Toro Greensmaster
3150, Service Manual

Page 1: ... 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 or CAUTION PERSONAL SAFETY INSTRUC This safety symbol means DANGER WARNING TION When you see this symbol carefully read the instructions that follow Failure to obey the instructi...

Page 2: ...This page is intentionally blank Greensmaster 3150 ...

Page 3: ...on 5 4 Troubleshooting 5 5 Electrical System Quick Checks 5 8 Component Testing 5 9 Service and Repairs 5 18 Chapter 6 Wheels and Brakes Specifications 6 2 Special Tools 6 2 Service and Repairs 6 3 Chapter 7 4 Bolt Adjust Cutting Units Specifications 7 2 Special Tools 7 3 Troubleshooting 7 5 Set Up and Adjustments 7 7 Service and Repairs 7 15 Chapter 8 Single Point Adjust Cutting Units Specificati...

Page 4: ...This page is intentionally blank Greensmaster 3150 ...

Page 5: ...Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS 2 Maintenance and Service 4 Before Operating 2 SAFETY AND INSTRUCTION DECALS 4 While Operating 3 Safety Greensmaster 3150 Page 1 1 Safety ...

Page 6: ...wearing sandals tennis shoes or sneakers Do not wear loose fitting clothing which could get caught in moving parts and cause personal injury 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 with the following safety instructi...

Page 7: ...d pressure level of 84 dB A at the operator s ear Ear protectors are recommended for prolonged expo sure to reduce the potential of permanent hearing dam age 17 Raise the cutting units when driving from one work area to another 18 Do not touch engine muffler or exhaust pipe while engine is running or soon after it is stopped because these areas could be hot enough to cause burns 19 If a cutting un...

Page 8: ...unit and the cutting units of the Greensmas ter 3150 If any decal becomes illegible or damaged in 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 ...

Page 9: ...ed and Steel Fasteners Metric Fasteners 5 Other Torque Specifications 6 Product Records Record maintenance and repair information about your Greensmaster 3150 on the MAINTENANCE SUPERVI SOR S WORKSHEET Use this information when refer ring to your machine MAINTENANCE 7 MAINTENANCE SUPERVISOR S WORKSHEET 8 Insert Operator s Manuals and Parts Catalogs for your Greensmaster 3150 traction unit and cutt...

Page 10: ...Equivalents and Conversions Product Records and Maintenance Page 2 2 Greensmaster 3150 ...

Page 11: ... s head or similar condition which affects the installation 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 faste...

Page 12: ...47 4 50 4 68 5 7 16 14 UNC 27 3 27 3 37 4 50 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 5 75 7 77 7 104 9 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 10 142 14 1 2 20 UNF 32 3 53 7 72 9 85 8 115 11 120 10 163 14 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 20 285 27 5 8 18 UNF 75 10 95 15 129 20 170 15 230 20 240 20 325 27 3 4 10 UNC 93 12 140 20 190 27 265 25 359 34 375 35 508 47 3 4 16 UNF ...

Page 13: ... 20 N m 229 22 ft lb 310 30 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 37 ft lb 610 50 N m Product Records and Maintenance 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 installing fasteners into...

Page 14: ...rews Thread Cutting Screws Zinc Plated Steel Zinc Plated Steel Type 1 Type 23 or Type F Thread Size Baseline Torque No 6 32 UNC 20 5 in lb No 8 32 UNC 30 5 in lb No 10 24 UNC 38 7 in lb 1 4 20 UNC 85 15 in lb 5 16 18 UNC 110 20 in lb 3 8 16 UNC 200 100 in lb Thread Size Size Threads per Inch Baseline Torque orque Baseline T Type A Type B No 6 18 20 20 5 in lb No 8 15 18 30 5 in lb No 10 12 16 38 7...

Page 15: ...d recommended service intervals for the Greensmaster Cutting Units are covered in the Cutting Unit Operator s Manual Refer to these publications when performing regular equipment maintenance Re fer to the Engine Operator s Manual for additional en gine specific maintenance procedures Greensmaster 3150 Page 2 7 Product Records and Maintenance Product Records and Maintenance ...

Page 16: ...________________ _______________________________ _______________________________ Product Records and Maintenance Page 2 8 Greensmaster 3150 Date ________________ C Service every 200 hours GREENSMASTER R Unit Designation Hours ______________ ___________________ Service to perform circle Remarks A Service every 50 hours B Service every 100 hours Check Battery Fluid Level Check Battery Cable Connecti...

Page 17: ...Engine 6 SPECIFICATIONS 3 Engine Removal 7 SERVICE AND REPAIRS 4 Engine Installation 7 Fuel Tank 4 BRIGGS STRATTON REPAIR MANUAL FOR Fuel Tank Removal and Installation 5 4 CYCLE V TWIN CYLINDER OHV HEAD ENGINES Greensmaster 3150 Page 3 1 Engine Engine ...

Page 18: ...cle V Twin Cylinder OHV Head Engi nes The use of some specialized test equipment is ex 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 Stratton Vanguard V Twin OHV engines are supplied through your local Briggs and Stratton dealer or distributor If no parts l...

Page 19: ...ed gas engine with cast iron cylinder sleeves Model 350447 Fuel Unleaded Regular Gasoline 85 Pump Octane Minimum Low Idle no load 1650 100 RPM High Idle no load 2850 50 RPM Engine Oil SAE 30 SG SH or SJ Crankcase Oil Capacity qt liters 1 75 1 65 with filter Greensmaster 3150 Page 3 3 Engine Engine ...

Page 20: ...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 12 Vehicle frame 18 Hose clamp 6 Grommet 13 Not used 19 Spacer 7 Flat washer Engine Page 3 4 Greensmaster 3150 ...

Page 21: ...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 fram...

Page 22: ... Screw 21 Engine mount plate 22 Lock washer 23 Cap screw 24 Engine mount 25 Cap screw 26 Hex nut 27 Spring washer 28 Cap screw 29 Engine wire harness 30 Pump hub 31 Hydraulic pump assembly 32 Hardened washer 33 Lock nut 34 Coupling spacer 35 Rubber coupling 36 Flat washer 37 Cap screw 38 Square head set screw 39 Key 40 Engine hub 41 Square head set screw 42 Lock washer 43 Cap screw 44 Key 1 1 2 2 ...

Page 23: ... and remove the three engine mount flange nuts 7 cap screws 1 flat wash ers 2 and spacers 3 9 Remove the engine 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...

Page 24: ...This page is intentionally blank Engine Page 3 8 Greensmaster 3150 ...

Page 25: ... Flow 36 Test No 9 Steering Control Valve 38 ADJUSTMENTS 40 Adjust Manifold Relief Valves R1 and R2 40 SERVICE AND REPAIRS 41 General Precautions for Removing and Installing Hydraulic System Components 41 Gear Pump 42 Gear Pump Service 44 Hydraulic System Start up 45 Hydrostatic Transmission 46 Piston Pump Service 49 Piston Pump Crush Ring Replacement 50 Wheel Motors 51 Wheel Motor Service 55 Flus...

Page 26: ...This page is intentionally blank Hydraulic System Page 4 2 Greensmaster 3150 ...

Page 27: ...800 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 Manifold Relief Valves Mow Circuit R1 2400 PSI 166 bar Cutting Unit Lower R2 300 PSI 21 0 bar over Charge Pressu...

Page 28: ...pin hole leaks or nozzles that eject hydraulic fluid under high pres 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 type of injury Gangrene may result from such an injury Hydraulic Fitting Installation O Ring Face Seal 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches ...

