 flat washers 18 and lock nuts 29 7
192. c system any time there is severe componentfailure or the system is contaminated oil appears milky or black or con tains metal particles IMPORTANT Flush hydraulic system when chang Ing from petroleum base hydraulic fluid Operate machine under normal operating conditions for at least four 4 hours before draining 1 Park machine on a level surface Lower cutting units stop engine and engage parking brake A CAUTION Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components 2 Clean area around hydrostat and pump inlet hose Clamp pump inlet hose Remove inlet hose from hydros tat release clamp and drain reservoir into a suitable container Drain hydraulic system while making sure lift cylinders hoses tube lines and all other components are drained from low points while the system is warm Discard filter Fig 39 3 Clean oil filter mounting area Remove filter and drain into a suitable container Discard filter Fig 40 4 Inspect and clean reservoir see Inspecting Reser voir Parts 5 sure filter mounting surface is clean Apply hy draulic oil to gasket on the new filter Screw filter on until gasket contacts mounting plate then tighten filter halfa turn Note Use only hydraulic fluids including biodegrad able specified in the Traction Unit Operator s Manual Other fluids could cause system damage 6 R
193. cam 9 brake shoes 12 backing plate 8 and retaining ring 10 4 Install brake assembly to the brake bracket 14 by securing the backing plate 8 to the brake bracket with four cap screws 26 and lock nuts 29 5 Securebrake lever 23 tothe brake cam 9 with the retaining clip 10 IMPORTANT DO NOT hit wheel hub 6 with a ham mer during installation Hammering may cause damage to the hydraulic wheel motor 20 Note Thebrake drum assembly consists ofthe wheel hub 6 brake drum 3 and drive stud 7 6 Make sure that wheel hub bore and wheel motor shaft are thoroughly cleaned Install key 13 to the hy draulic wheel motor 20 shaft Slide brake drum assem bly onto the motor shaft 7 Secure lock nut 24 to the hydraulic wheel motor 20 shaft Torque nut from 250 to 400 ft Ib 339 to 542 Nm 8 Installthe tire 2 and rim 3 to the brake drum as sembly Secure rim with lug nuts 1 Torque nuts from 70 to 90 ft Ib 95 to 122 Nm Hydraulic System Rev E 0 Ey gt Rear Wheel Motor Optional 3WD lt NX 12 11 30 80 to 100 in Ib 30ft Ib 9 0 11 3 Nm 41 Nm 70 to 90 ft Ib 95 to122 Nm Figure 37 Lock nut 12 Cap screw 22 Cap screw 2 Spacer 13 Lock nut 23 O ring 3 Grommet 14 Wheel motor amp hub assembly 24 O ring 4 Hose assembly 15 Adapter 25 O ring 5 Washer 16 Cap screw 26 O ring 6 Castor fork
194. cessive contact is main tained bedknife reel wear will be accelerated Un even wear can result and quality of cut may be adversely affected NOTE As the reel blades continue to run against the bedknife a slight burr will appear on the front cutting edge surface the full length of the bedknife If a file is occasionally run across the front edge to remove this burr improved cutting performance can be obtained NOTE After extended operation notches will eventually develop at both ends of the bedknife These notches must be rounded off or filed flush with cutting edge of bedknife to assure smooth operation Figure 6 1 Clutch snubber 2 Clutch knob 3 Quick up lever 2 Figure 7 1 Bedknife adjusting knob 2 Compression spring 3 Pivot bar Set Up and Adjustments Reel Bearing Service and Adjustment 1 Remove bedknife to reel contact by turning bedknife adjustment knob counterclockwise Fig 7 2 Loosen two 2 set screws and remove clutch knob Fig 6 Remove groomer reel housing cover from left side of cutting unit Fig 8 Loosen idler pulley and remove drive belt Fig 9 3 Reel bearing rolling torque should not exceed 7 inb Measure with a torque wrench at the nut on the right hand end of the reel shaft NOTE If bearing drag does not meet above specifica tion or if you do not have an inch pound torque wrench do remaining steps this procedure Figure 8 4 Remove n
195. ch or 3 4 inch by altering the position of blade spacers on the groomer GROOMER PENETRATION From 410 inch 10 4 mm above ground level to 0 125 inch 3 2 mm below ground level at mowing HOC range of 062 to 296 inch 1 6 to 7 5 mm WIDTH OF GROOMER 19 inches 48 3 cm HEIGHT ADJ USTMENT KNOB Allows a 0 003 inch 0 08 mm increment of height adjustment for each click of the adjuster UP DOWN FEATURE At lower height of cut settings allows groomer reel to be raised above the height depth adjustment for no groomer reel action while cutting At higher height of cut settings groomer may have to be in the raised position for effective groomer operation Groomer DPA Cutting Unit Rev A Page 10 1 2 Greensmaster 3150 General Information Groomer Position IMPORTANT Before changing groomer position make certain thatthe reel drive is in the disengaged position and that the cutting reel is not rotating To place the groomer reel in the raised non grooming position remove the lock screw and rotate the lift arm to raise the groomer reel Install the lock screw to retain groomer reel in the non grooming position Fig 1 To placethe groomer reel in the lowered grooming posi tion remove the lock screw and rotate the lift arm to low er the groomer reel Install the lock screw to retain the groomer reel in the grooming position Fig 2 Figure 1 1 Liftarm 2 Lock screw transport Figure 2
196. ch pin 6 Compression spring Greensmaster 3150 7 Clutch body drive pulley 8 Roller bearing 9 Belleville washer 2 10 Clutch release disk 11 Special screw 12 Flange bushing Page 9 31 13 Set screw 14 Clutch knob 15 Flat washer 16 Lock nut Repairs Bedknife to Ree Adjustment Knob Bearing Service 1 Turn bedknife adjustment knob counterclockwise to remove bedknife to reel contact 2 Remove two 2 pivot screws Fig 38 3 Rotate adjustment knob and pivot assembly clock wise left hand thread until it is unthreaded from the bedbar pivot 4 If necessary remove locknut securing die spring to shaft Fig 6b Slide pivot housing off adjustment knob threaded shaft Fig 38 5 Pull inner races from pivot housing Pull bearings from pivot housing Check condition of inner races and bear ings and replace if necessary 6 Install new o ring on each race if necessary 7 Install bearings and races in pivot housing Slide pivot housing onto shaft of knob 8 Install spring over adjusting knob threaded shaft and thread adjustment knob and pivot assembly into flat side of bedbar pivot Make sure there is an equal gap be tween each side of pivot assembly housing and frame supports Fig 29 Adjust before installing pivot screws by sliding bedbar pivot sideways IMPORTANT On hand adjustable type knobs check to make sure die spring is compressed to a dimen sion of 13 16 in by tightening loc
197. contact between the bedknife 3 Top adjustment screw and reel blades IMPORTANT If excessive bedknife to reel contact is maintained bedknife and reel wear will be ac celerated Uneven wear can result and quality of cut may be adversely affected P Figure 10 2 2 Figure 8 1 Bedknife 2 Bottom adjustment screw 3 3 8 inch wrench 4 Top adjustment screw Greensmaster 3150 Page 7 9 Set Up and Adjustments Leveling Rear Roller To Reel 1 Loosen rear roller brackets Adjust one bracket and tighten the nut on the capscrew See the table below for the proper adjustment Leave bracket on the other side mounted loosely Fig 11 Distance from bottom of rear roller bracket not bolt Height of Cut to bottom of 5101 1 8 0 125 in or below 1 16 0 0625 in 5 32 0 156 to 1 8 0 125 in 1 8 0 125 in 1 4 0 25 in or above center bracket in slot NOTE Position of rear roller bracket determines Figure 11 bedknife angle Recommendations for rear roller brack et position in above chart are designed to give the best 1 Rear roller bracket 3 Reel blades rear roller position and bedknife angle for different 2 1 4 Inch 6 mm steel plate 4 Bedknife heights of cut IMPORTANT Rear roller bracket position must be identical on all
198. ct across the entire reel No contact will dull the cutting edges Excessive contact accelerates wear of both edges Quality of cut is adversely affected by both conditions see Bedknife to Reel Adjustment in the Cutting Unit Operator s Manual Slightly dull cutting edges may be corrected by backlapping see Backlapping in this chapter of this manual Excessively dull cutting edges must be corrected by grinding the reel and bedknife see Preparing Reel for Grinding in this chapter of this manual Rear roller adjustment Adjust the rear roller brackets to hi or low position depending on the height of cut range desired See Rear Roller Adjustment in the Cutting Unit Operator s Manual Height of cut Effective or actual height of cut depends on the cutting unit weight and turf conditions Effective height of cut will be different from the bench set height of cut See Height of Cut Adjustment in the Cutting Unit Operator s Manual Proper bedknife selection for height of cut desired If the bedknife is too thick for effective height of cut poor quality of cut will result Stability of bedbar Make sure bedbar pivot bolts are seated securely Check condition of the bushings in the side plates See Bedbar Removal and Installation in this chapter of this manual Number of reel blades Use correct number of blades for clip frequency and optimum height of cut range Cutting unit alignment and pull frame ground following Check
199. d piston A CAUTION Use eye protection such as goggles when using compressed air to dry cylinder parts 6 Wash parts in clean solvent Dry parts with com pressed air Do not wipe parts dry with paper towels or cloth Lint in a hydraulic system will cause damage 7 Carefully inspect internal surface of barrel for dam age deep scratches out of round etc Inspect shaft both heads and piston for evidence of excessive scor ing pitting or wear Replace entire cylinder if internal components are found to be worn or damaged Greensmaster 3150 4 99 Rev Assembly Fig 73 or 74 NOTE Due to steering cylinder design for serial num bers above 270000000 the seal kit may include com ponents that cannot be accessed 1 Usea complete repair kit when rebuilding the cylin der Puta coating of clean hydraulic oil on all new seals back up rings and O rings 2 Install new u cup rod wiper back up ring and ring onto each head Position ring s piston ring and both wear rings to the piston 3 Forserial numbers below 260999999 Fig 73 lu bricate shaftand piston with clean hydraulic oil Careful ly slide piston onto shaft Install thread locker on set screw threads and tighten two 2 setscrews to secure piston to shaft 4 Lubricate shaft and piston assembly with clean hy draulic oil and carefully slide shaft assembly into cylin der barrel 5 Lubricate head assemblies with clean hydrau
200. de plate are a press fit Bearings in non drive side plate are slip fit Discard bearings Greensmaster 3150 Bearing Installation 1 Install new bearings in both side plate assemblies Fig 13 A Slide new bearings into non drive side plates Position extended inner race of bearings toward cen ter of side plate housing B Press new bearings into drive side plates apply ing pressure to outer bearing race only Position ex tended inner race of bearings toward center of side plate housing C Install new seals into side plates Note Seals should be installed so the lip side of the seal will face the center of the cutting reel When bearings are greased grease will purge from inner seals 2 Install non drive groomer side plate to cutting unit A Position non drive groomer side plate to cutting unit making sure that groomer arm lift rod is posi tioned through bushing in side plate B Apply antisieze lubricant to threads of lift arm as sembly stud Place spring washer and lock nut on lift rod threads Fig 15 Tighten lock nut C Position motor mount to groomer side plate Fig 14 Secure motor mount and groomer side plate to cutting unit with two 2 socket head screws and lock nuts D Install hydraulic reel motor to cutting unit see Hy draulic Reel Motor Installation in the Service and Re pairs section of Chapter 10 DPA Cutting Units 3 Install groomer reel and drive side groomer side plate see Groom
201. ded or damaged Fuse block or fuse is faulty Solenoid valve S3 and or S2 is faulty Diode D3 is open Raise switch and or raise relay K6 is faulty or grounded Wiring to lower circuit components see Wiring Schematics is loose corroded or damaged Fuse block or fuse is faulty Diode D2 is open Raise switch is faulty Lower switch is faulty Joystick relay K3 is faulty 6 second delay timer is faulty Solenoid valve S2 or S4 is faulty Lower relay 5 is faulty 5 7 Electrical System Electrical System Quick Checks Battery Test Use a multimeter to measure the voltage between the battery terminals Set the multimeter to the DC volts setting The battery should be at a temperature of 60 to 100 F 15 5 to 37 8 C The ignition key should be off and all accesso ries turned off Connect the positive meter lead to the positive battery post and the negative meter lead the the negative battery post Note This test provides a relative condition of the bat tery Load testing of the battery will provide additional and more accurate information Charging System Test This is a simple test used to determine if a charging sys tem is functioning It will tell you if the charging system has an output but not its capacity Use a digital multimeter set to DC volts Connect the positive multimeter lead to the positive battery post and the negative multimeter lead to the negative bat tery
202. der Bedbar Removal and Installa tion in this section of the book Greensmaster 3150 Page 9 27 Figure 42 1 Right side groomer plate ass y 4 Special stud 2 2 Right reel frame plate 5 Inside locknut 2 3 Groomer bearing adapter 6 Flange locknut 2 Figure 43 1 Bearing housing 2 Bolt Repairs l Groomer Reel Blade Service Inspect grooming reel blades frequently for damage and wear Straighten bent blades with a pliers Either replace worn blades or reverse the grooming reel shaft to put thesharpest blade edge forward Fig 44 See Groomer Reel Removal and Installation in this section of the book During blade inspection procedures check to make sure the right and left blade shaft end nuts are tight Figure 44 1 Grooming blade 2 Dull rounded edge 3 Sharp edge 4 Location mark Groomer Reel Drive Belt Replacement 1 Loosen two 2 set screws and remove clutch knob Fig 6 Remove groomer reel housing cover from left side of cutting unit Fig 39 2 Loosenthe backside idler pulley pivot screw Fig 45 Pivot idler to loosen and remove belt 3 Install the belt The belt should have a deflection of 1 4 in when 5 10 Ib of force is applied midway between the pulleys Pivot the idler to get proper tension and tighten the allen head screw to a torque of 7 10 ft Ib 4 Install groomer reel housing cover Install clutch knob and tighten two 2 s
203. djustable adjust upward until a solid clicking sound is achieved when adjusting knob is turned 16 Level bedknife to reel Level rear roller to reel Set height of cut If necessary backlap to get desired fit between reel and bedknife Equal gap Figure 32 Greensmaster 3150 Page 9 23 Repairs a Bedbar Bushing Replacement NOTE Only after making sure that all normal cutting unit adjustments are correct should the bushings be suspected as causing quality of cut problems The bedbar end bushings and pivot bushings Fig 33 contain rubber and are exposed to severe conditions It is recommended to replace these bushings and the plastic flange bushings every two years 1 Do steps 1 4 under Bedbar Removal and Installation in this section of the book 2 Remove bedbar end bushings with a punch and hammer Fig 34 Alternate from one side to other on bushing there two slots in bedbar bushing boss Figure 34 IMPORTANT Apply Never Seez or equivalent to outside surface of bedbar end bushings and pivot bushings before installing in bedbar 3 Press end bushings into bedbar far enough so plastic sleeve collar is below bedbar end face Fig 35 NOTE Bedbar end bushings have less rubber and more steel which is visible than bedbar pivot bushings Do not use bedbar end bushings in the pivot area as they are too rigid 4 Use an arbor press to remove bedbar pivot bushings Fig 36 DO NOT hammer on
204. djustable grass shield bar 10 Reel Greensmaster 3150 Special Tools NOTE Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PRODUCTS Some tools may be listed in the Greensmaster 3000 or 3000 D Parts Catalog Some tools may also be available from a local supplier Roller Bearing Replacement Tool Puller is used to remove bearings from front and rear rollers Driving tubes are used to install bearings into rollers Refer to instructions supplied with tool Used on swaged full and wiehle rollers Figure 1 Plastic Plug Insert plug in cutting unit bearing housing in place of reel motor when sharpening or grinding the reel Figure 2 Greensmaster 3150 Page 7 3 Special Tools Handle Assembly For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel assembly Figure 3 Bedknife Screw Tool Fits Toro bedknife attaching screws Use with torque wrench to secure bedknife to bedbar With clean bedbar threads and new screws tighten to a torque of 200 in Ib NOTE Remove all rust scale and corrosion from bedbar surface before installing bedknife DO NOT use an air impact wrench with this tool Ut Figure 4 Special Tools Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut some of which may be turf conditions Turf conditions such as excessive thatch sponginess
205. djustment 17 Greensmaster 3150 Page 8 1 Chapter 8 Single Point Adjust Cutting Units Bar 17 Pull Frame Adjustment 18 REPAIRS os saci Rhe neds 19 Cutting Unit Removal and Installation 19 Reel Lapping 20 Bedbar Removal and Installation 20 Bedbar Bushing Replacement 22 Bedknife Replacement 23 Preparing Cutting Unit for Reel Grinding 23 Reel Removal and Bearing Replacement 24 Bedknife Adjustment Knob Bearing Service 25 Lift Bail 26 Table of Contents Introduction Page 8 2 Greensmaster 3150 Specifications Height of Cut 3 32 0 094 in to 3 4 0 75 in Clip Frequency and Optimum Height of Cut Range Optimum Height Model No Clip max of Cut Range 04468 0 25 in 3 16 to 5 16 in 04450 0 18 in 1 8 to 7 32 in Roller Adjustment Front Micrometer hand adjustment with bolted clamp lock 1 turn 0 025 in height of cut change Rear Roller brackets allow adjustment for different heights of cut Screw adjustment for leveling Bedknife to Reel Adjustment Bedknife adjusts against reel with positive adjustment control knob lo cated at center of bedbar Adjustment knob contains detent with 001 in movement of bedknife for each in dexed position Pivot point at
206. djustment knob assembly is spring loaded Figure 39 4 Loosen idler pulley Fig 40 Remove nut and washer 1 Height of cut locknut 4 Grooming reel cover from clutch adapter shaft Pull clutch assembly off 2 Roller shaft clamp bolt 5 Cover screws amp washers adapter shaft and slide belt off driven pulley Remove 3 Height of cut knob clutch adapter from reel shaft Fig 49 5 Remove driven pulley from groomer shaft left hand thread Fig 40 6 Remove two 2 locknuts and flat head socket screws to remove bearing adapter and left side groomer hous ing Fig 41 7 Remove locknut from the right end of groomer reel shaft to remove groomer reel Remove grooming reel adjustment knob assembly from right side groomer plate assembly Fig 42 8 Remove two 2 flange locknuts ree motor mounting nuts Remove two 2 inside locknuts Use a stud Figure 40 removal tool or double nuts to remove special studs Remove groomer bearing adapter and right side 1 Drive belt 4 Groomer driven pulley groomer plate Fig 42 2 Drive belt idler pulley 5 Clutch assembly 3 Grooming reel adjustment 6 Groomer reel housing 9 Remove bearing adjustment locknut from left end of knobassembiy reel shaft Remove spline nut from right end of reel shaft IMPORTANT Remove grease fittings from bearing housing at each end of cutting unit Note that the straight fitting is on the right end and 90 fitting at the left end when viewed
207. e 17 45 hydraulic fitting 18 O ring 19 O ring 20 Hydraulic motor 21 Flat washer 22 Brake rod Page 4 60 23 Brake lever 24 Lock nut 25 Jam nut 26 Cap screw 27 Cap screw 28 Lock nut 29 Lock nut 30 Cap screw 31 Swivel clevis 32 Lock nut Greensmaster 3150 Front Wheel Motor Removal Fig 36 1 Before removing any parts from the hydraulic sys tem park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components 2 Chock front and rear of wheels not being lifted to preventthe machine from moving Liftfront wheel off the ground using a jack and place blocks beneath the frame 3 Remove lug nuts 1 tire 2 and rim 3 from drive studs 7 Loosen but do not remove lock nut 24 from hydraulic wheel motor 20 shaft IMPORTANT DO NOT hit wheel hub 6 with a ham mer during removal Hammering may cause dam age to the hydraulic wheel motor 20 Note Thebrake drum assembly consists ofthe wheel hub 6 brake drum 3 and drive stud 7 4 Use wheel hub puller see Special Tools to free wheel hub assembly from motor shaft Do not disas semble Remove lock nut 24 and key 13 from the hy draulic wheel motor 20 shaft 5 Remove retaining clip 10 from the brake cam 9 and brake lever 23 Sep
208. e 5 Inch Series Bolts and Screws Figure 1 Using a Torque Wrench with an Offset Wrench Use ofan offset wrench e g crowfoot wrench will affect torque wrench calibration due to the effective change of torque wrench length When using a torque wrench with an offset wrench multiply the listed torque recommen dation by the calculated torque conversion factor Fig 3 to determine proper tightening torque Tightening torque when using a torque wrench with an offset wrench will be lower than the listed torque recommen dation Example The measured effective length of the torque wrench distance from the center of the handle to the center of the square drive is 18 The measured effective length of the torque wrench with the offset wrench installed distance from the center of the handle to the center of the offset wrench is 19 The calculated torque conversion factor for this torque wrench with this offset wrench would be 18 19 0 947 Greensmaster 3150 Page 2 3 Rev E As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass material strength fastener size length of thread en gagement etc The standard method of verifying torque shall be per formed by marki
209. e 5 Neutral arm from the hydrostat without complete disassembly 3 Spring bracket 2 Disconnectthe extension spring 1 and damper 2 from the spring bracket and the neutral arm Fig 31 3 Removethe cap screw and pivot washer from cam plate shaft of hydrostat Fig 32 4 Remove both cap screws securing the cable sup port assembly to the hydrostat Fig 32 5 Liftand secure the neutral system assembly up and away from the hydrostat 3 5 55 gt Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components 35 1 screw 4 Hydrostat 2 Pivot washer 5 Cable support assembly 6 Label all hose connections for reassembly pur 3 Pump lever assembly 6 Capscrew poses 7 Clamp pump inlet hose 1 to prevent draining the hydraulic reservoir Fig 30 8 Separate gear pump from the hydrostat see Hy draulic Gear Pump Removal 9 Plug suction port at the end ofthe gear pump to pre vent possible leakage of hydraulic fluid Fig 33 10 Pull gear pump 2 and connected hoses assem blies 10 and 15 away from the hydrostat 12 and se cure Fig 30 11 Remove hose assemblies 19 20 and 44 and O rings 18 36 and 45 from the hydraulic fittings Allow hoses to drain into a suitable container SUCTION PORT Figure 33 Greensmaster 3150 Page 4 55 Hydraulic System Rev E 12 Loosen bot
210. e O ring with clean hydraulic oil Fitting threads should be clean with no lubricant applied IMPORTANT Before installing fitting into port de termine port material If fitting is to be installed into an aluminum port installation torque is reduced 4 Install the fitting into the port Then use a torque wrench and socket to tighten the fitting to the recom mended installation torque shown in Figure 10 NOTE Use of an offset wrench e g crowfoot wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offset wrench will be less than the recommended installation torque See Using a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 Product Records and Maintenance to determine necessary con version information 5 Ifa torque wrench is not available or if space at the port prevents use of atorque wrench an alternate meth od of assembly is the Flats From Finger Tight F F F T method A Install the fitting into the port and tighten it down full length until finger tight B If port material is steel tighten the fitting to the listed F F F T If port material is aluminum tighten fit ting to 60 of listed F F F T Size F F F T 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 5 8 in 1 50 0 25 12 3 4 1 50 0 25 16 1 in 1 5
211. e Screw Tool Fits Toro bedknife attaching screws Use with torque wrench to secure bedknife to bedbar With clean bedbar threads and new screws tighten to a torque of 200 in Ib NOTE Removeall rust scale and corrosion from bedbar surface before installing bedknife DO NOT use an air impact wrench with this tool OBS Figure 5 Greensmaster 3150 Page 8 5 Special Tools Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut some of which may be turf conditions Turf conditions such as excessive thatch sponginess or attempting to cut off too much grass height may not always be overcome by adjusting the machine It is important to remember that the lower the height of cut the more critical these factors are See the Adjustments and Repairs sections for detailed adjust ment and repair information Factors Affecting Quality of Cut Factor 1 Tire pressure 2 Engine governed speed 3 Reel bearing condition adjustment 4 Reel and bedknife sharpness 5 Bedknife parallel to reel 6 Bedknife to reel contact Possible Problem Correction Check tire pressure and adjust if necessary Must be equal in both front tires Check maximum governed engine speed Adjust to specification if necessary affects reel speed Check and adjust to specification Replace bearings
212. e Service 9 28 Leveling Rear Roller to Reel 9 14 Groomer Reel Drive Belt Replacement 9 28 Height 9 16 Groomer Reel Removal and Installation 9 29 Groomer Reel Depth Adjustment 9 18 Groomer Reel Clutch Service 9 30 Shield Height Adjustment 9 18 Bedknife Adjustment Knob Bearing Service 9 32 Bar 9 19 Lift Bail 9 33 Introduction See Chapter 7 4 Bolt Adjust Cutting Units for specific information about 4 Bolt Adjust Cutting Units equipped with Grooming Reels Specific information for 4 Bolt Adjust Cutting Units i e bedknife to reel adjust ment bedbar removal and installation and leveling rear roller to reel is not covered in this chapter Greensmasier 3150 Page 9 1 Introduction Introduction Page 9 2 Greensmasier 3150 Specifications Height of Cut 3 32 0 094 in to 3 4 0 75 in Clip Frequency and Optimum Height of Cut Range Optimum Height Model No Clip max of Cut Range 04460 8 blade reel 0 25 in 3 16 to 5 16 in 04465 11 blade reel 0 18 in 1 8 to 7 32 in Roller Adjustment Front Micrometer hand adjustment with bolted clamp lock 1 turn 0 025 in height of cut change Rear Roller brackets allow adjustment for different heights of cut Screw adjustment for leveling Bedknife to Reel
213. e cutting unit model with correct number of blades for clip frequency and optimum height of cut range Variable speed traction kit can be used to adjust clip frequency 14 Cutting unit alignment and pull frame Check pull frame alignment on all cutting units Adjust ground following or repair as necessary Check pull frames and lift arms for damage binding or bushing wear Repair if necessary 15 Roller condition All rollers must rotate freely Grease when needed or repair bearings if necessary 16 Reel speed All reels must rotate at same speed within 100 rpm All cutting units must have equal bedknife to reel con tact and reel bearing adjustment before checking Do not run the reel to long or it may get hot and rifle when no grass is being cut See Troubleshooting in Chapter 5 Hydraulic System 17 Traction speed Check maximum governed engine speed Adjust to specification if necessary See Troubleshooting in Chapter 5 Hydraulic System Install Variable Speed Traction Kit if necessary to con trol traction speed in varying conditions or with dif ferent attachments Will allow change in traction speed while maintaining full engine rpm and reel motor rpm 18 Cutting drop speed and sequence Center cutting unit must drop after front cutting unit See Troubleshooting in Chapter 5 Hydraulic System Greensmaster 3150 Page 8 7 Troubleshooting Set Up and Adjustments Adjustment Summary and Check List
214. e doing groomer A 6 Rotate both quick up levers to raise the grooming reel reel depth adjustment into transport position Make sure the clutch is dis engaged 2 Hold clutch snubber down and rotate the clutch clockwise to disengage the clutch Fig 6 Rotate both quick up levers to lower the grooming reel into grooming position 3 Hold a straight bar securely against the front and rear rollers on one side of the cutting unit Fig 19 While holding the bar in place lift and turn the micro adjust ment knob until the groomer blade just touches the bar rotating the groomer reel by hand will assist in deter mining if blades are lightly touching the bar 4 Repeat step 3 on the opposite side of the cutting unit then check the adjustment on the other side again Adjust again if necessary 5 Each notch on the micro adjustment knob equals approximately 0 007 in of groomer height depth Divide the desired height depth setting of the groomer reel by 0 007 to determine how many notches to turn the micro adjustment knob Make sure each knob is turned the same number of notches Turn counterclockwise to igure raise groomer reel and clockwise to lower 1 Bar 2 Front roller Example Desired groomer setting of 182 3 Rear roller 0 03125 in higher than bottom of rollers 4 Quick up lever 2 5 Micro adjustment knob 2 0 03125 0 007 4 46 4 or 5 notches 6 reel touching Shield Height
