Form No.

12191SL Rev B

Greensmaster® 3150
(Models 04358)

Original Instructions (EN)

 Revision History
Revision Date Description
-- 2012 Initial Issue.
A 02/2018 Added revision history.
B 04/2018 Revised bedknife installation procedure, added Universal Groomer
chapter.

© THE TORO COMPANY 2018

This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No
intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be
reproduced by a third party without the express written consent of The Toro Company (and/or the appropriate affiliated company).
 Reader Comments
The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality
and usefulness of its publications. To do this effectively, we encourage user feedback.
Please comment on the completeness, accuracy, organization, usability, and readability of this manual
by an e-mail to [email protected]

or Mail to:

Technical Publication Manager, Commercial

The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Phone: +1 952-887-8495
NOTES _
 Part No. 12191SL Rev. B

Service Manual
(Model 04358)

GreensmasterR 3150
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 (Model 04358).
This safety symbol means DANGER, WARNING
REFER TO THE TRACTION UNIT AND CUTTING or CAUTION, PERSONAL SAFETY INSTRUC-
UNIT OPERATOR’S MANUALS FOR OPERATING, TION. When you see this symbol, carefully read
MAINTENANCE AND ADJUSTMENT INSTRUC- the instructions that follow. Failure to obey the
TIONS. For reference, insert a copy of the Operator’s instructions may result in personal injury.
Manuals and Parts Catalogs for your machine into
Chapter 2 of this service manual. Additional copies of NOTE: A NOTE will give general information about the
the Operator’s Manuals and Parts Catalog are available correct operation, maintenance, service, testing or re-
on the internet at www.Toro.com. pair of the machine.
The Toro Company reserves the right to change product IMPORTANT: The IMPORTANT notice will give im-
specifications or this publication without notice. portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.

E The Toro Company − 2012, 2018

This page is intentionally blank.

Greensmaster 3150
Table Of Contents

Safety
Chapter 1 − Safety Chapter 5 − Electrical System

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 − 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 − 2

Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 − 5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 − 3

and Maintenance
Product Records
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 − 5 Turf Guardian Leak Detector
System Operation . . . . . . . . . . . . . . . . . . . . . . . . 5 − 5
Chapter 2 − Product Records and Maintenance Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 − 6
Electrical System Quick Checks . . . . . . . . . . . . . 5 − 11
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−1 Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 5 − 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−1 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 − 28
Equivalents and Conversions . . . . . . . . . . . . . . . . 2−2
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2−3 Chapter 6 − Chassis

Engine
Chapter 3 − Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 6−3
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3−2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−3 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6−4
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3−4
BRIGGS & STRATTON VANGUARD V-TWIN OHV Chapter 7 − DPA Cutting Units

Hydraulic
REPAIR MANUAL

System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 − 2
Chapter 4 − Hydraulic System General Information . . . . . . . . . . . . . . . . . . . . . . . . 7 − 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 − 4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 − 2 Factors That Can Affect Cutting Performance . . 7 − 7
General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 − 3 Set Up and Adjustments . . . . . . . . . . . . . . . . . . . . 7 − 10
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . 4 − 8 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 7 − 12

Electrical
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . 4 − 10

System
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 − 18 Chapter 8 − Belt Driven Groomer (Optional)
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 − 21
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 − 26 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8−2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 − 49 General Information . . . . . . . . . . . . . . . . . . . . . . . . 8−3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 − 50 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8−4
EATON, MEDIUM DUTY PISTON PUMP, REPAIR IN- Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8−6

Chassis
FORMATION, MODEL 70160 VARIABLE DIS- Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 8−7
PLACEMENT PISTON PUMP
PARKER TORQMOTORTM SERVICE PROCEDURE Chapter 9 − Universal Groomer (Optional)
(TC, TB, TE, TJ, TF, TG, TH and TL SERIES)
SAUER/DANFOSS STEERING UNIT TYPE OSPM Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 − 2
SERVICE MANUAL General Information . . . . . . . . . . . . . . . . . . . . . . . . 9 − 3

DPA Cutting
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 9 − 5

Units
Chapter 10 − Foldout Drawings

Electrical Drawing Designations . . . . . . . . . . . . . 10 − 2

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . 10 − 3 Groomer (Optional) Groomer (Optional)
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . 10 − 4
Belt Driven

Electrical Circuit Diagrams . . . . . . . . . . . . . . . . . . 10 − 5

Wire Harness Drawings . . . . . . . . . . . . . . . . . . 10 − 12
Universal

Greensmaster 3150
This page is intentionally blank.

Greensmaster 3150
 Chapter 1

Safety
Safety
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 4
JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 5
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 5

Greensmaster 3150 Page 1 -- 1 Safety

Safety Instructions
The Greensmaster 3150 was tested and certified by
Toro for compliance with national and international stan-
dards as specified in the Operator’s Manual. Although WARNING
hazard control and accident prevention partially are de-
pendent upon the design and configuration of the ma- To reduce the potential for injury or death, comply
chine, these factors are also dependent upon the with the following safety instructions.
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 Operator’s 8. Do not carry passengers on the machine. Keep ev-
Manual before starting and operating the machine. Be- eryone, especially children and pets, away from the
come familiar with all controls and know how to stop areas of operation.
quickly. Copies of the Operator’s Manual are available
on the internet at www.Toro.com. 9. Gasoline (fuel) is highly flammable; handle it careful-
ly.
2. Never allow children to operate the machine. Never
allow adults to operate it without proper instructions. A. Store fuel in containers specifically designed for
this purpose.
3. Become familiar with the controls and know how to
stop the engine quickly. B. Add fuel before starting the engine. Never re-
move the cap of the fuel tank or add fuel while the en-
4. Keep all shields, safety devices and decals in place. gine is running or when the engine is hot.
If a shield, safety device or decal is defective, illegible or
damaged: repair or replace it before operating the ma- C. Refuel outdoors only and do not smoke while
chine. refuelling.

5. Always wear substantial shoes. Do not operate ma- D. Fill fuel tank to a level no higher than to the bottom
chine while wearing sandals, tennis shoes or sneakers. of fuel tank filler neck. Do not overfill.
Do not wear loose fitting clothing which could get caught
in moving parts and cause personal injury. E. Replace all fuel tanks and container caps secure-
ly.
6. Wearing safety glasses, safety shoes, long pants
and a helmet is advisable and required by some local F. If fuel is spilled, do not attempt to start the engine
safety and insurance regulations. but move the machine away from the area of spillage
and avoid creating any source of ignition until fuel va-
7. Make sure work area is clear of objects which might pors have dissipated.
be picked up and thrown by the reels.
G. Wipe up any spilled fuel.

Safety Page 1 -- 2 Greensmaster 3150

While Operating

Safety
1. Do not run the engine in a confined area without ade- 7. Wear appropriate clothing including substantial foot-
quate ventilation. Exhaust fumes are hazardous and wear, hard hat, safety glasses and ear protection.
could be deadly.
8. Raise the cutting units when driving from one work
2. Sit on the seat when starting and operating the ma- area to another.
chine.
9. Do not touch engine, muffler or exhaust pipe while
3. Check the safety interlock switch daily for proper op- engine is running or soon after it is stopped because
eration; see Verify Interlock System Operation in Chap- these areas could be hot enough to cause burns.
ter 5 -- Electrical System. Replace any malfunctioning
switches before operating the machine. 10.If a cutting unit strikes a solid object or vibrates ab-
normally, stop immediately, turn engine off, wait for all
4. To start the engine: motion to stop and inspect for damage. A damaged reel
or bedknife must be repaired or replaced before opera-
A. Sit on the seat, make sure cutting units are disen- tion is continued.
gaged.
11. Before getting off the seat:
B. Verify that functional control lever is in neutral.
A. Make sure cutting units are disengaged.
C. Verify that parking brake is set.
B. Verify that functional control lever is in neutral.
D. Proceed to start engine.
C. Set the parking brake.
5. Using the machine demands attention. To prevent
loss of machine control: D. Stop the engine and remove key from ignition
switch.
A. Mow only in daylight or when there is good artifi-
cial light. 12.Traverse slopes carefully. Do not start or stop sud-
denly when traveling uphill or downhill.
B. Watch for holes or other hidden hazards.
13.Operator must be skilled and trained in how to drive
C. Do not drive close to sand traps, ditches, creeks on hillsides. Avoid wet slopes. Failure to use caution on
or other hazards. slopes or hills may cause loss of control and vehicle to
tip or roll possibly resulting in personal injury or death.
D. Reduce speed when making sharp turns. Avoid
sudden stops and starts. 14.If engine stalls or loses headway and cannot make
it to the top of a slope, do not turn machine around. Al-
E. Before backing up, look to the rear to be sure no ways back slowly straight down the slope.
one is behind the machine.
15.DON’T TAKE AN INJURY RISK! When a person or
F. Watch out for traffic when near or crossing roads. pet appears unexpectedly in or near the mowing area,
Always yield the right--of--way. STOP MOWING. Careless operation, combined with
terrain angles, ricochets or improperly positioned
G. Apply the service brakes when going downhill to
guards can lead to thrown object injuries. Do not resume
keep forward speed slow and to maintain control of
mowing until area is cleared.
the machine.
16.Whenever machine is left unattended, make sure
6. Keep hands, feet and clothing away from moving
cutting units are fully raised and reels are not spinning,
parts and the reel discharge area. The grass baskets
key is removed from ignition switch and parking brake
must be in place during operation of the reels or thatch-
is set.
ers for maximum safety. Shut the engine off before emp-
tying the baskets.

Greensmaster 3150 Page 1 -- 3 Safety

Maintenance and Service
1. Before servicing or making adjustments to the ma- 9. Do not overspeed the engine by changing governor
chine, stop the engine, remove key from switch to pre- settings. To assure safety and accuracy, have an Autho-
vent accidental starting of the engine. rized Toro Distributor check maximum engine speed
with a tachometer. Maximum governed engine speed
2. Be sure entire machine is in good operating condi- should be 2850 + 50 RPM.
tion. Keep all nuts, bolts, screws and hydraulic fittings
tight. 10.Engine must be shut off before checking oil or adding
oil to the crankcase.
3. Make sure all hydraulic line connectors are tight,and
all hydraulic hoses and lines are in good condition be- 11. If major repairs are ever needed or if assistance is
fore applying pressure to the system. desired, contact your Authorized Toro Distributor.

4. Keep body and hands away from pin hole leaks or 12.At the time of manufacture, the machine conformed
nozzles that eject hydraulic fluid under high pressure. to the safety standards for riding mowers. To assure op-
Use paper or cardboard, not hands, to search for leaks. timum performance and continued safety certification of
Hydraulic fluid escaping under pressure can have suffi- the machine, use genuine Toro replacement parts and
cient force to penetrate skin and do serious damage. If accessories. Replacement parts and accessories made
fluid is ejected into the skin it must be surgically removed by other manufacturers may result in non-conformance
within a few hours by a doctor familiar with this form of with the safety standards and the warranty may be
injury or gangrene may result. voided.

5. Before disconnecting or performing any work on the 13.When changing attachments, tires or performing
hydraulic system, all pressure in system must be re- other service, use correct blocks, hoists and jacks.
lieved by stopping engine and lowering cutting units and Make sure machine is parked on a solid level surface
attachments to the ground. such as a concrete floor. Prior to raising the machine, re-
move any attachments that may interfere with the safe
6. To reduce potential fire hazard, keep the engine area and proper raising of the machine. Always chock or
free of excessive grease, grass, leaves and accumula- block wheels. Use appropriate jack stands to support
tion of dirt. Never wash a warm engine or electrical con- the raised machine. If the machine is not properly sup-
nections with water. ported by jack stands, the machine may move or fall,
which may result in personal injury.
7. Check all fuel lines for tightness and wear on a regu-
lar basis. Tighten or repair fuel lines as needed.

8. If the engine must be running to perform a mainte-

nance adjustment, keep hands, feet, clothing and any
other parts of the body away from the cutting units, at-
tachments and any moving parts. Keep everyone away.

Safety Page 1 -- 4 Greensmaster 3150

Jacking Instructions
Rear End Jacking

Safety
CAUTION 1. Apply parking brake and chock both front tires to pre-
vent the machine from moving. Make sure that cutting
When changing attachments, tires or perform- units are fully lowered.
ing other service, use correct jacks and sup-
ports. Make sure machine is parked on a solid, 2. Place jack securely below the rear castor fork.
level surface such as a concrete floor. Prior to
3. Jack rear of machine off the ground.
raising machine, remove any attachments that
may interfere with the safe and proper raising of 4. Position appropriate jack stands under the frame to
the machine. Always chock or block wheels. Use support the machine.
jack stands to support the raised machine. If the
machine is not properly supported by jack
stands, the machine may move or fall, which
may result in personal injury.

Front End Jacking

1. Apply parking brake and chock rear tire to prevent

the machine from moving. Make sure that cutting units
are fully lowered.
1
2. Position jack securely under the frame jacking point:

A. The left side jacking point is the frame channel Figure 1

under the step behind the LH front wheel. 1. ROPS support bracket

B. The right side jacking point is the ROPS support

bracket behind the RH front wheel (Fig. 1).

3. Jack front of machine off the ground.

4. Position appropriate jack stands under the frame as

close to the wheel as possible to support the machine.

Safety and Instruction Decals

Numerous safety and instruction decals are affixed to
the traction unit and the cutting units of the Greensmas-
ter 3150. If any decal becomes illegible or damaged, in-
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 Page 1 -- 5 Safety

 This page is intentionally blank.

Safety Page 1 -- 6 Greensmaster 3150

 Chapter 2

Product Records and Maintenance

and Maintenance
Product Records
Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2
Decimal and Millimeter Equivalents . . . . . . . . . . . . 2
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 3
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . 3
Using a Torque Wrench with an Offset Wrench . . 3
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Inch Series). . . . . . . . . . . . . . . . 4
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric Fasteners). . . . . . . . . . . 5
Other Torque Specifications . . . . . . . . . . . . . . . . . . 6
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . 6

Product Records
Insert a copy of the Operator’s Manual and Parts Cata-
log for your Greensmaster 3150 at the end of this chap-
ter. Additionally, if any optional equipment or
accessories have been installed to your machine, insert
the Installation Instructions, Operator’s Manuals and
Parts Catalogs for those options at the end of this chap-
ter.

Maintenance
Maintenance procedures and recommended service in-
tervals for the Greensmaster 3150 are covered in the
Traction Unit Operator’s Manual. Maintenance proce-
dures and recommended service intervals for the
Greensmaster Cutting Units are covered in the Cutting
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 -- 1 Product Records and Maintenance

Equivalents and Conversions

0.09375

Product Records and Maintenance Page 2 -- 2 Greensmaster 3150

Torque Specifications
Recommended fastener torque values are listed in the As noted in the following tables, torque values should be
following tables. For critical applications, as determined reduced by 25% for lubricated fasteners to achieve
by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may
is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded
cified in this Service Manual. into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass

and Maintenance
Product Records
These torque specifications for the installation and tight- material strength, fastener size, length of thread en-
ening of fasteners shall apply to all fasteners which do gagement, etc.
not have a specific requirement identified in this Service
Manual. The following factors shall be considered when The standard method of verifying torque shall be per-
applying torque: cleanliness of the fastener, use of a formed by marking a line on the fastener (head or nut)
thread sealant (e.g. Loctite), degree of lubrication on the and mating part, then back off fastener 1/4 of a turn.
fastener, presence of a prevailing torque feature, hard- Measure the torque required to tighten the fastener until
ness of the surface underneath the fastener’s head or the lines match up.
similar condition which affects the installation.

Fastener Identification

Grade 1 Grade 5 Grade 8 Class 8.8 Class 10.9

Inch Series Bolts and Screws Metric Bolts and Screws

Figure 1 Figure 2

Using a Torque Wrench with an Offset Wrench

Use of an offset wrench (e.g. crowfoot wrench) will affect If the listed torque recommendation for a fastener is
torque wrench calibration due to the effective change of from 76 to 94 ft--lb, the proper torque when using this
torque wrench length. When using a torque wrench with torque wrench with an offset wrench would be from 72
an offset wrench, multiply the listed torque recommen- to 89 ft--lb.
dation by the calculated torque conversion factor (Fig.
3) to determine proper tightening torque. Tightening Offset wrench Torque wrench
torque when using a torque wrench with an offset (effective length of
wrench will be lower than the listed torque recommen- torque wrench)
A
dation.

Example: The measured effective length of the torque

wrench (distance from the center of the handle to the
center of the square drive) is 18”. B
(effective length of torque
The measured effective length of the torque wrench with wrench + offset wrench)
the offset wrench installed (distance from the center of
the handle to the center of the offset wrench) is 19”. TORQUE CONVERSION FACTOR = A / B

The calculated torque conversion factor for this torque Figure 3

wrench with this offset wrench would be 18 / 19 = 0.947.

Greensmaster 3150 Page 2 -- 3 Product Records and Maintenance

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Grade 1, 5, & SAE Grade 1 Bolts, Screws, Studs, & SAE Grade 5 Bolts, Screws, Studs, & SAE Grade 8 Bolts, Screws, Studs, &
Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts
Height Nuts (SAE J995 Grade 2 or Stronger Nuts) (SAE J995 Grade 2 or Stronger Nuts) (SAE J995 Grade 5 or Stronger Nuts)

in--lb in--lb N--cm in--lb N--cm in--lb N--cm

# 6 -- 32 UNC 15 + 2 170 + 20 23 + 2 260 + 20

10 + 2 13 + 2 147 + 23
# 6 -- 40 UNF 17 + 2 190 + 20 25 + 2 280 + 20

# 8 -- 32 UNC 29 + 3 330 + 30 41 + 4 460 + 45

13 + 2 25 + 5 282 + 30
# 8 -- 36 UNF 31 + 3 350 + 30 43 + 4 485 + 45

# 10 -- 24 UNC 42 + 4 475 + 45 60 + 6 675 + 70

18 + 2 30 + 5 339 + 56
# 10 -- 32 UNF 48 + 4 540 + 45 68 + 6 765 + 70

1/4 -- 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1125 + 100 140 + 15 1580 + 170

1/4 -- 28 UNF 53 + 7 65 + 10 734 + 113 115 + 10 1300 + 100 160 + 15 1800 + 170

5/16 -- 18 UNC 115 + 15 105 + 17 1186 + 169 200 + 25 2250 + 280 300 + 30 3390 + 340

5/16 -- 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2540 + 280 325 + 30 3670 + 340

ft--lb ft--lb N--m ft--lb N--m ft--lb N--m

3/8 -- 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 4 58 + 5

3/8 -- 24 UNF 17 + 2 18 + 2 24 + 3 35 + 3 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 115 + 15 165 + 25 224 + 34 300 + 25 407 + 34 420 + 35 569 + 47

7/8 -- 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81

7/8 -- 14 UNF 155 + 25 260 + 30 353 + 41 475 + 45 644 + 61 660 + 60 895 + 81

NOTE: Reduce torque values listed in the table above NOTE: The nominal torque values listed above for
by 25% for lubricated fasteners. Lubricated fasteners Grade 5 and 8 fasteners are based on 75% of the mini-
are defined as threads coated with a lubricant such as mum proof load specified in SAE J429. The tolerance is
oil, graphite or thread sealant such as Loctite. approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.

Product Records and Maintenance Page 2 -- 4 Greensmaster 3150

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)

Class 8.8 Bolts, Screws and Studs with Class 10.9 Bolts, Screws and Studs with
Thread Size Regular Height Nuts Regular Height Nuts
(Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts)

and Maintenance
Product Records
M5 X 0.8 57 + 5 in--lb 640 + 60 N--cm 78 + 7 in--lb 885 + 80 N--cm

M6 X 1.0 96 + 9 in--lb 1018 + 100 N--cm 133 + 13 in--lb 1500 + 150 N--cm

M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 27 + 2 ft--lb 36 + 3 N--m

M10 X 1.5 38 + 4 ft--lb 52 + 5 N--m 53 + 5 ft--lb 72 + 7 N--m

M12 X 1.75 66 + 7 ft--lb 90 + 10 N--m 92 + 9 ft--lb 125 + 12 N--m

M16 X 2.0 166 + 15 ft--lb 225 + 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

NOTE: Reduce torque values listed in the table above NOTE: The nominal torque values listed above are
by 25% for lubricated fasteners. Lubricated fasteners based on 75% of the minimum proof load specified in
are defined as threads coated with a lubricant such as SAE J1199. The tolerance is approximately + 10% of the
oil, graphite or thread sealant such as Loctite. nominal torque value.

NOTE: Torque values may have to be reduced when

installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.

Greensmaster 3150 Page 2 -- 5 Product Records and Maintenance

Other Torque Specifications
SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts

Recommended Torque Thread Size Recommended Torque*

Thread Size
Square Head Hex Socket 7/16 -- 20 UNF 65 + 10 ft--lb 88 + 14 N--m
Grade 5
1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb
1/2 -- 20 UNF 80 + 10 ft--lb 108 + 14 N--m
5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb Grade 5

3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3 ft--lb M12 X 1.25 80 + 10 ft--lb 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 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--lb No. 6 18 20 20 + 5 in--lb
No. 8 -- 32 UNC 30 + 5 in--lb No. 8 15 18 30 + 5 in--lb
No. 10 -- 24 UNC 38 + 7 in--lb No. 10 12 16 38 + 7 in--lb
1/4 -- 20 UNC 85 + 15 in--lb No. 12 11 14 85 + 15 in--lb
5/16 -- 18 UNC 110 + 20 in--lb ** Hole size, material strength, material thickness & fin-
ish must be considered when determining specific
3/8 -- 16 UNC 200 + 100 in--lb torque values. All torque values are based on non--lubri-
cated fasteners.

Conversion Factors
in--lb X 11.2985 = N--cm N--cm X 0.08851 = in--lb
ft--lb X 1.3558 = N--m N--m X 0.7376 = ft--lb

Product Records and Maintenance Page 2 -- 6 Greensmaster 3150

 Chapter 3

Engine
Table of Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Engine
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel Evaporative Control System . . . . . . . . . . . . . 10
BRIGGS & STRATTON VANGUARD V--TWIN OHV RE-
PAIR MANUAL

Greensmaster 3150 Page 3 -- 1 Engine

General Information
This Chapter gives information about specifications, Service and repair parts for Briggs & Stratton Vanguard
maintenance, troubleshooting, testing and repair of the V-Twin OHV engines are supplied through your local lo-
engine used in the Greensmaster 3150. cal Toro distributor. If no parts list is available, be sure to
provide your distributor with the Toro model and serial
Most repairs and adjustments require tools which are number along with the engine model and serial number.
commonly available in many service shops. Special
tools are described in the Briggs & Stratton Vanguard
V-Twin OHV Repair Manual. The use of some special-
ized test equipment is explained. 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.

Operator’s Manual
The Traction Unit Operator’s Manual provides informa-
tion regarding the operation, general maintenance and
maintenance intervals for your Greensmaster 3150 ma-
chine. Refer to the Operator’s Manual for additional in-
formation when servicing the machine.

Engine Page 3 -- 2 Greensmaster 3150

Specifications

Item Description

Make / Designation Briggs and Stratton, 4--cycle, V--Twin Cylinder,

OHV, Air Cooled, Gasoline Engine -- Model 356447

Bore x Stroke 2.83” x 2.76” (72 mm x 70 mm)

Total Displacement 34.8 in3 (570 cc)

Governor Mechanical Governor

Carburetor Float Feed

Engine
Fuel Pump Pulsating Crankcase Vacuum

Fuel Unleaded, regular grade gasoline

Fuel Tank Capacity 7.0 U.S. gallons (26.5 liters)

Low Idle (no load) 1650 + 100 RPM

High Idle (no load) 2850 + 50 RPM

Lubrication System Pressure Lubrication, Gear Driven Geroter Oil Pump

Engine Oil See Operator’s Manual

Crankcase Oil Capacity 1.75 U.S. quarts (1.65 liters) with new filter

Ignition System Flywheel magneto, twin electronic armatures

Spark Plugs Champion RC 14YC (or equivalent)

Spark Plug Gap 0.030” (0.76 mm)

Alternator 16 Amp

Dry Weight (approximate) 84 lb (38 kg)

Greensmaster 3150 Page 3 -- 3 Engine

Service and Repairs

Fuel Tank

13 4
20
21

22
5

3
18
1
2
14
2
15 12

6
16
17
7
6
16
7 8

9 9 10
6
11
7
18
8
RIGHT 19
Antiseize
Lubricant
FRONT 30 to 60 in--lb
(3.4 to 6.7 N--m)

Figure 1
1. Fuel filter 9. Cap screw (4 used) 16. Hose clamp
2. Hose clamp 10. Cap screw 17. Fuel hose (tank to shut--off valve)
3. Fuel hose (filter to engine) 11. Hose support clamp 18. Hose clamp
4. Fuel cap 12. Vehicle frame 19. Spacer
5. Fuel tank 13. Fuel tank vent fitting 20. Hose clamp
6. Grommet (4 used) 14. Fuel hose (shut--off valve to filter) 21. Fuel vent hose (fitting to cannister)
7. Flat washer (4 used) 15. Fuel shut--off valve 22. Grommet
8. Hose support clamp

Engine Page 3 -- 4 Greensmaster 3150

Fuel Tank Removal (Fig. 1) Fuel Tank installation (Fig. 1)

1. Park machine on a level surface, lower cutting units, IMPORTANT: After fuel tank is installed, make sure
stop the engine, engage parking brake and remove the that clearance between hydraulic reservoir and fuel
key from the ignition switch. tank if from 0.125” to 0.375” (3.2 to 9.5 mm).

1. Position fuel tank on the vehicle frame.

CAUTION A. Apply antiseize lubricant to the threads of the four
(4) cap screws (item 9).
The muffler and exhaust manifold may be hot.
Avoid possible burns, allow exhaust system to B. Secure the fuel tank to the vehicle frame with four
cool before working on the engine. (4) flat washers (item 7), grommets (item 6) and cap
screws (item 9). Make sure the grommets are
between the flat washers and the frame. Also, make
sure that fuel hose support clamps (item 8) are posi-
DANGER tioned correctly.

Engine
C. Torque cap screws from 30 to 60 in--lb (3.4 to 6.7
Gasoline is flammable. Use caution when storing
or handling it. Do not smoke while filling the fuel N--m).
tank. Do not fill fuel tank while engine is running
or in an enclosed area. Always fill fuel tank out- 2. Connect vent hose (item 21) to fuel tank vent fitting
side and wipe up any spilled fuel before starting (item 13) on top of tank and secure with hose clamp.
the engine. Store fuel in a clean, safety--ap- Make sure that hose is not kinked or obstructed.
proved container and keep the cap in place. Use
gasoline for the engine only; not for any other 3. Connect fuel hose (item 14) to the fuel shut--off valve
purpose. (item 15) and secure with hose clamp.

4. Open fuel shut--off valve and fill fuel tank with fuel.
2. Drain fuel tank as follows: Check all fuel hoses and tank for leaks.
A. Close fuel shut--off valve (item 15).

B. Disconnect fuel hose (item 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. Disconnect vent hose (item 21) from fuel tank vent fit-
ting (item 13) on top of tank.

4. Remove four (4) cap screws (item 9), grommets

(item 6) and flat washers (item 7) securing the fuel tank
to the vehicle frame. Remove the fuel tank from the ve-
hicle frame.

Greensmaster 3150 Page 3 -- 5 Engine

Engine

24 1 30 170 to 200 in--lb

2 (20 to 22 N--m)
1
3 4
2 39 6
40
29 21
22
29
31
16
11 8
7
25 17
24 16 32
11
27 28
25 to 38 ft--lb 23
(34 to 51 N--m) 22 5
27 10
20 28
18 to 23 ft--lb
(25 to 31 N--m) 19 27
33

34
29
11
38 12
55 26
42 37
50 36 35 34
49
43
45 13
46
47 15
53 56 9 12
52 54 48 14
51
46 18
44
45 43 Loctite #242
41 90 to 110 in--lb
42 Antiseize (10.2 to 12.4 N--m)
Lubricant

Figure 2
1. Cap screw (3 used) 20. Socket head screw (2 used) 39. Cap screw (2 used)
2. Flat washer (3 used) 21. Engine mount plate 40. Spring bracket
3. Spacer (3 used) 22. Lock washer (4 used) 41. Engine hub
4. Exhaust manifold 23. Cap screw (2 used) 42. Lock nut (4 used)
5. Regulator shield 24. Engine mount (3 used) 43. Coupling spacer (4 used)
6. Muffler clamp 25. Cap screw (6 used) 44. Rubber coupling
7. Flange nut (3 used) 26. Lock nut (4 used) 45. Flat washer (4 used)
8. Engine assembly 27. Spring washer (3 used) 46. Cap screw (4 used)
9. Muffler 28. Washer head screw (2 used)
47. Square head set screw (2 used)
10. Muffler shield 29. Engine wire harness
48. Key
11. Ground wires 30. Flange head screw (4 used)
12. Flat washer (8 used) 31. Gasket (2 used) 49. Cap screw
13. Muffler mount 32. Battery cable 50. Spacer
14. Cap screw (4 used) 33. Purge hose assy (to intake manifold) 51. Hardened washer (2 used)
15. Flat washer (4 used) 34. Hose clamp (2 used) 52. Lock washer (2 used)
16. Hex flange nut (10 used) 35. Barbed fitting 53. Cap screw (2 used)
17. Lock washer 36. Hose clamp 54. Pump hub
18. Cap screw (4 used) 37. Hose (to air cleaner base) 55. Piston pump assembly
19. Pump adapter 38. Hex nut 56. Key

Engine Page 3 -- 6 Greensmaster 3150

Engine Removal (Fig. 2) 11. Carefully move the engine away from the piston
pump until the crankshaft clears the engine hub. Re-
1. Park machine on a level surface, lower cutting units, move the engine from the machine. Locate and retrieve
stop engine, engage parking brake and remove key key (item 48) from crankshaft.
from the ignition switch.

2. Disconnect negative (--) battery cable from battery. 2

3

CAUTION 1
4

5
The muffler and exhaust manifold may be hot.
Avoid possible burns, allow exhaust system to 6
cool before working on the engine.
7

Engine
DANGER
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 Figure 3
or in an enclosed area. Always fill fuel tank out-
1. Engine assembly 5. Hose clamp
side and wipe up any spilled fuel before starting 2. Fuel supply hose 6. Spacer screw
the engine. Store fuel in a clean, safety--ap- 3. Cap screw 7. Washer
proved container and keep the cap in place. Use 4. Support clamp
gasoline for the engine only; not for any other
purpose.
25 to 38 ft--lb
(34 to 51 N--m) 4
3
3. Close fuel shut--off valve on fuel tank.
2
4. Remove the fuel hose support clamp and disconnect
fuel hose at the fuel pump (Fig. 3). Drain any fuel trapped 5
in the fuel filter and fuel hose into a suitable container.

5. Disconnect the fuel evaporative control system

hoses from engine (see Fuel Evaporative Control Sys- 6
tem in this section).

6. Disconnect the engine wiring harness (item 29), the 7

choke control cable, the throttle control cable and the
ground wires (item 11) at the engine. 1

7. Carefully disconnect extension spring on piston

pump control assembly from spring bracket that is at-
tached to engine mount plate (Fig. 4). Figure 4
1. Engine mount plate 5. Dampener hose
8. Loosen the two (2) set screws (item 47) securing the 2. Spring bracket 6. Extension spring
engine hub (item 41) to the engine shaft. 3. Lock washer (2 used) 7. Piston pump assembly
4. Cap screw (2 used)

9. Support the piston pump assembly and remove the

two (2) cap screws (item 53), lock washers (item 52) and Engine Installation (Fig. 2)
hardened washers (item 51) securing the pump to the
1. Make sure that all parts removed from the engine
pump adapter (item 19). Do Not disconnect the hydrau-
during maintenance or rebuilding are installed to the en-
lic hoses or neutral control linkage from the pump.
gine.
10.Support the engine assembly and remove the three
2. Apply antiseize lubricant to bore of engine hub.
(3) engine mount flange nuts (item 7), cap screws (item
Place key (item 48) into slot on the engine crankshaft.
1), flat washers (item 2) and spacers (item 3).

Greensmaster 3150 Page 3 -- 7 Engine

IMPORTANT: Make sure to not damage engine, fuel 8. Carefully connect extension spring on piston pump
hose, hydraulic hoses, electrical harness, control control assembly to spring bracket that is attached to en-
cables or other parts while installing the engine. gine mount plate (Fig. 4).
Make sure engine hub is in position before installing
the engine mount cap screws. 9. Connect the engine wiring harness (item 29) and
ground wires (item 11) to the engine.
3. Align the engine hub (item 41) with the engine shaft
and key (item 48). Slide crankshaft into hub and move 10.Connect and adjust the choke and throttle control
engine until the engine mount plate (item 21) is aligned cables.
with the three (3) engine mounts (item 24). Take care to
not damage the rubber coupling (item 44) during engine 11. Connect the fuel evaporative control system hoses
installation. to engine (see Fuel Evaporative Control System in this
section).
4. Install the three (3) engine mount cap screws (item
1), flat washers (item 2), spacers (item 3) and flange 12.Connect fuel hose to the fuel pump and secure with
nuts (item 7). hose clamp. Install the fuel hose support clamp.

5. Position the piston pump assembly to the pump 13.Secure negative (--) battery cable to battery.
adapter (item 19) and secure with two (2) cap screws
14.Open fuel shut--off valve on fuel tank. Check fuel
(item 53) lock washers (item 52) and hardened washers
hose for leaks.
(item 51).
15.Check engine oil level and adjust if necessary.
6. Position engine hub on crankshaft to best align the
rubber coupling. 16.Start the engine and check for proper engine opera-
tion.
7. Apply Loctite #242 (or equivalent) to threads of en-
gine hub set screws (item 47). Secure hub to crankshaft
with two (2) set screws. Torque set screws from 90 to
110 in--lb (10.2 to 12.4 N--m).

Engine Page 3 -- 8 Greensmaster 3150

 Engine
This page is intentionally blank.

Greensmaster 3150 Page 3 -- 9 Engine

Fuel Evaporative Control System

CARBON CHECK
CANNISTER VALVE

TO INTAKE
MANIFOLD
FUEL
TANK FRESH AIR
CHECK FILTER
VALVE

TO AIR
CLEANER

ENGINE

Figure 5

Greensmaster 3150 machines are equipped with a fuel The carbon canister is mounted on the hydraulic leak
evaporative control system designed to collect and detector tank (Fig. 6). The evaporative system includes
store evaporative emissions from the fuel tank. The two (2) connections to the engine: one to the intake man-
evaporate control system uses a carbon cannister to ifold and the second to the air cleaner base. Venting
collect these evaporative emissions. Fuel vapors from hose assemblies (purge hose assembly and t--hose as-
the fuel tank are vented to the canister. Vapors from the sembly) include check valves in two (2) locations as
canister are consumed when the engine is running. shown in Figure 5.

The fuel tank on Greensmaster 3150 machines uses a NOTE: The purge hose assembly (item 5 in Fig. 6) and
non--vented fuel cap. To connect the tank to the evapo- tee hose assembly (item 10 in Fig. 6) both include a
rative control system, a fuel tank vent fitting is positioned check valve as a component of the hose assembly. The
in the top of the tank that allows tank venting through the check valve is not available as a separate part. To en-
carbon cannister. sure proper operation of check valves, do not attempt to
remove them from the hose assembly. If either of these
NOTE: If there is restriction in the carbon cannister or hose assemblies is removed, make sure that they are
the fuel tank vent fitting, the fuel tank may distort due to correctly installed to ensure proper operation of the
venting issues. If the fuel tank returns to it’s normal evaporative control system.
shape when the fuel cap is removed, restriction in the
evaporative control system is likely.

Engine Page 3 -- 10 Greensmaster 3150

Disassembly (Fig. 6)
2 3

DANGER
6
1
Gasoline is flammable. Use caution when storing 7
or handling it. Wipe up any spilled fuel before
starting the engine. 4 8
9
5
1. Inspect carbon cannister and attached hoses for
damage or obvious leaks. A damaged or leaking cannis-
ter should be replaced.
4
2. Remove components as needed using Figure 6 as 8
a guide. 4
12

Engine
10
A. If either purge hose assembly (item 5) or T--hose
4 13
assembly (item 10) is to be removed, label ends of
hose for assembly purposes. Both of these assem- 11
blies include a check valve so direction of installation
is important for correct operation of the evaporative Figure 6
control system. The check valve is not available as a 1. Leak detector tank 8. Hose clamp
2. Carbon cannister 9. Hose (to t--fitting)
separate part so hose assembly replacement is nec- 3. Cable tie (2 used) 10. T--hose assembly
essary if the check valve or hose is faulty. To ensure 4. Hose clamp 11. Fresh air filter
proper operation of check valves, do not attempt to 5. Purge hose assembly 12. Hose (to air cleaner)
6. Hose clamp 13. Barbed fitting
remove them from the hose assembly. 7. Hose (to fuel tank vent)

Assembly

1. Install all removed components using Figure 6 as a

guide.

A. If either purge hose assembly (item 5) or T--hose

assembly (item 10) was removed, make sure that
installation is correct.

B. Make sure that fuel hoses are not kinked after

installation. Also, secure all hoses with hose clamps.

Greensmaster 3150 Page 3 -- 11 Engine

 This page is intentionally blank.

Engine Page 3 -- 12 Greensmaster 3150

 Chapter 4

Hydraulic System
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 50
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 General Precautions for Removing and
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installing Hydraulic System Components . . . . . 50
Check Hydraulic System Fluid . . . . . . . . . . . . . . . . . 3 Flush Hydraulic System . . . . . . . . . . . . . . . . . . . . . . 51
Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 4 Filtering Closed--Loop Traction Circuit . . . . . . . . . 52
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic System Start--up . . . . . . . . . . . . . . . . . . . 53
Hydraulic Hose and Tube Installation (O--Ring Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Face Seal Fitting) . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Gear Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . 56
Hydraulic Fitting Installation (SAE Straight Thread Piston (Traction) Pump . . . . . . . . . . . . . . . . . . . . . . 60
O--Ring Fitting into Component Port) . . . . . . . . . 6 Piston (Traction) Pump Service . . . . . . . . . . . . . . . 64
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 8 Piston Pump Crush Ring Replacement . . . . . . . . 66

Hydraulic
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . 10 Front Wheel Motors . . . . . . . . . . . . . . . . . . . . . . . . . 68

System
Traction Forward and Reverse . . . . . . . . . . . . . . . . 10 Rear Wheel Motor (Optional 3WD) . . . . . . . . . . . . 70
Raise and Lower Cutting Units . . . . . . . . . . . . . . . . 12 Wheel Motor Service . . . . . . . . . . . . . . . . . . . . . . . . 72
Mow and Backlap . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cutting Reel Motors . . . . . . . . . . . . . . . . . . . . . . . . . 74
Right and Left Turn . . . . . . . . . . . . . . . . . . . . . . . . . 16 Cutting Reel Motor Service . . . . . . . . . . . . . . . . . . . 78
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Front Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 82
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 21 Center Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 84
General Hydraulic System Problems . . . . . . . . . . 21 Lift Cylinder Service . . . . . . . . . . . . . . . . . . . . . . . . . 86
Traction Circuit Problems . . . . . . . . . . . . . . . . . . . 22 Hydraulic Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Mow Circuit Problems . . . . . . . . . . . . . . . . . . . . . . 23 Hydraulic Manifold Service . . . . . . . . . . . . . . . . . . . 90
Lift/Lower Circuit Problems . . . . . . . . . . . . . . . . . . 24 Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . 94
Steering Circuit Problems . . . . . . . . . . . . . . . . . . . 25 Steering Control Valve Service . . . . . . . . . . . . . . . 96
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Precautions for Hydraulic Testing . . . . . . . . . . . . . 26 Steering Cylinder Service . . . . . . . . . . . . . . . . . . . 100
Charge Relief Valve Pressure Test . . . . . . . . . . . . 28 Leak Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Wheel Motor Efficiency Test . . . . . . . . . . . . . . . . . . 30 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . 106
Piston (Traction) Pump Flow Test . . . . . . . . . . . . . 32 EATON, MEDIUM DUTY PISTON PUMP, REPAIR
Gear Pump (Rear Section) Flow Test . . . . . . . . . . 34 INFORMATION, MODEL 70160 VARIABLE DIS-
Implement Relief Valve Pressure Test . . . . . . . . . 36 PLACEMENT PISTON PUMP
Lower Cutting Units Relief Valve (R2) PARKER TORQMOTORTM SERVICE PROCEDURE
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 (TC, TB, TE, TJ, TF, TG, TH and TL SERIES)
Gear Pump (Front Section) Flow Test . . . . . . . . . 40 DANFOSS STEERING UNIT TYPE OSPM
Mow Circuit Relief Valve (S1R1) Pressure Test . 42 SERVICE MANUAL
Reel Motor Case Drain Flow Test . . . . . . . . . . . . . 44
Steering Control Valve Test . . . . . . . . . . . . . . . . . . 46
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Adjust Manifold Relief Valves (R2) . . . . . . . . . . . . 49

Greensmaster 3150 Page 4 -- 1 Hydraulic System

Specifications

Item Description

Piston (Traction) Pump Variable displacement piston pump

Maximum Pump Displacement (per revolution) 1.24 in3 (20.3 cc)
Charge Pressure 110 to 150 PSI (8 to 10 bar)

Gear Pump 2 section, positive displacement gear pump

Front Section (cutting reels) Displacement (per revolution) 0.58 in3 (9.5 cc)
Rear Section (steering/lift) Displacement (per revolution) 0.33 in3 (5.4 cc)

Front Wheel Motors Orbital rotor motor

Displacement (per revolution) 10.3 in3 (169 cc)

Rear Wheel Motor (Optional 3WD Kit) Orbital rotor motor

Displacement (per revolution) 20.6 in3 (337 cc)

Cutting Reel Motor Gear motor

Displacement (per revolution) 0.73 in3 (12 cc)

Steering Control Valve Distributor valve with rotary meter

Implement (Steering and Lift) Relief Pressure 1160 PSI (80 bar) above Charge Pressure

Hydraulic Manifold Relief Valves

Mow Circuit (S1R1) 3000 PSI (207 bar)
Cutting Unit Lower (R2) 400 PSI (28 bar) above Charge Pressure

Hydraulic Filter Spin--on cartridge type

Hydraulic Oil See Operator’s Manual

Hydraulic Reservoir Reservoir (with leak detector) capacity 8.5 gal. U.S. (32.2 L)

Hydraulic System Page 4 -- 2 Greensmaster 3150

General Information

Operator’s Manual
The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for your Greensmaster 3150. Refer to that pub-
lication for additional information when servicing the
machine.