Page 29: ...ays 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 Turn back the jam nut as far as possible Make sure O Ring Lock Nut Back up Washer the back up washer is not loose and is pushed up as far as possible Step 1 5 Install the fitting into the port and tighten finger tight Figure 4 until the washer contacts the face of the ...

Page 30: ...MANIFOLD BLOCK R5 V1 L R END 05 05 05 3 2 1 LOWER RAISE L3B L3A L1B L2B L2A P3 R4 FLOW CONTROL M4 M5 LOWER LOWER RAISE HOLD LOWER AND RAISE 75 PSI Hydraulic Schematic Greensmaster 3150 All solenoids are shown as de energized Serial Number Under 230000801 200 250 PSI BLEED Hydraulic Schematics OPTIONAL 3WD WHEEL MOTOR FORWARD BOTTOM TRACTION WHEEL MOTORS BOTTOM VALVE BOTTOM TOP OPTIONAL KIT FILTER ...

Page 31: ...FOLD BLOCK R5 V1 L R END 05 05 05 3 2 1 LOWER RAISE L3B L3A L1B L2B L2A P3 R4 FLOW CONTROL M4 M5 LOWER LOWER RAISE HOLD LOWER AND RAISE 75 PSI Hydraulic Schematic Greensmaster 3150 All solenoids are shown as de energized Serial Number 230000801 Up ORIFICE S6 125 200 250 PSI BLEED OPTIONAL 3WD WHEEL MOTOR FORWARD BOTTOM TRACTION WHEEL MOTORS BOTTOM VALVE BOTTOM TOP OPTIONAL KIT FILTER PORT PORT POR...

Page 32: ... back plate 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 i...

Page 33: ...IL COOLER OPTIONAL KIT ENGINE RPM OIL FILTER FC1 P1 PT ST GEAR PUMP P1 P2 25 PSI MA MB RD1 020 LC1 MOW BACKLAP M2 M3 FRONT PORT FRONT PORT M1 FRONT PORT REEL MOTORS S4 R2 S3 S2 OPTIONAL BACKLAP VALVES P2 P T E MANIFOLD BLOCK R5 V1 POWER STEERING VALVE L R BALL JOINT END 05 05 05 LIFT CYLINDERS 3 2 1 LOWER RAISE L3B L3A L1B L2B L2A P3 R4 FLOW CONTROL VALVE M4 M5 OPTIONAL 3WD TRACTION WHEEL MOTOR 75...

Page 34: ...ift 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 ...

Page 35: ...ST 1600 LOW IDLE 2850 HIGH IDLE OIL COOLER OPTIONAL KIT ENGINE RPM OIL FILTER FC1 P1 PT ST GEAR PUMP P1 P2 25 PSI MA MB RD1 020 LC1 MOW BACKLAP M2 M3 FRONT PORT FRONT PORT M1 FRONT PORT REEL MOTORS S4 R2 S3 S2 OPTIONAL BACKLAP VALVES P2 P T E MANIFOLD BLOCK R5 V1 POWER STEERING VALVE L R BALL JOINT END 05 05 05 LIFT CYLINDERS 3 2 1 LOWER RAISE L3B L3A L1B L2B L2A P3 R4 FLOW CONTROL VALVE M4 M5 OPT...

Page 36: ...els from rotating On units with the optional backlap kit installed flow through the manifold block is different Oil flow from port 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 ...

Page 37: ...IDLE 2850 HIGH IDLE OIL COOLER OPTIONAL KIT ENGINE RPM OIL FILTER FC1 P1 PT ST GEAR PUMP P1 P2 25 PSI MA MB RD1 020 LC1 MOW BACKLAP M2 M3 FRONT PORT FRONT PORT M1 FRONT PORT REEL MOTORS S4 R2 S3 S2 OPTIONAL BACKLAP VALVES P2 P T E MANIFOLD BLOCK R5 V1 POWER STEERING VALVE L R BALL JOINT END 05 05 05 LIFT CYLINDERS 3 2 1 LOWER RAISE L3B L3A L1B L2B L2A P3 R4 FLOW CONTROL VALVE M4 M5 OPTIONAL 3WD TR...

Page 38: ...ary 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 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 st...

Page 39: ...W IDLE 2850 HIGH IDLE OIL COOLER OPTIONAL KIT ENGINE RPM OIL FILTER FC1 P1 PT ST GEAR PUMP P1 P2 25 PSI MA MB RD1 020 LC1 MOW BACKLAP M2 M3 FRONT PORT FRONT PORT M1 FRONT PORT REEL MOTORS S4 R2 S3 S2 OPTIONAL BACKLAP VALVES P2 P T E MANIFOLD BLOCK R5 V1 POWER STEERING VALVE L R BALL JOINT END 05 05 05 LIFT CYLINDERS 3 2 1 LOWER RAISE L3B L3A L1B L2B L2A P3 R4 FLOW CONTROL VALVE M4 M5 OPTIONAL 3WD ...

Page 40: ...c 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 0 to 1000 PSI A protector valve cuts out when pressure is ...

Page 41: ... 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 Figure 9 Wheel Hub Puller TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wh...

Page 42: ...Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Transmission pressure is high due to load or brakes applied Oil 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 ...

Page 43: ...1 logic valve when Backlap Kit is installed is stuck open Gear pump P1 is damaged see Test 6 ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ Reel speed is erratic Á Á Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Reel to bedknife adjustment is too tight Reel bearing s are damaged The 020 orifice is plugged when Backlap Kit is installed ÁÁÁÁÁÁ...

Page 44: ...ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Spool and sleeve are sticking to steering control housing assembly see Test 9 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ Steering wheel can turn on its own Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Leaf springs in steering control valve are broken or stuck Spool and sleeve are sticking to steering control housing assembly see ...

Page 45: ...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 affe...

Page 46: ...4 M5 DUMP R4 P3 TESTER Flow 3WD OPTIONAL HOSE FROM UPPER FITTING BLEED 200 250 PSI B A High Pressure Low Pressure Return or Suction TRACTION WHEEL MOTORS VALVE HYDROSTAT FROM GEAR PUMP P2 TO HYDRAULIC RESERVOIR REAR WHEEL 3WD MOTOR VALVE TOP BOTTOM Hydraulic System Page 4 22 Greensmaster 3150 ...

Page 47: ...transport posi tion 8 Start engine and move throttle to full speed 2850 50 RPM position CAUTION Use extreme caution when taking gauge read move the machine forward ings The front tire on the ground will be trying to 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 f...

Page 48: ...TESTER Flow 3WD OPTIONAL CAP CAP HOSE FROM UPPER FITTING BLEED 200 250 PSI B A High Pressure Low Pressure Return or Suction TRACTION WHEEL MOTORS VALVE HYDROSTAT TO HYDRAULIC RESERVOIR REAR WHEEL 3WD MOTOR VALVE TOP BOTTOM Hydraulic System Page 4 24 Greensmaster 3150 ...

Page 49: ...ons as TEST NO 1 Traction Drive Hydrostat P3 Flow Make sure the tester flow control valve is fully open CAUTION Use extreme caution when performing test The chine wheel being tested will be trying to move the ma 12 Slowly push traction pedal in forward direction until 1000 PSI 69 bar is displayed on the tester pressure gauge 13 Wheel motor internal leakage will be shown on flow meter in GPM Flow s...

Page 50: ...GEAR PUMP CIRCUIT CIRCUITS AND LIFT CIRCUIT FROM LIFT Flow 3WD OPTIONAL BLEED 200 250 PSI B A CHARGE PORT PRESSURE GAUGE High Pressure Low Pressure Return or Suction TRACTION WHEEL MOTORS VALVE HYDROSTAT TO REEL MOTOR REAR WHEEL 3WD MOTOR TO STEERING VALVE TOP BOTTOM PUMP P3 Hydraulic System Page 4 26 Rev A Greensmaster 3150 ...