215. e excessive looseness in assembly but allow bracket to slide freely on side plate Set Up and Adjustments Page 9 14 Greensmaster 3150 6 Position 1 4 inch or thicker plate under the reel blades and against the front face of the bed knife Fig 15 NOTE Make sure plate covers full length of reel blades and 3 blades contact plate 8 blade reel 7 While holding reel securely on plate level roller by rotating lower left roller pivot bolt The pivot bolt has an offset thread which when rotated acts as a cam to raise or lower the roller On the bolt head there is an identifica tion dot Fig 16 which denotes the offset ofthe bolt Dot indicates in which direction left end of roller moves when bolt is turned 8 To verify if roller is level try inserting a piece of paper under each end of roller 9 When roller is level tighten left capscrew and pivot bolt nuts securely Hold the eccentric pivot bolt while tightening the nut to keep the proper roller position Greensmaster 3150 Page 9 15 Figure 15 1 1 4 plate 2 Bedknife 3 Reel Figure 16 1 Pivot bolt Set Up and Adjustments Height of Cut Height of cut as measured on the cutting unit and in the turf is different The grass prevents the cutting unit from settling all the way to the ground line as the machine moves across the turf Because of this the actual effective height of cut is higher than the height of cut set
216. e flat washer 7 and two thrust washers 6 onto the motor shaft Slide hub 2 onto the shaft with the short side first 5 Slide remaining thrust washers 6 and flat washer 7 onto the motor shaft Install remaining snap ring 8 into the shaft groove Slide remaining new grease seal 9 onto motor shaft IMPORTANT The hub 2 should spin freely in the forward direction but lock on the hydraulic motor shaft when itis spun in the reverse direction 6 Press grease seals 9 into the hub 2 so they are flush with the end of the hub Wheels and Brakes 6 8 OUTER BEARING EDGE MUST BE FLUSH WITH EDGE ARROWS ON BEARING TOWARDS LONG END Figure 6 Installation Fig 4 1 Secure wheel 28 to the four drive studs of the hy draulic motor and hub assembly 14 with four lug nuts 30 Torque nuts from 70 to 90 ft Ib 95 to 122 Nm 2 Reinstall grease fitting 31 into hydraulic motor and hub assembly 14 so it points away from the wheel 3 Install flangette 11 bearing 10 and relube flan gette 9 onto the motor shaft 4 Position hydraulic motor and hub assembly 14 flangettes 9 and 11 with bearing 10 and wheel 28 into the castor fork Make sure hose fittings on the motor face to the rear 5 Secure hydraulic motor and hub assembly 14 loosely to the left inside ofthe castor fork with both sock et head screws 16 lock nuts 13 6 Secure flanget
217. e sure bedknife to reel contact is removed by turning bedknife adjustment knob counterclockwise Fig 6 2 Reel bearing rolling torque should not exceed 7 Measure with an inch pound torque wrench Fig 7 If bearing drag does not meet above specifications adjust reel bearings NOTE If you do not have an inch pound torque wrench do steps 1 3 under Reel Bearing Adjustment below Reel Bearing Adjustment 1 Remove mounting nuts from counterbalance end cap and remove end cap from mounting studs Fig 7 2 Remove bolt mounted on the end of reel shaft This will make it possible for a large socket wrench to be mounted onthe reel bearing adjusting nut inside the side plate A CAUTION Do not use your hand to prevent reel from turning while servicing this can result in per sonal 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 NOTE If reel bearings will not hold adjustment during operation loosen adjustment nut tighten reel shaft spline nut on right hand end of reel shaft to a torque of 40 to 60 ft Ib then adjust reel bearings 3 Tighten the large reel bearing adjustment nut Fig 7 until all reel shaft end play is removed then tighten an additional 1 16 to 1 8 turn Be certain to remove all end play but do not over tighten NOTE Adjustment nut must have enough resistance against reel shaft threads to retain bearing ad
218. e the reel being ground to the desired cylinder shape Note When grinding be careful to not overheat the reel blades Remove small amounts of material with each pass of the grinder 3 Referto Toro General Service Training Book Reel Mower Basics part no 0916851 for reel grinding infor mation 4 After completing the grinding process A Install parts removed to mount cutting unit into grinder B Install bedbar assembly see Bedbar Removal and Installation C Complete cutting unit set up and adjustment se quence see Cutting Unit Operator s Manual Reel Grinding Specifications 5 06 in 128 5 mm 4 56 in 118 8 mm 20 to 40 0 040 in 1 0 mm 0 030 to 0 060 in 0 7 to 1 5 mm 0 040 in 1 0 mm REEL DIAMETER TAPER 0 Do Figure 24 Greensmaster 3150 10 19 Rev E Dual PointAdjust Cutting Units Front Roller Removal and Installation Removal Fig 25 1 Position machine on a clean and level surface low er cutting units stop engine engage parking brake and remove key from the ignition switch Note The front roller can be removed with the cutting unit either attached to the lift arm or removed from the lift arm Determine your maintenance needs 2 Loosen cap screws securing the roller shafts to each front bracket 3 Remove the lock nut tab washer and carriage screw securing one of the front roller brackets to the cut ting unit frame assembly
219. e the washer When properly installed the seal should be positioned 104 in below the inner edge of the side plate bore 10 Press the outer seal 9 into the side plate until it is flush with the the outer edge of the side plate bore IMPORTANT The outer grease seal 9 should be installed so the lip is facing out This helps keep contamination from entering and allows grease to vent or purge out if necessary Fig 22 11 Fill remaining voids behind inner grease seal 13 and outer grease seal 9 lips with Mobil High Tempera ture HP or equivalent grease Dual Point Adjust Cutting Units Page 10 16 Right Side Plate Service Fig 18 1 Remove the inner grease seal 13 and outer grease seal 9 from the side plate 10 2 Remove the bearing 12 Inspect the bearing to in sure that it spins freely and has minimal axial play The bearing balls must be free of deformation and scoring Replace the bearing if necessary 3 Remove the O ring 11 from the groove in the side plate bore 4 Remove all grease from the side plate bore Note Replacement Seal Kit Toro Part No 106 6937 is available for side plate service of dual point adjust cut ting units 5 Insert the O ring 11 into the groove in the side plate Apply a light coating of grease onto the O ring af ter it is installed 6 Packthe bearing 12 with Mobil High Temperature HP or equivalent grease Insert the bearing into the side plate until it
220. econnect all hydraulic hoses and lines that were disconnected prior to draining Fill hydraulic reservoir 7 Disconnect both engine spark plug wires from the spark plugs 8 Turn ignition key switch and engage starter for ten 10 seconds to the prime pump Return ignition switch to off and wait one minute to allow starter to cool Repeat step a second time Greensmaster 3150 Page 4 65 9 Connect both engine spark plug wires to the spark plugs 10 Start engine and let it idle at low speed for a mini mum of two 2 minutes Increase engine speed to high idle for a minimum of one 1 minute under no load 11 Raise and lower cutting units several times 12 Shut off engine and check for hydraulic oil leaks Check oil level in hydraulic reservoir and add correct oil if necessary 13 Operate the machine for two 2 hours under normal operating conditions 14 Check condition of hydraulic oil If the flushing fluid shows any signs of contamination or if you are changing to biodegradable fluid repeat steps 1 through 14 again 15 Assume normal operation and follow recom mended maintenance intervals i Figure 40 Hydraulic System Rev E 52 BF gt Reel Motors Reel motor Hose assembly Hose assembly Hose assembly 90 hydraulic fitting O ring O ring Straight hydraulic fitting O ring 10 O ring 11 909 hydraulic fitting Hydraulic System Rev E LEFT
221. ecure drive side groomer arm assembly to groomer side plate Fig 7 14 Center front roller and tighten cap screws item 20 to secure roller Figs 7 and 8 15 Install groomer drive belt and belt cover to side of cut ting unit see Groomer Belt Replacement in this sec tion 16 Install hydraulic reel motor onto cutting unit see Hy draulic Reel Motor Installation in the Service and Re pairs section of Chapter 10 DPA Cutting Units 17 If equipped install rotating rear roller brush to cutting unit 18 Lubricate groomer bearings see Groomer Reel Kit Installation Instructions Note After greasing groomer bearings operate groomer for 30 seconds stop machine and wipe excess grease from groomer shaft and seals 19 Check groomer reel height and mower height of cut settings Adjust as needed Greensmaster 3150 Groomer Reel Service Disassembly Fig 10 Inspect groomer reel blades frequently for damage and wear Straighten bent blades with a pliers Either replace worn blades or reverse worn blades on the groomer shaft to put the sharpest blade edge forward Fig 11 Blades that are rounded to the midpoint of the blade tip must be replaced or reversed for best groomer perfor mance 1 Remove groomer reel see Groomer Reel Removal in this section 2 Remove lock nut from either end of the shaft Fig 10 3 Remove spacers and blades as necessary Assembly Fig 10 1 Start by placing two 2 spacers agai
222. ed hex nut 28 securing the steering cylinder rod end 9 to the cas tor fork B Release the steering cylinder rod end from the castor fork C Remove the four hex head screws and flat wash ers securing the fuel tank to the frame D Tilt rear of fuel tank up to gain access to the top of the castor fork Support fuel tank securely A CAUTION Support the castor fork while removing the slotted hex nut 5 to prevent the fork from drop ping and causing personal injury E Remove cotter pin 6 and slotted hex nut 5 from the castor fork shaft Lower castor fork from the frame F Clean and inspect bearing cones 3 and bearing cups 2 for damage and replace if necessary 6 Remove lug nuts 11 from the drive studs 23 of the wheel hub assembly 17 Separate wheel and hub as semblies Wheels and Brakes Page 6 4 Figure 3 1 Bearing cup 4 Shaft seal 2 Wheel hub 5 Drive stud 3 Bearing cone Disassembly Fig 2 1 Ifdrive studs 23 are bent or damaged press studs from the wheel hub 21 2 Remove oil seals 18 Clean and inspect bearing cones 19 and bearing cups 20 for damage and re place if necessary Assembly Fig 3 1 Pack bearing cones 19 with No 2 multipurpose lithium base grease and Install bearing cones into the wheel hub 2 Grease inner edge of the new shaft seals 18 with No 2 multipurpose lithium base grease Install new shaft seals 18 into the hub with t
223. edv teg 15 Cutting Unit Removal and Installation 15 Reel Lapping 16 Bedbar Removal and Installation 17 Bedknife Replacement 18 Preparing Reel For Grinding 18 Reel Removal and Bearing Replacement 19 Lift Bail 20 Table of Contents Specifications Height of Cut 3 16 0 1875 in to 11 16 0 6875 in Clip Frequency and Optimum Height of Cut Range Optimum Height Model No Clip max of Cut Range 04408 0 25 in 3 16 to 5 16 in 04406 0 18 in 1 8 to 7 32 in Roller Adjustment Front Micrometer hand adjustment with bolted clamp lock 1 turn 0 025 in height of cut change Rear Pivot arm change on slot in side plate with locking nuts for paralleling roller to reel and adjusting bedknife attitude Bedknife to Reel Adjustment Bedknife adjusts against reel with opposed screw adjustment on each end of bedbar Reel Speed 1940 rpm engine speed 2800 rpm Bedknife Screw Torque 200 to 250 in Ib Reel Splined Drive Nut Torque 40 to 60 ft lbs Reel Bearing Rolling Torque 7 max Front or Rear Roller Run Out 0 014 in max Lift bail 5 Grease fittings reel bearings Grease fittings roller 7 Height of cut adjustment knob 2 PONS Specifications Height of cut adjustment locknut 6 Scraper adjusting nut 4 Pull rod studs 2 Page 7 2 8 Grass shield 9 A
224. eel Motor Case Drain Flow Test Steering Control Valve ADJUSTMENTS Adjust Manifold Relief Valves R1 and R2 SERVICE AND REPAIRS General Precautions for Removing and Installing Hydraulic System Components Gear PUMP osi meon teg Gear Pump Service Greensmaster 3150 Chapter 4 Hydraulic System Hydraulic System Start up 53 Hydrostatic Transmission 54 Piston Pump Service 58 Piston Pump Crush Ring Replacement 59 Front Wheel Motors 60 Rear Wheel Motor 62 Wheel Motor Service 64 Flush Hydraulic System 65 Heel MOtOrS sje nouit eere a idee leet 66 Reel Motor Service 68 Lift Cylinders 72 Lift Cylinder Service Serial Number Under 240000000 74 Lift Cylinder Service Serial Number Above 240000000 76 Hydraulic Manifold 78 Hydraulic Manifold Service Serial Number Under 260999999 80 Hydraulic Manifold Service Serial Number Above 270000000 82 Backlap Kit Optional Kit For Serial Number Under 260999999 86 Rear
225. eel shaft as follows A Check the reel shaft for bending and distortion by placing the shaft ends V blocks Replace the reel if necessary B Check the reel blades for bending or cracking Replace the reel if necessary C Check the drive adapter inside of the reel shaft Fig 21 The adapter should be free of bending and distortion Check the splines for excessive cracks or distortion Replace the reel if necessary D Check the service limit of the reel diameter Re place the reel if necessary 5 Using an appropriate 1 0 tube or sleeve press the speedi sleeve onto the reel shaft until it bottoms out on the spider cup Fig 22 IMPORTANT Do not nick or scratch the Speedi sleeve surface as seal failure could result 6 Slide the V ring onto the reel shaft with the thick shoulder of the V ring facing inward Fig 22 7 Fill the drive coupling 4 1 2 to 1 3 full with Mobil High Temperature HP or equivalent grease Also coat the outside of the drive coupling with grease 8 Install the retaining ring 5b Make sure it is seated into the groove 1 Reel shaft 2 Drive adapter Figure 21 3 Adapter spline 1 4 104 Seal Depth 1 Outer seal 2 Inner seal 3 Speedi sleeve Greensmaster 3150 Page 10 17 Figure 22 4 V ring 5 Left side plate Dual Point Adjust Cutting Units Reel Installation Fig 18 IMPORTANT Wipe any excess grease from the inner grease sea
226. eight of Cut HOC Cutting height is adjusted on the front roller by two vertical screws and held by two locking capscrews Standard bench height of cut range is 062 inch 1 6 mm to 375 inches 9 5 mm depending on type of bedknife installed Bench height of cut range with the High Height of Cut Kit installed is 285 inch 7 mm to 1 inch 25 mm Effective HOC may vary de pending on turf conditions type of bedknife rollers and attachments installed Reel Construction Reels are 5 inches 13 cm in di ameter 21 inches 53 3 cm in length High strength low alloy steel blades are thru hardened and impact resis tant Reels are available in 8 and 11 blade configura tions Reel Bearings Two double row self aligning ball bear ings 30 1 mm inside diameter slip fit onto reel shaft with lock nut Additional inboard and outboard seals for added protection Reel position maintained by a wave washer with no adjusting nut Reel Drive The reel weldment shaft is a 1 375 inch di ameter tube with drive inserts permanently pressed in both ends A replaceable floating coupler with an inter nal eight tooth spline is factory installed on the right end and held in place by a snap ring Frame Construction Precision machined die cast alu Bedknife Replaceable single edged high carbon steel bedknife is fastened to a machined cast iron bedbar with 13 screws Tournament bedknife is standard Bedknife Adjustment Dual screw adjustment t
227. ement etc Note The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 10 ofthe nominal torque value Product Records and Maintenance Product Records 5 lt Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size 1 4 20 UNC 140 20 in Ib 73 12 16 215 35 in Ib 145 20 in lb 5 16 18 UNC 3 8 16 UNC 35 10 ft lb 18 ft lb 50 10 ft lb 1 2 13 UNC 75 15 ft lb Thread Cutting Screws Zinc Plated Steel Type 1 Type 23 or Type F Thread Size Baseline Torque No 6 32 UNC 20 5 16 No 8 32 UNC 30 5 in Ib No 10 24 UNC 38 7 in Ib 1 4 20 UNC 85 15 in Ib 5 16 18 UNC 110 20 in Ib 3 8 16 UNC 200 100 in Ib Conversion Factors in Ib X 11 2985 N cm ft lb X 1 3558 N m Maintenance Maintenance procedures and recommended service in tervals for the Greensmaster 3150 are covered in the Traction Unit Operator s Manual Maintenance proce dures and recommended service intervals for the Greensmaster Cutting Units are covered in the Cutting Product Records and Maintenance Page2 6 Wheel Bolts and Lug Nuts Thread Size Recommended Torque 7 16 20 UNF 65 10 ft lb Grade 5 1 2 20 UNF 80 10 ft lb Grade 5 M12 X 1 25 80 10 ft lb Class 8 8 M12 X 1 5 80 10 ft Ib Class 8 8 Fo
228. en a left turn is made with the engine running the turning ofthe steering wheel positions the spool valve so that flow goes through the bottom of the spool Flow en tering the steering control valve at Port P goes through the spool and is routed to two places First most of the flow through the valve is by passed out port E back through solenoid valve S2 to the hydrostat Second the remainder of the flow is drawn through rotary meter V1 and out port L Pressure moves the piston in the direction for a left turn The rotary meter ensures that the oil flow to the cylinder is proportional to the amount of the turning on the steering wheel Fluid leaving the cylinder flows back through the spool valve and out port T The returning flow passes through the manifold block using ports ST and PT and on to the hydrostat The steering wheel and steering control valve return to the neutral position when turning is complete Hydraulic System Rev E 3 22 55 gt Special Tools Order these special tools from your Toro Distributor Hydraulic Pressure Test Kit TOR47009 Use to take various pressure readings for diagnostic tests Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools A high pressure hose is provided for remote readings Contains one each 1000 PSI 70 Bar 5000 PSI 350 Bar and 10000 PSI 700 Bar gauges Use gauges as recommended in the Testing sect
229. er 3150 Page 4 47 Before continuing further read and become fa miliar with Precautions for Hydraulic Testing D Read Precautions for Hydraulic Testing E Remove hydraulic hose from the 90 fitting on the rod end of the steering cylinder Plug the end of the hose F With the engine off continue turning the steering wheelto the left counterclockwise with the steering cylinder fully extended Observe the open fitting on the steering cylinder as the steering wheel is turned If oil comes out ofthe fitting while turning the steering wheel to the left the steering cylinder has internal leakage and must be repaired or replaced G Remove plug from the hydraulic hose Recon nect hose to the steering cylinder fitting 7 If steering problem exists and steering cylinder tested acceptably steering control valve requires ser vice see Steering Control Valve and Steering Control Valve Service in the Service and Repairs section of this chapter Hydraulic System Rev E 2 i gt Adjustments Adjust Manifold Relief Valves R1and R2 These relief valves are installed on the hydraulic man ifold Relief valve R1 is in the mow circuit machines with serial number under 260999999 and relief valve R2 is the lower cutting units relief Never adjust the relief valve with the hydraulic system pressurized Hydraulic oil may spray out ofthe valve with the cap off Personal injury may resul
230. er Bracket Hole Position 8 Blade Cutting Units Figure 13 Height of cut 3 16 187 in and below use the B position 1 Rear height of cut bracket 3 Bottom nut Height of cut 5 32 156 in and above Use the C position 2 Top capscrew and nut Height of cut between 5 32 156 and 3 16 187 in try C first if not satisfactory use B NOTE For Height of Cut 5 32 156 in and lower use 3 32 in tournament bed knife Tournament bed knife should not be necessary with the rear roller in the C position Rear Roller Bracket Hole Position 11 Blade Cutting Units Height of cut 3 16 187 in and below use the B position Height of cut 5 32 156 in and above Use the C position Height of cut between 5 32 156 and 3 16 187 in try B first if not satisfactory use C NOTE For Height of Cut 3 16 187 in and lower use 3 32 in tournament bed knife Tournament bed knife should not be necessary with the rear roller in the C position NOTE The B hole position normally is the best rear roller location for most low 3 32 1 8 cutting condi tions Figure 14 It may be necessary to change from the above sug 1 Right rear roller bracket capscrews gested ranges in certain turf conditions 4 After putting bracket into correct height of cut hole position make sure right hand rear roller bracket capscrews are tightened securely Fig 14 5 Left hand rear roller bracket capscrews are to be tightened only enough to remov
231. er Reel Installation in this section 4 Lubricate groomer bearings see Groomer Reel Kit Installation Instructions Note After greasing groomer bearings operate groomer for 30 seconds stop machine and wipe excess grease from groomer shaft and seals 5 Check and adjust groomer reel height and mower height of cut settings Greensmaster 3150 Page 10 1 13 Figure 14 Socket head screw Motor mount Groomer side plate RH 4 Cutting unit 5 Lock nut 2 used Figure 15 1 groomer side plate 2 Lock nut spring washer 3 LH groomer arm Groomer DPA Cutting Unit Rev A 5 D amp Idler Assembly toward center of cutting unit Seal lip toward center of cutting unit Figure 16 1 Locknut 6 Seal 11 Side plate bushing 2 Flat washer 7 Bearing 12 Idler bracket 3 Retaining ring 8 Grease fitting 13 Retaining ring 4 Idler bearing 9 Groomer drive side plate LH shown 14 Bushing 5 pulley 10 Pivot hub The groomer drive side plate assembly incorporates the idler system for tensioning the groomer drive belt The idler system uses a spring to maintain proper belt ten sion Note The groomer reel drive is located on the oppo site side ofthe cutting unit from the cutting reel hydraulic motor Figure 16 shows the groomer reel drive from the left side of the cutting unit Removal 1 Remove groomer belt cover drive belt and drive p
232. ers are available for 1 4 in 76 blades or 3 4 in 26 blades blade spacing 8 Reverse steps 1 5 to install groomer reel Check drive belt tension before installing cover See Groomer Reel Drive Belt Replacement in this section of the book Figure 46a 1 Groomer reel shaft 2 Locknut 3 R H groomer housing Figure 46b 1 Groomer reel shaft 2 Bearing Seal Facing Out Figure 47 1 Groomer reel shaft 2 Bearing 4 3 Bearing spacer 2 4 R H groomer housing Greensmaster 3150 9 29 4 R H groomer plate 5 Bearing 6 Bearing spacer 3 L H groomer housing 5 L H groomer housing 6 Locknut 7 Belt 8 Driven gear Repairs Groomer Reel Clutch Service Do not use your hand to prevent reel from turning while servicing this can result in per sonal 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 Removal and Disassembly 1 Loosen two 2 set screws and remove clutch knob Fig 51 Remove groomer reel housing cover from left side of cutting unit Fig 39 2 Loosen idler pulley pivot screw Fig 45 Pivot idler to loosen belt 3 Remove nut and washer from clutch adapter shaft Fig 51 Pull clutch assembly off adapter shaft and slide belt off driven pulley 5 Remove clutch adapter from reel shaft if necessary Fig 49 6 To disassemble clutch remove special screw
233. et screws against flats on release disk Repairs Page 9 28 Figure 45 1 Drive pulley and clutch assembly 2 Driven pulley 3 Drive belt backside idler pulley 4 Drive belt Greensmaster 3150 Groomer Reel Removal and Bearing Service 1 Loosen two 2 set screws and remove clutch knob Fig 6 Remove groomer reel housing cover from left side of cutting unit Fig 39 2 Loosenthe backside idler pulley pivot screw Fig 45 Pivot idler to loosen and remove belt 3 Remove groomer driven pulley from groomer reel shaft left hand thread Fig 45 4 Remove locknut from right end of groomer reel shaft Fig 46a 5 Remove three 3 screws and nuts securing bearing housing to right side groomer plate Fig 46a Remove right side bearing bracket from groomer reel shaft Remove groomer reel shaft from bearing support in left side groomer housing Fig 46b 6 Check condition of groomer shaft bearings and replace if necessary Fig 47 Bearings must be installed with seal facing out on each side of bearing housing For each groomer housing R H and L H install outer bearing and spacer first Install inner bearing so it is flush with the housing Fig 47 7 To replace groomer reel blades remove locknut on each end of groomer reel shaft Remove blades and spacers install new blades and previously removed spacers Install locknut on each end of groomer shaft to secure blades and spacers NOTE Spac
234. ete circuit for the solenoid Relay K2 has intermittent ground Battery is dead Wiring to the start circuit see Wiring Schematics components is loose corroded or damaged Battery cables are loose or corroded Battery ground to frame is loose or corroded Starter solenoid fusible link is open Fuse block is faulty 20 ampere fuse F1 is loose or blown Diode D1 B or start safety relay is faulty The ignition switch is faulty Starter solenoid is faulty Neutral sensor is out of adjustment or faulty 5 5 Electrical System Starting Problems continued Engine cranks but does not start Engine cranks but should not with the Functional Control Lever in the MOW or TRANSPORT position General Run and Transport Problems Engine kills when the Functional Control Lever is in the MOW or TRANSPORT position with the operator in the Battery does not charge Engine kills during operation operator sitting on seat Electrical System Page Possible Causes Wiring to start circuits see Wiring Schematics is loose corroded or damaged Wiring to engine is see Wiring Schematics is loose corroded or damaged Diode D1 A circuit is open Engine or fuel system is malfunctioning see Chapter 4 Engine Kill relay K1 is faulty or grounded Engine and fuel may be too cold Fuel solenoid is faulty Neutral sensor is out of adjustment faulty or short circuited Possible Causes Operator is sit
235. f roller shaft 2 Remove v ring from each end of roller 3 Carefully inspect seating surface and threads of bearing lock nuts Replace lock nut if any damage is found 4 Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until seal and bearing are removed from roller cavity Remove second seal and bearing from roller cavity by tapping on shaft 5 Clean bearing cavity in roller and remove any rust with crocus cloth Assembly 1 Place roller shaft into roller Note f bearing lock nuts are being replaced use original lock nuts for assembly purposes if possible This will preserve the patch lock feature in the new lock nuts Use the new nuts only after new bearings and seals have been installed Dual Point Adjust Cutting Units Page 10 24 Rev A 6 V ring 7 Bearing lock nut Figure 30 1 Roller 4 V ring 2 Ball bearing 5 Bearing lock nut 3 Seal 6 Roller shaft Figure 31 3 Bearing 1 Bearing lock nut 2 Black assembly washer Greensmaster 3150 Note Special tool TOR4105 see Special Tools be used instead of washers and spacer when installing bearings and seals in roller 2 Position a new bearing black assembly washer see Special Tools and original lock nut onto each end of the roller shaft Fig 31 3 Tighten nuts until the bearings are seated into e
236. fork 6 from the frame See Rear Wheel 2WD Removal in this chapter of this manual for additional information Figure 5 4 Drive stud 5 Grease fitting 6 Thrust washer 1 Hydraulic motor 2 Hub 3 Clutch roller bearing Greensmaster 3150 Page 6 7 7 Washer 8 Snapring 9 Grease seal Wheels and Brakes Disassembly Fig 5 1 Remove grease seal 9 and snap ring 18 from the long end of hub 2 2 Remove washer 7 two thrust washers 6 and hub 2 from the hydraulic motor shaft Remove remain ing twothrust washers 6 washer 7 snap ring 8 and grease seal 9 from the shaft 3 If drive studs 4 are bent or damaged press studs from the wheel hub 2 4 Press clutch roller bearings 3 from the hub 2 Assembly Fig 5 1 If drive studs 4 were removed press new studs into the wheel hub 2 2 Press roller clutch bearings 3 into the hub 2 as follows Fig 6 Note Arrow on the side of the clutch roller bearings 8 must point to the long side of the end of the hub 2 A Press two bearings into each end of the hub B The outer edge of the outer bearings must be flush with the recessed edge within the hub C Center bearings must not interfere with grease fitting hole 3 Grease inner edge ofthe new grease seals 9 with No 2 multipurpose lithium base grease Slide one seal onto motor shaft past groove closestto the motor Install snap ring 8 into groove 4 Slid
237. g 35 Remove large bearing ad justment nut from one end of reel shaft Fig 35 and special spline nut at opposite end of reel shaft 3 Remove machine screws securing bearing housing each end of cutting unit Fig 36 The machine screw heads will have to be cut off before the screw can be completely removed A Unscrew machine screw approximately two turns B Cut off machine screw head C Back out remaining part of screw from side plate with a screw driver outwards not inwards towards reel If machine screw does not have a screw driver slot use a pliers to back out screw IMPORTANT Remove grease fittings from bearing housing at each end of cutting unit Note that the straight fitting is on the right end and 90 fitting at the left end when viewed in the direction of travel 3 Use a soft face hammer to rotate bearing housing slightly Install bolts from outside of housing and turn bolts alternately against side plate to remove bearing housing Fig 37 Bearing housing will slip out of side plates Reel can be removed as soon as bearing hous ings are disassembled from side plates 4 Before installing reel install new special machine screws from inside of frame to secure bearing housings 5 necessary install new bearings and seals A Remove outer seal in counterbalance weight bearing cup bearing cone and inner seal B Bearing housing must be completely free of paint and foreign material before ins
