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1. P13 PARKING BRAKE J12 OPTIONAL A R EB OPTIONAL LIGHT 1 AN LIGHT 1 P29 SEAT SWITCH 1 2 P31 JOYSTICK LOWER SWITCH S P28 3 2 1 JOYSTICK RAISE SWITCH P26 INTERCONNECT 1 cR DCBA C a P27 J10 INTERCONNECT 2 IGNITION SWITCH I m P30 hii Oa uo I I I TIGNITION SWITCH LLI P31 OPTIONAL BACKLAP P14 Pah a MOW SWITCH LOWER z J11 P26 P3 RELAY K5 P7 OPTIONAL INTERCONNECT 1 P2 RAISE RELAY K6 BACKLAP START B A B EE 4 498 gt Be INTERCONNECT 3 ee go P24 m 2 B A P18 P15 lt ALARM 4 2 G3 RAISE ENGAGE TIME DELAY 3 D C SOLENOID S3 SOLENOID S1 A all B fl E A sti Q5 Gama L A ay wa i H S ba J4 J 5 P da B m LOAD1 J5 75 Na J18 DIODE 2 2 6l5 d 8 OPTIONAL LIGHT 2 E P27 TIME D
2. RELIEF VALVE R2 TO AND FROM REEL MOTORS MA JMB S6 OPTIONAL E BACKLAP a H ORIFICE i RD1 VALVES Ine hoy ea 1020 LIFT CYLINDERS Mee RU LOWER LC1 RAISE 125 xut T j IN ges 1 R1 IN e Si OIL o a FILTER REELS l i A sc AAN METIA qe FERAE NURSE T CONTROL 25 P1 P2 VALVE PSI Tom Na ya pn n Rec e cue a TRACTION CHARGE A CIRCUIT OILCOOLER ER OPTIONAL KIT n ENGINE RPM FROM HYDROSTAT High Pressure Low Pressure Return or Suction Flow Serial Number 230000801 amp Up Shown Hydraulic System Page 4 30 Greensmaster 3150 Procedure for Lower Cutting Units Relief Valve R2 Pressure Check 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 TEST NO 3 Charge Relief Valve R 4 Pres sure in this chapter 4 Use
3. Page 11 6 LEAK DETECTOR SOLENOID bh Jp Greensmaster 3150 E Raise Reels N Serial Number 230000801 amp Up Shown Power Current n naoga Control Current arf w o GY gina y CK NR Current Direction CLOSED DURING Y GY DELAY ON A HYDRAULIC FLUID LEAK STARTER ae l HOURMETER 9 2 A BU E 2d LIGHTS 1 i F120A F210A Y OPTIONAL HE E Lots NA R I E lw gt LIGHTS 2 Bie LIGHT TEST SWITCH OPTIONAL FUSIBLE LINK SEA o aa A AA AAP AAAH 1 gt VIO R BU 99 7430 Y aaa o8 ju BACKLAP RELAY K7 BK A PK BU PK BU B 87 eG E wn cs Bis p 85 UU 86 Ut Muda w 1 A UAE Wu gt I oaei a PaA dE STARTER A SWITCH l START SAFETY im BACKLAP oa 9 85 UU 86 LEES SOLENOID pk IGNITION SWITCH Y B G SWITCH 09 7430
4. Serial Number 230000801 amp Up Shown Figure 11 1 Hydraulic manifold 2 Relief valve R1 10 Disengage cutting units Open control valve on test er and shut off engine 11 Disconnect tester from manifold and hose Recon nect hose to the bulkhead connection 12 Correctly readjust bedknife o Tam O gt Greensmaster 3150 Page 4 35 Hydraulic System TEST NO 8 Reel Motor Case Drain Flow Using Tester with Flowmeter and Pressure Gauges x 3 4 Se a A NAN 7 3 7 i erp E i Lin gt T p 1 o gt A de j Ku i A dn ET 1 kg IN Ng ma S i Wa SW Y LEFT MOTOR CASE DRAIN RIGHT MOTOR 4 CASE DRAIN REAR MOTOR RETURN gt TI v RIGHT MOTOR IN MEASURING CONTAINER 4 gt REAR MOTOR i an V LEFT MOTOR AN High Pressure FROM MANIFOLD Low Pressure V PORT MA 3 TO MANIFOLD Return or Suction TO HYDRAULIC RESERVOIR PORT MB a gt Flow Page 4 36 Greensmaster 3150 Hydraulic System Procedure for Reel Motor Case Drain Flow Check 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 pa
5. frm a O Q S5 P Electrical Schematic JAN ALARM Serial Number Under 230000801 W All relays and solenoids are shown as de energized BU di GY 83 2280 LEAK DETECTOR 1 SECOND CLOSED DURING GY DELAY ON HYDRAULIC FLUID LEAK STARTER MO i 1 HOURMETER 2 yo s E BU e 3 LIGHTS 1 F120A F210A A OPTIONAL c 5 hko ANA 6 R T os 6 SP 0 W gt LIGHTS 2 BK LIGHT TEST SWITCH i y OPTIONAL FUSIBLE LINK 4 VIO E BU 99 7430 Suter gy Qu BACKLAP RELAY K7 BK PK BU PK BU C sg Saee 0 VIO gt BK 3 85 UL 86 YlO 0 z Na C W 1 A ma W BU SPSS C paLa 99 7430 WT x NEUTRAL a mag S AME SINAI STARTER SWITCH START SAFETY K2 SES o x a BK SOLENOID Pk IGNITION SWITCH y Ae PUES See HER V D1 A d o 99 7430 o GNR SYN 4 OFF RUN START OPTIONAL 87 BU BK a si A D1 B ba y F3 10A 87a REEL B A O de wee ORBK ql H ues ENGAGE OR gt p o 0 W o ja Y MOW RELAY K4 1 8 SEAT PARKING BK 4 p31 B BK 0 Le F4 10A SWITCH BRAKE GN BK be A CN ON POSITION S a MG 99 7430 A e 2 W E 30 p D1 D O i JOYSTICK ORIBK oo s BU BK Wd i LOWER 2 F MOW SWITCH D E E 85 Y J 88 9830 9 GY BK S TY T1 86 j PIRE CREME F E 1 a ame GN BK RELAY K3 Dic Y FRAME ENGINE B A RUN B I A and X Y GROUND GROUND 3 C 5 7 START B I S 1 p o BU 2 ex aS RAISE GY BK GN BK 92 2538 GN GY Y OR BK 2 B
6. 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 Check pull frame alignment on all cutting units Adjust or repair as necessary 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 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 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 Center cutting unit mus
7. JJ J w eg 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 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 are two slots in bedbar bushing boss 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 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 33 DO NOT hammer on pivot boss of bedbar 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 Bed
8. 15 Reel Lapping 0000 eee eee eee 16 Bedbar Removal and Installation 17 Bedknife Replacement 18 Preparing Reel For Grinding 18 Reel Removal and Bearing Replacement 19 Lift Bail Replacement 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 i 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 Hear 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 in Ib 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 PON Specifications 6 Scraper adjusting nut 4 Pull rod studs 2 Page 7 2 Height of cut adjustment locknut 8 Grass shield 9 Adjustable grass shield bar 10 Reel Greensmaster 3150 Specia
9. VIO BK 1 S2 Y Y RAISE LOWER p3 BURN 99 7430 ME S6 A aa ORIFICE x o7 BUR 4 GN GY Sme REELS RAISE i RAISE RELAY K6 BIS Ls M e BK mamas mamana sa a Ss qa al Page 11 9 LEAK DETECTOR SOLENOID ee ee Greensmaster 3150 80 9330 Ga ALARM Backlap N Serial Number 230000801 amp Up Shown Power Current Control Current gt arf Na a paya gt Current Direction LEAK DETECTOR 1 SECOND CLOSED DURING yo DELAY ON A HYDRAULIC FLUID LEAK STARTER mae HOURMETER gt 3 bibe R xis ER LIGHTS 1 F120A F210A Y BE OPTIONAL 5 yo E N ANA R il O ly LIGHTS 2 Bie LIGHT TEST SWITCH OPTIONAL FUSIBLE LINK A PA HA Ce ye e 1 gt VIO A BU 99 7430 Y
10. a D1 A KI OPTIONAL vy CNR 8 OFF RUN START BU BK a ert S1 2 8 2 0 i Pm EE ie ae Sa e Y tt gs W o she y MOW RELAY K4 as SEAT BK pat A SWITCH BBAKD SEN Aa E ON POSITION EXT enm d l 2 E 30 NI D1 D Y Y JOYSTICK oe OR BK o BU BK K 3 r 88 9830 V m apy 2 i 85 YYY 86 MOW SWITCH D E Ub d a S A E F E E qs Joystick lt FRAME ENGINE et M LIS Y GN BK RELAY K3 Y ui c SOUND GROUND Bj LA START B l S i L a m y Lo 1 a a cm am OS am 2m oy o B U am sig 2p L BK YE bius GY BK i GN BK y 92 2538 ae GN GY Y OR BK 42 guum a Xa NG da a uim C M 6 SECOND Pa ENGINE KY vi a SER DELAY OFF Y MAGNET lt o ALTERNATOR Bee Be Y and B 3 9 as A AE Sp TANAN pp E E LE EE qoe 85 UU 86 BK mE FUEL SOLENOID L Y aR SS Sn W BK mu y E A MENU Ner 87a D2 REELS LOWER LOWER RELAY K ERE eo 1 A P 2 B ba VIO BK gt Ma so V V RAISE LOWER Y d Ju R Yi Gur ae Sa SN ORIFICE L 0 0872 paa MA Y ca EL oun LL MM LL AT ee CNC ETT REELS RAISE RAISE RELAY K6 E
11. 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 Figure 21 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 22 A Figure 22 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 23 5 Reverse steps 1 4 to install the cutting unit Figure 23 1 Lift bail 3 Pull frame 2 Lift arm 4 Pull arm Greensmaster 3150 Page 8 19 Repairs A ae ae SAP A a A ea R 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 4 N 9 16 in socket can be installed onto the capscrew on CAUTION the reel shaft inside the counter balance weight on the Be careful when lapping the reel because con end of the cutting unit Backlap according to procedures tact with the reel or other moving parts can in the Toro publication Sharpening Reel amp Rotary result in personal injury Mowers Form No 80 300 PT 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 ro
12. 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 Page 4 74 A CAUTION Use eye protection such as goggles when using compressed air 4 Clean logic cartridge valve 10 using 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 LC 1 The valve should go in easily without binding Torque the valve to 35 ft lb 47 Nm Greens
13. Greensmaster 3150 wa sAs 21 ne3pAH 2 E 2 Ne ucc SERIE MUSS imd QN3 E r ta LIM TVNOLLdO 37101 H9IH 0882 gt UU PT ELI a dang AD Y A 7A ridi MOT 0091 Qo gt H31002 1SISOHGAH 2 1i gt TIO Be ee a A 5 KE LA E Wold n ssa 1 3NION3 5 EI ed Ed gt ps pees d I di 1 O le We 4 PT E E ISd JAIVA AA E 092 002 3318 INIVA 9NIH331S H3MOd Baa Zd 1S Ld i Y HY PIS ANWA E bs J JOHINOO S1334 bu MOTH o Co e Q e Q ISS X 9 va uan pm t ze go SEF A E AS Y O E g V INIYA dOL INOLLOS JAAG PST eo LH SO ud 9 V A n oS ee l lt t ASIVY VET d gt p es 3014140 A o H3M
14. 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 19 13 Connect the extension spring 1 and damper 2 to the spring bracket and the neutral arm Fig 18 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 Piston Pump Service Key Drive shaft Bearing Cap screw Cover plate O ring Shim kit for crush ring replacement Bearing cone Key 10 Camplate 11 Rotating kit 12 Gasket 13 Valve plate 14 Bearing 15 Dowel pin 16 Back plate 17 O ring Cae NS Note For repair of the piston pump see Eaton Me dium Duty Piston Pump Repair Information Model 70160 Variable Displacement Piston Pump at the end of this chapter Greensmaster 3150 ZU REAR Hf 22 OF TRACTION UNIT Parts not listed in partlist are not serviced separately Q O m Figure 21 18 Check valve 34 Shaft seal 19 Dump valve 35 Retaining ring 20 O ring 36 Retaining ring 21 Cap screw 37 O ring 22 Cap screw 38 O ring 23 Coupler 39 Seal kit 24 Roll pin 40 O ring 25 Cover plate 41 Charge relief housing 26 Camplate insert 42 Charge relief poppet R4 27 Shaft seal 43 Charge relief spring 28 Washer 44 Washer 29 Housing 45 Retaining ring 30 Retaining ring 46 Bleed off
15. 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 engine 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 INJURY RISK When a person or pet appears unexpectedly in or near the mowing area STOP MOWING Careless operation combined with terrain angles ricochets or improperly positioned guards can lead to thrown object injuries Do not resume mowing until area is cleared 25 Whenever machine is left unattended make sure cutting units are fully raised and reels are not spinning key is removed from ignition switch and parking brake is set Safety Maintenance and Service 26 B
16. BT PA Removal Fig 14 1 Remove bedbar see Bedbar Removal in this sec tion of this manual 2 Remove locknut 12 spring 11 and washer 10 from adjuster screw 3 Unscrew adjuster 6 from the adjuster shaft 1 4 Remove jam nut 5 and wave washer 4 from ad juster shaft and remove adjuster shaft from cutting unit frame 5 Inspect flange bushings 2 and remove if necessa ry 6 If the detent 7 is damaged remove it from the cut ting unit frame by removing the cap screw 9 and lock washer 8 Dual Point Adjust Cutting Units Adjuster screw Page 10 12 9 Cap screw 10 Washer 11 Spring 12 Lock nut Installation Fig 14 1 If the detent 7 was removed install the cap screw 9 and secure detent to the cutting unit frame with cap screw and lock washer 2 If flange bushings 2 were removed align key on bushing to slot in frame and install bushings 3 Apply antiseize lubricant on internal threads of ad juster shaft 1 and slide into flange bushings in cutting unit frame 4 Install wave washer 4 Apply Loctite 242 or equiva lent to the threads of the jam nut 5 Tighten jam nut from 15 to 20 ft lbs 20 to 27 Nm 5 Screw adjuster 6 into adjuster shaft 6 Install washer 10 spring 11 and lock nut 12 onto adjuster screw 7 Install bedbar see Bedbar Installation in this sec tion of this manual 8 Adjust cutting unit see Cutting Unit Operator s Ma
17. Groomer DPA Cutting Unit Rev A Page 10 1 16 J bolt 20 to 25 in Ib 2 3 to 2 8 N m 4 Groomer brush Figure 20 2 Lock nut Greensmaster 3150 Chapter 11 TORO Electrical Diagrams Table of Contents Electrical Schematics Wiring Diagram and Electrical Harness Drawings 0c aa 3 Electrical Schematic 3 E A BG 4 AUN 4o t o E A NA Ka 5 Raise Reels 0 ccc eee ees 6 Lower Reels 6 seconds 7 Y ier d O 8 Baila o an MA Ui na a 9 Electrical Harness Drawing 10 Winnog DAGAN so trio cag dea d CR Red 11 A Se Ss 5 ME o LO Greensmaster 3150 Page 11 1 Electrical Diagrams This page is intentionally blank Electrical Diagrams Page 11 2 Greensmaster 3150 LEAK DETECTOR SOLENOID Greensmaster 3150
18. 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 SN I ANN LS PA ADA 2 Apply thick coating of grease to special screw do not get on threads and cam surface of clutch release disk L Apply Loctite 271 or equivalent to threads of special screw before assembling to clutch pin Assemble so 5 RN NMAC KL AP A AV AF A clutch pin is 0 240 0 260 in out fromface of clutch body o SS when pin is in fully extended position NN 3 Install clutch adapter to reel shaft Fig 49 Tighten clutch adapter to a torque of 170 210 in Ib Figure 50 4 Hold belt on drive pulley of clutch and slide clutch on clutch adapter while sliding belt on driven pulley Install 1 Clutch body drive pulley washer and nut on clutch adapter shaft and tighten nut 2 Belleville washer 2 to a torque of 7 10 ft lb 3 Nut and washer 4 Clutch engage disengage knob 5 Clutch adapter 5 Adjust belt tension Install groomer reel housing cover 6 0 250 in 0 10 pin extended Fig 39 Install clutch knob and tighten two 2 set screws against flats of clutch release disk Figure 51 1 Set screw 7 Clutch body drive pulley 13 Set screw 2 Felt sea 8 Roller bearing 14 Clutch knob 3 Clutch adapter 9 Belleville washer 2 15 Flat washer
19. Square head set screw Key Engine hub Square head set screw Lock washer Cap screw Key Greensmaster 3150 Engine Removal Fig 4 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch A CAUTION The muffler and exhaust manifold may be hot Avoid possible burns allow exhaust system to cool before working on the engine 2 Disconnect the negative battery cable at the bat tery 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 3 Close fuel shut off valve 15 Fig 3 4 Remove the fuel hose support clamp 11 Fig 3 and disconnect fuel hose 3 Fig 3 at the carburetor Drain any fuel trapped in the fuel filter and fuel hose into a suit able container 5 Disconnect the engine wiring harness 29 the choke control cable the throttle control cable and the ground wires 11 at the engine 6 Loosen the two set screws 41 securing the pump hub 30 to the pump shaft 7 Support the hydraulic pump assembly and remove the two cap screws 43 lock washers 42
20. _ DEREN 12308 0 bro um Me 1 A Can gt T wey gt Ix dcr UNE PBA EU STARTER SWITCH START SAFETY im BACKLAP oa 9 85 UU 86 DIS SOLENOID IGNITION SWITCH H Sane nbl Wi BACKAR BG PK Y BIN d SWITCH 99 7430 ine GN R mn OFF RUN START OPTIONAL EM E BU BK ee S1 n D1 B ee REEL ae ee OoHBK d xh AMOWBEUN ENGAGE Y tt oa W o Lng y MOW RELAY K4 SEAT 3 A SWITCH BRAKE GNIBK ors n ON POSITION 99 7430 rt MP pro Y Y JOYSTICK S WG OR BK o BU BK 4 88 9830 y _ oe d E Em MOW SWITCH D z Pot pes Joystick i de wwe i y A 1 OP feste y mg Bi A START B I S papm V P db oc GEI Y OR EFC MERO NES GY BK Y GN BK a 92 2538 bd Y GN GY Y ORBK J 2 KILL RELAY K1 eee L L p Tawa nmt A a 2 G 6 SECOND n ENGINE pr BER DELAY OFF MAGNETO e TA Y ALTERNATOR PA OEE BINS deo 5 L E Eod ii 3 p ae L MEMOREM GEN amy Cabagan ubi ue ee a S Rs a l A Ae ecu gt maf Ya O ED a a al Po e Y us REELS LOWER LOWER RELAY K5 L ERN i 1 A 2 B VIO BK 1 Y E Y RAISE LOWER y D3 le 1 A 2 B Se S6 SE ORIFICE a uo BU R m s3 H anay EMs REELS RAISE RAISE RELAY K6
21. ek 5 85M a l D WR JOYSTICK d FRAME ENGINE E bas Mere Y GN BK RELAY K3 Y D1 C Y GROUND GROUND B A aro IE n c S Y BU Ka Be Sa ase T y i 92 2538 GN GY Y OR BK 2 po 3 3 KILL RELAY K1 MESSIS LOI J d a UR IN 2G 6 SECOND ru ENGINE W PKIBK DELAY OFF MAGNETO jo 87 x V FUSIBLE LINK 87a don 99 7430 ALTERNADOR Al A A A me m SP i a T PUE 86 ipa i M j gt MU W BK O Taa D2 REELS LOWER LOWER RELAY K5 y pem vA 2B MON AY ae Y Y RAISE LOWER y D3 Pi 1 A P 2 B PU 99 7430 S6 0 de En ORIFICE y 30 BU R away REELS RAISE RAISE RELAY K6 a X M ere 3 LEAK DETECTOR SOLENOID
22. 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 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 click at a time until first contact be one 1 more click to get light contact No contact dulls cutting edges Excessive contact increases wear Set to recommendations in chart on Page 9 12 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 re 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 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 Greensmast
23. 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 Quad Seal Figure 46 Hydraulic System o e Tam O eb pue o gt o Steering Cylinder 11 13 35 p pee FRONT M fat iu Pd m 18 Figure 47 l Steering cylinder 15 Dust seal 28 Drive stud 2 90 hydraulic fitting 16 Slotted hex nut 29 Grease fitting 3 O ring 17 Spacer 30 Castor fork 4 O ring 18 Cotter pin 31 Cap screw 5 Hoseassembly 19 Lug nut 32 Lock nut 6 Hose assembly 20 Valve stem 33 Adapter plate 7 Cotter pin 21 Tire 34 Lock nut 8 Slotted hex nut 22 Rim 35 Lock nut 9 Washer 23 Spacer 36 Motor plate 10 Bearing cup 24 Seal 37 Castor bolt 11 Bearing cone 25 Bearing cone 38 Cap screw 12 Jam nut 26 Bearing cup 39 Lock nut 13 Rod end 27 Hub 40 Flat washer 14 Grease fitting Hydraulic System Page 4 80 Rev C Greensmaster 3150 Removal Fig 47 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 Label all hose connections for reassembly pur poses 3 Remove hose assemblies and O rings from hy draulic
24. 4 Remove both cap screws securing the cable sup port assembly to the hydrostat Fig 19 5 Lift and secure the neutral system assembly up and away from the hydrostat o Tam O gt Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components Piguet 1 Cap screw 4 Hydrostat 2 Pivot washer 5 Cable support assembly 6 Label all hose connections for reassembly pur 3 Pump lever assembly 6 Cap screw poses 7 Clamp pump inlet hose 1 to prevent draining the hydraulic reservoir Fig 17 8 Separate gear pump from the hydrostat see Hy draulic Gear Pump Removal 9 Plug suction port at the end of the gear pump to pre vent possible leakage of hydraulic fluid Fig 20 10 Pull gear pump 2 and connected hoses assem blies 10 and 15 away from the hydrostat 12 and se cure Fig 17 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 20 Greensmaster 3150 Page 4 47 Hydraulic System 12 Loosen both set screws 23 on 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 wa
25. Bearing housing will slip out of side plates and reel assembly can be removed as soon as bearing housings are disassembled from side plates 5 Before installing reel install new special machine screws from inside of frame to secure bearing housing 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 weight 7 After installing reel tighten spline nut to 40 60 ft lb then adjust bearings See Reel Bearing Service and Adjustment in the Adjustments section of this chapter 8 Install bedbar Install front and rear roller assembly Greensmaster 3150 Page 7 19 2 Right reel bearing housing Figure 27 1 Reel bearing adjustment nut Figure 28 1 Left reel bearing housing 3 Machine screws Figure 29 1 Bearing housing rotate slightly 2 Bearing housing mount bolts thread against side plate to remove housing Repairs Lift Bail Replacement N N RN N N N N N N N N N N N N D c d Figure
26. WENN RU MU LILI EJ ET EI spum 288919 Ily ereougn peJuinboaJ 2214428 g pue y O peJuinboJ 2214408 V C J9U 9 2 9Jg 191114 Jv 99IN9S jueugsn py peojaid Duueeg jaay 198y9 juswa 3 491114 Jv eoejday SUOIJOBUUOD 9 ge leneg y2949 LI LI EJ EJ ET EI ET SINN DN jeeuM enbjo 7 Jeyt4 IIO euibu3 eoejdey 7 9497 pin 4 l9neg yoouD sinoy 00g Alona 3211198 9 sinoy QOL Alona 3211198 g sinoy 0G Ala Aa 2211435 Y UBI0IUYO9 1940 GD AV 8 9 119 Wopad O BDIAIAS SXIeuu9H O I OHOL uoneufiseg HUN esn sunno Jo abed siy ejyeordn OVE 19P10 YOM J1OSINISANS eoueuejure y OSLE Y H31S VINSN33H9 Greensmaster 3150 8 Page 2 Product Records and Maintenance TORO Table of Contents INTRODUCTION SPECIFICATIONS currar SERVICE AND REPAIRS Fuel TanK iu e eee xus Fuel Tank Removal and Installation Greensmaster 3150 Chapter 3 Engine ENGINE araa wand t bd beue 6 Engine Removal a 7 Engine Installation o 7 BRIGGS amp STRATTON REPAIR MANUAL FOR 4 CYCLE V TWIN CYLINDER OHV HEAD ENGINES Page 3 1 Engine Introduction This Chapter gives information about specifications maintenance troubleshooting testing and repair of the engine used in the Greensmaster 3150 Most repairs and adjustments require tools which are commonly available in many service shops Special tools are describ
27. 3 Frame supports 4 Adjustment knob 5 Bedbar pivot 6 Jam nuts 1 Rubber bushing 2 Flange bushing Repairs Page 9 22 4h CAUTION Be careful when lapping the reel because con tact with the reel or other moving parts can result in personal injury Figure 27 7 Left bedbar pivot bolt 8 Right bedbar pivot bolt 9 Steel washer 10 Plastic washer 11 Spring arm retaining capscrew 12 Compression spring Figure 28 3 Shoulder pivot bolt 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 4 go within 1 16 in 10 To install bedbar slide it into position between side plates making sure each end of bedbar is under shield Fig 30 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 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
28. 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 Hydraulic System Page 4 52 Rev A Front Wheel Motor Installation Fig 23 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 Remove caps or 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 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 Secure brake lever 23 to the brake cam 9 with the retaining clip 10 IMPORTANT DO NOT hit wheel hub 6 with a ham mer during removal or installation Hammering may cause damage to the hydraulic wheel motor 20 Note The brake drum assembly consists of the wheel hub 6 brake drum
29. BE M AA AA Page 11 8 LEAK DETECTOR SOLENOID Y pcr ee Greensmaster 3150 80 9330 M i 4 ALARM OW w Serial Number 230000801 amp Up Shown Power Current ee Control Current PU 9 f GY 83 2280 Current Direction LEAK DETECTOR 1 SECOND CLOSED DURING Y GY DELAY ON T A HYDRAULIC FLUID LEAK STARTER e l HOURMETER 2 dai BU TF 23 LIGHTS 1 R F1 20A F2 10A Y 4 OPTIONAL 0 W LIGHTS 2 l LIGHT TEST SWITCH OPTIONAL FUSIBLE LINK LJ am ee o gt D A A a L a a A A a ce ce e gt a AA a a A A A mara ma A D A das gt VIO Y BU 99 7430 a o 0373 111 BACKLAP RELAY K7 BK A PK BU PK BU VTL 87 ve ja en C ESTA 86 ki a ii W 1 A o7 o o W BU YM o
30. Figure 2 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 ej DO NOT use an air impact wrench with this tool a 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 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 svPw A E E Factor 1 Tire pressure 2 Engine governed speed 3 Reel bearing condition adjustment 4 Reel and bedknife sharpness 5 Bedknife parallel
31. 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 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 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 a 1 4 inch or thicker plate under the reel blades and against the front face o
32. 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 lb 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 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
33. V H ON SACKLAP e EN OFF RUN START y DER K OPTIONAL o GNR BU BK ES 387 S1 D1 B 30 a F3 10A 87a REEL a 2B Ue o rs ENGAGE A ASE s o W o 1 v MOW RELAY K4 1 B SEAT PARKING EK P31 B BK c F410A SWITCH BRAKE ia ON POSITION GN i Tum MUN 99 7430 V V FS NM HAHAHAHAHAHA KH xx CC cc00ceOU c v sssVm dn Ww 2 E NE E is 7 JOYSTICK po OR BK o BU BK i 2 LOWER 2 F MOW SWITCH D E r y 88 9830 SE TN v Gee A i CERES eee F z STOP NONE V 3 GN BK AASA cc V FRAME ENGINE El NAA T ad RELAY K3 D1 C ki GROUND GROUND aoe START Balas Lo 3 BU 2 Ng2 OR Y 20 RAISE BK GY BK GN BK 92 2538 ree T p e ta KILL RELAY K1 1 E E REN o Jj tenen I M 2 G 6 SECOND ENGINE sais gt ERE DELAY OFF MAGNETO a 30 sa VIO H FUSIBLE LINK 187a o l 99 7430 A ALTERNATOR 99 7430 a e S i SP M 85 UU 86 BR EE SE Y sam ammo ee a a oe qe e 0 W BK Y Y A S4 l0 LA 87a D2 REELS LOWER LOWER RELAY K5 Y VA 2B vogs s2 V RAISE LOWER i D3 SER om TM 1 A 2 B S6 p ORIFICE RUE i Y 30 A ae ae S3 aner NMM REELS RAIS
34. and then turn out counterclockwise 3 turns B Adjust knob no 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 Hydraulic System Q e Tam O gt Steering Control Valve 1 Steering arm 2 Cap screw 3 Cap screw 4 Setscrew 5 Lever 6 Handle 7 Friction plate 8 Steering wheel 9 Hexnut 10 Screw 11 Cover Hydraulic System Figure 43 Cap screw Steering mount Cap screw Steering column Lock nut Lock washer Flat washer Straight hydraulic fitting O ring O ring Hose assembly 5 Page4 76 Rev C 23 24 25 26 27 28 29 Knob 31 32 Straight hydraulic fitting O ring Panel nut Steering valve cover Cap screw Flat washer Spacer Lock nut Hair pin Greensmaster 3150 Removal Fig 43 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 screws 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 15 4 Remove screws 14 and remove the steering