Page 51: ...o 10 4 bar Record test results 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...

Page 52: ...e Gauges Flow P1 P2 ENGINE RPM GEAR PUMP CHARGE CIRCUIT CIRCUIT CIRCUIT FROM P T E R5 V1 L R TESTER High Pressure Low Pressure Return or Suction TO TRACTION TO STEERING AND LIFT CIRCUITS TO REEL MOTOR TO LIFT HYDROSTAT POWER STEERING VALVE PUMP DISCHARGE FITTING Hydraulic System Page 4 28 Greensmaster 3150 ...

Page 53: ...Use same tester connections as described above steps 3 and 4 Fully open control valve on the tester 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 ...

Page 54: ... MA MB V1 FLOW CONTROL TESTER FROM S4 S3 S1 S2 FRONT RIGHT Flow CHARGE TRACTION BACKLAP TO R5 25 PSI CIRCUIT 1 REELS T S1 R1 ORIFICE S6 125 Serial Number 230000801 Up Shown RELIEF S6 High Pressure Low Pressure Return or Suction VALVES LIFT CYLINDERS OIL COOLER FILTER STEERING CONTROL VALVE OPTIONAL KIT VALVE TO AND FROM REEL MOTORS HYDROSTAT VALVE R2 Hydraulic System Page 4 30 Greensmaster 3150 ...

Page 55: ...oid S4 C Connect male connector from solenoid S4 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 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 R...

Page 56: ...er and Pressure Gauges TO HYDRAULIC MANIFOLD PUMP P1 OUTLET TO HYDRAULIC MANIFOLD TO STEERING AND LIFT CIRCUITS P1 P2 ENGINE RPM GEAR PUMP TESTER High Pressure Low Pressure FROM HYDROSTAT Return or Suction Flow Hydraulic System Page 4 32 Greensmaster 3150 ...

Page 57: ... 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 CAUTION this test Do not engage the cutting units when performing 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 b...

Page 58: ...3B L3A OPTIONAL S2 S3 S4 R2 FC1 LC1 RD1 D1 TO MANIFOLD BLOCK MA MB TO AND FROM LIFT CYLRS HYDRAULIC VALVES RESERVOIR TO LEFT REEL MOTOR TO AND FROM REEL MOTORS P1 PT ST P2 FROM STEERING CIRCUIT High Pressure FROM GEAR PUMP P1 Low Pressure Return or Suction Flow Serial Number 230000801 Up Shown Hydraulic System Page 4 34 Greensmaster 3150 ...

Page 59: ...speed set ting fully open 2 1 FRONT S6 Serial Number 230000801 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 Hydraulic System CAUTION sonal injury from the rotating reel blades Keep away from r...

Page 60: ...RETURN RETURN CASE DRAIN RIGHT MOTOR RIGHT MOTOR REAR MOTOR REAR MOTOR LEFT MOTOR LEFT MOTOR MEASURING M1 M2 M3 FROM MANIFOLD RIGHT REAR LEFT Flow High Pressure Low Pressure Return or Suction CONTAINER PORT MA TO MANIFOLD PORT MB TO HYDRAULIC RESERVOIR MOTOR MOTOR MOTOR Hydraulic System Page 4 36 Greensmaster 3150 ...

Page 61: ...he tester and measures case drain leakage Make sure functional control lever is in NEUTRAL Start engine and move the throttle to full speed 2850 50 RPM 9 Use measuring container Tool TOR4077 see Spe cial Tools to collect hydraulic fluid for 15 seconds 10 Disengage cutting units by positioning functional control lever to NEUTRAL position Open control valve on tester and stop the engine 11 Measure t...

Page 62: ...eering Control Valve POWER L R E T P V1 STEERING STEERING CYLINDER PLUG Flow CYLINDER ROD R5 High Pressure Low Pressure Return or Suction VALVE LEFT TURN FULLY EXTENDED Hydraulic System Page 4 38 Greensmaster 3150 ...

Page 63: ...ecked 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 counterclockwis...

Page 64: ...ulic of the valve with the cap off Personal injury may 1 Locate relief valve and remove cap from valve Note An 1 8 turn of the adjustment socket is about 50 psi 3 5 bar or 1 turn is about 400 psi 27 6 bar 2 To increase pressure setting turn the adjustment socket inside the valve 1 8 of a turn clockwise 3 To decrease pressure setting turn the adjustment socket inside the valve 1 8 of a turn counter...

Page 65: ...r 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 After Repair or Replacement of Components 1 Check oil level in the hydraulic reservoir and add cor rect oil if necessary Drain and ...

Page 66: ...ize Lubricant 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 ...

Page 67: ...r pump from the hydrostat by removing both hex socket head screws and flat washers Remove O ring from between the gear pump and hydrostat 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 Posit...

Page 68: ...ont body 10 Pressure seal 17 Washer 4 Back body 11 Cap screw 18 Plug 5 Drive gear 12 O ring 19 Suction fitting 6 Front idler gear 13 Adapter plate 20 Washer 7 Back idler gear 14 Key 21 Shaft seal Note For repair of the gear pump see Eaton Gear Pumps Repair Information Series 26 Model 26000 Multiple Gear Pumps at the end of this chapter Hydraulic System Page 4 44 Greensmaster 3150 ...

Page 69: ...arter for fifteen 15 seconds to the prime pump 7 Reconnect electrical connector to the fuel stop sole noid 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 CAUTION Contact with the re...

Page 70: ... Lock nut 23 Square head set screw 24 Pump hub 25 Coupling spacer 26 Drive coupling 27 Flat washer 28 Cap screw 29 Lock nut 30 Engine hub 31 Flat washer 32 Cap screw 33 Flat washer 34 Lock washer 35 Cap screw 36 O ring 37 Support clamp 38 Cap screw 39 Flat washer 40 Tube assembly 41 O ring 42 90o hydraulic fitting 43 O ring 44 Hose assembly 45 O ring 46 45o hydraulic fitting 47 O ring Figure 17 An...

Page 71: ...t and secure the neutral system assembly up and away from the hydrostat 5 1 2 3 4 6 6 Figure 19 1 4 Hydrostat 2 5 Cable support assembly 3 Pump lever assembly 6 Cap screw Pivot washer Cap screw SUCTION PORT CAUTION and Installing Hydraulic System Components Before continuing further read and become fa miliar with General Precautions for Removing 6 Label all hose connections for reassembly pur pose...

Page 72: ...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 IMPORTANT Failure to remove the plug will cause excessive pressure in the hydrostat and damage seals 8 Remove plug from the suction port o...

Page 73: ...ining ring 31 Bearing race 32 Thrust bearing 33 Washer 34 Shaft seal 35 Retaining ring 36 Retaining ring 37 O ring 38 O ring 39 Seal kit 40 O ring 41 Charge relief housing 42 Charge relief poppet R4 43 Charge relief spring 44 Washer 45 Retaining ring 46 Bleed off valve poppet 47 Bleed off spring 48 O ring 49 Cartridge Figure 21 18 37 36 REAR OF TRACTION UNIT 44 42 43 41 40 49 47 48 46 45 4 Note Fo...

Page 74: ...r preload A If torque is too low add additional shims and re 1 Remove crush ring from the cover plate Measure peat steps 3 through 6 until the specified torque is thickness of crush ring achieved 2 Stack shims to the thickness of the crush ring B If torque is too high remove shims and repeat steps 3 through 6 until the specified torque is 3 Insert shims into the cover plate in the same location ac...