238. g and Installing Hydraulic System Components 2 Remove leak detector assembly see Leak Detector Removal in this chapter of this manual 3 Drain remaining hydraulic oil from hydraulic tank through pump inlet hose into a suitable container 4 Unplug oil level sensor harness connector 5 Disconnecthose assembly fromthe reel motor case drain fitting located below the right side of the frame Al low hose to drain to a suitable container Fig 73 6 Disconnect return hose 16 from hydraulic barb fit ting attank Allow hose to drain into a suitable container 7 Remove three cap screws 19 flat washers 20 and spacers 22 securing the hydraulic tank 6 to the vehicle frame 8 Remove hydraulic tank 9 Remove fittings and oil level sensor from hydraulic tank if necessary Inspecting Reservoir Parts Fig 72 1 Clean tank and filler screen with solvent 2 Inspect tank for leaks cracks or other damage 3 Replace hydraulic hoses if worn or leaking Installing Hydraulic Reservoir Fig 72 1 Install all removed fittings into hydraulic tank 2 If oil level sensor was removed from tank install sensor in tank making sure that arrow on sensor is point ing down Fig 74 3 Position tank onto the vehicle frame Greensmaster 3150 Page 4 103 4 Apply antiseize lubricant to threads of three cap screws 19 Secure hydraulic tank to the vehicle frame with three cap screws flat washers 20 and spacer
239. g Service and Adjustment in the Adjustments section of this chap ter 7 Grind the reel to remove any taper and renew cutting edges See Preparing Cutting Unit for Reel Grinding in this section of the book 8 Check size of hole in bedbar end bushings every time bedbar is removed Insert flange bushing into rubber bushing Fig 25 Insert clean shoulder bolt into flange bushing rubber bushing assembly If bolt slides easily into bushing replace all four bedbar bushings See Bedbar Bushing Replacement in this section of the book Figure 25 1 Rubber bushing 3 Shoulder pivot bolt 2 Flange bushing Repairs Page 8 20 Greensmaster 3150 9 With frame on level surface and pivot set screws installed measure from flat surface up to end of each setscrew Fig 26 If not within 1 16 in of each other carefully bend frame supports toline up screws Remove pivot set screws Measure distance between frame pivot supports Fig 26 If dimension is not between 1 9 16 in and 1 5 8 in carefully bend supports until correct Surface 10 To install bedbar slide it into into position between side plates making sure each end of bedbar is under shield Fig 27 IMPORTANT Always use McLUBE Toro Part No 505 35 on bedbar pivot and pivot bolts 11 Install jam nut on eccentric pivot bolt Put plastic washer between left side of bedbar and side plate Thread pivot bolt into side frame until distance from top
240. g clean mineral spirits Submerge valve in clean mineral spirits to flush out contamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves Use compressed air for cleaning 5 Reinstall logic cartridge valve 10 A Lubricate new O ring and backup ring of seal kit 9 with clean hydraulic oil and install The O ring and backup ring must be arranged properly on the cartridge valve for proper operation and sealing B Thread cartridge valve carefully into the port LC1 The valve should go in easily without binding Torque the valve to 35 ft lb 47 Nm Greensmaster 3150 Rear Lift Cylinder Flow Control Valve Serial Number Under 260999999 Removal 1 Before removing any parts from the hydraulic sys tem park machine on a level surface engage parking brake lower cutting units and stop the engine Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components 2 Labelall hydraulic connections for reassembly Dis connect hose assembly and O ring from the hydraulic Serial Number 230000801 To fitting Allow hose to drain into a suitable container 260999999 Shown 3 Remove hydraulic fitting and O ring from flow con Figure 59 trol valve Remove valve and O ring from hydraulic fit a manifold 5 m fitting m ow control valve Hydraulic hose ting Put caps or plug on hydraulic c
241. g reel blade spacing 5 Height of cut NOTE Because of weight difference bench set height of cut should be approximately 0 020 to 0 040 in higher on groomer equipped cutting units to get the same effective height of cut as cutting units without groomer reels 6 Grooming depth 7 How long grooming reel has been in use on a particular turf area 8 Type of grass 9 Overall turf management program i e irrigation fertilizing weed disease and pest control coring overseed ing sand dressing etc 10 Amount of traffic on turf 11 Stress periods for turf high temperatures high humidity unusually high traffic Troubleshooting Page 9 8 Greensmaster 3150 Grooming Reel Mechanical Problems Problem Possible Cause Correction 1 Groomer rotates when in raised position with Normal condition the groomer may still rotate in clutch disengaged raised position with minimal force when clutch dis engaged because of friction in the clutch assembly This condition may change over a period of time Clutch not fully disengaged Make sure clutch knob set screws are tight against flats on release disk and does not allow knob to slip IMPORTANT When engaging or disengaging clutch be sure to push snubber down and turn knob all the way will come to a firm stop Clutch pulley bearing seized Replace bearing Clutch damaged or assembled incorrectly Repair or re
242. ge Wash all metal parts in clean solvent Blow them dry with pressur ized air Do not wipe parts dry with paper towels or cloth Lint in a hydraulic system will cause damage NOTE Always use new seals and O rings when reassembling the steering control unit IMPORTANT During reassembly lubricate the new seals with petroleum jelly Also lubricate machined surfaces and bearings with clean hydraulic fluid 1 Install the quad seal A Put one of the bearing races and sleeve into the housing B Together the housing and bearing race create a groove into which the quad seal will be installed C Hold the bearing race tightly against the input end of the housing by pushing on the gerotor end of the sleeve D Fitthe quad seal into its seat through the input end of the housing Be sure the seal is not twisted E Remove the sleeve and bearing race 2 Lubricate and install the dust seal 3 Install the centering springs in the spool It is best to install the two flat pieces first Next install the curved pieces three at a time 4 Fit the retaining ring over the centering springs 5 Apply a light coating of clean hydraulic fluid to the spool and slide it into the sleeve Be sure the centering springs fit into the notches in the sleeve 6 Install the pin Greensmaster 3150 Page 4 93 7 Apply a light coating of petroleum jelly to the inner edge of the dust and quad seals 8 Put the thrust bearing and races i
243. groomer Height setting on both ends of groomer should be identi cal Groomer DPA Cutting Unit Rev A Page 10 1 6 Greensmaster 3150 Service and Repairs Groomer Belt Replacement 1 Park machine on a clean and level surface lower cutting units completely to the ground stop engine en gage parking brake and remove key from the ignition switch 2 If equipped remove rotating rear roller brush from cutting unit 3 Remove two 2 lock nuts that secure groomer belt cover then remove cover Fig 4 4 Pivot idler pulley by placing a 12mm wrench on pulley nut and rotating idler bracketto relax belt tension Slip groomer drive belt off pulleys Fig 5 Carefully re lease idler bracket Figure 4 1 Groomer belt cover 3 Cap 5 Install new drive belt to drive pulley idler pulley and gt Lock nut driven pulley observing correct belt routing Fig 5 6 Secure belt cover to housing with two 2 lock nuts Fig 4 If equipped install rotating rear roller brush to cutting unit Figure 5 1 Drive pulley 4 Driven pulley 2 Idler pulley 5 Groomer drive belt 3 Idler pulley nut 5 D amp Greensmaster 3150 Page 10 1 7 Groomer DPA Cutting Unit Rev A Groomer Reel 100 to 120 in Ib 19 11 3 to 13 5 N m 18 60 to 80 ft Ib 81 to 108 N m NS RIGHT FRONT Antisieze Lubricant 100 to 120 Pg 11 3 to 13 5 N m Figure 6 1 Lock n
244. h set screws 23 the pump hub 24 enough to allow the hydrostat shaft to be removed Support the hydrostat when removing its sup porting fasteners to prevent it from falling and causing personal injury 13 Remove both cap screws 35 lock washers 34 and flat washers 33 14 Separate hydrostat from the pump adapter and pump hub 24 Remove key 21 from the hydrostat shaft Installation Fig 30 1 Make sure the inside of the pump hub 24 is clean Apply antiseize lubricantto both the hydrostat 12 shaft and the inside of the pump hub 2 Coatkey 21 with petroleum jelly and insert it into the hydrostat shaft Position hydrostat to the pump adapter and pump hub 24 Slide the shaft into the hub with the key 3 Secure the hydrostat to the pump adapter with both cap screws 35 lock washers 34 and flat washers 33 Torque screws from 27 to 31 ft Ib 37 to 42 Nm 4 Torque both set screws 23 on the pump hub 24 from 90 to 110 in Ib 10 2 to 12 4 Nm Hydraulic System Rev E Page 4 56 5 Inspectthreads and sealing surfaces of hydraulic fit tings and hydraulic hose connectors Replace any dam aged or worn fittings or connectors 6 Lubricate all new O rings with clean hydraulic fluid 7 Install O rings 18 36 and 45 and hose assem blies 19 20 and 44 IMPORTANT Failure to remove the plug will cause excessive pressure in the hydrostat and damage seals 8 Remove plug from
245. he end of the charging mea sure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 003 change in specific gravity for three consecutive readings Electrical System This page is intentionally blank Electrical System Page 5 22 Greensmaster 3150 Chapter 6 TORO Wheels and Brakes Table of Contents SPECIFICATIONS 2 SERVICE AND REPAIRS 3 SPECIAL TOOLS 2 Rear Wheel WD 3 Rear Wheel Optional 3WD 6 Front Wheel and Brake 9 Greensmaster 3150 Page6 1 Rev A Wheels and Brakes Specifications Item Description Front tire pressure 19 x 10 50 x 2 ply 8 to 12 PSI 0 55 to 0 83 bar Rear tire pressure 19 x 10 50 x 2 ply 8 to 15 PSI 0 55 to 1 04 bar Wheel lug nut torque 70 to 90 ft Ib 95 to 122 Nm Special Tools Wheel Hub Puller TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors Figure 1 Wheels and Brakes Page6 2 Rev A Greensmaster 3150 Service and Repairs Rear Wheel 2WD 7 36 3 35 Antiseize RIGHT Lubricant FRONT Pd Steering cylinder Bearing cup Bearing cone Washer Slotted hex nut Cotter pin Grease fitting J am nut Rodend
246. he lip of the seals fac ing towards the inside 3 Ifremoved press new drive stud 23 into the wheel hub 21 Installation Fig 2 1 Slide wheel assembly onto the drive studs 23 Tighten lug nuts 11 to the drive studs evenly in a cris cross pattern to a torque of 70 to 90 ft lb 95 to 122 Nm 2 Ifthe bearings in the castor fork pivot housing were removed install castor fork 24 to the frame as follows A Press new bearing cups 2 into the castor fork pivot housing with the thick side of the cups facing towards the inside B Pack bearing cones 3 with No 2 multipurpose lithium base grease C Coat castor fork shaft with antiseize lubricant and place two steering washers 4 onto the castor fork shaft Slide lower bearing cone onto castor fork shaft with the wide edge of the bearing against the washers Greensmaster 3150 D Insert castor fork shaft up through the pivot housing and bearing cups E Place second bearing cone on the castor fork shaft with the wide edge up Place remaining steer ing washers on top of the bearing cone F Install slotted hex nut 5 onto castor fork shaft until drag is felt while turning the castor fork Back off hex nutto align the hole in the castor fork shaft to the nearest slot Install and secure cotter pin 6 G Install steering cylinder rod end 9 to the castor fork with spacer 29 slotted hex nut 28 and anew cotter pin 27 H Remove fuel tank support a
247. heck the continuity of the switch by connecting multimeter ohms setting across the connector termi nals 4 Withthe parking brake set there should be no conti nuity across the switch terminals Greensmaster 3150 Page 5 13 Figure 16 3 Parking brake sensor 1 Mounting plate 2 Latch assembly 5 Release the parking brake There should be conti nuity across the switch terminals 6 Connect switch electrical connector Reset the parking brake Electrical System Joystick Raise and Lower Switches The joystick raise and lower switches are located on the lift control mechanism The rear switch is used to lower the reels and the front switch to raise them Fig 17 The switches are identical and are shown in Figure 18 1 Make sure the engine and ignition switch is Off Re move the plastic cover and disconnect the harness con nectors from the switches 2 Checkthe continuity of the raise switch by connect ing a multimeter ohms setting across the switch con nector terminals as follows A With the joystick in the rest position continuity should only exist between the common and NC ter minals blue and green black wires B With the joystick in the raise position continuity should only exist between the common and NO ter minals blue and green gray wires 3 Checkthe continuity ofthe lower switch by connect ing a multimeter ohms setting across the switch con nector terminals as follows
248. horizontal frame tube Fig 38 from the top of the horizontal frame tube Make sure the lift bail is square to the side frame 2 Use a grinder to remove burrs from the stubs of the lift bail remaining on the cutting unit 5 Weld all around the bottom of the repair lift bail with mild steel rod both sides 3 Install the repair lift bail Part No 71 1600 Repairs Page 8 26 Greensmaster 3150 Chapter 9 Grooming Reel Cutting Units Table of Contents SPECIFICATIONS 9 3 Groomer Reel Drive Belt Adjustment 9 19 15 9 4 Pull Frame Adjustment 9 20 9 6 REPAIRS LEER 9 21 Factors Affecting Quality of Cut 9 6 Cutting Unit Removal and Installation 9 21 Factors Affecting Grooming 9 8 Reel Lapping 9 22 Groomer Mechanical Problems 9 9 Bedbar Removal and Installation 9 22 SET UP AND ADJUSTMENTS 9 10 Bedbar Bushing Replacement 9 24 Adjustment Summary and Check List 9 10 Bedknife Replacement 9 25 Bedknife to Reel Contact 9 11 Preparing Cutting Unit for Reel Grinding 9 25 Reel Bearing Service and Adjustment 9 12 Reel Removal and Bearing Replacement 9 26 Parallel Bedknife to 9 13 Groomer Reel Blad
249. hose assembly item 10 in Fig 9 both include a check valve as a component of the hose as sembly The check valve is not available as a separate part To ensure proper operation of check valves do not attempt to remove them from the hose assembly If ei ther of these hose assemblies is removed make sure that they are correctly installed to ensure proper opera tion of the evaporative control system Greensmaster 3150 NOGPWNE NOG PWNE FRAME MOUNTED CANNISTER Figure 8 Control panel 8 Hose Carbon cannister 9 Hose clamp 2 used Hose clamp 10 Cable tie Hose to fuel tank valve 11 Bracket Hose clamp 2 used 12 Screw 2 used Hose to intake manifold 13 Hose Check valve 14 Fresh air filter LEAK DETECTOR TANK MOUNTED CANISTER Figure 9 8 Hose clamp Leak detector tank Carbon cannister Cable tie 2 used Hose clamp Purge hose assembly Hose clamp Hose to fuel tank valve 3 9 Rev 9 Hose to t fitting 10 T hose assembly 11 Fresh air filter 12 Hose to air cleaner 13 Barbed fitting Engine Disassembly Assembly 1 Install all removed components using Figure 8 or 9 as a guide On machines with frame mounted carbon canis Gasoline is flammable Use caution when storing ter if check valve item 7 in Fig 8 was removed or handling it Wipe up any spilled fuel before make sure that arrow on valve body points toward starting the engine engine B On
250. ically operated control valves are actuated Return ignition switch to OFF when pressure has been relieved Remove key from the ignition switch 3 Putcapsor plugs on any hydraulic lines hydraulic fit tings and components left open or exposed to prevent contamination 4 Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed 5 Note the position of hydraulic fittings especially el bow fittings on hydraulic components before removal Mark parts if necessary to make sure they will be aligned properly when reinstalling hydraulic hoses and tubes Greensmaster 3150 Page 4 49 After Repair or Replacement of Components 1 Check oil level in the hydraulic reservoir and add cor rect oil if necessary Drain and refill hydraulic system reservoir and change oil filter if component failure was severe or system is contaminated see Flush Hydraulic System 2 Lubricate O rings and seals with clean hydraulic oil before installing hydraulic components 3 Make sure caps or plugs are removed from the hy draulic tubes hydraulic fittings and components before reconnecting 4 Use proper tightening methods when installing hy draulic hoses and fittings see Hydraulic Fitting Installa tion 5 After repairs check control linkages or cables for proper adjustment binding or broken parts 6 After disconnecting or replacing any hydraulic com ponents operate machine functio
251. ig 10 and tighten to a torque of 170 210 in lb 8 Hold belt on drive pulley and slide clutch on clutch adapter while sliding belt on driven pulley Install washer and nut removed step 4 on clutch adapter shaft and Figure 10 tighten nut to a torque of 7 10 ft lb Adjust drive belt tension before installing cover See Groomer Reel Drive 1 Clutch adapter shaft p 2 Reel shaft and bearing Belt Adjustment in this section of the book adjustment nut Set Up and Adjustments Page 9 12 Greensmaster 3150 Parallel Bedknife to Reel 1 Remove mower from traction unit and put on a level work surface Make sure reel contact is removed by turning bedknife adjustment knob counterclockwise 2 On right hand end of reel insert a long strip of newspaper between the reel and bedknife While slowly rotating reel forward turn bedknife adjusting knob Fig 11 clockwise one click at a time until paper is pinched lightly resulting in a slight drag when paper is pulled 3 Check for light contact at other end of reel using paper If light contact is not evident at both ends bedknife is not parallel to reel proceed to step 4 4 Loosen jam nut on left hand bedbar pivot bolt so bolt can be turned Left hand pivot bolt eccentric bolt has offset thread which when rotated acts as a cam to raise or lower the bedbar Identification dot on bolt head denotes offset of bolt When dot is in up position Fig 12 left end of bed
252. in this section of the book Note Some reel grinders may require rear roller as sembly be mounted to the cutting unit for proper support in reel grinder Rear roller must be parallel to reel shaft to remove taper when grinding 2 Raise or remove front roller assembly A Loosen the locknuts securing height of cut ad justing rods at both ends of the cutting unit and the roller shaft clamp bolts Fig 38 B Turn height of cut adjustment knobs to raise roll er out of way or remove roller if necessary For proper grinding of reel follow procedures in the Toro publication Sharpening Reel and Rotary Mowers Form No 80 300 PT 3 Do steps 8 16 under Bedbar Removal and Installa tion in this section of the book After grinding assemble cutting unit check bearing adjustment and adjust top shield and bar Backlap if necessary to get desired fit be tween reel and bedknife Greensmaster 3150 Page 9 25 SP Figure 37 Figure 38 Height of cut locknut Roller shaft clamp bolt Height of cut knob Grooming reel cover Cover screws and washers Repairs Reel Removal and Bearing Replacement 1 Do steps 1 4 under Bedbar Removal and Installation in this section of the book 2 Loosen two 2 set screws and remove clutch knob Remove groomer reel housing cover from left side of cutting unit Fig 39 3 Remove grooming reel adjustment knob assembly from groomer housing Fig 40 A CAUTION A
253. inch 12 7 mm of threads exposed on each screw 3 Install motor by rotating the motor clockwise so the motor flanges clear the flange head screws 4 Rotate the motor counterclockwise until the motor flanges are encircling the flange head screws Tighten flange head screws Backlapping Units without Optional Backlap Variable Reel Speed Kit Be careful when backlapping the reel because contact with the reel or other moving parts can result in personal injury 1 Remove reel motors from the cutting units and cut ting units from the lift arms and pull frame see Cutting Unit Removal and Installation 2 Connectthe backlapping machine to the cutting unit by inserting a piece of 3 8 inch socket extension drive into the splined reel drive coupling 3 Attach backlap motor or drive to the socket exten sion 4 Follow instructions and procedures for backlapping in the Toro General Service Training Book Reel Mower Basics part no 0916851 Dual Point Adjust Cutting Units 10 8 Rev E TOP FACE RELIEF ANGLE REMOVE BURR FRONT FACE FRONT ANGLE Figure 10 Note For a better cutting edge run a file across the front face of the bedknife when the lapping operation is completed This will remove any burrs or rough edges that may have built up on the cutting edge Greensmaster 3150 Backlapping Units with Optional Backlap Variable Reel Speed Kit TO AVOID PERSONAL INJ URY OR DEATH e Never
254. ing unit front roller to line on floor Must be equal within 3 16 0 1867 in Greensmaster 3150 Repairs Cutting Unit Removal and Installation Remove cutting unit from traction unit before doing adjustments or repairs 1 Remove basket from pull frame 2 Loosen reel motor mounting nuts Fig 21 Rotate the motor clockwise so motor flanges clear studs and pull motor off of cutting unit 3 Slide the sleeve back on the ball joint and disconnect the pull arm from each side of the cutting unit Fig 22 4 Slide cutting unit out from under pull frame disengag ing the lift arm from the lift bail Fig 23 5 Reverse steps 1 4 to install the cutting unit Greensmaster 3150 Page 8 19 Figure 21 1 Motor mount nuts 2 Motor shaft Figure 22 1 Slide back to mount 2 Ball stud 3 Swing up to remove down to install gt Figure 23 1 Lift bail 3 Pull frame 2 Lift arm 4 Pull arm Repairs Reel Lapping Check reel bearing adjustment and correct if necessary before backlapping Connect lapping machine to cutting unit with an extension coupler and a 9 16 in socket The 9 16 socket be installed onto the capscrew CAUTION the reel shaft inside the counter balance weight on the Be careful when lapping the reel because con end ofthe cutting unit Backlap according to procedures tact with the reel or
255. ings This can be done by observing the imprint layline on the hose Use two wrenches hold the hose straight with one wrench and tighten the hose swivel nut onto the fit ting with the other wrench see Hydraulic Hose and Tube Installation in this section If the hose has an el bow at one end tighten the swivel nut on that end before tightening the nut on the straight end of the hose For additional hydraulic hose information refer to Toro Service Training Book Hydraulic Hose Servicing Part Number 9481361 Greensmaster 3150 Page 4 3 Before disconnecting or performing any work on hydraulic system relieve all pressure in system see Relieving Hydraulic System Pressure in this section 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 cause serious injury If fluid is in jected into the skin it must be surgically re moved within a few hours by a doctor familiar with this type of injury Gangrene may resultfrom such an injury Hydraulic System Rev E D 22 gt Hydraulic Hose and Tube Installation O Ring Face Seal Fitting 1 Make sure threads and sealing surfaces ofthe hose tube and the fitting are free of burrs nicks scratches or any foreign material 2 Asapreventative meas
256. ings from dropping on the ground 4 Make sure the basket lips are the same distance from the reel blades at both ends of the reel If the basket is too close to the reel it is possible for the reel to contact the basket at the instant the cutting unit is raised off the ground 5 Make sure each of the three 3 cutting units track straight with the traction unit A smooth level surface draw a straight line on the floor Fig 23b Push traction unit forward removing slack from pull arms so center of each front wheel is on top of the line Use a plumb bob or square to make sure each wheel is centered on the line B Measure from each end of cutting unit front roller to chalk line Distance from each end of roller to line must be equal within 3 16 0 187 in C Loosen jam nuts on pull arms and adjust ball sockets so distance from each end of roller to line is within 3 16 0 187 in NOTE If a cutting unit cannot be adjusted to track correctly with the traction unit the pull frame or lift arm is damaged and or the lift arm and pull frame bushings are worn and must be replaced Set Up and Adjustments 1 Jam nut 2 Pull arm Draw line on floor and center wheels over line 1 Jam nut 2 Pull arm Page 9 20 Figure 23a 3 Ball joint adjust for clearance 4 1 4 1 2 in 6 13 mm clearance Measure from each end of cutting unit front roller to line on floor Must be equal within 3 16 0 1867
257. ion Greensmaster 3150 Page 4 67 Installation Fig 41 1 Inspectthreads and sealing surfaces of fittings Re place any worn or damaged fittings 2 Apply clean hydraulic oil to all O rings 3 Place O ring on the face seal of a hydraulic fitting Secure fitting to the reel motor Make sure that the match marks are aligned Repeat this step for the remaining fit tings 4 Inspect threads and sealing surfaces of connec tions Replace any worn or damaged connections 5 Install reel motor to the cutting unit see Cutting Unit Removal and Installation in Chapter 7 8 9 or 10 Cut ting Units 6 Secure hose connection to the proper hydraulic fit ting on the reel motor Repeatthis step for the remaining hose connections Hydraulic System Rev E 2 SS gt Reel Motor Service 215 to 280 in Ib 24to 32Nm gt Figure 42 1 Rear cover 5 Pressure seal 9 Idler gear 2 Drive gear 6 Back up ring 10 Cap screw 3 Seal 7 O ring 11 Front flange 4 Tab washer 8 Body 12 Washer if equipped Disassembly DIAGONAL MARK 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 reas sembly purposes Fig 43 Figure 43 Hydraulic System Rev E Page 4 68 Greensmaster 3150 IMPO
258. ion key switch hasthree positions OFF RUN and START The terminals are marked as shown The circuitry of the ignition switch is shown in the chart With the use of a multimeter ohms setting the switch func tions may be tested to determine whether continuity ex ists between the various terminals for each position Verify continuity between switch terminals SWITCH LOCK WASHER Figure 7 Hour Meter 1 Connect the positive terminal of a 12 VDC source to the positive terminal of the hour meter 2 Connect the negative terminal of the voltage source to the other terminal of the hour meter 3 Thehour meter should move a 1 10 of an hour in six minutes 4 Disconnectthe voltage source from the hour meter Figure 8 Greensmaster 3150 5 9 Electrical System Relays 1 Verify coil resistance between terminals 86 and 85 with a multimeter ohms setting Resistance should be from 80 to 90 ohms There should be continuity between terminals 87A and 30 2 Connect multimeter ohms setting leads to relay terminals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is ap plied and removed from terminal 85 3 Disconnectvoltage from terminal 85 and multimeter lead from terminal 87 4 Connect multimeter ohms setting leads to relay terminals 30 and 87A Apply 12 VDC to terminal 85 The relay should break
259. ion of this chapter Figure 13 Hydraulic Tester Pressure and Flow TOR214678 This tester requires O ring Face Seal ORFS adapter fittings for use on this machine see Hydraulic Test Fit ting Kit TOR4079 in this section 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 PRESSURE GAUGE 0 to 5000 PSI gauge to pro vide operating circuit pressure 4 FLOW METER This meter measures actual oil flow in the operating circuit with a gauge rated at 15 GPM Figure 14 5 OUTLET HOSE A hose from the outlet side of the hydraulic tester connects to the hydraulic system circuit O Ring Kit 16 3799 The O ring kit includes O rings in a variety of sizes for face seal and port seal hydraulic connections It is rec ommended that O rings be replaced whenever a hy draulic connection is loosened Figure 15 Hydraulic System Rev E Page 4 22 Greensmaster 3150 Hydraulic Test Fitting Kit TOR4079 This kit includes a variety of O ring face seal fittings to enable you to connect test gauges into the system The kit includes tee s unions reducers plugs caps and male test fittings Measuring Container TOR4077 Use this container for doing hydraulic motor efficiency testing motors with case drain lines only Measure effi ciency of a hydraulic motor b
260. ipment make sure tank is full 9 Check control linkages for improper adjustment binding or broken parts 10 All hydraulictests should be made with the hydraulic oil at normal operating temperature 11 Record the results of all performed hydraulic tests Hydraulic Testing 1 Use the Hydraulic Schematic Hydraulic Flow Dia grams and the Troubleshooting section found in this Chapter to assist in problem identification and solution 2 Hydraulic system problems e g low hydraulic oil level contaminated oil incorrect engine speed will af fect the entire hydraulic system 3 Fortraction related problems e g machine will not go up an incline use the following Tests A Traction Drive Hydrostat P3 Flow B Wheel Motor Efficiency C Charge Relief Valve R4 Pressure Greensmaster 3150 4 Problems with steering or lift lower circuit use the 5 Issues with cutting system use the following tests following tests A Gear Pump P1 Flow A Charge Relief Valve R4 Pressure B Mow Circuit Relief Valve R1 Pressure B Gear Pump P2 Flow and Implement Relief Valve R5 Pressure C Reel Motor Case Drain Flow C Lower Cutting Units Relief Valve R2 Pressure D Steering Control Valve 2g 3 22 55 gt Greensmaster 3150 4 29 Hydraulic System Rev E Traction Drive Hydrostat P3 Flow Test Using Tester with Flowmeter and Pressure Gauge TUBE UPPER FITTING E
261. is designed to re sist vibration induced plug loosening The zero leak plugs also have an O ring to provide a secondary seal If zero leak plug removal is necessary lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug the impact will allow plug removal with less chance of damage to the socket head ofthe plug When installing plugs into the manifold torque plugs to the values identified in Figure 55 Solenoid Operated Relief and Logic Control Car tridge Valves Fig 55 1 Make sure the manifold is clean before removing the cartridge valve and seal kit 2 If solenoid valve is to be removed from manifold re move nut securing solenoid to the cartridge valve Care fully slide solenoid off the valve IMPORTANT Usecare when removing the cartridge valve Slight bending or distortion of the stem tube can cause binding and malfunction Make sure that deep well socket fully engages the valve base 3 Make sure manifold is clean before removing the cartridge valve Remove cartridge valve from manifold with a deep well socket Note location of O rings and backup rings on valve Remove and discard removed seal kit 4 Visually inspectthe manifold port and cartridge valve for damage to sealing surfaces damaged threads and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in small valve orifices or seal areas causing valve malfunction