Check Hydraulic System Fluid

The hydraulic system on the Greensmaster 3150 is de-
signed to operate on high quality hydraulic fluid. Refer
to the Operator’s Manual for hydraulic fluid recommen- 2
dations.

IMPORTANT: Check level of hydraulic fluid before

engine is first started and daily thereafter. Do not
overfill hydraulic reservoir.

Hydraulic
System
NOTE: If changing from one type of hydraulic fluid to
another, be certain to remove all the old fluid from the
system, as some fluids are incompatible with others.
1
IMPORTANT: Use only types of hydraulic fluids
specified in the Operator’s Manual. Other fluids may Figure 1
cause system damage. 1. Sight window 2. Hydraulic oil cap

NOTE: A red dye additive for the hydraulic system fluid

is available in 2/3 oz bottles. One bottle is sufficient for
4 to 6 gallons of hydraulic fluid. Order Part No. 44--2500
from your Authorized Toro Distributor.

Greensmaster 3150 Page 4 -- 3 Hydraulic System

Towing Traction Unit
In case of emergency, the Greensmaster 3150 can be
towed for a short distance. However, Toro does not rec- 1
ommend this as a standard practice.

IMPORTANT: Do not tow the machine faster than 2

to 3 mph because drive system may be damaged. If
machine must be moved a considerable distance,
transport it on a truck or trailer.

1. Locate by--pass valve on the rear side of the piston

pump. Rotate valve 90o so the slot in the valve is vertical. 2

2. Before starting engine, close by--pass valve by rotat-

ing it back 90o so the slot in the valve is horizontal. Do Figure 2
not start engine when the valve is open. 1. Piston pump 2. By--pass valve

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- WARNING
tions or mishandling during operation and maintenance.
These conditions can cause hose damage and deterio- Before disconnecting or performing any work on
ration. Some hoses are more susceptible to these hydraulic system, relieve all pressure in system
conditions than others. Inspect all machine hydraulic (see Relieving Hydraulic System Pressure in this
hoses frequently for signs of deterioration or damage: section).

Hard, cracked, cut, abraded, charred, leaking or Keep body and hands away from pin hole leaks or
otherwise damaged hose. nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands, to
Kinked, crushed, flattened or twisted hose. search for leaks. Hydraulic fluid escaping under
pressure can have sufficient force to penetrate
Blistered, soft, degraded or loose hose cover.
the skin and cause serious injury. If fluid is in-
Cracked, damaged or badly corroded hose fittings. jected into the skin, it must be surgically re-
moved within a few hours by a doctor familiar
When replacing a hydraulic hose, be sure that the hose with this type of injury. Gangrene may result from
is straight (not twisted) before tightening the fittings. such an injury.
This can be done by observing the imprint (layline) on
the hose. Use two wrenches; hold the hose straight with
one wrench and tighten the hose swivel nut onto the fit-
ting with the other wrench (see Hydraulic Hose and
Tube Installation in this section). If the hose has an el-
bow at one end, tighten the swivel nut on that end before
tightening the nut on the straight end of the hose.

For additional hydraulic hose information, refer to Toro

Service Training Book, Hydraulic Hose Servicing (Part
Number 94813SL).

Hydraulic System Page 4 -- 4 Greensmaster 3150

Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting)
1. Make sure threads and sealing surfaces of the hose/ C. Use a second wrench to tighten the nut to the cor-
tube and the fitting are free of burrs, nicks, scratches or rect Flats From Wrench Resistance (F.F.W.R.). The
any foreign material. markings on the nut and fitting body will verify that the
connection has been properly tightened.
2. As a preventative measure against leakage, it is rec-
ommended that the face seal O--ring be replaced any Size F.F.W.R.
4 (1/4 in. nominal hose or tubing) 1/2 to 3/4
time the connection is opened. Make sure the O--ring is
6 (3/8 in.) 1/2 to 3/4
installed and properly seated in the fitting groove. Lightly 8 (1/2 in.) 1/2 to 3/4
lubricate the O--ring with clean hydraulic oil. 10 (5/8 in.) 1/2 to 3/4
12 (3/4 in.) 1/3 to 1/2
3. Place the hose/tube against the fitting body so that 16 (1 in.) 1/3 to 1/2
the flat face of the hose/tube sleeve fully contacts the O--
ring in the fitting. Swivel Nut Fitting Body
O--ring
4. Thread the swivel nut onto the fitting by hand. While
holding the hose/tube with a wrench, use a torque
wrench to tighten the swivel nut to the recommended
installation torque shown in Figure 5. This tightening
process will require the use of an offset wrench (e.g.
crowfoot wrench). Use of an offset wrench will affect

Hydraulic
System
torque wrench calibration due to the effective length
change of the torque wrench. Tightening torque when
Tube or Hose
using a torque wrench with an offset wrench will be lower
than the listed installation torque (see Using a Torque
Wrench with an Offset Wrench in the Torque Specifica- Figure 3
tions section of Chapter 2 -- Product Records and Main-
tenance).

5. If a torque wrench is not available or if space at the

Mark Nut Final
swivel nut prevents use of a torque wrench, an alternate and Fitting Position
method of assembly is the Flats From Wrench Resist- Body
ance (F.F.W.R.) method (Fig. 2).
Initial
A. Using a wrench, tighten the swivel nut onto the fit- Position
Extend Line
ting until light wrench resistance is reached (approxi-
mately 30 in--lb).
AT WRENCH RESISTANCE AFTER TIGHTENING

B. Mark the swivel nut and fitting body. Hold the

hose/tube with a wrench to prevent it from turning. Figure 4

Fitting Dash Size Hose/Tube Side Thread Size Installation Torque

4 9/16 -- 18 18 to 22 ft--lb (25 to 29 N--m)

6 11/16 -- 16 27 to 33 ft--lb (37 to 44 N--m)

8 13/16 -- 16 37 to 47 ft--lb (51 to 63 N--m)

10 1 -- 14 60 to 74 ft--lb (82 to 100 N--m)

12 1 3/16 -- 12 85 to 105 ft--lb (116 to 142 N--m)

16 1 7/16 -- 12 110 to 136 ft--lb (150 to 184 N--m)

20 1 11/16 -- 12 140 to 172 ft--lb (190 to 233 N--m)

Figure 5

Greensmaster 3150 Page 4 -- 5 Hydraulic System

Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port)
Non--Adjustable Fitting (Fig. 6) 5. If a torque wrench is not available, or if space at the
port prevents use of a torque wrench, an alternate meth-
1. Make sure all threads and sealing surfaces of fitting od of assembly is the Flats From Finger Tight (F.F.F.T.)
and component port are free of burrs, nicks, scratches method.
or any foreign material.
A. Install the fitting into the port and tighten it down
2. As a preventative measure against leakage, it is rec- full length until finger tight.
ommended that the O--ring be replaced any time the
connection is opened. B. If port material is steel, tighten the fitting to the
listed F.F.F.T. If port material is aluminum, tighten fit-
3. Lightly lubricate the O--ring with clean hydraulic oil. ting to 60% of listed F.F.F.T.
Fitting threads should be clean with no lubricant applied.
Size F.F.F.T.
IMPORTANT: Before installing fitting into port, de- 4 (1/4 in. nominal hose or tubing) 1.00 + 0.25
6 (3/8 in.) 1.50 + 0.25
termine port material. If fitting is to be installed into 8 (1/2 in.) 1.50 + 0.25
an aluminum port, installation torque is reduced. 10 (5/8 in.) 1.50 + 0.25
12 (3/4 in.) 1.50 + 0.25
4. Install the fitting into the port. Then, use a torque 16 (1 in.) 1.50 + 0.25
wrench and socket to tighten the fitting to the recom-
mended installation torque shown in Figure 7.
Fitting
NOTE: Use of an offset wrench (e.g. crowfoot wrench)
will affect torque wrench calibration due to the effective
length change of the torque wrench. Tightening torque
when using a torque wrench with an offset wrench will
be less than the recommended installation torque. See O--ring
Using a Torque Wrench with an Offset Wrench in the
Torque Specifications section of Chapter 2 -- Product
Records and Maintenance to determine necessary con- Figure 6
version information.

Fitting Fitting Port Side Installation Torque Into Installation Torque Into
Dash Size Thread Size Steel Port Aluminum Port

4 7/16 -- 20 15 to 19 ft--lb (21 to 25 N--m) 9 to 11 ft--lb (13 to 15 N--m)

5 1/2 -- 20 18 to 22 ft--lb (25 to 29 N--m) 11 to 15 ft--lb (15 to 20 N--m)

6 9/16 -- 18 34 to 42 ft--lb (47 to 56 N--m) 20 to 26 ft--lb (28 to 35 N--m)

8 3/4 -- 16 58 to 72 ft--lb (79 to 97 N--m) 35 to 43 ft--lb (48 to 58 N--m)

10 7/8 -- 14 99 to 121 ft--lb (135 to 164 N--m) 60 to 74 ft--lb (82 to 100 N--m)

12 1 1/16 -- 12 134 to 164 ft--lb (182 to 222 N--m) 81 to 99 ft--lb (110 to 134 N--m)

14 1 3/16 -- 12 160 to 196 ft--lb (217 to 265 N--m) 96 to 118 ft--lb (131 to 160 N--m)

16 1 5/16 -- 12 202 to 248 ft--lb (274 to 336 N--m) 121 to 149 ft--lb (165 to 202 N--m)

20 1 5/8 -- 12 247 to 303 ft--lb (335 to 410 N--m) 149 to 183 ft--lb (202 to 248 N--m)
Figure 7

Hydraulic System Page 4 -- 6 Greensmaster 3150

Adjustable Fitting (Fig. 8)

1. Make sure all threads and sealing surfaces of fitting

and component port are free of burrs, nicks, scratches
or any foreign material.

2. As a preventative measure against leakage, it is rec-

ommended that the O--ring be replaced any time the
connection is opened. Lock Nut

3. Lightly lubricate the O--ring with clean hydraulic oil.

Fitting threads should be clean with no lubricant applied.
Back--up Washer
4. Turn back the lock nut as far as possible. Make sure
the back up washer is not loose and is pushed up as far O--ring
as possible (Step 1 in Figure 9).
Figure 8
IMPORTANT: Before installing fitting into port, de-
termine port material. If fitting is to be installed into
an aluminum port, installation torque is reduced.

5. Install the fitting into the port and tighten finger tight Step 1 Step 3
until the washer contacts the face of the port (Step 2).

Hydraulic
System
6. To put the fitting in the desired position, unscrew it by
the required amount, but no more than one full turn
(Step 3).
Step 2 Step 4
7. Hold the fitting in the desired position with a wrench
and use a torque wrench to tighten the fitting to the rec-
ommended installation torque shown in Figure 7. This
tightening process will require the use of an offset
wrench (e.g. crowfoot wrench). Use of an offset wrench
Figure 9
will affect torque wrench calibration due to the effective
length change of the torque wrench. Tightening torque
when using a torque wrench with an offset wrench will
be lower than the listed installation torque (see Using a
Torque Wrench with an Offset Wrench in the Torque
Specifications section of Chapter 2 -- Product Records
and Maintenance).

8. If a torque wrench is not available, or if space at the

port prevents use of a torque wrench, an alternate meth-
od of assembly is the Flats From Finger Tight (F.F.F.T.)
method. Hold the fitting in the desired position with a
wrench and, if port material is steel, tighten the lock nut
with a second wrench to the listed F.F.F.T (Step 4). If port
material is aluminum, tighten fitting to 60% of listed
F.F.F.T.

Size F.F.F.T.
4 (1/4 in. nominal hose or tubing) 1.00 + 0.25
6 (3/8 in.) 1.50 + 0.25
8 (1/2 in.) 1.50 + 0.25
10 (5/8 in.) 1.50 + 0.25
12 (3/4 in.) 1.50 + 0.25
16 (1 in.) 1.50 + 0.25

Greensmaster 3150 Page 4 -- 7 Hydraulic System

 Greensmaster 3150
Steering Cylinder
Hydraulic Schematic Right Front 1.5” Bore
Reel (#3) 0.75” Rod
All solenoids are shown as .73
6.19” Stroke
de--energized
.73
CU #2 CU #1 CU #3
Center 2.0” Bore 1.50” Bore 2.0” Bore
Reel (#1) 0.75” Rod 0.75” Rod 0.75” Rod

Hydraulic System
.73
1.88” Stroke 3.38” Stroke 1.88” Stroke
L R
Raise
Left Front
Reel (#2)
Lower
MA MB L2B L2A L1B L1A L3A L3B
STEERING
0.055 FC2 0.030 0.055 VALVE
MR 4.5
BACKLAP 550 PSI
SWITCH
(SW)
PRV
R2
Hydraulic Schematic

400 PSI 1160 PSI

S4
FC1 OR1
OR2 0.013
P E T
0.060
S3
ST
LC

S2

G1
S1R1

Page 4 -- 8
P1 T G2 P2 PT

4.0 GPM

7.0 GPM
TRACTION PUMP
TOP
TRANSPORT = 14.1 GPM PORT
FILTER 25 PSI
A
LEAK DETECTOR BYPASS Right
Left 10.3 10.3
VALVE Motor Motor
3000
LEAK PSI
DETECTOR IN OPTIONAL ENGINE RPM
OIL COOLER GEAR .33 .58 1.24 3000
VOLUME PUMP PSI 2850/1650
OUT 20.6
110 to 70 to
EXPANSION 150 PSI 100 PSI B
TANK OPTIONAL
BOTTOM 3WD KIT
PORT

BREATHER
SUCTION
STRAINER

Greensmaster 3150
 Hydraulic
System
This page is intentionally blank.

Greensmaster 3150 Page 4 -- 9 Hydraulic System

 Greensmaster 3150 All solenoids are shown as
Steering Cylinder
Traction Forward Right Front de--energized.
1.5” Bore
Reel (#3) 0.75” Rod
High Pressure .73
6.19” Stroke
Low Pressure (Charge)
Return or Suction .73 CU #2 CU #1 CU #3
Flow Center 2.0” Bore 1.50” Bore 2.0” Bore
Reel (#1) 0.75” Rod 0.75” Rod 0.75” Rod

Hydraulic System
.73
1.88” Stroke 3.38” Stroke 1.88” Stroke
L R
Raise
Left Front
Reel (#2)
Lower
MA MB L2B L2A L1B L1A L3A L3B

0.055 FC2 0.030 0.055

MR 4.5
BACKLAP 550 PSI
SWITCH
(SW)
PRV
R2
400 PSI 1160 PSI
S4 STEERING
FC1 OR1 VALVE
OR2 0.013
P E T
0.060
S3
Hydraulic Flow Diagrams

ST
LC

S2

G1
S1R1

Page 4 -- 10
P1 T G2 P2 PT

4.0 GPM

7.0 GPM
TRACTION PUMP
TOP
TRANSPORT = 14.1 GPM PORT
FILTER 25 PSI
A
LEAK DETECTOR BYPASS Right
Left 10.3 10.3
VALVE Motor Motor
3000
LEAK PSI
DETECTOR IN OPTIONAL ENGINE RPM
OIL COOLER GEAR .33 .58 1.24 3000
VOLUME PUMP PSI 2850/1650
OUT 20.6
110 to 70 to
EXPANSION 150 PSI 100 PSI B
TANK OPTIONAL
BOTTOM 3WD KIT
PORT

BREATHER
SUCTION
STRAINER

Greensmaster 3150
Traction Forward and Reverse
Forward Reverse

The piston (traction) pump is driven directly by the en- The traction circuit operates essentially the same in re-
gine. The traction circuit of the hydraulic system acts es- verse as it does in the forward direction. However, the
sentially as a closed loop. Taking its suction directly from flow through the circuit is reversed.
the return side of the wheel motors of the traction circuit,
the piston pump supplies oil flow to the wheel motors With the engine running and traction pedal in the neutral
through the supply side of the traction circuit. position, the piston pump supplies no flow to the wheel
motors. When the traction pedal is pressed to the re-
With the engine running and traction pedal in the neutral verse position, the linkage from the pedal positions the
position, the piston pump supplies no flow to the wheel swash plate in the piston pump so oil flows out the bot-
motors. When the traction pedal is pressed to the for- tom port of the pump. Oil flow out of the bottom port goes
ward position, the linkage from the pedal positions the to the wheel motors and turns them in the reverse direc-
swash plate in the piston pump so oil flows out the top tion.
port of the pump. Oil flow out of the top port goes to the
wheel motors and turns them in the forward direction. Oil flowing out of the wheel motors returns to the top port
of the piston pump and is continuously pumped out the
Oil flowing out of the wheel motors returns to the bottom bottom port as long as the traction pedal is pressed for
port of the piston pump and is continuously pumped out the reverse direction.
the top port as long as the traction pedal is pressed for

Hydraulic
The charge circuit functions the same in reverse as it

System
the forward direction.
does in the forward direction.
Hydraulic oil is supplied to the traction charge circuit
from the rear gear pump section though the steering Traction Circuit Cooling
valve, control manifold and back through the charge cir-
cuit check valves in the piston (traction) pump. This oil The piston pump includes a shuttle valve that bleeds off
replaces oil losses from flow through the internal case a small amount of hydraulic fluid for cooling of the closed
drain, shuttle valve and small amounts of traction circuit loop traction circuit. This valve allows a small amount of
leakage. Charge circuit pressure is maintained by the hydraulic oil to pass from the low pressure side of the
charge relief valve that is attached to the piston pump traction circuit while operating the traction unit in either
back plate. direction. A relief valve in the piston pump back plate
prevents shuttle valve bleed off until the relief valve
opens (70 to 100 PSI / 5 to 7 bar). The charge circuit re-
plenishes oil that is bled from the traction circuit by the
shuttle valve.

NOTE: The shuttle valve assembly is located in the pis-

ton pump back plate. Access to the shuttle valve re-
quires removal of the back plate from the piston pump.

Greensmaster 3150 Page 4 -- 11 Hydraulic System

 Greensmaster 3150 Solenoids S2 and S3 are shown
in the energized position. Steering Cylinder
Raise Cutting Units Right Front 1.5” Bore
Reel (#3) All other solenoids are shown
High Pressure CU #2 CU #1 CU #3 0.75” Rod
.73 as de--energized.
Low Pressure (Charge) 2.0” Bore 1.50” Bore 2.0” Bore 6.19” Stroke
0.75” Rod 0.75” Rod 0.75” Rod
Return or Suction 1.88” Stroke 3.38” Stroke 1.88” Stroke
.73
Flow
Center

Hydraulic System
Reel (#1)
.73 L R
Raise
Left Front
Reel (#2)
Lower
MA MB L2B L2A L1B L1A L3A L3B

0.055 FC2 0.030 0.055

MR 4.5
BACKLAP 550 PSI
SWITCH
(SW)
PRV
R2
400 PSI 1160 PSI
S4 STEERING
FC1 OR1 VALVE
OR2 0.013
P E T
0.060
S3
ST
LC

S2

G1
S1R1

Page 4 -- 12
P1 T G2 P2 PT

4.0 GPM

7.0 GPM
TRACTION PUMP
TOP
TRANSPORT = 14.1 GPM PORT
FILTER 25 PSI
A
LEAK DETECTOR BYPASS Right
Left 10.3 10.3
VALVE Motor Motor
3000
LEAK PSI
DETECTOR IN OPTIONAL ENGINE RPM
OIL COOLER GEAR .33 .58 1.24 3000
VOLUME PUMP PSI 2850/1650
OUT 20.6
110 to 70 to
EXPANSION 150 PSI 100 PSI B
TANK OPTIONAL
BOTTOM 3WD KIT
PORT

BREATHER
SUCTION
STRAINER

Greensmaster 3150
Raise and Lower Cutting Units
The tandem gear pump is directly coupled to the piston Lower Cutting Units
(traction) pump. The rear gear pump section supplies
hydraulic flow for the steering circuit (priority flow), for Circuit operation for lowering the lift cylinders is similar
raising and lowering the cutting units and for the traction to raising them. However, the solenoid valve (S3) re-
charge circuit. The gear pump takes its suction from the mains de--energized and solenoid valve (S4) is ener-
hydraulic reservoir. Maximum circuit pressure of 1160 gized. Flow is reversed to and from the lift cylinders,
PSI (80 bar) is limited by the relief valve located in the lowering the cutting units.
steering valve.
When the cutting units are to be lowered, solenoid valve
During cutting unit hold (not raising or lowering) condi- (S2) is energized and blocks flow directly to the traction
tions, flow from the rear gear pump section is by--passed charge circuit. Flow is directed to de--energized sole-
through the steering valve and de--energized solenoid noid valve (S3), which directs flow to the lift cylinders.
valve (S2) in the hydraulic manifold directly to the trac- Hydraulic pressure against the cylinder pistons moves
tion charge circuit. Flow in excess of charge circuit re- their shafts causing the cutting units to lower. At the
quirements then returns to the gear pump inlet. same time, the pistons push the hydraulic fluid out of the
lift cylinders to energized solenoid valve (S4). Flow con-
Raise Cutting Units tinues back through solenoid valve (S3) to the charge
circuit. Lower speed for the front cutting units is con-
When the cutting units are to be raised, hydraulic man- trolled by the 0.055 orifice. A 0.030 orifice and adjust-
ifold solenoid valve (S2) is energized and blocks flow di- able flow control valve for the center cutting unit allows

Hydraulic
System
rectly to the traction charge circuit. Flow is directed to a slight delay in lowering that cutting unit.
energized solenoid valve (S3), which directs flow to de--
energized solenoid valve (S4) and the lift cylinders. Hy- To control pressure while lowering the cutting units, the
draulic pressure against the cylinder pistons moves system is equipped with adjustable relief valve (R2) in
their shafts causing the cutting units to raise. At the the hydraulic manifold.
same time, the pistons push the hydraulic fluid out of the
lift cylinders and back through energized solenoid valve When solenoid valves (S2) and (S4) de--energize,
(S3) to the charge circuit. Raise speed for the front cut- spring action returns the valves to their original position
ting units is controlled by a 0.055 orifice. A 0.030 orifice and by--passes flow back to the traction charge circuit
in the return line for the center cutting unit allows a slight stopping lift cylinder movement.
delay in raising that cutting unit.

When solenoid valves (S2) and (S3) de--energize,

spring action returns the valves to their original position
and by--passes flow back to the traction charge circuit
stopping lift cylinder movement. The lift cylinder position
is locked in place since there is no complete circuit of
flow to and from the lift cylinders.

Greensmaster 3150 Page 4 -- 13 Hydraulic System

 Greensmaster 3150 Solenoid S1R1 is shown
in the energized position. Steering Cylinder
Mow Right Front
All other solenoids are shown 1.5” Bore
High Pressure Reel (#3) 0.75” Rod
.73 as de--energized.
Low Pressure (Charge) 6.19” Stroke
Return or Suction
Flow .73
CU #2 CU #1 CU #3
Center 2.0” Bore 1.50” Bore 2.0” Bore
Reel (#1) 0.75” Rod 0.75” Rod 0.75” Rod

Hydraulic System
.73
1.88” Stroke 3.38” Stroke 1.88” Stroke
L R
Raise
Left Front
Reel (#2)
Lower
MA MB L2B L2A L1B L1A L3A L3B
STEERING
0.055 FC2 0.030 0.055 VALVE
MR 4.5
BACKLAP 550 PSI
SWITCH
(SW)
PRV
R2
400 PSI 1160 PSI
S4
FC1 OR1
OR2 0.013
P E T
0.060
S3
ST
LC

S2

G1
S1R1

Page 4 -- 14
P1 T G2 P2 PT

4.0 GPM

7.0 GPM
TRACTION PUMP
TOP
TRANSPORT = 14.1 GPM PORT
FILTER 25 PSI
A
LEAK DETECTOR BYPASS Right
Left 10.3 10.3
VALVE Motor Motor
3000
LEAK PSI
DETECTOR IN OPTIONAL ENGINE RPM
OIL COOLER GEAR .33 .58 1.24 3000
VOLUME PUMP PSI 2850/1650
OUT 20.6
110 to 70 to
EXPANSION 150 PSI 100 PSI B
TANK OPTIONAL
BOTTOM 3WD KIT
PORT

BREATHER
SUCTION
STRAINER

Greensmaster 3150
Mow and Backlap
The tandem gear pump is directly coupled to the piston Oil flow from manifold port (P1) flows through the reel
(traction) pump. The front gear pump section supplies speed control valve (FC1). Flow across the speed con-
oil flow to the hydraulic manifold block and to the cutting trol valve is pressure compensated by the logic cartridge
reel motors. The gear pump takes its suction directly valve (LC). The logic cartridge valve maintains a pres-
from the hydraulic reservoir. Maximum circuit pressure sure differential of 75 PSI (5.2 bar) across the speed
is limited by solenoid relief valve (S1R1) which is located control valve. Any excess flow above the speed control
in the hydraulic manifold. valve setting is by--passed to the reservoir through the
logic cartridge valve. With the backlap valve (MR) in the
With the engine running and the functional control and mow position, oil flows through the backlap valve, out
joystick levers positioned so the reels will not turn (see manifold port (MA) and to the reel motors that are con-
Operator’s Manual), solenoid relief valve (S1R1) in the nected in series. Oil flows through the left front reel mo-
hydraulic manifold is de--energized. The de--energized tor, right front motor and then center motor to turn the
(S1R1) by--passes flow from the front gear pump sec- reel motors in the mow direction.
tion to the oil filter and hydraulic reservoir. Additionally,
the manifold pressure reducing valve (PRV) will remain When in the mow position, mow circuit pressure will
seated to prevent the reel motors (and reels) from rotat- cause the hydraulic manifold pilot piston to shift and
ing. open the pressure reducing valve (PRV). The shifted
pressure reducing valve allows circuit oil to return to the
Mow reservoir through the manifold block, oil filter and oil
cooler (if equipped).

Hydraulic
System
With the engine running and the functional control and
joystick levers positioned so the reels will turn (see Op- Backlap
erator’s Manual), solenoid relief valve (S1R1) is ener-
gized. In the energized position, this valve directs oil flow Backlapping operation is the same as mowing opera-
to the reel motors and also functions as the mow circuit tion, except for the position of the backlap valve (MR).
relief valve. When the backlap valve (MR) is in the backlap position,
oil flows through the backlap valve, out manifold port
(MB) and to the reel motors that are connected in series.
Oil flows through the center reel motor, right front motor
and then left front motor as it turns the reel motors in the
backlap direction.

Greensmaster 3150 Page 4 -- 15 Hydraulic System

 Greensmaster 3150 All solenoids are shown
as de--energized. Steering Cylinder
Right Turn Right Front 1.5” Bore
Reel (#3) Power steering valve is 0.75” Rod
High Pressure .73
positioned for a right turn. 6.19” Stroke
Low Pressure (Charge)
Return or Suction .73 CU #2 CU #1 CU #3
Flow Center 2.0” Bore 1.50” Bore 2.0” Bore
Reel (#1) 0.75” Rod 0.75” Rod 0.75” Rod

Hydraulic System
.73
1.88” Stroke 3.38” Stroke 1.88” Stroke
L R
Raise
Left Front
Reel (#2)
Lower
MA MB L2B L2A L1B L1A L3A L3B

0.055 FC2 0.030 0.055

MR 4.5
BACKLAP 550 PSI
SWITCH
(SW)
PRV
R2
400 PSI 1160 PSI
S4 STEERING
FC1 OR1 VALVE
OR2 0.013
P E T
0.060
S3
ST
LC

S2

G1
S1R1

Page 4 -- 16
P1 T G2 P2 PT

4.0 GPM

7.0 GPM
TRACTION PUMP
TOP
TRANSPORT = 14.1 GPM PORT
FILTER 25 PSI
A
LEAK DETECTOR BYPASS Right
Left 10.3 10.3
VALVE Motor Motor
3000
LEAK PSI
DETECTOR IN OPTIONAL ENGINE RPM
OIL COOLER GEAR .33 .58 1.24 3000
VOLUME PUMP PSI 2850/1650
OUT 20.6
110 to 70 to
EXPANSION 150 PSI 100 PSI B
TANK OPTIONAL
BOTTOM 3WD KIT
PORT

BREATHER
SUCTION
STRAINER

Greensmaster 3150
Right and Left Turn
The tandem gear pump is directly coupled to the piston Left Turn
(traction) pump. The rear gear pump section supplies
hydraulic flow for the steering circuit (priority flow), for When a left turn is made with the engine running, the
raising and lowering the cutting units and for the traction turning of the steering wheel positions the spool valve in
charge circuit. The gear pump takes its suction from the the steering valve so that flow goes through the top of
hydraulic reservoir. Maximum circuit pressure of 1160 the spool (Fig. 10). Flow entering the steering valve at
PSI (80 bar) is limited by the relief valve located in the Port (P) goes through the spool and is routed to two
steering valve. places. First, most of the flow through the valve is by--
passed out steering valve port (E) and is available for
With the steering wheel in the neutral position and the raising and lowering the cutting units and for the traction
engine running, the spool valve in the steering valve is charge circuit. Second, the remainder of the flow is
in the center position. Flow enters the steering control drawn through the steering valve rotary meter and out
valve at Port (P) and goes through the spool valve, by-- steering valve port (L). Pressure moves the steering cyl-
passing the steering cylinder. Flow leaves the control inder piston to retract the cylinder for a left turn. The
valve out port (E) to be available for the raise/lower and rotary meter ensures that the oil flow to the cylinder is
traction charge circuits. proportional to the amount of turning on the steering
wheel. Fluid leaving the cylinder flows back through the
Right Turn spool valve then out steering valve port (T) and then to
the traction charge circuit.
When a right turn is made with the engine running, the

Hydraulic
System
turning of the steering wheel positions the spool valve in The steering valve returns to the neutral position when
the steering valve so that flow goes through the bottom turning is complete.
of the spool. Flow entering the steering 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 Steering Cylinder
1.5” Bore
steering valve port (E) and is available for raising and 0.75” Rod
6.19” Stroke
lowering the cutting units and for the traction charge cir-
cuit. Second, the remainder of the flow is drawn through
the steering valve rotary meter and out steering valve
port (R). Pressure moves the steering cylinder piston to L R
extend the cylinder for a right turn. The rotary meter en-
sures that the oil flow to the cylinder is proportional to the
amount of turning on the steering wheel. Fluid leaving
the cylinder flows back through the spool valve then out
steering valve port (T) and then to the traction charge 4.5

circuit.

The steering valve returns to the neutral position when

1160 PSI
turning is complete. STEERING
VALVE
P E T

To Manifold
Port ST

To Manifold
Port P2

From Gear Pump

Figure 10

Greensmaster 3150 Page 4 -- 17 Hydraulic System

Special Tools
Order these special tools from your Toro Distributor.

Hydraulic Pressure Test Kit

Use to take various pressure readings for diagnostic
tests. Quick disconnect fittings provided attach directly
to mating fittings on machine test ports without tools. A
high pressure hose is provided for remote readings.
Contains one each: 1000 PSI (70 Bar), 5000 PSI (350
Bar) and 10000 PSI (700 Bar) gauges. Use gauges as
recommended in the Testing section of this chapter.

Toro Part Number: TOR47009

Figure 11

Hydraulic Tester (Pressure and Flow)

This tester requires O--ring Face Seal (ORFS) adapter
fittings for use on this machine (see Hydraulic Test Fit-
ting Kit (TOR4079) in this section).

1. INLET HOSE: Hose connected from the system cir-

cuit to the inlet side of the hydraulic tester.

2. LOAD VALVE: A simulated working load is created

in the circuit by turning the valve to restrict flow.

3. PRESSURE GAUGE: 0 to 5000 PSI gauge to pro-

vide operating circuit pressure.

4. FLOW METER: This meter measures actual oil flow

in the operating circuit with a gauge rated at 15 GPM.
Figure 12
5. OUTLET HOSE: A hose from the outlet side of the
hydraulic tester connects to the hydraulic system circuit.

Toro Part Number: TOR214678

O--ring Kit
The O--ring kit includes O--rings in a variety of sizes for
face seal and port seal hydraulic connections. It is rec-
ommended that O--rings be replaced whenever a hy-
draulic connection is loosened.

Toro Part Number: 117--2727

Figure 13
Hydraulic System Page 4 -- 18 Greensmaster 3150
High Flow Hydraulic Filter Kit
The high flow hydraulic filter kit is designed with large
flow (40 GPM/150 LPM) and high pressure (5000
PSI/345 bar) capabilities. This kit provides for bi--direc-
tional filtration which prevents filtered debris from being
allowed back into the circuit regardless of flow direction.

If a component failure occurs in the closed loop traction

circuit, contamination from the failed part will remain in
the circuit until removed. When connecting hydraulic
test gauges in order to test traction circuit components
or after replacing a failed traction circuit component (e.g.
piston (traction) pump or wheel motor), the high flow hy-
draulic filter can be installed in the traction circuit. The
filter will ensure that contaminates are removed from the
closed loop and thus, do not cause additional compo-
nent damage. Figure 14

Toro Part Number: TOR6011

NOTE: This kit does not include hydraulic hoses (see

Hydraulic
System
Hydraulic Hose Kit TOR6007 above).

NOTE: Replacement filter element is Toro part number

TOR6012. Filter element cannister tightening torque is
25 ft--lb (34 N--m).

Hydraulic Hose Kit

This kit includes hydraulic fittings and hoses needed to
connect 40 GPM hydraulic tester (AT40002) or high flow
hydraulic filter kit (TOR6011) to machine hydraulic trac-
tion system components.

Toro Part Number: TOR6007

Figure 15

Greensmaster 3150 Page 4 -- 19 Hydraulic System

Hydraulic Test Fitting Kit
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)

The kit includes: tee’s, unions, reducers, plugs, caps

and male test fittings.

Toro Part Number: TOR4079

Figure 16

Measuring Container

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.

Toro Part Number: TOR4077

Figure 17

Wheel Hub Puller

The wheel hub puller allows safe removal of the wheel
hub from the shaft of wheel motors.

Toro Part Number: TOR4097

Figure 18

Hydraulic System Page 4 -- 20 Greensmaster 3150

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.

General Hydraulic System Problems

Problem Possible Cause

Hydraulic oil leaks from system. Fitting(s), hose(s) or tube(s) are loose or damaged.

O--ring(s) or seal(s) are missing or damaged.

Hydraulic fluid foams. Hydraulic reservoir oil level is low.

Hydraulic system has wrong type of oil.

The pump suction line has an air leak.

Hydraulic system operates hot. Hydraulic reservoir oil level is low.

Hydraulic
System
Suction screen in reservoir is loose or clogged.

Oil is contaminated or too light.

Brakes are applied or are incorrectly adjusted.

Piston pump by--pass valve is open or defective.

Working load of machine (e.g. high ambient temperatures, use of

verticutter) may require use of oil cooler.

Oil cooler (if installed) is damaged or plugged. Cooler by--pass re-

lief is stuck open or air flow is obstructed.

Charge pressure is low (see Charge Pressure Relief Valve Pres-

sure Test in the Testing section of this chapter).

Wheel motor(s) or cutting reel motor(s) are worn or damaged (see

Wheel Motor Efficiency and Reel Motor Case Drain Flow Tests in
the Testing section of this chapter).

Piston (traction) pump is worn or damaged (see Piston (Traction)

Pump Flow Test in the Testing section of this chapter).

Greensmaster 3150 Page 4 -- 21 Hydraulic System

Traction Circuit Problems

Problem Possible Cause

Neutral is difficult to find or machine External control linkage is misadjusted, disconnected, binding or
operates in one direction only. damaged.

Piston (traction) pump is worn or damaged (see Piston (Traction)

Pump Flow Test in the Testing section of this chapter).
Traction response is sluggish. Hydraulic oil is very cold.

Brakes are applied or are incorrectly adjusted.

Piston pump by--pass valve is open or defective.

Charge pressure is low (see Charge Pressure Relief Valve Pres-

sure Test in the Testing section of this chapter).

Piston (traction) pump relief valves are leaking or damaged.

Piston (traction) pump or wheel motor(s) are worn or damaged (see

Piston (Traction) Pump Flow and Wheel Motor Efficiency Tests in
the Testing section of this chapter).

No traction exists in either direction. Brakes are applied or are incorrectly adjusted.

Hydraulic reservoir oil level is low (other hydraulic circuits affected

as well).

Piston pump by--pass valve is open.

Charge pressure is low (see Charge Pressure Relief Valve Pres-

sure Test in the Testing section of this chapter).

Wheel motor(s) are worn or damaged (see Wheel Motor Efficiency

Test in the Testing section of this chapter).

Piston (traction) pump is worn or damaged (see Piston (Traction)

Pump Flow Test in the Testing section of this chapter).

Wheel motor will not turn. Brakes are binding.

Key on wheel motor shaft is sheared or missing.

Wheel motor is damaged.

Wheel motor will not hold load in Make up fluid from charge pump is not available.
neutral.
Piston (traction) pump relief valves are leaking or damaged.

NOTE: The piston (traction) pump used on Green-

smaster 3150 machines is equipped with relief valves
for both the forward and reverse direction. Due to engine
output, it is unlikely that traction pressure will reach relief
valve settings. If, however, a piston pump relief valve is
leaking or otherwise faulty, traction performance would
be affected.

Hydraulic System Page 4 -- 22 Greensmaster 3150

Mow Circuit Problems

Problem Possible Cause

Gear pump is noisy (cavitation). Hydraulic reservoir oil level is low (other hydraulic circuits affected
as well).

Hydraulic pump suction line is restricted.

Hydraulic pump suction line has an air leak.

Cutting reel motors will not turn. Hydraulic manifold solenoid valve S1R1 is stuck open (not shifting
to its energized position).

An electrical problem exists (see Chapter 5 -- Electrical System).

FC1 logic valve in control manifold is stuck open.

PRV valve in control manifold is stuck closed.

Pilot piston in control manifold is stuck or damaged.

Front section of gear pump is damaged (see Gear Pump (Front

Hydraulic
System
Section) Flow Test in the Testing section of this chapter).

Cutting reel speed is erratic. A cutting unit problem exists (see Chapter 7 -- DPA Cutting Units).

Hydraulic manifold reel circuit cartridge is leaking or damaged.

Hydraulic manifold orifice (OR1 or OR2) is plugged.

Cutting reel speed is low. A cutting unit problem exists (see Chapter 7 -- DPA Cutting Units).

Hydraulic manifold reel circuit cartridge is leaking or damaged.

Excessive internal wear in reel motor exists (see Reel Motor Case
Drain Flow Test in the Testing section of this chapter).

Greensmaster 3150 Page 4 -- 23 Hydraulic System

Lift/Lower Circuit Problems

Problem Possible Cause

Cutting units will not lift or lift slowly. Engine speed is too low.

Hydraulic reservoir oil level is low.

Lift cylinder linkage is binding or broken.

Lift cylinder bushings are binding or worn.

Charge circuit pressure is low (see Charge Relief Valve Pressure

Test in the Testing section of this chapter).

Implement relief valve is leaking or damaged (see Implement Relief

Valve Pressure Test in the Testing section of this chapter).

Hydraulic manifold solenoid valve (S2) is leaking or damaged (not

shifting to its energized position).

Relief valve (R2) is leaking or damaged (see Lower Cutting Units

Relief Valve (R2) Pressure Test in the Testing section of this
chapter).

Lift cylinders leak internally.

Spool in steering control valve is hung up (see Steering Control

Valve Test in the Testing section of this chapter).

Gear pump (rear section) is worn or damaged (see Gear Pump

(Rear Section) Flow Test in the Testing section of this chapter).
Cutting units raise, but will not stay Hydraulic manifold solenoid valve (S4) leaks or is damaged.
up.
Lift cylinders leak internally.

Hydraulic System Page 4 -- 24 Greensmaster 3150

Steering Circuit Problems

Problem Possible Cause

Steering wheel is hard to turn. Oil supply to the steering control valve is insufficient (traction
charge and lift circuits affected as well).

Emergency steering ball in steering control valve is missing or

damaged.
Regular adjustments to steering Leaf springs in steering control valve are worn or broken.
wheel are necessary because of dif-
ficulty of driving in a straight line. Gear wheel set in steering control valve is worn.

Steering cylinder is seized or its piston seals are worn (see Steer-
ing Control Valve Test in the Testing section of this chapter).

Steering wheel will not return to the Spool and sleeve are sticking to steering control housing assembly
neutral position. (see Steering Control Valve Test in the Testing section of this
chapter).
Steering wheel can turn on its own. Leaf springs in steering control valve are broken or stuck.

Hydraulic
System
Spool and sleeve are sticking to steering control housing assembly
(see Steering Control Valve Test in the Testing section of this
chapter).
Backlash results when turning steer- Cardan shaft fork is worn or broken.
ing wheel.
Leaf springs in steering control valve are worn or broken.
Rear wheel shimmies when the Air is in the steering cylinder.
steering wheel is turned.
Mechanical connections to the wheel or wheel bearing are worn.
The steering wheel can be turned The steering cylinder is worn.
without the rear wheel turning.
The gear set in the steering control valve is worn.
Steering response is too slow and Oil supply to the steering control valve is insufficient (traction
heavy when trying to turn quickly. charge and lift circuits affected as well).

Turning steering wheel turns ma- Hoses to the steering cylinder are reversed.
chine in the opposite direction.

Steering force (possibly to one side Hydraulic flow to steering control valve is low (traction charge and
only) is insufficient. lift circuits affected as well).