Page 75: ...15 Hydraulic hose 16 Hydraulic hose 17 45o hydraulic fitting 18 O ring 19 O ring 20 Hydraulic motor 21 Flat washer 22 Brake rod 23 Brake lever 24 Lock nut 25 Jam nut 26 Cap screw 27 Cap screw 28 Lock nut 29 Lock nut 30 Cap screw 31 Swivel clevis 32 Lock nut FRONT RIGHT 21 31 27 29 24 30 26 1 2 7 8 14 18 20 22 23 10 9 25 12 15 16 28 12 11 3 4 5 6 19 17 13 250 to 400 ft lb 339 to 542 Nm 70 to 90 ft ...

Page 76: ...r 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 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 ...

Page 77: ... 10 Bearing 11 Bearing flangette 12 Cap screw 13 Lock nut 14 Wheel motor hub assembly 15 Adapter 16 Cap screw 17 Bracket 18 Flat washer 19 Hose assembly 20 Tube assembly 21 Clamp 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 Figure 24 FRONT RIGHT 70 to 90 ft lb 95 to122 Nm 85 ft lb 115 Nm 30 ft lb 41 Nm 80 to 100 in lb ...

Page 78: ... nuts 30 and wheel assembly from the hub drive studs Note For disassembly of the hub from the rear wheel motor see Rear Wheel Optional 3WD Disassembly in structions in Chapter 6 Wheels and Brakes 24 Note For assembly 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 a...

Page 79: ...3 Drive link 22 Manifold 4 Back up washer 14 Cap screw 23 Commutator ring 5 Seal rings 15 Commutator seal 24 End cover 6 Back up washer 16 Commutator 25 Rotor set 7 Inner seal 17 Woodruff key 26 Commutator assembly 8 Thrust washer 18 Wear plate 27 Seal kit 9 Thrust bearing 19 Rotor 28 Housing assembly 10 Bearing Note For repair of the wheel motors see the Ross Torqmotor TM MG MF MP MB ME and MJ Se...

Page 80: ... 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 Di...

Page 81: ... 11 90o hydraulic fitting 12 O ring 13 O ring 14 Straight hydraulic fitting 15 O ring 16 O ring 17 Hose assembly 18 Hose assembly 19 Hose assembly 20 Hose assembly 21 Hose assembly 22 Hose assembly 23 90o hydraulic fitting 24 O ring 25 Washer 26 Spacer 27 Grommet 28 Bulkhead nut 29 Tee hydraulic fitting 30 O ring 31 Bulkhead nut Figure 28 31 30 29 30 25 24 24 23 26 27 28 25 22 21 20 11 12 13 5 6 7...

Page 82: ...o 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 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 ...

Page 83: ...11 Front flange 4 Tab washer 8 Body Disassembly 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 DIAGONAL MARK Hydraulic System Figure 30 Greensmaster 3150 Page 4 59 Hydraulic System ...

Page 84: ... push 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 shaf...

Page 85: ... to the body 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 s...

Page 86: ...d Installing Hydraulic System Components 2 Label all hydraulic connections for reassembly 3 Disconnect hose assemblies and O rings from the hydraulic fittings at the lift cylinder Allow hoses to drain into a suitable container 4 Remove cotter pin and clevis pin from the cylinder clevis 5 Support hydraulic cylinder to prevent it from drop ping A Remove cap screw and washer from the pivot pin B Pull...

Page 87: ...g 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 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 hyd...

Page 88: ...vis 9 Jam nut 10 Internal collar 11 Head 12 Rod 13 Piston 14 Lock nut 15 Barrel Figure 36 24 to 30 ft lb 33 to 41 Nm FRONT HYDRAULIC CYLINDER Loctite 242 1 Seal kit 2 T seal 3 O ring 4 Rod seal 5 O ring 6 Back up ring 7 Dust seal 8 Not used 9 Not used 10 Internal collar 11 Head 12 Rod 13 Piston 14 Lock nut 15 Barrel Figure 37 REAR HYDRAULIC CYLINDER 24 to 30 ft lb 33 to 41 Nm ÉÉ 1 2 3 5 6 4 7 10 1...

Page 89: ...dust seal with clean hydraulic oil A Install T ring and O ring on the piston B Install O ring back up ring and dust seal on the head IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surface before mount ing in a vice 3 Mount shaft securely in a vise by clamping on the cle vis or eye of the shaft A Coat shaft with clean hydraulic oil B Slide head onto the shaft Install rod s...

Page 90: ...s 11 Rod 12 Head 13 Retaining ring 14 Piston 15 Lock nut 16 Barrel Figure 38 FRONT HYDRAULIC CYLINDER 1 9 8 7 6 5 4 3 2 15 14 13 12 11 10 16 60 to 75 ft lb 82 to 101 Nm 1 Seal kit 2 Wear ring 3 Seal with loader 4 O ring 5 Back up ring 6 O ring 7 Seal 8 Wiper 9 Head 10 Rod 11 Retaining ring 12 Piston 13 Lock nut 14 Barrel Figure 39 REAR HYDRAULIC CYLINDER 60 to 75 ft lb 82 to 101 Nm 1 2 3 5 6 4 7 1...

Page 91: ...iper from the head Remove o ring from rod Assembly 1 Make sure all parts are clean before reassembly 2 Coat new seal kit components with clean hydraulic oil A Install wear ring and seal with loader on the pis ton B Install o ring back up ring and seal on the head C Install o ring to groove in rod IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surface before mount ing in a...

Page 92: ...o hydraulic fitting 16 O ring 17 O ring 18 Tube assembly 19 90o hydraulic fitting 20 O ring 21 O ring 22 Hose assembly 23 Straight hydraulic fitting 24 Hose assembly 25 Hose assembly 26 Cap screw 27 Straight hydraulic fitting 28 O ring 29 O ring 30 Hose assembly 31 Straight hydraulic fitting 32 O ring 33 O ring 34 Hose assembly 35 45o hydraulic fitting 36 Tube assembly 37 Tube assembly Figure 38 F...

Page 93: ...m 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 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...

Page 94: ... Figure 39 1 2 3 4 5 6 7 8 9 6 7 12 13 15 5 4 1 1 5 4 6 4 6 7 6 5 4 5 4 10 11 16 17 18 19 19 23 20 20 24 20 25 21 22 15 in lb 1 7 Nm 35 ft lb 47 Nm 35 ft lb 47 Nm 35 ft lb 47 Nm 15 in lb 1 7 Nm 35 ft lb 47 Nm Loctite 242 Loctite 242 PLUG TORQUE SAE 4 9 to 11 ft lb 12 to 14 Nm SAE 6 16 to 18 ft lb 22 to 24 Nm SAE 8 43 to 46 ft lb 58 to 62 Nm SAE 10 60 to 62 ft lb 81 to 84 Nm 5 4 2 FRONT RIGHT Seria...

Page 95: ...ld 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 C Torque cartridge valve using a deep socket to 35 ft lb 47 Nm D Make sure a new O ring is at each 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...

Page 96: ...ator plate 20 Spring 21 Spring 22 Detent plate 23 Set screw 24 Ball 25 Locating plate 26 Locating plate 27 Orifice 020 28 Manifold Figure 40 2 1 3 4 6 5 9 10 12 11 8 7 13 14 15 16 25 23 22 18 17 24 21 19 20 26 28 35 ft lb 47 Nm 35 ft lb 47 Nm FRONT RIGHT 27 Serial Number 230000801 Up Shown Note The ports on the manifold are marked for easy identification of components Example LC1 is for the reel l...