35. 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 Do not misplace washers 5 Replace and or grind bedknife to renew cutting edges NOTE For proper grinding of bedknife follow proce dures in the Toro publication Sharpening Reel and 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 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 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 Pivot screw 2 Bedknife pivot ass y
36. ciency see TEST NO 2 Wheel Motor Efficiency in this chapter 15 If testing is complete disconnect tester from pump fitting and hose Reconnect hose to pump fitting Hydraulic System o Tam O gt 2 TEST NO 2 Wheel Motor Efficiency HOSE FROM UPRER FITTING E a E ic TRACTION WHEEL MOTORS P CAP E e E E Pa uu aF E NW uii e GZ OPTIONAL REAR WHEEL 3WD A MOTO F A e A E 2 2 is f 1 H TESTER Y OED DUMP VALVE TOP BOTTOM A B O O R4 FROM GEAR PUMP BLEED 200 250 VALVE PSI J lt ai AG a High Pressure HYDROSTAT TO HYDRAULIC YY asa RESERVOIR Return or Suction Flow Hydraulic System Page 4 24 Greensmaster 3150 Procedure for Wheel Motor Efficiency Check Note Over a period of time a wheel motor can wear internally A worn motor may by pass oil to 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 approx
37. 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 If fuel is spilled do not attempt to start the engine but move the machine away from the area of spill 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 Check the safety interlock switch daily for proper op eration see Verify Interlock System Operation in Chap ter 5 Electrical System If a switch should fail replace the switch before operating the machine After every two years replace all interlock switches in the safe ty system regardless if they are working properly or not 13 To start the engine A Sit on the seat make sure cutting units are dis engage
38. 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 lb 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 Coat castor 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 Ko S o nx o 2a Rear Wheel Optional 3WD cre PO NUON Lock nut Spacer Grommet Hose assembly Washer Castor fork Bearing tab Lock nut Bearing flangette lube Bearing Bearing flangette Wheels and Brakes LA I M l I I I I I I 85 ft Ib 115 Nm Figure 4 12 Cap screw 13 Lock nut 14 Wheel motor amp hub asse
39. 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 fons 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 remove excessive looseness in assembly but allow bracket to slide freely on side plate Set Up and Adjustments Page 9 14 Greensmaster 3150 6 Position a 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
40. 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 5 Loosen large reel bearing adjustment nut Fig 10 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 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 Fig 10 and tighten to a torque of 170 210 in Ib 8 Hold belt on drive pulley and slide clutch on clutch adapter while sliding belt on driven pulley Install washer and nut removed in step 4 on clutch adapter shaft and tighten nut to a torque of 7 10 ft Ib Adjust drive belt tension before installing cover See Groomer Reel Drive Belt Adjustment in this section of the book Set Up and Adjustments Page 9 12 Figure 8 1 Height of cut locknut 4 Grooming reel cover 2 Roller shaft clamp bolt 5 Cover screws amp washers 3 Height of cut knob Figure 9 1 Drive
41. see Test 9 Page 4 19 Hydraulic System Problem Cutting units raise but will not stay up Possible Cause Lift cylinders leak internally Solenoid valve S4 leaks Solenoid valve S4 is not returning to its de energized position Relief valve R2 leaks see Test 5 Steering control valve has insufficient oil pressure Emergency steering ball in steering control valve is missing or damaged Regular adjustments to steering wheel are necessary because of dif ficulty of driving in a straight line Steering wheel will not return to the neutral position Backlash results when turning steer ing wheel Rear wheel shimmies when the steering wheel is turned Leaf springs in steering control valve are worn or broken Gear wheel set is worn Steering cylinder is seized or its piston seals are worn see Test 9 Spool and sleeve are sticking to steering control housing assembly see Test 9 Leaf springs in steering control valve are broken or stuck Spool and sleeve are sticking to steering control housing assembly see Test 9 Cardan shaft fork is worn or broken Leaf springs in steering control valve are worn or broken Splines on the steering column are worn Air is in the steering cylinder Mechanical connections to the wheel or wheel bearing are worn The steering wheel can be turned without the rear wheel turning Reservoir oil level is low The steering cylinder is worn T
42. wheels Used jack stands or solid wood blocks to sup port the raised machine If the machine is not properly supported 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 Chapter 2 TORO Product Records and Maintenance Table of Contents PRODUCT RECORDS leues 1 MAINTENANCE 0 00 ce eee ee eens 7 EQUIVALENTS AND CONVERSIONS 2 MAINTENANCE SUPERVISOR S WORKSHEET 8 Decimal and Millimeter Equivalents 2 U S to Metric Conversions 2 3 S TORQUE SPECIFICATIONS 3 ES Fastener Identification 3 cc Standard Torque for Dry Zinc Plated and E E Steel Fasteners Inch Series 4 os Standard Torque for Dry Zinc Plated and um Steel Fasteners Metric Fasteners 5 Other Torque Specifications 6 Product Records Record maintenance and repair information about your Insert Operator s Manuals and Parts Catalogs for your Greensmaster 3150 on the MAINTENANCE SUPERVI Greensmaster 3150 traction unit and cutting units at the SOR S WORKSHEET Use this information when refer end of this chapter ring to your machine Greensmaster 3150 Page 2 1 Product Records and M
43. 12 Vehicle frame 18 Hose clamp 6 Grommet 13 Not used 19 Spacer 7 Flat washer Engine Page 3 4 Greensmaster 3150 Fuel Tank Removal Fig 3 Fuel Tank installation Fig 3 1 Park machine on a level surface lower cutting units 1 Position fuel tank 5 on the vehicle frame 12 stop the engine engage parking brake and remove the key from the ignition switch A Apply antiseize lubricant to the threads of the four cap screws 9 Y CAUTION B Secure the fuel tank to the vehicle frame with four flat washers 7 and four cap screws 9 Make sure the fuel hose support clamps 8 are positioned The muffler and exhaust manifold may be hot correctly Avoid possible burns allow exhaust system to cool before working on the engine C Torque cap screws from 20 to 25 ft lb 27 to 34 Nm 2 Connect fuel hose 14 to the fuel shut off valve 15 with hose clamp 2 Gasoline is flammable Use caution when storing 3 Open fuel shut off valve 15 and fill fuel tank with or handling it Do not smoke while filling the fuel fuel see Filling Fuel Tank in the Traction Unit Operator s tank Do not fill fuel tank while engine is running Manual Check all fuel hoses and tank for leaks 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 pur
44. 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 Table of Contents SPECIFICATIONS 2 aaa aaa cee ee me 3 SPECIALE TOOLS 5 paba dour he NAA rra eses 4 TROUBLESHOOTING 005 6 SET UP AND ADJUSTMENTS 8 Adjustment Summary and Check List 8 Bedknife to Reel Contact 9 Reel Bearing Service and Adjustment 10 Parallel Bedknife to Reel 11 Leveling Rear Roller to Reel 12 Height of Cut 0 a 14 Front Roller Scraper Adjustment 16 Comb Adjustment o ooooooo 16 Shield Height Adjustment 17 Greensmaster 3150 Page 8 1 Chapter 8 Single Point Adjust Cutting Units Top Bar Adjustment 17 Pull Frame Adjustment 18 REPAIRS og aa paaa ahah edd ce pee 19 Cutting Unit Removal and Installation 19 Reel Lapping 0 20 cee ee eens 20 Be
45. 3150 Chapter 9 Grooming Reel Cutting Units Table of Contents SPECIFICATIONS 20 000 ee eee 9 3 Groomer Reel Drive Belt Adjustment 9 19 SPECIAL TOOLS 4 paka cones BOSS eRe be ee eee 9 4 Pull Frame Adjustment 9 20 TROUBLESHOOTING 0 9 6 REPAIRS Los x zat ard qned para dare 9 21 Factors Affecting Quality of Cut 9 6 Cutting Unit Removal and Installation 9 21 Factors Affecting Grooming 9 8 Reel Lapping 0000 eee 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 Heel Bearing Service and Adjustment 9 12 Heel Removal and Bearing Replacement 9 26 Parallel Bedknife to Reel 9 13 Groomer Reel Blade Service 9 28 Leveling Rear Roller to Reel 9 14 Groomer Reel Drive Belt Replacement 9 28 Height of Cut anaana anaana aaan 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 Top Bar Adju
46. 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 Page 4 71 Rev C C Torque cartridge valve using a deep socketto 35 ft lb 47 Nm D Make sure a new O ring is ateach end of the 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 39 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 sealing surfaces damaged threads 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 over
47. 8 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 30 seconds stop the engine and determine the cause Greensmaster 3150 Page 4 45 Be careful when operating the cutting unit reels Contact with the reel or other moving parts can result in personal injury 9 After the 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 10 minutes in both directions B If a reel motor drive pump was replaced or re built run the cutting units at the minimum speed set ting under no load for 10 minutes C If a traction pump or a wheel motor was replaced or rebuilt run the traction unit so the wheels slowly turn for 10 minutes 10 Operate the traction unit and cutting unit by gradual ly increasing their work load to full over a 10 minute peri od 11 Stop the machine Check reservoir and fill if neces sary Check hydraulic components for leaks and tighten any loose connections Hydraulic System Sg E E SF IO Hydrostatic Transmission Pump inlet hose Gear pump 90 hydraulic fitting 90 hydraulic fitting O ring O ring Hose clamp O ring O ring 10 Hose assembly 11 O ring 12 Hydrostat 13 Soc
48. 9 Metric Bolts and Screws Figure 2 Product Records and Maintenance Product Records e o c c LE nd E E c Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Grade 1 5 amp Thread Size 8 with Thin Height Nuts Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts 6 32 UNC 147 23 6 40 UNF 8 32 UNC 282 30 8 36 UNF 10 24 UNC 339 56 10 32 UNF 1 4 20 UNC 48 7 599 79 1 4 28 UNF 53 7 65 10 734 113 5 16 18 UNC 115 15 105 17 1186 169 5 16 24 UNF 138 17 128 17 1446 192 3 8 16 UNC 16 2 3 8 24 UNF 17 2 7 16 14 UNC 27 3 7 16 20 UNF 1 2 13 UNC 1 2 20 UNF 3273 5 8 11 UNC 65 10 88 12 119 16 5 8 18 UNF 75 10 95 15 129 20 3 4 10 UNC 93 12 140 20 190 27 3 4 16 UNF 115 15 165 25 224 34 7 8 9 UNC 140 20 225 25 305 34 7 8 14 UNF 155 25 260 30 353 41 Ww N ah ah O co 00 C2 o IH IH IH IH IH Co Co N N N O1 E M Nm C1 C no de 00 co N 00 Oo oo o al C2 IH IH IH I I I I I N N C2 oo N N N al al N 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 Note Torque values may have to be reduced when ins
49. 99 7430 RE NEUTRAL sg Ti GRRR agg a hy M STARTER SWITCH SER DIAS wa Y A BU KU UA ka BACKLAP 3 87a SOLENOID IGNITION SWITCH PK Y V DI A B lt SWITCH 99 7430 a E ls OFF RUN START La OPTIONAL BU BK _ gt 87 S1 D1 B o al REEL 2 B 2 C OR BK a ENGAGE Y a a a a i v MOW RELAY K4 T a SEAT PARKING BK P31 B 0 A switcuH BRAKE GN BK i A pa ON POSITION A m Ea l 2 E o 0 D1 D Y Y JOYSTICK i O F OR BK BU BK KT r 88 9830 Y d sv LAE ame MOW SWITCH D E B SECURE IK UEM F NE o STOP NONE ie sei RELAY NG D1 C FRAME ENGINE RUN B I A and X Y Y ne Y E pu GRUND BI LA START B l S AEN 4 ma o Y BL Y m 20 se L Lj BK OR HABE Ll d BO vex I Y GN BK OPA 92 2538 BR Y GN GY Loto E KILL RELAY K1 E L ae spe oop st te a BK ENGINE i di M 2 G 6 SECOND acute W VIENNE PK BK DELAY OFF VIO o 30 l Y ALTERNATOR Bee deo A ATONG i A AE D mL NE SS CE qo 85 UUJ 86 BK EM FUEL SOLENOID L mm Y M W BK lt N ANG d pt TE i o ve 87a ds REELS LOWER LOWER RELAY K5 VA 2B
50. ILYY MOT 38nS S 3d IN333VidsLd EW 21 gway28 IINEIP H m LAYHI J8NsSI8d ONY ILYA MOIS IN3H32V T4081 0 SHOLOW 1338 MEN z D 0G Le 19 ISeusuaalr 5 Hydraulic Flow Diagrams Traction Forward and Reverse Forward The hydrostat is driven directly by the engine The trac tion circuit 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 of the wheel motors returns to the bottom port of the hydrostat and is continuously pumped out the top port Hydraulic oil is supplied to the traction circuit from the gear pump P2 though the steering control valve and back through 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
51. 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 make sure bedknife to reel contact is removed by turning bedknife adjustment knob counterclockwise Fig 6 2 Reel bearing rolling torque should not exceed 7 in Ib 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 t
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53. Reel and Rotary Mowers part no 80300SL for bedknife grinding information Bedknife Grinding Specifications Bedknife relief angle 3 see Fig 17 Front Angle Range 13 to 17 3 Reinstall bedbar to cutting unit see Bedbar Installa tion Greensmaster 3150 Page 10 13 Figure 15 1 Screw 3 Bedknife S 89 OS OOO O O O O O O 13 11 9 7 5 3 1 2 4 6 8 Figure 16 Top Face Relief Angle Front Angle Figure 17 10 12 Remove Burr Front Face Dual Point Adjust Cutting Units Reel Assembly 2 y 17 to 20 ft Ibs General Purpose YP So 23 to 27 Nm Grease S General Purpose Grease Figure 18 1 Reel 10 Right side plate assembly 18 Flange nut 2 Speedi sleeve 11 O ring 19 Cap screw 3 V ring 12 Bearing 20 Lift hook 4 Drive coupler 13 Inner grease seal 21 Cap screw 5 Retaining ring 14 Retaining ring 22 Grass shield 6 Left side plate assembly 15 Wave washer 23 Washer 7 Shoulder bolt 16 Seal strip 24 Cap screw 8 Bearing lock nut 17 Frame assembly 25 Lock nut 9 Outer grease seal Dual Point Adjust Cutting Units Page 10 14 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 c
54. TEST NO 3 Charge Relief Valve R4 Pressure Using Tester with Flowmeter and Pres sure Gauges pu TRACTION WHEEL MOTORS OPTIONAL REAR WHEEL 3WD MOTOR A PUMP P3 CHARGE PORT DUMP TOP VALVE BOTTOM A B EN FROM LIFT CIRCUIT Iba TO REEL MOTOR CIRCUIT PRESSURE A GAUGE e E TO STEERING AND LIFT eiue CIRCUITS BLEED 200 250 VALVE PSI em WO f A ENGINE P1 ka A RPM De So ST HYDROSTAT i GEAR PUMP High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 26 Rev A Greensmaster 3150 Procedure for Charge Relief Valve R4 Pressure Check 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
55. Units 6 Secure hose connection to the proper hydraulic fit ting on the reel motor Repeat this step for the remaining hose connections Greensmaster 3150 Reel Motor Service 33 to 40 ft lb 45to55Nm Hydraulic System Figure 29 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 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 30 Figure 30 Greensmaster 3150 Page 4 59 Hydraulic System IMPORTANT Avoid using excessive clamping pressure on the motor flange to prevent distorting the casting 3 Clamp mounting flange of motor in a vise with the shaft end down 4 Loosen cap screws on the rear cover 5 Take motor from the vise and remove cap screws 6 Remove front flange from the body then remove rear cover Locate and remove dowel pins from body IMPORTANT Mark the relative positions of the gear teeth and the bearing blocks so they can be 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 on its side and push
56. aaa 87 BACKLAP RELAY K7 n id oe t VIO EN i ei BK 85 UWI ae C ERE nee MER UD i ES NEUTRAL T TES qe NI o ORE crm EU POMA I ns ER STARTER A switcH START SAFETY K2 BACKLAP za T BU BK H CKLAP Ra SOLENOID IGNITION SWITCH G PK Y B lt SWITCH 99 7430 l gms GNR NN a OFF RUN START S OPTIONAL BU BK E D1 B Y 9 al REEL 2 B EOU ws Nr a Peete Y tt Q o cec a V db MOW RELAY K4 AG l SEAT BK A SWITCH BRAKE GN BK oe T ON POSITION A Y sw i 2 E 5 sS D1 D V V JOYSTICK i ces OR BK 9 o BUBK X s LOWER 2 F MOW SWITCH D E e Pty 0g SER Lue ense IE La E STOP NONE I y P dunt eek mam D1 C LOVE ENGINE RUN B I A and X Y V i A ame Y l jm GROUND BI LA START B l S i L a Gai ws ete at Vi Y J Y gt s gt 2 Y pup uem x Qa Pi pE L Ll eco Y EN a maan ng aaa I 92 2538 BR Y GN GY Loto anac Ed E d c TuS ENGINE FX WE rip DS ee AA n vi a Deer DELAY OFF MAGNETO ue ntg d i y ALTERNATOR Bee deo A PAGA lm A BRE tit Ro P d U EONO WERK mM i Lio mc by on a MEM 87 B5 REELS LOWER LO
57. accurate information Electrical System Page 5 8 Voltage Measured Battery Charge Level 12 68 V or higher Fully charged 100 50 charged D charge 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 Ignition Switch The ignition key switch has three 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 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 The hour meter should move a 1 10 of an hour in six minutes 4 Disconnect the voltage source from the hour meter Greensmaster 3150 Page 5 9 When testing electrical components for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected HEX NUT SWITCH LOCK WASHER Figure 6 Figure 7 Electrical System o oO pe sad S o LLI z Qo im Y g
58. adjust the aggressiveness of the comb teeth Fig 17 proceed as follows A 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 bolt 2 Comb teeth NOTE Securing one end ofthe comb assembly at a 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 lowered 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 A
59. 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 t 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 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 Figure 18 to underside of screw head 1 Height of cut knob locknut 3 Screw head over bed
60. and hard ened washers 32 securing the pump to the pump adapter 19 Do Not disconnect the hydraulic hoses or neutral control linkage from the pump 8 Support the engine assembly and remove the three engine mount flange nuts 7 cap screws 1 flat wash ers 2 and spacers 3 9 Remove the engine Greensmaster 3150 Page 3 7 Engine Installation Fig 4 1 Support the engine assembly and align the engine mount plate 21 with the three engine mounts 24 IMPORTANT Make sure not to damage engine fuel hose hydraulic hoses electrical harness and wires control cables or other parts while installing the en gine Make sure pump hub is in position before installing the engine mount cap screws 2 Align the pump hub 30 with the pump shaft and key 42 and slide the pump hub over the pump shaft 3 Install the three engine mount flange nuts 7 cap screws 1 flat washers 2 and spacers 3 A 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 A Torque cap screws from 27 to 33 ft lb 36 to 45 Nm B Tighten pump hub set screws 41 from 7 to 9 ft Ib 9 to 12 Nm 5 Connect the engine wiring harness 29 and ground wires 11 to the engine 6 Connect and adjust the choke control cable see Adjusting the Choke Control in the Traction Unit Opera tor s Manu
61. 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 Roller shaft 2 Roller body 3 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 6 V ring 2 Smooth roller 5 Seal 7 Bearing lock nut 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 of 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 secu
62. back plate Hydraulic System Page 4 8 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 no 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 Oil flow out of the bottom port goes to the wheel motors and turns them in the reverse direction Oil flowing out of the wheel motors returns to the top port of the 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
63. 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 NOTE Shield can be lowered 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 Set Up and Adjustments Page 9 18 Figure 20 3 4 3 4 inches 4 Shield fasteners 1 Shield 2 Front crossbar Greensmaster 3150 A ee ee ee ASIS AAO AA As Greensmaster 3150 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 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 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 Figure 21 2 Bar mounting screws Groomer Reel Drive Belt Ad
64. 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 lbs 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 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
65. 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 17 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
66. chapter Set Up and Adjustments Page 8 10 Figure 7 1 Height of cut locknut 2 Roller shaft clamp bolt 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 cam to raise or lower the bedbar Identification dot on bolt 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 180 position when adjusting 5 Rotate left hand eccentric pivot bolt to raise or lower bedbar as required 6 Ch
67. clockwise or counterclockwise direction The direction of location mark rotation must remain constant on the shaft 3 For 1 2 inch 1 3 cm spacing make sure there are two spacers between blades Fig 11 4 When all blades have been installed place final 2 spacers on shaft and then thread lock nut onto the shaft 5 Position lock nuts to allow blades and spacers to be centered on the shaft Fig 12 Torque lock nuts from 200 to 250 in Ib 22 6 to 28 3 N m so spacers are not free to rotate 6 Install groomer reel back on cutting unit see Groom er Reel Installation in this section Greensmaster 3150 Page 10 1 11 1 Groomer blade 2 Location mark ROTATION Figure 10 3 Sharp edge 4 Dull rounded edge 200 to 250 in Ib 22 6 to 28 3 N m Figure 11 1 Groomer reel shaft 3 Spacer 2 Groomer blade 4 Locknut 1 Locknut 2 Shaft CENTER BLADES Figure 12 3 Spacer D D sc E oO ct a 4 Blade ea Groomer DPA Cutting Unit Rev A Groomer Reel Bearing Replacement Seal lip toward center of cutting unit a Seal lip 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 of the cutting unit from the cutting reel hydraulic motor Figure 13 shows the groomer reel drive from the left
68. 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 Ibs 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 a 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 The cutting unit must be aligned so the grinding wheel will travel parallel to the reel shaft This will result in the 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 After completing the grinding process A Install parts removed to mount cutting unit into grinder B Install bedbar assembly see
69. 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 of the 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 15 bolt nuts securely Hold the eccentric pivot bolt while tightening the nut to keep the proper roller position 1 1 4 plate 2 Bedknife 3 Reel Figure 16 1 Pivot bolt Greensmaster 3150 Page 9 15 Set Up and Adjustments e E 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 setting 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
70. cut If necessary backlap to get desired fit between reel and bedknife Equal gap Figure 32 Greensmaster 3150 Page 9 23 Repairs ns 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 ka bushing there are 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 E Fig 36 DO NOT ha
71. 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 isa clearance of approximately 1 32 of an inch between the scraper and roller Fig 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 To adjust the aggressiveness of the comb teeth Fig 15 proceed as follows T A Teeth touching the adjusting gauge bar gives an aggressive setting B Adjustment of the comb assembly so it is midway 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 cutting edge of the bedknife gives a light setting NOTE Securing one end of the comb assembly a
72. 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 Label hoses 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 Support wheel 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 hydraulic 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 80 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 Hydraulic System Page 4 54 Rear Wheel Motor Optional 3WD Installation Fig 24 Note For assembly
73. fittings at the cylinder Allow hoses to drain into a Suitable container 4 Remove lock nut and flat washer 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 Greensmaster 3150 Page 4 81 Rev C Installation Fig 47 1 Secure cylinder rod end to the castor fork with Spacer slotted hex nut and cotter pin to rear wheel cas tor fork 2 Install hydraulic fittings and O rings to the steering cylinder 3 Install steering cylinder over barrel mounting stud and secure with flat washer and lock nut 4 Connect hydraulic hoses and O rings to the hy draulic fittings Tighten hose connections Hydraulic System 2 g E 2 SF IO Steering Cylinder Service Figure 48 1 Seal kit 6 Wear ring 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 Cap 15 Rod Hydraulic System Page 4 82 Greensmaster 3150 Disassembly IMPORTANT To prevent damage when clamping cylinder barrel in a vise clamp only on pivot end 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 Mount cylinder in a vise by clamping vise on center mounting locati