Implement relief valve is leaking or damaged (see Implement Relief

Valve Pressure Test in the Testing section of this chapter).

Greensmaster 3150 Page 4 -- 25 Hydraulic System

Testing
The most effective method for isolating problems in the 1. Clean machine thoroughly before disconnecting or
hydraulic system is by using hydraulic test equipment disassembling any hydraulic components. Always keep
such as pressure gauges and flow meters in the circuits in mind the need for cleanliness when working on hy-
during various operational checks (see the Special draulic equipment. Contamination will cause excessive
Tools section in this Chapter). wear of components.

Before Performing Hydraulic Tests 2. To prevent hydraulic system contamination, put met-
al caps or plugs on any hydraulic lines left open or ex-
IMPORTANT: All obvious areas such as oil supply, posed during testing or removal of components.
filter, binding linkages, loose fasteners, improper
adjustments, solenoid valve operation or electrical 3. The engine must be in good operating condition. En-
connections/circuits must be checked before as- gine speed will affect test accuracy. Check pump speed
suming that a hydraulic component is the source of with a phototac when performing hydraulic tests.
the problem.
4. When using tester with pressure and flow capabili-
Precautions for Hydraulic Testing ties, the inlet and the outlet hoses must be properly con-
nected and not reversed to prevent damage to the
hydraulic tester or components.
CAUTION 5. When using tester with pressure and flow capabili-
ties, completely open load valve in the hydraulic tester
Failure to use gauges with recommended pres- to minimize the possibility of damaging components.
sure (psi) rating as listed in test procedures
could result in damage to the gauge and possible 6. Install fittings finger tight and far enough to make
personal injury from leaking hot oil. sure that they are not cross--threaded before tightening
them with a wrench.
All testing should be performed by two (2)
people. One person should be in the seat to oper- 7. Position tester hoses to prevent rotating machine
ate the machine and the other should read test-
parts from contacting and damaging the hoses or tester.
ing tools (e.g. pressure gauge) and record test
results.
8. Check oil level in the hydraulic reservoir. After con-
Operate all hydraulic controls to relieve system necting test equipment, make sure tank is full.
pressure and avoid injury from pressurized hy-
draulic oil. Controls must be operated with the 9. Check control linkages for improper adjustment,
ignition switch in OFF. Remove key from the igni- binding,or broken parts.
tion switch.
10.All hydraulic tests should be made with the hydraulic
oil at normal operating temperature.

WARNING 11. Record the results of all performed hydraulic tests.

Hydraulic Testing
Before disconnecting or performing any work on
the hydraulic system, all pressure in the system 1. Use the Hydraulic Schematic, Hydraulic Flow Dia-
must be relieved and all rotating machine parts grams and the Troubleshooting section found in this
must be stopped. Stop engine; lower or support Chapter to assist in problem identification and solution.
attachments.
2. Hydraulic system problems (e.g. low hydraulic oil
Keep body and hands away from pin hole leaks level, contaminated oil, incorrect engine speed) will af-
or nozzles that eject hydraulic fluid under high fect the entire hydraulic system.
pressure. Do not use hands to search for leaks;
use paper or cardboard. Hydraulic fluid escap- 3. For traction related problems (e.g. machine will not
ing under pressure can have sufficient force to go up an incline), consider performing the following hy-
penetrate the skin and cause serious injury. If draulic tests:
fluid is injected into the skin, it must be surgical- Charge Pressure Relief Valve Pressure Test
ly removed within a few hours by a doctor famil- Wheel Motor Efficiency Test
iar with this type of injury. Gangrene may result Piston (Traction) Pump Flow Test
from such an injury.

Hydraulic System Page 4 -- 26 Greensmaster 3150

4. For problems with steering or cutting unit lift/lower, 5. For issues with the cutting system, consider perform-
consider performing the following hydraulic tests: ing the following hydraulic tests:
Charge Pressure Relief Valve Pressure Test Mow Circuit Relief Valve (S1R1) Pressure Test
Lower Cutting Units Relief Valve (R2) Pressure Test Reel Motor Case Drain Flow Test
Implement Relief Valve Pressure Test Gear Pump (Front Section) Flow Test
Gear Pump (Rear Section) Flow Test
Steering Valve Test

Hydraulic
System

Greensmaster 3150 Page 4 -- 27 Hydraulic System

 Steering Cylinder
Right Front 1.5” Bore
Reel (#3) 0.75” Rod
.73
6.19” Stroke

.73 CU #2 CU #1 CU #3
Center 2.0” Bore 1.50” Bore 2.0” Bore
Reel (#1) 0.75” Rod 0.75” Rod 0.75” Rod

Hydraulic System
.73
1.88” Stroke 3.38” Stroke 1.88” Stroke
L R
Raise
Left Front
Reel (#2)
Lower
MA MB L2B L2A L1B L1A L3A L3B
STEERING
0.055 FC2 0.030 0.055 VALVE
MR 4.5
BACKLAP 550 PSI
SWITCH
(SW)
PRV
R2
400 PSI 1160 PSI
S4
FC1 OR1
OR2 0.013
P E T
0.060
S3
ST
LC

S2

G1
S1R1

P1 T G2 P2 PT

Page 4 -- 28
4.0 GPM

7.0 GPM
GAUGE
Charge Relief Valve Pressure Test (Using Pressure Gauge)

PRESSURE

TRACTION PUMP
TOP
LEAK DETECTOR TRANSPORT = 14.1 GPM PORT
FILTER 25 PSI
A
LEAK BYPASS Right
Left 10.3 10.3
DETECTOR IN VALVE Motor Motor
VOLUME 3000
OPTIONAL PSI
OUT OIL COOLER ENGINE RPM
GEAR .33 .58 1.24 3000
PUMP PSI 2850/1650
EXPANSION
TANK 20.6
110 to 70 to
150 PSI 100 PSI B
OPTIONAL
BOTTOM 3WD KIT
PORT

BREATHER
SUCTION
STRAINER

Greensmaster 3150
Procedure for Charge Relief Valve Pressure Test C. While monitoring the pressure gauge, push the
traction pedal to allow traction system load.
1. Make sure hydraulic oil is at normal operating tem-
perature by operating the machine for approximately ten D. The charge pressure should drop no more than
(10) minutes. 20% from no--load charge pressure measured in
step 6 above (e.g. if charge pressure in step 6 is 125
2. Park machine on a level surface with the cutting units PSI (9 bar), charge pressure in forward or reverse
lowered. Make sure engine is off and the parking brake under load should be more than 100 PSI (7 bar).
is engaged. Make sure the hydraulic reservoir is full.
E. If charge pressure is good under no load, but
drops below specification when under traction load,
CAUTION the piston (traction) pump and/or wheel motors
should be suspected of wear and inefficiency. When
the pump and/or traction motor(s) are worn or dam-
Before continuing further, read and become fa- aged, the charge pump is not able to keep up with in-
miliar with Precautions for Hydraulic Testing. ternal leakage in traction circuit components. Further
testing of the traction circuit should be completed
3. Install 1000 PSI (70 bar) pressure gauge with hy- (see Piston (Traction) Pump Flow and Wheel Motor
draulic hose attached to test port in the tee fitting on the Efficiency Tests in this section).
bottom of the control manifold (Fig. 19).
10.When charge pressure testing is complete, discon-
4. Make sure that traction pedal, steering wheel and nect pressure gauge from the test port and install dust
joystick control are in the neutral position. cap on test port.

Hydraulic
System
5. Start engine and operate at high idle speed (2850 +
50 RPM).

6. Pressure gauge should read approximately 100 to

150 PSI (7 to 10 bar). 1

7. Shut off engine. Record test results.

8. If specification is not met, remove piston pump back

plate assembly that contains the charge relief valve (see
Piston (Traction) Pump Service in the Service and Re-
pairs section of this chapter). Repair or replace relief
valve components as necessary.

9. A dynamic charge pressure test can be performed as

follows:

A. Position machine so that a load can be placed on

2
the traction system. For example, chain the machine
to an immovable object or chock all drive wheels to
prevent the machine from moving. Figure 19
1. Hydraulic manifold 2. Test port
B. With pressure gauge still connected to control
manifold test port, sit in the operator seat, start the
engine and move throttle so engine is running at high
idle speed. Move functional control lever to the trans-
port position.

Greensmaster 3150 Page 4 -- 29 Hydraulic System

Wheel Motor Efficiency Test (Using Tester with Flowmeter and Pressure Gauge)

PUMP
ASSEMBLY UPPER FITTING

WHEEL MOTOR EFFICIENCY TEST FOR

LEFT FRONT WHEEL MOTOR SHOWN

TO STEERING FROM MANIFOLD FRONT

VALVE PORT PT HOSE
TO MANIFOLD
PORT P1
TRACTION PUMP
TOP TESTER
PORT
TRANSPORT = 14.1 GPM

A
CAP Right
Motor
BYPASS Left
10.3 10.3
Motor
VALVE
3000 CAP
PSI
ENGINE RPM
GEAR .33 .58 1.24 3000
2850/1650
PUMP PSI
20.6

110 to 70 to
150 PSI 100 PSI
B
OPTIONAL
FROM BOTTOM 3WD KIT
RESERVOIR PORT

Procedure for Wheel Motor Efficiency Test

NOTE: Over a period of time, a wheel motor can wear CAUTION

internally. A worn motor may by--pass oil to its case drain
causing the motor to be less efficient. Eventually, Before continuing further, read and become fa-
enough oil loss will cause the wheel motor to stall under miliar with Precautions for Hydraulic Testing.
heavy load conditions. Continued operation with a worn,
inefficient motor can generate excessive heat, cause 3. Make sure that traction pedal is adjusted to the neu-
damage to seals and other components in the hydraulic tral position (see Traction Unit Operator’s Manual).
system and affect overall machine performance.
4. Attach a heavy chain to the rear of the machine frame
1. Make sure hydraulic oil is at normal operating tem- and an immovable object to prevent the machine from
perature by operating the machine for approximately ten moving during testing.
(10) minutes. Make sure the hydraulic tank is full.
5. If machine has 3 wheel drive, block up the rear wheel
2. Park machine on a level surface with the cutting units off the ground to allow flow through the rear wheel motor.
lowered and off. Make sure engine is off.

Hydraulic System Page 4 -- 30 Greensmaster 3150

6. Chock front wheel being tested to prevent rotation of 17.If machine has 3 wheel drive, test rear wheel motor:
the wheel.
A. Both front wheel motors should have hydraulic
7. Thoroughly clean junction of hydraulic lines and fit- lines connected. Block up both front wheels off the
tings at the front wheel motor that is not being tested. ground to allow flow through the rear wheel motors.
Disconnect hydraulic lines from front wheel motor that
is not being tested. Cap the disconnected hydraulic B. Attach a heavy chain to the rear of the machine
lines and plug ports in wheel motor. frame and an immovable object to prevent the ma-
chine from moving during testing.
8. Thoroughly clean junction of hydraulic hose and hy-
draulic tube that connects to the upper hydraulic fitting C. Position rear wheel on the ground and chock rear
on the front side of the piston pump (Fig. 20). Disconnect wheel to prevent it from turning.
hose from the tube.

9. Install tester with pressure gauge and flow meter in

series with the pump and the disconnected hose (same
CAUTION
tester connections as Piston (Traction) Pump Flow
Test). Make sure the tester flow control valve is fully Use extreme caution when performing test. The
open. rear wheel will be trying to move the machine.

D. Complete steps 10 to 15 for rear wheel motor

CAUTION testing.

Hydraulic
18.When testing is complete, disconnect tester from hy-

System
Use extreme caution when performing test. The draulic tube and hose. Reconnect hose to hydraulic
wheel being tested will be trying to move the ma- tube. Reconnect hydraulic lines to rear wheel motor.
chine.

10.Start engine and move throttle to high idle speed 1 4

(2850 + 50 RPM).

11. Slowly push traction pedal in forward direction until

1000 PSI (69 bar) is displayed on the tester pressure
gauge. Make sure that wheel does not rotate during test.

12.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.

13.Release traction pedal, rotate wheel being tested

and retest. Testing of wheel motor leakage in three (3)
different wheel positions will provide most accurate test FRONT
results. 2
3
14.Release traction pedal and shut engine off. Record
results of flow test. Figure 20
1. Piston pump 3. Hydraulic tube
15.If specification is not met, the tested wheel motor 2. Upper fitting 4. Hydraulic hose
needs to be repaired or replaced as necessary.

16.Test second front wheel motor. Reconnect hydraulic

lines to untested front wheel motor. Disconnect and cap
hydraulic lines to previously tested front wheel motor.
Complete steps 10 to 15 for the second front wheel mo-
tor.

Greensmaster 3150 Page 4 -- 31 Hydraulic System

Piston (Traction) Pump Flow Test (Using Tester with Flowmeter and Pressure Gauge)

PUMP
ASSEMBLY UPPER FITTING

FRONT
HOSE

TO STEERING FROM MANIFOLD

VALVE PORT PT

TO MANIFOLD
PORT P1
TRACTION PUMP
TOP TESTER
PORT
TRANSPORT = 14.1 GPM

A
Right
Motor
BYPASS Left
10.3 10.3
Motor
VALVE
3000
PSI
ENGINE RPM
GEAR .33 .58 1.24 3000
2850/1650
PUMP PSI
20.6

110 to 70 to
150 PSI 100 PSI
B
OPTIONAL
FROM BOTTOM 3WD KIT
RESERVOIR PORT

Procedure for Piston (Traction) Pump Flow Test

This test measures piston (traction) pump output (flow). CAUTION

During this test, pump load is created at the flowmeter
using the adjustable load valve on the tester. Before continuing further, read and become fa-
miliar with Precautions for Hydraulic Testing.
1. Make sure hydraulic oil is at normal operating tem-
perature by operating the machine for approximately ten
(10) minutes. 3. Make sure the traction assembly is adjusted to the
neutral position. Also, make sure that transport speed
2. Park machine on a level surface with the cutting units adjustment allows the piston pump to reach full stroke
lowered and off. Make sure engine is off. Make sure the (refer to Traction Unit Operator’s manual).
hydraulic reservoir is full.

Hydraulic System Page 4 -- 32 Greensmaster 3150

4. Block up front wheels off the ground (also rear wheel 13.If flow is less than 12.3 GPM (46.6 LPM), consider
if machine is equipped with 3WD) to allow flow through the following:
the traction circuit.
A. The traction pedal and/or traction speed may
5. Disconnect hydraulic hose from the hydraulic tube need adjustment (see the Traction Unit Operator’s
that connects to the upper hydraulic fitting on the front Manual).
side of the piston pump (Fig. 21).
B. The piston pump needs to be repaired or re-
6. Install tester in series with the pump and the discon- placed as necessary.
nected hose. Make sure flow control valve on the
tester is fully open. C. Make necessary repairs before performing addi-
tional tests.
7. Start engine and move throttle to high idle speed
(2850 + 50 RPM) position. 14.If piston pump flow test results are met and a traction
problem exists with machine, check wheel motor effi-
8. Move functional control lever to the transport posi- ciency (see Wheel Motor Efficiency Test in this chapter).
tion.
15.If testing is complete, disconnect tester from hydrau-
lic tube and hose. Reconnect hose to tube.
CAUTION
1 4
The drive wheels will be off the ground and rotat-
ing during this test. Make sure machine is well

Hydraulic
System
supported so it will not move and accidentally
fall to prevent injuring anyone near the machine.

9. Slowly push traction pedal into fully forward position.

10.Have second person carefully watch pressure gauge

on tester while slowly closing the flow control valve until
1000 PSI (69 bar) is obtained. Verify with a phototac that
the engine speed has not changed.
FRONT
NOTE: If engine speed drops, piston pump flow will de-
2
crease. 3
11. Observe flow gauge. If piston pump is in good condi-
tion, flow indication should be approximately 14.5 GPM Figure 21
(54.9 LPM). 1. Piston pump 3. Hydraulic tube
2. Upper fitting 4. Hydraulic hose
12.Release traction pedal, open control valve on tester
and turn off engine.

Greensmaster 3150 Page 4 -- 33 Hydraulic System

 Steering Cylinder
Right Front 1.5” Bore
Reel (#3) 0.75” Rod
.73
6.19” Stroke

.73 CU #2 CU #1 CU #3
Center 2.0” Bore 1.50” Bore 2.0” Bore
Reel (#1) 0.75” Rod 0.75” Rod 0.75” Rod

Hydraulic System
.73
1.88” Stroke 3.38” Stroke 1.88” Stroke
L R
Raise
Left Front
Reel (#2)
Lower
MA MB L2B L2A L1B L1A L3A L3B
STEERING
0.055 FC2 0.030 0.055 VALVE
MR 4.5
BACKLAP 550 PSI
SWITCH
(SW)
PRV
R2
400 PSI 1160 PSI
S4
FC1 OR1
OR2 0.013
P E T
0.060
S3
ST
LC

S2

G1
S1R1

P1 T G2 P2 PT

Page 4 -- 34
4.0 GPM

7.0 GPM

TRACTION PUMP
TOP
TRANSPORT = 14.1 GPM PORT
LEAK DETECTOR 25 PSI
FILTER A

TESTER
BYPASS Right
LEAK Left 10.3 10.3
VALVE Motor Motor
DETECTOR IN 3000
VOLUME PSI
OPTIONAL ENGINE RPM
OUT OIL COOLER GEAR .33 .58 1.24 3000
PUMP PSI 2850/1650
EXPANSION 20.6
TANK 110 to 70 to
150 PSI 100 PSI B
OPTIONAL
BOTTOM 3WD KIT
PORT

BREATHER
SUCTION
STRAINER
Gear Pump (Rear Section) Flow Test (Using Tester with Flowmeter and Pressure Gauge)

Greensmaster 3150
Procedure for Gear Pump (Rear Section) Flow Test 9. Flow gauge reading for a rear gear pump section in
good condition should be approximately 3.8 GPM (14.4
1. Make sure hydraulic oil is at normal operating tem- LPM). Record test results.
perature by operating the machine for approximately ten
(10) minutes. 10.Open control valve on tester and shut off engine.

2. Park machine on a level surface with the cutting units 11. If flow was less than 3.3 GPM (12.5 LPM) or a pres-
lowered. Make sure engine is off and the parking brake sure of 800 PSI (55 bar) cannot be obtained, check for
is engaged. Make sure the hydraulic tank is full. restriction in the pump intake line. If line is not restricted,
remove gear pump and repair or replace as necessary.

NOTE: Implement Relief Valve Pressure and Lower

CAUTION Cutting Units Relief Valve (R2) Pressure can be mea-
sured with tester positioned as described in this check
Before continuing further, read and become fa- (see Implement Relief Valve Pressure Test and Lower
miliar with Precautions for Hydraulic Testing. Cutting Units Relief Valve (R2) Pressure Test in this sec-
tion).
3. Thoroughly clean junction of hydraulic hose and the
hydraulic fitting in the rear gear pump section (Fig. 22). 12.After testing is complete, disconnect tester from the
This hose leads to port P in the steering valve. gear pump fitting and hose. Reconnect hose to the gear
pump fitting.
4. Disconnect the hose from the fitting in the rear gear
pump section.

Hydraulic
System
5. Install tester with pressure gauge and flow meter in 1
series with the gear pump fitting and the disconnected
hose. Make sure flow control valve on the tester is
fully open.

6. Make sure that traction pedal and joystick control are

in neutral and the parking brake is engaged.

7. Start engine and operate at high idle speed (2850 +

50 RPM).

IMPORTANT: Do not fully restrict oil flow through

tester. In this test, the flow tester is positioned be-
fore the circuit relief valve. Gear pump damage can
occur if the oil flow is fully restricted. 2

8. Watch flow and pressure gauge carefully while slow- Figure 22

ly closing the flow control valve on the tester until the
1. Gear pump 2. Rear section fitting
pressure gauge reads 800 PSI (55 bar).

Greensmaster 3150 Page 4 -- 35 Hydraulic System

 Steering Cylinder
Right Front 1.5” Bore
Gauge)
Reel (#3) 0.75” Rod
.73
6.19” Stroke

.73 CU #2 CU #1 CU #3
Center 2.0” Bore 1.50” Bore 2.0” Bore
Reel (#1) 0.75” Rod 0.75” Rod 0.75” Rod

Hydraulic System
.73
1.88” Stroke 3.38” Stroke 1.88” Stroke
L R
Raise
Left Front
Reel (#2)
Lower
MA MB L2B L2A L1B L1A L3A L3B
STEERING
0.055 FC2 0.030 0.055 VALVE
MR 4.5
BACKLAP 550 PSI
SWITCH
(SW)
PRV
R2
400 PSI S4 1160 PSI
FC1 OR1
OR2 0.013
P E T
0.060
S3
ST
LC

S2
G1
S1R1

P1 T G2 P2 PT

Page 4 -- 36
4.0 GPM

7.0 GPM

TRACTION PUMP
TOP
TRANSPORT = 14.1 GPM PORT
LEAK DETECTOR 25 PSI
FILTER A

TESTER
BYPASS Right
LEAK Left 10.3 10.3
VALVE Motor Motor
DETECTOR IN 3000
VOLUME PSI
OPTIONAL ENGINE RPM
OUT OIL COOLER GEAR .33 .58 1.24 3000
PUMP PSI 2850/1650
EXPANSION 20.6
TANK 110 to 70 to
150 PSI 100 PSI B
OPTIONAL
BOTTOM 3WD KIT
PORT

BREATHER
Implement Relief Valve Pressure Test (Using Tester with Flowmeter and Pressure

SUCTION
STRAINER

Greensmaster 3150
Procedure for Implement Relief Valve Pressure Test 10.Implement relief valve pressure should be 1050 to
1250 PSI (73 to 86 bar) higher than the charge relief
1. Make sure hydraulic oil is at normal operating tem- valve pressure (e.g. if the charge relief valve pressure
perature by operating the machine for approximately ten is 100 PSI (7 bar), the implement relief valve pressure
(10) minutes. should be from 1150 to 1350 PSI (80 to 93 bar)).

2. Park machine on a level surface with the cutting units IMPORTANT: Hold steering wheel at full lock only
lowered. Make sure engine is off. Make sure the hydrau- long enough to get a system pressure reading.
lic tank is full.
11. The implement relief valve is also activated by the
steering system. With tester still connected to gear
CAUTION pump outlet, start engine and watch the pressure
gauge. Turn the steering wheel completely in one direc-
tion and hold. Relief valve should open just after rear
Before continuing further, read and become fa- wheel gets to the full lock position. Relief pressure mea-
miliar with Precautions for Hydraulic Testing. sured with the steering system should be similar to re-
sults in step 10 above.
3. Measure and record charge relief valve pressure
(see Charge Relief Valve Pressure Test in this section). 12.If implement relief valve pressure is incorrect, in-
spect relief valve located in the steering valve (see
4. Thoroughly clean junction of hydraulic hose and the Steering Valve Service in the Service and Repairs sec-
hydraulic fitting in the rear gear pump section (Fig. 23). tion of this Chapter). Clean relief valve or service steer-
This hose leads to port P in the steering valve. ing valve as needed.

Hydraulic
System
5. Disconnect the hose from the fitting in the rear gear NOTE: Gear Pump (Rear Section) Flow Test and Low-
pump section. er Cutting Units Relief Valve Pressure can be measured
with tester positioned as described in this check (see
6. Install tester with pressure gauge and flow meter in Gear Pump (Rear Section) Flow Test and Lower Cutting
series with the gear pump fitting and the disconnected Units Relief Valve Pressure Test in this section).
hose (same connections as Gear Pump (Rear Section)
Flow Test). Make sure flow control valve on the tester 13.After testing is complete, remove tester from gear
is fully open. pump fitting. Reconnect hose to the gear pump fitting.

7. Start and run engine at full speed (2850 + 50 RPM).

1
CAUTION
When performing test, do not allow system pres-
sure to exceed 1400 PSI (83 bar).

8. Watch the pressure gauge on the tester and move

the joystick control to the raise position. Momentarily
hold the joystick with the cutting units fully raised caus-
ing the implement relief valve to open. Record pressure
at which the relief valve opens.

9. Release joystick to the neutral position and shut off

engine. 2

NOTE: The implement relief valve is in series with Figure 23

charge relief valve. Charge relief pressure will affect the
1. Gear pump 2. Rear section fitting
implement relief pressure.

Greensmaster 3150 Page 4 -- 37 Hydraulic System

 Steering Cylinder
Right Front 1.5” Bore
Reel (#3) 0.75” Rod
.73
6.19” Stroke

.73 CU #2 CU #1 CU #3
Center 2.0” Bore 1.50” Bore 2.0” Bore
Reel (#1) 0.75” Rod 0.75” Rod 0.75” Rod

Hydraulic System
.73
1.88” Stroke 3.38” Stroke 1.88” Stroke
L R
Pressure Gauge)

Raise
Left Front
Reel (#2)
Lower
MA MB L2B L2A L1B L1A L3A L3B
STEERING
0.055 FC2 0.030 0.055 VALVE
MR 4.5
BACKLAP 550 PSI
SWITCH
(SW)
PRV
R2
400 PSI S4 1160 PSI
FC1 OR1
OR2 0.013
P E T
0.060
S3
ST
LC

S2
G1
S1R1

P1 T G2 P2 PT

Page 4 -- 38
4.0 GPM

7.0 GPM

TRACTION PUMP
TOP
TRANSPORT = 14.1 GPM PORT
LEAK DETECTOR 25 PSI
FILTER A

TESTER
BYPASS Right
LEAK Left 10.3 10.3
VALVE Motor Motor
DETECTOR IN 3000
VOLUME PSI
OPTIONAL ENGINE RPM
OUT OIL COOLER GEAR .33 .58 1.24 3000
PUMP PSI 2850/1650
EXPANSION 20.6
TANK 110 to 70 to
150 PSI 100 PSI B
OPTIONAL
BOTTOM 3WD KIT
PORT

BREATHER
SUCTION
STRAINER
Lower Cutting Units Relief Valve (R2) Pressure Test (Using Tester with Flowmeter and

Greensmaster 3150
Procedure for Lower Cutting Units Relief Valve (R2) 10.If lower cutting units relief valve pressure is incorrect,
Pressure Test adjust control manifold relief valve (R2) (see Adjust
Manifold Relief Valves in the Adjustments section of this
1. Make sure hydraulic oil is at normal operating tem- Chapter). Retest relief valve pressure if adjustment is
perature by operating the machine for approximately ten performed.
(10) minutes.
NOTE: Gear Pump (Rear Section) Flow Test and Im-
2. Park machine on a level surface with the cutting units plement Relief Valve Pressure can be measured with
lowered. Make sure engine is off. Make sure the hydrau- tester positioned as described in this check (see Gear
lic tank is full. Pump (Rear Section) Flow Test and Implement Relief
Valve Pressure Test in this section).

CAUTION 11. After testing is complete, disconnect tester from gear

pump and hose. Reconnect hose to hydraulic fitting on
pump.
Before continuing further, read and become fa-
miliar with Precautions for Hydraulic Testing.

3. Measure and record charge relief valve pressure 1

(see Charge Relief Valve Pressure Test in this section).

4. Thoroughly clean junction of hydraulic hose and the

hydraulic fitting in the rear gear pump section (Fig. 24).

Hydraulic
System
This hose leads to port P in the steering valve.

5. Disconnect the hose from the fitting in the rear gear

pump section.

6. Install tester with pressure gauge and flow meter in

series with the gear pump fitting and the disconnected
hose (same connections as Gear Pump (Rear Section)
Flow Test). Make sure flow control valve on the tester
is fully open. 2

7. Start engine and move throttle to full speed (2850 + Figure 24

50 RPM). Make sure that cutting units are fully lowered
1. Gear pump 2. Rear section fitting
and then engage the cutting units.

NOTE: The LOWER function is electrically timed and RELIEF

automatically turns off after approximately six (6) sec- VALVE (R2) S3
onds.
S1R1
8. Watch pressure gauge carefully while moving the
joystick control lever to the LOWER position and note
pressure that relief valve opens. Shut off engine and re-
FRONT
cord test results.

NOTE: While performing this hydraulic test, if relief

pressure cannot be determined within the LOWER func-
tion six (6) second timeframe, repeat this test proce-
dure. S4

NOTE: The lower cutting units relief valve is in series S2

with the charge relief valve. Charge relief pressure will
affect the lower cutting units relief pressure. Figure 25

9. The lower cutting units relief valve pressure should

be approximately 400 PSI (28 bar) higher than charge
relief pressure (e.g. if charge relief valve pressure is
100 PSI (7 bar), the lower relief valve pressure should
be approximately 500 PSI (35 bar)).
Greensmaster 3150 Page 4 -- 39 Hydraulic System
 Steering Cylinder
Right Front 1.5” Bore
Gauge)
Reel (#3) 0.75” Rod
.73
6.19” Stroke

.73 CU #2 CU #1 CU #3
Center 2.0” Bore 1.50” Bore 2.0” Bore
Reel (#1) 0.75” Rod 0.75” Rod 0.75” Rod

Hydraulic System
.73
1.88” Stroke 3.38” Stroke 1.88” Stroke
L R
Raise
Left Front
Reel (#2)
Lower
MA MB L2B L2A L1B L1A L3A L3B
STEERING
0.055 FC2 0.030 0.055 VALVE
MR 4.5
BACKLAP 550 PSI
SWITCH
(SW)
PRV
R2
400 PSI S4 1160 PSI
FC1 OR1
OR2 0.013
P E T
0.060
S3
ST
LC

S2
G1
S1R1

P1 T G2 P2 PT

Page 4 -- 40
4.0 GPM

7.0 GPM

TRACTION PUMP
TOP
TRANSPORT = 14.1 GPM PORT
LEAK DETECTOR 25 PSI
FILTER A

TESTER
BYPASS Right
LEAK Left 10.3 10.3
VALVE Motor Motor
DETECTOR IN 3000
VOLUME PSI
OPTIONAL ENGINE RPM
OUT OIL COOLER GEAR .33 .58 1.24 3000
PUMP PSI 2850/1650
EXPANSION 20.6
TANK 110 to 70 to
150 PSI 100 PSI B
OPTIONAL
BOTTOM 3WD KIT
PORT

BREATHER
Gear Pump (Front Section) Flow Test (Using Tester with Flowmeter and Pressure

SUCTION
STRAINER

Greensmaster 3150
Procedure for Gear Pump (Front Section) Flow Test 7. Watch pressure gauge carefully while slowly closing
the flow control valve on the tester until 2000 PSI (138
1. Make sure hydraulic oil is at normal operating tem- bar) is obtained.
perature by operating the machine for approximately ten
(10) minutes. 8. Flow gauge reading for a gear pump section in good
condition should be approximately 6.7 GPM (25.3
2. Park machine on a level surface with the cutting units LPM). Record test results.
lowered. Make sure engine is off and the parking brake
is engaged. Make sure the hydraulic tank is full. 9. Once gear pump flow is recorded, open control valve
on tester and shut off engine.

10.If flow was less than 5.7 GPM (21.6 LPM) or a pres-
CAUTION sure of 2000 PSI (138 bar) cannot be obtained, check
for restriction in the gear pump intake line. If line is not
Before continuing further, read and become fa- restricted, remove gear pump and repair or replace as
miliar with Precautions for Hydraulic Testing. necessary.

3. Disconnect the hose from the fitting in the front gear 11. When testing is complete, disconnect tester from
pump section (Fig. 26). This hose leads to port P1 on the gear pump fitting and hydraulic hose. Connect hose to
hydraulic manifold. pump fitting.

4. Install tester with pressure gauge and flow meter in 12.Adjust reel speed knob on mow control manifold to
series with front gear pump section fitting and the dis- original setting.

Hydraulic
System
connected hose. Make sure the flow control valve on
the tester is fully open.

5. Make sure that reel speed is set to highest speed set- 1

ting (fully open) and that backlap knob on the hydraulic
manifold is in the mow position.

CAUTION
Do not engage the cutting units when performing
this test.

6. Start engine and operate at high idle speed (2850 +

50 RPM).
2
IMPORTANT: Do not fully restrict oil flow through
tester. In this test, the flow tester is positioned be-
fore the circuit relief valve. Gear pump damage can Figure 26
occur if the oil flow is fully restricted. 1. Gear pump 2. Front section fitting

Greensmaster 3150 Page 4 -- 41 Hydraulic System

 Right Front
Reel (#3)
.73

.73
Steering Cylinder
Center 1.5” Bore
Reel (#1) 0.75” Rod
6.19” Stroke
.73

Left Front

Hydraulic System
CU #2 CU #1 CU #3
Reel (#2) 2.0” Bore 1.50” Bore 2.0” Bore
Pressure Gauge)

0.75” Rod 0.75” Rod 0.75” Rod

1.88” Stroke 3.38” Stroke 1.88” Stroke
L R
Raise

Lower

TESTER
MA MB L2B L2A L1B L1A L3A L3B
STEERING
0.055 FC2 0.030 0.055 VALVE
MR 4.5
BACKLAP 550 PSI
SWITCH
(SW)
PRV
R2
400 PSI S4 1160 PSI
FC1 OR1
OR2 0.013
P E T
0.060
S3
ST
LC

S2
G1
S1R1

Page 4 -- 42
P1 T G2 P2 PT

4.0 GPM

7.0 GPM

TRACTION PUMP
TOP
TRANSPORT = 14.1 GPM PORT
LEAK DETECTOR 25 PSI
FILTER A
BYPASS Right
LEAK Left 10.3 10.3
VALVE Motor Motor
DETECTOR IN 3000
VOLUME PSI
OPTIONAL ENGINE RPM
OUT OIL COOLER GEAR .33 .58 1.24 3000
PUMP PSI 2850/1650
EXPANSION 20.6
TANK 110 to 70 to
150 PSI 100 PSI B
OPTIONAL
BOTTOM 3WD KIT
PORT
Mow Circuit Relief Valve (S1R1) Pressure Test (Using Tester with Flowmeter and

BREATHER
SUCTION
STRAINER

Greensmaster 3150
Procedure for Mow Circuit Relief Valve (S1R1) Pres- B. If relief valve pressure is not correct, remove so-
sure Test lenoid relief valve (S1R1) on hydraulic control man-
ifold (Fig. 28). Clean or replace valve (see Hydraulic
1. Make sure hydraulic oil is at normal operating tem- Manifold Service in the Service and Repairs section
perature by operating the machine for approximately ten of this chapter). After valve service, retest relief valve
(10) minutes. (S1R1) pressure.

2. Park machine on a level surface with the cutting units 11. When testing is complete, disconnect tester from
lowered. Make sure engine is off. Make sure the hydrau- reel motor fitting and hydraulic hose. Reconnect hose to
lic tank is full. the front motor fitting.

12.Correctly adjust cutting unit bedknife.

CAUTION
LH REEL MOTOR
Before continuing further, read and become fa-
miliar with Precautions for Hydraulic Testing.

3. Disconnect hydraulic hose from the front fitting of the FRONT 3

left front cutting reel motor (Fig. 27).

4. Install tester with pressure gauge and flow meter in 2

series with the disconnected hose and front reel motor
fitting. Make sure the flow control valve on the tester

Hydraulic
System
is fully open.
1
5. To prevent reel damage, temporarily adjust bedknife
to allow clearance between bedknife and reel (no con- Figure 27
tact). 1. LH reel motor 3. Hydraulic hose
2. Front fitting
6. Make sure that reel speed is set to highest speed set-
ting (fully open) and that backlap knob on the hydraulic
manifold is in the mow position. S2
FRONT S3

CAUTION S4

Keep away from reels during test to prevent per-

sonal injury from the rotating reel blades.

7. Start engine and move throttle to high idle speed S1R1

(2850 + 50 RPM). Engage the cutting units.

8. Watch pressure gauge carefully while slowly closing

the flow control valve on the tester to fully closed. R2

9. System pressure should be from 2700 to 3300 PSI Figure 28

(186 to 228 bar) as manifold relief valve (S1R1) opens.
Record test results.

10.After recording mow circuit relief pressure, disen-

gage cutting units. Open control valve on tester and shut
off engine.

A. If relief valve pressure is correct, go to step 11.

Greensmaster 3150 Page 4 -- 43 Hydraulic System

Reel Motor Case Drain Flow Test (Using Tester with Flowmeter and Pressure Gauge)

LH CASE LH RETURN
DRAIN

FRONT

RH CASE
DRAIN

RH RETURN

CENTER
RETURN

CENTER
CASE
DRAIN
Right Front TESTER
Reel (#3)
.73

PLUG
.73
MEASURING
Center
CONTAINER
Reel (#1)
.73

Left Front
Reel (#2)
CASE DRAIN FLOW TEST FOR
RIGHT FRONT REEL MOTOR SHOWN

FROM MANIFOLD
PORT MA

TO HYDRAULIC TO MANIFOLD
RESERVOIR PORT MB

Hydraulic System Page 4 -- 44 Greensmaster 3150

Procedure for Reel Motor Case Drain Flow Test: 10.After achieving 1000 PSI (69 bar), place discon-
nected motor case drain hose into a container gra-
1. Make sure hydraulic oil is at normal operating tem- duated in ounces or milliliters (Tool TOR4077: see
perature by operating the machine for approximately ten Special Tools) and collect hydraulic fluid for 15 seconds
(10) minutes. Make sure the hydraulic reservoir is full. (Fig. 29). After 15 seconds, remove hose end from con-
tainer.
2. Park machine on a level surface with the cutting units
lowered. Make sure engine is off. 11. Disengage cutting units. Open control valve on test-
er and stop the engine.

CAUTION 12.Measure the amount of oil collected in the container.

Record test results.

Before continuing further, read and become fa- 13.If case drain flow was greater than 16.0 ounces (473
miliar with Precautions for Hydraulic Testing. milliliters) (0.5 GPM/1.9 LPM) in 15 seconds, repair or
replace the reel motor as necessary.
3. For the suspected bad cutting reel motor, disconnect
return hose from the motor. The return hose connects to 14.When testing of the reel motor is completed, discon-
the fitting at the rear of the motor. nect tester from reel motor and return hose. Reconnect
return hose to the motor.
4. Install tester in series with the reel motor and the dis-
connected return hose. Make sure the flow control 15.Remove plug from bulkhead fitting. Reconnect case
valve on the tester is fully open. drain hose to the bulkhead fitting.

Hydraulic
System
5. Make sure backlap knob on the hydraulic manifold is 16.Test other cutting reel motors as needed.
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 with a steel plug.

B. Leave the case drain hose from the motor open

and place open end of disconnected hose into a
drain pan.

7. One person should sit on the seat and operate the

machine while a second person reads the tester and
measures case drain leakage.

8. Make sure functional control lever is in NEUTRAL. Figure 29

Start engine and move the throttle to high idle speed
(2850 + 50 RPM).

CAUTION
Keep away from reels during test to prevent per-
sonal injury from the rotating reel blades.

9. Move the functional control lever to the MOW posi-

tion and engage the cutting reels with the joystick con-
trol. While watching pressure gauge, slowly close flow
control valve on the tester until a pressure of 1000 PSI
(69 bar) is obtained. Figure 30

Greensmaster 3150 Page 4 -- 45 Hydraulic System

Steering Control Valve Test

Steering Cylinder
(CYLINDER ROD
FULLY EXTENDED)

PLUG

L R

TURNED FOR
RIGHT TURN

4.5

1160 PSI STEERING

VALVE
P E T

TO CONTROL
MANIFOLD
PORT ST

TO CONTROL
MANIFOLD
PORT P2

FROM GEAR
PUMP

Procedure for Steering Control Valve Test: B. Steering wheel movements should be followed
immediately by a corresponding rear wheel move-
1. Make sure the hydraulic reservoir is full. ment without the steering wheel continuing to turn.

2. Make sure hydraulic oil is at normal operating tem- 4. Stop the machine with the engine running. Turn
perature by operating the machine for approximately ten steering wheel with small quick movements in both
(10) minutes. directions. Let go of the steering wheel after each move-
ment.
3. Drive machine slowly in a figure eight on a flat level
surface. A. The steering wheel must go back immediately to
the neutral position.
A. There should be no shaking or vibration in the
steering wheel or rear wheel. B. The steering wheel should not continue to turn.
Hydraulic System Page 4 -- 46 Greensmaster 3150
NOTE: The steering wheel must be able to turn with no
more than 45 in--lb (5.1 N--m) of torque.

5. Perform the Implement Relief Valve Pressure and

Gear Pump (Rear Section) 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- 3
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. Apply the parking brake.
4
B. Turn the steering wheel all the way to the right
(clockwise) so the steering cylinder rod is fully ex-
tended.

Hydraulic
System
C. Turn engine off.
1 2

CAUTION FRONT

Before continuing further, read and become fa-

miliar with Precautions for Hydraulic Testing.
Figure 31
D. Read Precautions for Hydraulic Testing. 1. Steering cylinder 3. Rod end
2. Hydraulic hose 4. Castor fork
E. Remove hydraulic hose from the 90o fitting on the
rod end of the steering cylinder (Fig. 31). Install steel
plug in the end of the hose.

F. With the engine off, continue turning the steering

wheel to the right (clockwise) with the steering cylin-
der 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 right, the steering cylinder has internal
leakage and must be repaired or replaced.

G. Remove plug from the hydraulic hose. Recon-

nect hose to the steering cylinder fitting.

7. If steering problem exists and steering cylinder

tested acceptably, steering control valve requires ser-
vice (see Steering Control Valve and Steering Control
Valve Service in the Service and Repairs section of this
chapter).

Greensmaster 3150 Page 4 -- 47 Hydraulic System

 This page is intentionally blank.

Hydraulic System Page 4 -- 48 Greensmaster 3150

Adjustments

Adjust Manifold Relief Valve (R2)

The hydraulic manifold includes an adjustable relief
valve in the lift circuit (Fig. 32). If adjustment to this valve FRONT 2
is necessary, follow the following procedure.

NOTE: Do not remove relief valve from the hydraulic

manifold for adjustment.

WARNING
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 1
pressurizing the system.

Hydraulic
1. Locate relief valve on control manifold. Figure 32

System
1. Hydraulic manifold 2. Relief valve (R2)
2. Remove cap on relief valve with an allen wrench.