Page 97: ... 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 lb 47 Nm 7 Reinstall knob assembly A Install applicable locating plate 25 or 26 so that the pin seats into the locating hole B Turn the threaded cartridge valve 7 or 13 stem carefully clockwise until it stops C Fa...

Page 98: ...nction B If sealing surfaces appear pitted or damaged the hydraulic system may be overheating or there may be water in the system 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 press...

Page 99: ...mbly 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 fitti...

Page 100: ...rew 13 Steering mount 14 Cap screw 15 Steering column 16 Lock nut 17 Lock washer 18 Flat washer 19 Straight hydraulic fitting 20 O ring 21 O ring 22 Hose assembly 5 23 Straight hydraulic fitting 24 O ring 25 Panel nut 26 Steering valve cover 27 Cap screw 28 Flat washer 29 Spacer 30 Knob 31 Lock nut 32 Hair pin Figure 43 FRONT RIGHT 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 20 21 22 24 23 ...

Page 101: ...and remove O rings 21 and 24 from hydraulic fittings 19 and 23 Al low hoses to drain into a suitable container Note Disconnect hydraulic hose assemblies 22 at the manifold block P2 or ST ports at the steering cylin der or at the hydraulic pump if necessary Fig 44 P2 OUTPUT TO STEERING VALVE Figure 44 Installation Fig 43 1 Install hydraulic fittings 19 and 23 and O rings 20 to the steering control ...

Page 102: ...nents 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 4 Slide the spool and sleeve assembly fro...

Page 103: ...ings 5 Apply a light coating of clean hydraulic fluid to the spool and slide it into the sleeve Be sure the centering springs fit into the notches in the sleeve 6 Install the pin 7 Apply a light coating of petroleum jelly to the inner edge of the dust and quad seals 8 Put the thrust bearing and races into the housing The thrust bearing goes between the two races Fig 46 IMPORTANT Do not damage the ...

Page 104: ...eal 16 Slotted hex nut 17 Spacer 18 Cotter pin 19 Lug nut 20 Valve stem 21 Tire 22 Rim 23 Spacer 24 Seal 25 Bearing cone 26 Bearing cup 27 Hub 28 Drive stud 29 Grease fitting 30 Castor fork 31 Cap screw 32 Lock nut 33 Adapter plate 34 Lock nut 35 Lock nut 36 Motor plate 37 Castor bolt 38 Cap screw 39 Lock nut 40 Flat washer Figure 47 FRONT RIGHT 7 8 11 9 10 10 11 9 12 13 20 19 23 16 2 1 2 40 39 21...

Page 105: ...oses 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 Installation Fig 47 1 Secure cylinder rod end to the castor fork with spacer slotted hex nut and cotter pin to rear wheel...

Page 106: ...Steering Cylinder Service 1 Seal kit 2 Rod wiper 3 U cup 4 Back up ring 5 O ring 6 Wear ring 7 O ring 8 O ring 9 Set screw 10 Cap 11 Head 12 Piston 13 Barrel 14 Grease fitting 15 Rod Figure 48 8 2 3 1 4 6 7 9 2 3 4 5 5 10 11 12 13 14 10 9 11 15 6 ...

Page 107: ...rts 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 Asse...

Page 108: ...rene washer 5 Flat washer 6 Cap screw 7 Breather adapter 8 Breather cap 9 Cap screw 10 Spacer long 11 Sight gauge 12 O ring 13 Hose clamp 14 90o 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 23 Tank hose 24 Lock washer 25 Cap screw 26 Hose clamp 27 Overflow Hose 28 Straight barb fitting 29 Tether 30 Flat washer 31 Cap screw 32 Valve hose ...

Page 109: ...move 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 guide 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 Figure 50 PUMP INLET HOSE Assembly Fig 49 1 Coat all O rings with clean hydra...

Page 110: ...ee if all con nections are secure 11 Verify leak detector operation Hydraulic Reservoir 1 Straight hydraulic fitting 2 O ring 3 O ring 4 Oil level sensor 5 O ring 6 Hydraulic tank 7 Tether 8 Pin 9 Tank cap 10 Filler screen 11 Overflow hose 12 Hose clamp 13 Hydraulic barb fitting 14 O ring 15 Hose clamp 16 Return hose 17 Pump inlet hose 18 Plug early units only 19 Cap screw 20 Flat washer 21 Gromme...

Page 111: ...er 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 Figure 52 PUMP INLET HOSE REEL MOTOR CASE DRAIN FITTING Installing Hydraulic Reservoir Fig ...

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Page 113: ...ONENT TESTING 9 Ignition Switch 9 Hour Meter 9 Relays 10 Solenoid Valve Coils 10 Seat Switch 11 Fuse Block 11 Neutral and Mow Switches 12 Parking Brake Sensor 13 Joystick Raise and Lower Switches 14 Backlap Switch Optional 14 Lower Reels Time Delay 15 Leak Detector Alarm and Delay Timer 15 Leak Detector Float Switch 16 Leak Detector Solenoid Valve 16 Diodes 17 SERVICE AND REPAIRS 18 Verify Interlo...

Page 114: ...Electrical Schematics The electrical schematic and other electrical drawings for the Greensmaster 3150 are located in Chapter 11 Electrical Diagrams Electrical System Page 5 2 Greensmaster 3150 ...

Page 115: ...L 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 ele...

Page 116: ...iliary tank The float TANK stays in the raised position keeping alarm circuit open SIGHT GAUGE SOLENOID VALVE closed ALARM raised open MAIN HYDRAULIC TANK off FLOAT SWITCH Figure 4 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 Dur...

Page 117: ...arge is low Battery cables are loose or corroded Battery ground to frame is loose or corroded Wiring at starter is faulty Starter solenoid is faulty Starter mounting bolts are loose or not supplying a sufficient ground for solenoid Starter is faulty and causing an incomplete circuit for the solenoid Relay K2 has intermittent ground Nothing happens when start attempt is made Battery is dead Wiring ...

Page 118: ... Possible Causes Engine kills when the Functional Control Lever is in the MOW or TRANSPORT position with the operator in the seat Operator is sitting too far forward on the seat seat switch not depressed Parking brake is set Parking brake switch is faulty Seat switch is faulty Seat switch wiring is loose corroded or damaged Battery does not charge Wiring to the charging circuit see Wiring Schemati...

Page 119: ...unded 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 W...

Page 120: ...sso ries turned off Connect the positive meter lead to the positive battery post and the negative meter lead the the negative battery post Note This test provides a relative condition of the bat tery Load testing of the battery will provide additional and more accurate information Voltage Measured Battery Charge Level 12 68 V or higher Fully charged 100 12 45 V 75 charged 12 24 V 50 charged 12 06 ...

Page 121: ...wn 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 POSITION CIRCUIT OFF NONE RUN B I A X Y START B I S A B S Y X I SWITCH HEX NUT KEY LOCK WASHER Figure 6 Hour Meter 1 Connect the positive terminal of a 12 VDC source to the po...

Page 122: ... removed from terminal 85 5 Disconnect voltage from and multimeter leads from relay terminals Figure 8 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 ...

Page 123: ... 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 2 3 1 Figure 10 1 Seat bolts 3 Seat switch 2 Electrical connector Fuse Block Fuses can be removed to check continuity The test me ter should read less than 1 ohm Fuses su...

Page 124: ...uld have continuity Fig 12 4 If the neutral or mow switches do not satisfy any of the tests described 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 clos...

Page 125: ... 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 1 3 Figure 14 1 Mounting plate 3 Parking brake sensor 2 Latch...