74. 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 gaskets and seal grooves with a thin coat of petroleum jelly Lu bricate all other internal parts freely with clean hydraulic oil 2 Install new shaft seal into front flange 3 Install lubricated pressure seals into the grooves in the front flange and rear cover Follow by carefully plac ing the back up rings into the grooves 4 Install new o rings to the body Greensmaster 3150 Page 4 61 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 Gentl
75. 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 Hepair 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 Hepair 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 E pao c E O a Adjustments Never work on the cutting unit with the engine running Always 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 heigh
76. 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 e Light medium or aggressive setting 5 Check grass shield adjustment e 4 3 4 in from crossbar normal e Dry grass lower shield e Wet grass raise shield 6 Set top bar cut off bar adjustment e 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 adjustment during opera tion loosen adjustment nut tighten reel shaft spline nut on right hand end of reel shaftto a torque of 40 to 60 ft Ib 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
77. miliar with General Precautions for Removing and Installing Hydraulic System Components 2 Chock front and rear of wheels not being lifted to prevent the machine from moving Lift front 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 or installation Hammering may cause damage to the hydraulic wheel motor 20 Note The brake drum assembly consists of the wheel hub 6 brake drum 8 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 Separate 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 Label all connections for reassembly purposes 8 Disconnect both hose assemblies 15 or 16 and O rings 18 from the both hydraulic fittings 17 Allow hoses to drain into a suitable container
78. 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 Heel Installation in this sec tion 3 Check and adjust groomer reel height and mower height of cut settings Er D 4 AT r Y m a gt gt E AUUT Figure 17 1 Groomer side plate 3 Idler bracket 2 Drive pulley 4 Idler pulley w bearings Greensmaster 3150 Lift Arm Assembly Lubricant T ane pd 4 ID Antisieze Ka is D NCL I DOES 5 aa CO SS a m las Lubricant Antisieze Lubricant Figure 18 1 HOC groomer arm LH shown 7 Bushing 13 Wave washer 2 Flange nut 8 Lift arm assembly LH shown 14 Groomer adjuster 3 Grooved pin 9 Detent spring 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 Lock screw 12 Bushing 18 Bushing Disassembly 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 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 Fig
79. nut with another wrench to the correct flats from finger tight F F F T Step 4 Size F F F T 4 1 4 in nominal hose or tubing 1 00 25 6 3 8 in 1 50 25 8 1 2 in 1 50 25 10 5 8 in 1 50 25 12 3 4 in 1 50 25 16 1 in 1 50 25 Figure 5 Greensmaster 3150 Page 4 5 Hydraulic System Hydraulic Schematics ana Es pi E recae LIM TVNOLLdO 1NIOP Tlva AN ON 37101 HDIH 098Z pang l4 AAAA AVADE le amp 31G MO 0091 1 Eu x umooo 1S1SOHGAH 1i a TIO a AA FH Jj ANION iil Zd Id rf Ed m SH H C RANG NFA od EE om J 4 pa E alee ISd 3NA Bae Ea
80. of the hub to the 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 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 lb 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 hose both assemblies 4 and new O rings 23 to the hydraulic fittings at the hydraulic motor and hub assembly Greensmaster 3150 Wheel Motor S
81. 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 to 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 thes
82. 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 Greensmaster 3150 ANIWA TOHINOO MO l3 QN3 INIOf TIvd r JSIvH H3MO SH3QNI1AO Lil wa sAs 21 ne pAH dd JNION3 YS SINIYA dYINOVA IYNOLLdO s1334 aall llo an Gol 3013140 9S 32018 GIOSINVIN MO 4 UOHONS JO uinjeH aBrey eunsseJd MO 9 nSSald UyBIH pazibiaus ap se UMOUS 9 8 SpiOUS9JOS 13Y 10 Y u
83. 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 Loosen the 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 Figure 46a right side bearing bracket from groomer reel shaft Remove groomer reel shaft from bearing support in left 1 Groomer reel shaft 4 R H groomer plate side groomer housing Fig 46b 2 Locknut 5 Bearing 3 R H groomer housing 6 Bearing spacer 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 remov
84. 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 reel shaft as follows A Check the reel shaft for bending and distortion by placing the shaft ends in 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 diamete
85. 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 mount to 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 side 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 Posit
86. speed may be experienced Rev A Greensmaster 3150 wa sAs 91 ne1p H Mis ES Y LIM IVNOILdO NOTA TO annauvao Y HOOD E 110 Ndy RS 3NION3 H L j Y arr ld AATWA v TOH1NOO Zoe MO 13 s1334 f ES up IS wan Yi b ym 110 Aka Soe y ES paga NN E CH S0 LH Ny uon PESE lesa ZL MI L S0 ISd 3SIvH sd ag J Folio H H3MO1 ex S0 m em SNA y 9 dYINOVA T Su3QNI1AO LAN TVNOILdO ps Paka EN ERA gn YN 30018 GI0ZINYW N TE MON Don ane 1 1HOd eet LNOHH mj lt 1HOd aw 1NOH4 uonong JO WINGY oe PRENSA i abiey amssalg MOT ME PT 2 nsseld UIH Y Y pezibiaue ap C S UMOUS 9 8 SPIOUAJOS Y EW quoc A NOUS UMOYS AN LO8000067 JequnNjeues E Gy pJ
87. 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 motor 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
88. the two connector ter minals The resistance should be about 7 2 ohms 4 Replace solenoid if necessary Reconnect solenoid valve electrical connector Figure 8 N lt i a 3 Ne i Figure 9 1 Electrical connector 2 Solenoid Electrical System Page 5 10 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 Make 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 a multimeter ohms setting across the connector termi nals 4 With no operator 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 Connect switch 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 11 1 The 20 amp fuse F1 supplies power to the run a
89. valve cover 26 5 Remove screws 12 Remove steering column 15 and control valve 2 6 Cut and remove any cable ties from the hose as semblies Label all hydraulic connections for reassemb ly 2 E e 7 Disconnect hose assemblies 22 and remove O 2 Install any cable ties removed from the hose assem PE rings 21 and 24 from hydraulic fittings 19 and 23 Al blies low hoses to drain into a suitable container 3 Note Disconnect hydraulic hose assemblies 22 at the manifold block P2 or ST ports at the steering cylin der or at the hydraulic pump if necessary Fig 44 1 LE Ww EE TTT E ka es MIT LI MM mamang bling AA S A TET 5 d 4 NW qM qm SIM call m Figure 44 Installation Fig 43 1 Install hydraulic fittings 19 and 23 and O rings 20 to the steering control valve 2 Install hose assem blies 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 the hydrau lic pump if necessary Fig 44 Install steering column assembly 15 and steering control valve 2 to steering mount with cap screws 12 4 Install steering valve cover 26 with cap screws 14 5 Install steering wheel 8 and nut 9 Torque nut to 35 ft lb 47 Nm 6 Secure steering wheel cover 11 with screws 10 Greensmast
90. valve and remove cap from valve ADJUSTMENT Note An 1 8 turn of the adjustment socket is about HEX SOCKET 50 psi 3 5 bar or 1 turn is about 400 psi 27 6 bar 2 To increase pressure setting turn the adjustment socket inside the valve 1 8 of a turn clockwise 3 To decrease pressure setting turn the adjustment Figure 14 socket inside the valve 1 8 of a turn counterclockwise 4 Install and tighten cap to valve After adjustment re test pressure setting see TESTING Hydraulic System Page 4 40 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 electrically operated control valves are actuated Return ignition switch to OFF when pressure has been re
91. valve poppet 31 Bearing race 47 Bleed off spring 32 Thrust bearing 48 O ring 33 Washer 49 Cartridge IMPORTANT The shims 7 are used to replace a crush ring in the cover plate 25 If the camplate 10 cover plate 25 or housing 29 is replaced during servicing the old crush ring must be re placed using the procedure Piston Pump Crush Ring Replacement on the following page in con junction with the pump service manual Page 4 49 Rev A Hydraulic System Figure 22 1 Crush ring 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 22 Note The shims replace the crush ring in the cover plate If the 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 Stack shims to the thickness of the crush ring 3 Insert shims 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 at the end of this chapter Hydraulic System Page 4 50 5 Install washers and cap screws to the cover pla
92. 0 in Ib values All torque values are based on non lubricated fasteners Conversion Factors in lb X 11 2985 N cm N cm X 0 08851 in Ib ft Ib X 1 3558 N m N m X 0 7376 ft Ib Product Records and Maintenance Page 2 6 Greensmaster 3150 Maintenance Maintenance procedures and recommended service in Unit Operator s Manual Refer to these publications tervals for the Greensmaster 3150 are covered in the when performing regular equipment maintenance Re Traction Unit Operator s Manual Maintenance proce fer to the Engine Operator s Manual for additional en dures and recommended service intervals for the gine specific maintenance procedures Greensmaster Cutting Units are covered in the Cutting Product Records e o c c LE nd E E c Greensmaster 3150 Page 2 7 Product Records and Maintenance seuYnpeooud pue suoneoirioeds Jo enuen 9211199 pue s Jojeladg ses L L pasinba l 3911195 9 pue g y ooueJe9 eA eA euibu3 498y9 snid weds eoejideu 7 s1eo Z usn J ureJq qUe ouneJjp H J9y14 eny esejday 7 siea Z ysn y urelg JUEL any 9 1014 N pue ajp Wid eurbu3 198y9 7 s1es 2 seyoums jajes eoejdeu Jey4 IIO 9NeIP H eoejideu 7 L a s1es 2 sasoH Bui o N eoejdeu IIO oi neap H eoejdeu LI LI ET ET ET CI ET L LI O L O L L sjeinads pue 3911135 enuuy 19Y10 sinoy 008 Ala Aa eo2lAJeS IIO euiBu3 sebuey
93. 00076SL Tire pressure Governed engine speed Reel speed 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 oee 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 Factor Possible Problem C
94. 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 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals 4 With the parking brake set there should be no conti nuity across the switch terminals Greensmaster 3150 Page 5 13 Figure 14 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 SE Zg on o LLI 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 1 Make sure the engine and ignition switch is Off Re move the plastic cover and disconnect the electrical connectors from the switches 2 Check the 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 current should only flow across terminals 1 and 3 blue and green black wires B With the joystick in the raise position current should across terminals 1 and 2 blue and green gray wires 3 Check the continu
95. 2 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 096875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions 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 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 Product Records and Maintenance Page 2 2 2 Multiply by 5 9 Greensmaster 3150 Torque Specifications Recommended fastener torque values are listed in the following tables Fo
96. 2 E General Information oo oooooooo o 4 4 SDECHICANONS seemet dec Sa dead ca El ES Hydraulic Schematic ooo oo 4 6 Special Tools 0 ccc ee eee T Hydraulic Flow Diagrams 4 8 Troubleshooting 0 cee eee ees Special TOOS errentei ipo IRI Kan 4 16 Set Up and Adjustments Troubleshooting 0 aaa 4 18 Service and Repairs TESNO PAA ta dd 4 21 Adjustments sssee nn 4 40 Chapter 10 Dual Point Adjust Cutting Units E 5 Service and Repairs 4 41 E 35 Eaton Gear Pumps Repair Information Series 26 Specifications Ata Sa dy al A A Tr Model 26000 Multiple Gear Pumps Special Tools Lour ata ct aee died Ak ee ae od NG ee Eaton Medium Duty Piston Pump Troubleshooting ed digas ge oe wee ee ade EE depu ad Repair Information Model 70160 Set Up and Adjustments E ATE E EE E Variable Displacement Piston Pump Service and Repairs E ice Me AMT MONEMUS AE Chapter 10 1 Groomer DPA Cutting Unit E E Service Manual 2704 003 SDECHICATIONS uoce mecs ro ques edes 3 General Information SNA PIGE ort lecticavey ste Troubleshooting eee eee Electrical Schematic 0ooooooooooo 5 2 Adjustments coco Special Tools 0 cece 5 3 service and Repairs 1 1 eee eee Turf Guardian Leak Detector Chapter 11 Electrical Diagr
97. 23 Secure cam to the lever with the retain ing ring 10 4 Place antiseize lubricant on woodruff key 13 and inside of the wheel hub 6 Mount key into shaft of hy draulic wheel motor 20 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 Check and adjust brakes see Brake Adjustment in the traction unit Operator s Manual Greensmaster 3150 Table of Contents SPECIFICATIONS 0 000000 eee eee 2 SFECIALTOQUS 2e atari rra es 3 TROUBLESHOOTING 0 0 a 5 Factors Affecting Quality of Cut 5 SET UP AND ADJUSTMENTS 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 Of Cut ce eee 11 Front Roller Scraper Adjustment 12 Comb Adjustment o ooooooo 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 aay EP AP ds 15 Cutting Unit Removal and Installation
98. 3 and drive stud 7 6 Place antiseize lubricant on woodruff key 13 and inside of the wheel hub 6 Install key 13 to the hydrau lic wheel motor 20 shaft Slide brake drum assembly 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 Install the tire 2 and rim 3 to the brake drum as sembly Secure rim with lug nuts 1 Torque nuts from 70 to 90 ft lb 95 to 122 Nm Greensmaster 3150 85 ft lb 115 Nm 80 to 100 in Ib 30 ft Ib 9 0 to 11 3 Nm 41 Nm i rd d 70 to 90 ft Ib 95 to122 Nm Hydraulic System Figure 24 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 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 Greensmaster 3150 Page 4 53 Hydraulic System Rear Wheel Motor Optional 3WD Removal Fig 24 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
99. 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 9 If relief valve R2 pressure is incorrect adjust relief valve R2 See Adjust Manifold Relief Valves in the Ad justments section of this Chapter Retest relief valve pressure if adjustment is performed 10 Reconnect the following electrical connections A Disconnect the connectors for solenoids 3 and S4 atthe manifold block B Connect male connector from solenoid S 3 to the female connector blue red and black located on the wiring harness for solenoid S3 C Connect male connector from solenoid 54 to the female connector white black and black located on the wiring harness for solenoid S4 11 If testing is complete Disconnect test gauge from gear pump and hose Reconnect hose to hydraulic fit ting on pump Hydraulic System Lc E 2 SF IO TEST NO 6 Gear Pump P1 Flow Using Tester with Flowmeter and Pressure Gauges a B4 P 7 i E 3 PUMP P1 OUTLET TO HYDRAULIC MANIFOLD TO HYDRAULIC MANIFOLD TO STEERING AND LIFT CIRCUITS f ENGINE RPM High Pressure FROM HYDROSTAT Low Pressure Return or Suction Y Flow Hydraulic System Page 4 32 Greensmaster 3150 Procedure for Gear Pump P1 Check 1 Make sure hydraulic oil is at normal operating tem perature
100. 334 g a a Q l ums Da DE pi vel mon Han p c 1 bo 110 L ee j b ali KAN EE EE ae dor den iu AAA O AA PP g V lute DR 3ATVA dol y NOLLO8S id NEM MEM sel p P zs ari langga ISd 3sivH E A pa PE VET NG GOldlHO H3MO1 ex so l i gg E HOLOW 133HM gt E SANA X Ho NOLLOVHL AYINOVA ya GME TVNOLLAO SH3QNITAO L4 IYNOLLdO Wea aw VIN C DOTE TONN pe i N y eurer 1HOd QHvMHOJ MOJ lt LI NOH IH Wwolloa uonong JO unyay CA E abley eunssejd MO V g eisseid YH iNOW aud E o av uin JUHI e 10 peuonisod EN 7 GN si SAMBA bullaa s JAMO J EM Nore paziGiaua ap se T 3 T T SHOLOW 133HM NOILOVHL UMOYS 348 SPIOUAJOS Y UN a cuum 1NOH3 Ti UMOYS dN Y L080000 c 199WNN euas AA uin ybiy EN OSLE Ja sewsuda 9 SHOION SSH eee Hydraulic System Page 4 15 Greensmaster 3150 Special Tools Order these tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PRODUCTS 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
101. 4 Needle bearing 10 Clutch release disk 16 Lock nut 5 Clutch pin 11 Special screw 6 Compression spring 12 Flange bushing Greensmaster 3150 Page 9 31 Repairs Bedknife to Reel 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 adiustable 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 t
102. 6 Steering Control Valve Service 78 Steering Cylinder ccc cece eee 80 Steering Cylinder Service 82 Leak Detector cece 84 Hydraulic Reservoir asana 66 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 Hydraulic System Lc E 2 SF IO This page is intentionally blank Hydraulic System Page 4 2 Greensmaster 3150 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 2800 RPM and 98 Efficiency Wheel Motors Front Orbital 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 Manifo
103. 6 GPTIGBK W102 GPTIBGN_BKk A oa wW107 GPTI8W BU B 3 br ox al W109 GPTI8GYJBK C SP8 WiI8 GPT 8BU_BK n NG W143 GPTI8BK E A W142 GPTI8BK W138 GPTISBK W1 19 GPTI8BU_BK F B W152 GPTI8BK SPI WI44 GPTI8B 6 W105 GPTI8W_BU W104 GPTI8W_BU h ENGAGE S1 1 co DIODE PACK E PIG 2 E JI 8 W150 GPTI8BK W98 GPTI8PK BU g LOWER S4 W135 GPTI8BK W139 GPTISBK NJ L WI40 GPT18BK W134 GPTI4BK PI WI46 GPTI8BK SPII O W99 GPTISW START PIT SOLENOID w A W147 GPTI4BK e B WI49 GPTI8BK WI53 GPTI8BK PI W154 GPTI6BK RAISE LOWER S2 Ka L 5 W68 I8FL o al SP Es a E B a aa oO CO gt A c5 2 O o B WI5I GPTI8BK co a ES d nds o o Ka m PI2 RAISE 3 T 3 S E W84 GPTISY 4 A ups c A T T W106 GPTI8W_BU B NI59 GPTI8BU R l 0 VEG NEUTRAL SWITCH B W158 GPTISBK P31 E 7 ORIFICE S6 Serial Number 230000801 amp Up il W100 GPI16V10 A Kr W69 GPTIAR A V 2 W70 GPTI4PK W103 GPTIBW G JOYSTICK 3 LOWER 4 W128 GPTI6T WI16 GPTIBOR BK FRUTA 5 W71 GPTIA4OR in P14 6 W19 GPTI8Y 7 W72 GPTIAGN SP4 A P28 8 W75 GPTI8BU B fe W73 GPTIAW W92 GPTI8BU FUSE BLOCK MOW SWITCH 2 W83 GPTIBY SP3 SS W96 GPTI8GY W95 GPTI8GY JOYSTICK E IURE N97 GPTI6W 3 N94 GPTI8W Sr liga A 3 AE oo O ES a S gt pA 5 A A B C D 2 3 4 5 6 7 8 A B C A B C D 6 A B 2 A B A 8 P34 J13 J14 P21 J9 JI2 P26 P21 P22 P23 P24 P25 G
104. Bedbar Removal and Installation C Complete cutting unit set up and adjustment se quence see Cutting Unit Operator s Manual Reel Grinding Specifications Nominal Reel Diameter 5 06 in 128 5 mm Service Limit Reel Diameter 4 56 in 118 8 mm Relief Angle Range 20 to 40 Blade Land Width 0 040 in 1 0 mm Land Width Range 0 030 to 0 060 in 0 7 to 1 5 mm Service Limit Reel Taper 0 040 in 1 0 mm BLADE RELIEF ANGLE LILL bi REEL DIAMETER TAPER D3 Figure 24 Greensmaster 3150 Page 10 19 Dual Point Adjust 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 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
105. E RAISE RELAY K6 ii C M Ta H A e Un ES ere eke AA ee A A E Page 11 5 o qiio cte anc AE 4 2 Greensmaster 3150 99 80 9330 Run 4 ALARM E Serial Number 230000801 amp Up Shown Ww Power Current Control Current kp amd md GY 83 2280 Current Direction 1 SECOND CLOSED DURING y GY DELAYON A HYDRAULIC FLUID LEAK STARTER Ei HOURMETER St dae R Y zi Taas LIGHTS 1 F1 20A F2 10A jj OPTOMAN ae i 3 vh ly LIGHTS 2 BE LIGHT TEST SWITCH OPTIONAL FUSIBLE LINK SEC 522 iuc liii E SS gt 2323S52 gt Eg VIO Y BU 99 7430 emcee o8 ju BACKLAP RELAY K7 BK A PK BU PK BU Naa T l0 FX TU NG 85 JJ 86 BS O a gt ASA e e Lac e BBY VY nee d i A A W 1 A r NEUE T W BU MES AN OR BK 0 87 P31 A OTRO STARTER SWITCH Ue ane K2 BACKLAP d 87a 85 WAV 86 ES SOLENOID pk IGNITION SWITCH Y H EMO ecco s v D1 A K 99 7430 GN R CY OFF RUN START OPTIONAL BU BK s 87 81 Beh m 2 C Se ORBBK KZ ENGAGE V ah Ei ai TER i y MOW RELAY K4 i Ka SWITCH BRAKE sek i eet PR F4 10A IA See LM Ll ON POSITION 2 MB eme to yy E p D1 D o 1 D 7 y JOYSTICK Er OR BK o BU BK KI LOWER 2 F MOW SWITCH E 88 9830
106. ELAY REELS AB ALI Ba DA P21 amn P9 2 TEST LIGHT pal af a DIODE 3 aS SWITCH A B xc ay HGFEDCBA a P10 MOW RELAY K4 2 E s P17 B A P19 P1 DIODE PACK J1 RAISE LOWER ORIFICE HOURMETER JOYSTICK RELAY K3 ALARM B SOLENOID S2 SOLENOID S6 Serial Number 230000801 amp Up P22 a Baan ya n A B LEAK DETECTOR lam al EM SOLENOID E J2 T P16 STARTER SOLENOID LOWER m SOLENOID S4 B A P25 LEAK DETECTOR Greensmaster 3150 Electrical Harness Drawing Page 11 11 IGNITION SWITCH J10 P30 X Y A BS L p LI 2 3 4 5 a pa 2 a et lo E E oO D D S ME SP gt eo be a D co gt pa ona Q a Oo iC h pr D IT ES E o Oa r me oo gt A 8 OC OD A P26 INTERCONNECT m WI3 GPTI8GY_BK W72 GPTIS86N BK W70 GPTISBU r W14 GPTI8GN_G
107. EST NO 1 Traction Drive Hydrostat P3 Flow Using Tester with Flowmeter and Pressure Gauges HOSE FROM UPRER FITTING f4 E P i gt 3 2 Y a lle TRACTION WHEEL MOTORS AAA OPTIONAL E uM A M REAR WHEEL 3WD fi 2044 7771 MOT aut x me AA f K y k y i r a NE TESTER V HIFO DUMP VALVE TOP BOTTOM RS BK B X O R4 FROM GEAR PUMP P2 BLEED 200 250 VALVE PSI J High Pressure ete Low Pressure Y TO HYDRAULIC Wee I eeu ea TA Return or Suction RESERVOIR gt e Hydraulic System Page 4 22 Greensmaster 3150 Procedure for Traction Drive Hydrostat P3 Flow Check This test measures hydrostat pump output flow Dur ing this test pump load is created at the 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 t
108. Figure 20 1 Main hydraulic tank 2 Float switch Figure 21 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 S2 and S3 are energized through Raise relay H5 Diode D3 Th
109. Flow and Implement Relief Valve R5 Pressure Test No 5 Lower Cutting Units Relief Valve A A lee ad aee eo Test No 6 Gear Pump P1 Flow Test No 7 Mow Circuit Relief Valve R1 PIOSSHIO pocas heen tate da bird da Test No 8 Reel Motor Case Drain Flow Test No 9 Steering Control Valve ADJ USTMENTS Adjust Manifold Relief Valves R1and R2 Greensmaster 3150 Page4 1 Rev C Chapter 4 Hydraulic System SERVICE AND REPAIRS s enne 41 General Precautions for Removing and Installing Hydraulic System Components 41 Gean NM Dad EA 42 Gear PUMP SENICE dea ie PC ERES 44 Hydraulic System Start up 45 Hydrostatic Transmission sees 46 Piston Pump Service s eee eae 49 Piston Pump Crush Ring Replacement 50 Wheel Motors ccc aaa 51 Wheel Motor Service ccc cee ees 55 Flush Hydraulic System 56 Reel Motors ces 57 Reel Motor Service 0 aasa 59 LITE CDS cidad Ne ER e t 62 Lift Cylinder Service Serial Number Under 240000000 asirio 64 Lift Cylinder Service Serial Number Above 240000000 pirrer en REOR CR e ee daa 66 Hydraulic Manifold oo oooooooomo o o 68 Hydraulic Manifold Service 70 Backlap Kit Optional 72 Rear Lift Cylinder Flow Control Valve 15 Steering Control Valve ooooooooo 7
110. K 3 KILL RELAY K1 posto tts 86 WU BK idein ee 2 6 6 SECOND ENGINE AN Sia DELAY OFF MAGNETO 87 lp 4 VIO N 30 FUSIBLE LINK IC 99 7430 ALTERNATOR W 89 2430 Jb a ars Es NG SP 85 UUU 86 FUEL SOLENOID Y W BK PAM Y T Y 30 pu tA S4 MTS 872 D2 REIS LOWER RELAY K5 y LOWER 1 A 2 B i VIO BK MY S2 y RAISE LOWER _ 99 7490 UA 2 8 BK 87 4857 BUR 4 MAGA S3 85 aN GY TTT 88 P RAISE RELAY K6 BK BK Page 11 3 LEAK DETECTOR SOLENOID Greensmaster 3150 Y aa EP T Electrical Schematic Ww All relays and solenoids are shown as de energized BU ae GY i 83 2280 LEAK DETECTOR 1 SECOND CLOSED DURING GY DELAY ON HYDRAULIC FLUID LEAK STARTER MO HOURMETER 2 2 v 1 BU Ts 3 LIGHTS 1 F1 20A F2 10A OPTIONAL c 5 hko ANA 6 9 T VB SP 0 W g
111. Model 26000 Multiple Gear Pumps at the end of this chapter Hydraulic System Page 4 44 Not used Back gear Washer Plug Suction fitting Washer Shaft seal Greensmaster 3150 Hydraulic System Start up Note When initially 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 if necessary 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 Disconnect electrical connector to the fuel stop so lenoid to prevent the engine from starting 5 After repairs check control linkage for proper ad justment binding or broken parts 6 Make sure traction pedal is in neutral and the cut ting unit switch is off Turn ignition key switch engage starter for fifteen 15 seconds to the prime pump 7 Reconnect electrical connector to the fuel stop sole noid
112. O1 eg so Sel gg E HOLOW T33HM a cd SANIVA NOILOVH L dVIMOVE GME TYNOLLdO SHAGNITAO 147 IWNOILdO ps 32018 GIOsINVW A quvMHod Holy woog MOM lt i uogong JO uleH oy ley almssalig MO ainssaidq UBIH 6 3 g V SIN pazibiaus ap se 1331 INOLLOS mM SHOLOW 133HM NOILOVH L uonisod pezibJeuo ay ui UMOUS SI S Spiou9gJos UMOYS Qf L080000 2c JequinN elas MOIN 0GS LE Je1seuisueaJrc SHOLONTSSH Lo lt Greensmaster 3150 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 reservoir 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 of the steering wheel po
113. Operator s Manual for adjustment pro self sharpening action This feature maintains sharp cedures for the cutting units on the Greensmaster 3150 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 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 support tubes 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 Coat spline shaft of the motor with clean No 2 multi purpose l