262. ith cap screw and washer 2 Position clevis of the hydraulic cylinder to the lift arm Install clevis pin and cotter pin through cylinder cle vis 3 Connect hose assemblies and O rings to the hy draulic fittings Tighten hose connections Greensmaster 3150 REAR LIFT CYLINDER Figure 48 1 Frame 5 Hose assembly 9 Locknut 2 Straight hydraulic fitting 6 Capscrew 10 Lift arm 3 O ring 7 Washer 11 Hydraulic cylinder 4 O ring 8 Pivotpin Rear Cylinder Removal Fig 48 1 Before removing any parts from the hydraulic sys tem park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components 2 Label all hydraulic connections for reassembly 3 Disconnect hose assemblies and O rings from the hydraulic fittings at the lift cylinder Allow hoses to drain into a suitable container Greensmaster 3150 Page 4 73 4 Support hydraulic cylinder to prevent it from drop ping A Remove cap screw washer and lock nut from the pivot pin B Pull pivot pin from the frame and hydraulic cylin der C Remove hydraulic cylinder from the frame and lift arm Rear Cylinder Installation 1 Position rod end of the hydraulic cylinder on the lift arm 2 Position hydraulic cylinder in the frame Insert pivot pin through the frame br
263. ized and blocks flow directly to the hydros tat Flow is directed to de energized solenoid valve S3 which directs flow to the lift cylinders Hydraulic pressure againstthe cylinder pistons moves their shafts causing the cutting units to lower At the same time the pistons push the hydraulic fluid out of the lift cylinders to energized solenoid valve S4 Flow continues back through solenoid valves S3 to the hydrostat Flow into the flow control valve is slowed by the variable orifice to allow the rear cutting unit to lower after the front units To control pressure while lowering cutting units the sys tem is equipped with adjustable relief valve R2 in the hydraulic manifold When the solenoid valves de energize spring action returns the valves to their original position and by passes flow back to the hydrostat stopping lift cylinder movement Hydraulic System Rev E vV 52 gt HOLOW T33HM NOLLOVHL e 401108 58010 133HM 0112 41 MO lt lt uonongjo eisssejd YH pezibueue ep se UMOUS IPO Iv uonisod pezifreue ui UMOUS 25 pue zs spiousjos 000000042 9 oqy suu Bumn ssiey 0912 1 mags gt np ee eee m 1 0 1 NENIYBLS NOLLODS mex
264. just as necessary Greensmaster 3150 Page 7 7 Monthly Adjustments NOTE Remove cutting unit from traction unit before doing these checks and adjustments See Cutting Unit Removal and Installation in the Repairs section of this chapter 1 Visually check for sharp reel and bedknife Backlap or grind reel and bedknife if necessary 2 Adjust rear rollerfor proper bedknife angle and parallel to reel 3 Adjust front roller scraper to be 1 32 in from roller 4 Set comb or brush adjustment for desired action on grass Light medium or aggressive setting 5 Check grass shield adjustment 4 3 4 in from crossbar normal Dry grass lower shield Wet grass raise shield 6 Set top bar cut off bar adjustment 0 060 in from reel normal 7 Lower cutting units to the ground setting on both rollers remove reel motor and adjust bedknife to reel contact 8 Using a gauge bar set the height of cut adjustment Special Notes 1 A rifled reel and or bedknife must be corrected grinding 2 If reel bearings will not hold adjustment during opera tion loosen adjustment nut tighten reel shaft spline nut to a torque of 40 to 60 ft Ib then adjust reel bearings Set Up and Adjustments Reel Bearing Service and Adjustment 1 Adjust the bedknife so it is not in contact with the reel 2 Reel bearing drag should not exceed 7 This be measured with a torque wrench Fig 5
265. justment Replace adjustment nut if necessary 4 Install bolt into end of reel shaft and check rolling torque with an inch pound torque wrench Reel bearing rolling torque should not exceed 7 in Ib Repeat steps 2 and 3 if necessary 5 If bearings require replacement see Reel Removal and Bearing Replacement in the Repairs section of this chapter Set Up and Adjustments Page 8 10 Figure 7 1 Height of cut locknut 2 Roller shaft clamp boit 3 Height of cut knob 4 End cap mounting nuts 5 Counterbalance end cap 6 Reel bearing adjustment nut Greensmaster 3150 Parallel Bedknife to Reel 1 Remove mower from traction unit and position on a level work surface Make sure reel contact is removed by turning bedknife adjustment knob counterclockwise 2 On right hand end of reel insert a long strip of newspaper between front side of reel and bedknife While slowly rotating reel forward turn bedknife adjust ing knob Fig 8 clockwise one click at a time until paper is pinched lightly which results in a slight drag when paper is pulled 3 Check for light contact at other end of reel using paper If light contact is not evident at both ends bedknife is not parallel to reel proceed to step 4 4 Loosen jam nut on left hand bedbar pivot bolt so bolt can be turned Left hand pivot bolt eccentric bolt has offset thread which when rotated acts as a camto raise or lower the bedbar Identification dot on b
266. justment during opera tion loosen adjustment nut tighten reel shaft spline nut on right hand end of reel shaft to a torque of 40 to 60 46 then adjust reel bearings Greensmaster 3150 Bedknife to Reel Contact NOTE The single knob bedknife to reel adjustment sys tem simplifies the adjustment procedure needed to get the best mowing performance The precise adjustment possible with the single knob bedbar design gives the necessary control to provide a continual self sharpening action thus maintaining sharp cutting edges assuring good quality of cut and greatly reducing the need for routine backlapping In addition the rear roller position ing system permits optimum bedknife attitude and loca tion for varying heights of cut and turf conditions IMPORTANT Bedknife to reel contact must be checked and adjusted every day even though quality of cut is acceptable 1 Shut off engine and remove key Lower cutting units to the ground 2 Remove grass baskets 3 On each cutting unit loosen 2 flange nuts securing reel motor to cutting unit Twist motor clockwise to disengage from cutting unit and remove motor 4 Slowly rotate reel listening for reel to bedknife con tact If no contact is evident TURN BEDKNIFE ADJUST ING KNOB CLOCKWISE ONE 1 CLICK AT A TIME UNTIL FIRST CONTACT 15 FELT AND HEARD THEN TIGHTEN ONE 1 MORE CLICK TO GET LIGHT CON TACT Fig 6 5 If contact is felt turn bedknife adjusting
267. knut left hand thread Fig 6b 9 If equipped with hex head type pivot screws tighten pivot screws to 60 If equipped with hex socket head set screws and jam nuts tighten set screws finger tight then tighten 1 2 turn more total not each Tighten jam nut 10 Adjust bedknife to reel contact NOTE If quality of cut has deteriorated or the reel and bedknife have become rifled you must grind the reel and bedknife to remove rifle pattern Figure 52 1 Pivot housing 2 Bearing 2 3 Inner race 2 4 O ring 2 Repairs 5 Spring arm 6 Adjustment knob 7 Bedbar pivot 8 Spring Page 9 32 9 Pivot screw 2 10 Spring arm retaining capscrew Greensmaster 3150 Lift Bail Replacement TN 7 N a 4 gt N N N Figure 53 1 Use a saw to cut the lift bail off of the cutting unit Make 4 Support the lift bail so the bottom radius is 4 546 inches the cut 1 inch from the horizontal frame tube Fig 53 from the top of the horizontal frame tube Make sure the lift bail is square to the side frame 2 Use a grinder to remove burrs from the stubs of the lift bail remaining on the cutting unit 5 Weld all around the bottom of the repair lift bail with mild steel rod both sides 3 Install the repair lift bail Part No 71 1600 Greensmaster 3150 Page 9 33 Repairs This page is intentionally blank Repairs Page 9 34 Greensmaster 3150 TORO
268. l Number Above 270000000 Shown Power Current Control Current Indication Current PK BU VIO BK E m 85 ULV 86 w w Bu sm E Dow STARTER SOLENOID NEUTRA STON H START SAFETY K2 BACKLAP e 30 87 85 PS IGN SWITCH NOT IN NEUTRAL ICH a 5 WS Micah D OFFRUNSTAR D1 A 2 BACKLAP RELAY K7 87 GNR 1 30 o 26 A 26 BF3 10A 36 B 36 C A D1 B OR BK 87a REEL ENGAGE y ee Y SEAT SWITCH PARKING BRAKE BK MORERA KA 4 26 C F4 10 OCCUPIED OFF POSITION an gt B GN BK MEME VIO 4 5 87a RM oie cA V LL Di D ir JOYSTICK o 87 OR BK BU BK E Rp FRAMEGND LOWER ENGINE GND PK 4 aver 85 YYY 86 MOW SWITCH 2 36 F 10793 JOYSTICK RELAY vi h e C Di C 98 STOP NONE BU o 2 o RUN B H4A X Y EU 36 D eases 5 START B l S GY BK BK 8 g GN BK 4 a REGULATOR ev FUSIBLE LINK 71 BK dime s ete e leuc i RS NT SP 86 47 85 26 0 6 DELA
269. lace bedbar bushings and nylon flange bushings every two years 2 A rifled reel and or bedknife must be corrected by grinding 3 After extended running notches will develop at both ends of bedknife These notches must be rounded off or filed flush with cutting edge of bedknife to assure smooth operation 4 If reel bearings will not hold adjustment during opera tion loosen adjustment nut tighten reel shaft sp ine nut on right hand end of reel shaft to a torque of 40 to 60 ft Ib then adjust reel bearings Greensmaster 3150 pA on C Y Sis SS Bedknife to Reel Contact NOTE The single knob bedknife to reel adjustment sys tem simplifies the adjustment procedure needed to deliver optimum mowing performance The precise ad justment possible with the single knob bedbar design gives the necessary control to provide a continual self sharpening action thus maintaining sharp cutting edges assuring good quality of cut and greatly reduc ingthe need for routine backlapping In addition the rear roller positioning system permits optimum bedknife at titude and location for varying heights of cut and turf conditions IMPORTANT Bedknife to reel contact must be checked and adjusted every day even though quality of cut is acceptable 1 Shut off engine and lower cutting units to ground Remove the key 2 Remove grass baskets 3 Make sure the groomer reel
270. lic oil and carefully slide them onto shaft and into barrel 6 Secure heads to barrel A For serial numbers below 260999999 Fig 73 install and tighten threaded caps Secure both caps to barrel with set screws B For serial numbers above 270000000 Fig 74 align retaining ring hole in the head with the access slot in the barrel Insert the retaining ring hook into the hole and rotate head clockwise until the retain ing ring is completely pulled into the barrel and the ring ends are covered Hydraulic System Rev E S a gt Leak Detector Note See Turf Guardian Leak Detector System Chapter 5 Electrical System ofthis manual for leak de tector operation information 30 to 60 in Ib 26 3 4 to 6 8 Nm EN 17 to 21 f Ib 23 to 28 e c Figure 70 1 Hydraulic tank 12 O ring 2 Auxiliary tank 13 Hose clamp 3 Spacer short 14 90 barb fitting 4 Neoprene washer 15 O ring 5 Flat washer 16 Valve spool 6 Cap screw 17 O ring 7 Breather adapter 18 O ring 8 Breather cap 19 Solenoid 9 Cap screw 20 O ring 10 Spacer long 21 Lock nut 11 Sight gauge 22 Valve body Hydraulic System Rev E Page 4 100 23 24 25 26 27 28 29 30 31 32 100 to 125 in Ib 11 3 to 14 1 Nm Tank hose Lock washer Cap screw Hose clamp Overflow hose Straight barb fitting Tether Flat washer Cap screw Valve hose Greensmaster 3150
271. ll age and avoid creating any source of ignition until fuel vapors have dissipated G Wipe up any spilled fuel Greensmaster 3150 While Operating 10 Do not run the engine in a confined area without ad equate ventilation Exhaust fumes are hazardous and could be deadly 11 Sit on the seat when starting and operating the ma chine 12 Checkthe safety interlock switch daily for proper op eration see Verify Interlock System Operation in Chap ter 5 Electrical System Replace any malfunctioning switches before operating the machine 13 To start the engine A Siton the seat make sure cutting units are dis engaged B Verify that functional control lever is in neutral C Verify that parking brake is set D Proceed to start engine 14 Using the machine demands attention and to pre vent loss of control A Mow only in daylight or when there is good artifi cial light B Watch for holes or other hidden hazards C Do notdrive close to sand traps ditches creeks or other hazards D Reduce speed when making sharp turns Avoid sudden stops and starts E Before backing up look to the rear to be sure no one is behind the machine F Watch out for traffic when near or crossing roads Always yield the right of way G Apply the service brakes when going downhill to keep forward speed slow and to maintain control of the machine 15 Keep hands feet and clothing away from moving parts and the reel
272. lly open before starting the engine Greensmaster 3150 Page 4 41 A CAUTION Do notengage the cutting units when performing this test 7 Start engine and move throttle to full speed 2850 50 RPM 8 Watch pressure gauge carefully while slowly clos ing the flow control valve on the tester until 2000 PSI 138 bar is obtained 9 Flow indication should be 5 8 GPM minimum Re cord test results 10 Open control valve on tester and shut off engine 11 If flow was less than 5 8 GPM or a pressure of 2000 PSI 138 bar cannot be obtained check for restriction in the pump intake line If line is not restricted remove pump and repair or replace as necessary 12 If testing is complete disconnect tester from gear pump and hose Reconnect hose to the pump Hydraulic System Rev E 2 3 5 52 gt Circuit Relief Valve R1 Pressure Test Using Tester with Flowmeter and Pressure Gauge TO AND FROM TO LEFT REEL MOTORS ESS REEL MOTOR MANIFOLD BLOCK 54 56 OPTIONAL ORIFICE VALVES lt 5 4 TO HYDRAULIC RESERVOIR 2 7 EROM STEE
273. locknuts securing front roller adjusting screws to height of cut brackets Fig 18 3 On gauge bar Part No 1 8789 set head of screw to desired height of cut This measurement is from bar face to underside of screw head 4 Place bar across front and rear rollers and adjust height of cut knob until underside of screw head engages bedknife cutting edge Fig 18 Check and adjust on each end of bedknife then tighten height of cut adjustment locknuts on each end Changing To A Different Type of Cutting Unit or Adding Cutting Unit Accessories When changing to a different type of cutting unit or adding cutting unit accessories it is recommended that you change only one cutting unit and keep the other two existing cutting units on the machine 1 Setthe new cutting unitto a height of cut approximate ly 1 16 0 06 in higher than the old cutting unit 2 Do a mowing test and compare results between the new cutting unit and old cutting units 3 Adjust the new cutting unit to match the cut of the old cutting units 4 The other two cutting units can now be replaced Adjust these two new cutting units so they are the same as the other new cutting unit that was tested Greensmaster 3150 Page 9 17 Figure 18 1 Height of cut knob locknut 3 Screw head over bedknife 2 Gauge bar 1 8789 4 Adjustment knob Set Up and Adjustments Groomer Reel Depth Adjustment 1 Adjust cutting unit height of cut befor
274. log Some tools may also be available from a local supplier McLube Aerosol or liquid lubricant Apply to bedbar pivot and bedbar pivot bolts Figure 1 Roller Bearing Replacement Tool Puller is used to remove bearings from front and rear rollers Driving tubes are used to install bearings into rollers Refer to instructions supplied with tool Used on swaged full and wiehle rollers Figure 2 Special Tools 9 4 Greensmaster 3150 Plastic Plug Insert plug in cutting unit bearing housing in place of reel motor when sharpening or grinding the reel Figure 3 Handle Assembly For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel assembly Figure 4 Bedknife Screw Tool Fits Toro bedknife attaching screws Use with torque wrench to secure bedknife to bedbar With clean bedbar threads and new screws tighten to a torque of 200 in Ib NOTE Remove all rust scale and corrosion from bedbar surface before installing bedknife ef DO NOT use an air impact wrench with this tool RS Figure 5 Greensmaster 3150 Page 9 5 Special Tools Troubleshooting Factors Affecting Quality of Cut There are a number of factors that can contribute to unsatisfactory quality of cut some of which may be turf conditions Turf conditions such as excessive thatch sponginess or attempting to cut off too much grass height may not always be overcome b
275. low Test Cutting units raise but will not stay Solenoid valve S4 is leaking or damaged up Lift cylinders leak internally Steering wheel is hard to turn Steering control valve has insufficient oil flow Emergency steering ball in steering control valve is missing or damaged Regular adjustments to steering Leaf springs in steering control valve are worn or broken wheel are necessary because of dif ficulty of driving in a straight line Gear wheel set in steering control valve is worn Steering cylinder is seized or its piston seals are worn see Steer ing Control Valve Test Steering wheel will not return to the Spool and sleeve are sticking to steering control housing assembly neutral position see Steering Control Valve Test Steering wheel can turn on its own Leaf springs in steering control valve are broken or stuck Spool and sleeve are sticking to steering control housing assembly see Steering Control Valve Test Backlash results when turning steer Cardan shaft fork is worn or broken ing wheel Leaf springs in steering control valve are worn or broken Splines on the steering column are worn Hydraulic System Rev E Page 4 26 Greensmaster 3150 Greensmaster 3150 Page 4 27 Hydraulic System Rev E E 52 BF gt Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and fl
276. low access to retaining ring on upper end of spool Remove upper retaining ring C Push spool down until lower O ring and back up ring are exposed on bottom of manifold Remove lower O ring and back up ring from spool D Pull spool up and out of manifold Remove O rings and back up ring from spool E Discard removed O rings and back up rings 2 Visually inspectthe spool and manifold port for dam age to the sealing surfaces and contamination 3 Install mow backlap spool into manifold A Install O rings and back up ring to upper grooves on spool Apply a light coating of grease to Figure 57 O rings 1 Retaining ring 4 O ring 2 O ring 5 Spool handle B Carefully push spool down into manifold port until 3 Back up ring 6 Rotary spool lower O ring and back up ring groove is exposed on bottom of manifold Install lower O ring and back up ring to spool Apply a light coating of grease to O ring 5 L3 gt C Install lower retaining ring to spool D Carefully raise mow backlap spool until upper re taining ring groove on spool is exposed on top of manifold Install upper retaining ring E If handle was removed from spool position spool so handle location of spool is between stop pins in manifold Apply Loctite 603 Retaining Compound or equivalent to threads on handle and install handle into spool F Place ball and dowel pin in backlap switch man ifold port Install ne
277. low gauge reading should be 3 1 GPM Record test results 9 Open control valve on tester and shut off engine 10 If specification is not met check for restriction in the pump intake line If no restriction is found repair or re place gear pump 2 Procedure for Implement Relief Valve R5 Pressure Test A CAUTION Do not allow pressure to exceed 1400 PSI 82 8 bar 1 Measure and record charge relief valve R4 pres sure see Charge Relief Valve R4 Pressure Test in this section 2 Usesame tester connections as described above in Procedure for Gear Pump P2 Flow Test steps 3 and 4 Fully open control valve on the tester Greensmaster 3150 Page 4 37 Rev 3 Startand run engine at full speed 2850 50 RPM 4 Watch the pressure gauge on the tester and move the lift lever to the raise position Momentarily hold the lift lever with the cutting units fully raised causing the re lief valve R5 to open Record pressure at which the re lief valve R5 opens 5 Open control valve on tester and shut off engine Note The implement relief valve R5 is in series with charge relief valve R4 R4 pressure will affect R5 pressure 6 Implement relief valve R5 pressure should be 1050 to 1250 PSI 72 5 to 86 3 bar higher than the charge relief valve R4 pressure e g ifthe charge re lief valve pressure is 100 PSI the implement relief valve R5 pressure should be 1150 to 1350 PSI 7
278. ls 13 where the reel shaft V rings 3 make contact The V rings should run dry 1 Slide the left hand side plate 6 onto the reel shaft Make sure the reel shaft threads do not damage the grease seals in the side plate 2 Apply a film of No 2 general purpose grease to the reel shaft threads and install the left side reel bearing locknut 8 3 Slide the right hand side plate 10 onto the reel shaft Make sure the reel shaft threads do not damage the grease seals in the side plate 4 Apply a film of No 2 general purpose grease to the reel shaft threads and install the right side reel bearing locknut 8 5 Mount the frame assembly 17 to the side plates with the four shoulder bolts 7 Torque the shoulder bolts to 17 to 20 ft Ibs 23 to 27 Nm 6 Secure the grass shield 22 to the side plates with two capscrews 24 washers 23 and lock nuts 25 7 Torque the reel bearing locknuts 8 to 50 to 60 ft Ibs 68 to 81 Nm 8 Install the bedbar assembly see Bedbar Installation in this chapter 9 Install the rear roller as follows Fig 23 A On one of the saddle clamps remove one of the screws and nuts securing it to the side plate B Install rear roller into saddle clamps and loosely secure it with the screw and nut previously re moved C Center the roller between side plates Tighten the saddle clamp screws and nuts to secure the roll er Dual Point Adjust Cutting Units Page 10 18
279. lubri cant to the threads of each bedbar pivot bolt 7 Greensmaster 3150 Page 10 11 Figure 13 1 Sideplate 5 Washer metal 2 Rubber bushing 6 Bedbar 3 Flange bushing 7 Bedbar pivot bolt 4 Washer plastic 8 Flange nut 4 Slide one metal washer 5 and one plastic washer 4 onto each bedbar pivot bolt The metal washer 5 must contact the flange nut 8 Fig 13 5 Position bedbar 6 into cutting unit Slide the top of the bedbar arms between washers on each adjuster as sembly 6 Position one metal washer 5 and one plastic wash er 4 between bedbar and each side plate The metal washer 5 must contact the bedbar Fig 13 7 Install the bedbar pivot bolt assemblies Tighten each bedbar pivot bolt from 190 to 240 in Ibs 21 to 27 Nm 8 Tighten both flange nuts 8 to remove end play at the outer washers Do not over tighten the flange nuts or distort the side plates 9 Tighten the lock nut 15 on each bedbar adjuster assembly until the adjuster spring is fully compressed then loosen lock nut 1 2 turn 10 Adjust cutting unit see Cutting Unit Operator s Manual Dual Point Adjust Cutting Units Bedbar Adjuster Service Figure 14 1 Adjuster shaft early production 6 Adjuster screw 1l Spring 2 Flange bushing 7 Detent 12 Lock nut 3 Cutting unit frame 8 Lock washer 13 Adjuster shaft later production 4 Wave washer 9 Capscrew
280. lways stop the engine and remove the key from the ignition switch before working on the mower Note See Cutting Unit Operator s Manual for adjust ment procedures for the cutting units on the Green smaster 3150 Height Depth of Groomer Adjustment Note Grooming is performed above the soil level When adjusting groomer height depth groomer blades should never penetrate the soil 1 Park machine on a clean and level surface lower cutting units completely to the ground stop engine en gage parking brake and remove key from the ignition switch 2 Make sure rollers are clean and cutting reel is set to the desired height of cut See Cutting Unit Operator s Manual for cutting unit adjustment procedures 3 Position the groomer reel to the lowered grooming position Fig 3 Figure 3 1 Height adjustment knob 2 Lock screw lowered Note Improper or over aggressive use of the groom er reel i e too deep or too frequent grooming may cause unnecessary stress on the turf leading to severe greens damage Use the groomer cautiously 4 On one end of the groomer reel measure the dis tance from the lowest tip of the groomer blade to the working surface Lift and turn height adjustment knob to raise or lower the blade tip Fig 3 Each notch on the adjustment knob changes the groomer height approxi mately 0 003 inch 0 08 mm 5 Repeat step 4 on the opposite end of the groomer Then recheck setting on the first side of
281. m Operation 5 4 Troubleshooting 5 5 Electrical System Quick Checks 5 8 Component Testing 5 9 Service and Repairs 5 18 Greensmaster 3150 Rev E Chapter 6 Wheels and Brakes Specifications Special Tools Service and Repairs Chapter 7 4 Bolt Adjust Cutting Units Set Up and Adjustments Service and Repairs D3 TREE os Specifications 88 Special Tools Troubleshooting EE Chapter 8 Single Point Adjust Cutting Units Specifications Special Tools Troubleshooting Set Up and Adjustments Service and Repairs Chapter 9 Grooming Reel Cutting Units Specifications Special Tools Troubleshooting Set Up and Adjustments Service and Repairs Hydraulic System Chapter 10 Dual Point Adjust Cutting Units Electrical System Specifications Special Tools Troubleshooting Set Up and Adjustments Service and Repairs Brakes Chapter 10 1 Groomer DPA Cutting Unit Wheels and Specifications General Information Troubleshooting Adjustments Service and Repairs Chapter 11 Electrical Diagrams Electrical Schematics Electrical Circuit Diagrams Serial Number Under 270000000 Electrical Circuit Diagrams Serial Number Above 270000000 Wire Harness Drawings
282. m top of pivot bolt to side plate is 1 5 16 in with identification dot toward the rear Fig 31 Do not tighten jam nut 12 Install jam nut on straight pivot bolt Put plastic washer and steel washer between right side of bedbar and side plate with plastic washer closest to bedbar Thread pivot bolt into side plate Adjust right hand pivot bolt until left end of bedbar firmly seats against the plastic washer and side plate clamping the plastic washer snugly This removes end play from bedbar Bedbar must pivot without binding Hold right hand pivot bolt to keep it from moving and tighten jam nut Figure 30 IMPORTANT Apply NEVER SEEZ or equivalent to 1 Bedbar 2 Shield the threads of the handle assembly 13 Thread adjustment knob and pivot assembly into flat side of bedbar pivot left hand thread Make sure there is an equal gap between each side of pivot assembly housing and frame supports Fig 32 Adjust before installing pivot screws by sliding bedbar pivot sideways IMPORTANT On hand adjustable knobs check to make sure die spring is compressed to 13 16 in by tightening locknut left hand thread 14 If equipped with hex head type pivot screws tighten Figure 31 pivot screws to 60 ft Ib If equipped with hex socket head set screws and jam nuts tighten set screws finger tight then tighten an additional 1 2 turn total not each Tighten jam nuts 15 Secure spring arm to pivot assembly If spring arm is a
283. machines with the carbon canister mounted l Inspect carbon cannister and attached hoses for to the leak detector tank if either purge hose as damage orobvious leaks A damaged orleaking cannis sembly item 5 in Fig 9 or T hose assembly item ter should be replaced 10 in Fig 9 was removed make sure that installa tion is correct 2 Remove components as needed using Figure 8 or 9 as a guide C Make sure that evaporative system fuel hoses are not kinked after installation Also secure all A On machines with frame mounted carbon canis hoses with hose clamps ter if check valve item 7 in Fig 8 is removed note direction of arrow on valve body for assembly pur poses B On machines with the carbon canister mounted to the leak detector tank if either purge hose as sembly item 5 in Fig 9 or T hose assembly item 10 in Fig 9 is to be removed label ends of hose for assembly purposes Both of these assemblies in clude a check valve so direction of installation is im portant for correct operation of the evaporative control system The check valve is notavailable as a separate part so hose assembly replacement is necessary ifthe check valve or hose is faulty To en sure proper operation of check valves do not at tempt to remove the check valve from the hose assembly Engine Page3 10 Rev F Greensmaster 3150 TORO Table of Contents SPECIFICATIONS GENERAL INFORMATION
284. mber 2410 30 Turf Evaluator Tool Many turf discrepancies are subtle and require closer examination In these instances the Turf Evaluator grass viewing tool is helpful It can assist turf managers and service technicians in determining causes for poor reel mower performance and in comparing the effective height of cut of one mowed surface to another This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the TurfEvaluator part no 9793151 Toro Model Number 04399 epe Figure 6 Figure 7 Figure 8 Figure 9 Dual Point Adjust Cutting Units 10 4 Rev E Greensmaster 3150 Troubleshooting There are a number of factors that can contribute to un satisfactory quality of cut some of which may be turf conditions Turf conditions such as excessive thatch sponginess or attempting to cut off too much grass height may not always be overcome by adjusting the cutting unit It is important to remember that the lower the height of cut the more critical these factors are See Adjustments in the Cutting Unit Operator s Manual Factors That Can Affect Quality of Cut and the Service and Repairs section in this chapter of this manual for detailed adjustment and repair informa tion For additional information regarding cutting unit trouble shooting see Aftercut Appearance Troubleshooting Aid Toro part 0007651 Tire pressure Governed engine speed Reel speed