Page 126: ...e 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 insta...

Page 127: ...2VDC 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 Figure 17 TIME DELAY Figure 18 3 2 1 4 5 LOAD INPUT VOLTAGE TIMING RESISTOR 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 o...

Page 128: ...position 1 2 Figure 20 1 Main hydraulic tank 2 Float switch 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 ...

Page 129: ...l Sensor and Seat switch by allowing a ground path for the Start Safety relay K2 when it de energizes D1 A D1 B D1 C D1 D DIODE CIRCUIT BOARD Diode D1 C Figure 23 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 e...

Page 130: ...y 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 i...

Page 131: ...filler caps are on tightly oil Clean the battery with a solution of baking soda 4 Remove battery from the battery compartment to a and water then rinse it with clean water service area This will minimize possible battery dam D Check that the cover seal is not broken away age and allow better access for inspection and service Replace the battery if the seal is broken or leaking Inspection Maintenan...

Page 132: ...nufacturer 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 Minimum Voltage Battery Electrolyte Temperature 9 6 70oF and up 21 1oC and up 9 5 60oF 15 6oC 9 4 50oF 10 0oC 9 3 40oF 4 4oC 9 1 30oF 1...

Page 133: ...onnection is made 4 Charge the battery following the manufacturer s Battery Charge Level Specific Gravity Open Circuit Voltage 100 1 265 12 68 75 1 225 12 45 50 1 190 12 24 25 1 155 12 06 0 1 120 11 89 2 Determine the charging time and rate using the manufacturer s battery charger instructions or the following table instructions 5 Occasionally check the temperature of the battery electrolyte If th...

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Page 135: ...and Brakes Table of Contents SPECIFICATIONS 2 SERVICE AND REPAIRS 3 SPECIAL TOOLS 2 Rear Wheel 2WD 3 Rear Wheel Optional 3WD 6 Front Wheel and Brake 9 Greensmaster 3150 Page 6 1 Rev A Wheels and Brakes Wheels and Brakes ...

Page 136: ...ear 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 Page 6 2 Rev A Greensmaster 3150 ...

Page 137: ...ter pin 3 Bearing cone 16 Spacer 28 Slotted hex nut 4 Washer 17 Hub assembly 29 Spacer 5 Slotted hex nut 18 Seal 30 Adapter plate 6 Cotter pin 19 Bearing cone 31 Lock nut 7 Grease fitting 20 Bearing cup 32 Lock nut 8 Jam nut 21 Hub 33 Motor adapter plate 9 Rod end 22 Grease fitting 34 Castor bolt 10 Dust seal 23 Drive stud 35 Cap screw 11 Lug nut 24 Castor fork 36 Lock nut 12 Wheel assembly 25 Cap...

Page 138: ...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 4 1 2 3 5 3 5 1 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 bear...

Page 139: ...ers Make sure the fuel hose support clamps are positioned correctly I Torque cap screws from 20 to 25 ft lb 27 to 34 Nm 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...

Page 140: ...earing flangette lube 10 Bearing 11 Bearing flangette 12 Cap screw 13 Lock nut 14 Wheel motor hub assembly 15 Adapter 16 Cap screw 17 Bracket 18 Flat washer 19 Hose assembly 20 Tube assembly 21 Clamp 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 Figure 4 FRONT RIGHT 70 to 90 ft lb 95 to122 Nm 85 ft lb 115 Nm 30 ft lb 41...

Page 141: ...hydraulic motor and hub as sembly to the castor fork C Lower wheel and hydraulic motor and hub as sembly from the castor fork 4 Loosen set screws 27 on bearing 10 Pull flan gettes 9 and 11 and bearing from the hydraulic motor shaft 5 Remove grease fitting 31 from the hydraulic motor and hub assembly 14 Remove four lug nuts 30 and wheel 28 from the hub drive studs 6 If damage to the castor fork bea...

Page 142: ...ve 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 OUTER BEARING EDGE ARROWS ON BEARING TOWARDS LONG END MUST BE FLUSH WITH EDGE Figure 6 Installation Fig 4 1 Secure wheel 28...

Page 143: ...et 15 Hydraulic hose 16 Hydraulic hose 17 45o Hydraulic fitting 18 O ring 19 O ring 20 Hydraulic motor 21 Flat washer 22 Brake rod 23 Brake lever 24 Lock nut 25 Jam nut 26 Cap screw 27 Cap screw 28 Lock nut 29 Lock nut 30 Cap screw 31 Swivel clevis 32 Lock nut FRONT RIGHT 21 31 27 29 24 30 26 1 2 7 8 14 18 20 22 23 10 9 25 12 15 16 28 12 11 3 4 5 6 19 17 13 250 to 400 ft lb 339 to 542 Nm 70 to 90 ...

Page 144: ...e 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 shoe...

Page 145: ... ADJUSTMENTS 7 Cutting Unit Removal and Installation 15 Adjustment Summary and Check List 7 Reel Lapping 16 Reel Bearing Service and Adjustment 8 Bedbar Removal and Installation 17 Bedknife To Reel Adjustment 9 Bedknife Replacement 18 Leveling Rear Roller to Reel 10 Preparing Reel For Grinding 18 Height Of Cut 11 Reel Removal and Bearing Replacement 19 Front Roller Scraper Adjustment 12 Lift Bail ...

Page 146: ...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 lb Reel Splined Drive Nut Torque 40 to 60 ft lbs Reel Bearing Rolling Torque 7 in lb max Front or Rear Roller Run Out 0 014 in max 1 Lift bail 5 Height of cut adjustment locknut 8 Gras...

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Page 162: ...er 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 are disconnected from...

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Page 165: ...20 Bedknife to Reel Contact 9 Bedbar Removal and Installation 20 Reel Bearing Service and Adjustment 10 Bedbar Bushing Replacement 22 Parallel Bedknife to Reel 11 Bedknife Replacement 23 Leveling Rear Roller to Reel 12 Preparing Cutting Unit for Reel Grinding 23 Height of Cut 14 Reel Removal and Bearing Replacement 24 Front Roller Scraper Adjustment 16 Bedknife Adjustment Knob Bearing Service 25 C...

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Page 167: ...knife adjusts against reel with positive adjustment control knob lo 1 Lift bail 4 Pull rod studs 2 Height of cut adjustment knob 5 Grass shield 3 Height of cut adjustment locknut 6 Reel 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 Reel Speed 1940 rpm engine speed 2800 rpm Bedknife S...

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Page 187: ...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 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 ...

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Page 191: ... 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 Groomer Reel Drive Belt Adjustment 9 19 Pull Frame Adjustment 9 20 REPAIRS 9 21 Cutting Unit Removal and Installation 9 21 Reel Lapping 9 22 Bedbar Remova...

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Page 193: ...w 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 Reel 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 lb max Front or Rear Roller Run Out 0 014 in max Groomer Reel Drive Belt Tension 1 4 in deflection when a force ...

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Page 215: ...f this chapter 1 Do steps 1 6 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 remove taper when grinding 2 Raise or remove front roller assembly A Loosen the locknuts securing height of cut ad justing rods at bo...

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Page 225: ...l Speed Kit 9 Dual Point Adjust Cutting Units Table of Contents Bedbar Assembly 10 Bedbar Removal and Installation 11 Bedbar Adjuster Service 12 Bedknife Replacement and Grinding 13 Reel Assembly 14 Reel Removal 15 Left Side Plate Service 16 Right Side Plate Service 16 Reel Service 17 Reel Installation 18 Preparing a Reel for Grinding 19 Front Roller Removal and Installation 20 Roller Service Roll...