114. Page 4 39 n Wena E M TU LL t 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 wheel to 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 of the 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 steering problem exists and steering cylinder tested acceptably steering control valve requires ser vice See Steering Control Valve and Steering Control Valve Service Hydraulic System Sg FE EZ Se IO Adjustments Adjust Manifold Relief Valves R1 and R2 These relief valves are installed on the hydraulic man ifold Relief valve R1 is in the mow circuit 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 of the valve with the cap off Personal injury may result Always install the cap and tighten before pressurizing the system 1 Locate relief
115. Rev A Greensmaster 3150 TORO Table of Contents Chapter 10 1 Groomer DPA Cutting Unit SPECIFICATIONS ee In SERVICE AND REPAIRS 0005 7 GENERAL INFORMATION 0 Groomer Belt Replacement 7 Transport Mode 0 0 cece ene eee Groomer Reel a 8 TROUBLESHOOTING 2 eed n Rn tms Groomer Reel Service 11 Factors Affecting Grooming Groomer Reel Bearing Replacement 12 Groomer Reel Mechanical Problems Idler ASSembly 2 p bd pce He eoe 14 ADJUSTMENTS 323235321 dadas Lift Arm Assembly 00 cece eee 15 Height Depth of Groomer Adjustment Groomer Brush eeu 16 Greensmaster 3150 Page 10 1 1 Groomer DPA Cutting Unit Rev A E pao c E O a 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 inch 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 ADJUSTMENT KNOB Allows a 0 003 inch 0 08 mm increment of h
116. SE RELAY K6 BK Page 11 4 LEAK DETECTOR SOLENOID Greensmaster 3150 fTTYY Be O a 80 9330 C ran k F ALARM Serial Number 230000801 amp Up Shown W Power Current Control Current i m mg 83 2280 b a Current Direction LEAK DETECTOR 1 SECOND CLOSED DURING GY DELAY ON nna HYDRAULIC FLUID LEAK STARTER i lt 1 HOURMETER 2 ye Bu Ba LIGHTS 1 ET A F120A F210A P OPTIONAL gt R T sue 1 7 yE W LIGHTS 2 BK LIGHT TEST SWITCH OPTIONAL FUSIBLE LINK gue sa ee a Vie e ao J o o Y n BU 99 7430 A anO a Qo o8 ju BACKLAP RELAY K7 T Ba Pee res E a a cc a cad lc RE kaa E 4 a O 11 1 BK gt 1 O H AA A A E CES cut TE o m w 1 A pu z gt r W BU z gt NN mz pata 99 7430 STARTER switcH START SAFETY EN BACKLAP Gai UU se BK SOLENOID px IGNITION SWITCH
117. SF IO 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 11 Hose assembly 12 Hose assembly 13 45 hydraulic fitting or oe Ww IE 14 15 16 17 18 19 20 21 22 23 24 25 Figure 38 Hose assembly 90 hydraulic fitting O ring O ring Tube assembly 90 hydraulic fitting O ring O ring Hose assembly Straight hydraulic fitting Hose assembly Hose assembly 26 27 28 29 30 31 32 33 34 35 36 37 A FRONT RIGHT Serial Number 230000801 amp Up 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 R 1 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 Page 4 68 Rev C Greensmaster 3150 Removal Fig 38 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
118. SI 7 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 or replace relief 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 TEST NO 5 in this chapter 9 f testing is complete disconnect tester from the pump and hose Reconnect hose to the pump Hydraulic System Lc E 2 SF IO TEST NO 5 Lower Cutting Units Relief Valve R2 Pressure
119. STMENT 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 e Remove burrs nicks and rounded edges 3 Visually check groomer reel for wear and damage Straighten bent blades e Replace worn blades or reverse groomer reel to put sharpest blade edge forward e 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 1S FELT AND HEARD THEN TIGHTEN ONE 1 MORE CLICK TO GET LIGHT CONTACT e No contact will dull the cutting edges Excessive contact accelerates wear quality of cut may be adversely affected It is 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 w
120. 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 reel 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 ee Qu nj sus mm J n Bedbar Removal and Installation 1 Remove rear roller assembly 2 Remove capscrew and nut anchoring the rear roller height of cut bracket
121. TORO Preface The purpose of this 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 Space is provided in Chapter 2 of this book to insert the Operator s Manuals and Parts Catalogs for your machine Replacement Operator s Manuals and Parts Catalogs are available by sending complete Mod el and Serial Number to The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 1196 The Toro Company reserves the right to change product specifications or this publication without notice Part No 03113SL Rev C Service Manual Greensmaster 3150 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 portant instructions which must be followed to pre vent damage to systems or components on the machine uk m 2 o The Toro Company 2003 2004 2005 2006 This page is intentionally blank Greensmaster 3150 Table Of Conten
122. TS POWER STEERING VALVE gt TO TRACTION CHARGE CIRCUIT R5 TO LIFT CIRCUIT M HYDROSTAT GEAR PUMP High Pressure Low Pressure Return or Suction Y Flow Hydraulic System Page 4 28 Greensmaster 3150 Procedure for Gear Pump P2 Flow Check 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 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 soeed 2850 50 RPM 7 Watch flow and pressure gauges carefully while Slowly closing the flow control valve on the tester until the pressur
123. WER RELAY K5 y i ates l oak frm Y Y RAISE LOWER y D3 ae Y BU R 99 7430 Ue he S6 D m eee um BU R ema P i S3 HL evev SMS REELS RAISE RAISE RELAY K6 ES Ls M T e PAA QQ e P A AA Page 11 10 N A 0 00 el A P11 FUSE BLOCK J9
124. Y E WII GPTI8GN_BK W68 GPTISY W69 GPTI8W TER P21 INTERCONNECT 2 P29 SEAT SWITCH BACKLAP HOUR METER KILL RELAY KI START SAFETY K2 JOYSTICK RELAY K3 MOW RELAY K4 LONER RELAY K5 RAISE RELAY K6 OPTIONAL JII P31 PI P2 P3 P4 P5 A B 2 3 2 3 4 5 2 3 4 5 2 3 4 2 3 4 5 4 5 2 a a z i 3 3 i 3 3 3 18 z E 5 WE E 5 eo PEN E eo eo Eus co gt 2 a W132 GPTI8BU_BK F W122 GPTI8W BK W123 GPTI8W BK A W127 GPTI8VIO BK B Cm W126 GPTISVIO BK J4 DIODE 2 WI13 GPTI8PK_BK W129 IGPTI8NIO Serial Number Under 230000801 LOAD 1 SP6 KA W124 GPTISBU R hi W125 GPTISBU_R CHONG B WI14 GPTISOR_BK NI TIME DIODE 3 DELAY O WI21 GPTI8GN_R 323 REELS db WI12 GPTI8GN_GY o PIO a WIOI GPTI8GN BK 2 13
125. a miliar with Precautions for Hydraulic Testing 3 Disconnect hose connection 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 to allow clearance between bedknife and reel no contact 6 If a backlap kit is installed make sure backlap knob on the hydraulic manifold is in the mow position Make sure reel speed knob FC1 is set to highest speed set ting fully open A CAUTION Keep away from reels during test to 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 Watch pressure gauge carefully while slowly clos ing the flow control valve on the tester to fully closed 9 System pressure should be from 2160 to 2640 PSI 149 to 182 2 bar Note If a dethatching kit is installed system pressure should be from 2700 to 3300 PSI 186 3 to 227 7 bar Record test results A If specification is not met shut off engine and adjust relief valve R1 Fig 11 see Adjust Man ifold Relief Valves in the Adjustments section of this Chapter After adjustment retest relief valve R1 pressure B If this specification is met go to step 10
126. age cutting units by positioning functional control lever to NEUTRAL position Open control valve on tester and stop the engine 11 Measure the amount of oil collected in the container Divide the number of ounces collected by 32 to get gal lons per minute divide the number of milliliters collected by 250 to get liters per minute use chart in Fig 12 Re cord test results 12 If flow was greater than 0 25 GPM 1 0 LPM repair 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 Reconnect case drain hose to the bulkhead fitting Test other reel motors as needed MRE aT Gaman Figure 12 Hydraulic System Ze E e5 ER IO TEST NO 9 Steering Control Valve STEERING CYLINDER CYLINDER ROD FULLY EXTENDED PLUG O POWER STEERING VALVE LEFT TURN High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 38 Greensmaster 3150 Procedure for Steering Control Valve Check 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 vibration in the steeri
127. aintenance Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 16 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 9375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11116 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 71 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 04 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 7 544 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 084375 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 3
128. ak 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 Disconnect hose assembly from the reel motor case drain fitting located below the right side of the frame Al low hose to drain to a suitable container Fig 52 6 Disconnect return hose 16 from hydraulic barb fit ting at tank Allow hose to drain to 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 Inspecting Reservoir Parts Fig 51 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 Greensmaster 3150 Page 4 87 Rev C Figure 52 Installing Hydraulic Reservoir Fig 51 1 Place antiseize lubricant into all three inserts at the bottom of the hydraulic tank 6 Position tank onto the vehicle frame 2 Secure hydraulic tank to the vehicle frame with three cap screws 19 flat washers 20 and spacers 22 Torque cap screws from 30 to 60 in Ib 3 4 to 6 8 Nm 3 Secure return hose 16 to hydraulic barb fitting at tank 4 Secure pump inlet hose to hydrostat with hose clamp Fig 52 5 Connect hose assembly to reel motor case drain fit ting located below the right side of the fram
129. aking care not to 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 lb 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 secure 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 be
130. al 7 Connect and adjust the throttle control cable see Adjusting the Throttle Control in the Traction Unit Opera tor s Manual 8 Connect fuel hose 3 Fig 3 to the carburetor with hose clamp 18 Fig 3 Install the fuel hose support clamp 11 Fig 3 9 Open fuel shut off valve 15 Fig 3 and fill fuel tank with fuel see Filling Fuel Tank in the Traction Unit Oper ator s Manual Check fuel hose for leaks 10 Start the engine and check for proper operation Engine This page is intentionally blank Engine Page 3 8 Greensmaster 3150 TORO Table of Contents SPECIFICATIONS GENERAL INFORMATION 0 0 00a Ayarallle HOSES usaron adams Hydraulic Fitting Installation HYDRAULIC SCHEMATICS aaa HYDRAULIC FLOW DIAGRAMS Traction Forward and Reverse Raise and Lower Cutting Units Mow and Backlap 0 cece eee eee eee Right and Left Turn SPECIAL TOOLS Hydraulic Pressure TestKit Hydraulic Tester P ressure and Flow Hydraulic Test Fitting Kit Measuring Container aaa Wheel Hub Puller oooooooomom o o TROUBLESHOOTING cece eee TESTING Precautions for Hydraulic Testing Test No 1 Traction Drive Hydrostat P3 Flow Test No 2 Wheel Motor Efficiency Test No 3 Charge Relief Valve R4 Pressure Test No 4 Gear Pump P 2
131. al does not depress the inter lock system is operating correctly Correct problem if not operating properly 2 Sit on the seat engage parking brake keep traction pedal in neutral and place Functional Control Lever in MOW or TRANSPORT Try to start the engine If the en gine does not crank the interlock system is operating correctly Correct problem if not operating properly 3 Sit on 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 Sit on 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 Sit on the 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 Sit on the seat and set the parking brake Start the engine and move the functional control lever to MOW If the engine stops the interlock system is operating cor rectly Correct problem if not operating properly Greensmaster 3150 Battery Service The battery is the heart of the electrical system With r
132. ams System Operation s usus 5 4 Troubleshooting UVA sia a AN a 5 5 Electrical Schematics Wiring Diagrams and Electrical System Quick Checks 5 8 Harness Drawings oes Component Testing IN Service and Repairs 5 18 Electrical Diagrams Greensmaster 3150 Rev A This page is intentionally blank Greensmaster 3150 Chapter 1 TORO Safety Table of Contents SAFETY INSTRUCTIONS a Ge nd Lido a hee 2 Maintenance and Service 4 Before Operating 00 ccc cece ees 2 SAFETY AND INSTRUCTION DECALS 4 While Operating llle 3 Greensmaster 3150 Page 1 1 Safety Safety Instructions The GREENSMASTER 3150 was tested and certified by TORO for compliance with the B71 4 1990 specifica tions of the American National Standards Institute 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 qui
133. an 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 6 Page 4 73 Rev C 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 operation and sealing B Thread valve carefully into the applicable port RD1 or FC1 The valve should go in easily without binding Torque valve to 35 ft Ib 47 Nm 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 o
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135. ashers 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 e Use newspaper as a feeler gauge e Dot on eccentric bolt must face rear of mower e Turn bedknife adjustment knob to hold paper on right hand end of bedknife e Turn eccentric left bedbar bolt to hold paper on left hand end of bedknife e Hold eccentric bedbar bolt while securing locknut 2 Adjust rear roller parallel to reel eccentric bolt faces to rear 3 Check grass shield adjustment e 4 3 4 in from crossbar normal e Dry grass lower shield e Wet grass raise shield 4 Set top bar cut off bar adjustment e 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 Replace 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 notch
136. 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 27 Rev A 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 A dynamic 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 15 from initial test reading Step 6 above A pres sure drop of more than 1596 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 TESTS NO 1 and 2 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 Sg E E SF IO TEST NO 4 Gear Pump P2 Flow and Implement Relief Valve R5 Pressure Using Tester with Flowmeter and Pressure Gauges Mii Aud wit i Aw AUAM a kee ct po m aa ut WW ES y LY B PSP Ig TO REEL MOTOR CIRCUIT TO STEERING AND LIFT CIRCUI
137. bar Removal and Installation in this section of the book Figure 30 1 Bedbar end bushing 2 3 Flange bushing 4 2 Bedbar pivot bushing 2 Repairs Page 8 22 Figure 31 Figure 32 Figure 33 Greensmaster 3150 Bedknife Replacement 1 Do steps 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 Do steps 1 4 under Bedbar 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 remov
138. belt 4 Groomer driven pulley 2 Drive belt idler pulley 5 Clutch assembly 3 Grooming reel adjustment 6 Groomer ree housing knob assembly Figure 10 1 Clutch adapter shaft 2 Reel shaft and bearing adjustment nut 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 Figure 11 4 Loosen jam nut on left hand bedbar pivot bolt so bolt can be turned Left hand pivot bolt eccentric bolt has 1 Bedknife adjusting knob 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 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 180 position when adjusting 5 Rotate left hand eccentric pivot bolt to raise or lower bedba
139. 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 If a backlap kit is installed on the machine make sure backlap knob on the manifold block is in the mow position and reel speed is set to maximum 6 Make sure tester load valve is fully open before starting the engine Greensmaster 3150 Page 4 33 A CAUTION Do not engage 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 te
140. ckly A replacement manual is available by sending complete Model and Serial Number to The Toro Company Attn Technical Publications 8111 Lyndale Avenue South Minneapolis Minnesota 55420 1196 2 Never allow 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 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 Safety Page 1 2 The safety alert symbol means CAUTION WARNING or DANGER personal safety instruction Read and under stand the instruction because it has to do with safety Failure to comply with the instruc tion may result in personal injury A 4h WARNING To reduce the potential for injury or death comply with the following safety instructions 6 Wearing safety glasses safety shoes long pants and a helmet is advisable and required by some local safety and insurance regulations 7 Make sure work area is clear of objects which might be picked up and thrown by the reels 8 Donot carry passengers on the machine Keep ev eryone
141. conditions such as excessive thatch Adjustments and Repairs sections for detailed adjust sponginess or attempting to cut off too much grass ment and repair information height may not always be overcome by adjusting the Factors Affecting Quality of Cut 1 Tire pressure Possible Problem Correction Check tire pressure adjust to specification if necessary Must be equal in two front tires 2 Engine governed speed Check maximum governed engine speed Adjust to specification if necessary affects reel 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 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 installin
142. cy 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 lift arms pull frames for binding bushing wear or damage Repair if necessary All rollers must rotate freely Grease when needed or repair bearings if necessary 14 Roller condition 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 15 Reel speed See Troubleshooting in Chapter 5 Hydraulic System Check maximum governed engine speed Adjust to specification if necessary 16 Traction speed 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 See Troubleshooting in Chapter 5 Hydraulic System 17 Cutting drop speed and sequence Troubleshooting Page 7 6 Greensmaster 3150 Set Up and Adjustments Adjustment Summary and Check Li
143. d 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 not drive 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 discharge area The grass baskets must be in place during operation of the reels or thatch ers for maximum safety Shut the engine off before emp tying the baskets Greensmaster 3150 Page 1 3 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
144. d Fuse block or fuse is faulty Solenoid valve S1 is faulty Mow switch and or mow relay K4 is faulty or grounded Raise or lower switch and or joystick relay K3 is faulty or grounded Cutting units will not raise Wiring to raise circuit components see Wiring Schematics is loose corroded 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 Cutting units will not lower Wiring to lower circuit components see Wiring Schematics is loose corroded or damaged Fuse block or fuse is faulty SE 2 on o A LLI 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 K5 is faulty Greensmaster 3150 Page 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
145. d Piston Lock nut Barrel REAR HYDRAULIC CYLINDER Head Rod Piston Lock nut Barrel Greensmaster 3150 Disassembly 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 not close 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 surface before mount ing in a vice 4 Mount shaft securely in a vise by clamping on the cle vis or eye of the 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 Reassembly 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 Greensmaster 3150 Page 4 65 IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surface before mount ing in a vice 3 Mount shaft
146. d 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 work on the hydraulic system all pressure in the system must be relieved and all rotating machine parts must be 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 cause serious injury If fluid is injected into the skin it must be surgical ly removed within a few hours by a doctor famil iar with this type of injury Gangrene may result from such an injury Greensmaster 3150 Page 4 21 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 Put metal caps or plugs on any hydraulic lines left open or exposed during testing or removal of compo nents 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 The inlet and the outlet hoses must be properly con nected and not reversed tester with pressure and
147. d 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 7 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 brackets 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 sc
148. d 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 e 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 VE MORE CLICK TO GET LIGHT CONTACT e No contact will dull the cutting edges e Excessive contact accelerates wear quality of cut may be adversely affected It is 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 setting Monthly Adjustments NOTE Remove cutting unit from traction unit Set Up and Adjustments Page 8 8 1 Parallel bedknife to reel e Use newspaper as a feeler gauge e Dot on eccentric bolt must face rear of mower e Turn S P A adjustment knob to hold paper on right hand end of bedknife e Turn eccentric
149. dbar 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 Replacement 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 cated at center of bedbar Adjustment knob contains detent with 001 in movement of bedknife for each in dexed position Pivot point at top of bedbar is grea seable Model No Clip max of Cut Range 04468 0 25 in 3 16 to 5 16 in Reel Speed 1940 rpm engine speed 2800 rpm 04450 0 18 in 1 8 to 7 82 in Bedknife Screw Torque 200 to 250 in Ib 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 Reel Splined Drive Nut Torque 40 to 60 ft lbs Reel Bearing Rolling Torque 7 in Ib max Front or Rear Roller Run Out 0 014 in max Bedknife to Reel Adjustment Bedknife adjusts against reel with positive adjustment control knob lo 1 Lift bail 4 Pull rod studs 7 Heignt of cut brackets 2 2 Height of cut adjustment knob 5 Grass shield 8 Be
150. djust 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 betweentop 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 NO ls O SIE pe nt A A ii Nore ud teri LET APA ma Ea ES ti a NAIS ST 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 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 baske
151. dknife adjusting knob 3 Height of cut adjustment locknut 6 Reel Greensmaster 3150 Page 8 3 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 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 DO NOT use an air impact wrench with this tool Figure 5 Greensmaster 3150 Page 8 5 Special Tools Troublesh
152. e Fig 52 6 Connectoil level sensor harness connector 7 Install leak detector assembly see Leak Detector Installation in this chapter of this manual Hydraulic System o e Tam O gt This page is intentionally blank Hydraulic System Page4 88 Rev C Greensmaster 3150 TORO Table of Contents ELECTRICAL SCHEMATICS SPECIAL TOOLS TURF GUARDIAN LEAK DETECTOR SYSTEM OPERATION TROUBLESHOOTING Starting Problems General Run amp Transport Problems Cutting Unit Operating Problems ELECTRICAL SYSTEM QUICK CHECKS Battery Test Open Circuit COMPONENT TESTING Ignition Switch Hour Meter Relays Solenoid Valve Coils Greensmaster 3150 Chapter 5 Electrical System 2 Seal SWIIGN esos bina e 11 3 FUSE BIOCK 2a pama KAKA a io 11 Neutral and Mow Switches 12 4 Parking Brake Sensor 13 5 Joystick Raise and Lower Switches 14 5 Backlap Switch Optional 14 6 Lower Reels Time Delay 15 7 Leak Detector Alarm and Delay Timer 15 8 Leak Detector Float Switch 16 8 Leak Detector Solenoid Valve 16 9 DIOGOGS cuarta bo 17 9 SERVICE AND REPAIRS 18 9 Verify Interlock System Operation 18 10 Battery Service 0 ccc eee 19 10 Page 5 1 Electrical System SE Zg on o LLI Electrical Schematics The electrical schematic and
153. e 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 Chap ters 7 8 9 or 10 Cutting Units in this manual 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 contamination Hydraulic System Page 4 58 Installation Fig 28 1 Inspect threads 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 Cutting
154. e connection is opened 3 Lubricate the O ring with a light coating of oil 4 Put the tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight 5 Mark the nut and fitting body Hold the body with a Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved by stopping the engine and low ering or supporting the reels and or other attach ments Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pres sure 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 removed within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Nut Figure 1 wrench Use another wrench to tighten the nut to the cor rect flats from finger tight F F F T The markings on the nut and fitting body will verify that the connection has dod been tightened RHOD Mark Nut Size F F F T and Body 4 1 4 in nominal hose or tubing 75 25 Extend Line du 6 3 8 in 751 25 8 1 2 in 75 25 10 5 8 in 1 00 4 25 Finger Tight After Proper Tightening 12 3 4 in 751 25 16 1 in 75 4 25 Figure 2 Hydraulic System Page4 4 Greensmaster 3150 SAE Straight Thread O R