3. To increase pressure setting, turn the adjustment

socket on the valve in a clockwise direction. A 1/8 turn
on the socket will make a measurable change in relief
pressure.

4. To decrease pressure setting, turn the adjustment

socket on the valve in a counterclockwise direction. A CAP
1/8 turn on the socket will make a measurable change
in relief pressure.

5. Install and tighten cap on relief valve.

6. Recheck relief pressure and readjust as needed.

ADJUSTMENT
HEX SOCKET

Figure 33

Greensmaster 3150 Page 4 -- 49 Hydraulic System

Service and Repairs

General Precautions for Removing and Installing Hydraulic System Components

Before Repair or Replacement of Components After Repair or Replacement of Components

1. Before removing any parts from the hydraulic sys- 1. Check oil level in the hydraulic reservoir and add cor-
tem, park machine on a level surface, engage parking rect oil if necessary. Drain and refill hydraulic system
brake, lower cutting units or attachments and stop en- reservoir and change oil filter if component failure was
gine. Remove key from the ignition switch severe or system is contaminated (see Flush Hydraulic
System).
2. Clean machine before disconnecting, removing or
disassembling any hydraulic components. Make sure 2. Lubricate O--rings and seals with clean hydraulic oil
hydraulic components, hoses connections and fittings before installing hydraulic components.
are cleaned thoroughly. Always keep in mind the need
for cleanliness when working on hydraulic equipment. 3. Make sure caps or plugs are removed from the hy-
draulic tubes, hydraulic fittings and components before
reconnecting.
CAUTION 4. Use proper tightening methods when installing hy-
draulic hoses and fittings (see Hydraulic Fitting Installa-
Operate all hydraulic controls to relieve system tion).
pressure and avoid injury from pressurized hy-
draulic oil. Controls must be operated with the 5. After repairs, check control linkages or cables for
ignition switch in RUN and the engine OFF. Make proper adjustment, binding or broken parts.
sure all electrically operated control valves are
actuated. Return ignition switch to OFF when 6. After disconnecting or replacing any hydraulic com-
pressure has been relieved. Remove key from ponents, operate machine functions slowly until air is
the ignition switch. out of system (see Charge Hydraulic in this section).

7. Check for hydraulic oil leaks. Shut off engine and cor-
3. Put caps or plugs on any hydraulic lines, hydraulic fit-
rect leaks if necessary. Check oil level in hydraulic reser-
tings and components left open or exposed to prevent
voir and add correct oil if necessary.
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.

Hydraulic System Page 4 -- 50 Greensmaster 3150

Flush Hydraulic System
IMPORTANT: Flush the hydraulic system any time 7. Disconnect both spark plug wires from spark plugs
there is a severe component failure or the system is to prevent the engine from starting.
contaminated (oil appears milky or black or con-
tains metal particles). 8. Turn ignition key switch; engage starter for ten (10)
seconds to prime the hydraulic pumps. Allow the starter
IMPORTANT: Flush hydraulic system when chang- to cool for one (1) minute and then repeat this step
Ing from petroleum base hydraulic fluid. Operate again.
machine under normal operating conditions for at
least four (4) hours before draining. 9. Reconnect both spark plug wires to spark plugs.

1. Park the machine on a level surface, engage the 10.Start engine and let it idle at low speed for a minimum
parking brake, lower the cutting units and stop the en- of two (2) minutes. Increase engine speed to high idle for
gine. Remove key from the ignition switch. minimum of one (1) minute under no load.

11. Raise and lower cutting units several times. Rotate

CAUTION steering wheel in both directions several times.

12.Shut off engine and check for hydraulic oil leaks.

Before continuing further, read and become fa- Check oil level in hydraulic reservoir and add correct oil
miliar with General Precautions for Removing if necessary.

Hydraulic
and Installing Hydraulic System Components.

System
13.Operate the machine for two (2) hours under normal
operating conditions.
2. Clean area around gear pump and pump inlet hose
(Fig. 34). Clamp pump inlet hose. Remove hose from 14.Check condition of hydraulic oil. If the new hydraulic
gear pump, release clamp and drain reservoir into a suit- oil shows any signs of contamination, or if you are
able container. Drain hydraulic system while making changing to biodegradable fluid, repeat steps 1 through
sure lift cylinders, hydraulic hoses, hydraulic tubes and 13 again.
all other components are drained from low points while
the system is warm. 15.Assume normal operation and follow recommended
maintenance intervals.
3. Clean hydraulic oil filter mounting area. Remove fil-
ter and drain into a suitable container. Discard filter.
PUMP INLET HOSE
4. Inspect and clean hydraulic reservoir (see Hydraulic
Reservoir in the Service and Repairs section of this
chapter).

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 3/4
turn further.

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.
Figure 34

Greensmaster 3150 Page 4 -- 51 Hydraulic System

Filtering Closed--Loop Traction Circuit
Filtering of a closed--loop hydraulic system after a major IMPORTANT: While engaging the traction circuit,
component failure (e.g. piston (traction) pump or wheel monitor the indicator on the high flow hydraulic fil-
motor) is a requirement to prevent debris from transmit- ter. If the indicator should show red, either reduce
ting throughout the system. If a closed--loop hydraulic pressure on the traction pedal or reduce engine
system filtering tool is not used to ensure system cleanli- speed to decrease hydraulic flow through the filter.
ness, repeat failures, as well as subsequent damage to
other hydraulic components in the affected system, will 7. With engine running at low idle speed, slowly move
occur. To effectively remove contamination from the traction pedal to the forward direction to allow flow
closed--loop traction circuit, use of the Toro high flow hy- through the traction circuit and high flow filter. Keep trac-
draulic filter and hydraulic hose kits are recommended tion circuit engaged for five (5) minutes while gradually
(see Special Tools in this chapter). increasing both forward pressure on traction pedal and
engine speed. Monitor filter indicator to make sure that
1. Park machine on a level surface with engine stopped green color is showing during operation.
and key removed from ignition switch.
IMPORTANT: If using a filter that is not the bi--direc-
2. Raise machine so all driven wheels are off the tional Toro high flow filter, do not press the traction
ground. Support raised machine with appropriate jack- pedal in the reverse direction. If flow is reversed
stands. when using a filter that is not bi--directional, debris
from the filter will re--enter the traction circuit.
NOTE: If wheel motor was replaced, install high flow fil-
ter to the inlet of new motor instead of to piston (traction) 8. With engine running at high idle speed, alternately
pump fitting. This will prevent system contamination move traction pedal from forward to reverse. While mon-
from entering and damaging the new motor. itoring filter indicator, continue this process for an addi-
tional five (5) minutes.
3. Thoroughly clean junction of hydraulic hose and
lower fitting on side of piston pump (Fig. 35). Disconnect 9. Shut engine off and remove key from ignition switch.
hose from lower pump fitting.
10.Remove high flow hydraulic filter and hydraulic hose
4. Connect Toro high flow hydraulic filter in series be- kit from machine. Connect hydraulic hose to lower pis-
tween lower piston pump fitting and disconnected hose. ton pump fitting. Make sure to properly tighten hose (see
Use hydraulic hose kit (see Special Tools in this chapter) Hydraulic Hose and Tube Installation in the General In-
to connect filter to machine. Make sure that fitting and formation section of this chapter).
hose connections are properly tightened.
11. Lower machine to ground.
IMPORTANT: Use only hydraulic fluids specified in
Traction Unit Operator’s Manual. Other fluids could 12.Check oil level in hydraulic reservoir and add correct
cause system damage. oil if necessary.

5. After installing high flow filter to machine, check and

fill hydraulic reservoir with new hydraulic oil as required. 1
6. Start engine and run at idle speed. Check for any hy-
draulic leakage from filter and hose connections. Cor-
rect any leaks before proceeding.

CAUTION
All driven wheels will be off the ground and rotat-
ing during this operation. Make sure machine is 2
well supported so it will not move and accidental-
ly fall. Figure 35
1. Piston pump 2. Lower pump fitting

Hydraulic System Page 4 -- 52 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 CAUTION
used. This procedure reduces the chance of damaging
the system or its components from not purging the sys- Be careful when operating the cutting unit reels.
tem of air. Contact with the reel or other moving parts can
result in personal injury.
1. After the hydraulic system components have been
properly installed and if the traction pump was rebuilt or 10.After the hydraulic system starts to show signs of fill,
replaced, make sure traction pump housing is at least accomplish the following:
half full of clean hydraulic oil.
A. If a reel motor was replaced or rebuilt, run the cut-
2. Make sure all hydraulic connections and lines are se- ting units at the minimum speed setting (under no
cured tightly. load) for ten (10) minutes in both directions.
3. Make sure hydraulic reservoir is full. Add correct oil B. If the gear pump was replaced or rebuilt, run the
if necessary. Drain, flush and refill hydraulic system res- cutting units at the minimum speed setting (under no
ervoir and change oil filter if component failure was se- load) for ten (10) minutes.
vere or system is contaminated.
C. If the piston pump or a wheel motor was replaced

Hydraulic
4. After repairs, check control linkage for proper adjust-

System
or rebuilt, run the traction unit so the wheels turn
ment, binding or broken parts. slowly for ten (10) minutes.
5. Make sure functional control lever is in neutral. 11. Operate the traction unit and cutting units by gradu-
ally increasing their work load to full over a ten (10) min-
6. Disconnect both spark plug wires from spark plugs
ute period.
to prevent the engine from starting.
12.Stop the machine. Check reservoir and fill if neces-
7. Turn ignition key switch and engage starter for ten
sary. Check hydraulic components for leaks and tighten
(10) seconds to prime pump. Return ignition switch to off
any loose connections.
and wait one (1) minute to allow starter to cool. Repeat
step a second time.

8. Reconnect spark plug wires to spark plugs.

9. Make sure functional control lever is in neutral and

cutting unit switch is off. Start engine and run at low idle
speed. The charge pump should pick up oil and fill the
hydraulic system. If there is no indication of fill in thirty
(30) seconds, stop the engine and determine the cause.

Greensmaster 3150 Page 4 -- 53 Hydraulic System

Gear Pump

16

17 2
13 12
14 11

3
4
6
RIGHT
9

FRONT 10

15

Figure 36
1. Pump inlet hose 7. Hose clamp (2 used) 13. Socket head screw (2 used)
2. Gear pump 8. O--ring 14. Flat washer (2 used)
3. Hydraulic fitting 9. O--ring 15. Hydraulic hose
4. Hydraulic fitting 10. Hydraulic hose 16. Hose connector
5. O--ring 11. O--ring 17. O--ring
6. O--ring 12. Piston pump

Hydraulic System Page 4 -- 54 Greensmaster 3150

Removal (Fig. 36) 4. Secure gear pump to the piston pump with two (2)
socket head screws and flat washers.

5. Inspect threads and sealing surfaces of hydraulic fit-

CAUTION tings and hydraulic hose connectors. Replace any dam-
aged or worn fittings or hoses.
Before continuing further, read and become fa-
miliar with General Precautions for Removing 6. Lubricate and place new O--rings onto gear pump
and Installing Hydraulic System Components. hydraulic fittings. Install fittings into pump openings
making sure that fitting orientation is as noted during re-
moval. Tighten fittings (see Hydraulic Fitting Installation
1. Before removing any parts from the hydraulic sys-
in the General Information section of this chapter).
tem, park machine on a level surface, engage parking
brake, lower cutting units and stop engine. Remove key 7. Remove plugs that were placed during disassembly
from the ignition switch. from hydraulic hoses.
2. Label all hose connections for assembly purposes. 8. Using labels placed during gear pump removal, lubri-
cate new O--rings and connect hydraulic hoses to lower
3. Clamp pump inlet hose to prevent draining the hy- gear pump fittings. Tighten hose connections (see Hy-
draulic reservoir. draulic Hose and Tube Installation in the General Infor-
mation section of this chapter).
4. Loosen hose clamp and remove pump inlet hose
from the gear pump. Allow clamped hose to drain into a 9. Install pump inlet hose to the hose connector on gear
suitable container.

Hydraulic
pump. Secure hose with hose clamp.

System
5. Disconnect hydraulic hoses from fittings on bottom 10.Remove clamp from pump inlet hose to allow hy-
of the gear pump. Allow hoses to drain into a suitable draulic oil flow to the gear pump.
container. Plug hoses to prevent contamination.
11. Check oil level in hydraulic reservoir and add correct
IMPORTANT: Note position of hydraulic fittings for oil if necessary.
assembly purposes.
12.Follow Hydraulic System Start--up procedures (see
6. Mark hydraulic fitting orientation to allow correct as- Hydraulic System Start--up in this section).
sembly. Remove hydraulic fittings and O--rings from
gear pump.
Remove plugs
7. Support gear pump to prevent it from shifting. Sepa- before installing
rate gear pump from the piston pump by removing both 2
gear pump to
socket head screws and flat washers. Remove O--ring piston pump
from between the gear pump and piston pump.

NOTE: A case drain exists in the piston (traction) pump

and a suction port is near the input shaft of the gear
pump (Fig. 37). When the gear pump is removed from
the piston pump, plug piston pump case drain hole to
prevent draining the piston pump.

8. Discard all removed O--rings.

Installation (Fig. 36) 1

1. Make sure mounting and O--ring sealing surfaces on

the gear pump and piston pump are clean.

2. Lubricate and place new O--ring (item 11) on the gear Figure 37
pump. 1. Piston pump case drain 2. Gear pump suction port

3. Position gear pump to the piston pump so that the

pump inlet is facing up.

Greensmaster 3150 Page 4 -- 55 Hydraulic System

Gear Pump Service

19
18
16
15
12
11

9
8
6
2 22
21
13
17 14 20
14
13

10
3 33 ft--lb
4 (45 N--m)
7
5
3 4
1

Figure 38
1. O--ring 9. Dowel pin 16. Drive gear
2. Front cover 10. O--ring 17. Idler gear
3. Back--up seal 11. Housing 18. Thrust plate
4. Pressure seal 12. Coupler 19. O--ring
5. Thrust plate 13. Back--up seal 20. End cover
6. Drive shaft 14. Pressure seal 21. Socket head screw (4 used)
7. Idler gear 15. Thrust plate 22. Washer (4 used)
8. Thrust plate

Gear Pump Disassembly (Fig. 38)

NOTE: Disassemble gear pump for cleaning, inspec- MARKER LINES

tion and seal replacement only. Individual gears, hous-
ings and thrust plates are not available separately. If
internal components are worn or damaged, the gear
pump must be replaced as a complete assembly.

IMPORTANT: Keep gears and thrust plates for each

pump section together; do not mix parts between
pump sections.

1. Plug pump ports and thoroughly clean exterior of

pump with cleaning solvent. Make sure work area is
clean.

2. Use a marker to make a “V” across the front cover,

housing and end cover for assembly purposes (Fig. 39).
Figure 39
IMPORTANT: Use caution when clamping gear
pump in a vise to avoid distorting any pump compo- 4. Loosen the four (4) socket head screws that secure
nents. Also, use a vise with soft jaws. pump assembly.
3. Secure the front cover of the pump in a vise with soft 5. Remove pump from vise and remove fasteners.
jaws with the drive shaft pointing down.

Hydraulic System Page 4 -- 56 Greensmaster 3150

6. Support the pump assembly and gently tap the Gear Pump Assembly (Fig. 38)
pump housing with a soft face hammer to loosen the
pump sections. Be careful to not drop parts or disen- 1. Apply clean hydraulic oil to all parts before assem-
gage gear mesh. bling.

IMPORTANT: Mark the relative positions of the gear NOTE: Pressure and back--up seals fit in grooves ma-
teeth and the thrust plates so they can be as- chined into thrust plates. Body O--rings fit in grooves ma-
sembled in the same position. Do not touch the gear chined in housing.
surfaces as residue on hands may be corrosive to
gear finish. 2. Assemble pump sections starting at front cover end.
Apply grease or petroleum jelly to new section seals to
7. Remove the thrust plates and seals from each pump hold them in position during gear pump assembly.
section. Before removing each gear set, apply marking
dye to mating teeth to retain ”timing”. Pump efficiency 3. After pump has been assembled, tighten socket
may be affected if the teeth are not installed in the same head screws by hand. Rotate the drive shaft to check for
position during assembly. Keep the parts for each pump binding. Protect the shaft if using a pliers to rotate shaft.
section together; do not mix parts between sections.
4. Tighten the socket head screws evenly in a crossing
8. Clean all parts. Check all components for burrs, pattern to a torque of 33 ft--lb (45 N--m).
scoring, nicks and other damage.

9. Replace the entire pump assembly if any pump com-

ponents are excessively worn or scored.

Hydraulic
System

Greensmaster 3150 Page 4 -- 57 Hydraulic System

Piston (Traction) Pump Neutral Assembly

25 to 38 ft--lb
(34 to 51 N--m)
24 8
28
7 33 18
25 32 38
13
22 12 21
25 35
1 19

15 36
6
5 14
28
20
4
30 26
34 18 16
18 29 11
17

2
Antiseize 3 31 10
Lubricant 34
23
37

RIGHT 27
9
FRONT
39

Figure 40
1. Lock nut 14. Bearing spacer 27. Traction control cable
2. Pivot tube 15. Ball bearing 28. Flat washer (2 used)
3. Cap screw 16. Extension spring 29. Pivot plate
4. Damper lever 17. Cap screw (2 used) 30. Mount (3 used)
5. Pivot spacer 18. Flange nut (3 used) 31. Cap screw (3 used)
6. Pump lever 19. Cap screw 32. Lock nut (3 used)
7. Flat washer 20. Cap screw 33. Washer (3 used)
8. Cap screw 21. Lock washer (2 used) 34. Nylon washer (2 used)
9. Cable support 22. Cable ball joint 35. Spring bracket
10. Flat washer (2 used) 23. Flange nut 36. Mount plate
11. Neutral arm 24. Cap screw 37. Piston pump assembly
12. Thrust washer 25. Flat washer (2 used) 38. Cap screw (2 used)
13. Traction stud 26. Dampener hose 39. Key

Hydraulic System Page 4 -- 58 Greensmaster 3150

Disassembly (Fig. 40)
4
1. Park machine on a level surface, engage parking 3
brake, lower cutting units and stop engine. Remove key
from the ignition switch. 6

CAUTION
The extension spring (item 16) is under tension 5
and may cause personal injury during removal.
Use caution when removing the spring from the
pump neutral assembly.
1
2
2. Remove components from traction neutral assembly
as needed using Figure 40 as a guide. Figure 41
1. Piston pump 4. Pump lever
Assembly (Fig. 40) 2. Neutral arm 5. Cable support
3. Cap screw 6. Traction cable
1. Install removed components to traction neutral as-
sembly using Figure 40 as a guide along with the follow-
ing:

Hydraulic
System
CAUTION
The extension spring (item 16) is under tension
and may cause personal injury during installa-
tion. Use caution when installing the spring to
the pump neutral assembly.

A. If pivot plate (item 29) was removed from pump

trunnion shaft, make sure that both trunnion shaft
and plate bore are thoroughly cleaned before instal-
ling plate to shaft.

B. If damper lever (item 4) was removed, apply anti-

seize lubricant to pivot tube (item 2) before inserting
into the bore of cable support (item 9).

C. Make sure that ball bearing (item 15) on neutral

arm (item 11) is properly positioned in pump lever
(item 6) after assembly.

2. After traction neutral assembly has been installed,

make sure that the transmission is adjusted for the neu-
tral position so that the machine does not move or creep
when the traction pedal is in neutral.

Greensmaster 3150 Page 4 -- 59 Hydraulic System

Piston (Traction) Pump

15
4

RIGHT

FRONT

26

3 15 37 Loctite #242
27 27 to 33 ft--lb
5 30 (37 to 44 N--m)
36 25
35
23
81 to 99 ft--lb Loctite #242
(110 to 134 N--m) 2 90 to 110 in--lb
(10.2 to 12.4 N--m)

25 6 1
38 18 34 28
33 29 7
23 24
9
30 33
10

31 11
39
34
32 13
3
19 16
33 10
17 8
21 9
33 7
81 to 99 ft--lb 20
14 6 12
(110 to 134 N--m) Antiseize
22 Lubricant

Figure 42
1. Pump hub 14. Flat washer 27. Hose connector
2. Piston pump 15. Hose clamp (2 used) 28. Spacer
3. Flat washer (4 used) 16. Lock washer (2 used) 29. Cap screw
4. Pump inlet hose 17. Cap screw (2 used) 30. O--ring
5. Gear pump 18. Hydraulic fitting 31. Hydraulic hose
6. Lock nut (4 used) 19. 90o hydraulic fitting 32. Hydraulic hose
7. Coupling spacer (4 used) 20. Hydraulic tube 33. O--ring
8. Rubber coupling 21. Support clamp 34. O--ring
9. Flat washer (4 used) 22. Cap screw 35. O--ring
10. Cap screw (4 used) 23. 90o hydraulic fitting (2 used) 36. O--ring
11. Square head set screw (2 used) 24. 90o hydraulic fitting 37. Hydraulic hose
12. Square key 25. O--ring 38. O--ring
13. Engine hub 26. Socket head screw (2 used) 39. Key

NOTE: The complete piston (traction) and gear pump

assembly can be removed from the machine with the
neutral assembly attached to the piston pump. See Pis-
ton (Traction) Pump Neutral Assembly in this section for
information regarding servicing the neutral assembly.

Hydraulic System Page 4 -- 60 Greensmaster 3150

Piston Pump Removal (Fig. 42)

1. Park machine on a level surface, engage parking 3

brake, lower cutting units and stop engine. Remove key
from the ignition switch.

CAUTION
2
Before continuing further, read and become fa-
1
miliar with General Precautions for Removing
and Installing Hydraulic System Components. 4

2. Disconnect the traction control cable ball joint and Figure 43

jam nuts from the neutral arm (Fig. 43). Position traction 1. Piston pump 3. Jam nut (2 used)
cable away from the pump assembly. 2. Traction cable 4. Cable ball joint

3
CAUTION 2 4

1
The extension spring attached to the neutral arm

Hydraulic
is under tension and may cause personal injury

System
during removal. Use caution when removing the
spring from the pump neutral arm.

3. Disconnect one end of the extension spring attached 5

to the neutral arm (Fig. 44).

4. Remove two (2) cap screws (item 10), flat washers Figure 44
(item 9), coupling spacers (item 7) and lock nuts (item 1. Extension spring 4. Mount plate
6) that secure pump hub to rubber coupling (item 8). 2. Dampener hose 5. Neutral arm
3. Spring bracket
5. Thoroughly clean hydraulic hose ends and fittings on
gear and piston (traction) pumps to prevent hydraulic
system contamination.
Remove plugs
2 before installing
6. Label all hydraulic hose connections on gear and gear pump to
piston pumps for assembly purposes. piston pump

7. Clamp pump inlet hose (item 4) to prevent draining

the hydraulic reservoir.

8. Loosen hose clamp and remove inlet hose from the

gear pump.

9. Disconnect hydraulic hoses from fittings on pump

assembly. Allow hoses to drain into a suitable container.
Plug hoses and fittings to prevent contamination.
1

CAUTION
Support the pump assembly when removing its Figure 45
supporting fasteners to prevent it from falling 1. Piston pump case drain port
and causing personal injury. 2. Gear pump suction port

10.Support pump assembly to prevent it from falling.

Greensmaster 3150 Page 4 -- 61 Hydraulic System
11. Remove two (2) cap screws (item 17), lock washers 6. Lubricate and place new O--rings onto all removed
(item 16) and flat washers (item 3) that secure pump as- hydraulic fittings. Install fittings into pump openings
sembly to pump adapter mounted to engine. Separate making sure that fitting orientation is as noted during re-
pump assembly from the pump adapter and remove moval. Tighten fittings (see Hydraulic Fitting Installation
from machine. in the General Information section of this chapter).

12.If necessary, remove pump hub (item 1) from pump 7. Position pump assembly to pump adapter on engine
input shaft. Locate and retrieve key (item 39). and align pump hub with rubber coupling (item 8). Se-
cure pump assembly to pump adapter with two (2) cap
13.Separate gear pump from the piston pump (see Gear screws (item 17), lock washers (item 16) and flat wash-
Pump in this section). ers (item 3).

IMPORTANT: If fittings are going to be removed 8. Secure pump hub to rubber coupling (item 8) with
from piston pump, note position of fittings for as- two (2) cap screws (item 10), flat washers (item 9), cou-
sembly purposes. pling spacers (item 7) and lock nuts (item 6).
14.If fitting removal from piston pump is necessary,
mark hydraulic fitting orientation to allow correct assem-
bly. Remove hydraulic fittings and O--rings from piston CAUTION
pump. Discard removed O--rings.
The neutral arm extension spring is under ten-
15.If necessary, remove the neutral assembly attached sion and may cause personal injury during
to the piston pump (see Piston (Traction) Pump Neutral installation. Use caution when installing the
Assembly in this section). spring to the pump neutral arm.
Piston Pump Installation (Fig. 42)
9. Connect the extension spring to the neutral arm (Fig.
1. If any neutral assembly components were removed 44).
from piston pump, install them to pump (see Piston
(Traction) Pump Neutral Assembly in this section). 10.Connect the traction control cable to the neutral arm
(Fig. 43):
2. Make sure the flange surfaces of the gear pump and
piston pump are thoroughly clean. A. Secure traction cable ball joint to neutral arm.

IMPORTANT: A case drain exists in the piston (trac- B. Secure control cable to neutral arm with cable
tion) pump and a suction port is near the input shaft jam nuts. Make sure that a washer is positioned on
of the gear pump (Fig. 45). Before the gear pump is each side of the neutral arm.
installed to the piston pump, make sure that plugs
11. Remove plugs from hydraulic fittings and hoses that
placed in either of these ports are removed. Failure
were placed during pump removal.
to remove plugs will cause excessive pressure in
the piston pump and damage seals. 12.Using labels placed during pump removal, lubricate
new O--rings and connect hydraulic hoses to gear pump
3. Install gear pump to the piston pump (see Gear
and piston pump fittings. Tighten hose connections (see
Pump in this section).
Hydraulic Hose and Tube Installation in the General In-
4. If removed, secure hub (item 1) to piston pump shaft: formation section of this chapter).

A. Make sure that pump shaft and bore of hub are 13.Make sure that gear pump inlet hose is installed to
thoroughly cleaned. pump fitting and secured with hose clamp. Remove
clamp from gear pump inlet hose.
B. Position key (item 39) to pump shaft.
14.Check oil level in hydraulic reservoir and add correct
C. Apply Loctite #242 (or equivalent) to the threads oil if necessary.
of the cap screw used to secure hub to pump shaft.
15.Follow Hydraulic System Start--up procedures (see
D. Slide hub onto pump shaft and secure with Hydraulic System Start--up in this section).
spacer (item 28) and cap screw (item 29). Torque
cap screw from 27 to 33 ft--lb (37 to 44 N--m). 16.Check neutral position of the traction pedal. If adjust-
ment is required, see Adjust Transmission for Neutral in
5. Inspect threads and sealing surfaces of hydraulic fit- the Traction Unit Owner’s Manual.
tings and hydraulic hose connectors. Replace any dam-
aged or worn fittings or connectors.
Hydraulic System Page 4 -- 62 Greensmaster 3150
 Hydraulic
System
This page is intentionally blank.

Greensmaster 3150 Page 4 -- 63 Hydraulic System

Piston (Traction) Pump Service

36
37
20 21
19
17
23
22
18

16
REAR
15 41 OF TRACTION UNIT
14
15
4
8 40
24
27 38 9
13
29

28
12
5 11

26
7
39 6
8
3 10
2 28
1
4
38
6
30
39
31
32 4
31 25
35
33 30
34

Figure 46
1. Key 15. Dowel pin 29. Housing
2. Drive shaft 16. Back plate 30. Retaining ring
3. Bearing 17. O--ring 31. Bearing race
4. Cap screw (3 used per plate) 18. Forward relief valve 32. Thrust bearing
5. Cover plate 19. Bypass valve 33. Washer
6. O--ring 20. O--ring 34. Shaft seal
7. Shim kit (for crush ring replacement) 21. Cap screw (2 used) 35. Retaining ring
8. Bearing cone 22. Cap screw (2 used) 36. Retaining ring
9. Key 23. Coupler 37. Plug
10. Swash plate 24. Roll pin 38. Plug with O--ring (2 used)
11. Rotating kit 25. Cover plate 39. Bearing cup
12. Gasket 26. Swash plate insert 40. Shuttle relief valve with O--ring
13. Valve plate 27. Shaft seal 41. Reverse relief valve
14. Bearing 28. Washer

Hydraulic System Page 4 -- 64 Greensmaster 3150

For repair of the piston pump, see Eaton, Medium Duty
Piston Pump, Repair Information, Model 70160 Variable
Displacement Piston Pump at the end of this chapter. 1

NOTE: The charge relief valve is attached to the piston 2

pump back plate (shown in Fig. 47). The back plate must
be removed to service the relief valve.

NOTE: The piston pump is equipped with relief valves

(items 18 and 41) for both the forward and reverse direc-
tion. Due to engine output, it is unlikely that traction pres-
sure will reach relief valve settings. If, however, a piston
pump relief valve is leaking or otherwise faulty, traction CHARGE RELIEF
performance would be affected. VALVE

IMPORTANT: The shim kit (item 7) is used to replace

the original crush ring (not shown) in the cover plate
(item 25). If the swash plate (item 10), cover plate
3
(item 25) or housing (item 29) is replaced during ser-
vicing, the old crush ring must be replaced. For in-
4
formation on crush ring replacement, see Piston
Pump Crush Ring Replacement in this section in 5
7 6
conjunction with the piston pump service manual at 8

Hydraulic
the end of this chapter.

System
Figure 47
1. Back plate 5. Poppet
2. Charge relief valve 6. Spring
3. O--ring 7. Washer
4. Housing 8. Retaining ring

Greensmaster 3150 Page 4 -- 65 Hydraulic System

Piston Pump Crush Ring Replacement

4
5

29 ft--lb
2 (39 N--m)

v
3
9
10

1
6

Figure 48
1. Crush ring 5. Swash plate (control shaft) 8. O--ring
2. Shims 6. Bearing cone 9. Washer (3 used)
3. Cover plate 7. Bearing cup 10. Cap screws (3 used)
4. Housing

NOTE: The shims replace the crush ring in the cover 5. Install washers and cap screws to the cover plate
plate. If the camplate, cover plate or housing is replaced and housing. Torque cap screws to 29 ft--lbs (39 N--m).
during servicing of the pump, the old crush ring can not
be used to make sure of proper preload. 6. Check torque required to rotate control shaft. Torque
should be 5 to 15 in--lbs (0.6 to 1.7 N--m).
1. Remove crush ring from the cover plate. Measure
thickness of crush ring. A. If torque is too low, add additional shims and re-
peat steps 3 through 6 until the specified torque is
2. Stack shims to the thickness of the crush ring. achieved.

3. Insert shims into the cover plate in the same location B. If torque is too high, remove shims and repeat
that the crush ring was removed from. steps 3 through 6 until the specified torque is
achieved.
4. Assemble housing sub assembly consisting of the
housing, camplate, bearing cone, bearing cup and cov- 7. Complete assembly of the pump (see Eaton, Me-
er plate (see Eaton, Medium Duty Piston Pump, Repair dium Duty Piston Pump, Repair Information, Model
Information, Model 70160 Variable Displacement Piston 70160 Variable Displacement Piston Pump at the end of
Pump at the end of this chapter). this chapter).

Hydraulic System Page 4 -- 66 Greensmaster 3150

 Hydraulic
System
This page is intentionally blank.

Greensmaster 3150 Page 4 -- 67 Hydraulic System

Front Wheel Motors

2
250 to 400 ft--lb
(339 to 542 N--m)
3

6
1
5
8
11
15
14
13
18
12 17
19

70 to 90 ft--lb 7 9
16
(95 to122 N--m)
21

10
4

23
24
RIGHT
25
26 20
FRONT 27

22

Figure 49
1. Lug nut (4 per wheel) 10. Retaining ring 19. O--ring
2. Wheel assembly 11. Cap screw (4 per brake) 20. Hydraulic motor
3. Lock nut 12. Lock nut (4 per brake) 21. Cap screw (4 per motor)
4. Brake lever 13. Woodruff key 22. Lock nut (4 per motor)
5. Brake drum 14. Brake bracket 23. Brake rod
6. Wheel hub 15. Hydraulic hose 24. Jam nut
7. Drive stud (4 per hub) 16. Hydraulic hose 25. Clevis pin
8. Brake assembly 17. 45o Hydraulic fitting (2 per motor) 26. Swivel clevis
9. Brake cam 18. O--ring 27. Cotter pin

Hydraulic System Page 4 -- 68 Greensmaster 3150

Front Wheel Motor Removal (Fig. 49) Front Wheel Motor Installation (Fig. 49)

1. Before removing any parts from the hydraulic sys- 1. Position hydraulic wheel motor and brake bracket
tem, park the machine on a level surface, engage the (item 14) to the frame. Make sure ports of motor face the
parking brake, lower the cutting units and stop the en- rear of the machine. Secure motor and brake bracket to
gine. the frame with four (4) cap screws (item 21) and lock
nuts (item 22).
2. Remove front wheel, brake drum assembly and
brake assembly from machine (see Front Wheel and 2. Remove plugs from wheel motor ports. Lubricate
Brake in the Service and Repairs section of Chapter 6 and place new O--rings onto fittings. Install fittings into
-- Chassis). motor openings making sure that fitting orientation is as
noted during removal. Tighten fittings (see Hydraulic Fit-
ting Installation in the General Information section of this
CAUTION chapter).

3. Remove caps from disconnected hydraulic lines.

Before continuing further, read and become fa-
miliar with General Precautions for Removing 4. Lubricate and position new O--rings to fittings on
and Installing Hydraulic System Components. wheel motor. Use labels placed during the removal pro-
cess to properly install hydraulic lines to wheel motor fit-
3. Label all wheel motor hydraulic connections for as- tings (see Hydraulic Hose and Tube Installation in the
sembly purposes. General Information section of this chapter).

5. Install brake assembly, brake drum assembly and

Hydraulic
4. Disconnect both hose assemblies and O--rings from

System
the hydraulic fittings on the wheel motor. Allow hoses to front wheel to machine (see Front Wheel and Brake in
drain into a suitable container. Discard removed O-- the Service and Repairs section of Chapter 6 -- Chas-
rings. sis).

5. Mark wheel motor fitting orientation to allow correct

assembly. Remove hydraulic fittings and O--rings from
motor. Discard removed O--rings.
WARNING
6. Put caps or plugs on disconnected hoses and motor Failure to maintain proper wheel lug nut and
port openings to prevent contamination. wheel hub lock nut torque could result in failure
or loss of wheel and may result in personal injury.
7. Remove four (4) cap screws (item 21) and lock nuts
(item 22) that secure brake bracket (item 14) and hy- 6. Make sure to properly torque lock nut from 250 to
draulic wheel motor to machine. Remove brake bracket 400 ft--lb (339 to 542 N--m) and wheel lug nuts from 70
and motor from the frame. to 90 ft--lb (95 to 122 N--m).

7. Check oil level in hydraulic reservoir and add correct

oil if necessary.

8. Follow Hydraulic System Start--up procedures (see

Hydraulic System Start--up in this section).

Greensmaster 3150 Page 4 -- 69 Hydraulic System

Rear Wheel Motor (Optional 3WD)

6
4 100 ft--lb
7
(135 N--m)
1
5

16

3 22
30
5 21
17
26
2
20
9

31

29
25
19 27
10
14 8 11
12
23 18 Loctite #242
80 to 100 in--lb
15
(9.0 to 11.3 N--m)
24 40 ft--lb
(55 N--m)

FRONT
13 70 to 90 ft--lb
28 (95 to122 N--m) RIGHT

Figure 50
1. Lock nut (2 used) 12. Cap screw (3 used) 22. Lock nut (3 used)
2. Spacer (2 used) 13. Lock nut (2 used) 23. O--ring
3. Grommet (2 used) 14. Wheel motor & hub assembly 24. O--ring
4. Hydraulic hose assembly 15. Adapter (2 used) 25. O--ring
5. Washer (4 used) 16. Socket head screw (2 used) 26. O--ring
6. Castor fork 17. Bulkhead bracket 27. Set screw
7. Mount spacer (2 used) 18. Lug nut (4 used) 28. Wheel assembly
8. Grease fitting 19. Hydraulic hose assembly 29. Grease fitting
9. Bearing flangette (lube) 20. Hydraulic tube assembly 30. Hydraulic hose assembly
10. Bearing 21. Washer (3 used) 31. Washer head screw (2 used)
11. Bearing flangette

NOTE: For service of the hub and motor assembly

(item 14) on machines equipped with 3WD, see Rear
Wheel (Optional 3WD) and Rear Wheel Hub and Motor
Assembly (Optional 3WD) in the Service and Repairs
section of Chapter 6 -- Chassis.

Hydraulic System Page 4 -- 70 Greensmaster 3150

 Hydraulic
System
This page is intentionally blank.

Greensmaster 3150 Page 4 -- 71 Hydraulic System

Wheel Motor Service

13
12
11

10
9 8
8
7
6 14
3 5
4
2
1
15
16
17

24

23
5

22

5
21
20
19
5
18

Figure 51
1. Dirt seal 9. Thrust bearing 17. Woodruff key
2. Bearing 10. Bearing 18. Wear plate
3. Housing 11. Coupling shaft 19. Rotor
4. Back--up washer 12. Thrust bearing 20. Vane
5. Seal ring 13. Drive link 21. Stator
6. Back--up washer 14. Cap screw 22. Manifold
7. Inner seal 15. Commutator seal 23. Commutator ring
8. Thrust washer 16. Commutator 24. End cover

NOTE: For repair of the wheel motors, see the Parker

TorqmotorTM Service Procedure (TC, TB, TE, TJ, TF,
TG, TH and TL Series) at the end of this chapter.

Hydraulic System Page 4 -- 72 Greensmaster 3150

 Hydraulic
System
This page is intentionally blank.

Greensmaster 3150 Page 4 -- 73 Hydraulic System

Cutting Reel Motors

RH BULKHEAD
1
19 ASSEMBLY
LH BULKHEAD 34
ASSEMBLY 16 16
18 17
18
17 6 16 19
35
16 16 19 1
6
32 17 18 7
7 1
36 33
29
16 13 22 37
34 32 5
33 13
33 3

34

9
14
1
3

27
4
2

28 15
8 30
20 13
11 13 31
10 12 26
16
17

21 18
FRONT CENTER BULKHEAD
ASSEMBLY 24
25
RIGHT
23
22 16
19

Figure 52
1. Hydraulic hose (2 used) 14. LH reel motor 26. Washer head screw
2. Hydraulic hose 15. Bulkhead fitting 27. RH reel motor
3. Hydraulic hose 16. Washer 28. Hydraulic manifold
4. Hydraulic tube 17. Spacer 29. Bulkhead bracket
5. Hydraulic tube 18. Rubber grommet 30. O--ring
6. Hydraulic hose 19. Bulkhead nut 31. O--ring
7. Hydraulic hose 20. Bulkhead tee fitting 32. Hydraulic tube
8. Center reel motor 21. Bulkhead bracket 33. Hydraulic tube
9. Hydraulic tube 22. Bulkhead nut 34. Hydraulic tube
10. Hydraulic hose 23. Cap screw 35. Washer
11. Hydraulic hose 24. Flat washer 36. Bulkhead nut
12. Hydraulic hose 25. Flange nut 37. Bulkhead tee fitting
13. O--ring
Hydraulic System Page 4 -- 74 Greensmaster 3150
Removal (Fig. 52)
2
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. 1

CAUTION
Before continuing further, read and become fa-
miliar with General Precautions for Removing 3
and Installing Hydraulic System Components.

NOTE: The position of hydraulic fittings on the reel mo- Figure 53

tor is critical to properly connect hydraulic hoses to the 1. Cutting reel motor 3. Cutting unit
motors. 2. Flange head screw

2. Label all hydraulic hose connections for assembly

purposes. Matchmark reel motor and all hydraulic fit- RH REEL MOTOR
7
tings for assembly purposes. 6
3. Remove hose connections from the hydraulic fittings

Hydraulic
5

System
on the reel motor. Allow hydraulic oil to drain from hoses
into a suitable container. Put caps or plugs on ends of FRONT 4
hoses to prevent contamination.
4 3
4. Loosen two (2) flange head screws that secure the
hydraulic reel motor to the cutting unit side plate (Fig. 2
53). Rotate motor clockwise and remove motor from cut- 3
ting unit. 1
2
5. Inspect reel insert splines for wear. Replace if neces-
sary (see Reel Assembly Removal and Installation in Figure 54
1. RH cutting reel motor 5. O--ring
the Service and Repairs section of Chapter 7 -- DPA Cut- 2. O--ring 6. Hydraulic fitting
ting Units). 3. Hydraulic fitting 7. O--ring
4. O--ring
6. Remove hydraulic fittings and O--rings from the reel
motor (Figs. 54, 55 and 56). Put caps or plugs in motor
openings to prevent contamination. LH REEL MOTOR 7
6
Installation (Fig. 52)

1. Inspect threads and sealing surfaces of fittings and 5

hydraulic hoses. Replace any worn or damaged fittings. FRONT 4
2. If fittings were removed from reel motor, lubricate 3
4
and place new O--rings onto fittings. Install fittings into 2
motor ports using marks made during the removal pro-
cess to properly orientate fittings (Figs. 54, 55 and 56). 8
2 1
Tighten fittings (see Hydraulic Fitting Installation in the
General Information section of this chapter).
Figure 55
3. Coat spline shaft of the reel motor with No. 2 multi- 1. LH cutting reel motor 5. O--ring
purpose lithium base grease. 2. O--ring 6. Hydraulic fitting
3. Hydraulic fitting 7. O--ring
4. O--ring 8. Hydraulic fitting
4. Install the flange head screws for the reel drive motor
into the cutting unit side plate and leave approximately
1/2 inch (13 mm) of threads exposed on each screw.