285. measure from flat surface up to end of each setscrew If not within 1 16 in of each other bend ears on cutting unit frame to line up screws Check to make sure adj knob pivot assembly is centered in bedbar arm yoke and frame ears so that an equal gap exists on each side of pivot housing before pivot screws are installed Make sure bedknife adj knob pivot assembly is held firmly in place between frame supports Tighten pivot screws if necessary Use cutting unit model with correct number of blades for clip frequency and optimum height of cut range Variable speed traction kit can be used to adjust clip frequency 12 Number of reel blades Check pull frame alignment on all cutting units Adjust or repair as necessary 13 Cutting unit alignment and pull frame ground following Check pull frames and lift arms for damage binding and bushing wear Repair if necessary All rollers must rotate freely Grease when needed or repair bearings if necessary All reels must rotate at same speed within 100 rpm cutting units must have equal bedknife to reel con tact and reel bearing adjustment before checking Do not run the reel to long or it may get hot and rifle when no grass is being cut 14 Roller condition 15 Reel speed See Troubleshooting in Chapter 5 Hydraulic System Check maximum governed engine speed Adjust to specification if necessary 16 Traction speed
286. motor s or reel motor s are worn or damaged Traction pump P3 is worn or damaged see Traction Drive Hy drostat P3 Flow Test Neutral is difficult to find or unit op erates in one direction only Traction response is sluggish Hydraulic oil is very cold Parking brake is applied or incorrectly adjusted Hydrostat by pass valve is open or defective Charge pressure is low Traction pump or wheel motor s are worn or damaged see Traction Drive Hydrostat P3 Flow and Wheel Motor Efficiency Tests Hydraulic System Rev E Page 4 24 Greensmaster 3150 No traction exists in either direction Parking brake is applied or incorrectly adjusted Oil level in reservoir is low Hydrostat by pass valve is open Charge pressure is low Wheel motor s are worn or damaged see Wheel Motor Efficiency Test Traction pump P3 is worn or damaged see Traction Drive Hy drostat P3 Flow Test Wheel motor will not turn Brakes are binding Key on wheel motor shaft is sheared or missing Wheel motor is damaged Wheel motor will not hold load in Make up fluid from charge pump not available neutral Hydrostat ball check valves are damaged Reel motor drive pump is noisy Reservoir oil level is low cavitation Hydraulic pump suction line is restricted Hydraulic pump suction line has an air leak Reels will not turn Solenoid valve S1 is stuck open not shifting to its energized posi tion Hydrauli
287. moves across the turf Because of this the actual effective height of cut is higher than the height of cut setting on the cutting unit bench set height of cut Fig 14 Machine conditions such as cutting unit weight roller type bedknife thickness speed of travel and clip Top of Grass Ground Line frequency influence effective height of cut Turf condi tions such as grass type grass density and amount of thatch also influence effective height of cut Changing the machine such as adding a wiehle roller or changing from a 4 bolt adjust cutting unit to a heavier single point adjust cutting unit will increase penetration into the turf and lower the effective height of cut Difference between bench set and effective T height of cut Figure 14 Set Up and Adjustments Page 8 14 Greensmaster 3150 Height of Cut Adjustment IMPORTANT Lower heights of cut are limited by thickness of bedknife Select proper bedknife for desired height of cut If bedknife is too thick for height of cut poor quality of cut will result and excessive pressure from turf on bottom of bedknife can cause rifling of bedknife and reel 1 Make sure that rear roller brackets are in correct hole positions for desired height of cut and that rear roller is level Also check that bedknife to reel contact is correct 2 Turn cutting unit over and loosen locknuts securing front roller adjusting screws to height of cut bracket
288. n in the steering wheel or rear wheel B Steering wheel movements should be followed immediately by a corresponding rear wheel move ment withoutthe steering wheel continuing to turn 4 Stopthe unit with the engine running Turn steering wheel with small quick movements in both directions Let go of the steering wheel after each movement A steering wheel must go back immediately to the neutral position B The steering wheel should not continue to turn Note The steering wheel must be able to turn with no more than 45 in Ib 5 1 Nm of torque 5 Perform the Implement Relief Valve R5 Pressure and Gear Pump P2 Flow tests to make sure that relief valve and gear pump are functioning correctly Note This steering test procedure will be affected by incorrect rear tire pressure binding in the hydraulic steering cylinder extra weight on the vehicle and or binding of the steering fork assembly Make sure that these items are checked before proceeding with any hy draulic testing procedure 6 Ifeither ofthese performance tests indicate a steer ing problem determine if the steering cylinder is faulty using the following procedure A Park machine on a level surface with the cutting units lowered and off Make sure engine is off andthe parking brake is engaged B Turn the steering wheel all the way to the left counterclockwise so the steering cylinder rod is ful ly extended C Turn engine off Greensmast
289. n of the hydraulic lines and cartridge valves at each port location Hydraulic System Rev E Page 4 78 Greensmaster 3150 Removal Fig 53 1 Before removing any parts from the hydraulic sys tem park machine on a level surface engage parking brake lower cutting units and stop the engine Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components 2 Disconnect solenoid valve electrical connectors If an optional backlap kit is installed disconnect electrical connector to the ball switch 3 Label all hydraulic connections and electrical con nections for reassembly IMPORTANT Before disconnecting any hydraulic hoses from the hydraulic fittings make sure each hose is labeled to ensure it is reconnected to the correct manifold fitting port 4 Disconnect hose and tube assemblies and remove their respective O rings from the hydraulic fittings Al low hoses and tubes to drain into a suitable container 5 Remove both cap screws 26 from the hydraulic manifold Remove manifold assembly from the ma chine Greensmaster 3150 Page 4 79 IMPORTANT Before disconnecting any hydraulic fittings from the hydraulic manifold block make sure the position of each fitting is observed and re corded to ensure proper installation 6 Disconnect hydraulic fittings and O rings from the manifold Installation Fig 53 Note Fitting
290. nce between the lip of the basket and the reel blades Fig 20 This prevents grass clippings from dropping on the ground 4 Make sure the basket lips are the same distance from the reel blades at both ends of the reel If the basket is too close to the reel it is possible for the reel to contact the basket at the instant the cutting unit is raised off the ground 5 Make sure each of the three 3 cutting units track straight with the traction unit A a smooth level surface draw a straight line on the floor Fig 20b Push traction unit forward removing slack from pull arms so center of each front wheel is on top of the line Use a plumb bob or square to make sure each wheel is centered on the line B Measure from each end of cutting unit front roller to chalk line Distance from each end of roller to line must be equal within 3 16 0 187 in C Loosen jam nuts on pull arms and adjust ball sockets so distance from each end of roller to line is within 3 16 0 187 in NOTE If a cutting unit cannot be adjusted to track correctly with the traction unit the pull frame or lift arm is damaged and or the lift arm and pull frame bushings are worn and must be replaced 1 Jam nut 2 Pull arm Draw line on floor and center wheels over line Set Up and Adjustments Page 8 18 Figure 20a 3 Ball joint adjust for clearance 4 1 4 1 2 in 6 13 mm clearance Figure 20b Measure from each end of cutt
291. nce between the sensing end of each switch and the mounting bracket should be 0 725 to 0 775 inch 18 4 to 19 7 mm Fig 15 B To adjust or install actuator place lever in neu tral position actuator in lever until the NEUTRAL switch just closes and then rotate the actuator two complete turns closer to switch C When adjusting switches or actuator tighten jam nuts 30 past finger tight D After switch or actuator adjustment repeat the tests described in steps 1 2 or 3 If either switch does not satisfy any one of the tests replace the switch 5 Connect electrical connectors and check interlock operation See Verify Interlock System Operation in this chapter of this manual Figure 14 1 Mow reed switch 3 Actuator 2 Neutral reed switch TRACTION BRACKET Figure 15 Electrical System Page5 12 Rev F CONNECTOR Greensmaster 3150 Parking Brake Sensor The parking brake sensor is normally closed and opens when the operator sets the parking brake If the Func tional Control Lever is moved out of neutral neutral switch opens andthe parking brake brake is set the en gine magneto will ground and the engine will stop The sensor and its electrical connector are located directly under the operator foot panel 1 Park machine on a level surface Make sure the en gine and ignition switch is Off Set brake and block front wheels 2 Disconnect electrical connector from the parking brake sensor 3 C
292. nd lock nuts Make sure that the J bolts are installed with the threaded portion on the outside of the brush Fig 20 Torque lock nuts from 20 to 25 in Ib 2 3 to 2 8 N m 1 J bolt Groomer DPA Cutting Unit Rev A Page 10 1 16 20 to 25 in Ib 2 3 to 2 8 N m 4 Groomer brush Figure 20 2 Locknut Greensmaster 3150 Chapter 11 TORO Electrical Diagrams Table of Contents ELECTRICAL SCHEMATICS 3 Serial Number Under 230000801 3 Serial Number 230000801 To 250999999 4 Serial Number 260000001 To 260999999 5 Serial Number Above 270000000 6 ELECTRICAL CIRCUIT DIAGRAMS Serial Number Under 270000000 7 Crank Circuits 7 RUN CirCUitS a Rl 8 Raise Reels Circuits 9 Lower Reels 6 seconds Circuits 10 Mow Circuits 11 Backlap Circuits 12 ELECTRICAL CIRCUIT DIAGRAMS Serial Number Above 270000000 13 Crank Circuits 13 RUN emo GO 14 Raise Reels Circuits 15 Lower Reels 6 seconds Circuits 16 Mow CircuitS 17 Backlap Circuits 18 WIRE HARNESS DRAWINGS 20 Wire Harness Drawing Serial Number Under 260000000
293. nd lower tank onto frame Apply antiseize lubricantto the threads of the four cap screws and secure fuel tank to the frame with cap screws and flat washers Make sure the fuel hose support clamps are positioned correctly Torque cap screws from 20 to 25 ft Ib 27 to 34 Nm Greensmaster 3150 Page 6 5 3 Insert spacers 16 in wheel hub assembly Position and support wheel and hub assembly between adapter plates 30 and 33 4 Coatcastor bolt 34 with antiseize lubricant and sli de castor bolt into motor adapter plate 33 right side spacer 16 wheel and hub assembly left side spacer 16 and adapter plate 30 5 Position bent lip of the castor bolt 34 head under the bottom edge of the motor adapter plate 33 Install and tighten locknut 26 Do not overtighten locknut make sure the wheel rotates freely 6 Wipe grease fittings 7 and 22 clean Pump grease into grease fitting 22 until grease is seen exiting at both oil seals 18 Pump grease into grease fitting 7 until grease is seen exiting at both ends of the pivot housing Wipe up excess grease Wheels and Brakes Rear Wheel Optional 3WD 85 ft Ib 115 Nm lt 30 80 to 100 in Ib 30ft Ib 9 0 11 3 Nm 41 Nm 70 to 90 ft Ib 95 to122 Nm Figure 4 1 Lock nut 12 Cap screw 22 Cap screw 2 Spacer 13 Lock nut 23 O ring 3 Grommet 14 Wheel motor amp hub assembly 24 O ring 4 Hose assembly 15 Adapter
294. nder 4 Install steering cylinder over barrel mounting stud and secure with flat washer and lock nut 5 Connect hydraulic hoses and O rings to the hy draulic fittings Tighten hose connections MEASURE LENGTH FOR ASSEMBLY PURPOSES Figure 72 Hydraulic System Rev E S gt Steering Cylinder Service SERIAL NUMBER BELOW 260999999 Figure 73 1 Sealkit 6 Wearring 11 Head 2 Rod wiper 7 O ring 12 Piston 3 U cup 8 O ring 13 Barrel 4 Back up ring 9 Setscrew 14 Grease fitting 5 O ring 10 Threaded cap 15 Rod SERIAL NUMBER ABOVE 270000000 Figure 74 l Sealkit 7 Wear ring 13 Piston 2 Rod wiper 8 O ring 14 Retaining ring 3 Seal 9 Back up ring 15 Rod 4 Head 10 Seal 16 Grease fitting 5 Back up ring 11 Wear ring 17 Barrel 6 O ring 12 Retaining ring NOTE On machines with serial number above exists on either of the heads items 4 all seals on the 270000000 Fig 74 the steering cylinder design does head can be replaced The piston outer seals items 9 not allow removal of the piston item 13 from the rod and 10 and wear ring item 11 can be replaced as well This cylinder design prevents replacing the O ring on If leakage or damage exists to the bore of the piston the inside ofthe piston item 8 If a steering cylinder leak steering cylinder replacement will be necessary Hydraulic System Rev E Page4 98 Rev F Greensmaster 3150 Disassembly Fig 73 or 74 I
295. ne stalls or loses headway and cannot make it to the top of a slope do not turn machine around Al ways back slowly straight down the slope 24 DON T TAKE AN INJ URY 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 Maintenance and Service 26 Before servicing or making adjustments to the ma chine stop the engine remove key from switch to pre vent accidental starting of the engine 27 Be sure entire machine is in good operating condi tion Keep all nuts bolts screws and hydraulic fittings tight 28 Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition be fore applying pressure to the system 29 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 suffi cient force to penetrate skin and do serious damage If fluid is ejected into the skin it must be surgically removed within a few hours by a doctor familiar with this form of
296. ng a line on the fastener head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Class 8 8 Class 10 9 Metric Bolts and Screws Figure 2 If the listed torque recommendation for a fastener is from 76 to 94 ft lb the proper torque when using this torque wrench with an offset wrench would be from 72 to 89 ft lb Offset h Torque wrench pie effective length of 3 torque wrench i A F effective length of torque wrench offset wrench TORQUE CONVERSION FACTOR A B Figure 3 Product Records and Maintenance Product Records 2 lt Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Grade 1 5 amp 5 Grade 1 Bolts Screws Studs amp B SAE Grade 5 Bolts Screws Studs amp 5 Grade 8 Bolts Screws Studs amp Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts 147 23 350 30 485 45 6 32 UNC 6 40 UNF 8 32 UNC 8 36 UNF 675 70 10 24 UNC 475 45 339 56 o lt gt fie gt o 765 70 10 32 UNF 540 45 1 4
297. ng holes B thru E are designed to optimize bedknife location for different heights of cut Rear Roller Bracket Hole Position 8 Blade Cutting Units Height of cut 3 16 187 in and below use the B position Height of cut 5 32 156 in and above Use the C position Height of cut between 5 32 156 and 3 16 187 in try C first if not satisfactory use B NOTE For Height of Cut 5 32 156 in and lower use 3 32 in tournament bed knife Tournament bed knife should not be necessary with the rear roller in the C position Rear Roller Bracket Hole Position 11 Blade Cutting Units Height of cut 3 16 187 in and below use the B position Height of cut 5 32 156 in and above Use the C position E Height of cut between 5 32 156 and 3 16 187 in try B first if not satisfactory use C NOTE For Height of Cut 3 16 187 in and lower use 3 32 in tournament bed knife Tournament bed knife should not be necessary with the rear roller in the C position NOTE The B hole position normally is the best rear roller location for most low 3 32 1 8 cutting condi tions It may be necessary to change from the above sug gested ranges in certain turf conditions 4 After putting bracket into correct height of cut hole position make sure right hand rear roller bracket capscrews are tightened securely Fig 11 5 Left hand rear roller bracket capscrews are to be tightened only enough to remove excessive looseness
298. ns slowly until air is out of system see Charge Hydraulic System 7 Check for hydraulic oil leaks Shut off engine and cor rect leaks if necessary Check oil level in hydraulic reser voir and add correct oil if necessary Hydraulic System Rev E 3 SE 55 gt Gear Pump Antiseize Lubricant 27 to 31 ft Ib 37 to 42 Nm Figure 28 1 Pumpinlethose 6 O ring 11 O ring 2 Gearpump 7 Hoseclamp 12 Hydrostat 3 Hydraulic fitting 8 O ring 13 Hex socket screw 4 Hydraulic fitting 9 O ring 14 Flat washer 5 O ring 10 Hydraulic hose 15 Hydraulic hose Hydraulic System Rev E Page 4 50 Greensmaster 3150 Removal Fig 28 Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components 1 Before removing any parts from the hydraulic sys tem park machine on a level surface engage parking brake lower cutting units and stop engine 2 Clamp pump inlet hose to prevent draining the hy draulic tank 3 Label all hose connections for reassembly pur poses 4 Loosen hose clamp and remove pump inlet hose from the gear pump Allow hydraulic oil to drain from hose into a suitable container 5 Remove hydraulic hoses and O rings from hydrau lic fittings Allow hydraulic oil to drain from hoses into a suitable container IMPORTANT Note position of hydraulic fittings for reassembly purposes 6 Remove hydraulic fi
299. nspect the manifold port and cartridge valve for damage to sealing surfaces damaged threads and contamination A Contamination may cause valves to stick or hang up it can become lodged in small valve orifices or seal areas causing valve malfunction B Ifsealing surfaces appear pitted or damaged the hydraulic system may be overheating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air 4 If necessary clean cartridge valve using clean min eral spirits Submerge valve in clean mineral spirits to flush out contamination Particles as fine as talcum pow der can affect the operation of high pressure hydraulic valves Clean and dry with compressed air IMPORTANT Use when installing the rotary cartridge valve Slight bending or distortion of the stem tube can cause binding and malfunc tion Make sure that deep well socket fully en gages the valve base B Lubricate threads on cartridge valve with clean hydraulic oil Thread rotary cartridge valve carefully into the manifold port The valve should go in easily without binding Torque valve to specification shown in Figure 55 Install rotary handle Fig 56 Place handle base on flow control valve and posi tion alignment mark on base with number 1 on man ifold Secure base with two 2 set screws Apply a light coating of grease to chamfer on top of base to ease seal installation B Make sure
300. nst the lock nut installed on one end of groomer shaft Then place first blade against spacers Fig 10 Note Early production groomer shafts were hex shaped Later production shafts have a D shaped cross section When installing groomer blades on ear lier hex shaped shafts rotate location mark on each installed blade one flat of the shaft either in a clockwise or counterclockwise direction The direction of location mark rotation must remain constant on the shaft 2 For 1 2 inch 1 3 cm spacing make sure there are two 2 spacers between blades Fig 10 3 When all blades have been installed place final two 2 spacers on shaft and then thread lock nut onto the shaft 4 Position lock nuts to allow blades and spacers to be centered on the shaft Fig 12 Torque lock nuts from 200 to 250 22 6 to 28 3 N m so spacers not free to rotate 5 Install groomer reel back on cutting unit see Groom er Reel Installation in this section Page 10 1 Rev D Greensmaster 3150 11 200 to 250 in Ib 22 6 to 28 3 N m Figure 10 1 Groomer reel shaft 3 Spacer 2 Groomer blade 4 Locknut ON GROOMER ROTATION Figure 11 1 Groomer blade D shaft 4 Sharp edge 2 Blade hex shaft 5 Dull rounded edge 3 Location mark CENTER BLADES Figure 12 1 Lock nut 3 Spacer 2 Shaft 4 Blade Groomer DPA Cutting Unit Rev A 5 D S E 3 amp Groomer
301. nto the housing The thrust bearing goes between the two races Fig 65 IMPORTANT Do not damage the dust or quad seals when installing the spool and sleeve assembly 9 Apply a light coating of clean hydraulic fluid to the spool and sleeve assembly and slide carefully the as sembly into the housing 10 Clamp the housing in a vise Use only enough clamp ing force to hold the housing securely 11 Lubricate and install a new O ring seal in the groove in the housing 12 Install the wear plate and align screw holes in the wear plate with threaded holes in the housing NOTE The holes in the wear plate are symmetrical 13 Install the geroter drive making sure the slot in the drive engages the pin 14 Lubricate and install new O ring in wear plate groove 15 Install the gerotor and align the screw holes 16 Lubricate and install new o ring in gerotor ring groove 17 Lubricate and install new o ring and seal ring in gero tor star groove 18 Install the spacer 19 Install the end cap and seven cap screws Tighten the cap screws in a crossing pattern from 140 to 160 16 to 18 Nm 20 Remove the steering control unit from the vise 21 Install the relief valve and plug Tighten the plug to 150 in Ib 17 Nm Thrust Bearing and Race 2 Dust Seal Quad Seal Figure 65 Hydraulic System Rev E vV 52 gt Steering Control Valve Service Serial Number Over 28000
302. o sion D Measure the temperature of the center cell E Connect a battery load tester to the battery ter minals following the manufacturer s instruc tions Connect a digital multimeter to the battery terminals Apply atest load of one half the Cranking Perfor mance see Battery Specifications rating ofthe bat tery for 15 seconds G Take a voltage reading at 15 seconds then re move the load Electrical System Page 5 20 H Using the table below determine the minimum voltage for the cell temperature reading Minimum Battery Electrolyte Voltage Temperature 96 709F 21 19 and up 9 5 609F 15 69C 9 4 50 F 10 0 C 4 49 11 89 209F 6 79C 1220 l Ifthe test voltage is below the minimum replace the battery If the test voltage is at or above the mini mum return the battery to service 9 3 409F Installation IMPORTANT To prevent possible electrical prob lems install only a fully charged battery 1 Make sure the ignition switch and all accessories are off 2 Make sure the battery compartment is clean painted if necessary 3 Make sure all battery cables and connection are in good condition and thatthe battery hold down clamp has been repaired or replaced 4 Lift seat and place the battery in its compartment Make sure battery is level and flat Push the positive cable connector onto positive battery post Do not ham mer this will damage
303. o flow to the wheel mo tors When the traction pedal is pressed to the reverse position the linkage from the pedal positions the swash plate in the hydrostat so oil flows out the bottom port of the pump flow out of the bottom port goes to the wheel motors and turns them in the reverse direction Oil flowing out ofthe wheel motors returns to the top port ofthe hydrostat and is continuously pumped out the bot tom port The charge circuit functions the same in reverse as it did in the forward direction Traction Circuit Cooling The traction circuit is cooled by a bleed off circuit in the hydrostat The bleed off circuit includes an internal bleed valve which allows about 1 gpm of hydraulic oil to pass from the reverse side of the hydrostat while operating the traction unit in the forward direction The internal bleed valve closes when operating the traction in the re verse direction Note The bleed valve threads into the hydrostat back plate Access to the bleed valve requires removal of the back plate from the hydrostat Note While operating the traction unit in the reverse direction under light loads a slight surge in ground speed may be experienced Hydraulic System Rev E Sa gt
304. o the reel detents corresponding to 0007 inch 018 mm bedknife movement for each indexed position Front Roller A variety of sealed bearing and through shaft front rollers are available for use with these cutting units The front roller brackets control the height of cut by using two vertical adjustment screws and are held in position by a horizontal locking screw Rear Roller Steel full 2 inch 5 1 cm diameter with sealed bearings and through shaft The rear roller has two positions allowing user to change the cutting unit at titude and the behind center distance of bedknife from reel center line Counterbalance Weight A cast iron weight mounted opposite to the drive motor balances the cutting unit Grass Shield Non adjustable shield with adjustable cut off bar to improve grass discharge from reel in dry conditions Maximum Reel Speed 2200 RPM minum cross member with two bolt on die cast alumi Weight D id is num side plates i 9 Dual Point Adjust Cutting Units Page 10 2 Greensmaster 3150 Special Tools Order Special Tools from your Toro Distributor Gauge Bar Assembly Used to verify height of cut Toro Part Number 13 8199 Backlapping Brush Assembly Used to apply lapping compound to cutting units while keeping the operator s hands ata safe distance from the rotating reel Toro Part Number TOR299100 Bedknife Screw Tool This screwdriver type bit is made to fit Toro bedknife at taching sc
305. of blades for clip frequency and optimum height of cut range Variable speed traction kit can be used to adjust clip frequency 13 Cutting unit alignment and pull frame Check pull frame alignment on all cutting units Adjust ground following or repair as necessary Check lift arms pull frames for binding bushing wear or damage Repair if necessary 14 Roller condition All rollers must rotate freely Grease when needed repair bearings if necessary 15 Reel speed All reels must rotate at same speed within 100 rpm All cutting units must have equal bedknife to reel con tact and reel bearing adjustment before checking Do not run the reel to long or it may get hot and rifle when no grass is being cut See Troubleshooting in Chapter 5 Hydraulic System 16 Traction speed Check maximum governed engine speed Adjust to specification if necessary See Troubleshooting in Chapter 5 Hydraulic System Install Variable Speed Traction Kit if necessary to con trol traction speed in varying conditions or with dif ferent attachments Will allow change in traction speed while maintaining full engine rpm and reel motor rpm 17 Cutting drop speed and sequence Center cutting unit must drop after front cutting unit See Troubleshooting in Chapter 5 Hydraulic System Troubleshooting 7 6 Greensmaster 3150 Set Up and Adjustments Adjustment Summary and Check List DETAILED ADJUSTMENT INSTRUCTIONS FOLLOW
306. of engine hub Place key into sloton the engine crankshaft IMPORTANT Make sure to not damage engine fuel hose hydraulic hoses electrical harness and wires control cables orother parts while installing the en gine Make sure engine hub is in position before installing the engine mount cap screws 2 Align the engine hub 30 with the engine shaft and key 42 Slide crankshaft into hub and move engine un til the engine mount plate 21 is aligned with the three engine mounts 24 Take care to not damage the hy drostat coupler during engine installation 3 Install the three engine mount flange nuts 7 cap screws 1 flatwashers 2 and spacers 3 Torque cap screws from 27 to 33 ft lb 36 to 45 Nm 4 Mount the hydraulic pump assembly to the pump adapter 19 using two cap screws 43 lock washers 42 and hardened washers 32 Torque cap screws from 27 to 33 ft lb 36 to 45 Nm 5 Position engine hub on crankshaft to best align the rubber coupling 6 Apply Loctite 242 or equivalent to threads of en gine hub screws 38 Secure hub to crankshaft with two set screws Torque set screws from 90 to 110 in Ib 10 2 to 12 4 Nm 7 Connectthe engine wiring harness 29 and ground wires 11 to the engine 8 Connectand adjust the choke and throttle control cables see Traction Unit Operator s Manual 9 Connectfuel supply hose to the fuel pump and se cure with hose clamp 10 If machine is equipped wi
307. of pivot bolt to side plate is 1 5 16 in with identification dot toward the rear Fig 28 Do not tighten jam nut 12 Install jam nut on straight pivot bolt Put plastic washer and steel washer between right side of bedbar and side plate with plastic washer closest to bedbar Thread pivot bolt into side plate Adjust right hand pivot bolt until left end of bedbar firmly seats against side plate clamping the plastic washer snugly This removes end play from bedbar Bedbar must pivot without bind ing Hold right hand pivot bolt to keep it from moving and tighten jam nut Figure 27 IMPORTANT Apply NEVER SEEZ or equivalent to 1 Bedbar 2 Shield the threads of the handle assembly 13 Thread adjustment knob and pivot assembly into flat side of bedbar pivot left hand thread Make sure there is an equal gap between each side of pivot assembly housing and frame supports Fig 29 Adjust before installing pivot screws by sliding bedbar pivot sideways IMPORTANT On hand adjustable type knobs check to make sure die spring is compressed to 13 16 in by tightening locknut left hand thread Fig 6b 14 If equipped with hex head type pivot screws tighten Figure 28 pivot screws to 60 ft Ib If equipped with hex socket head set screws and jam nuts tighten set screws finger tight then tighten an additional 1 2 turn total not each Tighten jam nuts 15 Secure spring arm to pivot assembly If spring arm is adjustable adj