155. e 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 doi i E s E num side plates ade 34 kg Dual Point Adjust Cutting Units Page 10 2 Greensmaster 3150 Special Tools OTC Owatonna Tool Company supplies special tools for servicing Toro Commercial Products The TORO SPECIAL TOOLS AND APPLICATIONS GUIDE shows service tool applications Gauge Bar Assembly Used to verify height of cut Toro Model Number 13 8199 Backlapping Brush Assembly Used to apply lapping compound to cutting units while keeping the operator s hands at a safe distance from the rotating reel Toro Model Number TOR299100 Bedknife Screw Tool This screwdriver type bit is made to fit Toro bedknife at taching screws Use this bit with a torque wrench to se cure the bedknife to the b
156. e gauge reads 800 PSI 55 2 bar 8 Minimum flow 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 P 2 Procedure for Implement Relief Valve R5 Pressure Check Do not allow pressure to exceed 1400 PSI 82 8 bar 1 Measure and record charge relief valve R4 pres sure see TEST NO 3 Charge Relief Valve R4 Pres sure Check in this chapter 2 Use same tester connections as described above steps 3 and 4 Fully open control valve on the tester Greensmaster 3150 Page 4 29 Rev C 3 Start and 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 R 5 is in series with charge relief valve R4 R4 pressure will affect R 5 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 if the charge re lief valve pressure is 100 PSI the implement relief valve R5 pressure should be 1150 to 1350 P
157. e nominal torque values listed above for Grade 5 and 8 fasteners are based on 75 of the mini mum proof load specified in SAE J429 The tolerance is approximately 10 of the nominal torque value Thin height nuts include jam nuts Greensmaster 3150 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Class 8 8 Bolts Screws and Studs with Thread Size Regular Height Nuts Class 8 or Stronger Nuts M5 X 0 8 57 5 in lb M6 X 1 0 96 9 in Ib M8 X 1 25 M10 X 1 5 M12 X 1 75 M16 X 2 0 M20 X 2 5 Note Reduce torque values listed in the table above by 2596 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite 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 Page2 5 Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 640 60 N cm 885 80 N cm 1018 100 N cm 133 13 in lb z 1500 150 N cm 19 2 ft lb 26 3 N m 27 2 ft lb 36 3 N m 38 4 ft lb 52 5 N m 53 5 ft lb 72 7 N m 66 7 ft lb 90 10 N m 92 9 ft lb 125 12 N m 166 15 ft lb 225 20 N m 229 22 ft lb 310 30 N m 325 33 ft lb 440 45 N m 450 37 ft lb 610 50 N m on the fastener size the aluminum or base material strength length of thread e
158. e 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 Ib 95 to 122 Nm 2 If the 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 nut to 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 a new cotter pin 27 H Remove fuel tank support and lower tank onto frame Apply antiseize lubricant to the threads of the
159. e 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 Dosteps 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 o SDN 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 men 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 Fig 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 on 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 Unscre
160. e 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 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 ed
161. e with an inch pound torque wrench Fig 7 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 Page 7 8 Greensmaster 3150 nn 5 5 5 5 5 5 5 5 5 555 5 55 5 5 n 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 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 bal Mya BROKEN reel make sure that both D Meee O the top and the bottom adjustment screws are secured Io a AA at both ends of cutting unit Fig 8 9 E 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 It should be possible to 2 Bedknife further from reel 5 Bedknife cut paper with minimum con
162. eMJ0 UOHnoeJ NET OSLE 4e1seulsueeirc SHOLOW 1338 bt 1 1S1SOHGAH TA 37101 HDIH 0882 amp 37101 MOT 0091 dl dd dl e g INOLLOS INIYA diNnG HOLOIN 133HM NOILOVEL CAME IVNOLLAO GYVMHOS Holy YN nollog 1331 WOLLOG SHOLOIN 133HM NOILOVEL Hydraulic System Page 4 9 Greensmaster 3150 Raise and Lower Cutting Units The gear pump P 2 is directly coupled to the hydrostat through gear pump P 1 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 P 2 takes its suction from the hydraulic reservoir Maximum circuit pressure is limited by relief valve R5 During cutting unit hold not raising or lowering condi tions flow from the 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 units are to be raised solenoid valve 52 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 cyl inder piston
163. eaks Shut off engine and cor rect leaks if necessary Check oil level in hydraulic reser voir and add correct oil if necessary Hydraulic System Sg E E SF IO Gear Pump Antiseize Lubricant 27 to 31 ft lb 37 to 42 Nm Figure 15 1 Pump inlet hose 6 O ring 11 O ring 2 Gear pump 7 Hose clamp 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 Page 4 42 Greensmaster 3150 Removal Fig 15 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 fittings and O rings from the gear pump 7 Support gear pump Separate gear pump from the hydrostat by remov
164. eal 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 Pack the bearing 12 with Mobil High Temperature HP or equivalent grease Insert the bearing into the side plate until it is against the bottom of the bore 7 Pack the 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
165. earing 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 Pack the bearing 12 with Mobil High Temperature HP or equivalent grease Insert the bearing into the side plate against the wave washer 7 Press the retaining ring 14 into the groove slightly compressing the bearing and wave washer 8 Pack the 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 Remove 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 s
166. eck 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 positioning 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
167. ecu t E a A an E A a RENS IM ics ie ABN ge J Page 11 7 o 3 FRAME GROUND GROUND LEAK DETECTOR SOLENOID Y BK A s5 Greensmaster 3150 C ALARM Lower Reels 6 seconds w Serial Number 230000801 amp Up Shown Power Current p arf IG GY 83 2280 Control Current LEAK DETECTOR 1 SECOND gt Current Direction CLOSED DURING yo DELAY ON HYDRAULIC FLUID LEAK STARTER HOURMETER gt 2 A R y xis EET LIGHTS 1 F1 20A F2 10A 4 OPTIONAL 5 yo 4 N ANA R L Sy l w LIGHTS 2 Bie LIGHT TEST SWITCH OPTIONAL FUSIBLE LINK LJ am A o gt D A A A A L a a A A ara mma D Tr e gt a AA a a A A A mara ma A D A das gt VIO vi Al enm A A NES 87a ji BACKLAP RELAY K7 BK PK BU PK BU d 87 Vio gt 00 BK
168. ed spacers Install locknut on each end of groomer shaft to secure blades and spacers NOTE Spacers are available for 1 4 in 76 blades or 3 4 in 26 blades blade spacing Figure 46b 8 Reverse steps 1 5 to install groomer reel Check drive 1 Groomer reel shaft 3 L H groomer housing belt tension before installing cover See Groomer Reel 2 Bearing Drive Belt Replacement in this section of the book Figure 47 1 Groomer reel shaft 5 L H groomer housing 2 Bearing 4 6 Locknut 3 Bearing spacer 2 7 Belt 4 R H groomer housing 8 Driven gear Greensmaster 3150 Page 9 29 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 and clutch pin Fig 51 IMPORTANT The special screw and clutch pin were assembl
169. ed 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 cost of the test equipment and 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 at liters 1 75 1 65 with filter Greensmaster 3150 Page 3 3 Engine Service and Repairs Fuel Tank ANTISEIZE LUBRICANT 20 to 25 ft lb 27 to 34 Nm Figure 3 1 Fuel filter 8 Hose support clamp 14 Fuel hose shut off valve to filter 2 Hose clamp 9 Cap screw 15 Fuel shut off valve 3 Fuel hose filter to engine 10 Cap screw 16 Hose clamp 4 Fuel cap 11 Hose support clamp 17 Fuel hose tank to shut off valve 5 Fuel Tank
170. ed 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 in Ib 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 ft lb 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 Figure 48 1 Belt drive clutch assembly 2 Clutch engage disengage knob 3 Allen head set screw 2 4 Nut and washer 5 Clutch adapter shaft Figure 49 1 Clutch adapter shaft 2 Reel shaft Greensmaster 3150
171. edbar IMPORTANT DO NOT use and air or manual impact wrench with this tool so damage to the bedbar will be prevented Toro Model 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 107 3505 Bearing installation washer yellow 104 6126 Greensmaster 3150 Page 10 3 Rev A Some tools may have been supplied with your mower or available as TORO parts Some tools may also be avail able from a local supplier Figure 2 Figure 3 oe Figure 4 Y Seal Installation Spacer Bearing Installation Seal Installation Washer Washer Figure 5 Dual Point Adjust Cutting Units Bearing and Seal Installer TOR4105 Used to install bearings and seals into front and rear roll ers that have a threaded roller shaft 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 pre
172. eel assembly 13 Valve stem DOLOR ON Greensmaster 3150 70 to 90 ft Ib 95 to 122 Nm a 3 Cr Figure 2 14 Tire 15 Rim 16 Spacer 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 o G D o D c 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 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 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 slotted hex nut 28 securing the steering cylinder rod end 9 to the cas tor f
173. eel 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 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 sc
174. efore 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 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 Instructio
175. egular 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 80 F 26 7 C Discharged less than 1 240 Battery Specifications BCI Group Size U1 300 Amp Cranking Performance at 0 F 17 8 C 28 Minute Reserve Capacity at 80 F 26 7 C Removal Fig 25 and 26 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 battery terminal posts for corrosion Use a terminal brush or steel wool to clean c
176. eight 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 that the 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 the groomer reel in the non grooming position Fig 1 To place the 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 Lift arm 2 Lock screw transport Figure 2 1 Lift arm 2 Lock screw grooming D E O lt a 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 i
177. el Speed 3200 rpm Bedknife Screw Torque 200 to 250 in lb Reel Splined Drive Nut Torque 40 to 60 ft lbs Reel Bearing Rolling Torque 7 in Ib 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 lb Clutch Assembly Locknut Torque 140 in Ib remov ing all end play Lift bail Height of cut adjustment knob 2 Height of cut adjustment locknut 2 Pull rod studs 2 oN o N So Greensmaster 3150 Grass shield Reel Groomer micro adjust locknut 2 Bedknife adjusting knob Page 9 3 9 Groomer reel 10 Groomer clutch snubber 11 Clutch engage disengage knob 12 Groomer quick up down lever Specifications PA A ee TU NA Te A 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 Special Tools Page 9 4
178. embly 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 reel 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 knob assembly 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 in the direct
179. enoid is faulty Engine cranks but should not with the Functional Neutral sensor is out of adjustment faulty or short Control Lever in the MOW or TRANSPORT position circuited General Run and Transport Problems Engine kills when the Functional Control Lever is in the Operator is sitting too far forward on the seat seat MOW or TRANSPORT position with the operator in the switch not depressed Parking brake is set Parking brake switch is faulty Seat switch is faulty Seat switch wiring is loose corroded or damaged Battery does not charge Wiring to the charging circuit see Wiring Schematics components is loose corroded or damaged Voltage regulator alternator is faulty Alternator fusible link is open Ignition switch is faulty Battery is dead Engine kills during operation operator sitting on seat 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 Electrical System Page 5 6 Greensmaster 3150 Cutting Unit Operating Problems Cutting units run but should not when raised Joystick relay K3 is faulty or shorted Solenoid valve S1 is faulty Mow relay K4 is faulty or shorted Mow switch is shorted Cutting units do not run when lowered with the Wiring to run mow backlap circuits components see Functional Control Lever in the MOW position Wiring Schematics is loose corroded or damage
180. er 3150 Factor 12 Stability and position of bedbar 13 Number of reel blades 14 Cutting unit alignment and pull frame ground following 15 Roller condition 16 Reel speed 17 Traction speed 18 Cutting drop speed and sequence Greensmaster 3150 Possible Problem Correction 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 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 C
181. er 3150 Page 4 77 Rev C Hydraulic System Steering Control Valve Service 140 to 160 in Ib 16 to 18 Nm Figure 45 l 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 22 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 45 3 Remove the plug and relief valve Hydraulic System Page 4 78 Rev C 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 9 Carefully slide the spool out of the sleeve The cen tering springs and spring retaining ring will stay
182. er of blades for clip frequency and optimum height of cut range Cutting unit alignment and pull frame ground following Check 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 Up and Adjustments Characteristics 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 Never install or work on the cutting units or lift 1 Adjust the bedknife parallel to the reel arms with the engine running Always stop en gine and remove key first 2 Determine desired height of cut range and install rear roller mounting shim accordingly The dual knob bedknife to reel adjustment system in corporated in this cutting unit simplifies the adjustment 3 Adjust the height of cut procedure needed to deliver optimum mowing perfor 4 Adjust the cut off bar mance The precise adjustment possible with this de sign gives the necessary control to provide a continual See Cutting Unit
183. ersonal injury Greensmaster 3150 Page 10 9 CLOCKWISE Figure 11 1 Directional valve knob 3 Flow control valve knob 2 Ball switch 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 position 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 Service Training Book Sharpening Reel and Rotary Mowers part no 80300SL Dual Point Adjust Cutting Units Bedbar Assembly a 190 to 240 in Ibs Qy 21 to 27 Nm f Antiseize Lubricant Figure 12 1 Side plate 7 Bedbar pivot bolt 13 Cap screw 2 Rubber
184. ervice 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 Figure 25 1 Dirt seal 11 Coupling shaft 2 Bearing 12 Thrust bearing 3 Housing 13 Drive link 4 Back up washer 14 Cap screw 5 Sealrings 15 Commutator seal 6 Back up washer 16 Commutator 7 Inner seal 17 Woodruff key 8 Thrust washer 18 Wear plate 9 Thrust bearing 19 Rotor 10 Bearing Note For repair of the wheel motors see the Ross Torqmotor MG MF MP MB ME and MJ Series Ser vice Procedure Service Manual 2704 003 at the end of this chapter Greensmaster 3150 Page 4 55 20 21 22 23 24 25 26 27 28 o O m Vane Stator Manifold Commutator ring End cover Rotor set Commutator assembly Seal kit Housing assembly Hydraulic System Flush Hydraulic System IMPORTANT Flush the hydraulic system any time there is a severe component failure 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 Before continuing further read and become fa miliar with General Precautions for Removing and Installin
185. es 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 spline nut on right hand end of reel shaft to a torque of 40 to 60 ft Ib then adjust reel bearings ZA Greensmaster 3150 Em RR VU RU UM NADAN ACNE EC UU aaa 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 ing the 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 is in the raised position Raise the 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 disengag
186. f 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 or lower the roller On the bolt head there is an identifica tion dot Fig 13 which denotes the offset of the 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 ae ne A u m s 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 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 spee
187. fe 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 reel See Reel Bearing Service and Adjustment in S the Adjustments section of this chapter 1 Remove bedbar 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 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 DAS BBL SCrEW Bedbar mounting bolts moved from the cutting unit by pulling evenly on Bedknife adjusting screws both sides Height of cut rod locknuts Roller shaft clamp bolts Height of cut adjustment knob WO Or gw aN For proper grinding of reel follow procedures in the T
188. flow capabilities to prevent damage to the hydraulic tester or components 5 When using tester with pressure and flow capabili ties open load valve completely 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 Check oil level in the hydraulic reservoir After con necting test equipment make sure tank is full 9 Check control linkages for improper adjustment binding or broken parts 10 All hydraulic tests 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 For traction related problems e g machine will not go up an incline use Tests 1 2 and or 3 4 Problems with steering lift lower and traction charge pressure use Tests 3 4 5 and or 9 5 Issues with cutting system use Tests 6 7 and or 8 Hydraulic System Sg E Ez SF IO T
189. ft lb 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 in lb 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 under Bedba
190. 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 69 Rev C 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 38 Note Fitting 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
191. g 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 26 3 Clean oil filter mounting area Remove filter and drain into a suitable container Discard filter Fig 27 4 Inspect and clean reservoir see Inspecting Reser voir Parts 5 Make 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 half a turn Note Use only hydraulic fluids including biodegrad able specified in the Traction Unit Operator s Manual Other fluids could cause system damage 6 Reconnect all hydraulic hoses and lines that were disconnected prior to draining Fill hydraulic reservoir 7 Disconnect both engine spark plug wires at the spark plugs 8 Turn ignition key switch engage starter for 10 se conds to the prime pump Repeat this step again 9 Connect both engine spark plug wires to the spark plugs Hydraulic System Page 4 56 10 Start engine and let it idle at low speed for a mini mum 2 minutes Increase engine speed to high idle for minimum of 1 minute under no load 11 Raise and lower cutt
192. g 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 bracket to relax belt tension Slip groomer drive belt off pulleys Fig 5 Carefully re lease idler bracket Figure 4 5 Install new drive belt to drive pulley idler pulley and P ae belt cover 3 Cap driven pulley observing correct belt routing Fig 5 6 Secure belt cover to housing with two 2 lock nuts Fig 4 7 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 E D E E O a 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 8 17 16 15 PING TETE AN 0 TX 60 to 80 ft Ib 81 to 108 N m Antisieze Lubricant 100 in Ib 100 to 120 eee 11 3 to 13 5 N m Figure 6 1 Lock nut 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 r
193. g nuts Do not overtighten to prevent cracking or dis torting the battery case Fig 25 6 Apply a light coat of grease on all battery posts and cable connectors to reduce corrosion after connections are made 7 Connect a digital multimeter set to amps between the negative battery post and the negative ground cable connector The reading should be less than 0 1 amp If the 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 Level Gravity 2 Determine the charging time and rate using the manufacturer s battery charger instructions or the following table Open Circuit Voltage 12 68 12 45 12 24 12 06 11 89 Battery Battery Charge Level Reserve Percent of Fully Charged Capacity ines 80 or less 3 8hrs 7 5hrs 11 3 hrs 15
194. g 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 Page 7 5 Troubleshooting Factor Possible Problem Correction Make sure bed bar pivot bolts are securely seated maximum 40 ft lb 11 Stability of bedbar 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 Use cutting unit model with correct number of blades for clip frequen
195. gauge bar verify correct height of cut setting and adjust 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 roller for 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 e Light medium or aggressive setting 5 Check grass shield adjustment e 4 3 4 in from crossbar normal e Dry grass lower shield e Wet grass raise shield 6 Set top bar cut off bar adjustment e 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 by 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 in Ib Th
196. gauges Use gauges as recommended in the Testing section of this chapter Hydraulic Tester Pressure and Flow TOR214678 Figure 7 This tester requires O ring face seal ORFS adapter fit tings for use on this machine Use hydraulic tester as recommended in the Testing section of this chapter 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 LOW PRESSURE GAUGE Low range gauge to pro vide accurate reading at low pressure O to 1000 PSI A protector valve cuts out when pressure is about to exceed the normal range for the gauge The cutout pressure is adjustable Hydraulic System Page 4 16 4 HIGH PRESSURE GAUGE High range gauge which accommodates pressures beyond the capacity of the low pressure gauge O to 5 000 PSI 5 FLOW METER This meter measures actual oil flow in the operating circuit with a gauge rated at 15 GPM 6 OUTLET HOSE A hose from the outlet side of the hydraulic tester connects to the hydraulic system circuit 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 TORO TEST FITTING KIT NO TOR4079 rima rootnumeer Union 1 ea Tora Ho The kit includes tee s unions reducers plugs caps and male test fi
197. ge 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 in Ib Measure with a torque wrench at the spline 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 in this procedure 4 Remove nut and washer from clutch adapter shaft Pull clutch assembly off adapter shaft Fig 9 Remove clutch adapter from reel shaft Fig 10 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 widex 8
198. h sock et head screws 16 lock nuts 13 6 Secure flangettes 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 16 to 85 ft Ib 115 Nm 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 lb 3 Po di 339 to 542 Nm 24 70 to 90 ft Ib 95 to122 Nm Antiseize Lubricant 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 o G Y o D c Greensmaster 3150 Page 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 bloc
199. hapter 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 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 b
200. he 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 raise groomer reel and clockwise to lower Example Desired groomer setting of V32 0 03125 in higher than bottom of rollers 0 03125 0 007 4 46 4 or 5 notches 6 Rotate both quick up levers to raise the grooming reel into transport position Make sure the clutch is dis engaged Figure 19 1 Bar 2 Front roller 3 Rear roller 4 Quick up lever 2 5 Micro adjustment knob 2 6 Groomer reel touching bar 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 20 2 Height of shield from crossbar for normal cutting conditions should