Greensmaster 3150 Page 4 -- 75 Hydraulic System

5. Rotate the motor clockwise so the motor flanges
clear the cap screws in the cutting unit side plates. Align CENTER REEL MOTOR 6
reel motor shaft splines with cutting reel insert splines. 7
4
Slide motor shaft into reel insert.
5
6. Rotate the motor counter--clockwise until the motor FRONT
flanges are encircling the cap screws. Tighten two (2) 3
flange head screws to secure reel motor to cutting unit. 8
2
7. Remove caps or plugs from hydraulic fittings and 4
hoses. Connect hydraulic hoses to reel motor (see Hy- 1
draulic Hose and Tube Installation in the General Infor- 2
mation section of this chapter).
Figure 56
8. After assembly is completed, verify that hydraulic 1. Center cutting reel motor 5. O--ring
hoses and fittings are not contacted by any moving com- 2. O--ring 6. Hydraulic fitting
3. Hydraulic fitting 7. O--ring
ponents. 4. O--ring 8. Hydraulic fitting

9. Check oil level in hydraulic reservoir and add correct

oil if necessary.

Hydraulic System Page 4 -- 76 Greensmaster 3150

 Hydraulic
System
This page is intentionally blank.

Greensmaster 3150 Page 4 -- 77 Hydraulic System

Cutting Reel Motor Service

10

215 to 280 in--lb

1 (24 to 32 N--m)
6

7
2
5

11

3
12
4

Figure 57
1. Rear cover 5. Pressure seal 9. Idler gear
2. Drive gear 6. Back--up ring 10. Cap screw
3. Seal 7. O--ring 11. Front flange
4. Tab washer 8. Body 12. Washer (if equipped)

Disassembly
DIAGONAL MARK
1. Plug motor ports and clean the outside of the motor
thoroughly. After cleaning, remove plugs and drain any
oil out of the motor.

2. Use a marker or scribe to make a diagonal mark

across the front flange, body and rear cover for reas-
sembly purposes (Fig. 58).

Figure 58

Hydraulic System Page 4 -- 78 Greensmaster 3150

IMPORTANT: Avoid using excessive clamping
pressure on the motor flange to prevent distorting 1
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 2

cover. Locate and remove dowel pins from body.
Figure 59
IMPORTANT: Mark the relative positions of the gear 1. Motor body 2. Bearing block & gear set
teeth and the bearing blocks so they can be re-
assembled in the same position. Do not touch the
gear surfaces as residue on hands may be corrosive
to gear finish.

7. Place the motor on its side and push on the rear bear-
ing block to remove the bearing block and gear set
(Fig. 59).

Hydraulic
System
8. Carefully remove and discard O--rings, pressure
seals and back--up rings (Fig. 60) from motor. Do not
cause any damage to the machined grooves during the
removal process.

IMPORTANT: Make sure to not damage the counter

bore when removing the shaft seal from the front
plate.

9. Position front flange with seal side up. Remove shaft

seal. Figure 60

Inspection

1. Remove any nicks and burrs from all motor compo-

nents with emery cloth.

2 1

CAUTION
Use eye protection such as goggles when using
compressed air.
3

2. Clean all motor components with solvent. Dry all

parts with compressed air.

Figure 61
1. Drive gear 3. Bearing block
2. Idler gear

Greensmaster 3150 Page 4 -- 79 Hydraulic System

3. Inspect drive gear, idler gear and bearing blocks 5. Lubricate gear faces and bearing surfaces of drive
(Fig. 61) for the following: gear, idler gear and bearing blocks. Carefully assemble
bearing blocks and gears noting identification marks
A. Gear shafts should be free of rough surfaces and made during disassembly.
excessive wear at bushing points and sealing areas.
Scoring, rough surfaces or wear on gear shafts indi- 6. Position the motor body on its side. Carefully slide
cates need for replacement. bearing block and gear assembly into the body cavity
using identification marks made during disassembly.
B. Gear teeth should be free of excessive scoring
and wear. Any broken or nicked gear teeth must be 7. Remove any excess lubrication from mating sur-
replaced. faces of body, rear cover and front flange. Make sure
that these surfaces are clean and dry.
C. Inspect gear face edge for sharpness. Sharp
edges of gears will mill into bearing blocks and, thus, 8. Install dowel pins in body.
must be replaced.
IMPORTANT: Do not dislodge O--rings, pressure
D. Bearing areas of bearing blocks should not have seals or back--up rings during final assembly.
excessive wear or scoring.
9. Gently slide the rear cover onto the assembly using
E. Face of bearing blocks that are in contact with marker or scribe mark for proper location. Firm hand
gears should be free of wear, roughness or scoring. pressure should be sufficient to engage the dowel pins.

4. Inspect front flange and rear cover for damage or 10.Position the motor with rear cover downwards. Care-
wear. fully slide the front flange onto the assembly using mark-
er or scribe mark for proper location.
Assembly
11. Install the four (4) cap screws and hand tighten.
NOTE: When reassembling the motor, check the identi-
fication marks made during disassembly to make sure IMPORTANT: Avoid using excessive clamping
the parts are properly aligned during reassembly. pressure on the motor housing to prevent distorting
the housing.
1. Lubricate O--rings, pressure seals, back--up gaskets
and seal grooves with a thin coat of petroleum jelly. Lu- 12.Place motor front flange in a vise and alternately
bricate all other internal parts freely with clean hydraulic torque the cap screws from 215 to 280 in--lb (24 to 32
oil. N--m).

2. Install new shaft seal into front flange. 13.Put a small amount of hydraulic oil in port on motor
and rotate driveshaft one revolution. Protect the shaft if
3. Install lubricated pressure seals into the grooves in using a pliers. If drive shaft binds, disassemble motor
the front flange and rear cover. Follow by carefully plac- and repeat assembly process.
ing the back--up rings into the grooves.
14.Remove motor from vise.
4. Install new O--rings to the body.

Hydraulic System Page 4 -- 80 Greensmaster 3150

 Hydraulic
System
This page is intentionally blank.

Greensmaster 3150 Page 4 -- 81 Hydraulic System

Front Lift Cylinders

16
3 22
13 5

2 3
14 4 2
4
9 12 15
19
21 10 3 2
1 8 12
6
7 20 6 2 3
7 4 4
14
16
9 13
10
11

8
7
18 6
17
18

20
7
6

RIGHT
FRONT

Figure 62
1. RH lift arm 9. Cotter pin 16. Grease fitting
2. Straight hydraulic fitting 10. Clevis pin 17. LH torsion spring
3. O--ring 11. LH lift arm 18. Grease fitting
4. O--ring 12. Spacer 19. Hydraulic hose
5. Hydraulic hose 13. Spacer 20. Hinge pin
6. Cap screw 14. Hydraulic cylinder 21. RH torsion spring
7. Washer 15. Hydraulic hose 22. Hydraulic hose
8. Pivot pin

Hydraulic System Page 4 -- 82 Greensmaster 3150

Front Lift Cylinder Removal (Fig. 62) Front Lift Cylinder Installation (Fig. 62)

1. Before removing any parts from the hydraulic sys- 1. If fittings were removed from lift cylinder, lubricate
tem, park the machine on a level surface, engage the and place new O--rings onto fittings. Install fittings into
parking brake, lower the cutting units and stop the en- lift cylinder ports. Tighten fittings (see Hydraulic Fitting
gine. Installation in the General Information section of this
chapter).

CAUTION 2. Position lift cylinder to the machine.

3. Insert pivot pin (item 8) through the outer frame

Before continuing further, read and become fa- bracket, thinner spacer, lift cylinder, thicker spacer and
miliar with General Precautions for Removing inner frame bracket. Secure pin to frame with cap screw
and Installing Hydraulic System Components. and washer.

4. Position clevis of the lift cylinder to the lift arm. Se-

2. Label all hydraulic connections for assembly pur-
cure lift cylinder clevis to the lift arm with clevis pin and
poses.
cotter pin.
3. Disconnect hydraulic hoses and O--rings from the
5. Connect hydraulic hoses with new O--rings to the hy-
hydraulic fittings at the lift cylinder. Allow hoses to drain
draulic fittings on the lift cylinder. Tighten hose connec-
into a suitable container.
tions (see Hydraulic Hose and Tube Installation in the
4. Remove cotter pin and clevis pin that secure the lift General Information section of this chapter).

Hydraulic
System
cylinder clevis to the lift arm.
6. Make sure that hydraulic reservoir is at correct level.
5. Support lift cylinder to prevent it from dropping.
7. Start machine. Run machine at idle for several min-
A. Remove cap screw and washer from the pivot pin utes to circulate hydraulic fluid and remove any air
(item 8). trapped in the system. Stop machine and recheck hy-
draulic reservoir level.
B. Pull pivot pin from the frame, spacers and lift cyl-
inder. Note that thicker spacer is toward the center of
the machine.

C. Remove hydraulic cylinder from the frame.

6. If necessary, remove hydraulic fittings from lift cylin-

der.

NOTE: See Lift Cylinder Service in this section for in-

formation on lift cylinder service.

Greensmaster 3150 Page 4 -- 83 Hydraulic System

Center Lift Cylinder

6
14 7
16 4
12 13
5
4 3
2

15 11
9

10

RIGHT

FRONT

Figure 63
1. Pull frame 7. Washer 12. 45o hydraulic fitting
2. Straight hydraulic fitting 8. Pivot pin 13. Cotter pin
3. O--ring 9. Lock nut 14. Clevis pin
4. O--ring 10. Lift arm 15. Grease fitting
5. Hydraulic hose 11. Hydraulic cylinder 16. Hydraulic hose
6. Cap screw

Hydraulic System Page 4 -- 84 Greensmaster 3150

Center Lift Cylinder Removal (Fig. 63) Center Cylinder Installation (Fig. 63)

1. Before removing any parts from the hydraulic sys- 1. If fittings were removed from lift cylinder, lubricate
tem, park the machine on a level surface, engage the and place new O--rings onto fittings. Install fittings into
parking brake, lower the cutting units and stop the en- lift cylinder ports. Tighten fittings (see Hydraulic Fitting
gine. Installation in the General Information section of this
chapter).

CAUTION 2. Position lift cylinder to the machine.

3. Insert pivot pin (item 8) through the frame brackets

Before continuing further, read and become fa- and lift cylinder. Secure pin to frame with cap screw,
miliar with General Precautions for Removing washer and lock nut.
and Installing Hydraulic System Components.
4. Position clevis of the lift cylinder to the lift arm. Se-
cure lift cylinder clevis to the lift arm with clevis pin (item
2. Label all hydraulic connections for assembly pur- 14) and cotter pin.
poses.
5. Connect hydraulic hoses with new O--rings to the hy-
3. Disconnect hose assemblies and O--rings from the draulic fittings on the lift cylinder. Tighten hose connec-
hydraulic fittings at the lift cylinder. Allow hoses to drain tions (see Hydraulic Hose and Tube Installation in the
into a suitable container. General Information section of this chapter).
4. Support lift cylinder to prevent it from dropping. 6. Make sure that hydraulic reservoir is at correct level.

Hydraulic
System
A. Remove cap screw, washer and lock nut from the 7. Start machine. Run machine at idle for several min-
pivot pin (item 8). Pull pivot pin from the frame and lift utes to circulate hydraulic fluid and remove any air
cylinder. trapped in the system. Stop machine and recheck hy-
draulic reservoir level.
B. Remove cotter pin from clevis pin (item 14). Slide
clevis pin from lift cylinder and lift arm.

C. Separate hydraulic cylinder from the frame and

lift arm. Remove cylinder from machine.

5. If hydraulic fitting removal is necessary, matchmark

lift cylinder and 45o hydraulic fitting for assembly pur-
poses. Remove hydraulic fittings from lift cylinder.

NOTE: See Lift Cylinder Service in this section for in-

formation on lift cylinder service.

Greensmaster 3150 Page 4 -- 85 Hydraulic System

Lift Cylinder Service

FRONT HYDRAULIC CYLINDER

1
2
3

4
5
6
16
7
15 8
9

10
14
60 to 75 ft--lb
13
(82 to 101 N--m)
12

11

Figure 64
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

CENTER HYDRAULIC CYLINDER

2
3
4
5

14 6

7
13
8

12
11
60 to 75 ft--lb
(82 to 101 N--m) 10
9

Figure 65
1. Seal kit 6. O--ring 11. Retaining 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 -- 86 Greensmaster 3150

Disassembly (Figs. 64 and 65) Assembly (Figs. 64 and 65)

1. Remove the oil from the cylinder by slowly pumping 1. Make sure all parts are clean before reassembly.
the cylinder shaft while holding the cylinder over a drain
pan. Plug both ports and clean the outside of the cylin- 2. Coat new seal kit components with clean hydraulic
der. oil.

IMPORTANT: Prevent damage when clamping the A. Install wear ring and seal with loader on the pis-
hydraulic cylinder into a vise; clamp on the cap end ton.
only. Do not close vise enough to distort the barrel.
B. Install O--ring, back--up ring and seal on the head.
2. Mount lift cylinder in a vise. Use of a vise with soft
jaws is recommended. C. Install O--ring to groove in rod.

3. Using a spanner wrench, rotate head clockwise until IMPORTANT: Do not clamp vise jaws against the
the edge of the retaining ring appears in the barrel open- shaft surface. Protect shaft surface before mount-
ing. Insert a screwdriver under the beveled edge of the ing in a vise.
retaining ring to start the retaining ring through the open-
3. Mount shaft securely in a vise by clamping on the cle-
ing. Rotate the head counter--clockwise to remove re-
vis or eye of the shaft. Use of a vise with soft jaws is rec-
taining ring from barrel and head.
ommended.
4. Extract shaft, head and piston by carefully twisting
A. Coat shaft with clean hydraulic oil.
and pulling on the shaft.

Hydraulic
System
B. Carefully slide head onto the shaft. Install wiper
IMPORTANT: Do not clamp vise jaws against the
onto shaft and into head.
shaft surface. Protect shaft surface before mount-
ing in a vise. C. Install piston and nut onto the shaft. Torque nut
from 60 to 75 ft--lb (82 to 101 N--m).
5. Mount shaft securely in a vise by clamping on the cle-
vis or eye of the shaft. Remove lock nut and piston from D. Remove shaft from the vise.
the shaft. Slide head off the shaft.
IMPORTANT: Prevent damage when clamping the
6. Remove wear ring and seal with loader from the pis- hydraulic cylinder into a vise; clamp on the cap end
ton. Remove O--ring, back--up ring, seal and wiper from only. Do not close vise enough to distort the barrel.
the head. Remove O--ring from rod.
4. Mount barrel in a vise.

CAUTION 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.
Use eye protection such as goggles when using
compressed air to dry cylinder parts. 6. Secure head in barrel by installing retaining ring.
Align retaining ring hole in the head with the access slot
7. Wash parts in clean solvent. Dry parts with com- in the barrel. Insert the retaining ring hook into the hole
pressed air. Do not wipe parts dry with paper towels or and rotate head clockwise until the retaining ring is com-
pletely pulled into the barrel and the ring ends are cover-
cloth. Lint in a hydraulic system will cause damage.
ed.
8. Carefully inspect internal surface of barrel for dam-
age (deep scratches, out--of--round, etc.). Inspect shaft,
head and piston for evidence of excessive scoring, pit-
ting or wear. Replace entire cylinder if internal compo-
nents are found to be worn or damaged.

Greensmaster 3150 Page 4 -- 87 Hydraulic System

Hydraulic Manifold

16 17 31

1
5
5
17
32
12
33
5
23 10
38
30 22 18
36

17
15
1 7
17 39
8 5
37 14
23
5 17 11
22 27
55 to 65 ft--lb 6 37 21
(75 to 88 N--m) 28
13
34
35 4 9
29
26
25 10
3
28 20

FRONT
19
RIGHT
24 28
2

Figure 66
1. 90o hydraulic fitting (4 used) 14. 45o hydraulic fitting 27. Hydraulic tube
2. Tee hydraulic fitting 15. Hydraulic tube 28. O--ring
3. Hydraulic test fitting 16. Straight hydraulic fitting 29. O--ring
4. Dust cap 17. O--ring 30. Hydraulic hose
5. O--ring 18. Hydraulic tube 31. Hydraulic hose
6. 90o hydraulic fitting 19. Hydraulic hose 32. Hydraulic hose
7. 90o hydraulic fitting 20. O--ring 33. Hydraulic hose
8. 90o hydraulic fitting 21. Hydraulic hose 34. O--ring
9. 90o hydraulic fitting 22. O--ring 35. O--ring
10. Straight hydraulic fitting (2 used) 23. O--ring 36. Hydraulic hose
11. 45o hydraulic fitting 24. Hydraulic hose 37. O--ring
12. Hydraulic manifold assembly 25. Hydraulic hose 38. O--ring
13. Cap screw (2 used) 26. Hydraulic hose 39. O--ring

NOTE: The ports on the manifold are marked for easy

identification of components. Example: FC1 is the reel
circuit flow control valve and P1 is the gear pump con-
nection port (see Hydraulic Schematic to identify the
function of the hydraulic lines and cartridge valves at
each port location).

Hydraulic System Page 4 -- 88 Greensmaster 3150

Removal (Fig. 66) Installation (Fig. 66)

1. Before removing any parts from the hydraulic sys- 1. Install hydraulic fittings and their respective O--rings
tem, park machine on a level surface, engage parking to the manifold assembly and orient to position recorded
brake, lower cutting units and stop the engine. during removal. Torque fittings to the values identified in
Figure 66.

CAUTION 2. Position manifold assembly to the support frame.

Secure assembly to the frame with two (2) cap screws
(item 13).
Before continuing further, read and become fa-
miliar with General Precautions for Removing 3. Using labels placed during disassembly, connect hy-
and Installing Hydraulic System Components. draulic hoses and tubes and their respective O--rings to
correct hydraulic fittings.
2. Label all hydraulic connections and electrical con-
A. When installing hydraulic tube (item 15) to 90o
nections for assembly.
hydraulic fitting in manifold port T, torque tube from
3. Disconnect wire harness connectors from manifold 55 to 65 ft--lb (75 to 88 N--m).
solenoid coils and backlap switch.
4. Connect wire harness connectors to manifold sole-
IMPORTANT: Before disconnecting any hydraulic noid coils and backlap switch.
lines from the hydraulic fittings, make sure each line
5. Make sure that hydraulic reservoir is at correct level.
is labeled to ensure it is reconnected to the correct

Hydraulic
System
manifold fitting/port. 6. Start machine. Run machine at idle for several min-
utes to circulate hydraulic fluid and remove any air
4. Disconnect hose and tube assemblies and remove
trapped in the system. Stop machine and recheck hy-
their respective O--rings from the hydraulic fittings. Al-
draulic reservoir level.
low hoses and tubes to drain into a suitable container.

5. Remove two (2) cap screws (item 13) from the hy-
draulic manifold. Remove manifold assembly from the
machine.

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.

IMPORTANT: A flow control orifice is located be-

neath the fitting in manifold port L1A. If this fitting
is removed from the manifold, make sure to remove
orifice and label its position for assembly purposes.
When installing the orifice in the manifold, make
sure that the orifice is flat in the base of the port.
Manifold damage is possible if the orifice is cocked
in the port.

6. If necessary, remove hydraulic fittings and O--rings

from the manifold.

Greensmaster 3150 Page 4 -- 89 Hydraulic System

Hydraulic Manifold Service

60 in--lb
(6.7 N--m) 20 ft--lb 60 in--lb
(27 N--m) (6.7 N--m)
25 ft--lb 26
(34 N--m) 26
29
20 ft--lb 21
(27 N--m) 2 21
18 25 ft--lb
16 14 (34 N--m)
15
29
13
11
2
60 in--lb
(6.7 N--m)
17 10
12

7 40 ft--lb
20 ft--lb (54 N--m)
(27 N--m) 7
4 25 ft--lb
1
(34 N--m)
9
7 VIEW FROM
50 ft--lb 8
3
BELOW
(68 N--m)
6
6
9
1
6 20
22 6 UP
19 6
5 24
23
6
20 ft--lb
(27 N--m) 20 ft--lb
(27 N--m) 6

8 8
4 7 25
PLUG TORQUE
SAE #4: 20 ft--lb (27 N--m)
27 28
Zero Leak #4: 20 ft--lb (27 N--m) 7
Zero Leak #6: 25 ft--lb (34 N--m)
20 ft--lb 25 ft--lb
Zero Leak #8: 50 ft--lb (68 N--m)
(27 N--m) (34 N--m)

Figure 67
1. Manifold body 11. Rotary handle assembly 21. Solenoid coil
2. Solenoid coil 12. Pilot piston 22. Dowel pin
3. Flow control orifice (.060) 13. Relief cartridge valve (PRV) 23. Ball switch (N.O.)
4. Orifice plug (.055) (2 used) 14. Solenoid cartridge valve (S2) 24. O--ring
5. Flow control orifice (.013) 15. Solenoid relief cartridge valve (S1R1) 25. Flow control cartridge valve (FC2)
6. Plug (Zero Leak #4) (12 used) 16. Solenoid cartridge valve (S3) 26. Nut
7. Plug (Zero Leak #6) (5 used) 17. Solenoid cartridge valve (S4) 27. Flow control orifice (.025)
8. Plug (Zero Leak #8) (3 used) 18. Relief cartridge valve (R2) 28. Hydraulic fitting
9. Plug (SAE #4) (2 used) 19. Logic control cartridge valve (OR1) 29. Nut
10. Rotary cartridge valve (FC1) 20. Ball

Hydraulic System Page 4 -- 90 Greensmaster 3150

NOTE: The ports on the hydraulic manifold are marked
for easy identification of components. Example: FC1 is
the flow control valve and P1 is the gear pump connec- CAUTION
tion port (see Hydraulic Schematic to identify the func-
tion of the hydraulic lines and cartridge valves at each Use eye protection such as goggles when using
port location). compressed air.

NOTE: The hydraulic manifold shown in Figure 67 uses 5. Cleaning cartridge valves:
several zero leak plugs. These plugs have a tapered
sealing surface on the plug head that is designed to re- A. For non--solenoid operated valves:
sist vibration induced plug loosening. The zero leak Submerge valve in clean mineral spirits to flush out
plugs also have an O--ring to provide a secondary seal. contamination. If valve design allows, use a probe to
If zero leak plug removal is necessary, lightly rap the push the internal spool in and out 20 to 30 times to
plug head using a punch and hammer before using an flush out contamination. Particles as fine as talcum
allen wrench to remove the plug: the impact will allow powder can affect the operation of high pressure hy-
plug removal with less chance of damage to the socket draulic valves. Clean and dry cartridge with com-
head of the plug. When installing plugs into the manifold, pressed air.
torque plugs to the values identified in Figure 67.
B. For solenoid operated valves:
IMPORTANT: A flow control orifice (item 27) is lo- Temporarily install solenoid on cartridge valve and
cated beneath the fitting in manifold port L1A. If this connect a 12 volt power source to the solenoid. While
fitting is removed from the manifold, make sure to energized, flush out any contamination with a non-
remove orifice and label its position for assembly flammable aerosol brake cleaner. De-energize the

Hydraulic
System
purposes. When installing the orifice in the man- solenoid. Repeat the flush while energized proce-
ifold, make sure that the orifice is flat in the base of dure 5 or 6 times. Particles as fine as talcum powder
the port. Manifold damage is possible if the orifice can affect the operation of high pressure hydraulic
is cocked in the port. valves. Remove solenoid from cartridge.
Solenoid Operated, Relief and Logic Control Car- 6. Reinstall the cartridge valve into the manifold:
tridge Valves (Fig. 67)
A. Lubricate new O-rings and backup rings of seal
1. Make sure the manifold is clean before removing the kit with clean hydraulic oil and install on cartridge.
cartridge valve and seal kit. The O-rings and backup rings must be arranged
properly on the cartridge valve for proper operation
2. If solenoid valve is to be removed from manifold, re- and sealing.
move nut securing solenoid to the cartridge valve. Care-
fully slide solenoid off the valve. IMPORTANT: Use care when installing the car-
tridge valve. Slight bending or distortion of the
IMPORTANT: Use care when removing the cartridge stem tube can cause binding and malfunction.
valve. Slight bending or distortion of the stem tube Make sure that deep well socket fully engages
can cause binding and malfunction. Make sure that the valve base.
deep well socket fully engages the valve base.
B. Lubricate threads on cartridge valve with clean
3. Make sure manifold is clean before removing the hydraulic oil. Thread cartridge valve carefully into
cartridge valve. Remove cartridge valve from manifold correct manifold port. The valve should go in easily
with a deep well socket. Note location of O--rings and without binding.
backup rings on valve. Remove and discard removed
seal kit. C. Torque cartridge valve using a deep well socket
to specification shown in Figure 67.
4. Visually inspect the manifold port and cartridge valve
for damage to sealing surfaces, damaged threads and 7. For solenoid valve, slide solenoid coil onto the car-
contamination. tridge valve. Install and torque nut to 60 in--lb (6.7 N--m).
A. Contamination may cause valves to stick or hang 8. If problems still exist, remove valve and clean again
up. Contamination can become lodged in small valve or replace valve.
orifices or seal areas causing valve malfunction.

B. If valve sealing surfaces appear pitted or dam-

aged, the hydraulic system may be overheating or
there may be water in the system.

Greensmaster 3150 Page 4 -- 91 Hydraulic System

Rotary Cartridge Valve IMPORTANT: Use care when installing the rotary
cartridge valve. Slight bending or distortion of
1. Remove rotary handle from valve (Fig. 68): the stem tube can cause binding and malfunc-
tion. Make sure that deep well socket fully en-
A. Loosen two (2) set screws that secure handle gages the valve base.
cap.
B. Lubricate threads on cartridge valve with clean
B. Remove screw and then lift handle cap from hydraulic oil. Thread rotary cartridge valve carefully
valve. into the manifold port. The valve should go in easily
without binding. Torque valve to specification shown
C. Locate and retrieve detent pin, compression
in Figure 67.
spring, bushing and lip seal. The sleeve bearing
should stay in the cap. 6. Install rotary handle (Fig. 68):
D. Loosen two (2) set screws that secure handle A. Place handle base on flow control valve and posi-
base to flow control valve and remove base. tion alignment mark on base with number 1 on man-
ifold. Secure base with two (2) set screws. Apply a
IMPORTANT: Use care when removing the rotary
light coating of grease to chamfer on top of base to
cartridge valve. Slight bending or distortion of the
ease seal installation.
stem tube can cause binding and malfunction. Make
sure that deep well socket fully engages the valve B. Make sure that sleeve bearing is in handle cap. If
base. necessary, press sleeve bearing into cap. Install lip
seal on cap with seal lip facing down.
2. Make sure manifold is clean before removing the
rotary cartridge valve. Remove cartridge valve from C. While pressing on the cap to keep the lip seal in
manifold with a deep well socket. Note location of O-- place, rotate cap in a clockwise direction until the ar-
rings and backup rings on valve. Remove and discard row on the cap aligns with number 1 on the manifold.
removed seal kit. By rotating the cap clockwise, the valve will remain
closed. Install screw to retain cap.
3. Visually inspect the manifold port and cartridge valve
for damage to sealing surfaces, damaged threads and D. Make sure that alignment marks on cap and base
contamination. are in line and that arrow on cap is pointing to number
1 on manifold. Tighten two (2) set screws to secure
A. Contamination may cause valves to stick or hang
handle cap.
up, it can become lodged in small valve orifices or
seal areas causing valve malfunction.
8
B. If sealing surfaces appear pitted or damaged, the
hydraulic system may be overheating or there may
be water in the system. 6 2

9
CAUTION 10
11
Use eye protection such as goggles when using 4
compressed air. 3 5
7
4. If necessary, clean cartridge valve using clean min- 1
eral spirits. Submerge valve in clean mineral spirits to
flush out contamination. Particles as fine as talcum pow-
der can affect the operation of high pressure hydraulic
valves. Clean and dry with compressed air.

5. Reinstall rotary cartridge valve into manifold port: Figure 68

1. Handle Base 7. Set Screw (2 used)
A. Lubricate new O-rings and backup rings of seal 2. Handle Cap 8. Screw
3. Detent Pin 9. Lip Seal
kit with clean hydraulic oil and install. The O-rings 4. Compression Spring 10. Sleeve Bearing
and backup rings of seal kit must be arranged prop- 5. Bushing 11. Flow Control Valve
erly on the cartridge valve for proper operation and 6. Set Screw (2 used)
sealing.
Hydraulic System Page 4 -- 92 Greensmaster 3150
Mow/Backlap Spool (Fig. 69)
1 2
1. Remove mow/backlap spool from manifold: 4
Loctite #603
A. Remove backlap switch from manifold before re- 3
moving mow/backlap spool. Remove dowel pin and
ball from manifold port after switch is removed. Re-
move and discard O--ring from switch. 6
20 ft--lb
B. Remove lower retaining ring from mow/backlap (27 N--m) 5
spool. Raise mow/backlap spool to allow access to
retaining ring on upper end of spool. Remove upper
retaining ring.

C. Push spool down until lower O--ring and back--up

ring are exposed on bottom of manifold. Remove
lower O--ring and back--up ring from spool.

D. Pull spool up and out of manifold. Remove O--

rings and back--up ring from spool.
8
E. Discard removed O--rings and back--up rings. 10

2. Visually inspect the spool and manifold port for dam-

Hydraulic
4

System
age to the sealing surfaces and contamination.
7 3
3. Install mow/backlap spool into manifold:
1
A. Install O--rings and back--up ring to upper 9
grooves on spool. Apply a light coating of grease to
O--rings. Figure 69
1. Retaining ring 6. Rotary spool
B. Carefully push spool down into manifold port until 2. O--ring 7. Ball
3. Back--up ring 8. Dowel pin
lower O--ring and back--up ring groove is exposed on 4. O--ring 9. O--ring
bottom of manifold. Install lower O--ring and back--up 5. Spool handle 10. Backlap switch
ring to spool. Apply a light coating of grease to O--
ring.

C. Install lower retaining ring to spool.

D. Carefully raise mow/backlap spool until upper re-

taining ring groove on spool is exposed on top of
manifold. Install upper retaining ring.

E. If handle was removed from spool, position spool

so handle location of spool is between stop pins in
manifold. Apply Loctite #603 Retaining Compound
(or equivalent) to threads on handle and install han-
dle into spool.

F. Place ball and dowel pin in backlap switch man-

ifold port. Install new O--ring onto backlap switch.
Thread backlap switch into port and torque 20 ft--lb
(27 N--m).

Greensmaster 3150 Page 4 -- 93 Hydraulic System

Steering Control Valve

4 5 6
3 8 15
10
2 7 11

1 9

21
27 19 12
20
28
29
18
14
17
16
24 20 to 26 ft--lb
23 13
20 (28 to 35 N--m)
25
22
30

29
28 27

26
31
RIGHT 32

FRONT

Figure 70
1. Steering arm 12. Cap screw (4 used) 23. Straight hydraulic fitting (2 used)
2. Cap screw (2 used) 13. Steering mount 24. O--ring
3. Cap screw 14. Cap screw (6 used) 25. Panel nut (6 used)
4. Set screw 15. Flat washer 26. Steering valve cover
5. Lever 16. Lock nut (2 used) 27. Cap screw (2 used)
6. Handle 17. Lock washer (2 used) 28. Flat washer (2 used)
7. Friction plate 18. Flat washer (2 used) 29. Spacer (2 used)
8. Steering wheel 19. Straight hydraulic fitting (2 used) 30. Knob
9. Hex nut 20. O--ring 31. Lock nut (2 used)
10. Screw 21. O--ring 32. Hair pin
11. Steering wheel cover 22. Steering valve

Hydraulic System Page 4 -- 94 Greensmaster 3150

Removal (Fig. 70) Installation (Fig. 70)

1. Before removing any parts from the hydraulic sys- 1. If fittings were removed from steering control valve,
tem, park the machine on a level surface, engage the lubricate and place new O--rings onto fittings. Install fit-
parking brake, lower the cutting units and stop the en- tings into steering valve openings. Tighten fittings (see
gine. Hydraulic Fitting Installation in the General Information
section of this chapter).

CAUTION 2. Position steering control valve to steering mount.

3. Using labels placed during control valve removal, lu-

Before continuing further, read and become fa- bricate new O--rings and connect hydraulic hoses to
miliar with General Precautions for Removing steering control valve. Tighten hose connections (see
and Installing Hydraulic System Components. Hydraulic Hose and Tube Installation in the General In-
formation section of this chapter).
2. Remove screw (item 10) and steering wheel cover 4. Install any cable ties removed from the hose assem-
(item 11) from the steering wheel. blies.
3. Remove steering wheel nut (item 9), flat washer 5. Slide steering control valve (with hydraulic hoses at-
(item 15) and steering wheel from the steering valve tached) to steering mount. Secure steering valve to
shaft. mount with four (4) cap screws (item 12).
4. Remove screws (item 14) and remove the steering 6. Install steering valve cover (item 26) with cap screws

Hydraulic
System
valve cover (item 26). (item 14).
5. Remove cap screws (item 12) that secure steering 7. Install steering wheel, flat washer (item 15) and nut
control valve to steering mount. (item 9). Torque nut from 20 to 26 ft--lb (28 to 35 N--m).
6. Lower steering control valve (with hydraulic hoses 8. Secure steering wheel cover (item 11) with screw
attached) from steering mount. (item 10).
7. Label all hydraulic hoses connected to the steering
control valve for assembly purposes. Thoroughly clean 2
hydraulic hose ends. 3
1
8. Disconnect hydraulic hoses from fittings on the
steering control valve. Allow hoses to drain into a suit-
able container. Cap or plug hoses and control valve fit-
tings to prevent contamination.

9. Remove steering control valve from machine.

10.If necessary, remove hydraulic fittings and O--rings 5 4

from steering control valve. Discard all removed O--
rings. Figure 71
1. T port 4. P port
2. R port 5. L port
3. E/Ls port

Greensmaster 3150 Page 4 -- 95 Hydraulic System

Steering Control Valve Service

16
15
13 14
11
12
11

7 8
9 10
6 25

5
26 v

4
3
2 27
28 24
29
23

22
21

1 18
20 20 to 24 ft--lb
(27 to 33 N--m)
18
17 18 19

Figure 72
1. Plug 11. Thrust washer 21. Inner gearwheel
2. Plug 12. Bearing 22. End cover
3. Spring 13. Cross pin 23. O--ring (5 used)
4. Relief valve 14. Ring 24. Cap screw (5 used)
5. Dust seal 15. Sleeve 25. Spring set
6. T port 16. Spool 26. Ball stop
7. Housing 17. Cardan shaft 27. Ball
8. R port 18. O--ring 28. P port
9. E port 19. Distribution plate 29. L port
10. Shaft seal 20. Outer gearwheel

NOTE: For service of the steering control valve shown

in Figure 72, see the Sauer/Danfoss Steering Unit Type
OSPM Service Manual at the end of this chapter.

Hydraulic System Page 4 -- 96 Greensmaster 3150

 Hydraulic
System
This page is intentionally blank.

Greensmaster 3150 Page 4 -- 97 Hydraulic System

Steering Cylinder

5 6
4

3
2
7

70 to 90 ft--lb
(95 to 122 N--m)

3
9
4 8
10 12
11

34 16

15
1 13

18 17
19
20
21
22
14 23
20
19
18
27
33 24
RIGHT 32 25
31
FRONT 16
30 29 28 26 65 to 85 ft--lb
(89 to 115 N--m)

Figure 73
1. Steering cylinder 13. Washer 24. Castor fork
2. Bearing cup (2 used) 14. Lock nut 25. Flange head screw (3 used)
3. Bearing cone (2 used) 15. Cap screw (2 used) 26. Lock nut
4. Washer (4 used) 16. Spacer (2 used) 27. Castor bolt
5. Slotted hex nut 17. Hub assembly 28. Jam nut (2 used)
6. Cotter pin 18. Seal (2 used) 29. Flat washer
7. Grease fitting 19. Bearing cone (2 used) 30. Adapter plate
8. Jam nut 20. Bearing cup (2 used) 31. Lock nut (2 used)
9. Rod end 21. Hub 32. Lock nut (3 used)
10. Dust seal 22. Grease fitting 33. Motor adapter plate
11. Lug nut (4 used) 23. Drive stud (4 used) 34. Grease fitting
12. Wheel assembly

Hydraulic System Page 4 -- 98 Greensmaster 3150

Removal (Fig. 73) Installation (Fig. 73)

1. Before removing any parts from the hydraulic sys- 1. If rod end (item 9) was removed from cylinder rod, ful-
tem, park machine on a level surface, set brake, lower ly retract cylinder shaft and thread rod end onto shaft so
cutting units and stop engine. that distance is as measured during removal process
(Fig. 74). Tighten jam nut to retain rod end.

CAUTION 2. Install hydraulic fittings and O--rings to the steering

cylinder. Make sure that fittings are orientated as noted
during removal.
Before continuing further, read and become fa-
miliar with General Precautions for Removing 3. Thoroughly clean tapered surfaces of steering cylin-
and Installing Hydraulic System Components. der ball joint and cylinder attachment bore on castor
fork.
2. Label all hose connections for assembly purposes 4. Secure cylinder rod end to the castor fork with two (2)
jam nuts and flat washer. Install first jam nut and torque
3. Remove hose assemblies and O--rings from hydrau-
from 65 to 85 ft--lb (89 to 115 N--m). Then, while holding
lic fittings at the steering cylinder. Allow hoses to drain
first jam nut with wrench, tighten second jam nut and
into a suitable container.
torque from 65 to 85 ft--lb (89 to 115 N--m).
4. Remove lock nut and flat washer from barrel mount-
5. Install steering cylinder over barrel mounting stud
ing stud. Remove steering cylinder from barrel stud.
and secure with flat washer and lock nut.

Hydraulic
5. Remove two (2) jam nuts and flat washer from cylin-

System
6. Connect hydraulic hoses and O--rings to the hydrau-
der rod end at rear wheel castor fork.
lic fittings. Tighten hose connections (see Hydraulic
6. Remove steering cylinder from traction unit. Hose and Tube Installation in the General Information
section of this chapter).
7. Note fitting orientation on cylinder for assembly pur-
poses. Remove fittings and O--rings from cylinder ports.
Discard O--rings.

8. If rod end (item 9) is to be removed from cylinder rod,

fully retract cylinder rod and measure distance from cen-
ter of rod end to end of cylinder for assembly purposes
(Fig. 74). Record measured distance. Loosen jam nut
and then remove rod end and jam nut from cylinder rod. MEASURE LENGTH
FOR ASSEMBLY PURPOSES

Figure 74

Greensmaster 3150 Page 4 -- 99 Hydraulic System

Steering Cylinder Service

4
12
v
17

16

14 15
13 3 2
12 8 5
6
4 7

11
10 1
9
5 6
7
3
2

Figure 75
1. Seal kit 7. Wear ring 13. Piston
2. Rod wiper 8. O--ring 14. Retaining ring
3. Seal 9. Back--up ring 15. Rod
4. Head 10. Seal 16. Grease fitting
5. Back--up ring 11. Wear ring 17. Barrel
6. O--ring 12. Retaining ring

NOTE: The steering cylinder design does not allow re-

moval of the piston (item 13) from the rod. This cylinder
design prevents replacing the O--ring (item 8) or retain-
ing ring (item 14) on the inside of the piston. If leakage
or damage exists at the piston O--ring, steering cylinder
replacement will be necessary.

Hydraulic System Page 4 -- 100 Greensmaster 3150

Disassembly (Fig. 75) Assembly (Fig. 75)

1. Pump oil out of cylinder into a drain pan by slowly 1. Identify components from seal kit that are to be used
moving rod in and out of cylinder bore. Plug ports and in cylinder repair. Put a coating of clean hydraulic oil on
clean outside of cylinder. all new seals, back--up rings and O--rings.

IMPORTANT: To prevent damage when clamping 2. Install new wear rings (item 7), seals (item 3), rod
cylinder barrel in a vise, clamp only on ball joint wipers (item 2), back--up rings (item 5) and O--rings
location. Do not clamp the vise jaws against the cyl- (item 6) onto both heads (item 4). Position backup ring,
inder barrel or rod surface. seal and wear ring to the piston (item 13).

2. Mount cylinder in a vise by clamping vise on barrel IMPORTANT: During cylinder assembly, pay careful
ball joint location of cylinder. Use of a vise with soft jaws attention to the retaining ring slots in the barrel to
is recommended. insure that the piston and head seals do not lodge
in the slots.
3. Remove both heads from the barrel:
3. Coat all internal cylinder parts with a light coat of
A. Use a spanner wrench to rotate head clockwise clean hydraulic oil. Carefully slide rod assembly into the
until the edge of the retaining ring appears in the bar- barrel being careful to not damage seals on piston.
rel opening.
4. Lubricate head (item 4) assemblies with clean hy-
B. Insert a screwdriver under the beveled edge of draulic oil and carefully slide them onto rod and into bar-
the retaining ring to start the retaining ring through rel.
the opening. Rotate the head counter--clockwise to

Hydraulic
System
remove retaining ring from barrel and head. 5. Secure both heads to barrel:

C. Slide head from cylinder barrel and rod. A. Align retaining ring hole in the head with the ac-
cess slot in the barrel.
4. Grasp end of rod and use a twisting and pulling mo-
tion to carefully extract rod assembly (with piston) from B. Insert the retaining ring hook into the hole and ro-
cylinder barrel. tate head clockwise until the retaining ring is com-
pletely pulled into the barrel and the ring ends are
NOTE: Piston (item 13) is not removable from cylinder covered.
rod.
C. Apply silicone sealer to barrel access slot.
5. Remove and discard rod wipers (item 2), seals (item
3), O--rings (item 6), back--up rings (item 5) and wear
rings (item 7) from both heads (item 4). Also, remove
seal (item10), back--up ring (item 9) and wear ring (item
11) from piston.

CAUTION
Use eye protection such as goggles when using
compressed air to dry cylinder parts.