308. oir Maximum circuit pressure is limited by relief valve R5 With the steering wheel in the neutral position rear wheel positioned straight ahead and the engine run ning the spool valve is in the center position Flow en ters the steering control valve at Port P and goes through the spool valve by passing the steering cylin der Flow leaves the control valve out port E and con tinues through solenoid valve S2 to the hydrostat Right Turn When a right turn is made with the engine running the turning ofthe steering wheel positions the spool valve so that flow goes through the top ofthe spool Flow entering the steering control valve at Port P goes through the spool and is routed to two places First most ofthe flow through the valve is by passed out port E back through solenoid valve S2 to the hydrostat Second the remainder of the flow is drawn through the rotary me ter V1 and out port R Pressure moves the piston in the direction for a right turn The rotary meter ensures that the oil flow to the cylinder is proportional to the Greensmaster 3150 Page 4 21 amount of the turning on the steering wheel Fluid leav ing the cylinder flows back through the spool valve and out port T The returning flow passes through the man ifold block using ports ST and PT and onto the hydros tat The steering wheel and steering control valve return to the neutral position when turning is complete Left Turn Wh
309. ol valve on the tester is fully open 5 Ifaback lap kitis installed make sure backlap knob on the hydraulic manifold is in the mow position and reel speed is set to maximum 6 Disconnecthose from case drain of the motor to be tested at the bulkhead fitting A Plug the bulkhead port B Leave the case drain hose from the motor open and place open end of disconnected hose into a drain pan 7 One person should sit on the seat and operate the machine while another person reads the tester and measures case drain leakage Make sure functional control lever is in NEUTRAL Start engine and move the throttle to full speed 2850 50 RPM A CAUTION Keep away from reels during test to prevent per sonal injury from the rotating reel blades 8 Engage reels by positioning the functional control lever to MOW position While watching pressure gauge slowly close flow control valve on the tester until a pres sure of 1000 PSI 69 bar is obtained Greensmaster 3150 9 After achieving 1000 PSI 69 bar place discon nected motor case drain hose into a container gra duated in ounces or milliliters Tool TOR4077 see S pecial Tools and collect hydraulic fluid for 15 seconds Fig 28 After 15 seconds remove hose end from con tainer 10 Disengage cutting units by positioning functional control lever to NEUTRAL position Open control valve on tester and stop the engine 11 Measure the amountof oil collected in the containe
310. olt head denotes offset of bolt When dot is in up position Fig 9 left end of bedbar is raised As bolt is turned clockwise and dot is lowered so is left end of bedbar Identification dot must be positioned within rear 1809 position when adjusting 5 Rotate left hand eccentric pivot bolt to raise or lower bedbar as required 6 Check adjustments by repeating steps 2 and 3 7 After getting light contact on paper at each end of bedknife tighten left hand jam nut while holding pivot bolt in position Check to make sure pivot bolt did not get out of adjustment when turning jam nut Adjust again if necessary NOTE If the reel has worn so you cannot get the bedknife parallel to the reel by turning the eccentric bolt the reel will require grinding to remove taper The reel normally wears faster on the lead in side which results in the described taper Greensmaster 3150 Page 8 11 Figure 8 1 Bedknife adjusting knob Figure 9 Set Up and Adjustments Leveling Rear Roller to Reel 1 Put cutting unit on a flat level surface 2 Assemble rear height of cut brackets to desired posi tion by loosening top capscrew and nut and removing bottom nut on right and left hand sides of cutting unit Fig 10 3 Slide bolts thru each bracket until brackets can be realigned with appropriate mounting hole See table for proper position on brackets NOTE The different rear roller bracket positioni
311. oo tight NOTE New bedknife must be ground after installing on bedbar to match bedknife to bedbar Reel must have light contact all across bedknife No contact will dull the cutting edges Excessive contact accelerates wear quality of cut may be adversely af fected Adjust backlap or grind if necessary Adjust rear roller brackets to proper location in slots of side plate See Leveling Rear Roller to Reel in the Ad justments section Check and adjust as necessary to avoid mismatch be tween cutting units All cutting units set at same height of cut Set with front roller must be equal at both ends of roller Bench set height of nd actual effective height of cut are dif ferent Effective height of cut depends on cutting unit weight cutting unit accessories and turf conditions If bedknife is too thick for effective height of cut poor quality of cut will result Set scraper 1 32 in clearance from roller Set comb the same on all cutting units for height of cut and turf condi tions Must be same height at both ends of comb Troubleshooting Factor Possible Problem Correction 11 Stability of bedbar Make sure bed bar pivot bolts are securely seated maximum 40 ft Ib Make sure opposing bedknife adjustment screws are tight To prevent distortion of the adjustment screw mounting plate and bedbar breakage do not over tighten the screws 12 Number of reel blades Use cutting unit model with correct number
312. or shield Muffler clamp Hex nut 3 used Engine assembly Muffler 10 Muffler shield 11 Ground wires 12 Flat washer 13 Muffler support bracket 14 Cap screw 4 used 15 Flat washer 4 used Engine Loctite 242 90 to 110 in Ib 10 2 to 12 4 Nm 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Figure 6 Hex flange nut Lock washer Screw Pump adapter Screw 2 used Engine mount plate Lock washer 2 used Cap screw 2 used Engine mount 3 used Cap screw Hex nut Spring washer Cap screw Engine wire hamess Pump hub Page3 6 ST S SAS SSS SSE iii Hydraulic pump assembly Hardened washer Lock nut Coupling spacer Rubber coupling Flat washer Cap screw Square head set screw Key Engine hub Square head set screw Lock washer Cap screw Key Greensmaster 3150 Engine Removal Fig 6 1 Parkmachine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Disconnect negative battery cable from battery A CAUTION The muffler and exhaust manifold may be hot Avoid possible burns allow exhaust system to cool before working on the engine Gasoline is flammable Use caution when storing or handling it Do notsmoke while filling the fuel tank Do not fill fuel tank while engine is running or in an enclosed area
313. orientation is determined by viewing the manifold assembly from the side with its solenoids fac ing up 1 Install hydraulic fittings and their respective O rings to the manifold assembly and orient to position re corded during removal 2 Position manifold assembly to the support frame Secure assembly to the frame with both cap screws 26 3 Connect hose assemblies and their respective O rings to hydraulic fittings 4 Connect solenoid valve electrical connectors If an optional backlap kit is installed connect electrical con nector for the ball switch Hydraulic System Rev E 2g 3 SE 52 gt Hydraulic Manifold Service Serial Number Under 260999999 PLUG TORQUE SAE 4 9 to 11 ft Ib 12 to 14 Nm SAE 6 16 to 18 ft Ib 22 to 24 Nm SAE 48 43 to 46 ft Ib 58 to 62 Nm SAE 10 60 to 62 ft Ib 81 to 84 Nm 15 in Ib 1 7 Nm e 35 ft lb 7 47 Nm 20 6 494 13 p 15in lb N 3 1 7 Nm 7 SA amp N00 19 GM MS Serial Number 230000801 To Yy Xx 1 260999999 Shown Figure 54 1 20 wattsolenoid 10 Plug SAE 8 19 Solenoid seal 2 N O cartridge Ports S1 amp S2 11 O ring 20 Seal kit 3 4Way 2Position cartridge Port S3 12 Manifold body 21 Seal kit 4 Plug SAE 2 13 150 PSI relief cartridge Port R2 22 Seal kit 5 O ring 14 N O cartridge Port 56 23 Seal kit 6 Plug Gae 6 15 Cavity plug Port LC1 24 Seal kit 7 O ring 16 O ring 25
314. ote Monitor hydraulic fluid level in sight glass As air is removed from the hydraulic circuit auxiliary tank may need to be topped off after initial fill Hydraulic System Rev E E 5 5 gt gt wn 8 Remove from main hydraulic tank and slowly fill to cold filllevel mark nextto sight gauge 11 on auxiliary tank 10 If the buzzer fails to sound check to see if all con nections are secure 11 Verify leak detector operation 9 Check leak detector with ignition key switch in ON RUN position The buzzer should sound when leak de tector test switch is held down for one 1 second Hydraulic Reservoir Hydraulic System Rev E o MOgRUNH 30 to 60 in Ib 3 4 to 6 8 Nm Straight hydraulic fitting O ring O ring Oil level sensor O ring Hydraulic tank Tether Pin 19 7 Antiseize Lubricant 3 Figure 72 Tank cap Filler screen Overflow hose Hose clamp Hydraulic barb fitting O ring Hose clamp Return hose Page 4 102 Pump inlet hose Plug early units only Cap screw Flat washer Grommet Spacer Tank pad Greensmaster 3150 Removing Hydraulic Reservoir Fig 72 1 Before removing any parts from the hydraulic sys tem park machine on a level surface set brake lower cutting units and stop engine Before continuing further read and become fa miliar with General Precautions for Removin
315. other moving parts can in the Toro publication Sharpening Reel amp Rotary result in personal injury Mowers Form No 80 300 PT face of bedknife when lapping operation is completed This will remove any burrs or rough edges that may have NOTE For a better cutting edge run a file across front built up on the cutting edge Bedbar Removal and Installation 1 Loosen pivot screws securing bedknife pivot assemb ly to reel frame supports Fig 24 2 Rotate adjustment knob and pivot assembly clock wise left hand thread until it is unthreaded from bedbar pivot Fig 24 3 Loosen jam nuts retaining right and left bedbar pivot bolts Remove pivot bolts Fig 24 IMPORTANT Note position of plastic washer and steel washer on right end of bedbar and plastic washer on left end of bedbar for reinstallation 4 Slide bedbar down and out from under cutting unit Figure 24 Do not misplace washers 1 Pivot screw 7 Left bedbar pivot bolt 5 Replace and or grind bedknifeto renew cutting edges 2 Bedknife pivotass y 8 Right bedbar pivot bolt 3 Frame supports 9 Steel washer NOTE For proper grinding of bedknife follow proce Adjustment knob 10 Plastic washer d in the T blicati Shar ina Reel d 5 Bedbar pivot 11 Spring arm retaining capscrew ures in ihe toro arpening an 6 Jam nuts 12 Compression spring Rotary Mowers Form No 80 300 PT 6 Adjust the reel bearings See Reel Bearin
316. ow meters in the circuits during various operational checks see the Special Tools section in this Chapter Before Performing Hydraulic Tests IMPORTANT All obvious areas such as oil supply filter binding linkages loose fasteners improper adjustments solenoid valve operation or electrical connections circuits must be checked before as suming thata hydraulic componentis the source of the problem Precautions for Hydraulic Testing Failure to use gauges with recommended pres sure psi rating as listed in test procedures could resultin damageto the gauge and possible personal injury from leaking hot oil All testing should be performed by two 2 people One person should be in the seatto oper ate the machine and the other should read and record test results Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil Controls must be operated with the ignition switch in OFF Remove key from the igni tion switch Before disconnecting or performing any workon the hydraulic system all pressure in the system must be relieved and all rotating machine parts mustbe stopped Stop engine lower or support attachments Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Do not use hands to search for leaks use paper or cardboard Hydraulic fluid escap ing under pressure can have sufficient force to penetrate the skin and cau
317. pe T la RN d 7 42 wo 4 1808 gt 1108 Nu Ia 9 Y gt ally l 50 ud SHOLOW 133HM 011 1 A2N3I2IJd3 86 ONY 008 Iv 0319102195 Jive M01 EE oo Y on 18e TX 14003 INO 1804 3n aio 2 Kiva E 583041713 LI Se UMOUS L00000042 jeues gt 5 DONUM 0612 Jo1seuisueaJr Hydraulic System Rev E 4 9 Greensmaster 3150 Hydraulic Flow Diagrams PME Y SDISIVNOMEO 098Z dnd
318. pivot boss of bedbar Figure 35 without support You will break the casting 5 Press center pivot bushings into place Fig 36 DO NOT hammer on pivot boss of bedbar without support You will break the casting 6 Dosteps 5 16 under Bedbar Removal and Installation in this section of the book Figure 36 Figure 33 1 Bedbar end bushing 2 3 Flange bushing 4 2 Bedbar pivot bushing 2 Repairs Page 9 24 Greensmaster 3150 Bedknife Replacement 1 1 4 under Bedbar Removal and Installa tion in this section of the book 2 Remove bedknife screws and remove bedknife 3 Remove all rust scale and corrosion from bedbar surface before installing the bedknife 4 Install new bedknife with new bedknife screws 57 4910 Apply clean SAE 30 oil to the screws before installing screws Tighten the screws to a torque of 200 to 250 in Ib working from the center toward each end of the bedbar Fig 37 5 Grind the new bedknife to match it to the bedbar Note For proper grinding of bedknife follow proce dures in the Toro publication Sharpening Reel and Rotary Mowers Form No 80 300 PT 6 Dosteps 6 16under Bedbar Removal and Installa tion in this section of the book Preparing Reel for Grinding IMPORTANT Adjust reel bearings before grinding reel See Reel Bearing Service and Adjustment in the Adjustments section of this chapter 1 Dosteps 1 6 under Bedbar Removal and Installa tion
319. place clutch if necessary Clutch not fully engaged Make sure clutch knob set screws are tight against flats on release disk and does not allow knob to slip IMPORTANT When engaging or disengaging the clutch be sure to push the snubber down and turn the knob all the way it will come to a firm stop 2 Clutch is engaged but does not provide power to groomer reel Clutch damaged or assembled incorrectly Repair or replace clutch if necessary Belt is out of adjustment If belt has slipped it will probably be damaged and must be replaced Belt broken or damaged Repair or replace belt if neces sary A broken or worn belt could be the result of im proper belt adjustment or seized groomer reel bearings Bent damaged or missing groomer blades Replace blades if necessary 3 Turf damage or uneven grooming Bent or damaged groomer reel shaft Replace groomer shaft Grooming depth not equal on both ends of groomer reel Adjust if necessary Check and adjust cutting unit set up level bedknife to reel level rear roller to reel set height of cut etc Groomer reel interfering with cutting unit frame side plate Check side plate for proper cut out and modify if necessary 4 Groomer reel does not raise completely to transport position quick up levers do not rotate completely to rear or have free play Incorrect front roller extension plate installed Single Point Adjust
320. place hands or feet in the reel area while the engine is running e While backlapping the reels may stall and then restart e Do not attempt to restart reels by hand or foot e Do notadjustreels while the engine is running e Ifa reel stalls stop engine before attempting to clear the reel e Reelmotors areconnected in series moving one motor moves the other two 1 Position machine on a clean and level surface low er cutting units stop engine engage parking brake and remove key from the ignition switch 2 Move functional control lever to the Neutral Backlap position IMPORTANT Do notattemptto rotate the direction al valve knob when the machine or reels are run ning 3 Raise seat and rotate directional valve knob fully clockwise to the backlap position 4 Rotate flow control valve knob to position 6 5 On all cutting units make initial reel to bedknife ad justments appropriate for backlapping see Bedknife to Reel Adjustment in Cutting Unit Operator s Manual 6 Startengine and move Raise Lower Mow control forward to start the reels 7 Rotate flow control valve knob to position 1 8 Apply lapping compound with a long handled brush see Special Tools Be careful when backlapping the reel because contact with the reel or other moving parts can result in personal injury Greensmaster 3150 Page 10 9 Rev E CLOCKWISE Figure 11 1 Directional valve knob 3 Flow control valve
321. post Keep the test leads connected to the battery posts and record the battery voltage NOTE Upon starting the engine the battery voltage will drop and then should increase once the engine is running NOTE Depending upon the condition of the battery charge and battery temperature the battery voltage will increase at different rates as the battery charges Electrical System 5 8 Voltage Measured Battery Charge Level 12 68 V or higher Fully charged 10096 7596 charged 12 45V 12 24 V 5096 charged 12 06 V 2596 charged 11 89 V 096 charged Start the engine and run at high idle 3200 RPM Allow the battery to charge for at least 3 minutes Record the battery voltage After running the engine for at least 3 minutes battery voltage should be at least 0 50 volt higher than initial bat tery voltage An example of a charging system that is functioning At least 0 50 volt over initial battery voltage Initial Battery Voltage 12 30 Battery Voltage after 3 Minute Charge 12 85 Greensmaster 3150 Component Testing For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit e g unplug the ignition switch connector before doing a continuity check When testing electrical components for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected Ignition Switch The ignit
322. r Record test results 12 If case drain flow was greater than 16 0 ounces 473 milliliters 0 5 GPM 1 9 LPM in 15 seconds re pair or replace the reel motor as necessary 13 Disconnect tester from motor and return hose Re connect hose to the pump 14 Remove plug from bulkhead fitting Reconnectcase drain hose to the bulkhead fitting Test other reel motors as needed Figure 28 GPM Milliliters in 15 sec Ounces in 15 sec 4 95 3 2 2 189 6 4 3 284 9 6 4 378 12 8 5 473 16 0 6 568 19 2 7 662 22 4 8 756 25 6 9 852 28 8 10 946 32 0 Figure 29 Page 4 45 Rev Hydraulic System Rev E 5 CS a gt Steering Control Valve Test STEERING CYLINDER CYLINDER ROD FULLY EXTENDED PLUG STEERING VALVE LEFT TURN High Pressure Low Pressure Return or Suction Flow Hydraulic System Rev E Page 4 46 Greensmaster 3150 Procedure for Steering Control Valve Test 1 Make sure the hydraulic tank is full 2 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 3 Drive machine slowly in a figure eight on a flat level surface A There should be no shaking or vibratio
323. r Do not wipe parts dry with paper towels or cloth Lint in a hydraulic system will cause damage 8 Carefully inspect internal surface of barrel for dam age deep scratches out of round etc Inspect shaft head and piston for evidence of excessive scoring pit ting or wear Replace entire cylinder if internal compo nents are found to be worn or damaged Greensmaster 3150 Page 4 77 Assembly Figs 51 and 52 1 sure all parts are clean before reassembly 2 Coat new seal kit components with clean hydraulic oil A Install wear ring and seal with loader on the pis ton B Install O ring back up ring and seal on the head C Install O ring to groove in rod IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surface before mount ing in a vice 3 Mount shaft securely in a vise by clamping on the clevis or eye of the shaft Use of a vise with soft jaws is recommended A Coat shaft with clean hydraulic oil B Carefully slide head onto the shaft Install wiper onto shaft and into head C Install piston and nut onto the shaft Torque nut from 60 to 75 ft Ib 82 to 101 Nm D Remove shaft from the vise IMPORTANT Prevent damage when clamping the hydraulic cylinder into a vise clamp on the cap end only Do notclose vise enough to distort the barrel 4 Mount barrel in a vice 5 Coat all internal parts with a light coat of clean hy draulic oil Slide piston shaft
324. r is not loose and is pushed up as far O ring as possible Step 1 in Figure 12 Figure 11 IMPORTANT Before installing fitting into port de termine port material If fitting is to be installed into an aluminum port installation torque is reduced 5 Install the fitting into the port and tighten finger tight until the washer contacts the face of the port Step 2 6 Toputthe 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 use a torque wrench to tighten the fitting to the rec ommended installation torque shown in Figure 10 This tightening process will require the use of an offset wrench e g crowfoot wrench Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offset wrench will be lower than the listed installation torque see Using a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 Product Records and Maintenance Figure 12 8 If atorque wrench is not available or if space at the port prevents use of a torque wrench an alternate meth od of assembly is the Flats From Finger Tight F F F T method Hold the fitting in the desired position with a wrench and if port material is steel tighten the lock nut with a second wrench to the listed F
325. r off of cutting unit Figure 19 1 Motor mount nuts 2 Motor shaft 3 Slide the sleeve back on the ball joint and disconnect the pull arm from each side of the cutting unit Fig 20 Figure 20 1 Slide back to mount 2 Ball stud 3 Swing up to remove down to Install 4 Slide cutting unit out from under pull frame disengag ing the lift arm from the lift bail Fig 21 5 Reverse steps 1 4 to install the cutting unit Figure 21 1 Lift bail 3 Pull frame 2 Lift arm 4 Pull arm Greensmaster 3150 Page 7 15 Repairs Reel Lapping Check reel bearing adjustment and correct if necessary before backlapping Connect a lapping machine to the cutting unit with an extension coupler and a 9 16 socket The 9 16 socket can be positioned onto the capscrew on the reel shaft inside the counter balance weight on the end of the cutting unit Fig 22 Backlap according to procedures in the Toro publication Sharpening Reel amp Rotary Mowers Form No 80 300 PT NOTE For a better cutting edge run a file across the front face of the bedknife when the lapping operation is completed This will remove any burrs or rough edges that may have built up on the cutting edge A CAUTION Be careful when lapping the ree because con Figure 22 tact with the reel or other moving parts can result in personal injury 1 Counterbalance weight Repairs Page 7 16 Greensmaster 3150 Bedbar Removal and Installation
326. r steel wheels and non lubricated fasteners 88 14 N m 108 14 N m 108 14 N m 108 14 N m Thread Cutting Screws Zinc Plated Steel Thread Threads per Inch Size Baseline Torque Type B 11 i 85 15 in Ib Hole size material strength material thickness amp finish must be considered when determining specific torque values All torque values are based on non lubricated fasteners X 0 08851 in Ib N m X 0 7376 ft Ib Unit Operator s Manual Refer to these publications when performing regular equipment maintenance Re fer to the Engine Operator s Manual for additional en gine specific maintenance procedures Greensmaster 3150 Rev D Chapter 3 Table of Contents INTRODUCTION 2 SPECIFICATIONS 3 SERVICE AND REPAIRS 4 eer ED e er s 4 Fuel Tank Removal 5 Fuel Tank Installation 5 lame 6 Engine 7 Engine Installation 7 Fuel Evaporative Control S ystem Serial Number Above 310000365 8 BRIGGS amp STRATTON REPAIR MANUAL FOR 4 CYCLE V TWIN CY LINDER OHV HEAD ENGINES Greensmaster 3150 Page3 1 Rev F Engine Introduction This Chapter gives information about specifications maintenance troubleshooting testing and
327. ration and sealing B Thread valve carefully into the applicable port RD1 or The valve should go in easily without binding Torque valve to 35 ft Ib 47 Nm 7 Reinstall knob assembly A Install applicable locating plate 25 or 26 so that the pin seats into the locating hole B Turn the threaded cartridge valve 7 or 13 stem carefully clockwise until it stops C Face detent plate 22 counterbore down Thread detent plate down onto the valve stem until it is stopped by the locating plate Turn detent plate back counterclockwise 1 4 turn D Center one detent plate hole over a locating plate indentation Drop a ball 24 into each hole then drop a spring 20 or 21 into each hole E Onflow control valve 7 place indicator plate 6 overthe detent plate Make sure the arrow points di rectly at the number 1 on the locating plate F On directional cartridge cartridge valve 13 place indicator plate 19 over the detent plate Make sure the arrow points to the right at 459 G While pushing down on the indicator plate 6 or 19 and compressing the springs thread down a jam nut 18 While tightening the set screw 23 tighten jam nut at the same time using a 7 16 inch wrench H Thread second jam nut all the way down the valve stem Apply Loctite 242 or equivalent on the valve stem threads Screw knob 17 all the way down until it hits the upper jam nut l Ondirectional cartridge valve 7 turn
328. red in dry grass conditions clippings fall over top of baskets or raised to allow for heavy wet grass conditions clippings build up on rear edge of baskets Figure 18 1 Shield 3 4 3 4 inches 2 Front crossbar 4 Shield fasteners Top Cut Off Bar Adjustment Adjust top bar to make sure clippings are cleanly dis charged from reel area 1 Loosen screws securing top bar Fig 19 Insert 0 060 _ inchfeeler gauge between top of reel and bar and tighten screws Make sure bar and reel are equal distance apart across complete reel 2 Repeat settings on remaining cutting units NOTE Bar is adjustable to compensate for changes in turf conditions Bar should be adjusted closer to reel when turf is extremely wet By contrast adjust bar further away from reel when turf conditions are dry Bar should be parallel to reel to get optimum performance and should be adjusted whenever shield height is adjusted or whenever reel is Sharpened on a reel grinder Greensmaster 3150 Page 8 17 Figure 19 1 Top bar 2 Bar mounting screws Set Up and Adjustments Pull Frame Adjustment 1 Put the basket on the pull frame 2 Level baskets to cutting unit by loosening nut at one end of pull frame roller Loosen bolt and move roller shaft in slot as necessary Tighten bolt 3 Loosen the jam nuts on the pull arms and adjust the ball sockets until there is 1 4 in to 1 2 in 6 to 13 mm cleara
329. rews Use this bit with a torque wrench to se cure the bedknife to the bedbar IMPORTANT DO NOT use and air or manual impact wrench with this tool so damage to the bedbar will be prevented Toro Part Number TOR510880 Roller Bearing Installation Tools Washers and spacer used to install bearings and seals into front and rear rollers that have a threaded roller shaft Seal installation washer black 107 8133 Seal installation spacer 4 107 3505 Bearing installation washer yellow 104 6126 Figure 2 Figure 3 2 Figure 4 Seal Installation Bearing Installation Seal Installation Spacer Washer Washer Figure 5 Greensmaster 3150 Page 10 3 Rev E Dual Point Adjust Cutting Units Bearing and Seal Installer Usedto install bearings and seals into front and rear roll ers that have a threaded roller shaft Toro Part Number TOR4105 NOTE TOR4105 is an alternative to using washers and spacers listed above Inner Grease Seal Installation Washer Inner grease seal installation washer Toro Part Number 104 0532 This washer is used when replacing the reel bearing in ner grease seal It enables pressing the grease seal to a depth of 104 in 2 64 mm below the surface of the cutting unit side plate Toro Part Number 104 0532 Plastic Plug This cap is used for placement into the bearing housing when the reel motor is removed It prevents dirt and de bris from entering the housing Toro Part Nu
330. rf conditions are dry Bar should be parallel to reel to get optimum performance and should be adjusted whenever shield height is adjusted or whenever reel is sharpened on a reel grinder Figure 21 2 Bar mounting screws Groomer Reel Drive Belt Adjustment 1 Loosen two 2 set screws and remove clutch knob Fig 6 Remove groomer reel housing cover from left side of cutting unit Fig 8 2 Apply 5 10 Ib of force on the belt midway between the pulleys to check tension on the drive belt There should be 1 4 inch belt deflection If deflection is not 1 4 inch loosen the idler pulley pivot screw Fig 22 Pivot the idler to get proper tension and tighten the allen head screw to a torque of 7 10 ft lb 3 Install groomer reel housing cover Install clutch knob and tighten two 2 set screws against flats on release disk Page 9 19 Figure 22 1 Drive pulley and clutch assembly 2 Driven pulley 3 Drive belt backside idler pulley 4 Drive belt Set Up and Adjustments pa el Pull Frame Adjustment 1 Put the basket on the pull frame 2 Level baskets to cutting unit by loosening nut at one end of pull frame roller Loosen bolt and move roller shaft in slot as necessary Tighten bolt 3 Loosen the jam nuts on the pull arms and adjust the ball sockets until there is 1 4 in to 1 2 in 6 to 13 mm clearance between the lip of the basket and the reel blades Fig 23a This prevents grass clipp
331. rface before mount ing in a vice 4 Mountshaft securely ina vise by clamping on the cle vis or eye ofthe shaft Remove lock nut and piston from the shaft Slide head off the shaft 5 Remove T ring and O ring from the piston Remove O ring back up ring rod seal and dust seal from the head A CAUTION Use eye protection such as goggles when using compressed air to dry cylinder parts 6 Wash parts in clean solvent Dry parts with com pressed air Do not wipe parts dry with paper towels or cloth Lint in a hydraulic system will cause damage 7 Carefully inspect internal surface of barrel for dam age deep scratches out of round etc Inspect shaft head and piston for evidence of excessive scoring pit ting or wear Replace entire cylinder if internal compo nents are found to be worn or damaged Greensmaster 3150 Page 4 75 Reassembly Figs 49 and 50 1 Make sure all parts are clean before reassembly 2 Coat new O rings T ring rod seal back up ring and dust seal with clean hydraulic oil A Install T ring and O ring on the piston B Install O ring back up ring and dust seal on the head IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surface before mount ing in a vice 3 Mountshaftsecurely in a vise by clamping on the cle vis or eye of the shaft A Coat shaft with clean hydraulic oil B Slide head onto the shaft Install rod seal onto shaft and into he