201. he gear set in the steering control valve is worn Steering response is too slow and heavy when trying to turn quickly Turning steering wheel turns ma chine in the opposite direction Steering force possibly to one side only is insufficient Hydraulic System Oil supply to the steering control valve is insufficient Hoses to the steering cylinder are reversed Pressure to steering control valve is low Page 4 20 Greensmaster 3150 Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks See the Special Tools section in this Chapter 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 that a hydraulic component is 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 result in damage to 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 seat to oper ate the machine and the other should read and record test results Operate all hydraulic controls to relieve system pressure an
202. he ground also rear wheel if machine is equipped with 3WD to allow flow through the traction circuit 5 Disconnect hose from the upper hydraulic fitting on the side of the hydrostat 6 Install tester in series with the pump and the discon nected hose Make sure flow control valve on the tester is fully open 7 Make sure functional lever is in the transport posi tion 8 Start engine and move throttle to full speed 2850 4 50 RPM position Greensmaster 3150 Page 4 23 Use extreme caution when taking gauge read ings The front tire on the ground will be trying to move the machine forward 9 Slowly push traction pedal into fully forward posi tion Note Make sure transport speed is properly adjusted See Adjusting the Transport Speed 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 13 3 GPM Record test results 12 Release traction pedal open control valve on tester and turn off machine 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
203. he hydraulic circuit auxiliary tank may need to be topped off after initial fill Hydraulic System o pm O eb pue o gt o 8 Remove cap from main hydraulic tank and slowly fill 10 If the buzzer fails to sound check to see if all con to cold fill level mark next to sight gauge 11 on auxiliary nections are secure tank 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 1 second Hydraulic Reservoir Antiseize 30 to 60 in Ib Lubricant 3 qu 3 4 to 6 8 Nm 19 9 Figure 51 l Straight hydraulic fitting 9 Tankcap 17 Pump inlet hose 2 O ring 10 Filler screen 18 Plug early units only l 3 O ring 11 Overflow hose 19 Cap screw 4 Oil level sensor 12 Hose clamp 20 Flat washer 5 O ring 13 Hydraulic barb fitting 21 Grommet 6 Hydraulic tank 14 O ring 22 Spacer 7 Tether 15 Hose clamp 23 Tank pad 8 Pin 16 Return hose Hydraulic System Page 4 86 Rev C Greensmaster 3150 Removing Hydraulic Reservoir Fig 51 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 Remove leak detector assembly see Le
204. heating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air 5 Clean cartridge 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 Ib 47 Nm Hydraulic System Lc E 2 SF IO Backlap Kit Optional a 15 ba aN CC in Y So AS OA Q 35 ft Ib ps a 9 47Nm gt A OA RS MA 27 RIGHT Q FRONT IG NN Serial Number 230000801 amp Up Shown ES Figure 40 1 Backlap bracket 11 Seal kit 20 2 N O ball switch 12 Detent kit 21 3 Socket head screw 13 Flow control cartridge Port FC1 22 4 Flatwasher 14 J umper wire 23 5 Detentkit 15 Harness 24 6 Indicator kit 16 Relay 25 7 Directional cartridge valve Port RD1 17 Knob 26 8 Sealkit 18 Jam nut 27 9 Sealkit 19 Indicator plate 28 10 Logic cartridge Port LC1 Note The p
205. heck pull frame alignment on all cutting units Adjust or repair as necessary Check pull frames and lift arms for damage binding or 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 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 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 Center cutting unit must drop after front cutting unit See Troubleshooting in Chapter 5 Hydraulic System Page 8 7 Troubleshooting Set Up and Adjustments Adjustment Summary and Check List 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 recommende
206. hrs 3 amps 3amps 3amps 3 amps 81 to 125 5 3hrs 10 5 hrs 15 8 hrs 21 hrs Q Q Q Q 4 amps 4 amps 4 amps 4 amps 126 to 5 5 hrs 11hrs 16 5 hrs 22 hrs 170 O O oamps 5 amps 5amps 5 amps 171 to 5 8hrs 11 5 hrs 17 3 hrs 23 hrs 250 Q Q Q Q 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 250 Q Q Q Q 10 amps 10 amps 10 amps 10 amps Greensmaster 3150 Page 5 21 Do not charge a frozen battery because it can 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 not smoke 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 nect the 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 69C or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 6 Three hours prior to the end of the charging mea sure the specific gravity of a battery ce
207. ic lines and cartridge valves at each port location Hydraulic System Page 4 70 Rev C Greensmaster 3150 Solenoid Operated Cartridge Valves Fig 39 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 Remove cartridge valve with a deep socket wrench Remove seal kit 4 Visually inspect the port in the manifold for damage to the 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 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
208. il level in reservoir is low or inlet filter is loose or clogged Oil is contaminated or too light Working load of machine may require use of oil cooler Oil cooler when installed is damaged or plugged By pass relief is stuck open or air flow is obstructed Charge pressure is low Hydrostat by pass valve is open or defective Wheel motor s or reel motor s are worn or damaged Traction pump P3 is worn or damaged see Test 1 Neutral is difficult to find or unit op erates in one direction only External control linkage is misadjusted disconnected binding or damaged Traction pump P3 is worn or damaged see Test 1 Traction response is sluggish Charge pressure is low Hydraulic oil is very cold Towing by pass valve is open or worn Brake is not released Traction pump P3 or wheel motor s are worn or damaged see Tests 1 and 2 No traction exists in either direction Brake is not released Oil level in reservoir is low Hydrostat by pass valve is open Charge pressure is low Traction pump P3 or wheel motor s are worn or damaged see Tests 1 and 2 Hydraulic System Page 4 18 Greensmaster 3150 Problem Wheel motor will not turn Wheel motor will not hold load in neutral Possible Cause Internal parts in wheel motor are damaged O Brakes are binding Key on wheel motor shaft is sheared or missing Make up fluid from charge pump is not available Hydrostat bal
209. imately 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 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 off the 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 hose from the upper hydraulic fitting on the side of the hydrostat 10 Install flow tester in series with the pump and the disconnected hose same tester connections as TEST NO 1 Traction Drive Hydrostat P3 Flow 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 25 12 Slowly push traction pedal in forward direction until 1000 PSI 69 bar is displayed o
210. ing Port Nonadjustable 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 4 Install the fitting into the port and tighten it down full length until finger tight Figure 3 5 Tighten the fitting to the correct flats from finger tight F F F T Size F F F T 4 1 4 in nominal hose or tubing 1 00 25 6 3 8 in 1 50 25 8 1 2 in 1 50 25 10 5 8 in 1 50 25 12 3 4 in 1 50 25 16 1 in 1 50 25 SAE Straight Thread O Ring Port Adjustable 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage E Lock Nut s D 3 Lubricate the O ring with a light coating of oil zo 4 Turn back the jam nut as far as possible Make sure ep Back up Washer the back up washer is not loose and is pushed up as far N as possible Step 1 O Ring 5 Install the fitting into the port and tighten finger tight Figure 4 until the washer contacts the face of the port Step 2 6 To put the fitting in the desired position unscrew it by the required amount but no more than one full turn Step 3 7 Hold the fitting in the desired position with a wrench and turn the jam
211. ing both hex socket head screws and flat washers Remove O ring from between the gear pump and hydrostat Greensmaster 3150 Page 4 43 Installation Fig 15 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 Apply antiseize lubricant to 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 lb 37 to 42 Nm 7 Inspect threads 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 Sg E Ez SF IO Gear Pump Service 1 Front plate 8 2 Back plate 9 3 Front body 10 4 Backbody 11 5 Drive gear 12 6 Front idler gear 13 7 Back idler gear 14 Figure 16 Back up gasket Wear plate Pressure seal Cap screw O ring Adapter plate Key Note For repair of the gear pump see Eaton Gear Pumps Repair Information Series 26
212. ing 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 2 hours under normal oper ating 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 ni MERFI a IESU m LA EI E E E c Ne r m a E Lj te Sf Figure 27 Greensmaster 3150 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 90 hydraulic fitting OO NP OI Greensmaster 3150 LEFT REEL MOTOR 12 13 14 15 16 17 18 19 20 21 CENTER REEL MOTOR Figure 28 O ring O ring Straight hydraulic fitting O ring O ring Hose assembly Hose assembly Hose assembly Hose assembly Hose assembly Page 4 57 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 Hydraulic System Hydraulic Removal Fig 28 1 Before removing any parts from the hydraulic sys tem park machine on a level surface engage parking brak
213. ining ring 2 Wear ring 7 Seal 12 Piston 3 Seal with loader 8 Wiper 13 Lock nut 4 O ring 9 Head 14 Barrel 5 Back up ring 10 Rod Hydraulic System Page 4 66 Rev C Greensmaster 3150 Disassembly 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 not close vise enough to distort the barrel 2 Mount lift cylinder in a vice Use of a vise with soft jaws is recommended 3 Using a spanner wrench rotate head clockwise until the edge of the retaining ring appears in the barrel open ing Insert a screwdriver under the beveled edge of the retaining ring to start the 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 cle vis 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 Assembly 1 Make sure all
214. ion 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 Groomer 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 Pa Bs pa a I os Re ISS ee ae c OU uel m STS NN NGA SERM
215. ion 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 po 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 bearing cup 12 After installing reel tighten spline nut to 40 60 ft lb 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 tool 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 23 27
216. is can be measured with a torque wrench Fig 5 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 onthe 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 lb 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 torqu
217. is diode prevents current flow 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 CIRCUIT D1 D iri A BC Dj E DIODE CIRCUIT BOARD Greensmaster 3150 Page 5 17 Figure 24 Electrical System o O pe Par O o LLI z Qo bd Y el OP 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 Re gardless if switches are operating properly or not replace them every two years to assure max imum safety The purposes of the interlock switches are to A Prevent the 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 Shut off the engine if the operator leaves the seat without the Functional Control Lever in NEUTRAL D Shut off the reels if the Functional Control Lever is moved to NEUTRAL or TRANSPORT Electrical System Page 5 18 1 Sit on the seat engage parking brake and move Functional Control Lever to NEUTRAL Try to depress traction pedal If the ped
218. it 2 Place a 1 4 inch 6 mm or thicker plate under the reel blades and against the cutting edge of the bedknife 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 roller assembly until it contacts the working surface across the full length of the roller Fig 12 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 Figure 11 1 Rear roller bracket 3 Reel blades 2 1 4 inch 6 mm steel plate 4 Bedknife Figure 12 1 Unit on level surface 2 Hold unit securely 3 Push down on roller Greensmaster 3150 RD ERR E ERR A MR K r J P n nsms 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 also influence effective height of cut Changing the machine such as adding a wiehle roller wil
219. ithium base grease 2 Install the flange head screws for the reel drive mo tor into the motor adapter plate and leave approximately 1 2 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 Connect the 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 Service Training Book Sharpening Reel and Rotary Mowers part no 80300SL Dual Point Adjust Cutting Units Page 10 8 TOP FACE REMOVE RELIEF ANGLE BURR FRONT FACE FRONT ANGLE Figure 10 Note Fora 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 G
220. ity of the lower switch by connect ing a multimeter ohms setting across the switch con nector terminals as follows A With the joystick in the rest position current should only flow across terminals 1 and 3 open ter minal and green black wires B With the joystick in the lower position current should flow across terminals 1 and 2 green black and gray black wires 4 Connect the electrical connectors and reinstall the plastic cover Backlap Switch Optional 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 clockwise to the backlap 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 Turn the backlap knob counterclockwise to the mow position while watching the multimeter Continuity should be broken as the switch opens 5 Reconnect the electrical connector 1 Joystick assembly 2 Raise switch Figure 15 3 Lower switch Serial Number 230000801 amp Up Shown 1 Connector 2 Backlap switch Electrical System Page 5 14 Figure 16 3 Backlap knob Greensmaster 3150 Lower Reels Time Delay This is a
221. justment 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 A n nt X HMM REM ET 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 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
222. ket head screw 14 Flat washer 15 Hose assembly 16 O ring OO OES NS Hydraulic System 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Antiseize Lubricant 27 to 31 ft Ib 37 to 42 Nm Figure 17 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 46 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 17 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 Use caution when removing the lock nut from the pin The extension spring is under tension and may cause personal injury during removal Figure 18 1 Extension spring 4 Adapter plate Note The neutral system assembly can be removed 2 Dampener hose 5 Neutral arm from the hydrostat without complete disassembly 3 Spring bracket 2 Disconnect the extension spring 1 and damper 2 from the spring bracket and the neutral arm Fig 18 3 Remove the cap screw and pivot washer from cam plate shaft of hydrostat Fig 19
223. knife 4 Place bar across front and rear rollers and adjust 2 Gauge bar 1 8789 4 Adjustment knob 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 Set the new cutting unit to 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 Set Up and Adjustments Groomer Reel Depth Adjustment 1 Adjust cutting unit height of cut before doing groomer reel depth adjustment 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 t
224. ks beneath the frame under the hydraulic wheel mo tor 20 3 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 Page6 10 Rev A Figure 8 3 Brake cam 4 Backing plate 1 Return spring 2 Brake shoe 3 Install brake cam 9 into the backing plate 8 and brake lever
225. l 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 m Figure 4 Special Tools Troubleshooting There are a number of factors that can contribute to machine It is important to remember that the lower the unsatisfactory quality of cut some of which may be turf height of cut the more critical these factors are See the conditions Turf
226. l check valves are damaged Reel motor drive pump is noisy cavitation Reels will not turn Reel speed is erratic Reel motor case drain flow is exces sive Flow is greater than 0 5 GPM 1 9 LPM at 1000 PSI Cutting units will not lift or lift slowly Greensmaster 3150 AE me SES EN Reservoir oil level is low Suction line is restricted Suction line has an air leak Solenoid valve S1 is stuck open not shifting to its energized posi tion An electrical problem exists See Chapter 5 Electrical System Relief valve R1 is stuck open see Test 7 LC1 logic valve when Backlap Kit is installed is stuck open Gear pump P1 is damaged see Test 6 Reel to bedknife adjustment is too tight Reel bearing s are damaged The 020 orifice is plugged when Backlap Kit is installed 2 E O Excessive internal wear in reel motor exists see Test 8 Reel bearing s are damaged an Mm a TE v eee ee Charge pump P2 is damaged see Test 4 Lift cylinder linkage is binding or broken Lift cylinder bushings bind Reservoir oil level is low Charge pump pressure or flow is insufficient see Test 3 and 4 Implement relief valve R5 is stuck open see Test 4 Solenoid valve S2 is damaged not shifting to its energized posi tion Lift cylinders leak internally Relief valve R2 is stuck open see Test 5 Spool in steering control valve is hung up
227. l 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 Putthe 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 accessories it is recommended that you change only one cutting unit and keep the other two existing
228. ld 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 Greensmaster 3150 Page 4 3 Hydraulic System 2 Tam O gt a 2 o gt o 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 or maintenance These conditions can cause damage or premature dete rioration Some hoses are more susceptible to these conditions than others Inspect the hoses frequently for signs of deterioration or damage When replacing a hydraulic hose be sure that the hose is straight not twisted before tightening the fittings This can be done by observing the imprint on the hose Use two wrenches hold the hose straight with one and tighten the hose swivel nut onto the fitting with the other Hydraulic Fitting Installation O Ring Face Seal 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Make sure the O ring is installed and properly seated in the groove It is recommended that the O ring be replaced any time th
229. liar 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 63 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 brackets 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 o Tam O gt Lift Cylinder Service Serial Number Under 240000000 FRONT HYDRAULIC CYLINDER Seal kit T seal O ring Rod seal O ring ae WIE Seal kit T seal O ring Rod seal O ring ae NS Hydraulic System 24 to 30 ft Ib 33 to 41 Nm 0 90 Figure 36 Back up ring Dust seal Rod clevis Jam nut 10 Internal collar 24 to 30 ft Ib 33 to 41 Nm POON Figure 37 Back up ring Dust seal Not used Notused 0 Internal collar Page4 64 Rev C Head Ro
230. lieved Remove key from the ignition switch 3 Put caps or 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 41 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 functions slowly until air is out of system see Charge Hydraulic System 7 Check for hydraulic oil l
231. ll 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 oO pe sad S o LLI z Qo imd 2 e Mm This page is intentionally blank Electrical System Page 5 22 Greensmaster 3150 Chapter 6 TORO Wheels and Brakes Table of Contents SPECIFICATIONS paang ABA AA Aa mad 2 SERVICE AND REPAIRS 00 3 SPECIAL TOOLS mc a Ak eve ER heeded 2 Rear Wheel 2WD 0c cee eee 3 Rear Wheel Optional 3WD 6 Front Wheel and Brake 9 E o Ox y 2a 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 lb 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 N RIGHT FRONT Pd Steering cylinder Bearing cup Bearing cone Washer Slotted hex nut Cotter pin Grease fitting Jam nut Rod end 10 Dust seal 11 Lug nut 12 Wh
232. ller 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 If the 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 If valve 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 noid valve 12 volts should be present
233. lt 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 11 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 10 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 11 3 Remove spacers and blades as necessary Assembly Fig 11 1 Start by placing two spacers against a lock nut installed on one end of groomer shaft Then place first blade against spacers Fig 11 2 Rotate location mark on each installed blade one flat of the shaft either in a
234. mage to the castor fork bearings is suspected remove the castor fork 6 from the frame See Rear Wheel 2WD Removal in this chapter of this manual for additional information Figure 5 1 Hydraulic motor 4 Drive stud 2 Hub 5 Grease fitting 6 Thrust washer 3 Clutch roller bearing Greensmaster 3150 Page 6 7 7 Washer 8 Snap ring 9 Grease seal Wheels and Brakes po S o nx o 2a 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 two thrust 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 3 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 of the new grease seals 9 with No 2 multipurpose lithium base grease Slide one seal o
235. master 3150 Rear Lift Cylinder Flow Control Valve Serial Number 230000801 amp Up Shown Figure 41 1 Hydraulic manifold assembly 4 O ring 2 Flow control valve 5 O ring 3 Straight swivel hydraulic fitting 6 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 Label all hydraulic connections for reassembly Dis connect hose assembly and O ring from the hydraulic fitting Allow hose to drain into a suitable container 3 Remove hydraulic fitting and O ring from flow con trol valve Remove valve and O ring from hydraulic fit ting Put caps or plug on hydraulic cylinder fitting to prevent contamination Installation 1 Lubricate all new O rings with clean hydraulic oil 2 Install O ring and hydraulic fitting to the flow control valve Greensmaster 3150 90 hydraulic fitting Page 4 75 Rev C Hose assembly Tee hydraulic fitting Hose assembly p Figure 42 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
236. mbly 15 Adapter 16 Cap screw 17 Bracket 18 Flat washer 19 Hose assembly 20 Tube assembly 21 Clamp Page 6 6 30 ft lb 80 to 100 in Ib 9 0 to 11 3 Nm 41 Nm Da 70 to 90 ft lb 95 to122 Nm 22 Cap screw 23 O ring 24 O ring 25 O ring 26 O ring 27 Set screw 28 Wheel assembly 29 Lock nut 30 Lug nut 31 Grease fitting 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 ROTATION 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 da
237. mmer on 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 Do steps 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 Figure 37 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 6 under Bedbar Removal a
238. 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 IS FELT AND HEARD THEN TIGHTEN ONE 1 MORE CLICK TO GET LIGHT CON TACT Fig 6 5 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 6 install hydraulic motor to cutting unit IMPORTANT LIGHT CONTACT MUST BE MAIN TAINED AT ALL TIMES
239. mping 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 i idus pivot screws to 60 ft lb 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 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 Equa gap between reel and bedknife Figure 29 Greensmaster 3150 Page 8 21 Repairs nn s F
240. mportant to in spect the 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 The 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 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
241. n 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 Page 1 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 standards 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
242. n 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 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 Disconnect tester from hydraulic fitting and hose Reconnect hose to pump connection Hydraulic System SC E ot SF q 9
243. nd mow relays 2 The 10 amp fuse F2 supplies power 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 10 amp fuse F4 supplies power to leak detec tor solenoid and the joystick raise and lower switches 1 Seat bolts 2 Electrical connector Greensmaster 3150 Page 5 11 Figure 10 3 Seat switch Electrical System SE Zg on o LLI 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 NEUTRAL Check continuity of both switches by connecting a multimeter ohms setting across the connector terminals There should be no continuity across either switch 2 Place the Functional Control Lever in the NEUTRAL position The NEUTRAL reed switch should have conti nuity and the MOW switch should be open Fig 12 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 12 4 Ifthe neutral or mow switches do not satisfy any of the tests de
244. nd 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 38 Figure 38 Height of cut locknut Roller shaft clamp bolt Height of cut knob Grooming reel cover Cover screws and washers B Turn height of cut adjustment knobs to raise roll er out of way or remove roller if necessary Teo NS For proper grinding of reel follow procedures in the Toro publication Sharpening Reel and Rotary Mowers Form No 80 300 PT 3 Dosteps 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 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 Adjustment knob ass