6. Wash cylinder parts in clean solvent. Dry parts with

compressed air. Do not wipe parts dry with paper or cloth
towels. Lint from towels in a hydraulic system will cause
damage.

7. Carefully inspect internal surface of barrel for dam-

age (deep scratches, out--of--round, etc). Inspect rod,
both heads and piston for evidence of excessive scor-
ing, pitting or wear. Replace entire steering cylinder if in-
ternal components are damaged.

Greensmaster 3150 Page 4 -- 101 Hydraulic System

Leak Detector

Antiseize
Lubricant
30 to 60 in--lb
RIGHT (3.4 to 6.7 N--m)

FRONT 19 14
20
16
17
3
13
29
8
27 12
30 12
28
7
11 18
5
15
17 to 21 ft--lb 6
(23 to 28 N--m)
40 to 50 ft--lb
9 (55 to 67 N--m)
10 22
4

1 23 1
25 31
2
2
31 2
24

21

2
1

26
1

17 to 21 ft--lb
(23 to 28 N--m)

Figure 76
1. Hose clamp (4 used) 12. Neoprene washer (4 used) 22. Cap screw (2 used)
2. O--ring 13. Flat washer (2 used) 23. Lock washer (2 used)
3. O--ring 14. Cap screw (2 used) 24. Solenoid valve assembly
4. Hydraulic reservoir 15. Leak detector tank 25. Overflow hose
5. Hose (to tee fitting) 16. Plug 26. Tank valve hose
6. Straight barb fitting 17. Cap screw (2 used) 27. Hose clamp
7. Hose clamp 18. Long spacer (2 used) 28. Purge hose assembly
8. Canister bracket 19. Carbon canister 29. Hose clamp
9. Hose clamp (2 used) 20. Cable tie (2 used) 30. Vent hose (to fuel tank vent)
10. Valve hose 21. 90o barb fitting 31. 90o barb fitting (2 used)
11. Short spacer (2 used)

NOTE: See Turf Guardiant Leak Detector System in

Chapter 5 -- Electrical System for leak detector opera-
tion information.
Hydraulic System Page 4 -- 102 Greensmaster 3150
Removal (Fig. 76)
PUMP INLET HOSE
1. Before removing any parts from the hydraulic sys-
tem, park machine on a level surface, set brake, lower
cutting units and stop engine.

CAUTION
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 hydraulic pump assembly
to collect hydraulic oil.
Figure 77
3. Clamp pump inlet hose to control drainage. Remove
inlet hose from gear pump (Fig. 77). Release clamp from
hose and drain about 2 gallons (7.6 liters) from the hy- Loctite #242 10 in--lb
draulic reservoir. (1.1 N--m)

Hydraulic
System
4. Clamp pump inlet hose to prevent draining additional
hydraulic oil. 4
5
5. Unplug leak detector solenoid harness from the ma- 1
chine wire harness. 6
2
3
6. Remove four (4) cap screws (items 14 and 17), flat
washers (item 13), neoprene washers (item 12) and
spacers (items 11 and 18).
35 ft--lb 4
7. Carefully position carbon canister and bracket away (47 N--m)
from leak detector tank. Figure 78
8. Loosen either hose clamp (item 9) and disconnect 1. Manifold 4. O--ring
2. Valve seal 5. Solenoid coil
overflow hose (item 25). 3. Solenoid valve 6. Nut

9. Lift leak detector tank slightly, loosen hose clamp

Installation (Fig. 76)
(item 1) and disconnect valve hose (item 10) at barb fit-
ting (item 31) on solenoid valve assembly. Remove leak 1. During assembly, coat all O--rings with clean hydrau-
detector tank assembly. lic oil.
10.If necessary, remove solenoid valve assembly, fit- 2. If removed, assemble solenoid valve manifold (Fig
tings and hoses using Figure 76 as a guide. 78):
11. If needed, disassemble solenoid valve manifold us- A. When installing cartridge valve, torque valve 35
ing Figure 78 as a guide. ft--lb (47 N--m).
12.Inspect leak detector components for the following: B. When installing solenoid coil, apply a drop of Loc-
tite #242 (or equivalent) to threads of valve and
A. Leaking, cracked or damaged leak detector tank.
torque nut 10 in--lb (1.1 N--m).
B. Worn or leaking hydraulic hoses. Replace if nec-
C. If fittings were removed from manifold, torque fit-
essary.
tings from 40 to 50 ft--lb (55 to 67 N--m).
C. Visibly worn or damaged parts.

Greensmaster 3150 Page 4 -- 103 Hydraulic System

3. If removed, install solenoid valve assembly, fittings 8. Connect leak detector harness to main wire harness.
and hoses using Figure 76 as a guide.
9. Connect pump inlet hose to gear pump and secure
A. Torque fittings to values shown in Figure 76. with hose clamp (Fig. 77).

B. If solenoid valve manifold was removed from hy- NOTE: Monitor hydraulic fluid level in sight window on
draulic reservoir, apply antiseize lubricant to threads leak detector tank. As air is removed from the hydraulic
of cap screws (item 22). Torque screws from 30 to 60 circuit, fluid level may need to be topped off after initial
in--lb (3.4 to 6.7 N--m). fill.

4. Position leak detector tank to hydraulic reservoir. 10.Remove cap from hydraulic reservoir and slowly fill
Connect valve hose (item 10) to solenoid valve fitting to the cold fill level mark.
and secure with hose clamp (item 1).
11. Check leak detector with ignition key switch in RUN
5. Connect overflow hose (item 25) and secure with position. The leak detector alarm should sound when
hose clamp (item 9). leak detector test switch is held down for one (1) second.

6. Position carbon canister and bracket to the leak de- 12.If the alarm fails to sound, check to see if all connec-
tector tank. tions are secure.

IMPORTANT: Do not over tighten cap screws that 13.Verify leak detector operation.
secure leak detector tank. Threads in hydraulic
reservoir may become damaged if screws are over
tightened.

7. Secure leak detector tank to hydraulic reservoir:

A. Apply antiseize lubricant to threads of cap screws

(items 14 and 17) used to secure leak detector tank.

B. Install four (4) cap screws (items 14 and 17), flat

washers (item 13), neoprene washers (item 12) and
spacers (items 11 and 18).

C. Torque cap screws from 30 to 60 in--lb (3.4 to 6.7

N--m).

Hydraulic System Page 4 -- 104 Greensmaster 3150

 Hydraulic
System
This page is intentionally blank.

Greensmaster 3150 Page 4 -- 105 Hydraulic System

Hydraulic Reservoir

Antiseize
19 14 Lubricant
30 to 60 in--lb
RIGHT 16 (3.4 to 6.7 N--m)
17
3
FRONT 13
8
12
12
11 18
17 to 21 ft--lb
(23 to 28 N--m) 15 40 to 50 ft--lb
6 (55 to 67 N--m)

9
5
110 to 140 in--lb
10 22
(12.5 to 15.8 N--m) 4

1
1 23
25 31
2
2
17 to 21 ft--lb
32 31 2 (23 to 28 N--m)
20
24

21

2 2
1
33
34 26
35 38 1

17 to 21 ft--lb 7
(23 to 28 N--m) 41 40
37 39
28 30
27 70 to 80 ft--lb
36 29
Antiseize (95 to 108 N--m)
Lubricant
70 to 80 ft--lb 30 to 60 in--lb
(95 to 108 N--m) (3.4 to 6.7 N--m)

Figure 79
1. Hose clamp (4 used) 15. Leak detector tank 29. Cap screw (3 used) v
2. O--ring 16. Plug 30. Flat washer (3 used)
3. O--ring 17. Cap screw (2 used) 31. 90o barb fitting (2 used)
4. Hydraulic reservoir 18. Long spacer (2 used) 32. O--ring
5. Reservoir cap 19. Carbon canister 33. Straight hydraulic fitting
6. Straight barb fitting 20. Oil level sensor 34. O--ring
7. Strainer 21. 90o barb fitting 35. Hydraulic hose
8. Canister bracket 22. Cap screw (2 used) 36. Hydraulic hose
9. Hose clamp (2 used) 23. Lock washer (2 used) 37. O--ring
10. Valve hose 24. Solenoid valve assembly 38. O--ring
11. Short spacer (2 used) 25. Overflow hose 39. Hydraulic hose (pump inlet)
12. Neoprene washer (4 used) 26. Tank valve hose 40. Hose clamp
13. Flat washer (2 used) 27. Hose clamp 41. Flange bushing (3 used)
14. Cap screw (2 used) 28. Barbed fitting

Hydraulic System Page 4 -- 106 Greensmaster 3150

Removing Hydraulic Reservoir (Fig. 79) 3. Position hydraulic reservoir onto the machine frame.

1. Before removing any parts from the hydraulic sys- IMPORTANT: After hydraulic reservoir is installed,
tem, park machine on a level surface, set brake, lower make sure that clearance between hydraulic reser-
cutting units and stop engine. voir and fuel tank if from 0.125” to 0.375” (3.2 to 9.5
mm).

CAUTION 4. Apply antiseize lubricant to threads of three (3) cap

screws (item 29). Secure hydraulic reservoir to the ma-
chine frame with three (3) cap screws, flat washers (item
Before continuing further, read and become fa- 30) and bushings (item 41). Torque cap screws from 30
miliar with General Precautions for Removing to 60 in--lb (3.4 to 6.7 N--m).
and Installing Hydraulic System Components.
5. Using notes taken during reservoir removal, connect
2. Remove leak detector assembly (see Leak Detector hydraulic hoses to the reservoir fittings. Tighten hose
in this section). connections (see Hydraulic Hose and Tube Installation
in the General Information section of this chapter).
3. Drain remaining hydraulic oil from hydraulic reser-
voir through pump inlet hose into a suitable container. 6. Secure pump inlet hose to gear pump with hose
clamp (Fig. 80).
4. Unplug wire harness connector from oil level sensor
(item 20). 7. Connect wire harness connector to oil level sensor
(item 20).

Hydraulic
5. Label all hydraulic reservoir hose connections for as-

System
sembly purposes. 8. Install leak detector assembly (see Leak Detector in
this section). Make sure that reservoir oil level is correct.
6. Remove hose assemblies from reservoir hydraulic
fittings. Allow hoses to drain into a suitable container. PUMP INLET HOSE
7. Remove three (3) cap screws (item 29), flat washers
(item 30) and bushings (41) securing the hydraulic
reservoir to the machine frame.

8. Remove hydraulic reservoir from machine.

9. Remove hydraulic fittings and oil level sensor from

hydraulic reservoir if necessary.

Inspecting Reservoir Parts (Fig. 79)

1. Clean reservoir and filler screen with solvent.

2. Inspect reservoir for leaks, cracks or other damage.

Figure 80
3. Replace hydraulic hoses if worn or leaking.

Installing Hydraulic Reservoir (Fig. 79)

2
1. Install all removed hydraulic fittings into hydraulic
reservoir ports. Torque fittings to values shown in Figure
79.

2. If oil level sensor was removed from reservoir, install

sensor in reservoir making sure that arrow on sensor is
pointing down (Fig. 81). Torque sensor nut from 110 to 1
140 in--lb (12.5 to 15.8 N--m).
Figure 81
1. Oil level sensor 2. Sensor arrow

Greensmaster 3150 Page 4 -- 107 Hydraulic System

 This page is intentionally blank.

Hydraulic System Page 4 -- 108 Greensmaster 3150

 Chapter 5

Electrical System
Table of Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Neutral and Mow Switches . . . . . . . . . . . . . . . . . . 15
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Parking Brake Sensor . . . . . . . . . . . . . . . . . . . . . . 16
Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Joystick Raise and Lower Switches . . . . . . . . . . . 17
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Lower Reels Time Delay . . . . . . . . . . . . . . . . . . . . 18
TURF GUARDIANt LEAK DETECTOR Starter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . 5 Solenoid Valve Coils . . . . . . . . . . . . . . . . . . . . . . . . 20
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 6 Backlap Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
General Run & Transport Problems . . . . . . . . . . . . 8 Fusible Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cutting Unit Operating Problems . . . . . . . . . . . . . . 9 Leak Detector Test/Light Switch . . . . . . . . . . . . . . 24
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . . 11 Leak Detector Alarm and Delay Timer . . . . . . . . 25
Battery Test (Open Circuit) . . . . . . . . . . . . . . . . . . . 11 Leak Detector Float Sensor . . . . . . . . . . . . . . . . . 26
Charging System Test . . . . . . . . . . . . . . . . . . . . . . . 11 Leak Detector Solenoid Valve . . . . . . . . . . . . . . . . 27
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . 12 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 28
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Verify Interlock System Operation . . . . . . . . . . . . 28
Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Electrical
System
Safety Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Greensmaster 3150 Page 5 -- 1 Electrical System

General Information

Operator’s Manual
The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for your Greensmaster 3150. Refer to that pub-
lication for additional information when servicing the
machine.

Electrical Drawings
The electrical schematic and other electrical drawings
for the Greensmaster 3150 are located in Chapter 9 --
Foldout Drawings.

Electrical System Page 5 -- 2 Greensmaster 3150

Special Tools
Order special tools from your Toro Distributor. Some
tools may also be available from a local supplier.

Multimeter
The multimeter can test electrical components and cir-
cuits for current, resistance or voltage. Obtain this tool
locally.

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-

Electrical
tective skin which helps waterproof electrical switches

System
and contacts.

Toro Part Number: TOR50547

Figure 2

Battery Terminal Protector

Aerosol spray that should be used on battery terminals
to reduce corrosion problems. Apply terminal protector
after the battery cable has been secured to the battery
terminal.

Toro Part Number: 107--0392

Figure 3

Greensmaster 3150 Page 5 -- 3 Electrical System

Dielectric Lubricant/Sealant
Dielectric lubricant should be used to prevent corrosion
of connection terminals. To ensure complete coating of
terminals, liberally apply lubricant to both component
and wire harness connector, plug connector to compo-
nent, unplug connector, reapply lubricant to both sur-
faces and reconnect harness connector to component.
Connectors should be thoroughly packed with lubricant
for effective results.

Toro Part Number: 107--0342 Figure 4

Battery Hydrometer
Use the Battery Hydrometer when measuring specific
gravity of battery electrolyte. Obtain this tool locally.

Figure 5

Electrical System Page 5 -- 4 Greensmaster 3150

Turf Guardiant Leak Detector System Operation

Before Start-Up (Cold Oil)

With ignition switch in the OFF position, solenoid valve
is open. Before start-up, hydraulic fluid is at level mark AUXILIARY FLOAT SENSOR
of sight gauge (oil cold). Float is in raised position, keep- TANK (raised/open)
ing alarm circuit open.
SIGHT
GAUGE
ALARM
(off)

SOLENOID
VALVE
(open)

MAIN HYDRAULIC TANK

Figure 6

Normal Operation (Warm Oil)

When ignition switch is turned to the RUN position, sole-
noid valve closes. During normal operation, hydraulic AUXILIARY FLOAT SENSOR
fluid expands, causing it to overflow into auxiliary tank. TANK (raised/open)
The float stays in the raised position keeping alarm cir-
cuit open. SIGHT

Electrical
System
GAUGE
ALARM
(off)

SOLENOID
VALVE
(closed)

MAIN HYDRAULIC TANK

Figure 7

Leak Alert!
If hydraulic fluid leaks during operation, the fluid level in
the main hydraulic tank drops. This causes the float to AUXILIARY FLOAT SENSOR
TANK (lowered/closed)
lower, closing the alarm circuit. The alarm will sound af-
ter a one second time delay.
SIGHT
GAUGE
NOTE: During normal operation, with cutting units low- ALARM
ered, approximately 5 oz (148 ml) of hydraulic fluid will (off)
leak before the float closes the alarm circuit and acti-
vates the alarm. SOLENOID
VALVE
(closed)

MAIN HYDRAULIC TANK

Figure 8
Greensmaster 3150 Page 5 -- 5 Electrical System
Troubleshooting
For effective troubleshooting and repairs, you must
CAUTION have a good understanding of the electrical circuits and
components used on this machine (see Chapter 9 --
Foldout Drawings).
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 solenoid clicks, but starter will not crank. Battery charge is low.
NOTE: 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 starter operation.

Starter is faulty.

Nothing happens when start attempt is made. Functional control lever is not in the neutral position.

Battery cables are loose or corroded.

Battery ground to frame is loose or corroded.

Fuse F1 (20 amp) is loose or faulty.

Fuse F3 (10 amp) is loose or faulty.

Fusible link at starter solenoid (included in main wire

harness) is faulty.

Wiring to the start circuit components is loose,

corroded or damaged (see Electrical Schematic and
Circuit Diagrams in Chapter 9 -- Foldout Drawings).

Start safety relay (K2) is faulty.

Neutral switch is out of adjustment or faulty.

Starter solenoid fusible link is faulty.

Ignition switch is faulty.

Starter solenoid is faulty.

Fuse block is faulty.

Battery is faulty.

Electrical System Page 5 -- 6 Greensmaster 3150

Starting Problems (continued)

Problem Possible Causes

Engine cranks, but does not start. Wiring to start circuits is loose, corroded or damaged
(see Electrical Schematic and Circuit Diagrams in
Chapter 9 -- Foldout Drawings).

Wiring to engine is is loose, corroded or damaged (see

Electrical Schematic and Circuit Diagrams in Chapter 9
-- Foldout Drawings).

Diode D1--A circuit is open.

Engine or fuel system is malfunctioning (see Chapter 3

-- Engine).

Kill relay (K1) is faulty.

Engine and fuel may be too cold.

Engine fuel solenoid is faulty.

Engine cranks (but should not) with the functional Neutral switch is out of adjustment, faulty or short
control lever in the MOW or TRANSPORT position. circuited.

Electrical
System

Greensmaster 3150 Page 5 -- 7 Electrical System

General Run and Transport Problems

Problem Possible Causes

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).
seat.
Parking brake is set.

Parking brake sensor is faulty.

Seat switch is faulty.

Seat switch wiring is loose, corroded or damaged.

Battery does not charge. Wiring to the charging circuit components is loose,
corroded or damaged (see Electrical Schematic and
Circuit Diagrams in Chapter 9 -- Foldout Drawings).

Voltage regulator is loose or not grounded to engine.

Voltage regulator is faulty.

Alternator stator (under engine flywheel) is faulty.

Alternator fusible link (included in engine wire harness)

is open.

Ignition switch is faulty.

Battery is faulty.

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 components are faulty or

disconnected (see Electrical Schematic and Circuit
Diagrams in Chapter 9 -- Foldout Drawings).

Engine or fuel system is malfunctioning (see Chapter 3

-- Engine).

Electrical System Page 5 -- 8 Greensmaster 3150

Cutting Unit Operating Problems

Problem Possible Causes

Cutting units run (but should not) when raised. Joystick relay (K3) is faulty.

Mow relay (K4) is faulty.

Mow switch is out of adjustment or faulty.

A hydraulic problem exists (see Chapter 4 -- Hydraulic

System).

Cutting units do not run when lowered with the Wiring to run/mow/backlap circuits components is
functional control lever in the MOW position. loose, corroded or damaged (see Electrical Schematic
and Circuit Diagrams in Chapter 9 -- Foldout
Drawings).

Fuse block or fuse is faulty.

Solenoid coil S1R1 is faulty.

Mow switch and/or mow relay (K4) is faulty.

Raise or lower switch and/or joystick relay (K3) is

faulty.

A hydraulic problem exists (see Chapter 4 -- Hydraulic

System).

Cutting units will not raise. Wiring to raise circuit components is loose, corroded or

Electrical
System
damaged (see Electrical Schematic and Circuit
Diagrams in Chapter 9 -- Foldout Drawings).

Fuse block or fuse is faulty.

Diode D3 is open.

Raise switch is faulty.

Raise relay (K6) is faulty.

Solenoid coil S3 and/or S2 is faulty.

A hydraulic problem exists (see Chapter 4 -- Hydraulic

System).

Greensmaster 3150 Page 5 -- 9 Electrical System

Cutting Unit Operating Problems (Continued)

Problem Possible Causes

Cutting units will not lower. Wiring to lower circuit components is loose, corroded
or damaged (see Electrical Schematic and Circuit
Diagrams in Chapter 9 -- Foldout Drawings).

Fuse block or fuse is faulty.

Diode D2 is open.

Raise switch is faulty.

Lower switch is faulty.

Joystick relay (K3) is faulty.

Lower relay (K5) is faulty.

6 second delay timer is faulty.

Solenoid coil S2 or S4 is faulty.

Electrical System Page 5 -- 10 Greensmaster 3150

Electrical System Quick Checks

Battery Test
Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level
battery terminals.
12.68 V (or higher) Fully charged (100%)
Set the multimeter to the DC volts setting. The battery 12.45 V 75% charged
should be at a temperature of 60o to 100o F (16o to 38o
12.24 V 50% charged
C). The ignition key should be off and all accessories
turned off. Connect the positive (+) meter lead to the 12.06 V 25% charged
positive battery post and the negative (--) meter lead to 11.89 V 0% charged
the negative battery post.

NOTE: This test provides a relative condition of the bat-

tery. Load testing of the battery will provide additional
and more accurate information.

Charging System Test

This is a simple test used to determine if a charging sys- Start the engine and run at high idle (2850 RPM). Allow
tem is functioning. It will tell you if the charging system the battery to charge for at least three (3) minutes. Re-
has an output, but not its capacity. cord the battery voltage.

Use a digital multimeter set to DC volts. Connect the After running the engine for at least three (3) minutes,
positive (+) multimeter lead to the positive battery post battery voltage should be at least 0.50 volt higher than
and the negative (--) multimeter lead to the negative bat- initial battery voltage.

Electrical
System
tery post. Keep the test leads connected to the battery
posts and record the battery voltage. An example of a charging system that is functioning:

NOTE: Upon starting the engine, the battery voltage At least 0.50 volt over initial battery voltage.
will drop and then should increase once the engine is
running. Initial Battery Voltage = 12.30 v
Battery Voltage after 3 Minute Charge = 12.95 v
NOTE: Depending upon the condition of the battery
charge and battery temperature, the battery voltage will Difference = +0.65 v
increase at different rates as the battery charges.

Greensmaster 3150 Page 5 -- 11 Electrical System

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 CAUTION
doing a continuity check on the switch).
When testing electrical components for continu-
ity with a multimeter (ohms setting), make sure
that power to the circuit has been disconnected.

Ignition Switch
The ignition (key) switch has three (3) positions (OFF,
RUN and START). The terminals are marked as shown
in Figure 9. The circuitry of the ignition switch is shown
in the chart below. With the use of a multimeter (ohms
setting), the switch functions may be tested to determine A
whether continuity exists between the various terminals
B
for each position. Verify continuity between switch termi-
nals.

Y
POSITION CIRCUIT S
OFF NONE X

RUN B + I + A, X + Y
I
START B+I+S

Figure 9

Fuse Block
Fuses can be removed to check continuity. Use a multi-
meter to make sure that fuse resistance is less than 1
ohm. F2 F1
F4 F3
Fuses supply power to the following (Fig. 10):

1. The 20 amp fuse (F1) supplies power to engine run

circuits and also to the hydraulic solenoid coils.

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

run circuits and also to the hydraulic solenoid coils.

4. The 10 amp fuse (F4) supplies power to leak detec-

tor solenoid and the cutting unit control circuits. Figure 10

Electrical System Page 5 -- 12 Greensmaster 3150

Hour Meter
The hour meter is located on the control panel.

Testing
Hobbs
1. Connect the positive (+) terminal of a 12 VDC source QUARTZ
1
to the positive terminal of the hour meter. 00001 10
HOURS
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

(6) minutes.
+
4. Disconnect the voltage source from the hour meter.

5. Replace the hour meter if necessary.

BACK

Figure 11

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 op- 2
erator raises out of the seat, the engine magneto will

Electrical
System
ground and the engine will stop. The switch and its elec-
trical connector are located directly under the seat.

Testing

1. Make sure the engine and ignition switch is OFF. 3

2. Remove seat from the support assembly by remov- 1

1
ing four (4) lock nuts from the seat bolts.

3. Disconnect electrical connector from the seat switch. Figure 12

4. Check the continuity of the switch by connecting a 1. Seat bolts 3. Seat switch
2. Electrical connector
multimeter (ohms setting) across the connector termi-
nals.

5. With no operator in the seat, there should be no con-

tinuity between the terminals.

6. Press directly onto the seat switch through the seat

cushion. There should be continuity as the seat cushion
approaches the bottom of its travel.

7. Connect switch electrical connector.

8. Secure seat to support assembly with removed fas-

teners.

Greensmaster 3150 Page 5 -- 13 Electrical System

Safety Relays
Several safety relays are used on Greensmaster 3150 3. Disconnect wire harness connector from relay that is
machines. The safety relays are identical, five (5) termi- to be tested. If desired, remove relay from machine for
nal relays that are used for circuit control. testing.

Safety Relay Function NOTE: Use illustration in Figure 13 to identify relay ter-
minals.
The start safety relay ensures that the functional control
lever is in neutral before engine starting is allowed. The 4. Use a multimeter (ohms setting) to measure resist-
start relay is located under the control panel on the left ance between the following relay terminals:
side of the operator seat.
A. There should be continuity between terminals
When energized, the kill relay provides a complete cir- 87A and 30
cuit to allow the starter solenoid to be energized. Also,
when de--energized, the kill relay provides a ground for B. There should not be continuity between terminals
the engine magnetos which stops the engine. The kill 87 and 30.
relay is located under the control panel on the left side
of the operator seat. C. Resistance between terminals 86 and 85 (relay
coil) should be from 80 to 90 ohms.
The charge circuit relay allows alternator output to reach
the machine electrical circuits as long as the engine is 5. Connect multimeter (ohms setting) leads to relay ter-
running. The charge circuit relay is located under the op- minals 30 and 87. Ground terminal 86 and apply +12
erator seat. VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as 12 VDC is ap-
When energized, the lower relay allows current flow to plied and removed from terminal 85.
hydraulic solenoid coils S2 and S4 causing the cutting
units to lower. The lower relay is located under the con- 6. Disconnect voltage from terminal 85 and multimeter
trol panel on the left side of the operator seat. lead from terminal 87.

The joystick relay allows cutting unit operation when en- 7. Connect multimeter (ohms setting) leads to relay ter-
ergized by the joystick lower switch. The joystick relay minals 30 and 87A. Apply +12 VDC to terminal 85. The
is located under the control panel on the left side of the relay should break and make continuity between termi-
operator seat. nals 30 and 87A as 12 VDC is applied and removed from
terminal 85.
The mow relay allows the reel engage solenoid coil
(S1R1) to be energized for cutting reel operation. The 8. Disconnect ground, voltage and multimeter leads
mow relay is located under the control panel on the left from relay terminals.
side of the operator seat.
9. Replace relay if testing determines that relay is
When energized, the raise relay allows current flow to faulty.
hydraulic solenoid coils S2 and S3 causing the cutting
10.When testing is complete, secure relay to machine
units to raise. The raise relay is located under the control
if it was removed. Connect wire harness connector to
panel on the left side of the operator seat.
relay.
When in backlap, the backlap relay prevents the cutting
reels from being engaged during engine cranking. The
backlap relay is located near the functional control lever.

NOTE: Refer to Circuit Diagrams in Chapter 9 -- Fold- 86 87A 87

out Drawings for additional relay operation information.

Relay Testing

1. Park machine on a level surface. Make sure the en- 85 30

gine and ignition switch are OFF.

2. Locate relay that is to be tested. Figure 13

Electrical System Page 5 -- 14 Greensmaster 3150

Neutral and Mow Switches
The neutral and mow switches are used to determine
when the functional control lever is in the NEUTRAL or
MOW position. These switches are identical and are
normally open reed switches. They close when the ac- 1
tuator comes in close proximity to the switch. The
switches are attached to the functional control lever 2
bracket under the console panel (Fig. 14). The actuator
is attached to the functional control lever.

Testing 4

1. Park machine on a level surface. Make sure the en-

gine and ignition switch are OFF.

2. Remove console from right side of operator seat. 3

3. Disconnect electrical connectors to both switches.

Check continuity of both switches by connecting a multi-
meter (ohms setting) across the connector terminals.
Figure 14
4. Place the functional control lever in the NEUTRAL
position. The NEUTRAL switch should be closed (conti- 1. Functional control lever 3. Neutral switch
2. Mow switch 4. Actuator
nuity) and the MOW switch should be open (Fig. 14).

5. Place the functional control lever in the MOW posi-

tion. The NEUTRAL switch should be open and the 0.725 to 0.775 inch
MOW switch should be closed (continuity) (Fig. 14). (18.4 to 19.7 mm)

Electrical
System
SWITCH
6. The distance between the sensing end of each
switch and the traction bracket should be from 0.725 to
0.775 inch (18.4 to 19.7 mm) (Fig. 15).

7. To adjust or install actuator, place functional control

lever in the NEUTRAL position. Position actuator in le-
ver until the NEUTRAL switch just closes and then rotate SWITCH
TRACTION BRACKET
actuator two (2) complete turns closer to the NEUTRAL CONNECTOR
LOCATION
switch.
Figure 15
8. When adjusting the switches or actuator, torque jam
nuts from 40 to 60 in--lb (4.5 to 6.7 N--m).

9. After switch or actuator adjustment, check continuity

of both switches and interlock operation (See Verify In-
terlock System Operation in the Service and Repairs
section of this chapter). Readjust switch or actuator if
necessary.

10.Install console to right side of operator seat.

Greensmaster 3150 Page 5 -- 15 Electrical System

Parking Brake Sensor
The parking brake sensor is normally closed and opens
when the operator sets the parking brake. If the function-
al control lever is moved out of neutral (neutral switch
1
opens) and the parking brake is set, the engine magneto
will ground and the engine will stop. The sensor and its
electrical connector are located directly under the oper-
ator foot panel.

Testing
2
1. Park machine on a level surface. Make sure the en- 3
gine and ignition switch are OFF. Set brake and block
front wheels.

2. Disconnect electrical connector from the parking

brake sensor. Figure 16
1. Mounting plate 3. Parking brake sensor
3. Check the continuity of the sensor by connecting a 2. Latch assembly
multimeter (ohms setting) across the connector termi-
nals.

4. With the parking brake set, there should be no conti-

nuity (open) across the sensor terminals.

5. Release the parking brake. There should be continu-

ity (closed) across the sensor terminals.

6. Connect sensor electrical connector. Reset the park-

ing brake.

Electrical System Page 5 -- 16 Greensmaster 3150

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 4
the reels and the front switch to raise them (Fig. 17). The 7
switches are identical and are shown in Figure 18. 4
1
3 12
Testing 2
3
1. Make sure the engine and ignition switch are OFF.
Remove the plastic cover and disconnect the harness 5 11
connectors from the joystick switches.
6
2. Check the continuity of the raise switch by connect-
ing a multimeter (ohms setting) across the switch con- 8
nector terminals as follows: FRONT
9 13
10
A. With the joystick in the rest position, continuity
should only exist between the common and NC ter-
minals (blue and green/black wires). Figure 17
1. Cap screw 8. Screw (4 used)
2. Flat washer 9. Raise switch
B. With the joystick in the raise position, continuity 3. Spring washer (2 used) 10. Speed nut (2 used)
should only exist between the common and NO ter- 4. Bushing (2 used) 11. Lower switch
minals (blue and green/gray wires). 5. Spacer 12. Joystick bracket
6. Joystick 13. Lock nut
7. Spring
3. Check the continuity of the lower switch by connect-
ing a multimeter (ohms setting) across the switch con-
nector terminals as follows:
1

Electrical
A. With the joystick in the rest position, continuity

System
should only exist between the common and NC ter- 2
4
minals (open terminal and green/black wires).

B. With the joystick in the lower position, continuity

should only exist between the common and NO ter- 3
minals (green/black and gray/black wires).

4. After testing, connect the harness connectors to the Figure 18

1. Common terminal 3. NC terminal
joystick switches and reinstall the plastic cover. 2. NO terminal 4. Switch lever

Greensmaster 3150 Page 5 -- 17 Electrical System

Lower Reels Time Delay
The lower reels time delay is a solid state timer used to
energize the lower relay (K5) long enough to make sure
that the cutting units will lower fully when the joystick is
moved. When the lower relay is energized, hydraulic
manifold solenoid valves S2 and S4 are energized caus-
ing the cutting unit lift cylinders to retract and lower the TIME
DELAY
cutting units.

Upon the application of electrical power to the time

delay, the load is energized and the time delay is started.
After six (6) seconds the load is de--energized.

Testing

1. Park machine on a level surface. Make sure the en-

gine and ignition switch are OFF.
Figure 19
2. Raise seat to allow access to lower reels time delay
(Fig. 19).
+ --
3. Connect voltmeter across test load and test load to
timer. Connect 12VDC source to timer and load. Make
INPUT VOLTAGE
sure to observe polarity. After six (6) seconds, there
should be no voltage across the load.

4. After testing is complete, disconnect timer from

12VDC source and test load.
LOAD
5. Lower operator seat.

3 2 1
TIMING
RESISTOR

Figure 20

Electrical System Page 5 -- 18 Greensmaster 3150

Starter Solenoid
The starter solenoid used on the Greensmaster 3150 al-
lows current flow from the battery to the engine starter 3
motor when energized. The starter solenoid is attached
to the rear frame in front of the battery (Fig. 21).

Testing 4

1. Park machine on a level surface. Make sure the en-

gine and ignition switch are OFF. 1

2. Disconnect negative (black) cable from battery and

then disconnect positive (red) cable (see Battery Ser-
2
vice in the Service and Repairs section of this chapter).

3. Note wire locations on starter solenoid for assembly

purposes. Disconnect cables and wire harness connec-
tors from solenoid.

NOTE: Prior to taking small resistance readings with a

digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this val-
ue from the measured value of the component you are
FRONT
testing.

4. Apply 12 VDC directly across the solenoid coil posts.

Electrical
System
The solenoid should click as the solenoid coil is ener- Figure 21
gized. Make sure resistance across the main contact 1. Starter solenoid 3. Positive (+) cable
posts is less than 1 ohm. 2. Battery 4. Negative (--) cable

5. Remove voltage from solenoid coil posts. The sole-

noid should click as the solenoid coil is de--energized. 2
Make sure resistance across the main contact posts is
infinite ohms.
1
6. When testing is complete, secure cables and wire 1
harness connections to solenoid. Torque nuts on sole-
noid coil posts from 15 to 20 in--lb (1.7 to 2.3 N--m) and
nuts on main contact posts from 50 to 60 in--lb (5.7 to
6.8 N--m).

WIRING
DIAGRAM
2
2

1 1

Figure 22
1. Main contact post 2. Solenoid coil post

Greensmaster 3150 Page 5 -- 19 Electrical System

Solenoid Valve Coils
The Greensmaster hydraulic control manifold uses sev-
eral hydraulic solenoid valve coils for system control. 3
When the solenoid coils are energized, hydraulic valve
shift occurs to control hydraulic circuit flow. Testing of the 1
coils can be done with the coil installed on the hydraulic 4
valve.

Testing

1. Determine solenoid coil(s) that is to be tested and lo- 2

cate coil on hydraulic manifold (Fig. 23). Disconnect har-
ness electrical connector from solenoid valve coil.

NOTE: Prior to taking small resistance readings with a

digital multimeter, short the meter test leads together.
The meter may display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this val-
ue from the measured value of the solenoid coil being Figure 23
testing. 1. Solenoid S1R1 (7.1 ohm) 3. Solenoid S3 (7.1 ohm)
2. Solenoid S2 (8.6 ohm) 4. Solenoid S4 (8.6 ohm)
NOTE: Solenoid coil resistance should be measured
with solenoid at approximately 68oF (20oC). Resistance
may be slightly different than listed at different tempera-
tures. Typically, a failed solenoid coil will either be
shorted (very low or no resistance) or open (infinite re-
sistance).

2. Using a multimeter (ohms setting), measure resis-

tance between the two (2) connector terminals on the
solenoid valve coil. The resistance for the solenoid coils
is identified below:

Solenoid Valve Coil Resistance

S1R1 and S3 7.1 ohms
S2 and S4 8.6 ohms

3. If solenoid coil resistance is incorrect, replace sole-

noid coil (refer to control manifold service procedures in
the Service and Repairs section of Chapter 4 -- Hydrau-
lic System).

NOTE: To assist in troubleshooting, identical solenoid

valve coils can be exchanged. If the problem follows the
exchanged coil, an electrical problem likely exists with
the coil. If the problem remains unchanged, something
other than the solenoid coil is the problem source (e.g.
switch, circuit wiring, hydraulic problem). The control
manifold S1R1 coil is the same as the manifold S3 coil.
The manifold S2 and S4 coils are identical.

4. After coil testing is completed, connect wire harness

electrical connector to the solenoid valve coil.

5. Secure all machine components that were removed

to access hydraulic manifold.
Electrical System Page 5 -- 20 Greensmaster 3150
Backlap Switch
The backlap switch is a normally open ball switch that is
in the normal, open state when the backlap lever is in the
mow position. When the backlap lever is in the backlap
position, the switch closes. The backlap switch is at-
tached to the front of the hydraulic control manifold lo- 2
cated under the operator seat (Fig. 24). 20 ft--lb
(27 N--m)
Testing

1. Park machine on a level surface. Make sure the en-

gine and ignition switch are OFF.
5
2. Raise operator seat to allow access to hydraulic con- 1
1
trol manifold. Locate the backlap switch on the front of
the manifold. Disconnect the wire harness electrical
connector from the backlap switch.
3
3. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the switch connector 4
terminals.
Figure 24
4. With the ignition switch in the OFF position, turn the 1. Backlap switch 4. Dowel
backlap lever to the backlap position while watching the 2. Backlap lever 5. O--ring
multimeter. Continuity should be made as the switch clo- 3. Ball
ses.

5. Turn the backlap lever to the mow position while

Electrical
System
watching the multimeter. Continuity should be broken as
the switch opens.

6. If the backlap switch is faulty, replace switch. Make

sure that dowel and ball are placed in the manifold port
before installing new switch in manifold. Torque switch
to 20 ft--lb (27 N--m).

7. If the backlap switch tests correctly and a circuit

problem still exists, check wire harness (see Electrical
Schematic and Wire Harness Drawings in Chapter 9 --
Foldout Drawings).

8. After testing is completed, connect wire harness

electrical connector to the backlap switch. Lower opera-
tor seat.

Greensmaster 3150 Page 5 -- 21 Electrical System

Diodes
The main wiring harness contains six (6) diodes. Diodes
D2 and D3 are connected to the harness at separate DIODE PLUG-IN
CIRCUIT D1--D DIODE
locations. Diodes D1--A, D1--B, D1--C and D1--D are
BOARD 1/A 2/B
connected to the main harness by a four (4) position cir- D1--A
cuit board located near the front of the left side control D1--C
panel. The diodes are used for circuit protection from in- D1--B
ductive voltage spikes and for safety circuit logic.

Apply dielectric grease (Toro part number 107--0342) to

circuit board contacts whenever the circuit board is
installed into the wire harness.
Figure 25
Diode D1--A
DIODE CIRCUIT BOARD D1--A
Allows the engine to start only with the functional control
lever in NEUTRAL (neutral switch closed). Also, it allows D1--B
the engine to continue to run with either the functional
control lever in NEUTRAL (neutral switch closed) or the D1--C
operator sitting in the seat (seat switch closed). D1--D

Diode D1--B

Prevents a negative spike from damaging the neutral

switch and seat switch by allowing a ground path for the Figure 26
start safety relay (K2) when it de--energizes.
Type Red (+) Black (--) Continuity
Diode D1--C
H A YES
Maintains current flow to the joystick relay (K3) after the A H NO
momentary lower switch of the joystick opens.
G B YES
Diode D1--D B G NO
Circuit
Prevents a negative spike from damaging the mow and Board F C YES
backlap switches by allowing a ground path for the mow C F NO
relay (K4) when it de--energizes.
E D YES
Diode D2
D E NO
This diode prevents current flow to solenoid S4 when so- 1/A 2/B YES
lenoids S2 and S3 are energized through raise relay Plug-In
2/B 1/A NO
(K6).

Diode D3

This diode prevents current flow to solenoid S3 when so-

lenoids S2 and S4 are energized through lower relay DIODE
(K5). CIRCUIT BOARD

Testing

The diodes can be individually tested using a digital

multimeter (ohms setting) and the table to the right.

Figure 27

Electrical System Page 5 -- 22 Greensmaster 3150

Fusible Links
The electrical system on Greensmaster 3150 machines Testing
includes two (2) fusible links for machine circuit protec-
tion. Make sure that ignition switch is OFF. Disconnect nega-
tive (--) battery cable from battery terminal and then dis-
One of these fusible links is included in the main wire connect positive (+) cable from battery (see Battery
harness. This fusible link and the positive (+) battery Service in the Service and Repairs section of this chap-
cable attach to one of the starter solenoid main contact ter). Locate fusible link in wire harness. Use a multimeter
posts. The second fusible link is included in the engine to make sure that continuity exists across the fusible
wire harness. This fusible link connects to the output link. If a fusible link is open, replace the fusible link.
lead at the regulator/rectifier.
After testing is complete, make sure that all wire harness
If either of these links should fail, current to the protected connectors are secured. Connect positive (+) battery
circuit will cease. Refer to the electrical schematic and cable to battery terminal first and then connect negative
wire harness drawings in Chapter 9 -- Foldout Drawings (--) cable to battery.
for additional circuit information.

Electrical
System

Greensmaster 3150 Page 5 -- 23 Electrical System

Leak Detector Test/Light Switch
The leak detector test/light switch is used to perform two
machine functions. When the switch is pressed to the 2
rearward, momentary position, the leak detector alarm 1
can be tested. The switch is also used to operate the op-
tional lights by pressing the front of the switch. The leak
detector test/light switch is located on the control panel
(Fig. 28).

Testing

1. Park machine on a level surface. Make sure the en-

gine and ignition switch are OFF.

2. Remove control panel shield to gain access to leak

detector test/light switch.
Figure 28
3. Make sure ignition switch is in the OFF position. Dis- 1. Control panel 2. Leak test/light switch
connect machine wire harness electrical connector from
the switch.