332. right end and 90 fitting at the left end when viewed in the direction of travel 4 Use a plastic headed hammer to rotate bearing hous ing slightly install bolts from outside of housing and turn bolts alternately against side plate to remove bearing housing Fig 29 Bearing housing will slip out of side plates and reel assembly can be removed as soon as bearing housings are disassembled from side plates Figure 28 5 Before installing reel install new special machine 1 Left reel bearing housing 3 Machine screws screws from inside of frame to secure bearing housing 2 Right reel bearing housing bet 6 If necessary install new bearings and seals A Remove outer seal in counterbalance weight bearing cup bearing cone and inner seal B Bearing housing must be completely free of paint and foreign material before installing bearing cup If necessary remove any flash from bearing housing that may interfere with accurate seating of bearing Install new inner seal Install bearing cup C Install bearing housing to frame Pack bearing cone with grease and install over reel shaft into bearing cup Install outer seal in counterbalance h weight f 7 After installing reel tighten spline nut to 40 60 ft lb Figure 29 then adjust bearings See Reel Bearing Service and Adjustment in the Adjustments section of this chapter 1 Bearing housing rotate slightly 2 Bearing housing mount bolts thread against
333. rotor motor Wheel Motor Optional Rear Orbital rotor motor Reel Motor Gear motor Steering Control Valve Distributor valve with rotary meter Implement Steering and Lift Relief Pressure R5 1150 PSI 79 4 bar over Charge Pressure Hydraulic Manifold Relief Valves Mow Circuit R1 Cutting Unit Lower R2 2400 PSI 166 bar 300 PSI 21 0 bar over Charge Pressure Hydraulic Filter 5 Micron spin on cartridge type Hydraulic Oil See Operator s Manual Hydraulic Reservoir Reservoir with leak detector capacity 8 5 gal U S 32 0 L Hydraulic System Rev E Page 4 2 Greensmaster 3150 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 condi tions or mishandling during operation and maintenance These conditions can cause hose damage and deterio ration Some hoses are more susceptible to these conditions than others Inspect all machine hydraulic hoses frequently for signs of deterioration or damage Hard cracked cut abraded charred leaking or otherwise damaged hose Kinked crushed flattened or twisted hose Blistered soft degraded or loose hose cover Cracked damaged or badly corroded hose fittings When replacing a hydraulic hose be sure that the hose is straight not twisted before tightening the fitt
334. rque nut from 15 to 20 ft Ibs 20 to 27 Nm B Onlater production cutting units install retaining ring 14 to adjuster shaft 13 Make sure that ring is fully seated into shaft groove 6 Apply antiseize lubricant to threads of adjuster screw 6 and install into adjuster shaft 7 Install washer 10 spring 11 and lock nut 12 onto adjuster screw 8 Install bedbar see Bedbar Installation in this sec tion of this manual 9 Adjust cutting unit see Cutting Unit Operator s Manual Greensmaster 3150 Bedknife Replacement and Grinding Removal 1 Remove bedbar from frame see Bedbar Removal 2 Remove screws from bedbar using a socket wrench and bedknife screw tool see Special Tools Discard screws Remove bedknife from the bedbar Fig 15 3 Use scraper to remove all rust scale and corrosion from bedbar surface before installing bedknife Replacement Figure 15 1 Make sure bedbar threads are clean Use new 1 Screw 3 Bedknife screws Apply clean SAE 30 oil to the screws before 2 Bedbar installing IMPORTANT Do notuse an impact wrench to tight en screws into the bedbar 2 Using a torque wrench and bedknife screw tool tighten screws to a torque of 200 to 250 in Ib 22 to 28 Nm Use a torquing pattern working from the center toward each end of the bedknife Fig 16 3 Install bedbar to frame see Bedbar Installation Grindin 9 8 8 96 Since there can be
335. s 22 Torque cap screws from 30 to 60 1 3 4 to 6 8 Nm 5 Secure return hose 16 to hydraulic barb fitting at tank 6 Secure pump inlet hose to hydrostat with hose clamp Fig 73 7 Connecthose assembly to reel motor case drain fit ting located below the right side of the frame Fig 73 8 Connect level sensor harness connector 9 Install leak detector assembly see Leak Detector Installation in this chapter of this manual Figure 73 1 Reel motor case drain 2 Pump inlet hose Figure 74 1 Oillevel sensor 2 Sensor arrow Hydraulic System Rev E 2 E gt This page is intentionally blank Hydraulic System Rev E Page 4 104 Greensmaster 3150 Chapter 5 TORO Electrical System Table of Contents ELECTRICAL SCHEMATICS 2 Solenoid Valve Coils 10 SPECIAL TOOLS 1 Aule re ete EP 3 Seat Switch x set ER Esp 11 TURF GUARDIAN LEAK DETECTOR F se Block ee e eee fes 11 SYSTEM OPERATION 4 Neutral and Mow Switches 12 TROUBLESHOOTING 5 Parking Brake 13 Starting Problems 5 Joystick Raise and Lower Switches 14 General Run amp Transport Problems 6 Backlap Switch If Equipped 14 Cutting Unit Operating Problems
336. s Fig 15 3 On gauge bar Part No 1 8789 set head of screw to desired height of cut This measurement is from bar face to underside of screw head 4 Place bar across front and rear rollers and adjust height of cut knob until underside of screw head engages bedknife cutting edge Fig 14 Check and adjust on each end of bedknife then tighten height of cut adjustment locknuts on each end Changing To A Different Type of Cutting Unit or Adding Cutting Unit Accessories When changing to a different type of cutting unit or adding cutting unit accessories it is recommended that you change only one cutting unit and keep the other two existing cutting units on the machine 1 Set the new cutting unit to a height of cut approximately 1 16 0 06 in higher than the old cutting unit 2 Do a mowing test and compare results between the new cutting unit and old cutting units 3 Adjust the new cutting unit to match the cut of the old cutting units 4 The other two cutting units can now be replaced Adjust these two new cutting units so they are the same as the other new cutting unit that was tested Greensmaster 3150 Page 8 15 Figure 15 1 Height of cut knob locknut 3 Height of cut knob 2 Gauge bar 1 87891 5 Roller shaft clamp bolt 3 Gauge bar screw head Set Up and Adjustments Front Roller Scraper Adjustment The front roller scraper should be adjusted so there is a clearance of approximately 1 32 of
337. s in pivot housing Slide pivot housing onto shaft of knob 8 Install spring over adjusting knob threaded shaft and thread adjustment knob and pivot assembly into flat side of bedbar pivot Make sure there is an equal gap be tween each side of pivot assembly housing and frame supports Fig 29 Adjust before installing pivot screws by sliding bedbar pivot sideways IMPORTANT On hand adjustable type knobs check to make sure die spring is compressed to a dimen sion of 13 16 in by tightening locknut left hand thread Fig 6b 9 If equipped with hex head type pivot screws tighten pivot screws to 60 ft lb If equipped with hex socket head set screws and jam nuts tighten set screws finger tight then tighten 1 2 turn more total not each Tighten jam nut 10 Adjust bedknife to reel contact NOTE If quality of cut has deteriorated or the reel and bedknife have become rifled you must grind the reel and bedknife to remove rifle pattern Figure 38 1 Pivot housing 4 O ring 2 7 Bedbar pivot 2 Bearing 2 5 Spring arm 8 Spring 3 Inner race 2 Greensmaster 3150 6 Adjustment knob Page 8 25 9 Pivot screw 2 10 Spring arm bolt Repairs Lift Bail Replacement N 5 22 i N USERS 2227727222 Figure 39 1 Use a saw to cut the lift bail off ofthe cutting unit Make 4 Support the lift bail so the bottom radius is 4 546 inches the cut 1 inch from the
338. s the same as mowing opera tion except for the position of the backlap valve MR When the backlap valve MR is in the backlap position oil flows through the rear M1 right M3 and then left M2 reel motor as it turns the motors in the backlap direction Hydraulic System Rev E 3 5 52 gt A A Y 1 LIA IVNOLdO HOIH 0982 E A 0091 I Rig cad 21009 lS1SOHGAH 1 gt e el m gt v 1 11 1 lt 4 INVA 4 052 0024 aang 9NIH331S Re ey i zal 15 ld y T Z Y INVA 18
339. se serious injury If fluid is injected into the skin it mustbe surgical ly removed within a few hours by a doctor famil iar with this type of injury Gangrene may result from such an injury Hydraulic System Rev E Page 4 28 1 Clean machine thoroughly before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hy draulic equipment Contamination will cause excessive wear of components 2 To prevent hydraulic system contamination put metal 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 Engine speed will affect test accuracy Check pump speed with a phototac when performing hydraulic tests 4 When using tester with pressure and flow capabili ties the inlet and the outlet hoses must be properly con nected and not reversed to prevent damage to the hydraulic tester or components 5 When using tester with pressure and flow capabili ties completely open load valve in the hydraulic tester to minimize the possibility of damaging components 6 Install fittings finger tight and far enough to make sure that they are not cross threaded before tightening them with a wrench 7 Position tester hoses to prevent rotating machine parts from contacting and damaging the hoses or tester 8 Checkoillevel in the hydraulic reservoir After con necting test equ
340. t 11 Front roller scraper and comb adjustment Troubleshooting weight cutting unit accessories and turf conditions Page8 6 If bedknife is too thick for effective height of cut poor quality of cut will result Set scraper for 1 32 in clearance from roller Set comb the same on all cutting units for height of cut and turf conditions Must be same height at both ends of comb Greensmaster 3150 Possible Problem Correction 12 Stability and position of bedbar Make sure bedbar bolt plastic washers are snug against bedbar Bedbar must pivot without binding Check bedbar end bushings pivot bushings and nylon flange bushings for wear or damage and replace if necessary Make sure proper bushings are installed in each location bedbar end bushings are different Check adjustment knob to make sure detent holds ad justment Repair if necessary With adj knob pivot assembly removed pivot set screws installed and frame on level surface measure from flat surface up to end of each setscrew If not within 1 16 in of each other bend ears on cutting unit frame to line up screws Check to make sure adj knob pivot assembly is centered in bedbar arm yoke and frame ears so that an equal gap exists on each side of pivot housing before pivot screws are installed Make sure bedknife adj knob pivot assembly is held firmly in place between frame supports Tighten pivot screws if necessary 13 Number of reel blades Us
341. t Always install the cap and tighten before pressurizing the system ADJUSTMENT 1 Locate relief valve and remove cap from valve HEX SOCKET Note An 1 8 turn of the adjustment socket is about 50 psi 3 5 bar or 1 turn is about 400 psi 27 6 bar 2 To increase pressure setting turn the adjustment N socket inside the valve 1 8 of a turn clockwise Figure 27 3 To decrease pressure setting turn the adjustment socket inside the valve 1 8 of a turn counterclockwise 4 Installand tighten capto valve After adjustment re test pressure setting see TESTING Hydraulic System Rev E Page 4 48 Greensmaster 3150 Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1 Before removing any parts from the hydraulic sys tem park machine on a level surface engage parking brake lower cutting units or attachments and stop en gine Remove key from the ignition switch 2 Clean machine before disconnecting removing or disassembling any hydraulic components Make sure hydraulic components hoses connections and fittings are cleaned thoroughly Always keep in mind the need for cleanliness when working on hydraulic equipment Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil Controls must be operated with the ignition switch in RUN and the engine OFF Make sure all electr
342. t it from turning Fitting Dash Size Hose Tube Side Thread Size C Use a second wrench to tighten the nut to the cor rect Flats From Wrench Resistance F F W R The markings on the nut and fitting body will verify that the connection has been properly tightened Size F F W R 4 1 4 in nominal hose or tubing 1 2 to 3 4 6 3 8 in 1 2 to 3 4 8 1 2 in 1 2 to 3 4 10 5 8 in 1 2 to 3 4 12 8 4 in 1 8 to 1 2 16 1 in 1 8 to 1 2 Swivel Nut Fitting Body Tube or Hose Figure 6 Mark Nut Final Position Initial Extend Line Position AT WRENCH RESISTANCE AFTER TIGHTENING Figure 7 Installation Torque 9 16 18 18 to 22 ft Ib 25 to 29 N m 11 16 16 27 to 33 ft Ib 37 to 44 N m 13 16 16 37 to 47 ft Ib 51 to 63 N m 1 14 60 to 74 ft Ib 82 to 100 N m 13 16 12 85 to 105 ft Ib 116 to 142 N m 1 7 16 12 110 to 136 ft Ib 150 to 184 N m 1 11 16 12 140 to 172 ft lb 190 to 233 N m Figure 8 Hydraulic System Rev E 4 4 Greensmaster 3150 Hydraulic Fitting Installation SAE Straight Thread O Ring Fitting into Component Port Non Adjustable Fitting Fig 9 1 Make sure all threads and sealing surfaces of fitting and component port are free of burrs nicks scratches or any foreign material 2 Asapreventative measure against leakage it is rec ommended that the O ring be replaced any time the connection is opened 3 Lightly lubricate th
343. talling bearing cup If necessary remove any flash from bearing housing that may interfere with accurate seating of bearing Install new inner seal Install bearing cup C Install bearing housing to frame Pack bearing cone with grease and install over reel shaft into bearing cup Install new outer seal in counterbalance weight Repairs Page 8 24 6 After installing reel tighten spline to a torque of 40 to 60 ft lb then adjust bearings See Reel Bearing Ser vice and Adjustment in the Adjustments section of this chapter 7 Dosteps 5 16 under Bedbar Removal and Installation in this section of the book Figure 36 1 Left ree bearing housing 2 Right reel bearing housing 3 Machine screws Figure 37 1 Bearing housing 2 Bolt Greensmaster 3150 Bedknife Adjustment Knob Bearing Service 1 Turn bedknife adjustment knob counterclockwise to remove bedknife to reel contact 2 Remove two 2 pivot screws Fig 38 3 Rotate adjustment knob and pivot assembly clock wise left hand thread until it is unthreaded from the bedbar pivot 4 If necessary remove locknut securing die spring to shaft Fig 6b Slide pivot housing off adjustment knob threaded shaft Fig 38 5 Pull inner races from pivot housing Pull bearings from pivot housing Check condition of inner races and bear ings and replace if necessary 6 Install new o ring on each race if necessary 7 Install bearings and race
344. tector can be disassembled using the leak detector assembly drawing Fig 70 as a guide 2 Inspect parts for the following A Leaking cracked or damaged auxiliary tank B Wornorleaking hydraulic hoses Replace if nec essary C Visibly worn or damaged parts Greensmaster 3150 Page 4 101 Figure 71 Assembly Fig 70 1 Coatall O rings with clean hydraulic oil 2 Secure sight gauge 11 and new O ring 12 to the auxiliary tank Torque gauge from 100 to 125 in Ib 11 3 to 14 1 Nm 3 Secure hydraulic barb fittings 28 and new O ring 15 to the auxiliary tank Torque fitting from 17 to 21 ft Ib 23 to 28 Nm 4 Secure valve hose 32 to the barb fitting 28 with hose clamp 13 5 Secure both hydraulic barb fittings 14 and O rings 15 to the valve body 22 Installation Fig 70 1 Connect tank hose 23 and install valve assembly if previously removed 2 Connect pump inlet hose to hydrostat Fig 71 3 Connect overflow hose 27 4 Position auxiliary tank over hydraulic tank and con nect valve hose 32 IMPORTANT Do not over tighten cap screw Threads in tank may become damaged 5 Install four spacers 3 and 10 neoprene washers 3 flat washers 4 and cap screws 6 and 9 Tighten cap screws from 30 to 60 in Ib 3 4 to 6 8 Nm 6 Connect leak detector harness to main wire har ness 7 Secure tether to the auxiliary tank with cap screw 81 and flat washer 30 N
345. teners Metric Fasteners Other Torque Specifications Product Records 8 Insert a copy of the Operator s Manual and Parts Cata log for your Greensmaster 3150 D at the end of this chapter Additionally if any optional equipment or ac cessories have been installed to your machine insert the Installation Instructions Operator s Manuals and Parts Catalogs for those options at the end of this chap ter Greensmaster 3150 Page2 1 Rev D Chapter 2 Product Records and Maintenance Product Records and Maintenance Product Records 5 co 59 Decimal and Millimeter Equivalents Equivalents and Conversions Rev D Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 82 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 09375 2 881 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 4762
346. tes 9 and 11 and bearing 10 loosely to the right inside of the castor fork with cap screws 12 bearing tab 7 lock nuts 8 and 29 and flat washer 18 A Position flangette grease fitting facing down ward B Torque socket head screws 1 115 Nm 6 to 85 ft lb C Torque cap screws 12 to 30 ft Ib 41 Nm 7 Apply loctite to both set screws 27 Torque set screws from 80 to 100 in Ib 9 to 11 Nm Greensmaster 3150 Front Wheel and Brake 250 to 400 ft Ib 4 339 to 542 Nm 3 5 i 70 to 90 ft Ib 95 to122 Nm N RIGHT Antiseize Lubricant FRONT Pd Figure 7 1 Lug nut 12 Brake shoe 23 Brake lever 2 Tire 13 Woodruff key 24 Lock nut 3 Rim 14 Brake bracket 25 Jam nut 4 Valve stem 15 Hydraulic hose 26 Cap screw 5 Brake drum 16 Hydraulic hose 27 Cap screw 6 Wheel hub 17 45 Hydraulic fitting 28 Lock nut 7 Drive stud 18 O ring 29 Lock nut 8 Backing plate 19 O ring 30 Cap screw 9 Brake cam 20 Hydraulic motor 31 Swivel clevis 10 Retaining ring 21 Flat washer 32 Lock nut 11 Return spring 22 Brake rod Greensmaster 3150 6 9 Wheels and Brakes Removal Fig 7 1 Park machine on a level surface Make sure engine is off Make sure brake is in the OFF position 2 Block front and rear of wheels not being jacked up Lift front wheel off the ground using a jack and place blocks beneath the frame under the hydraulic wheel mo tor 20 3
347. th a fuel evaporative con trol system connectsystem hose s to engine see Fuel Evaporative Control System Serial Number Above 310000365 in this section 11 Secure negative battery cable to battery 12 Open shut off valve on fuel tank and fill fuel tank with fuel Check fuel hose for leaks 13 Check and adjust oil level in engine 14 Startthe engine and check for proper engine opera tion Engine Fuel Evaporative Control System Serial Number Above 310000365 CARBON CANISTER MOUNTED TO FRAME TO INTAKE MANIFOLD CARBON CANNISTER FRESH AIR FILTER CARBON CHECK HH E CANNISTER VALVE SS MANIFOLD 2 i FRESH AIR CHECK S FILTER VALVE TOAIR CLEANER Figure 7 Engine Page3 8 Rev F Greensmaster 3150 Greensmaster 3150 machines with serial number above 310000365 are equipped with a fuel evaporative control system EVAP designed to collect and store evaporative emissions from the fuel tank The EVAP uses a carbon cannister to collect these evaporative emissions F uel vapors from the fuel tank are vented to the canister where they are stored Vapors from the can ister are consumed when the engine is running which purges the canister The fuel tank on these Greensmaster 3150 machines uses a non vented fuel cap To connect the tank to the evaporative control system a fuel vent valve is posi tioned in the top of the tank that allows tank venting
348. that sleeve bearing is in handle cap If necessary press sleeve bearing into cap Install lip seal on cap with seal lip facing down C While pressing on the cap to keep the lip seal in place rotate cap in a clockwise direction until the ar row on the cap aligns with number 1 on the manifold By rotating the cap clockwise the valve will remain closed Install screw to retain cap D Make surethat alignment marks on cap and base areinline and that arrow on capis pointing to number 1 on manifold Tighten two 2 set screws to secure handle cap 5 Reinstall rotary cartridge valve into manifold port Figure 96 1 Handle Base 7 SetScrew 2 used ri i 2 Handle Cap 8 Screw A Lubricate new O rings and backup rings of seal 3 9 Lip Seal kit with clean hydraulic oil and install The O rings 4 Compression Spring 10 Sleeve Bearing and backup rings of seal kit must be arranged prop 5 Bushing 11 Flow Control Valve erly on the cartridge valve for proper operation and 6 Set Screw sealing Hydraulic System Rev E Page 4 84 Greensmaster 3150 Mow Backlap Spool Fig 57 1 Remove mow backlap spool from manifold A Remove backlap switch from manifold before re Loctite 603 moving mow backlap spool Remove dowel pin and ball from manifold port after switch is removed Re move and discard O ring from switch B Remove lower retaining ring from mow backlap spool Raise mow backlap spool to al
349. the Service and Re pairs section of Chapter 10 DPA Cutting Units 3 If equipped remove rotating rear roller brush from cutting unit 4 Remove groomer belt cover item 3 and groomer drive belt item 36 from groomer drive side of mower see Groomer Belt Replacement in this section 5 Loosen cap screws item 20 that secure front roller shaft to groomer arms Figs 7 and 8 6 Remove lock nut item 25 and spring washer item 24 that secure drive side groomer arm lift rod to drive side plate Fig 7 Greensmaster 3150 7 Remove lock nut item 35 tab washer item 34 and plow bolt item 27 that secure drive side groomer arm assembly to drive side plate Do not change height of cut screw adjustment Remove drive side groomer arm assembly from cutting unit 8 Remove front roller assembly from cutting unit Note prevent groomer shaft from turning when re moving driven pulley use wrench on shaft flats to hold shaft 9 Removethe flange nut item 17 that secures driven pulley item 32 to groomer shaft Remove driven pulley from shaft Locate and retrieve square key item 31 that locates pulley on shaft wa Figure 7 Note To prevent cutting reel from turning when re 1 screw 3 Groomer shaft assembly 2 Frontroller shaft 4 Locknut spring washer moving drive pulley block reel with piece of wood 10 Remove flange head screw item 4 and washer item 5 that secure drive pulley item
350. the cutting unit frame Remove the side plate from the reel shaft and the roller shafts Figure 19 1 Counter weight Figure 20 1 Front roller set screw 2 Rear roller saddle strap screws Greensmaster 3150 Page 10 15 Dual Point Adjust Cutting Units Left Side Plate Service Fig 18 1 Remove the inner grease seal 13 and outer grease seal 9 from the side plate 6 2 Remove the retaining ring 14 securing the bearing in the side plate Remove the bearing 12 Inspect the bearing to insure that it spins freely and has minimal ax ial play The bearing balls must be free of deformation and scoring Replace the bearing if necessary 3 Remove the wave washer 15 4 Remove all grease from the side plate bore 5 Insert the wave washer 15 into the side plate Note Replacement Seal Kit Toro Part No 106 6937 is available for side plate service of dual point adjust cut ting units 6 Packthe bearing 12 with Mobil High Temperature HP or equivalent grease Insert the bearing into the side plate against the wave washer 7 Pressthe retaining ring 14 into the groove slightly compressing the bearing and wave washer 8 Packthe cavity of the inner seal 13 with Mobil High Temperature HP or equivalent grease 9 Using inner grease seal installation washer Toro Part Number 104 0532 press the inner seal 13 into the side plate until the washer is flush with the outer edge of the side plate bore Remov
351. the float closes the alarm circuit and acti vates the alarm Electrical System AUXILIARY TANK SOLENOID VALVE AUXILIARY TANK SIGHT GAUGE Y SOLENOID VALVE closed AUXILIARY TANK SIGHT GAUGE SOLENOID VALVE closed Page5 4 Figure 4 Figure 5 Figure 6 FLOAT SWITCH raised open FLOAT SWITCH raised open FLOAT SWITCH lowered closed Greensmaster 3150 Troubleshooting Remove all jewelry especially rings watches before doing any electrical trouble shooting or testing Disconnect the battery cables unless the test requires battery voltage Starting Problems Starter solenoid clicks but starter will not crank if solenoid clicks problem is not in safety interlock System Nothing happens when start attempt is made Greensmaster 3150 Page For effective troubleshooting and repairs you must have a good understanding of the electrical circuits and components used on this machine see Chapter 11 Wiring Schematics in this manual If the machine has any interlock switches by passed they must be reconnected for proper troubleshooting and safety Possible Causes Battery charge is low Battery cables are loose or corroded Battery ground to frame is loose or corroded Wiring at starter is faulty Starter solenoid is faulty Starter mounting bolts are loose or not supplying a sufficient ground for solenoid Starter is faulty and causing an incompl
352. three 3 cutting units so bedknifes are at the same angle If bedknifes are not at the same angle there will be a difference in the ap pearance of the cut grass mismatch for each cut ting unit 2 Place a 1 4 inch 6 mm or thicker plate under the reel blades and against the cutting edge of the bedknife j A Fig 11 NOTE Be sure the plate covers the full length of reel blades 3 With cutting unit reel blades positioned on the plate hold cutting unit securely and push down on the rear Figure 12 roller assembly until it contacts the working surface across the full length of the roller Fig 12 1 Unit on level surface 2 Hold unit securely 4 Tighten nut on rear roller bracket that was not tightened in step 1 to secure roller in place Set Up and Adjustments Page 7 10 Greensmaster 3150 pE M DUM UNUM RU Height Of Cut Height of cut as measured in the turf and on the cutting unit is different The grass prevents the cutting unit from settling all the way to the ground line as the machine moves across the turf Because of this the actual effective height of cut is higher than the bench set height of cut Machine conditions such as cutting unit weight roller type bedknife thickness speed of travel and clip in fluence effective height of cut Turf conditions such as grass type grass density and amount of thatch
353. ting on the cutting unit bench set height of cut Fig 17 Machine conditions such as cutting unit weight roller type bedknife thickness speed of travel and clip Top of Grass Ground Line frequency influence effective height of cut Turf condi tions such as grass type grass density and amount of thatch also influence effective height of cut Changing the machine such as adding a wiehle roller or changing to a heavier grooming reel cutting unit will increase penetration into the turf and lower the effective height of cut Difference bench set and effective F height of cut Figure 17 Set Up and Adjustments Page 9 16 Greensmaster 3150 Height of Cut Adjustment IMPORTANT Lower heights of cut are limited by thickness of bedknife Select proper bedknife for desired height of cut If bedknife is too thick for height of cut poor quality of cut will result and excessive pressure from turf on bottom of bedknife can cause rifling of bedknife and reel NOTE Because of weight difference bench set height of cut should be approximately 0 020 to 0 040 in higher on grooming reel cutting units to get the same effective height of cut as cutting units without groomers 1 Make sure that rear roller brackets are in correct hole positions for desired height of cut and that rear roller is level Also check that bedknife to reel contact is correct 2 Turn cutting unit over and loosen
354. ting too far forward on the seat seat switch not depressed Parking brake is set Parking brake switch is faulty Seat switch is faulty Seat switch wiring is loose corroded or damaged Wiring to the charging circuit see Wiring Schematics components is loose corroded or damaged Voltage regulator is loose or not grounded to engine Voltage regulator alternator is faulty Alternator fusible link is open Ignition switch is faulty Battery is faulty Operator moved too far forward on the seat seat switch not depressed Wiring to the run circuits see Wiring Schematics components became broken or disconnected 5 6 Rev D Greensmaster 3150 Cutting Unit Operating Problems Cutting units run but should not when raised Cutting units do not run when lowered with the Functional Control Lever in the MOW position Cutting units will not raise Cutting units will not lower Greensmaster 3150 Page Possible Causes Joystick relay K3 is faulty or shorted Solenoid valve S1 is faulty Mow relay K4 is faulty or shorted Mow switch is shorted Wiring to run mow backlap circuits components see Wiring Schematics is loose corroded or damaged Fuse block or fuse is faulty Solenoid valve S1 is faulty Mow switch and or mow relay 4 is faulty or grounded Raise or lower switch and or joystick relay K3 is faulty or grounded Wiring to raise circuit components see Wiring Schematics is loose corro
355. to lose springs 20 or 21 Remove springs C Loosen setscrew 23 and slide detent plate 22 off the applicable cartridge valve 7 or 13 stem D Remove the applicable locating plate with pin 25 or 26 from the cartridge valve stem and man ifold 27 2 Remove cartridge valve 7 or 13 and seal kit 8 or 11 3 Visually inspect the port in the manifold 27 for damage to the sealing surfaces damaged threads and contamination 4 Visually inspect cartridge valve 7 or 13 for dam aged sealing surfaces and contamination A Contamination may cause valves to stick or hang up it can become lodged in small valve ori fices or seal areas causing malfunction B If sealing surfaces appear pitted or damaged the hydraulic system may be overheating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air 5 If necessary clean cartridge valve 7 or 13 using clean mineral spirits Submerge valve in clean mineral spirits to flush out contamination Particles as fine as tal cum powder can affect the operation of high pressure hydraulic valves Use compressed air for cleaning Greensmaster 3150 Page 4 87 6 Reinstall the cartridge valve 7 or 13 A Lubricate new O ring and backup ring of seal kit 8 or 11 with clean hydraulic oil and install The O ring and backup ring of seal kit must be arranged properly on the cartridge valve 7 or 13 for proper ope