Page 226: ...s factory installed on the right end and held in place by a snap ring Frame Construction Precision machined die cast alu minum cross member with two bolt on die cast alumi num side plates 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...

Page 227: ... TOR299100 Figure 3 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 bedbar 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 Figure 4 Roller Bearing Installation Tools Washers and spacer used to install...

Page 228: ...Plug This cap is used for placement into the bearing housing when the reel motor is removed It prevents dirt and de bris from entering the housing Toro Part Number 2410 30 Figure 8 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 determinin...

Page 229: ... engine speed Adjust engine to specifications if necessary See Maintenance section in the Traction Unit Operator s Manual and or the Briggs Stratton Repair Manual for 4 cycle V Twin Cylinder OHV Head Engines Reel speed 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 backl...

Page 230: ...ctive 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 S...

Page 231: ...ting edges assures good quality of cut and greatly reduces the need for routine backlapping In addition the rear roller positioning system allows for two height of cut ranges If a cutting unit is determined to be out of adjustment complete the following procedures in the specified order to adjust the cutting unit properly 1 Adjust the bedknife parallel to the reel 2 Determine desired height of cut...

Page 232: ... 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 CAUTION Be careful when backl...

Page 233: ...lapping compound with a long handled brush see Special Tools CAUTION Be careful when backlapping the reel because contact with the reel or other moving parts can result in personal injury CLOCKWISE 1 2 3 4 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 ...

Page 234: ... Nm Figure 12 1 Side plate 7 Bedbar pivot bolt 13 Cap screw 2 Rubber bushing 8 Flange nut 14 Rear roller assembly 3 Flange bushing 9 Flange nut 15 Lock nut 4 Washer plastic 10 Shim 16 Bedknife 5 Washer metal 11 Spacer 17 Bedknife screw 6 Bedbar 12 Retainer Dual Point Adjust Cutting Units Page 10 10 Greensmaster 3150 ...

Page 235: ...l 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 ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÂÂÂÂ ÂÂÂÂ ÂÂÂÂ ÂÂÂÂ ÂÂÂÂ ÂÂÂÂ ÂÂÂÂ ÂÂÂÂ ÂÂÂÂ 1 2 3 4 5 6 7 8 5 4 Figure 13 1 Sideplate 5 Washer metal 2 Rubber bushing 6 Bedbar 3 Flange bushing 7 Bedbar pivot bolt 4 Washer pla...

Page 236: ...adjuster shaft 1 3 Apply antiseize lubricant on internal threads of ad 4 Remove jam nut 5 and wave washer 4 from ad juster shaft 1 and slide into flange bushings in cutting juster shaft and remove adjuster shaft from cutting unit unit frame frame 4 Install wave washer 4 Apply Loctite 242 or equiva 5 Inspect flange bushings 2 and remove if necessa lent to the threads of the jam nut 5 Tighten jam nu...

Page 237: ...rinding Since there can be variations in the mounting surface of the bedbar a new bedknife will not be perfectly flat after Figure 16 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 Relief Angle Front Angle Top Face knife and grind only enough to make sure the top surface 1 2...

Page 238: ... 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...

Page 239: ...trap 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 sid...

Page 240: ...and outer grease seal 9 lips with Mobil High Tempera ture HP or equivalent grease 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 th...

Page 241: ...ould be free of bending and distortion Check the splines for excessive cracks or distortion Replace the reel if necessary D Check the service limit of the reel diameter Re place the reel if necessary 5 Using an appropriate 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 f...

Page 242: ...e 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 2 1 Figure 23 1 Rear roller 2 Saddle clamp 10 Install the front roller see Front Roller Installation in ...

Page 243: ...ding 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 Reel Grinding Specifications Nominal Reel Diameter 5 06 in 128 5 mm Service Limit Reel Diameter 4 56 in 118 8...

Page 244: ...ller bracket if necessary Installation Fig 25 1 Place cutting unit on a level working surface 2 If both front roller brackets were removed A Insert carriage screw through the cutting unit side plate and front bracket Secure carriage screw and roller bracket with tab washer and lock nut 2 4 3 5 6 1 Figure 25 1 Cap screw 4 Carriage screw 2 Roller assembly 5 Lock nut 3 Front roller bracket 6 Tab wash...

Page 245: ...This page is intentionally blank Greensmaster 3150 Page 10 21 Rev A Dual Point Adjust Cutting Units Cutting Units ...

Page 246: ...ugh the seal removal tool and into the drilled holes in the seal 188 in dia 2 625 in dia 1 4 20 UNC 2 625 in 625 in 1 05 in 1 05 in 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 Insta...

Page 247: ...aring cavity and remove any rust or corrosion with an abrasive cloth 6 Inspect bearings roller shaft spiral retaining rings and roller body for wear or damage Replace compo nents as necessary Bearing Installation 1 Pressing against the outer race of the bearing only drive one bearing all the way into either end of the roller body Fig 28 2 Slide roller shaft through roller body and installed bearin...

Page 248: ...ller assembly in bench vise and lightly tap one end of roller shaft until seal and bearing are removed from roller cavity Remove second seal and bearing from roller cavity by tapping on shaft 5 Clean bearing cavity in roller and remove any rust with crocus cloth Assembly 1 Place roller shaft into roller Note If bearing lock nuts are being replaced use original lock nuts for assembly purposes if po...

Page 249: ...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 If original bearing lock ...

Page 250: ...This page is intentionally blank Dual Point Adjust Cutting Units Page 10 26 Rev A Greensmaster 3150 ...

Page 251: ...Mode 3 Groomer Reel 8 TROUBLESHOOTING 4 Groomer Reel Service 11 Factors Affecting Grooming 4 Groomer Reel Bearing Replacement 12 Groomer Reel Mechanical Problems 5 Idler Assembly 14 ADJUSTMENTS 6 Lift Arm Assembly 15 Height Depth of Groomer Adjustment 6 Groomer Brush 16 Greensmaster 3150 Page 10 1 1 Groomer DPA Cutting Unit Rev A Groomer DPA Cutting Unit ...

Page 252: ...evel 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 height adjustment for each click of the adjuster UP DOWN FEATURE At lower height of cut settings allows groomer reel to be raised above the height depth adjustment for no groomer reel action while cuttin...

Page 253: ...aise 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 2 1 Lift arm 2 Lock screw transport 1 2 Figure 2 1 Lift arm 2 Lock s...

Page 254: ...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...

Page 255: ...s it probably is worn and must be replaced Repair or replace belt if necessary A broken or worn belt could be the result of improper belt routing or seized bearings in groomer assem bly The turf is damaged or has uneven grooming The groomer reel blades are bent damaged or missing Repair or replace blades if neces sary The groomer reel shaft is bent or damaged Replace groomer reel shaft Grooming de...

Page 256: ...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 low...

Page 257: ...pulley nut and rotating idler bracket to relax belt tension Slip groomer drive belt off pulleys Fig 5 Carefully re 2 lease idler bracket Figure 4 3 Cap 5 Install new drive belt to drive pulley idler pulley and 1 Groomer belt cover 2 Lock nut 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 ...

Page 258: ...o 80 ft lb 81 to 108 N m Antisieze Lubricant 32 100 to 120 in lb 11 3 to 13 5 N m 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 gr...

Page 259: ...r shaft to the non drive side plate 14 Pull the groomer reel from 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 grea...

Page 260: ...rm 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 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 ite...

Page 261: ...aft either in a 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 ...

Page 262: ...emove 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 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...

Page 263: ...isieze 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 ...

Page 264: ...otor 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 W...