4. The leak detector test/light switch terminals are iden-

tified in Figure 29 and the circuitry of the switch is shown
in Figure 30. With the use of a multimeter (ohms setting),
the switch functions may be tested to determine whether
continuity exists between the various terminals for each
switch position. Verify continuity between switch termi-
nals.
BACK OF SWITCH
5. Replace leak detector test/light switch if testing de-
termines that it is faulty. Figure 29

6. If the leak detector test/light switch tests correctly

SWITCH NORMAL OTHER
and a circuit problem still exists, check wire harness
POSITION CIRCUITS CIRCUITS
(see Electrical Schematics and Wire Harness Drawings
in Chapter 9 -- Foldout Drawings). RAISE 2+1 5+4
OFF NONE NONE
7. After testing is complete, connect machine wire har-
ness connector to leak detector test/light switch. Secure LOWER 2+3 5+6
control panel shield to machine with removed fasteners.
Figure 30

Electrical System Page 5 -- 24 Greensmaster 3150

Leak Detector Alarm and Delay Timer
The leak detector alarm is used to notify the operator
that a hydraulic leak has occurred. To prevent the leak
detector system from sounding false alarms during nor-
mal operation, the alarm circuit includes a one (1) sec-
ond delay timer.

NOTE: For information on leak detector operation refer

to Turf Guardiant Leak Detector System Operation in
this chapter.

Testing
2
1. Park machine on a level surface. Make sure the en- 1
gine and ignition switch are OFF.

2. Turn ignition switch to the RUN position (do not start

the engine), then move leak detector test switch rear-
ward and hold. After a one (1) second time delay, the
alarm should sound.
Figure 31
1. Alarm 2. Delay timer

Electrical
System

Greensmaster 3150 Page 5 -- 25 Electrical System

Leak Detector Float Sensor
The leak detector float sensor closely monitors the hy-
draulic fluid level in the main hydraulic tank. The sensor
contacts are open when the float is in the raised position
and oil level in the hydraulic tank is correct. The sensor
closes when the float is in the lowered position caused
by a low oil level and potential oil leak. 1

NOTE: For information on leak detector operation refer

to Turf Guardiant Leak Detector System Operation in
this chapter.

Testing

1. If the float sensor is connected to the main harness, 3

remove hydraulic tank cap and screen from filler neck of
hydraulic tank. Turn ignition switch to the RUN position 2
(do not start the engine). Insert a clean rod or screw driv-
er into filler neck and gently push down on sensor float
(Fig. 33). Alarm should sound after a one (1) second 110 to 140 in--lb
time delay. (12.5 to 15.8 N--m)

2. If the float sensor is removed or disconnected from

the main harness, connect a continuity tester across the Figure 32
float sensor wire terminals. There should be continuity 1. Main hydraulic tank 3. O--ring
2. Float sensor
across the terminals only when the float is pushed down.
There should be no continuity across the terminals
when the float is in the raised position.
CLEAN ROD OR FLOAT SENSOR
3. If oil level sensor was removed from reservoir, install SCREWDRIVER (lowered/closed)
oil level sensor into reservoir making sure that arrow on
sensor is pointing down (Fig. 34). Torque sensor nut
from 110 to 140 in--lb (12.5 to 15.8 N--m).
ALARM
(on)
4. After testing, make sure that hydraulic oil level in res-
ervoir is correct.

Figure 33

Figure 34
1. Oil level sensor 2. Sensor arrow

Electrical System Page 5 -- 26 Greensmaster 3150

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 2
the auxiliary tank prior to starting the machine. The valve
closes when the ignition switch is in the RUN position
3
and during machine operation.
4
NOTE: For information on leak detector operation refer
to Turf Guardiant Leak Detector System Operation in
this chapter.
1
Testing

1. Disconnect the wiring connector at the valve sole-

noid.

2. Connect 12VDC 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 the valve.

4. To check the solenoid valve supply power, turn the

ignition switch to the RUN position (do not start the en-
gine). Use a multimeter to make sure that the solenoid
valve wire harness connector has 12 volts present.

Electrical
System
Figure 35
1. Main hydraulic tank 3. Valve spool
2. Valve body 4. Solenoid

Greensmaster 3150 Page 5 -- 27 Electrical System

Service and Repairs

Verify Interlock System Operation

2. Sit on the seat, engage parking brake, keep traction
CAUTION 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
The interlock switches are for the operator’s correctly. Correct problem if not operating properly.
protection; do not disconnect them. Check the
operation of the switches daily to assure the in- 3. Sit on the seat and start engine. Move functional con-
terlock system is operating. If a switch is defec- trol lever to MOW. Raise off the seat. If the engine stops,
tive, replace it before operating the machine. the interlock system is operating correctly. Correct prob-
lem if not operating properly.
The purposes of the interlock switches are to:
4. Sit on the seat and start engine. Move functional con-
A. Prevent the engine from cranking or starting un- trol lever to TRANSPORT. Raise off the seat. If the en-
less the functional control lever is in NEUTRAL. gine stops, the interlock system is operating correctly.
Correct problem if not operating properly.
B. Prevent operating the traction pedal with the
functional control lever in NEUTRAL. 5. Sit on the seat, engage parking brake, keep traction
pedal in neutral and place functional control lever in
C. Shut off the engine if the operator leaves the seat NEUTRAL. Start the engine. Move Raise / Lower -- Mow
without the functional control lever in NEUTRAL. Control Lever forward to lower the cutting units. If the
units do not start rotating, the interlock system is operat-
D. Shut off the reels if the functional control lever is ing correctly. Correct problem if not operating properly.
moved to NEUTRAL or TRANSPORT.
6. Sit on the seat and set the parking brake. Start the
1. Sit on the seat, engage parking brake and move engine and move the functional control lever to MOW.
functional control lever to NEUTRAL. Try to depress If the engine stops, the interlock system is operating cor-
traction pedal. If the pedal does not depress, the inter- rectly. Correct problem if not operating properly.
lock system is operating correctly. Correct problem if not
operating properly.

Electrical System Page 5 -- 28 Greensmaster 3150

Battery Care
1. Battery electrolyte level must be properly main- 3. Battery cables must be tight on battery terminals to
tained. The top of the battery must be kept clean. lf the provide good electrical contact.
machine is stored in a location where temperatures are
extremely high, the battery will discharge more rapidly
than if the machine is stored in a location where temper-
atures are cool. WARNING
Connecting battery cables to the wrong battery
post could result in personal injury and/or dam-
WARNING age to the electrical system.

Wear safety goggles and rubber gloves when 4. If corrosion occurs at battery terminals, disconnect
working with battery electrolyte. Charge battery battery cables. Always disconnect negative (--) cable
in a well ventilated place so gasses produced first. Clean cable clamps and terminals separately. Re-
while charging can dissipate. Since the gases connect battery cables with positive (+) cable first. Coat
are explosive, keep open flames and electrical terminals with battery terminal protector (see Special
sparks away from the battery; do not smoke. Tools in this chapter) or a light coat of grease to reduce
Nausea may result if the gases are inhaled. Un- corrosion after connections are made.
plug charger from electrical outlet before con-
necting or disconnecting charger leads to or 5. Check battery electrolyte level every twenty five (25)
from battery posts. operating hours and every thirty (30) days if machine is
in storage.
2. Keep top of battery clean by washing periodically
with a brush dipped in baking soda (sodium bicarbon- 6. Maintain battery cell level with distilled or demineral-
ate) solution. Flush top surface with water after clean- ized water. Do not fill cells above the fill line.
ing. Do not remove the fill caps while cleaning.

Electrical
System
Battery Storage
If the machine will be stored for more than thirty (30) 3. Store battery in a cool atmosphere to avoid quick de-
days: terioration of the battery charge.

1. Make sure ignition switch is in the OFF position. Re- 4. To help prevent the battery from freezing during stor-
move the battery and charge it fully (see Battery Service age, make sure it is fully charged (see Battery Service
in this section). in this section).

2. Either store battery on a shelf or on the machine.

Leave cables disconnected if the battery is stored on the
machine.

Greensmaster 3150 Page 5 -- 29 Electrical System

Battery Service
The battery is the heart of the electrical system. With 4. Place the battery into battery tray. Make sure battery
regular and proper service, battery life can be extended. is level and flat. Push the positive (+) cable connector
Additionally, battery and electrical component failure onto positive battery post. Do not hammer as this will
can be prevented. damage the battery. Tighten cable clamp fasteners with
two (2) wrenches.
Battery Specifications
5. Install and secure battery hold down rod with two (2)
BCI Group Size U1 wing nuts. Do not overtighten to prevent cracking or dis-
300 Amp Cranking Performance at 0oF (--18oC) torting the battery case.
28 Minute Reserve Capacity at 80oF (27oC)
Electrolyte Specific Gravity (fully charged): from 1.250 6. Connect a digital multimeter (set to amps) between
to 1.280 the negative battery post and the negative (--) cable con-
Electrolyte Specific Gravity (discharged): 1.240 nector. The reading should be less than 0.1 amp. If the
reading is 0.1 amp or more, the unit’s electrical system
should be tested and repaired.
CAUTION 7. Connect the negative (ground) cable connector to
the negative battery post. Tighten cable clamp fasteners
When working with batteries, use extreme cau- with two (2) wrenches.
tion to avoid splashing or spilling electrolyte.
Electrolyte can destroy clothing and burn skin or 8. Coat terminals with battery terminal protector (see
eyes. Always wear safety goggles and a face Special Tools in this chapter) or a light coat of grease to
shield when working with batteries. reduce corrosion after connections are made.

Battery Removal (Fig. 36)

3 4 7
13 12
IMPORTANT: Be careful to not damage terminal 5
posts or cable connectors when removing the bat-
tery cables. 9
2
1. Disconnect the ground cable (--) first to prevent short
circuiting the battery, other components or the operators 8
hands. Then, disconnect the positive (+) cable.
1
2. Remove two (2) wing nuts and battery hold down rod.

3. Make sure that the battery filler caps are on tightly. 10

4. Remove battery from the battery compartment to a 6

service area. This will minimize possible battery dam-
11
age and allow better access for inspection and service.

Battery Installation (Fig. 36)

IMPORTANT: To prevent possible electrical prob-

lems, install only a fully charged battery.

1. Make sure the ignition switch and all accessories are

FRONT
off.

2. Make sure the battery compartment is clean and re-

painted if necessary. Figure 36
1. Battery 7. Hex nut (2 used)
3. Make sure battery cables and battery retainer are in 2. Negative (--) cable 8. Cap screw (2 used)
good condition. 3. Positive (+) cable 9. O--ring (2 used)
4. Hold down rod 10. Battery tray
5. Wing nut (2 used) 11. Drain tube
6. Battery post (2 used)

Electrical System Page 5 -- 30 Greensmaster 3150

Battery Inspection and Maintenance 2. Perform a high--discharge test with an adjustable
load tester.
1. Check for cracks caused by overly tight or loose hold
down rod. Replace battery if cracked or leaking. This is one of the most reliable means of testing a battery
as it simulates the cold--cranking test. A commercial bat-
2. Check battery terminal posts for corrosion. Use a ter- tery load tester is required to perform this test.
minal brush or steel wool to clean corrosion from the bat-
tery terminal posts.

IMPORTANT: Before cleaning the battery, tape or CAUTION

block the vent holes to the filler caps and make sure
the caps are on tightly. Follow the manufacturer’s instructions when us-
ing a battery tester.
3. Check for signs of wetness or leakage on the top of
the battery which might indicate a loose or missing filler
cap, overcharging, loose terminal post or overfilling. A. Check the voltage across the battery terminals
Clean the battery with a solution of baking soda and wa- prior to testing the battery. If the voltage is less than
ter, then rinse it with clean water. 12.0 VDC, recharge the battery.

IMPORTANT: Make sure the area around the cells is B. If the battery has been charged, apply a 150 amp
clean before opening the battery caps. load for fifteen (15) seconds to remove the surface
charge. Use a battery load tester following the
4. Check the electrolyte level in each cell. If necessary, manufacturer’s instructions.
fill all cells with distilled water to the bottom of the cap
tubes. Charge at 15 to 25 amps for fifteen (15) minutes C. Make sure the battery terminals are free of corro-
to allow sufficient mixing of the electrolyte. sion.

Battery Testing D. Measure the temperature of the center cell.

1. Conduct a hydrometer test of the battery electrolyte. E. Connect a battery load tester to the battery termi-
nals following the manufacturer’s instructions. Con-

Electrical
System
IMPORTANT: Make sure the area around the cells is nect a digital multimeter to the battery terminals.
clean before opening the battery caps.
F. Apply a test load of 270 amps (one half the battery
A. Measure the specific gravity of each cell with a Cranking Performance Specification) to the battery
hydrometer. Draw electrolyte in and out of the for fifteen (15) seconds.
hydrometer barrel prior to taking a reading to warm--
up the hydrometer. At the same time take the tem- G. Take a battery voltage reading at fifteen (15) se-
perature of the cell. conds, then remove the load.

B. Temperature correct each cell reading. For each H. Using the table below, determine the minimum
10oF (6oC) above 80oF (27oC) add 0.004 to the spe- voltage for the cell temperature reading.
cific gravity reading. For each 10oF (6oC) below 80oF
(27oC) subtract 0.004 from the specific gravity read- Minimum Battery Electrolyte
ing. Voltage Temperature
Example: Cell Temperature 100oF 9.6 70oF (and up) 21oC (and up)
Cell Gravity 1.245 9.5 60oF 16oC
ADD (20o above 80oF) 0.008
Correction to 80oF 1.253 9.4 50oF 10oC
9.3 40oF 4oC
C. If the difference between the highest and lowest
cell specific gravity is 0.050 or greater or the lowest 9.1 30oF --1oC
cell specific gravity is less than 1.225, charge the bat- 8.9 20oF --7oC
tery. Charge at the recommended rate and time (see
8.7 10oF --12oC
Battery Charging below) or until the specific gravity
of all cells is 1.225 or greater with the difference in 8.5 0oF --18oC
specific gravity between the highest and lowest cell
less than 0.050. If these charging conditions can not I. If the test voltage is below the minimum, replace
be met, replace the battery. the battery. If the test voltage is at or above the mini-
mum, return the battery to service.

Greensmaster 3150 Page 5 -- 31 Electrical System

Battery Charging

To minimize possible damage to the battery and allow CAUTION

the battery to be fully charged, the slow charging meth-
od is presented here. This charging method can be ac- Do not charge a frozen battery because it can ex-
complished with a constant current battery charger plode and cause injury. Let the battery warm to
which is available in most shops. 60oF (15oC) before connecting to a charger.

Charge the battery in a well--ventilated place to

dissipate gases produced from charging. These
CAUTION 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-
Follow the manufacturer’s instructions when us- plug the charger from the electrical outlet before
ing a battery charger. connecting or disconnecting the charger leads
from the battery posts.
NOTE: Using specific gravity of the battery cells is the
most accurate method of determining battery condition. 3. Following the manufacturer’s instructions, connect
the charger cables to the battery. Make sure a good con-
1. Determine the battery charge level from either its nection is made.
open specific gravity or circuit voltage.
4. Charge the battery following the manufacturer’s
Battery Charge Specific Open Circuit instructions.
Level Gravity Voltage
5. Occasionally check the temperature of the battery
100% 1.265 12.68
electrolyte. If the temperature exceeds 125oF (52oC) or
75% 1.225 12.45 the electrolyte is violently gassing or spewing, the
50% 1.190 12.24 charging rate must be lowered or temporarily stopped.

25% 1.155 12.06 6. Three (3) hours prior to the end of the charging, mea-
0% 1.120 11.89 sure the specific gravity of a battery cell once per hour.
The battery is fully charged when the cells are gassing
2. Determine the charging time and rate using the freely at a low charging rate and there is less than a
manufacturer’s battery charger instructions or the fol- 0.003 change in specific gravity for three (3) consecu-
lowing table. tive readings.

Battery Battery Charge Level

Reserve (Percent of Fully Charged)
Capacity
(Minutes) 75% 50% 25% 0%
80 or 3.8 hrs 7.5 hrs 11.3 hrs 15 hrs
less @ @ @ @
3 amps 3 amps 3 amps 3 amps
81 to 125 5.3 hrs 10.5 hrs 15.8 hrs 21 hrs
@ @ @ @
4 amps 4 amps 4 amps 4 amps
126 to 5.5 hrs 11 hrs 16.5 hrs 22 hrs
170 @ @ @ @
5 amps 5 amps 5 amps 5 amps
171 to 5.8 hrs 11.5 hrs 17.3 hrs 23 hrs
250 @ @ @ @
6 amps 6 amps 6 amps 6 amps
above 6 hrs 12 hrs 18 hrs 24 hrs
250 @ @ @ @
10 amps 10 amps 10 amps 10 amps

Electrical System Page 5 -- 32 Greensmaster 3150

 Chapter 6

Chassis
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4
Front Wheel and Brakes . . . . . . . . . . . . . . . . . . . . . 4
Rear Wheel (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rear Wheel (Optional 3WD) . . . . . . . . . . . . . . . . . . 8
Rear Wheel Hub and Motor Assembly
(Optional 3WD) . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rear Castor Fork . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cutting Unit Pull Frame . . . . . . . . . . . . . . . . . . . . . 14

Chassis

Greensmaster 3150 Page 6 -- 1 Chassis

Specifications

Item Description

Front tire pressure (18 x 9.50 x 8, 2 ply) 8 to 12 PSI (55 to 83 kPa)

Rear tire pressure (18 x 9.50 x 8, 2 ply) 8 to 15 PSI (55 to 103 kPa)

Wheel lug nut torque 70 to 90 ft--lb (95 to 122 N--m)

Chassis Page 6 -- 2 Greensmaster 3150

General Information

Operator’s Manual
The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for your Greensmaster 3150. Refer to that pub-
lication for additional information when servicing the
machine.

Special Tools
Order this special tool from your Toro Distributor.

Wheel Hub Puller

The wheel hub puller allows safe removal of the wheel
hub from the shaft of wheel motors.

Toro part number: TOR4097

Figure 1

Chassis

Greensmaster 3150 Page 6 -- 3 Chassis

Service and Repairs

Front Wheel and Brakes

2 250 to 400 ft--lb

(339 to 542 N--m)
3

6
1
5 8
11
14 15
13
18
12 17
19

70 to 90 ft--lb 9
7 16
(95 to122 N--m)
21
10
4

RIGHT 23
24
25
FRONT
26 20
27

22

Figure 2
1. Lug nut (4 per wheel) 10. Retaining ring 19. O--ring
2. Wheel assembly 11. Cap screw (4 per brake) 20. Hydraulic motor
3. Lock nut 12. Lock nut (4 per brake) 21. Cap screw (4 per motor)
4. Brake lever 13. Woodruff key 22. Lock nut (4 per motor)
5. Brake drum 14. Brake bracket 23. Brake rod
6. Wheel hub 15. Hydraulic hose 24. Jam nut
7. Drive stud (4 per hub) 16. Hydraulic hose 25. Clevis pin
8. Brake assembly 17. 45o Hydraulic fitting (2 per motor) 26. Swivel clevis
9. Brake cam 18. O--ring 27. Cotter pin

Removal (Fig. 2) 4. Remove lug nuts and wheel assembly from drive
studs.
1. Park the machine on a level surface, engage the
parking brake, lower the cutting units and stop the en- IMPORTANT: DO NOT hit wheel hub (item 6) with a
gine. Remove key from the ignition switch. hammer during removal or installation. Hammering
may cause damage to the hydraulic wheel motor.
2. Loosen, but do not remove, lug nuts (item 1) and lock
nut (item 3). Loosen lock nut at least two (2) turns. NOTE: The brake drum assembly consists of the wheel
hub (item 6), brake drum (item 5) and drive studs (item
3. Chock front and rear of wheels not being lifted to pre- 7).
vent the machine from moving. Lift front wheel off the
ground using a jack and place appropriate jackstands 5. Make sure that lock nut (item 3) on wheel motor shaft
beneath the frame to support the raised machine (see is loosened at least two (2) turns. Use hub puller (see
Jacking Instructions in Chapter 1 -- Safety). Special Tools in this chapter) to loosen brake drum as-
sembly from wheel motor.

Chassis Page 6 -- 4 Greensmaster 3150

6. Remove lock nut and brake drum assembly. Locate 4. Make sure that wheel hub bore and wheel motor
and retrieve woodruff key (item 13). shaft are thoroughly cleaned. Install woodruff key (item
13) to the wheel motor shaft. Slide brake drum assembly
7. Remove return springs from brake shoes (Fig. 3). over shaft and key.
Remove brake shoes from backing plate.
5. Secure brake drum assembly to motor shaft with lock
8. Remove brake backing plate to machine if neces- nut (item 3).
sary:
6. Install front wheel and secure with four (4) lug nuts.
A. Remove retaining clip (item 10) from the brake Tighten lug nuts evenly in a crossing pattern.
cam (item 9). Separate brake lever (item 4) from
brake cam.

B. Remove four (4) cap screws (item 11), lock nuts WARNING
(item 12) and brake backing plate from the brake
bracket (item 14). Failure to maintain proper wheel lug nut and
wheel hub lock nut torque could result in failure
9. Brake parts should be clean and free of rust. Inspect or loss of wheel and may result in personal injury.
contact surfaces of brake shoes and brake drum for ex-
cessive wear. Replace any worn or damaged parts. 7. Lower machine to ground. Torque lock nut from 250
to 400 ft--lb (339 to 542 N--m) and wheel lug nuts from
10.If wheel hub (item 6), brake drum (item 5) or drive 70 to 90 ft--lb (95 to 122 N--m).
studs (item 7) need replacement, press four (4) drive
studs from wheel hub and separate hub from brake 8. Check and adjust brakes.
drum.

Installation (Figs. 2 and 3)

1 3
1. If wheel hub was separated from brake drum, posi-
tion hub to drum and secure by pressing four (4) drive
studs through hub. Make sure that studs are pressed ful-
ly into hub.

2. If brake backing plate was removed from machine:

A. Secure backing plate to the brake bracket (item

14) with four (4) cap screws (item 11) and lock nuts
(item 12).

Chassis
B. Install brake cam into backing plate if it was re-
moved.

C. Apply antiseize lubricant to spline area of brake

cam. Slide brake lever (item 4) onto brake cam and 2
2
secure with retaining clip (10). Make sure that brake 1
lever pivot is inserted into machine frame during as-
sembly.
Figure 3
3. Position both brake shoes on the backing plate (Fig.
1. Return spring 3. Brake cam
3). Insert return springs into the holes of both brake 2. Brake shoe
shoes.

Greensmaster 3150 Page 6 -- 5 Chassis

Rear Wheel (2WD)

5 6
4

3
2
7
70 to 90 ft--lb
(95 to 122 N--m)

3
9
4 8
10 12
11

34 16

15
1 13

18 17
19
20
21
22
14 23
20
19
18
27
33 24
RIGHT 32 25
31
FRONT 16
30 29 28 26 65 to 85 ft--lb
(89 to 115 N--m)

Figure 4
1. Steering cylinder 13. Washer 24. Castor fork
2. Bearing cup (2 used) 14. Lock nut 25. Flange head screw (3 used)
3. Bearing cone (2 used) 15. Cap screw (2 used) 26. Lock nut
4. Washer (4 used) 16. Spacer (2 used) 27. Castor bolt
5. Slotted hex nut 17. Hub assembly 28. Jam nut (2 used)
6. Cotter pin 18. Seal (2 used) 29. Flat washer
7. Grease fitting 19. Bearing cone (2 used) 30. Adapter plate
8. Jam nut 20. Bearing cup (2 used) 31. Lock nut (2 used)
9. Rod end 21. Hub 32. Lock nut (3 used)
10. Dust seal 22. Grease fitting 33. Motor adapter plate
11. Lug nut (4 used) 23. Drive stud (4 used) 34. Grease fitting
12. Wheel assembly

Chassis Page 6 -- 6 Greensmaster 3150

Removal (Fig. 4)
6
1. Park the machine on a level surface, engage the 3 1 3
1
parking brake, lower the cutting units and stop the en-
gine. Remove key from the ignition switch.

2. Chock both front wheels to prevent the machine from

moving.

3. Use a jack or hoist to lift rear wheel off the ground and
then place appropriate jackstands beneath the frame to 5
support the raised machine. 4 2 4

4. Remove lock nut (item 26) from castor bolt (item 27). Figure 5
Pull bolt from both adapter plates (items 30 and 33), two 1. Bearing cup (2 used) 4. Shaft seal (2 used)
(2) rear spindle spacers (item 16) and the wheel and hub 2. Wheel hub 5. Drive stud (4 used)
assembly. 3. Bearing cone (2 used) 6. Grease fitting

5. Remove wheel and hub assembly from the castor Installation (Fig. 4)
fork.
1. If wheel was removed from hub, slide wheel assem-
6. If necessary, remove four (4) lug nuts (item 11) from bly onto the drive studs. Secure wheel to wheel hub as-
the drive studs (item 23). Separate wheel and hub as- sembly with four (4) lug nuts (item 11). Torque lug nuts
semblies. evenly in a crossing pattern to a torque from 70 to 90 ft--
lb (95 to 122 N--m).
NOTE: If castor fork removal is necessary, see Rear
Castor Fork in this section. 2. Install wheel and hub assembly into the castor fork.
Insert castor bolt (item 27) into motor adapter plate (item
Wheel Hub Disassembly (Fig. 5) 33) mounting hole. Install a spindle spacer (item 16) and
slide bolt through the wheel and hub assembly.
NOTE: The wheel hub assembly consists of the wheel
hub, oil seals, bearing cones, bearing cups, grease fit- 3. Install second spindle spacer onto the bolt. Route the
ting and drive studs (Fig. 5). bolt through the adapter plate (item 30) mounting hole.

1. If drive studs are bent or damaged, press studs from 4. Position bent lip of the bolt head under the bottom
the wheel hub. edge of the motor adapter plate. Install and tighten lock
nut (item 26) to secure wheel to the castor fork. Do not
2. Pull oil seals, bearing cones and bearing cups from overtighten lock nut, the wheel must rotate freely.

Chassis
the wheel hub.
5. Lower machine to ground.
Wheel Hub Assembly (Fig. 5)
6. Clean grease fitting (item 22) on hub. Pump grease
1. Press new bearing cups into the wheel hub with the into hub until grease is seen exiting at both hub seals
thick edges towards the inside. (item 18). Wipe up excess grease.
2. Pack new bearing cones with #2 multi--purpose lithi-
um base grease.

3. Install new bearing cones into the wheel hub. Press

new oil seals into the hub with the lip of the seals facing
towards the inside.

4. If removed, press new drive studs into the wheel hub

fully to the shoulder of the stud flange.

Greensmaster 3150 Page 6 -- 7 Chassis

Rear Wheel (Optional 3WD)

6
4 100 ft--lb
7
(135 N--m)
1
5

16

3 22
30
5 21
17
26
2
20
9

31

29
25
19 27
10
14 8 11
12
23 18 Loctite #242
80 to 100 in--lb
15
(9.0 to 11.3 N--m)
24 40 ft--lb
(55 N--m)

FRONT
13 70 to 90 ft--lb
28 (95 to122 N--m) RIGHT

Figure 6
1. Lock nut (2 used) 12. Cap screw (3 used) 22. Lock nut (3 used)
2. Spacer (2 used) 13. Lock nut (2 used) 23. O--ring
3. Grommet (2 used) 14. Wheel motor & hub assembly 24. O--ring
4. Hydraulic hose assembly 15. Adapter (2 used) 25. O--ring
5. Washer (4 used) 16. Socket head screw (2 used) 26. O--ring
6. Castor fork 17. Bulkhead bracket 27. Set screw
7. Mount spacer (2 used) 18. Lug nut (4 used) 28. Wheel assembly
8. Grease fitting 19. Hydraulic hose assembly 29. Grease fitting
9. Bearing flangette (lube) 20. Hydraulic tube assembly 30. Hydraulic hose assembly
10. Bearing 21. Washer (3 used) 31. Washer head screw (2 used)
11. Bearing flangette

Chassis Page 6 -- 8 Greensmaster 3150

Removal (Fig. 6) Installation (Fig. 6)

1. Park machine on a level surface. Make sure engine 1. Secure wheel (item 28) to the drive studs of the hy-
is off. Set brake and block front wheels. draulic motor and hub assembly with four (4) lug nuts
(item 18). Torque nuts from 70 to 90 ft--lb (95 to 122
2. Loosen, but do not remove, lug nuts (item 18). N--m).

3. Chock both front wheels to prevent the machine from 2. Reinstall grease fitting (item 8) into hydraulic motor
moving. and hub assembly so it points away from the wheel.

4. Use a jack or hoist to lift rear wheel off the ground and 3. Install flangette (item 11), bearing (item 10) and re-
then place appropriate jackstands beneath the frame to lube flangette (item 9) onto the motor shaft.
support the raised machine.
4. Position hydraulic motor and hub assembly, flan-
gettes with bearing and wheel into the castor fork. Make
CAUTION sure hose fittings on the motor face to the rear.

5. Loosely secure hydraulic motor and hub assembly to

Support wheel (item 28) and motor and hub as- the right inside of the castor fork with both socket head
sembly (item 14) to prevent dropping the assem- screws (item 16) and lock nuts (item 13).
bly and causing personal injury.
6. Position flangette grease fitting facing downward.
Then, loosely secure flangettes (items 9 and 11) and
5. Support rear wheel, hydraulic motor and hub assem-
bearing (item 10) to the left inside of the castor fork with
bly to prevent it from falling.
cap screws (item 12), mount spacers (item 7), washers
6. Remove wheel (item 28) and hydraulic motor and (item 21) and lock nuts (item 22).
hub assembly (item 14) from the castor fork (item 6) as
7. Secure wheel (item 28) and hydraulic motor and hub
follows:
assembly (item 14) to the castor fork:
A. Remove cap screws (item 12), lock nuts (item 22)
A. Torque socket head screws (item 16) to 100 ft--lb
and washers (item 21) securing flangettes (items 9
(135 N--m).
and 11) and mount spacers (item 7) to castor fork.
B. Torque cap screws (item 12) to 40 ft--lb (55 N--m).
B. Remove both socket head screws (item 16) and
lock nuts (item 13) securing the hydraulic motor and 8. Apply loctite to bearing set screw (item 27). Torque
hub assembly to the castor fork.
set screw from 80 to 100 in--lb (9.0 to 11.3 N--m).

Chassis
C. Lower wheel and hydraulic motor and hub as- 9. Lower machine to the ground. Check that lug nuts
sembly from the castor fork.
are properly torqued from 70 to 90 ft--lb (95 to 122
N--m).
7. Loosen set screw (item 27) on bearing (item 10). Pull
flangettes (items 9 and 11) and bearing from the hydrau-
lic motor shaft.

8. Remove grease fitting (item 8) from the hydraulic

motor and hub assembly. Remove four (4) lug nuts (item
18) and wheel (item 28) from the hub drive studs.

NOTE: If wheel hub and motor assembly need to be

serviced, see Rear Wheel Hub and Motor Assembly
(Optional 3WD) in this section. If castor fork removal is
necessary, see Rear Castor Fork in this section.

Greensmaster 3150 Page 6 -- 9 Chassis

Rear Wheel Hub and Motor Assembly (Optional 3WD)

9
8
7
6

3 5
FREE
ROTATION
2

6
7
8

4 9

Figure 7
1. Hydraulic motor 4. Drive stud (4 used) 7. Washer
2. Hub 5. Grease fitting 8. Snap ring
3. Clutch roller bearing 6. Thrust washer 9. Grease seal

The following procedures assume the rear wheel hub 3. Place rear wheel hub and motor assembly on a clean
and motor assembly has been removed from the ma- workbench.
chine (see Rear Wheel (Optional 3WD) in this section).
4. Remove grease seal (item 9) and snap ring (item 8)
Disassembly (Fig. 7) from the long end of hub.

5. Remove washer (item 7), two (2) thrust washers

CAUTION (item 6) and hub (item 2) from the hydraulic motor shaft.
Remove remaining two (2) thrust washers (item 6),
washer (item 7), snap ring (item 8) and grease seal (item
Before continuing further, read and become fa- 9) from the shaft.
miliar with General Precautions for Removing
and Installing Hydraulic System Components in 6. If drive studs (item 4) are bent or damaged, press
the Service and Repairs section of Chapter 4 -- studs from the wheel hub.
Hydraulic System.
7. Press clutch roller bearings (item 3) from the hub.
1. Thoroughly clean junction of hydraulic hoses and fit-
tings on hydraulic motor (Fig. 8). 8. If rear wheel motor needs to be serviced, see Wheel
Motor Service in the Service and Repairs section of
2. Label hydraulic hoses that connect to rear wheel mo- Chapter 4 -- Hydraulic System.
tor for assembly purposes. Remove hose assemblies
and O--rings from the hydraulic fittings on the hydraulic
motor. Allow hoses to drain into a suitable container.

Chassis Page 6 -- 10 Greensmaster 3150

Assembly (Fig. 7)
5
1. If drive studs (item 4) were removed, press new 4
studs fully to the shoulder of the wheel hub. 3

NOTE: Arrow on the side of the clutch roller bearings 2

6
(item 3) must point to the long side of the end of the hub.
4
2. Press clutch roller bearings (item 3) into the hub as
follows (Fig. 9): 3

A. Press three (3) roller bearings into flange end of 2

the hub. The outer edge of the third bearing must be
flush with the recessed edge within the hub.

B. Press final roller bearing into opposite end of hub. 1

The outer edge of the bearing must be flush with the
recessed edge within the hub. Figure 8
1. Hub and motor assembly 4. O--ring
C. The installed bearings must not interfere with 2. O--ring 5. Hydraulic hose
grease fitting hole in the hub. 3. Adapter 6. Hydraulic hose

3. Grease inner edge of the new grease seals (item 9)

OUTER BEARING EDGE
with No. 2 multipurpose lithium base grease. Slide one MUST BE FLUSH WITH EDGE
(1) seal onto motor shaft past groove closest to the mo-
tor. Install snap ring (item 8) into groove.

4. Slide flat washer (item 7) and two (2) thrust washers

(item 6) onto the motor shaft. Slide hub onto the shaft
with the short end first.

5. Slide remaining thrust washers (item 6) and flat

washer (item 7) onto the motor shaft. Install remaining
snap ring (item 8) into the shaft groove. Slide remaining
new grease seal (item 9) onto motor shaft. ARROWS ON BEARING
TOWARDS LONG END
IMPORTANT: The hub should spin freely in the for-
ward direction, but lock on the hydraulic motor Figure 9

Chassis
shaft when it is rotated in the reverse direction.

6. Press grease seals (item 9) into the hub so they are

flush with the end of the hub.

7. Lubricate and position new O--rings to fittings on hy-

draulic motor. Use labels placed during the removal pro-
cess to properly install hydraulic hoses to motor
adapters (see Hydraulic Hose and Tube Installation in
the General Information section of Chapter 4 -- Hydrau-
lic System).

8. Install rear wheel hub and motor assembly to rear

castor fork of machine (see Rear Wheel (Optional 3WD)
in this section).

Greensmaster 3150 Page 6 -- 11 Chassis

Rear Castor Fork

5 6
4

3
2
7
70 to 90 ft--lb
(95 to 122 N--m)

3
9
8
4
10 12
11

34 16

15
1 13

18 17
19
20
21
22
14 23
20
19
18
27
33 24

RIGHT 32 25
31
FRONT 16
30 29 28 26 65 to 85 ft--lb
(89 to 115 N--m)

Figure 10
1. Steering cylinder 13. Washer 24. Castor fork
2. Bearing cup (2 used) 14. Lock nut 25. Flange head screw (3 used)
3. Bearing cone (2 used) 15. Cap screw (2 used) 26. Lock nut
4. Washer (4 used) 16. Spacer (2 used) 27. Castor bolt
5. Slotted hex nut 17. Hub assembly 28. Jam nut (2 used)
6. Cotter pin 18. Seal (2 used) 29. Flat washer
7. Grease fitting 19. Bearing cone (2 used) 30. Adapter plate
8. Jam nut 20. Bearing cup (2 used) 31. Lock nut (2 used)
9. Rod end 21. Hub 32. Lock nut (3 used)
10. Dust seal 22. Grease fitting 33. Motor adapter plate
11. Lug nut (4 used) 23. Drive stud (4 used) 34. Grease fitting
12. Wheel assembly

Chassis Page 6 -- 12 Greensmaster 3150

Removal (Fig. 10) Installation (Fig. 10)

1. Park machine on a level surface. Make sure engine 1. If bearing cups (item 2) were removed from frame,
is off. Engage parking brake and block front wheels. press new cups into the castor fork pivot housing with
the thick side of the cups facing each other. Make sure
2. Jack up and secure the rear wheel off the ground. that cups are pressed fully to shoulder of frame housing.

3. Remove rear wheel assembly from the castor fork 2. Pack both bearing cones (item 3) with #2 multi--
(see Rear Wheel (2WD) or Rear Wheel (Optional 3WD) purpose lithium base grease.
in this section).
3. Place two (2) washers (item 4) onto the castor fork
4. Remove fuel tank from machine to allow access to shaft. Place lower bearing cone on top of washers with
castor fork (see Fuel Tank in the Service and Repairs the thick edge touching the washers.
section of Chapter 3 -- Engine).
4. Insert castor fork shaft up through the frame pivot
5. Remove both jam nuts (item 28) and flat washer housing and bearing cups.
(item 29) securing the steering cylinder ball joint (item 9)
to the castor fork. Separate ball joint from castor fork. 5. Place upper bearing cone on the castor fork shaft
with the wide edge up. Place two (2) washers on top of
the bearing cone.
CAUTION 6. Thread slotted hex nut (item 5) onto castor fork shaft
until drag is felt while rotating the castor fork. Back--off
Support castor fork while removing the slotted hex nut to align shaft hole with a slot in the nut. Install
hex nut (item 5) to prevent the fork from dropping and secure new cotter pin (item 6) to the shaft.
and causing personal injury.
7. Secure steering cylinder ball joint (item 9) to the cas-
6. Support the castor fork to prevent it from falling. tor fork with flat washer (item 29) and both jam nuts (item
28). Torque jam nuts from 65 to 85 ft--lbs (89 to 115
7. Remove cotter pin (item 6) and slotted hex nut (item N--m).
5) from the castor fork shaft. Lower castor fork from
frame. 8. Install fuel tank to the machine (see Fuel Tank in the
Service and Repairs section of Chapter 3 -- Engine).
8. Remove bearing cones (item 3) and washers (item
4) from the castor fork and frame. Note location of wash- 9. Install rear wheel to castor fork (see Rear Wheel
ers for assembly purposes. (2WD) or Rear Wheel (Optional 3WD) in this section).

9. Inspect upper and lower bearing cups (item 2) in 10.Lower machine to the ground.

Chassis
frame for damage and replace if necessary.
11. Clean grease fitting (item 7) on frame pivot housing.
Pump grease into pivot housing until grease is seen exit-
ing at both ends of the housing. Wipe up excess grease.

Greensmaster 3150 Page 6 -- 13 Chassis

Cutting Unit Pull Frame

28 35 36 13
29
31
37
35
9 10 5
28
11
37
7

6
38 34
30
8

12

18
15 16
38
1 3
19 38
27 20
16
39
4
2 15
27 24
38
40 27 17
6
41 14
38
26 16
32
25
42
33
23
22 20
RIGHT 21 19
42 1
FRONT 27

Figure 11
1. Roller shaft screw (2 used) 15. Shim washer (as needed) 29. Spacer
2. Nut (2 used) 16. Thrust washer (6 used) 30. Spacer
3. Grease fitting 17. Pivot hinge 31. Hydraulic hose
4. Ball joint receiver (2 used) 18. Pull frame (RH shown) 32. Bumper (2 used)
5. Hydraulic lift cylinder 19. Lock washer (2 used) 33. Washer head screw (2 used)
6. Flat washer (3 used) 20. Flat washer (2 used) 34. Torsion spring
7. Cap screw (3 used) 21. Pull arm 35. O--ring
8. Hinge pin 22. Roller 36. Hydraulic hose
9. Pivot pin 23. Spring washer (2 used) 37. O--ring
10. Clevis pin 24. Pivot pin 38. Bushing
11. Cotter pin 25. Pull arm 39. Ball joint sleeve (2 used)
12. Lift arm 26. Roller shaft 40. Ball bearing (2 used)
13. Grease fitting 27. Grease fitting 41. Oil seal (2 used)
14. Grease fitting 28. Hydraulic fitting (2 used) 42. Flange bushing (2 per pull arm)

Chassis Page 6 -- 14 Greensmaster 3150

NOTE: The pull frame assemblies used on Greens-
master 3150 machines are slightly different depending 1
on location (right front, left front and center positions).
Service of the pull frame assembly is similar regardless
of position on the machine. The right front pull frame as-
sembly is shown in Figure 11.

Disassembly (Fig. 11)

1. Park machine on a level surface with cutting units 2

lowered to the ground. Make sure engine is off. Engage
parking brake.

NOTE: Depending on service that is required, it might

be easier to remove cutting unit from pull frame. 3

2. Remove cutting unit pull frame components from Figure 12

machine as required using Figure 11 as a guide.
1. Pull frame 3. Cutting unit ball stud
2. Pull arm
Assembly (Fig. 11)

1. Install all removed cutting unit pull frame compo-

nents to machine using Figure 11 as a guide.

A. If bushings (item 38) in lift arm or pivot hinge are

being replaced, install new bushing so that grease
groove opening is orientated inward. The bushing
with grease groove is shown in Figure 13.

B. If pivot hinge (item 17) was removed, make sure 1

that side play clearance of pivot hinge is less than
0.060” (1.5 mm). Adjust clearance with shims (item 2
15) and thrust washers (item 16) as required.

C. If roller assembly was disassembled, install oil Figure 13

seal with seal lip toward end of roller (Fig. 14). Also,
1. Bushing 2. Grease groove
ball bearing should be installed with seal toward end
of roller.