356. topping the reels from rotating Greensmaster 3150 Page 4 17 On machines with backlap capabilities flow through the manifold block when in mow is somewhat different Oil flow from manifold port P1 flows through the reel speed control valve FC1 Flow across the speed con trol valve is pressure compensated by the logic cartridge valve LC1 The logic cartridge valve maintains a pres sure differential of 75 PSI 5 2 bar across the speed control valve Any excess flow above what the speed control valve is set for is by passed to the reservoir through the logic cartridge valve With the backlap valve RD1 inthe mow position oil flows through the backlap valve out manifold port MA and to the reel motors that are connected in series Oil flows through the left M2 right M3 and then rear reel motor M1 as it turns the motors in the mow direc tion The oil then returns through the manifold block oil filter and then to the reservoir Backlap On machines with backlap capabilities backlapping op eration is the same as mowing operation except for the position of the backlap valve RD1 When the backlap valve RD1 is in the backlap position oil flows through the rear M1 right M3 and then left M2 reel motor as it turns the motors in the backlap direction Hydraulic System Rev E vV gt 1915080 108 1
357. ts not designed to carry it Figure 1 Skin Over Grease Special non conductive grease which forms a light pro tective skin which helps waterproof electrical switches and contacts em sro 112 1809 Toro Part Number 505 165 Figure 2 Battery Terminal Protector Aerosol spray that should be used on battery terminals to reduce corrosion problems Apply terminal protector after the battery cable has been secured to the battery terminal Toro Part Number 107 0392 FLEXIBL Greensmaster 3150 Page5 3 Rev D Electrical System Turf Guardian Leak Detector System Operation Before Start Up Cold Oil With ignition switch Off solenoid valve is open Before start up hydraulic fluid is at level mark of sight gauge oil cold Float is in raised position keeping alarm circuit open Normal Operation Warm Oil When ignition switch is turned On solenoid valve closes During normal operation hydraulic fluid ex pands causing itto overflow into auxiliary tank The float stays in the raised position keeping alarm circuit open Leak Alert If hydraulic fluid leaks during operation the fluid level in the main hydraulic tank drops This causes the float to lower closing the alarm circuit The alarm will sound af ter a one second time delay Note During normal operation with cutting units low ered approximately 5 oz 148 ml of hydraulic fluid will leak before
358. tting Monthly Adjustments NOTE Remove cutting unit from traction unit Set Up and Adjustments Page 8 8 1 Parallel bedknife to reel Use newspaper as a feeler gauge Dot on eccentric bolt must face rear of mower Turn S P A adjustment knob to hold paper on right hand end of bedknife Turn eccentric left bedbar bolt to hold paper on left hand end of bedknife Hold eccentric bedbar bolt while securing locknut 2 Adjust rear roller parallel to reel eccentric bolt faces to rear 3 Adjust the front roller scraper to be 1 32 in from roller 4 Set comb or brush adjustment for desired action on grass Light medium or aggressive setting 5 Check grass shield adjustment 4 3 4 in from crossbar normal Dry grass lower shield Wet grass raise shield 6 Set top bar cut off bar adjustment 0 060 in from reel normal 7 Set cutting unit on ground setting on both rollers and remove reel motor Adjust bedknife to reel contact 8 Use a gauge bar to set the height of cut Special Notes 1 Replace the bedbar bushings and nylon flange bush ings every two years 2 A rifled reel and or bedknife must be corrected by grinding 3 After extended running notches will eventually develop at both ends of the bedknife These notches must be rounded off or filed flush with cutting edge of bedknife to assure smooth operation 4 If reel bearings will not hold ad
359. ttings and O rings from the gear pump 7 Support gear pump Separate gear pump from the hydrostat by removing both hex socket head screws and flat washers Remove O ring from between the gear pump and hydrostat Greensmaster 3150 Page 4 51 Installation Fig 28 1 Make sure mounting and O ring sealing surfaces on the gear pump and hydrostat are clean 2 Replace all O rings with new ones Apply clean hy draulic oil to all O rings 3 Place O ring on the gear pump 4 Applyantiseize lubricantto gear pump shaft splines 5 Position gear pump to the hydrostat so that the pump inlet is facing up 6 Secure gear pump to the hydrostat with both hex socket head screws and flat washers Torque screws from 27 to 31 ft Ib 37 to 42 Nm 7 nspectthreads and sealing surfaces of hydraulic fit tings and hydraulic hose connectors Replace any dam aged or worn fittings or connectors 8 Install O rings into gear pump Install fittings and tighten to positions noted during removal 9 Secure pump inlet hose and hose clamp to the gear pump Tighten hose clamp 10 Remove clamp from pump inlet hose to allow hy draulic oil flow to the gear pump Hydraulic System Rev E 2g 3 SE 52 gt Gear Pump Service Figure 29 1 Frontplate 8 Back up gasket 15 Notused 2 Back plate 9 Wear plate 16 Back gear 3 Frontbody 10 Pressure seal 17 Washer 4 Backbody 11 screw 18 Plug 5 Drive gear 12 O ring 19
360. uction Decals Chapter 2 Product Records and Maintenance Product Records 2 1 Equivalents and Conversions 2 2 Torque Specifications 2 9 Maintenance 2 6 Chapter 3 Engine MOGUCOM EGET 3 2 Specifications 3 3 Service and Repairs 3 4 Briggs and Stratton Repair Manual for 4 Cycle V Twin OHV Head Engines Chapter 4 Hydraulic System Specifications 4 2 General Information 4 9 Hydraulic Schematics 4 7 Hydraulic Flow Diagrams 4 10 Special Tools 4 22 Troubleshooting 4 24 TOSUNG opere 4 28 4 48 Service and Repairs 4 49 Eaton Gear Pumps Repair Information Series 26 Model 26000 Multiple Gear Pumps Eaton Medium Duty Piston Pump Repair Information Model 70160 Variable Displacement Piston Pump Ross Torqmotor MG MF MP and MJ Series Service Procedure Service Manual 2704 003 Sauer Danfoss Steering Unit Type OSPM Service Manual Chapter 5 Electrical System Electrical Schematics 5 2 Special Tools re freee tres 5 3 Turf Guardian Leak Detector Syste
361. ulic tank 2 Float switch Figure 24 noid valve 12 volts should be present 1 Main hydraulic tank 3 Valve spool 2 Valve body 4 Solenoid Electrical System Page 5 16 Greensmaster 3150 Diodes The main wiring harness contains six diodes Diodes D2 and D3 are connected to the harness at separate loca tions Diodes D1 A D1 B D1 C and D1 D are con nected to the main harness by a small four position circuit board located near the front of the left side control panel The diodes are used for circuit protection from in ductive voltage spikes and for safety circuit logic Diode D1 A Allows the engine to start only with the Functional Con trol Lever in NEUTRAL neutral sensor closed Also it allows the engine to continue to run with either the Func tional Control Lever in NEUTRAL Neutral Sensor closed or the operator sitting in the seat Seat switch closed Diode D1 B Prevents a negative spike from damaging the Neutral Sensor and Seat switch by allowing a ground path for the Start Safety relay K2 when it de energizes Diode D1 C Maintains current flow to the Joystick relay after the mo mentary Lower switch of the Joystick opens Diode D1 D Prevents a negative spike from damaging the Mow and Backlap switches by allowing a ground path for the mow relay when it de energizes Diode D2 This diode prevents current flow to solenoid S4 when so lenoids 52 and S3 are energized through Raise relay R5 Diode D
362. ulley from groomer drive side of mower see Groomer Reel Removal in this section 2 Using Figures 16 and 17 as guides remove idler bracket idler pulley and or idler bearings as needed Installation 1 Reassemble components using Figures 16 and 17 as guides Note When properly installed the idler pulley should move freely from side to side on the idler bracket pin Groomer DPA Cutting Unit Rev A Page 10 1 14 2 Install drive pulley drive belt and belt cover to right side of mower see Groomer Reel Installation in this sec tion 3 Check and adjust groomer reel height and mower height of cut settings 2 p Figure 17 1 Groomer side plate 3 Idler bracket 2 Drive pulley 4 Idler pulley w bearings Greensmaster 3150 Lift Arm Assembly Antisieze zT Lubricant Antisieze 4 amp Lubricant Antisieze Lubricant Figure 18 1 HOC groomer arm LH shown 7 Bushing 13 Wave washer 2 Flange nut 8 Liftarm assembly LH shown 14 Groomer adjuster 3 Grooved pin 9 Detentspring 15 Side plate LH shown 4 E ring 10 Spring washer 16 Lock nut 5 Groomer lift rod 11 Cap screw 17 Spring washer 6 Lockscrew 12 Bushing 18 Bushing Disassembly Assembly 1 Remove flange nut item 2 that secures lift arm to HOC groomer arm Remove lock nut item 16 and spring washer item 17 that secure lift arm to side plate Loosen lock screw item 6 completely 2 Remove lift
363. units are to be raised solenoid valve S2 is energized and blocks flow directly to the hydros tat Flow is directed to energized solenoid valve S3 which directs flow to de energized solenoid valve S4 andthe lift cylinders Hydraulic pressure against the cyl inder pistons moves their shafts causing the cutting units to raise At the same time the pistons push the hy draulic fluid out of the lift cylinders and back through so lenoid valves S3 to the hydrostat When the solenoid valves de energize spring action returns the valves to their original position and by passes flow back to the hydrostat stopping lift cylinder movement The lift cylinder position is locked in place since there is no complete circuit of flow to and from the lift cylinders Note On traction units with serial number from 230000801 to 260999999 solenoid valve S6 is ener gized when the cutting units are raised This forces the return flow from the reel motors through the 125 orifice putting back pressure on the reel circuit and preventing the reels from rotating when raised Greensmaster 3150 Page 4 13 Lower Cutting Units Circuit operation for lowering the lift cylinders is similar to raising them However the solenoid valve S3 re mains de energized and solenoid valve S4 is ener gized Flow is reversed to and from the lift cylinders lowering the cutting units When the cutting units are to be lowered solenoid valve S2 is energ
364. ure against leakage it is rec ommended that the face seal O ring be replaced any time the connection is opened Make sure the O ring is installed and properly seated in the fitting groove Lightly lubricate the O ring with clean hydraulic oil 3 Place the hose tube against the fitting body so that the flat face of the hose tube sleeve fully contacts the ring in the fitting 4 Thread the swivel nut onto the fitting by hand While holding the hose tube with a wrench use a torque wrench to tighten the swivel nut to the recommended installation torque shown in Figure 8 This tightening process will require the use of an offset wrench e g crowfoot wrench Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using atorque wrench with an offset wrench will be lower than the listed installation torque see Using a Torque Wrench with an Offset Wrench in the Torque Specifica tions section of Chapter 2 Product Records and Main tenance 5 Ifa torque wrench is not available or if space at the swivel nut prevents use of a torque wrench an alternate method of assembly is the Flats From Wrench Resist ance F F W R method Fig 2 A Using a wrench tighten the swivel nut onto the fit ting until light wrench resistance is reached approxi mately 30 B Mark the swivel nut and fitting body Hold the hose tube with a wrench to preven
365. ure correct each cell reading For each 109F 5 59C above 809F 26 79C add 0 004 to the specific gravity reading For each 109F 5 59C be low 80 F 26 7 C subtract 0 004 from the specific gravity reading Example Cell Temperature 100 F Cell Gravity 1 245 ADD 20 above 80 F 0 008 Correction to 80 F 1 253 C Ifthe difference between the highest and lowest cell specific gravity is 0 050 or greater or the lowest cell specific gravity is less than 1 225 charge the battery Charge at the recommended rate and time given in Charging or until all cells specific gravity is 1 225 or greater with the difference in specific grav ity between the highest and lowest cell less than 0 050 If these charging conditions can not be met replace the battery 3 Perform a high discharge test with an adjustable load tester This is one of the most reliable means of testing a battery as it simulates the cold cranking test A commercial bat tery load tester is required to perform this test A CAUTION Follow the manufacturer s instructions when us ing a battery tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 0 VDC recharge the battery B Ifthe battery has been charged apply a 150 amp load for 15 seconds to remove the surface charge Use a battery load tester following the manufactur er s instructions C Make sure the battery terminals are free of corr
366. ust upward until a solid clicking sound is achieved when adjusting knob is turned 16 Level bedknife to reel Level rear roller to reel Set height of cut If necessary backlap to get desired fit Equa gap between reel and bedknife Figure 29 Greensmaster 3150 Page 8 21 Repairs a Bedbar Bushing Replacement NOTE Only after making sure that all normal cutting unit adjustments correct should the bushings be suspected as causing quality of cut problems The bedbar end bushings and pivot bushings Fig 30 contain rubber and are exposed to severe conditions It is recommended to replace these bushings and the plastic flange bushings every two years 1 Do steps 1 4 under Bedbar Removal and Installation in this section of the book 2 Remove bedbar end bushings with a punch and hammer Fig 31 Alternate from one side to other on bushing there two slots bedbar bushing boss Figure 31 IMPORTANT Apply NEVER SEEZ or equivalent to outside surface of bedbar end bushings and pivot bushings before installing in bedbar 3 Press end bushings into bedbar far enough so plastic sleeve collar is below bedbar end face Fig 32 NOTE Bedbar bushings have less rubber and more steel which is visible than bedbar pivot bushings Do not use bedbar end bushings in the pivot area as they are too rigid 4 Use an arbor press to remove bedbar pivot bushings Fig 33 D
367. ut 2 used 14 Non drive side plate RH shown 26 Lock nut 4 used 2 Cap screw 15 Reel motor mount 27 Plow bolt 2 used 3 Groomer belt cover 16 Allen head screw 2 used 28 Cap screw 2 used 4 Flange head screw 17 Flange nut 2 used 29 Front roller assembly 5 Washer 18 Grease fitting 30 Groomer reel assembly 6 Decal 19 Non drive groomer arm assembly 31 Square key 7 Drive pulley 20 Cap screw 32 Driven pulley 8 Shoulder nut 2 used 21 Cap plug 33 Drive groomer arm assembly 9 Spring 22 Bearing 34 Tab washer 10 Drive side plate LH shown 23 Bushing 2 used 35 Lock nut 11 Groomer shim 24 Spring washer 2 used 36 Groomer drive belt 12 Height of cut screw 2 used 25 Lock nut 2 used 37 Cap 13 Cutting reel assembly Remove the groomer reel to reverse the shaft replace individual blades or replace the shaft The shaft can be reversed so that the sharpest edge of the groomer blades are forward Note The groomer reel drive is located on the oppo site side of the cutting unit from the cutting reel hydraulic motor Figure 6 shows the groomer reel drive on the left side of the cutting unit Removal 1 Park machine on a clean and level surface lower cutting units completely to the ground stop engine en gage parking brake and remove key from the ignition switch Groomer DPA Cutting Unit Rev A Page 10 1 8 2 Remove hydraulic reel motor from cutting unit see Hydraulic Reel Motor Removal in
368. ut and washer from clutch adapter shaft 1 Height of cut locknut 4 Grooming reel cover Pull clutch assembly off adapter shaft Fig 9 Remove 2 Roller shaft clamp bolt 5 Cover screws amp washers clutch adapter from reel shaft Fig 10 3 Height of cut knob A CAUTION Do not use your hand to prevent reel from turning while servicing this can result in per sonal 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 NOTE If reel bearings will not hold adjustment during operation loosen adjustment nut tighten reel shaft spline nut on right hand end of reel shaft to a torque of 40 to 60 ft lb then adjust reel bearings Figure 9 5 Loosen large reel bearing adjustment nut Fig 10 Tighten nut until all reel shaft end play is removed then 1 Drive belt 4 Groomer driven pulley tighten an additional 1 16 to 1 8 turn Be certain to 2 Drive belt idler pulley 5 Clutch assembly 3 Grooming reel adjustment 6 Groomer ree housing knob assembly remove all end play but do not over tighten Rolling torque should not exceed 7 in Ib NOTE Adjustment nut must have enough resistance against reel shaft threads to retain bearing adjustment Replace adjustment nut if necessary 6 If bearings require replacement see Reel Removal and Bearing Replacement in the Repairs section of this chapter 7 Install clutch adapter on reel shaft F
369. variations in the mounting surface of Bo vois Ub oo uma 10 12 the bedbar a new bedknife will not be perfectly flat after itis installed Because of this itis necessary to backlap or grind a new bedknife after installing it to the bedbar Follow the existing angle that was ground into the bed Figure 16 knife and grind only enough to make surethe top surface Earum is true Fig 17 Relief Angle B 1 Remove bedbar from the cutting unit see Bedbar Front Removal Face Note When grinding be careful to not overheat the Front Angle bedknife Remove small amounts of material with each pass of the grinder 2 Use Toro General Service Training Book Reel Figure 17 Mower Basics part 0916851 for bedknife grinding information Bedknife Grinding Specifications Bedknife relief angle 3 see Fig 17 Front Angle 13 Front Angle Range 13 to 17 3 Reinstall bedbar to cutting unit see Bedbar Installa tion Greensmaster 3150 Page 10 13 Rev E Dual Point Adjust Cutting Units Reel Assembly General Purpose Grease Reel Speedi sleeve V ring Drive coupler Retaining ring Left side plate assembly Shoulder bolt Bearing lock nut Outer grease seal Dual Point Adjust Cutting Units General Purpose Grease Figure 18 Right side plate assembly O ring Bearing Inner grease seal Retaining ring Wave washer Seal strip Fr
370. w O ring onto backlap switch Thread backlap switch into port and torque 15 ft Ib 20 N m Greensmaster 3150 Page 4 85 Hydraulic System Rev E Backlap Kit Optional Kit For Serial Number Under 260999999 Figure 58 1 Backlap bracket 11 Seal kit 20 Spring 2 ball switch 12 Detent kit 21 Spring 3 Socket head screw 13 Flow control cartridge Port FC1 22 Detent plate 4 Flat washer 14 J umper wire 23 Set screw 5 Detent kit 15 Harness 24 Ball 6 Indicator kit 16 Relay 25 Locating plate 7 Directional cartridge valve Port RD1 17 Knob 26 Locating plate 8 Seal kit 18 Jam nut 27 Orifice 020 9 Sealkit 19 Indicator plate 28 Manifold 10 Logic cartridge Port LC1 Note The ports onthe manifold are marked for easy identification of components Example LC1 is for the reel logic cartridge and RD1 is forthe directional cartridge valve see Hydraulic Schematics to identify the function ofthe hydrau lic lines and cartridge valves at each port location Hydraulic System Rev E Page 4 86 Greensmaster 3150 Optional Backlap KitFlow Control and Two Position Directional Valves Fig 58 Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components 1 Remove knob assembly A Unscrew and remove knob 17 Remove both jam nuts 18 B Slide off applicable indicator plate 6 or 19 being careful not
371. wheel motor 14 Release traction pedal rotate wheel being tested and retest Testing of wheel motor leakage in three dif ferent wheel positions will provide most accurate test re sults 15 Release traction pedal and shut engine off Record results of flow test 16 If specification is not met the tested wheel motor needs to be repaired or replaced as necessary 17 Test second front wheel motor Reconnect hydraulic lines to untested front wheel motor Disconnect and cap hydraulic lines to tested front wheel motor Complete steps 11 to 16 for the second front wheel motor 18 If machine has 3 wheel drive test rear wheel motor A Both front wheel motors should have hydraulic lines connected Block up both front wheels off the ground Release parking brake so front wheels can turn freely B Attach a heavy chain to the rear of the machine frame and an immovable object to prevent the ma chine from moving during testing C Position rear wheel on the ground and chock rear wheel to prevent it from turning A CAUTION Use extreme caution when performing test The rear wheel will be trying to move the machine D Complete steps 11 to 16 19 Disconnecttester from hydraulic tube and hose Re connect hose to tube Hydraulic System Rev E 22 Charge Relief Valve R4 Pressure Test Using Tester with Flowmeter and Pressure Gauge TRACTION WHEEL MOTORS
372. ws both sides Height of cut rod locknuts Roller shaft clamp bolts Height of cut adjustment knob For proper grinding of reel follow procedures the Toro publication Sharpening Reel and Rotary Mowers Form No 80 300 PT 3 Install bedbar After grinding assemble cutting unit and do all adjustments Backlap if necessary to get de sired fit between reel and bedknife Repairs Page 7 18 Greensmaster 3150 Reel Removal and Bearing Replacement 1 Remove the front and rear roller assembly Remove E bedbar TO 1 2 Remove counterbalance end cap from left hand side j of cutting unit Fig 27 Remove large bearing adjust ment nut from left hand end of reel shaft Fig 27 and special spline nut from opposite end of reel shaft 3 Remove machine screws securing bearing housing on each end of cutting unit Fig 28 Machine screw heads will have to be cut off before screw can be completely removed A Unscrew machine screw approximately two turns Figure 27 B Cut head off of machine screw 1 Reel bearing adjustment nut C Use a screw driver to back out remaining part of screw from side plate outwards not inwards towards reel If machine screw does not have a screw driver slot use a pliers to back out screw IMPORTANT Remove grease fittings from bearing housing at each end of cutting unit Note that the straight fitting is on the
373. y between the adjusting gauge bar and the cutting edge of the bedknife gives a medium setting C Adjusting the comb assembly so it is even with the Figure 15 cutting edge of the bedknife gives a light setting 1 Roller shaft clamp bolt 2 Comb teeth NOTE Securing one end of the comb assembly at atime simplifies the above procedure 3 Tighten the roller shaft bolts Set Up and Adjustments Page 7 12 Greensmaster 3150 Shield Height Adjustment Adjust shield to get proper grass clipping discharge into basket 1 Set cutting unit in normal cutting position and measure distance from top of front crossbar to shield at each end of cutting unit Fig 16 2 Height of shield from crossbar for normal cutting conditions should be 4 34 inches Loosen cap screws and nuts securing shield to each side plate adjust shield to correct height and tighten fasteners Fig 16 3 Repeat adjustment on remaining cutting units and adjust top bar See Top Bar Adjustment in this section of the book NOTE Shield can be lowered in dry grass conditions clippings fly over top of baskets or raised to allow for heavy wet grass conditions clippings build up on rear edge of basket Figure 16 1 Shield 3 4 3 4 Inches 12 1 cm 2 Front crossbar 4 Shield fasteners Top Cut Off Bar Adjustment Adjust top bar to make sure clippings are cleanly dis charged from reel area 1 Loosen screws securing top bar Fig 17
374. y adjusting the Factor 1 Tire pressure 2 Engine governed speed 3 Reel bearing condition adjustment 4 Reel and bedknife sharpness 5 Bedknife parallel to reel 6 Bedknife to reel contact 7 Bedknife attitude rear roller bracket hole position 8 Rear roller parallel to reel 9 Height of cut 10 Proper bedknife for height of cut Troubleshooting machine It is important to remember that the lower the height of cut the more critical these factors are See the Adjustments and Repairs sections for detailed adjust ment and repair information Possible Problem Correction Check tire pressure adjust to specification if necessary Must be equal in both front tires Check maximum governed engine speed Adjust if necessary affects reel speed traction speed and clip frequency Check and adjust to specification Replace bearings if worn or damaged Bearing cones must be installed square to bearing housing make sure there is no flash paint or other foreign material in housing before installing new bearing cone Reel and or bedknife that has rounded edge cannot be corrected by tightening bedknife to reel contact Grind reel to remove taper cone shape and or rifling grooved or ribbed appearance Grind bedknife to sharpen and or remove rifling Most common cause of rifling is bedknife to reel contact that is too tight NOTE New bedknife must be ground after installing on bedbar to match
375. y restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system Wheel Hub Puller TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors Greensmaster 3150 TORO TEST FITTING KIT NO TOR4079 TOOL NUMBER Union 1 ea Tere No Swivel Nut Run Tee 2 Toro Mo 10 12 8 WS Pipe Tha TOR437923 Figure 17 Figure 18 Page 4 23 Hydraulic System Rev E 2 E i gt Troubleshooting The charts that follow contain information to assist in Refer to the Testing section of this Chapter for precau troubleshooting There may possibly be more than one tions and specific test procedures cause for a machine malfunction Hydraulic oil leaks from system Hydraulic fluid foams Oil level in reservoir is low Hydraulic system has wrong type of oil The pump suction line has an air leak Hydraulic system operates hot Oil level in reservoir is low or inlet filter is loose or clogged Oil is contaminated or too light Parking brake is applied or incorrectly adjusted Hydrostat by pass valve is open or defective Working load of machine may require use of oil cooler Oil cooler if installed is damaged or plugged By pass relief is stuck open or air flow is obstructed Charge pressure is low Wheel
376. y terminal posts for corrosion Use a terminal brush or steel wool to clean corrosion from the battery terminal posts IMPORTANT Before cleaning the battery tape or block the vent holes to the filler caps and make sure the caps are on tightly Greensmaster 3150 Page5 19 Rev A Figure 28 1 Wing nut 2 Battery retainer COVER SEAL Figure 29 C Check for signs of wetness or leakage on the top of the battery which might indicate a loose or mis sing filler cap overcharging loose terminal post or overfilling Also check the battery case for dirt and oil Clean the battery with a solution of baking soda and water then rinse it with clean water D Check that the cover seal is not broken away Replace the battery if the seal is broken or leaking E Check the electrolyte level in each cell If the lev el is below the tops of the plates in any cell fill all cells with distilled water to the bottom of the cap tubes Charge at 15 to 25 amps for 15 minutes to al low sufficient mixing of the electrolyte 2 Conducta hydrometer test of the battery electrolyte IMPORTANT Make sure the area around the cells is clean before opening the battery caps A Measure the specific gravity of each cell with a hydrometer Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm up the hydrometer At the same time take the tem perature of the cell Electrical System B Temperat
377. ylinder fitting to 3 Straight hydraulic fitting 8 Hydraulic tee fitting prevent contamination 4 O ring 9 Hydraulic hose 5 O ring Installation 1 Lubricate all new O rings with clean hydraulic oil 2 Install O ring and hydraulic fitting to the flow control valve 3 Install flow control valve and O ring to the hydraulic fitting on the hydraulic cylinder Make sure adjustment knob faces forward 4 Install O ring and hose assembly to the hydraulic fitting 5 Adjust flow control valve as follows A Turn adjustment knob in fully clockwise and Figure 60 then turn out counterclockwise 3 turns 1 Flow control valve 2 Hydraulic cylinder B Adjust knob more than 1 2 turn in either direc tion until the number 8 is aligned with the dimple on the valve body Lock adjustment knob by tightening set screw Figure 61 Greensmaster 3150 Page 4 89 Hydraulic System Rev E Hydraulic Steering Control Valve Steering arm Cap screw 2 used Cap screw Set screw Lever Handle Friction plate Steering wheel Hexnut 10 Screw 11 Cover 12 Cap screw 4 used og OU Hydraulic System Rev E 13 14 15 16 17 18 19 20 21 22 23 Figure 62 Steering mount Cap screw 6 used Steering column below 270999999 Lock nut 2 used Lock washer 2 used Flat washer 2 used Straight hydraulic fitting O ring O ring Hose assembly 5 Straight hydraulic fitting Page 4 90
378. zed S1R1 by passes flow from the gear pump P1 to the oil filter and hydraulic reservoir Addi tionally manifold pressure reducing valve PRV will re main seated to prevent the reel motors and reels from rotating Mow With the engine running and the Functional Control and Raise Lower Mow levers positioned so the reels will turn see Operators Manual solenoid relief valve S1R1 is energized In the energized position this valve directs oil flow to the reel motors and also func tions as the mow circuit relief valve Greensmaster 3150 Page 4 19 flow from manifold port P1 flows through the reel speed control valve FC1 Flow across the speed con trol valveis pressure compensated by the logic cartridge valve EP The logic cartridge valve maintains a pres sure differential of 75 PSI 5 2 bar across the speed control valve Any excess flow above the speed control valve setting is by passed to the reservoir through the logic cartridge valve With the backlap valve MR in the mow position oil flows through the backlap valve out manifold port MA and to the reel motors that are con nected in series Oil flows through the left M2 right andthen rear reel motor M1 as it turns the motors in the mow direction When in the mow position manifold pressure reducing valve PRV will shift allowing oil to return to the reservoir through the manifold block and oil filter Backlap Backlapping operation i

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