Page 265: ...e 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 Figure 18 are the same on both sides of cutting unit Note Grooved pin item 3 is used to retain lock screw item 6 to lift arm assembly Assembly 1 Assemble lift arm using Figure 18 as a guide 2 Apply an...

Page 266: ...on 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 Figure 20 Torque lo...

Page 267: ...hematics Wiring Diagram and Electrical Harness Drawings 3 Electrical Schematic 3 Crank 4 Run 5 Raise Reels 6 Lower Reels 6 seconds 7 Mow 8 Backlap 9 Electrical Harness Drawing 10 Wiring Diagram 11 Greensmaster 3150 Page 11 1 Electrical Diagrams Electrical Diagrams ...

Page 268: ...This page is intentionally blank Electrical Diagrams Page 11 2 Greensmaster 3150 ...

Page 269: ...AL P31 A 30 87a 87 86 85 85 86 87 30 87a 99 7430 80 9330 BK S1 REEL ENGAGE BK 86 85 99 7430 87 87a 30 D1 D BU BK E D D1 C C F OR BK GY BK MOW SWITCH BK OR BK PK BK BK Y 92 2538 6 SECOND W BK VIO BK S4 REELS LOWER S2 RAISE LOWER D2 D3 BK 1 2 3 1 A 1 A Y BK BU R GN GY S3 REELS RAISE 99 7430 99 7430 86 85 87 87a 30 86 85 87 87a 30 BK GN GY GN BK BU 2 G JOYSTICK LOWER RAISE 2 D JOYSTICK Y GN BK 2 E 2 ...

Page 270: ...ITCH OPTIONAL P31 A 30 87a 87 86 85 85 86 87 30 87a 99 7430 80 9330 BK S1 REEL ENGAGE BK 86 85 99 7430 87 87a 30 D1 D BU BK E D D1 C C F OR BK GY BK MOW SWITCH BK OR BK PK BK BK Y 92 2538 6 SECOND W BK VIO BK S4 REELS LOWER S2 RAISE LOWER D2 D3 1 2 3 1 A 1 A Y BK BU R GN GY S3 REELS RAISE 99 7430 99 7430 86 85 87 87a 30 86 85 87 87a 30 BK GN GY GN BK BU 2 G JOYSTICK LOWER RAISE 2 D JOYSTICK Y GN B...

Page 271: ...7 86 85 85 86 87 30 87a 99 7430 80 9330 BK S1 REEL ENGAGE BK 86 85 99 7430 87 87a 30 D1 D BU BK E D D1 C C F OR BK GY BK MOW SWITCH BK OR BK PK BK BK Y 92 2538 6 SECOND W BK VIO BK S4 REELS LOWER S2 RAISE LOWER D2 D3 1 2 3 1 A 1 A Y BK BU R GN GY S3 REELS RAISE 99 7430 99 7430 86 85 87 87a 30 86 85 87 87a 30 BK GN GY GN BK BU 2 G JOYSTICK LOWER RAISE 2 D JOYSTICK Y GN BK 2 E 2 F 99 7430 86 85 87 8...

Page 272: ... 86 85 85 86 87 30 87a 99 7430 80 9330 BK S1 REEL ENGAGE BK 86 85 99 7430 87 87a 30 D1 D BU BK E D D1 C C F OR BK GY BK MOW SWITCH BK OR BK PK BK BK Y 92 2538 6 SECOND W BK VIO BK S4 REELS LOWER S2 RAISE LOWER D2 D3 1 2 3 1 A 1 A Y BK BU R GN GY S3 REELS RAISE 99 7430 99 7430 86 85 87 87a 30 86 85 87 87a 30 BK GN GY GN BK BU 2 G JOYSTICK LOWER RAISE 2 D JOYSTICK Y GN BK 2 E 2 F 99 7430 86 85 87 87...

Page 273: ...a 87 86 85 85 86 87 30 87a 99 7430 80 9330 BK S1 REEL ENGAGE BK 86 85 99 7430 87 87a 30 D1 D BU BK E D D1 C C F OR BK GY BK MOW SWITCH BK OR BK PK BK BK Y 92 2538 6 SECOND W BK VIO BK S4 REELS LOWER S2 RAISE LOWER D2 D3 1 2 3 1 A 1 A Y BK BU R GN GY S3 REELS RAISE 99 7430 99 7430 86 85 87 87a 30 86 85 87 87a 30 BK GN GY GN BK BU 2 G JOYSTICK LOWER RAISE 2 D JOYSTICK Y GN BK 2 E 2 F 99 7430 86 85 8...

Page 274: ...30 87a 87 86 85 85 86 87 30 87a 99 7430 80 9330 BK S1 REEL ENGAGE BK 86 85 99 7430 87 87a 30 D1 D BU BK E D D1 C C F OR BK GY BK MOW SWITCH BK OR BK PK BK BK Y 92 2538 6 SECOND W BK VIO BK S4 REELS LOWER S2 RAISE LOWER D2 D3 1 2 3 1 A 1 A Y BK BU R GN GY S3 REELS RAISE 99 7430 99 7430 86 85 87 87a 30 86 85 87 87a 30 BK GN GY GN BK BU 2 G JOYSTICK LOWER RAISE 2 D JOYSTICK Y GN BK 2 E 2 F 99 7430 86...

Page 275: ... 86 85 85 86 87 30 87a 99 7430 80 9330 BK S1 REEL ENGAGE BK 86 85 99 7430 87 87a 30 D1 D BU BK E D D1 C C F OR BK GY BK MOW SWITCH BK OR BK PK BK BK Y 92 2538 6 SECOND W BK VIO BK S4 REELS LOWER S2 RAISE LOWER D2 D3 1 2 3 1 A 1 A Y BK BU R GN GY S3 REELS RAISE 99 7430 99 7430 86 85 87 87a 30 86 85 87 87a 30 BK GN GY GN BK BU 2 G JOYSTICK LOWER RAISE 2 D JOYSTICK Y GN BK 2 E 2 F 99 7430 86 85 87 87...

Page 276: ...87 86 85 85 86 87 30 87a 99 7430 80 9330 BK S1 REEL ENGAGE BK 86 85 99 7430 87 87a 30 D1 D BU BK E D D1 C C F OR BK GY BK MOW SWITCH BK OR BK PK BK BK Y 92 2538 6 SECOND W BK VIO BK S4 REELS LOWER S2 RAISE LOWER D2 D3 1 2 3 1 A 1 A Y BK BU R GN GY S3 REELS RAISE 99 7430 99 7430 86 85 87 87a 30 86 85 87 87a 30 BK GN GY GN BK BU 2 G JOYSTICK LOWER RAISE 2 D JOYSTICK Y GN BK 2 E 2 F 99 7430 86 85 87 ...

Page 277: ... LIGHT 1 J12 OPTIONAL LIGHT 1 P13 PARKING BRAKE P26 INTERCONNECT 1 P27 INTERCONNECT 2 P18 INTERCONNECT 3 A B C D P15 ENGAGE SOLENOID S1 P18 RAISE SOLENOID S3 P24 ALARM TIME DELAY P7 RAISE RELAY K6 P6 LOWER P2 KILL RELAY K1 SWITCH P3 START 1 2 5 4 3 1 2 5 4 3 1 2 5 4 3 1 2 5 4 3 1 2 5 4 3 SAFETY K2 RELAY K5 1 2 5 4 3 B A B A B A B A B A A SWITCH B B A B A A B C D E F G H B A A B B A 1 2 3 4 5 6 7 8...

Page 278: ...Page 11 12 Wiring Diagram Greensmaster 3150 ORIFICE S6 P19 Serial Number 230000801 Up Serial Number Under 230000801 ...