245. neuieuos oineJp H LAYHI 34NSSIYA ONY ILYA MOT LNSWIIVIdS O SHOLOW 1334 PERPE OS Le JOjseuusueeaJt Greensmaster 3150 Page4 6 Hydraulic System wa sAs 21 ne3pAH 5 GN3 ES NIRO O LD TYNOILdO Y 1NIOP Tlva PERRA A 37101 HDIH 0982 gt ae l4 MO llocs 4 37101 MOT 0091 D re 831009 id 9 1 gt C 110 Bearer wage eas ee AAA mi Jj ANION n Ho D Gd bd d 2 l gt G yl fas bos SEE u L L PN ln ri d p at IN YA x EN mS ISd INA A A T i 092 002 43319 INIYA 9NIH331S H3MOd Y En V Zd 1S ld ld ISd pam
246. ng wheel or rear wheel B Steering wheel movements should be followed immediately by a corresponding rear wheel move ment without the steering wheel continuing to turn 4 Stop the 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 The 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 If either of these 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 and the 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 Greensmaster 3150
247. ngagement 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 of the nominal torque value Product Records and Maintenance Product Records e o c c CU d E E c Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Recommended Torque Square Head Hex Socket 7 16 20 UNF 654 10 ft lb 88 14 N m 1 4 20 UNC 140 20 in Ib 73 12 in Ib Recommended Torque Thread Size Grade 5 1 2 20 UNF 80 10 ft lb f 108 14 N m 5 16 18 UNC 215 35 in Ib 145 20 in Ib Grade 5 3 8 16 UNC 35 10 ft lb 18 3 ft lb M12 X 1 25 80 10 ft lb f 108 14 N m Class 8 8 1 2 13 UNC 75 15 ft lb 50 10 ft lb M12 X 1 5 80 10 ft lb f 108 14 N m Class 8 8 For steel wheels and non lubricated fasteners Thread Cutting Screws Thread Cutting Screws Zinc Plated Steel Zinc Plated Steel Type 1 Type 23 or Type F Thread Threads per Inch Size Baseline Torque Thread Size Baseline Torque Type A Type B No 6 32 UNC 20 5 in Ib No 8 32 UNC 30 5 in lb No 10 24 UNC 38 7 in Ib No 10 12 16 38 7 in Ib 1 4 20 UNC 85 15 in lb 85 15 in Ib 5 16 18 UNC 110 20 in Ib Hole size material strength material thickness amp finish must be considered when determining specific torque 3 8 16 UNC 200 10
248. noid clicks but starter will not crank Battery charge is low if solenoid clicks problem is not in safety interlock system 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 incomplete circuit for the solenoid Relay K2 has intermittent ground Nothing happens when start attempt is made Battery is dead Wiring to the start circuit see Wiring Schematics components is loose corroded or damaged SE O Par Oo O 25 LLI 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 Greensmaster 3150 Page 5 5 Electrical System Starting Problems continued Engine cranks but does not start 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 sol
249. nstalling 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 Page 4 62 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 with 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 35 1 Frame 5 Hose assembly 9 Lock nut 2 Straight hydraulic fitting 6 Cap screw 10 Lift arm 3 O ring 7 Washer 11 Hydraulic cylinder 4 O ring 8 Pivot pin Rear Cylinder Removal Fig 35 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 mi
250. ntact 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 If bedknife is too thick for effective height of cut poor quality of cut will result Page 9 6 Greensmaster 3150 Factor 11 Stability and position of bedbar 12 Number of reel blades 13 Cutting unit alignment and pull frame ground following 14 Roller condition 15 Reel speed 16 Traction speed 17 Cutting drop speed and sequence Greensmaster 3150 Possible Problem Correction Make sure bedbar bolt plastic washers are snug against bedbar Bedbar must pivot without binding 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 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
251. nto motor shaft past groove closest to the motor Install snap ring 8 into groove 4 Slide 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 it is 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 Page 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 of the castor fork with bot
252. nual 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 1 Make sure bedbar threads are clean Use new screws Apply clean SAE 30 oil to the screws before installing IMPORTANT Do not use 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 Grinding Since there can be variations in the mounting surface of the bedbar a new bedknife will not be perfectly flat after it is installed Because of this it is necessary to backlap or grind a new bedknife after installing it to the bedbar Follow the existing angle that was ground into the bed knife and grind only enough to make sure the top surface is true Fig 17 1 Remove bedbar from the cutting unit See Bedbar Removal Note When grinding be careful to not overheat the bedknife Remove small amounts of material with each pass of the grinder 2 Use Toro Service Training Book Sharpening
253. o 60 ft Ib 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 1 Pivot housing 2 Bearing 2 3 Inner race 2 4 O ring 2 Repairs Figure 52 9 Pivot screw 2 10 Spring arm retaining capscrew 5 Spring arm 6 Adjustment knob 7 Bedbar pivot 8 Spring Page 9 32 Greensmaster 3150 Lift Bail Replacement N IHA N 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 4 516 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 Table of Contents SPECIFICATIONS scort rra SPECIAL TOOLS aces Ke rita ate Rees TROUBLESHOOTING 000 0 cee eens Factors Affecting Qualit
254. oat 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 the float closes the alarm circuit and acti vates the alarm Electrical System Page 5 4 AUXILIARY 10000 FLOAT SWITCH TANK raised open Ik SIGHT GAUGE y SOLENOID VALVE open Figure 3 AUXILIZ TY 3 0 FLOAT SWITCH TANI raised open SIGHT GAUGE me SOLENOID Y VALVE closed Figure 4 ADEM 0818 FLOAT SWITCH TANK a lowered closed SIGHT GAUGE SOLENOID ff VALVE closed Figure 5 Greensmaster 3150 Troubleshooting 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 Remove all jewelry especially rings and watches before doing any electrical trouble If the machine has any interlock switches by passed shooting or testing Disconnect the battery they must be reconnected for proper troubleshooting cables unless the test requires battery voltage and safety Starting Problems Problem Possible Causes Starter sole
255. 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 under the hydrostat to collect hydrau lic oil 3 Clamp pump inlet hose to 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 50 4 Clamp pump inlet hose to 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 and lock washers 24 securing the valve assembly to the hydraulic tank and remove the valve assembly Disassembly and Inspection Fig 49 1 The leak detector can be disassembled using the leak detector assembly drawing Fig 49 as a g
256. on of cylinder Do not close vise so firmly that cylinder barrel could become distorted 3 Loosen set screws and remove threaded cap from each end of the cylinder barrel 4 Grasp end of rod and use a twisting and pulling mo tion to carefully extract rod assembly and head from cyl inder barrel Remove head from other end of barrel 5 Loosen set screws that secure piston to shaft and carefully remove piston Slide head and threaded cap from shaft 6 Remove and discard all seals back up rings and O rings from both heads and piston 7 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 8 Carefully inspect internal surface of barrel for dam age deep scratches out of round etc Replace en tire cylinder if barrel is damaged Inspect shaft both heads and piston for evidence of excessive scoring pit ting or wear Replace any damaged parts Greensmaster 3150 Page 4 83 Rev C Assembly 1 Use a 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 o ring onto each head Position two o rings inner and outer piston ring and both wear rings to the piston 3 Lubricate shaft with clean hydraulic oil Slide threaded cap head and piston onto shaft Install thread locker on set
257. on the rear bear ing block to remove the bearing block and gear set Fig 31 8 Carefully remove and discard o rings pressure seals and back up rings Fig 32 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 plate 9 Position front flange with seal side up Remove shaft seal 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 ENG Figure 31 1 Motor body 2 Bearing block amp gear set bue Pressure Seal Backup Ring Figure 32 Figure 33 1 Drive gear 3 Bearing block 2 Idler gear Hydraulic System Page 4 60 Greensmaster 3150 3 Inspect drive gear idler gear and bearing blocks Fig 33 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
258. onisod pezibJouo ay ui UMOUS 9 8 S pue ZS spiougjos UMOYS dN Y L080000 zc 1equinN jeues syun Dunn esiey 0GS LE 4e1seujsueeiurc dV MOVd SIN SHOLON 1534 AAA A A a nin ta 3701 HOIH 0S8Z amp 37101 MOT 0091 ISLSOHGAH d om Y ISd INIVA 082 002 d3319 Y pre ve E aaa E m ANIVA dOL INOLLOS aig HOLOW 133HM NOILOVH L GME IVNOILAO GHYVMHOS 1iHolH nollog abr i SIN 1331 INOLLOS SHOLOIN 133HM NOI LOVH L Hydraulic System Page 4 11 Greensmaster 3150 Mow and Backlap Mow The gear pump P1 is directly coupled to the the hydros tat which is driven directly by the engine Taking its suc tion directly from the hydraulic reservoir the gear pump P1 supplies oil flow to the hydraulic manifold block and to the cutting reel motors 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 valve 1 is de energized S1 by passes flow from the gear pump P1 directly to the hydraulic reservoir 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 Flow is diverted to the reel motors Note On traction units with serial number
259. ooting 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 e 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 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 11 Front roller scraper and comb adjustment Troubleshooting tween reel and bedknife is felt or heard then tighten Page 8 6 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 if worn or damaged Bearing cones must be installed square to bearing housing make sure there is no
260. ork 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 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 n Figure 3 1 Bearing cup 4 Shaft seal 2 Wheel hub 5 Drive stud 3 Bearing cone Disassembly Fig 2 1 If drive 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 the lip of the seals fac ing towards the inside 3 If removed press new driv
261. oro 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 NANA NE A Reel Removal and Bearing Replacement 1 Remove the front and rear roller assembly Remove bedbar 2 Remove counterbalance end cap from left hand side 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 B Cut head off of machine screw 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 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
262. orque 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 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 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 adjustment 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
263. orrection Bedknife to reel adjustment Check bedknife to reel contact daily The bedknife must have light contact 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 numb
264. orrosion 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 Page 5 19 Rev A Figure 25 1 Wing nut 2 Battery retainer COVER SEAL Figure 26 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 Conduct a 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 SE Zg on 25 LLI B Temperature correct each cell reading For each 10 F 5 59C ab
265. orts on the manifold are marked for easy identification of components 9 U a Pd Spring Spring Detent plate Set screw Ball Locating plate Locating plate Orifice 020 Manifold Example LC1 is for the reel logic cartridge and RD1 is for the directional cartridge valve See Hydraulic Schematics to identify the function of the hy draulic lines and cartridge valves at each port location Hydraulic System Page 4 72 Greensmaster 3150 Optional Backlap Kit Flow Control and Two Position Directional Valves Fig 40 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 to lose springs 20 or 21 Remove springs C Loosen setscrew 23 and slide detent plate 22 offthe 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 fold 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 c
266. 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 the TORO SPECIAL TOOLS Some tools may also be available from a local supplier AND APPLICATIONS GUIDE COMMERCIAL PROD UCTS 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 circuits 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 SE Zg on 25 LLI Figure 2 Greensmaster 3150 Page 5 3 Electrical System Turf Guardian Ledk 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 it to overflow into auxiliary tank The fl
267. oval 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 a thin 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 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
268. ove 80 F 26 7 C add 0 004 to the specific gravity reading For each 10 F 5 5 C 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 If the 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 If the 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 corro sion D Measure the temperature of the cen
269. 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 Greensmaster 3150 Page 4 67 Rev C 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 cle vis or eye of the shaft Use of a vise with soft jaws is rec ommended A Coatshaft 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 lb 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 not close vise enough to distort the barrel 4 Mount barrel in a vice 5 Coatall internal parts with a light coat of clean hy draulic oil Slide piston shaft and head assembly into the barrel being careful notto 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 Lc E 2
270. ped 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 i e high temperatures high humidity unusually high traffic Troubleshooting Page 9 8 Greensmaster 3150 eee eee Grooming Reel Mechanical Problems Problem 1 Groomer rotates when in raised position with clutch disengaged 2 Clutch is engaged but does not provide power to groomer reel 3 Turf damage or uneven grooming 4 Groomer reel does not raise completely to transport position quick up levers do not rotate completely to rear or have free play Greensmaster 3150 Page 9 9 Possible Cause Correction Normal condition the groomer may still rotate in 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 bea
271. pose 2 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 E Remove the spare length of fuel hose from the fuel shut off valve 3 Remove four cap screws 9 and flat washers 7 se curing the fuel tank to the vehicle frame 12 Remove the fuel tank from the vehicle frame Greensmaster 3150 Page 3 5 Engine Cap screw Flat washer Spacer Exhaust manifold Regulator shield Muffler clamp Hex nut Engine assembly Muffler 10 Muffler shield 11 Ground wires 12 Flat washer 13 Muffler support bracket 14 Cap screw 15 Flat washer EOS A N Engine Figure 4 Hex flange nut Lock washer Screw Pump adapter Screw Engine mount plate Lock washer Cap screw Engine mount Cap screw Hex nut Spring washer Cap screw Engine wire harness Pump hub Page3 6 Hydraulic pump assembly Hardened washer Lock nut Coupling spacer Rubber coupling Flat washer Cap screw
272. r Re place the reel if necessary 5 Using an appropriate I D 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 5 Make sure it is seated into the groove Figure 21 1 Reel shaft 3 Adapter spline 2 Drive adapter 2 4 G a Sn NN Mah Je BS Pr NDA ZORROS TEN 77 Ae A ZZ NAN A Y Ces 27 N Ze mil LK 1 104 Seal Depth Figure 22 1 Outer seal 4 V ring 2 Inner seal 5 Left side plate 3 Speedi sleeve Greensmaster 3150 Page 10 17 Dual Point Adjust Cutting Units Reel Installation Fig 18 IMPORTANT Wipe any excess grease from the inner grease seals 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
273. r Removal and Installa tion in this section of the book 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 Greensmaster 3150 Page 9 27 Repairs a IA aps A 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 the sharpest 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 Loosen the 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 set screws against flats on
274. r 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 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 Roller Bracket Hole Position 8 Blade Cutting Units Figure S 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
275. r 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 Grade 1 Grade 5 Inch Series Bolts and Screws Figure 1 Greensmaster 3150 Page 2 3 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 marking 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
276. re roller assembly in bench vise and Figure 30 lightly tap one end of roller shaft until seal and bearing 1 Roller 4 V ring are removed from roller cavity Remove second seal and 2 Ball bearing 5 Bearing lock nut bearing from roller cavity by tapping on shaft 3 Seal 6 Roller shaft 5 Clean bearing cavity in roller and remove any rust with crocus cloth Assembly 1 Place roller shaft into roller Note If 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 Figure 31 1 Bearing lock nut 3 Bearing 2 Black assembly washer Dual Point Adjust Cutting Units Page 10 24 Rev A Greensmaster 3150 Note Special tool TOR4105 see Special Tools can 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 each 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 su
277. reensmaster 3150 Backlapping Units with Optional Backlap Variable Reel Speed Kit TO AVOID PERSONAL INJURY OR DEATH e Never 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 not adjust reels while the engine is running e Ifa reel stalls stop engine before attempting to clear the reel e Reel motors are connected 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 not attempt to 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 Start engine 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 p
278. reensmaster 3150 TIME DELAY LEAK Wiring Diagram INTERCONNECT 3 OPTIONAL LIGHT 2 TEST LIGHT SWITCH OPTIONAL LIGHT INTERCONNECT 1 INTERCONNECT 2 LEAK DETECTOR SON ALARM AAPM DETECTOR Page 11 12
279. 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 A a NUS NERO TET Se PANT ERIT WE Ee eT EY YT ORS TERS SCL SETEE dha ov petra se ae IS 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 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
280. rew 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 ee 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 16 Figure 16 e aaa 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
281. rews 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 Ib 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 Figure 39 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 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
282. rews 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 To prevent groomer shaft from turning when re moving driven pulley use wrench on shaft flats to hold shaft 9 Remove the 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 Note To prevent cutting reel from turning when re 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 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 13 Remove the flange nut that secures the groomer shaft to the non drive side plate 14 Pull the groomer reel from
283. rface 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 f 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 2 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 Figure 32 1 Bearing lock nut 3 Grease nut surface 2 Seal 4 Pack with grease E EN eee ENE T Job e P EN Y Y Figure 33 1 Bearing lock nut 2 Seal EN SA 27879 A KH SITZ Figure 34 1 Bearing lock nut 3 Assembly spacer 2 Yellow assembly washer 4 Seal Greensmaster 3150 Page 10 25 Rev A Dual Point Adjust Cutting Units This page is intentionally blank Dual Point Adjust Cutting Units Page 10 26
284. ring seized Replace bearing Clutch damaged or assembled incorrectly Repair or replace 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 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 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 Incorrect front roller extension plate installed Single Point Adjust and 4 Bolt Adjust cutting units require dif ferent front roller extension plates Troubleshooting ee ee ee Set Up and Adjustments Adjustment Summary and Check List DETAILED ADJU
285. rking brake is engaged A CAUTION Before continuing further read and become fa miliar with Precautions for Hydraulic Testing 3 For the suspected bad reel motor disconnect return hose from motor 4 Install tester in series with the reel motor and the dis connected return hose Make sure the flow control valve on the tester is fully open 5 If aback lap kit is installed make sure backlap knob on the hydraulic manifold is in the mow position and reel speed is set to maximum 6 Disconnect hose from case drain of the motor to be tested at the bulkhead fitting A Plug the bulkhead port B Put case drain hose into measuring container tool TOR4077 see Special Tools to collect and measure case drain leakage 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 soeed 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 gauges slowly close flow control valve on the tester until a pressure of 1000 PSI 69 bar is obtained Greensmaster 3150 Page 4 37 9 Use measuring container Tool TOR4077 see Spe cial Tools to collect hydraulic fluid for 15 seconds 10 Diseng
286. s 230000801 and up solenoid valve S6 is energized when the cutting units are raised This forces the return flow from the reel motors through the 125 orifice putt ing back pressure on the reel circuit and stopping the reels from rotating On units with the optional backlap kit installed flow through the manifold block is different Oil flow from port Hydraulic System Page 4 12 P1 flows through the reel speed control valve FC1 Flow across the speed control valve is pressure com pensated by the logic cartridge valve LC1 The logic cartridge valve maintains a pressure 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 optional backlap valve RD1 in the mow posi tion oil flows through the valve out 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 and oil filter and then to the reservoir Backlap Backlapping operation is the same as mowing opera tion except for the position of the backlap valve RD1 When the backlap valve RD1 is in the backlap posi tion oil flows through the rear M1 right M3 and then left M2 reel motor as it turns the motors in the backlap direction
287. s moves their shafts causing the cutting units to raise Atthe 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 numbers 230000801 and up solenoid valve S6 is energized when the cutting units are raised This forces the return flow from the reel motors through the 125 orifice putt ing back pressure on the reel circuit and stopping the reels from rotating Hydraulic System Page4 10 Rev C 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 52 is energized and blocks flow directly to the hydros tat Flow is directed to de energized solenoid valve 53 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
288. same tester connections as described in TEST NO 4 Gear Pump P2 Flow and Implement Relief Valve R5 Pressure Fully open control valve on the tester Note The lower function is electrically timed and au tomatically turns off after a few seconds For this hydrau lic test it is necessary to reverse the lower raise functions so the hydraulic lower function can be checked using the raise electrical circuit without the timer 5 Change the following electrical connections to re verse the lower raise function A Disconnect the connectors for solenoids S3 and S4 atthe manifold block B Connect male connector from solenoid S 3 to the female connector white black and black located on the wiring harness for solenoid S4 C Connect male connector from solenoid 54 to the female connector blue red and black located on the wiring harness for solenoid S3 6 Start engine and move throttle to full speed 2850 50 RPM Engage the cutting units Greensmaster 3150 Page 4 31 Rev C 7 Watch pressure gauge carefully while moving the Raise Lower Mow Control lever to the RAISE position Hold the control lever in the RAISE position until the re lief valve opens Release control lever and shut off en gine Record test results Note The lower cutting units relief valve R 2 Is in se ries with charge relief valve R 4 R4 pressure will af fect R2 pressure 8 The lower cutting units relief pressure R2 should be
289. screw threads and tighten two set screws to secure piston to shaft 4 Puta coating of clean hydraulic oil on all cylinder parts to ease assembly 5 Slide shaft assembly into cylinder barrel Slide sec ond head assembly into open end of barrel 6 Install and tighten threaded caps Secure both caps to barrel with set screws Hydraulic System 2 g E 2 SF IO Leak Detector Note See Turf Guardian Leak Detector System in Chapter 5 Electrical System of this manual for opera tion information Hydraulic tank Auxiliary tank Spacer short Neoprene washer Flat washer Cap screw Breather adapter Breather cap Cap screw 10 Spacer long 11 Sight gauge io Hydraulic System 30 to 60 in Ib A s di 3 4 to 6 8 Nm ie amp 17 to 21 ft Ib efi nm 23 to 28 Nm M Eo O f Figure 49 12 O ring 13 Hose clamp 14 90 barb fitting 15 O ring 16 Valve spool 17 O ring 18 O ring 19 Solenoid 20 O ring 21 Lock nut 22 Valve body Page 4 84 Rev C BA g E EN c NIY 3 Ng 2 Ng 23 24 25 26 27 28 29 30 31 32 10 100 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 Removal Fig 49 1 Before removing any parts from the hydraulic sys tem park machine
290. scribed in steps 1 2 or 3 adjust the switches as follows A The distance 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 13 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 Electrical System 2 1 7 J js dl id Aj gt A Ka MIC i 1 nie Figure 12 Mow reed switch 3 Actuator 2 Neutral reed switch Page 5 12 0 725 to 0 775 inch 18 4 to 19 7 mm ba REED SWITCH CONNECTOR TRACTION BRACKET Figure 13 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 and the 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
291. securely in a vise by clamping on the cle vis or eye of the shaft A Coatshaft with clean hydraulic oil B Slide head onto the shaft Install rod seal onto shaft and into head C Install piston and nut onto the shaft Torque nut from 24 to 30 ft lb 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 not close 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 Lc E 2 SF IO Lift Cylinder Service Serial Number Above 240000000 FRONT HYDRAULIC CYLINDER 60 to 75 ft Ib 82 to 101 Nm Figure 38 1 Seal kit 7 Seal 12 Head 2 Wear ring 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 up ring 11 Rod 16 Barrel 6 O ring REAR HYDRAULIC CYLINDER 60 to 75 ft Ib 82 to 101 Nm Figure 39 1 Seal kit 6 O ring 11 Reta
292. shers 33 14 Separate hydrostat from the pump adapter and pump hub 24 Remove key 21 from the hydrostat shaft Installation Fig 17 1 Make sure the inside of the pump hub 24 is clean Apply antiseize lubricant to both the hydrostat 12 shaft and the inside of the pump hub 2 Coat key 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 lb 37 to 42 Nm 4 Tighten both set screws 23 on the pump hub 24 5 Inspect threads 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 Hydraulic System Page 4 48 IMPORTANT Failure to remove the plug will cause excessive pressure in the hydrostat and damage seals 8 Remove plug from the suction port on the gear pump Fig 20 9 Install gear pump to the hydrostat see Hydraulic Gear Pump Installation 10 Remove clamp from pump inlet hose 1 11 Install the neutral system cable support assembly to the hydrostat with cap screws 6 Fig 19 Torque screws from 27 to 31 ft lb 37 to 42 Nm
293. shing 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 to line 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 a o 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 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 cla
294. 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 Cap screw 4 Carriage screw 2 Roller assembly 5 Lock nut 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 Page 10 21 Rev A 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 Rear roller body 6 Front roller body Seal Removal 188 in dia 2 1 Make a seal removal tool from a 1 4 x3 x 3 in 63 x 7 6 x 7 6 cm piece of steel as shown Fig 27 625 in dia 2 Slide seal removal over roller end of roller shaft 3 Use the tool as a template to locate mark and drill two 7 64 in diameter holes in the outer face of the seal poss 4 4 20 UNG 2 4 Thread two No 8 x 3 4 in long 164 in diameter self tapping screws through the seal rem
295. sitions the spool valve so that flow goes through the top of the spool Flow entering 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 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 Hydraulic System Page 4 14 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 on to the hydros tat The steering wheel and steering control valve return to the neutral position when turning is complete Left Turn When a left turn is made with the engine running the turning of the 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 ens
296. 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 ed Upon the application of power the load is energized and the time delay is started After 6 seconds the load is de energized INPUT VOLTAGE 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 Disconnect timer from 12VDC source and test load TIMING RESISTOR ee ie qae 7 v Figure 18 ho Figure 17 Leak Detector Alarm and Delay Timer To prevent the leak detector system from sounding false alarms during normal operation the alarm circuit in cludes a one second delay timer Electrical System 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 19 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 in the raised position and closed when the float is in the lowered position 1 If the float switch is connected to the main harness remove hydraulic tank cap and screen from fi
297. st 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 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 e t 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 e No contact 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
298. stable to compensate for changes in turf conditions Bar should be adjusted closer to reel whenturf is extremely wet By contrast adjust barfurther 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 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
299. sting is complete disconnect tester from gear pump and hose Reconnect hose to the pump Hydraulic System Ze E Ez SF IO TEST NO 7 Mow Circuit Relief Valve R1 Pressure Using Tester with Flowmeter and Pressure Gauges TO HYDRAULIC RESERVOIR Hydraulic System TO LEFT REEL MOTOR TO AND FROM REEL MOTORS ow pa AR QUES jma MB eee LA 2 S4 S6 z X RD1 OPTIONAL om ORIFICE VALVES a AA D1 R2 s3 ja PCL NF E V LCi HA al s2 fi E 125 NM ad K 77 LJ l R1 Ca TG Q REELS E OM A P1 PT ST P2 lt lt X lt x FROM STEERING CIRCUIT High Pressure Low Pressure Return or Suction Flow FROM GEAR PUMP P1 Serial Number 230000801 amp Up Shown Page 4 34 Greensmaster 3150 Procedure for Mow Circuit Relief Valve R1 Pres sure Check 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 f
300. stment 9 19 Lift Bail Replacement 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 Greensmaster 3150 Page 9 1 Introduction pm m ee RUE A A AA oe A A LY Introduction Page 9 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 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 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 Groomer Reel Raised Height 5 16 0 312 in from grooming reel height depth adjustment Reel Speed 1940 rpm engine speed 2800 rpm Groomer Re
301. t Repairs Page 8 24 6 After installing reel tighten spline nut to a torque of 40 to 60 ft Ib 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 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 sc
302. t Mm 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 Disconnect voltage from terminal 85 and multimeter lead from terminal 87 4 Connect multimeter ohms setting lead to relay ter minal 30 and 87A Apply 12 VDC to terminal 85 The relay should break and make continuity between termi nals 30 and 87A as 12 VDC is applied and removed from terminal 85 5 Disconnect voltage from and multimeter leads from relay terminals Solenoid Valve Coils Note Prior to taking small resistance readings with a digital multimeter short the 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 2 Apply 12VDC source directly to the solenoid Listen for solenoid to switch on Remove voltage source from solenoid 3 Measure resistance between
303. t LIGHTS 2 BK LIGHT TEST SWITCH i y OPTIONAL FUSIBLE LINK VIO BU 99 7430 Suter gy Qu BACKLAP RELAY K7 BK PK BU PK BU 8r inc EN ng j 85 UU ae 6 G m W 1 A W BU SITY LS amia ee AEA 99 7430 WT x NEUTRAL a mag S PAESI IC STARTER SWITCH a START SAFETY KO BACKLAP asUiU ae PK SOLENOID pk _ IGNITION SWITCH y AE PUES See HEN V D1 A K 4 99 7430 GN R YY OFF RUN START OPTIONAL 87 BU BK paba S1 A D1 B MM om o F3 10A 87a REEL B i O de wee ORBK ql H ues ENGAGE OR gt p o 0 W o ja Y MOW RELAY K4 1 B SEAT PARKING BK p31 B BK 0 Le F4 10A SWITCH BRAKE GN BK be A EN ON POSITION S SG MG 99 7430 A e 2 W E 30 p D1 D O i JOYSTICK ORIBK oo s BU BK Wd i LOWER 2 F MOW SWITCH D E ba 85 Y N Ped yi GY BK gt i A F al 1 3 STOP NONE 3 GN BK Seeds m pic V FRAME ENGINE B A RUN B I A and X Y GROUND GROUND 3 C START B I S ko il S LY BU e SE ne RAISE GY BK GN BK 92 2538 GN GY OR BK 2 BK 3 KILL RELAY K1 TT88UXU BK aa 2 G 6 SECOND ENGINE aa BEBE DELAY OFF MAGNETO ja 87 ee a E 0 FUSIBLE LINK 87a 99 7430 ALTERNATOR 89 2430 A ars Es SP 85 UUU 86 SEE FUEL SOLENOID y W BK om Y Y a o S4 NE 87a ae REELS LOWER LOWER RELAY K5 y 1 A 2 B vork MN S2 RAISE LOWER D3 E y 2 1 A 2 B S6 99 7430 ro ORIFICE a B0 e Y 3 BUR MMA 4 S3 85 GN GY PAAN_86 REELS RAISE BK RAI
304. t atime simplifies the above procedure 3 Tighten the roller shaft bolts Set Up and Adjustments Page 7 12 Figure 15 1 Roller shaft clamp bolt 2 Comb teeth Greensmaster 3150 xang SSSR Shield Height Adjustment Adjust shield to get proper grass clipping discharge into basket i 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 n Adjust top bar to make sure clippings are cleanly dis charged from reel area 1 Loosen screws securing top bar Fig 17 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 adju
305. t 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 7 Apply a light coating of petroleum jelly to the inner edge of the dust and quad seals Greensmaster 3150 Page 4 79 Rev C 8 Put the thrust bearing and races into the housing The thrust bearing goes between the two races Fig 46 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 in Ib 16 to 18 Nm
306. t 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 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 groomer Height setting on both ends of groomer should be identi cal Groomer DPA Cutting Unit Rev A Page 10 1 6 1 Figure 3 Height adjustment knob 2 Lock screw lowered 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 parkin
307. t drop after front cutting unit See Troubleshooting in Chapter 5 Hydraulic System Page 9 7 Troubleshooting J oJa 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 Itis important to remember that 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 i e 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 Grooming 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 equip
308. t 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 On 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 cutting unit front roller to line on floor Must be equal within 3 16 0 1867 in Greensmaster 3150 a Repairs Cutting Unit Removal and Installation Remove cutting unit from traction unit before doing adjustments or repairs
309. tact 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 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 PUP BANAT ee MAABOT AS eee A AAA E EYA YY ee A Aye Be p ON OU id im dd 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 slot 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 bedknife angle Recommendations for rear roller brack et position in above chart are designed to give the best rear roller position and bedknife angle for different heights of cut IMPORTANT Rear roller bracket position must be identical on all 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 un
310. talling fasteners into threaded aluminum or brass The specific torque value should be determined based Product Records and Maintenance SAE Grade 1 Bolts Screws Studs amp SAE Grade 5 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts al al C2 C2 A oo N al O al O 00 CO N al I I I I I I I I I al al C2 wm A wm C2 NO N N O A A al 00 N ah I I I N N A A 200 25 225 25 l O C2 C2 NO NO NO al CO N A NO I I H I I I CO CO A A C2 oO Page 2 4 SAE Grade 8 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J995 Grade 5 or Stronger Nuts 170 20 23 2 260 20 190 20 25 2 280 20 330 30 41 4 460 45 350 30 43 4 485 45 42 4 475 45 60 6 675 70 540 45 68 6 765 70 100 10 1125 100 140 15 1580 170 115 10 1300 100 160 15 1800 170 2250 280 300 30 3390 340 2540 280 325 30 3670 340 104 9 75 8 102 11 105 10 142 14 85 4 8 115 11 120 10 163 14 150 15 203 20 210 20 285 27 170 15 230 20 240 20 325 27 265 25 359 34 375 35 508 47 300 25 407 34 420 35 569 47 430 45 583 61 600 60 813 81 475 45 644 61 660 60 895 81 N 2 la RK N jo jo o 4 2 a a o lo a om o amp H I o o o on the fastener size the aluminum or base material strength length of thread engagement etc Note Th
311. te 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 If torque 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 of the pump See pump service manual at the end of this chapter Rev B Greensmaster 3150 Wheel Motors 250 to 400 ft lb 3 pt asi 339 to 542 Nm 24 70 to 90 ft Ib 95 to122 Nm Antiseize Lubricant 2 o gt Ro Figure 23 1 Lugnut 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 Page 4 51 Hydraulic System Front Wheel Motor Removal Fig 23 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
312. ter 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 F Apply a test load of one half the Cranking Perfor mance see Battery Specifications rating of the 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 70 F and up 21 19C and up 9 5 609F 15 69C 9 3 409F 4 49C l If the 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 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 and re painted if necessary 3 Make sure all battery cables and connection are in good condition and that the 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 the battery Tighten bolts with two wrenches 5 Secure battery retainer to the battery with the two win
313. 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 lubri cant to the threads of each bedbar pivot bolt 7 Greensmaster 3150 Page 10 11 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 Adjuster shaft Jam nut Flange bushing Cutting unit frame Wave washer Detent Lock washer
314. 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 On 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 1 Jam nut 2 Pull arm Draw line on floor and center wheels over line 1 Jam nut 2 Pull arm Set Up and Adjustments 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 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
315. the non drive side plate 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 drive side plate bearings taking care not to damage seal in side plate Thread flange nut item 17 onto the shaft threads but do not tighten 4 Make sure that groomer shim item 11 is installed on groomer drive side of cutting unit 5 Carefully place drive side plate onto groomer shaft taking care not to damage seals in side plate Position side plate to the cutting unit frame and secure with two shoulder nuts item 8 Greensmaster 3150 Page 10 1 9 1 Cap screw 2 Front roller shaft Figure 7 3 Groomer shaft assembly 4 Locknut spring washer Figure 8 1 Roller retaining cap screw 2 Cap plug 1 Drive side plate 2 Drive pulley Figure 9 3 Driven pulley Wh e Ei i 1 ES c EL LL s a 2 bk E y Groomer DPA Cutting Unit Rev A D E O lt a 6 Apply grease to drive pulley splines and pulley hub t
316. 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 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 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 co
317. 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 Figure 23 IMPORTANT When installing the bedbar assembly be sure to position the center portion of the grass 1 Rear roller height of cut bracket shield over the rear edge of the bedbar Fig 24 2 Allen set screw Securely seat the 2 bedbar pivot bolts to a maxi 3 Bedbar mounting bolts mum torque of 40 ft Ibs Always check reel bearing 4 Bedknife adjusting screws 5 Height of cut rod locknuts 6 Roller shaft clamp bolts 7 Height of cut adjustment knob 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 2 6 Reverse steps 1 5 to install the bedbar Figure 24 1 Bedbar under lip of shield Greensmaster 3150 Page 7 17 Repairs Bedknife Replacement 1 Remove bedbar 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 bedkni
318. ts Chapter 1 Safety Chapter 6 Wheels and Brakes Safety Instructions o o oooooooo o 1 2 SPCCIICAIONS raras AWA Spore qd m OE Safety and Instruction Decals 1 4 Special Tools oooooooccooccnoo Service and Repairs Chapter 2 Product Records and Maintenance Chapter 7 4 Bolt Adjust Cutting Units Product Records ccc aaa 2 1 38 Equivalents and Conversions 2 2 SPECHICAIONS stu exe iesus andrea 3 x Torque Specifications oooooooo 2 3 Special Tools 0cccecceeceeuceeecs cz MailitelhdliG Borse det edat tuf tee Kasa 2 7 Troubleshooting c cece cece neces EF Maintenance Supervisors Worksheet 2 8 Set Up and Adjustments E E a o Service and Repairs 7 Chapter 3 Engine Chapter 8 Single Point Adjust Cutting Units IMTFOCUCION cir dai dadas 3 2 Specifications ooooooooooonooommo 3 3 Specifications oooooooooooooooomo Service and Repairs 3 4 Special Tools 00 eee Briggs and Stratton Repair Manual for 4 Cycle Troubleshooting cece eee eee eee V Twin OHV Head Engines Set Up and Adjustments Service and Repairs Chapter 4 Hydraulic System Chapter 9 Grooming Reel Cutting Units o SPECIICATONS kaaa tre Eh dew d i a e 4 3
319. ttings m GD ja somes o PF i 1 Mo Binio 8 TORAUTE Reducer 1 an Tera Mo Mo TO ho Ma amp TORO Mo 1255 Ha 4 TOOTS Test Cap Fitting 2 en Bize Toro Ha TOPRAGTE T0 TORAGTE 11 TORAGTE 21 Test Fitting 2 en Siga Tora Ha T 8 20 ORB TOR4OTO 22 V8 Pipe Thi TORAOTD z3 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 by restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system Tam O gt a Figure 9 Wheel Hub Puller TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors Figure 10 Greensmaster 3150 Page 4 17 Rev A Hydraulic System 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 Fitting s hose s or tube s are loose or damaged O ring s or seal s are missing or damaged Oil level in reservoir is low Hydraulic fluid foams Hydraulic system has wrong type of oil The pump suction line has an air leak Hydraulic system operates hot Transmission pressure is high due to load or brakes applied O
320. ugh 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 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 bedknife to renew cutting edges 2 Bedknife pivot ass y 8 Right bedbar pivot bolt 3 Frame supports 9 Steel washer NOTE For proper grinding of bedknife follow proce Aa b Edna pam POP dures in the Toro publication Sharpening Reel and E dame 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 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 bu
321. uide 2 Inspect parts for the following A Leaking cracked or damaged auxiliary tank B Worn or leaking hydraulic hoses Replace if nec essary C Visibly worn or damaged parts Greensmaster 3150 Page 4 85 Rev C Figure 50 Assembly Fig 49 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 49 1 Connecttank hose 23 and install valve assembly If previously removed 2 Connect pump inlet hose to hydrostat Fig 50 3 Connectoverflow 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 31 and flat washer 30 Note Monitor hydraulic fluid level in sight glass As air is removed from t
322. ure 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 Assembly 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 lift arm 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 E D E E O a e 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 uses the same procedure as removal and installation of the groomer reel see Groomer Reel in this section To remove the groomer brush from the shaft remove the lock nut and J bolt from both ends of the brush and slide the brush from the shaft When assembling the brush to the shaft secure the assembly with J bolts and 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
323. ures 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 Greensmaster 3150 wa sAs 9i ne1p H ES CC UU GN3 Y Peet ces ew LIM TVNOILdO 37101 HOIH 098Z NOE d Y 7 a rai MOT 0091 431009 1S1SOHGOAH To a AA AA dH MEER Je 1 jJ SNIONA d E a a ft a 3NWA 092 002 d3318 A INIYA ONIH331S H3MOd AA A y Id V IM Mz 3ATVA y ISd JOHINOO gt Bieta bu MOT s1
324. vents dirt and de bris from entering the housing Toro Part Number 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 Heel Mower Performance and Using the TurfEvaluator Toro part no 97931SL Toro Model Number 04399 SS Figure 6 Figure 7 Figure 8 Figure 9 Dual Point Adjust Cutting Units Page 10 4 Rev A 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 no
325. ver a locating plate indentation Drop a ball 24 into each hole then drop a spring 20 or 21 into each hole E On flow control valve 7 place indicator plate 6 over the 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 45 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 On directional cartridge valve 7 turn 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 and turn knob so it is tight and the arrow is point ing atthe number 1 on the locating plate 19 Hydraulic System Lc E 2 SF IO Optional Backlap Kit Logic Cartridge Valves Fig 40
326. w 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 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 new outer seal in counterbalance weigh
327. 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 2 g E 2 SF IO Hydraulic Manifold Service PLUG TORQUE SAE 4 9 to 11 ft lb 12 to 14 Nm N RIGHT FRONT SAE 6 16 to 18 ft Ib 22 to 24 Nm SAE 8 43 to 46 ft lb 58 to 62 Nm SAE 10 60 to 62 ft Ib 81 to 84 Nm 15 in lb 1 7 Nm Loctite 242 2 sa NG S d Serial Number 230000801 amp Up Shown Figure 39 1 20 watt solenoid 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 S6 23 Seal kit 6 Plug SAE 6 15 Cavity plug Port LC1 24 Seal kit 7 O ring 16 O ring 25 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 R 1 is the reel circuit relief valve and P1 is the gear pump connection port See Hydraulic Schematic to identify the function of the hydraul
328. with the spool as itis removed Greensmaster 3150 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 leakage 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 Fit the 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 ata time 4 Fitthe retaining ring over the centering springs 5 Apply a ligh
329. x SATS EN Se un SIT Figure 14 1 Socket head screw 4 Cutting unit 2 Motor mount 5 Locknut 2 used 3 Groomer side plate RH ed VN Figure 15 1 LH groomer side plate 3 LH groomer arm 2 Lock nut spring washer Greensmaster 3150 Page 10 1 13 Groomer DPA Cutting Unit Rev A E D E E O a Idler Assembly toward center of cutting unit Seal lip toward center of cutting unit Figure 16 1 Lock nut 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 Idler 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 of the 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 pulley 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
330. y of Cut SET UP AND ADJUSTMENTS Characteristics 2 c Sex EE PEE RE E SERVICE AND REPAIRS esr Re Ea Hydraulic Reel Motor Removal Inspection and Installation Backlapping Units without Optional Backlap Variable Reel Speed KID xd acte adt Resa ud ee Kamuka Backlapping Units with Optional Backlap Variable Reel SPEEd KID MEER EROR RNC ER di rise Greensmaster 3150 Page 10 1 Rev A Chapter 10 Dual Point Adjust Cutting Units Bedbar Assembly Ls 10 Bedbar Removal and Installation 11 Bedbar Adjuster Service 12 Bedknife Replacement and Grinding 13 Reel Assembly seess 14 Reel Removal 0a 15 Left Side Plate Service 16 Right Side Plate Service 16 Reel Service aa 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 Height 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
331. y 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 cap screws and hand tighten IMPORTANT Avoid using excessive clamping pressure on the motor housing to prevent distorting the housing 12 Place motor front flange in a vise and alternately torque the cap screws from 33 to 40 ft lb 45 to 55 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 Hydraulic System Sg E Ez SF IO Lift Cylinders RIGHT LIFT CYLINDER LEFT LIFT CYLINDER Figure 34 1 Frame 6 Cap screw 11 Lift arm 2 Straight hydraulic fitting 7 Washer 12 Spacer 3 O ring 8 Pivot pin 13 Spacer 4 O ring 9 Cotter pin 14 Hydraulic cylinder 5 Hose assembly 10 Clevis pin Front Cylinder Removal Fig 34 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 I

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