Chassis
1
3

Figure 14
1. Roller 3. Ball bearing
2. Oil seal

Greensmaster 3150 Page 6 -- 15 Chassis

 This page is intentionally blank.

Chassis Page 6 -- 16 Greensmaster 3150

 Chapter 7

DPA Cutting Units

Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Cutting Unit Operator’s Manual . . . . . . . . . . . . . . . 3
Supporting Cutting Unit when Servicing . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FACTORS THAT CAN AFFECT CUTTING
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SET UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . 10
Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Leveling Rear Roller . . . . . . . . . . . . . . . . . . . . . . . . 11
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 12
Backlapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Bedbar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Bedknife Replacement and Grinding . . . . . . . . . . 16
Bedbar Adjuster Service . . . . . . . . . . . . . . . . . . . . 18
Reel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Reel Assembly Removal . . . . . . . . . . . . . . . . . . 21
Reel Assembly Installation . . . . . . . . . . . . . . . . 21
Reel Assembly Service . . . . . . . . . . . . . . . . . . . . . 24
Preparing Reel for Grinding . . . . . . . . . . . . . . . . . 26
Front Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Rear Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Roller Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Rear Roller Brush (Optional) . . . . . . . . . . . . . . . . . 32

DPA Cutting
Units

Greensmaster 3150 Page 7 − 1 DPA Cutting Units

Specifications

Figure 1

Frame Construction: Precision machined die cast alu- Bedknife Adjustment: Dual screw adjustment to the
minum cross member with two (2) bolt−on cast alumi- reel; detents corresponding to 0.0007 inch (0.018 mm)
num side plates. bedknife movement for each indexed position.

Reel Construction: Reels are 21 inches (53.3 cm) in Front and Rear Rollers: Greaseless through−shaft
length and 5 inch (12.7 cm) in diameter. High strength, front and rear rollers are used with the Greensmaster
low alloy steel blades are thru hardened and impact re- 3150 DPA cutting units. All greens rollers use the same
sistant. Reels are available in 8, 11 and 14 blade config- heavy duty ball bearing and seal package.
urations.
Counterbalance Weight: A cast iron weight mounted
Reel Bearings: Two (2) sealed stainless steel, deep opposite to the hydraulic reel motor balances the cutting
groove ball bearings support the reel shaft with inboard unit.
seal for protection.
Cutting Unit Weight (Approximate):
Reel Drive: The reel weldment shaft is a 1.350 inch 8 Blade 65 lb (30 kg)
(34.3 mm) diameter tube with a drive insert threaded 11 Blade 68 lb (31 kg)
into the right end. The reel drive insert has an internal 14 Blade 71 lb (32 kg)
eight (8) tooth spline.
Options:
Height−of−Cut (HOC): Cutting height is adjusted on Refer to Cutting Unit Operator’s Manual for available op-
the front roller by two (2) vertical screws. Effective HOC tions for your Greensmaster 3150 DPA cutting unit.
may vary depending on turf conditions, type of bedknife,
roller type and installed attachments.

Bedknife: Replaceable, single edged, high carbon

steel bedknife is fastened to a machined cast iron bed-
bar with thirteen (13) screws. Optional bedknives are
available.

DPA Cutting Units Page 7 − 2 Greensmaster 3150

General Information

Cutting Unit Operator’s Manual

The Cutting Unit Operator’s Manual provides informa-
tion regarding the operation, general maintenance and
maintenance intervals for the DPA cutting units on your
Greensmaster 3150 machine. Additionally, if optional
kits have been installed on the cutting units (e.g. rear
roller brush), the installation instructions for the kit in-
cludes set−up and operation information. Refer to those
publications for additional information when servicing
the cutting units.

Supporting Cutting Unit when Servicing

Whenever the cutting unit has to be tipped to expose the
bedknife or cutting reel, support the rear of the cutting
unit to make sure the lock nuts on the back of the bedbar
adjuster screws are not resting on the work surface.

2
1

Figure 2
1. Lock nut 2. Support

DPA Cutting
Units

Greensmaster 3150 Page 7 − 3 DPA Cutting Units

Special Tools
Special tools for servicing Toro Commercial Products
are available from your Toro Distributor. Some of these
tools may have been supplied with your machine or are
available as Toro parts.

Gauge Bar Assembly

Use gauge bar to verify height−of−cut adjustment.

Toro Part Number: 108−6715

Used for Height−of−

Cut adjustment

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: To prevent damage to the bedbar, DO

NOT use an air or manual impact wrench with this
tool.

Toro Part Number: TOR510880

Figure 4

Handle Assembly
For applying lapping compound to cutting units while
keeping hands a safe distance from the rotating reel.

Toro Part Number: 29−9100

Components for the handle assembly are available indi-

vidually as follows:

Brush 36−4310
Handle 29−9080
Handle cap 2410−18 Figure 5

DPA Cutting Units Page 7 − 4 Greensmaster 3150

Roller Bearing Installation Tools
Washers and spacer used to install bearings and seals
into front and rear rollers (Fig. 6).

Seal installation washer: 107−8133

Seal installation spacer: 107−3505
Bearing installation washer: 104−6126

As an alternative to using washers and spacers listed Seal Installation Seal Installation Bearing Installation
above, a special tool set is available that can be used for Washer Spacer Washer
(black) (yellow)
roller bearing and seal installation (Fig. 7).
Figure 6
Toro Part Number: TOR4105

Figure 7

Diameter/Circumference Measuring Tape

Spring steel measuring tape for accurately measuring
the circumference and outside diameter of cutting reel
and other spherical components. Tape calibration is in
fixed inch readings (no adjustments).

Toro Part Number: TOR6023

Figure 8

DPA Cutting
Turf Evaluator Tool

Units
Many turf discrepancies are subtle and require closer
examination. In these instances, the Turf Evaluator
grass viewing tool is helpful. It can assist turf managers
and service technicians in determining causes for poor
reel mower performance and in comparing the effective
height−of−cut of one mowed surface to another. This
tool should be used with the Toro Guide to Evaluation
Reel Mower Performance and Using the TurfEvaluator
(Toro part no. 97931SL).

Toro Model Number: 04399

Figure 9

Greensmaster 3150 Page 7 − 5 DPA Cutting Units

Bedknife Top Angle Indicator and Mount
Toro Part Numbers: 131−6828 and 131−6829

Because the top grind angle on bedknives is critical for

edge retention, and therefore after− cut appearance, 1
Toro has developed these service tools for accurately 2
measuring the top grind angle on all bedknives. 3

Since there can be variations in the mounting surface of

the bedbar, it is necessary to grind the bedknife after
installing it to the bedbar.

1. Place the angle indicator on the bottom side of the

bedknife with the digital display facing you as shown
(Fig. 10).
Figure 10
2. Press the Alt Zero button on the angle indicator. 1. Bedknife 3. Bedbar
2. Angle indicator
3. Remove the angle indicator and place the angle−in-
dicator mount on the edge of the bedknife so the face of
the magnet is flat against the top of the bedknife
(Fig. 11). 2
1
4. Place the angle indicator on the mount with the digital
display facing you as shown (Fig. 11). The angle dis-
played on the indicator is the current bedknife top angle. 5
3

Figure 11
1. Angle indicator mount 4. Angle indicator
2. Magnet 5. Bedbar
3. Bedknife

DPA Cutting Units Page 7 − 6 Greensmaster 3150

Factors That Can Affect Cutting Performance
There are a number of factors that can contribute to un- Refer to the Cutting Unit’s Operator’s Manual for de-
satisfactory quality of cut, some of which may be turf tailed cutting unit adjustment procedures. For cutting
conditions. Turf conditions such as excessive thatch, unit repair information, refer to the Service and Repairs
“sponginess” or attempting to cut off too much grass section of this chapter.
height may not always be overcome by adjusting the
cutting unit. It is important to remember that the lower NOTE: For additional information regarding cutting unit
the height−of−cut, the more critical these factors are. troubleshooting, see Aftercut Appearance Trouble-
shooting Aid (Toro part no. 00076SL).

Factor Possible Problem/Correction

Tire pressure Check tire pressure of all traction unit tires. Adjust tire
pressure as necessary.

See the Traction Unit Operator’s manual.

Governed engine speed For best cutting performance and appearance, engine
should be run at maximum governed speed during
machine operation. Check maximum governed engine
speed. Adjust engine to specifications if necessary.

See Chapter 3 − Engine.

Reel speed All cutting reels must rotate at the same speed (within
100 rpm) (see Troubleshooting in Chapter 4 −
Hydraulic System).

All cutting units must have equal bedknife to reel and

height−of−cut adjustments.

Make sure that reel speed selection is correct (see

Reel Speed Chart in Traction Unit Operator’s Manual).

Reel bearing condition Check reel bearings for wear and replace if necessary.

See Reel Assembly Service in the Service and Repairs

section of this chapter.

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

DPA Cutting
adversely affected by both conditions (see Bedknife to

Units
Reel Adjustment in the Cutting Unit Operator’s
Manual).

Greensmaster 3150 Page 7 − 7 DPA Cutting Units

Factor Possible Problem/Correction

Reel and bedknife sharpness 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 cutting 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.

Dull cutting edges must be corrected by grinding the

bedknife and cutting reel (see Preparing Reel for
Grinding in the Service and Repairs section of this
chapter).

A new bedknife must be ground flat (within 0.002”)

after installation to the bedbar. Backlapping may
be required to properly mate the reel and bedknife
after installation into the cutting unit.

NOTE: On cutting units equipped with optional

bedknives, slightly dull cutting edges may be corrected
by backlapping (see Backlapping in the Service and
Repairs section of this chapter).

Rear roller adjustment Adjust the rear roller brackets to correct 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 incorrect for effective height−of−cut,
poor quality of cut will result.

See Cutting Unit Operator’s Manual for bedknife

options.

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 the Service

and Repairs section of this chapter.

Number of reel blades Use correct number of reel blades for clip frequency
and optimum height−of−cut range.

DPA Cutting Units Page 7 − 8 Greensmaster 3150

Factor Possible Problem/Correction

Roller condition and roller type Make sure rollers rotate freely. Repair roller bearings
as necessary.

See Roller Service in the Service and Repairs section

of this chapter.

Refer to Cutting Unit Operator’s Manual for roller

options.

Cutting unit accessories A variety of cutting unit accessories are available that
can be used to enhance aftercut appearance. Refer to
Operator’s Manual for a listing of available
accessories.

DPA Cutting
Units

Greensmaster 3150 Page 7 − 9 DPA Cutting Units

Set Up and Adjustments

Characteristics
If a cutting unit is determined to be out of adjustment,
CAUTION complete the following procedures in the specified order
to adjust the cutting unit properly.

Never install or work on the cutting units or cut- 1. Adjust the bedknife parallel to the reel.
ting unit suspension with the engine running. Al-
ways stop engine and remove key first. 2. Determine desired height−of−cut range and install
rear roller mounting shim(s) accordingly.

The dual knob bedknife−to−reel adjustment system in- 3. Adjust the height−of−cut.
corporated in this cutting unit simplifies the adjustment
procedure needed to deliver optimum mowing perfor- See Cutting Unit Operator’s Manual for cutting unit ad-
mance. The precise adjustment possible with this de- justment procedures for your Greensmaster 3150 ma-
sign gives the necessary control to provide a continual chine.
self−sharpening action. This feature maintains sharp
cutting edges, assures good quality of cut and greatly
reduces the need for routine backlapping.

In addition, the rear roller positioning system allows for

various height-of-cut ranges and aggressiveness of cut
selections.

DPA Cutting Units Page 7 − 10 Greensmaster 3150

Leveling Rear Roller
The precision machined components of the cutting unit
frame keep the rear roller and cutting reel in alignment
2
(parallel). If the side plates are disassembled or as the
cutting reel wears, a limited amount of side plate adjust- 2
ment is possible to make sure that the cutting unit is
properly aligned. 1

1. Place the assembled cutting unit on a surface plate.

2. Make sure that bedknife is properly adjusted to cut-

ting reel.

3. Using the surface plate, check if rear roller is level to

cutting reel by using a 0.005” (0.13 mm) shim at each
end of rear roller. If the shim will pass under the roller at
one end but not the other, a frame adjustment should be
made. 3

4. Loosen, but do not remove, the two (2) shoulder Figure 12

bolts that secure the side plate to the frame opposite the 1. Side plate 3. Rear roller
side that is not level (Fig. 12). 2. Shoulder bolt

5. Adjust the position of the side plate to parallel the

rear roller and cutting reel. Then, tighten the shoulder
bolts to a torque from 210 to 240 in−lb (24 to 27 N−m).

6. After tightening the side plate, recheck the rear roller.

If necessary, loosen and adjust second side plate.

7. After leveling rear roller, complete cutting unit set−up

and adjustment sequence.

DPA Cutting
Units

Greensmaster 3150 Page 7 − 11 DPA Cutting Units

Service and Repairs

Backlapping

DANGER 2
1
TO AVOID PERSONAL INJURY OR DEATH:
D Never place hands or feet in the reel area
while the engine is running.
D When backlapping, run engine at idle speed 3
only.
D While backlapping, the reels may stall and
then restart.
D Do not attempt to restart reels by hand or foot.
D Do not adjust reels while the engine is
running.
D If a reel stalls, stop engine before attempting Figure 13
to clear the reel.
1. Hydraulic manifold 3. Backlap lever
D Reel motors are connected in series: rotating 2. Reel speed control
one motor causes rotation in other motors.

NOTE: Additional instructions and procedures on

backlapping are available in the Toro General Service
Training Book, Reel Mower Basics (part no. 09168SL).

1. Position the machine on a level surface, lower the

cutting units, stop the engine and engage the parking
brake.

2. Raise the operator seat to access hydraulic mow

manifold.
1
3. Locate the reel speed control and backlap lever on
the hydraulic mow manifold (Fig. 13). Rotate the reel
speed control to position “1” and the backlap lever to the Figure 14
R (backlap) position.
1. Long Handle Brush
4. Make initial reel to bedknife adjustments appropriate
for backlapping on all cutting units which are to be back-
lapped. DANGER
5. Start engine and run at low idle speed.
Reels may stall while backlapping. Do not
6. Use joystick on the control console to engage the attempt to restart reels by hand or touch reels
cutting units. while backlapping. Stop engine and turn reel
speed adjustment knob one position toward
IMPORTANT: To prevent damage to the reel, do not ”9.”
rotate the backlap lever from the backlap position to
the mow position while the engine is running. 8. If reels stall or become erratic while backlapping,
stop backlapping by disengaging the PTO with the joys-
7. Apply lapping compound to cutting unit blades with
tick. Once the reels have stopped, move the reel speed
a long handle brush (see Special Tools in this chapter)
selector knob one position closer to “9.” Resume back-
(Fig. 14). Never use a short handled brush to apply lap-
lapping by engaging the PTO with the joystick.
ping compound.

DPA Cutting Units Page 7 − 12 Greensmaster 3150

9. To make an adjustment to the cutting units while
backlapping, disengage the PTO with the joystick and 2
1 3
turn the engine OFF. Wait for all machine movement to
stop. After adjustments have been completed, repeat
steps 5 through 8.
4
10.When the backlapping operation is completed, stop
the engine and remove the key from the ignition switch. 5
Run a file across the front face of the bedknife. This will
remove any burrs or rough edges that may have built up
on the cutting edge (Fig. 15).
Figure 15
11. Repeat procedure for all cutting units to be backlap-
1. Top angle 4. Front surface
ped. 2. Top surface 5. Front angle
3. Remove burr
12.When backlap operation has been completed, return
the backlap lever to the F (mow) position, set reel speed
control to desired speed, lower operator seat and wash
all lapping compound off cutting units. Adjust cutting unit
reel to bedknife as needed.

NOTE: If the backlap lever is not returned to the F

(mow) position after backlapping, the cutting units will
not function properly.

DPA Cutting
Units

Greensmaster 3150 Page 7 − 13 DPA Cutting Units

Bedbar Assembly

200 to 250 in−lb

(23 to 28 N−m)
1

17
16
2

3
190 to 240 in−lb
(22 to 27 N−m)
6
7 13
12
11
4 Antiseize
9 Lubricant
8

15

RIGHT
14
18
FRONT 5 16
17 10

Figure 16
1. Bedbar 7. Detent (2 used) 13. Lock nut (2 used)
2. Bedknife 8. Wave washer (2 used) 14. Rubber bushing (2 used)
3. Screw (13 used) 9. Retaining ring (2 used) 15. Nylon bushing (2 used)
4. Bedbar adjuster screw (2 used) 10. Lock nut (2 used) 16. Plastic washer (4 used)
5. Bedbar adjuster shaft (2 used) 11. Washer (2 used) 17. Metal washer (4 used)
6. Cap screw (2 used) 12. Compression spring (2 used) 18. Bedbar pivot bolt (2 used)

Bedbar Removal (Fig. 16) 4. Loosen the lock nuts (item 13) on the end of each
bedbar adjuster assembly until washer (item 11) is
1. Position machine on a clean and level surface, lower loose.
cutting units, stop engine, engage parking brake and re-
move key from the ignition switch. 5. Loosen the lock nuts (item 10) on each bedbar pivot
bolt (item 18).
2. Remove the cutting unit from the machine and place
cutting unit on a flat work area. 6. Remove two (2) bedbar pivot bolts (item 18), four (4)
metal washers (item 17) and four (4) plastic washers
3. Tip the cutting unit to expose the bedknife. Support (item 16) from the cutting unit side plates.
the rear of the cutting unit (see Supporting Cutting Unit
when Servicing in the General Information section of
this chapter).

DPA Cutting Units Page 7 − 14 Greensmaster 3150

 6. Position one (1) metal washer (item 17) and one (1)
CAUTION plastic washer (item 16) between bedbar and each cut-
ting unit side plate (Fig. 17).

Contact with the reel, bedknife or other cutting 7. Install the bedbar pivot bolt assemblies. Make sure
unit parts can result in personal injury. Use that plastic washers are not caught on the threads of the
heavy gloves when handling the bedbar. pivot bolts. Torque each bedbar pivot bolt from 190 to
240 in−lb (22 to 27 N−m).
7. Remove bedbar assembly from cutting unit. 8. Tighten both lock nuts (item 10) until outside wash-
ers do not have any endplay but still can be rotated. Do
8. Inspect nylon bushings (item 15) and rubber bush-
not over tighten the lock nuts as this can distort the side
ings (item 14) in side plates for wear or damage. Re-
plates and affect reel bearing adjustment. When the lock
move bushings and replace if necessary.
nut is correctly tightened, there may be a gap at the in-
Bedbar Installation (Fig. 16) side washers.

1. If rubber bushing was removed from either cutting 9. Tighten the lock nut (item 13) on each bedbar adjust-
unit side plate, apply grease to outside surface of new er assembly until the adjuster spring is fully com-
bushing and install into side plate. The bushing should pressed, then loosen lock nut 1/2 turn.
be installed flush with the inside of the side plate (Fig.
10.Adjust cutting unit (see Cutting Unit Operator’s
17).
Manual).
2. If removed, install the nylon bushings (item 15) with
11. Install cutting unit to machine.
flange facing outward. Apply antiseize lubricant to inside
of flange bushing.
Antiseize

ÇÇÇÇ
3. Apply antiseize lubricant to the bedbar threads and Lubricant 1 8
the shoulder area of each bedbar pivot bolt (Fig. 17). 7

ÇÇÇÇ
ÇÇÇÇ
IMPORTANT: When installing washers (items 16

ÇÇÇÇ
and 17), make sure that plastic washers are posi-
tioned on either side of the cutting unit sideplate
(Fig. 17).

4. Slide one (1) metal washer (item 17) and then one (1)
plastic washer (item 16) onto each bedbar pivot bolt.

ÇÇÇÇ
CAUTION ÇÇÇÇ 3
6 5 4 2 4 5
Contact with the reel, bedknife or other cutting
unit parts can result in personal injury. Use
Figure 17

DPA Cutting
heavy gloves when handling the bedbar.
1. Cutting unit sideplate 5. Metal washer

Units
2. Rubber bushing 6. Bedbar
3. Nylon bushing 7. Bedbar pivot bolt
5. Position bedbar into cutting unit. Make sure that the 4. Plastic washer 8. Lock nut
top of each bedbar arm is between washer (item 11) and
adjuster screw flange (item 4).

Greensmaster 3150 Page 7 − 15 DPA Cutting Units

Bedknife Replacement and Grinding
Bedknife Removal

1. Remove bedbar from cutting unit (see Bedbar Re-

moval in this section).
2
2. Remove screws from bedbar using a socket wrench
and bedknife screw tool (see Special Tools in this chap-
ter). Discard screws. Remove bedknife from the bedbar
(Fig. 18).

3. See bedknife grinding information on the following

pages.

Bedknife Installation

1. Use scraper to remove all rust, scale and corrosion

from bedbar surface. Lightly oil bedbar surface before 3
installing bedknife.
Antiseize
2. Make sure that screw threads in bedbar Lubricant
(5/16−18UNC−2A) are clean.

IMPORTANT: Do not use an impact wrench to tight- 200 to 250 in−lb 1

en screws into the bedbar. (23 to 28 N−m)
Lightly Oil
3. Use new screws to secure bedknife to bedbar. Apply Bedbar Surface
antiseize lubricant to the threads of new screws. Do not
Figure 18
apply antiseize lubricant to the taper of the screw heads.
1. Screw (13) 3. Bedknife
2. Bedbar
4. Install all screws but do not tighten.

5. Using a torque wrench and bedknife screw tool,

tighten the 2 outer screws to 10 in−lb (1 N−m).

6. Working from the center of the bedknife toward each

end (Fig. 19), tighten screws from 200 to 250 in−lb (23
to 28 N−m).

7. After installing bedknife to bedbar, grind bedknife.

# TOR510880

1st − 10 in−lb (1 N−m)

1 2

15 13 11 9 7 5 3 4 6 8 10 12 14

2nd − 200 to 250 in−lb (23 to 28 N−m)

Figure 19

DPA Cutting Units Page 7 − 16 Greensmaster 3150

Bedknife Grinding Bedknife Grinding Specifications (see Fig. 21)
Standard bedknife relief angle 3o minimum
Since there can be variations in the mounting surface of
the bedbar, it is necessary to grind the bedknife after in- Fairway bedknife relief angle 3o minimum
stalling it to the bedbar. Follow the bedknife grinding Extended bedknife relief angle 7o minimum
specifications provided (Fig. 20). Grind only enough so Front Angle Range 13o to 17o
the top surface of the bedknife is true (Fig. 21).
Figure 20
IMPORTANT: Do Not grind the bedknife below it’s
service limit (Fig 22). Operating the cutting unit with
1 2 3
the bedknife below the service limit may result in
poor after−cut appearance and reduce the struc-
tural integrity of the bedknife.
4
The bedknife service limit occurs when the reel contacts
the back of the bedknife scallop during operation. Check 5
for reel contact marks at the back of the bedknife scallop
prior to grinding. The bedknife service limit may also oc-
cur when the bottom of the bedknife scallop is reached
when grinding the bedknife. Figure 21
When grinding the bedknife, be careful to not overheat 1. Top angle 4. Front surface
2. Top surface 5. Front angle
the bedknife. Remove small amounts of material with 3. Remove burr
each pass of the grinder. Also, clean and dress grind- (without dulling sharp
ing stone often during the grinding process. corner)

NOTE: EdgeMaxR bedknives are extremely hard. Us-

ing a diamond grinding wheel is recommended to pre- 1
vent overheating or damaging the bedknife edge while
grinding.

Because the top grind angle on bedknives is critical for

edge retention, and therefore after−cut appearance, 2
Toro has developed special service tools for accurately
measuring the top grind angle on all bedknives; refer to
Figure 22
the Angle Indicator and Magnetic Mount in the Special
Tools section of this Chapter. 1. Service limit 2. Service limit
(reel contacts back of (bottom of bedknife
bedknife scallop during scallop reached when
1. Use Toro General Service Training Book, Reel Mow- operation) grinding)
er Basics (part no. 09168SL) and grinder manufactur-
er’s instructions for bedknife grinding information.

2. After bedknife grinding is complete, install bedbar to

cutting unit (see Bedbar Installation in this section).

DPA Cutting
Units
NOTE: Always adjust the cutting unit after grinding the
reel and/or bedknife; refer to the Cutting Unit Operator’s
Manual. If a properly adjusted cutting unit does not cut
paper cleanly after grinding, the grind angle may be in-
correct. To extend the cutting unit performance by allow-
ing the reel and the bedknife to hold their edge longer,
an additional adjustment may be required after the first
few minutes of operation as the reel and bedknife con-
form to each other.

Greensmaster 3150 Page 7 − 17 DPA Cutting Units

Bedbar Adjuster Service

Antiseize
Lubricant 3
2
6 11

10
9
8

RIGHT

5
FRONT
4

Figure 23
1. Bedbar assembly 5. Flange bushing 9. Retaining ring
2. Compression spring 6. Cap screw 10. Bedbar adjuster screw
3. Lock nut 7. Detent 11. Washer
4. Bedbar adjuster shaft 8. Wave washer

DPA Cutting Units Page 7 − 18 Greensmaster 3150

Removal (Fig. 23) Installation (Fig. 23)

1. Remove lock nut (item 3), compression spring (item 1. If detent (item 7) was removed, secure detent to cut-
2) and washer (item 11) from bedbar adjuster screw. ting unit side plate with cap screw.

2. Remove bedbar (see Bedbar Removal in this sec- 2. If flange bushings (item 5) were removed, align key
tion). on bushing to slot in frame and install bushings.

NOTE: Bedbar adjuster shaft (item 4) has left−hand 3. Slide adjuster shaft (item 4) into flange bushings in
threads. cutting unit side plate. Secure adjuster shaft with wave
washer (item 8) and retaining ring (item 9).
3. Unscrew bedbar adjuster shaft (item 4) from the bed-
bar adjuster screw (item 10). NOTE: Bedbar adjuster shaft (item 4) has left−hand
threads.
4. Remove retaining ring (item 9) and wave washer
(item 8) from adjuster shaft and remove adjuster shaft 4. Apply antiseize lubricant to threads of bedbar adjust-
from cutting unit frame. er screw that fit into adjuster shaft. Thread bedbar ad-
juster screw (item 10) into adjuster shaft.
5. Inspect flange bushings (item 5) in cutting unit side
plate and remove if necessary. 5. Install bedbar (see Bedbar Installation in this sec-
tion).
6. If detent (item 7) is damaged, remove it from cutting
unit side plate by removing the cap screw (item 6). 6. Install washer (item 11), spring (item 2) and lock nut
(item 3) onto adjuster screw. Tighten the lock nut on
each bedbar adjuster assembly until the compression
spring is fully compressed, then loosen lock nut 1/2 turn.

7. Adjust cutting unit (see Cutting Unit Operator’s

Manual).

DPA Cutting
Units

Greensmaster 3150 Page 7 − 19 DPA Cutting Units

Reel Assembly

210 to 240 in−lb

(24 to 27 N−m)

16 4
3 9
13

210 to 240 in−lb

15 (24 to 27 N−m)
5
7 1
11
5
5

5 4
2

Grease OD
surface
12

RIGHT Grease OD
surface 14
11 17
FRONT
10
8

Figure 24
1. Crossmember 7. O−ring 13. Grass shield
2. LH side plate 8. Cap screw (2 used) 14. Flat wire spring
3. Flange head screw (2 used) 9. RH side plate 15. Reel motor adapter
4. Shoulder bolt (2 used per side plate) 10. Weight 16. Socket head screw (2 used)
5. Flange nut (2 used per side plate) 11. Hex nut (4 used) 17. Expansion plug
6. Cutting reel assembly 12. O−ring

NOTE: This section provides the procedure for remov- NOTE: Removal of the cutting reel requires removal of
ing and installing the cutting reel assembly (cutting reel, the LH side plate from the cutting unit crossmember.
flocked seals, reel bearings, bearing lock screw and reel The RH side plate does not have to be removed from the
nut) from the cutting unit. Refer to Reel Assembly Ser- frame when using the following procedure.
vice later in this section for information on servicing the
cutting reel assembly.

DPA Cutting Units Page 7 − 20 Greensmaster 3150

Reel Assembly Removal (Fig. 24)
90 to 110 ft−lb
5 (123 to 149 N−m)
(Right Hand Threads)
CAUTION
90 to 110 ft−lb
(123 to 149 N−m)
Contact with the reel, bedknife or other cutting
unit parts can result in personal injury. Use (Left Hand Threads)
heavy gloves when removing the cutting reel. 3
2

1. Position machine on a clean and level surface, lower 6

cutting units, stop engine, engage parking brake and re- 1
move key from the ignition switch.
7
2. Remove the cutting unit from the machine and place
cutting unit on a flat work area. 2
3 4
3. If cutting unit is equipped with an optional groomer or
rear roller brush, remove drive components for those Figure 25
options from cutting unit. See Service and Repairs sec- 1. Cutting reel 5. Bearing lock screw
2. Flocked seal (2 used) 6. Reel nut (LH threads)
tion of Chapter 8 − Groomer for information on groomer. 3. Bearing (2 used) 7. Reel groove location
See Rear Roller Brush in this section for information on 4. Plug (2 used)
rear roller brush.
Reel Assembly Installation (Fig. 24)
4. Remove two (2) cap screws and nuts that secure
weight (item 10) to the LH side plate. Remove weight 1. Thoroughly clean side plates and other cutting unit
from the cutting unit. Remove and discard O−ring from components. Inspect side plates for wear or damage
weight. and replace components if needed.

NOTE: The reel nut on the left end of the cutting reel 2. Make sure that flocked seals, reel bearings and reel
has a black finish and has LH threads. The left end of the nuts are properly positioned on cutting reel (see Reel
cutting reel shaft is identified with a groove that is just in- Assembly Service in this section). Apply thin coat of
side of the reel spider (Fig. 25). grease to outside of bearings on cutting reel to ease reel
installation.
5. If bearings or seals are to be removed from cutting
reel, put a block of wood between the cutting reel blades
to prevent the reel from rotating. Loosen reel nuts to al-
low easier removal after reel assembly is removed from CAUTION
cutting unit (Fig. 25).
Contact with the reel, bedknife or other cutting
6. Remove the bedbar pivot bolt and washers from the unit parts can result in personal injury. Use
LH side plate. Note location of plastic and steel washers heavy gloves when installing the cutting reel.
for assembly purposes (see Bedbar Removal in this

DPA Cutting
section).

Units
3. Position the cutting unit on a flat work area. The roll-
7. Loosen fasteners that secure front and rear rollers to ers, bedbar and cutting unit crossmember should be at-
LH side plate (see Front Roller Removal and Rear Roller tached to RH side plate.
Removal in this section).
4. Carefully slide the cutting reel assembly (with
8. Support cutting reel to prevent it from shifting or fal- flocked seals, reel bearings and reel nuts) into the RH
ling. side plate. Make sure that bearing is fully seated into
side plate.
9. Remove shoulder bolts (item 4) and flange nuts (item
5) that secure the LH side plate to the cutting unit cross- 5. Place flat wire spring (item 14) into bearing bore of
member. Remove the LH side plate from the reel shaft, LH side plate. Carefully slide the LH side plate onto the
rollers, bedbar and cutting unit crossmember. cutting reel assembly, front roller and rear roller. Make
sure that side plate is fully seated onto bearing on reel
10.Carefully slide the cutting reel assembly (with shaft.
flocked seals, reel bearings and reel nuts) from the RH
side plate.

Greensmaster 3150 Page 7 − 21 DPA Cutting Units

6. Install shoulder bolts (item 4) and flange nuts (item 11. Adjust cutting unit (see Cutting Unit Operator’s
5) to secure the LH side plate to the crossmember. Manual).
Torque the shoulder bolts from 210 to 240 in−lb (24 to
27 N−m). NOTE: The parallel position of the rear roller to the cut-
ting reel is controlled by the precision machined cross-
NOTE: The reel nut on the left end of the cutting reel member and side plates of the cutting unit. If necessary,
has a black finish and has LH threads. The left end of the the cutting unit side plates can be loosened and a slight
cutting reel shaft is identified with a groove that is just in- adjustment can be made to parallel the rear roller with
side of the reel spider (Fig. 25). the cutting reel (see Leveling Rear Roller in the Set−Up
and Adjustments section of this Chapter).
7. If reel nuts were loosened during cutting reel service,
put a block of wood between the cutting reel blades to 12.Install new O−ring (item 12) on weight (item 10). Se-
prevent the reel from rotating. Torque reel nuts from 90 cure weight to LH side plate with two (2) cap screws and
to 110 ft−lb (123 to 149 N−m) (Fig. 25). nuts.

8. Thoroughly fill spline area of reel nuts with grease. 13.If cutting unit is equipped with optional groomer or
rear roller brush, install components for those options to
9. Secure the bedbar assembly to LH side plate (see cutting unit. See Service and Repairs section of Chapter
Bedbar Installation in this section). Make sure that plas- 8 − Groomer for information on groomer. See Rear Roll-
tic and steel washers are properly positioned. er Brush in this section for information on rear roller
brush.
10.Secure front and rear rollers to LH side plate (see
Front Roller Installation and Rear Roller Installation in 14.Install cutting unit to the machine.
this section).

DPA Cutting Units Page 7 − 22 Greensmaster 3150

 This page is intentionally blank.

DPA Cutting
Units

Greensmaster 3150 Page 7 − 23 DPA Cutting Units

Reel Assembly Service

4 3

90 to 110 ft−lb
(123 to 149 N−m)
(Right Hand Threads) 2
3

1 4

RIGHT

FRONT 90 to 110 ft−lb

(123 to 149 N−m) 6
(Left Hand Threads)

Figure 26
1. Cutting reel 3. Bearing (2 used) 5. Reel nut (RH thread)
2. Flocked seal (2 used) 4. Plug (2 used) 6. Reel nut (LH thread)

NOTE: The reel nuts (items 5 and 6) are different. The

reel nut with left hand threads (item 6) has a black finish
and has notches on the head. The reel nut with right
hand threads (item 5) has a zinc finish and does not
have notches on the head.

DPA Cutting Units Page 7 − 24 Greensmaster 3150

Disassembly of Cutting Reel (Fig. 26)

1. Remove reel nuts (items 5 and 6) from cutting reel. 3 1

The black reel nut (item 6) has LH threads and is
installed in end of reel shaft identified with a groove that
is just inside of reel spider (Fig. 27).

2. Slide bearings from reel shaft.

3. Note orientation of flocked seals for assembly pur-

poses. Remove seals from reel shaft. 2

Inspection of Cutting Reel (Fig. 26)

Figure 27
1. Inspect reel bearings to insure that they spin freely 1. LH threads 3. RH threads
and have minimal axial play. 2. Groove

2. Inspect the reel shaft as follows. If reel damage is de-

tected, replace reel.

A. Check the reel shaft for bending and distortion by

placing the shaft ends in V−blocks.

B. Check the reel blades for bending or cracking.

C. Check the service limit of the reel diameter (see

Preparing a Reel for Grinding in this section).

D. Check threads in ends of reel shaft.

3. Check the splines in the reel nuts (items 5 and 6) for

excessive wear or distortion. Replace reel nuts if dam-
age is evident.

Assembly of Cutting Reel (Fig. 26)

1. If bearings and/or flocked seals were removed from

reel shaft, discard removed components and replace.

IMPORTANT: The flocked seal should be installed

so the flocked side of the seal is toward the bearing
location.

2. Slide flocked seals (flocked side orientated toward

bearing location) and bearings fully onto reel shaft.

DPA Cutting
Bearings and seals should bottom on reel shaft shoul-

Units
der.

3. Install reel nuts (items 5 and 6) into reel shaft to se-

cure bearings. Black reel nut (item 6) has LH threads
and should be installed in end of reel shaft identified with
a groove that is just inside of reel spider (Fig. 27).

NOTE: Installation torque for reel nuts is from 90 to 110

ft−lb (123 to 149 N−m). It is easiest to torque these
items after the cutting reel is installed in the cutting unit
frame (see Reel Assembly Removal and Installation in
this section).

4. Thoroughly fill spline area of reel nuts with grease.

Greensmaster 3150 Page 7 − 25 DPA Cutting Units

Preparing Reel for Grinding
NOTE: Before grinding a cutting reel, make sure that all Reel Grinding Specifications
cutting unit components are in good condition. Depend- Reel Diameter (New) 5.06 in (128.5 mm)
ing on type of grinder used, faulty cutting unit compo-
Service Limit - Reel
nents can affect grinding results. Diameter
4.50 in (114.3 mm)

NOTE: When grinding, be careful to not overheat the Reel Shaft Diameter (OD) 1.375 in (34.9 mm)
cutting reel blades. Remove small amounts of material Blade Relief Angle 30o
with each pass of the grinder. Blade Relief Angle Range 28o to 32o
Blade Land Width 0.040 in (1.0 mm)
1. Follow reel grinder manufacturer’s instructions to
grind cutting reel to Toro specifications (see Reel Grind- Blade Land Width Range 0.030 to 0.050 in (0.8 to 1.2 mm)
ing Specifications chart to the right). Additional reel Service Limit -
0.010 in (0.25 mm)
Reel Diameter Taper
grinding information can be found in the Toro General
Service Training Book, Reel Mower Basics (part no.
09168SL).

2. After completing the reel grinding process, adjust

cutting unit (see Cutting Unit Operator’s Manual).

Blade Relief Angle

Reel Diameter Rotation

Blade Land
Width

D1 D2

Reel Diameter Taper = D1 − D2

Figure 28

DPA Cutting Units Page 7 − 26 Greensmaster 3150

 This page is intentionally blank.

DPA Cutting
Units

Greensmaster 3150 Page 7 − 27 DPA Cutting Units

Front Roller
Removal (Fig. 29)

1. Position machine on a clean and level surface, lower

cutting units, stop engine, engage parking brake and re-
move key from the ignition switch.

2. Remove the cutting unit from the machine and place

on a level working surface. Use appropriate support to Antiseize
raise front roller from work surface. Lubricant
4
3. Loosen cap screw (item 1) that secures the front roll-
er shaft to each front height−of−cut arm.

4. On one of the height−of−cut arms, remove HOC nut 5

(item 7), HOC washer (item 6) and plow bolt (item 4) that 6
3
secure HOC arm to the cutting unit side plate. Remove
the HOC arm from the cutting unit. 7

5. Slide the front roller assembly from the remaining 2 1

HOC arm on the cutting unit.
8
6. If necessary, remove the second HOC arm from the Figure 29
cutting unit.
1. Cap screw 5. HOC screw
2. HOC arm 6. HOC washer
Installation (Fig. 29) 3. Front roller assembly 7. HOC nut
4. Plow bolt 8. Ball stud
1. Place cutting unit on a level working surface and use
appropriate support to support front of cutting unit.

2. Inspect condition of HOC screws (item 5) in both 3

HOC arms. If necessary, apply antiseize lubricant to
threads of new HOC screw. Thread new HOC screw into
HOC arm. 4

NOTE: When assembling HOC arms to side plates,

make sure that ring on HOC screw fits into the notch on
the side plate.

3. If both HOC arms were removed from cutting unit

side plate, position one of the arms to side plate. Secure
arm to side plate with plow bolt (item 4), HOC washer
(item 6) and HOC nut (item 7). Tab on HOC washer
1
should be positioned into HOC arm slot and orientated
down toward the roller.

4. Slide front roller shaft into arm attached to the cutting 2

unit. Slide second HOC arm onto the other end of roller
Figure 30
shaft. Secure second arm to cutting unit side plate with
plow bolt (item 4), HOC washer (item 6) and HOC nut 1. Front roller assembly 3. HOC screw
2. HOC arm 4. HOC washer & nut
(item 7).

5. Center front roller to the cutting reel and secure to

HOC arms with cap screws (item 1).

6. Adjust cutting unit (see Cutting Unit Operator’s

Manual).

DPA Cutting Units Page 7 − 28 Greensmaster 3150

Rear Roller
Removal (Fig. 31)

1. Position machine on a clean and level surface, lower

cutting units, stop engine, engage parking brake and re- 4
move key from the ignition switch.

2. Remove the cutting unit from the machine and place 5

on a level working surface. Place support blocks under
bedbar to raise rear roller from work surface.

3. Loosen two (2) flange nuts that secure the rear roller
shaft to each rear roller shaft retainer. 2

4. On one of the rear roller shaft retainer assemblies:

6
NOTE: On cutting units equipped with optional High 1
Height of Cut Kit, there will be additional roller shims
3
installed between roller height spacer and cutting unit
side plate.
Figure 31
A. Note quantity and location of roller shims for as- 1. Rear roller assembly 4. Flange nut
2. Roller height spacer 5. Roller shim
sembly purposes. 3. Socket head screw 6. Shaft retainer

B. Remove flange nuts and socket head screws that

3. Slide rear roller shaft into the retainer assembly at-
secure shaft retainer, roller height spacer and roller
tached to the cutting unit. Slide second rear roller shaft
shims to the cutting unit side plate.
retainer, roller height spacer and roller shims onto the
C. Remove the shaft retainer, height spacer and roll- other end of roller shaft. Secure second retainer assem-
er shims from the rear roller and cutting unit. bly to cutting unit side plate with two (2) carriage screws
and flange nuts. Do not fully tighten flange nuts.
5. Slide the rear roller assembly from the remaining
rear roller retainer assembly on the cutting unit. 4. Center rear roller to the cutting reel and secure in
place by tightening four (4) flange nuts.
6. If necessary, remove the second rear roller retainer
assembly from the cutting unit. 5. Adjust cutting unit (see Cutting Unit Operator’s
Manual).
Installation (Fig. 31)

1. Place cutting unit on a level working surface.

NOTE: Refer to Cutting Unit Operator’s Manual for

DPA Cutting
number of roller shims required for various height of cut

Units
settings.

2. If both rear roller retainer assemblies were removed

from cutting unit, position shaft retainer, roller height
spacer and roller shims to one of the side plates. Install
two (2) carriage screws and flange nuts to retain assem-
bly in position but do not fully tighten flange nuts.

Greensmaster 3150 Page 7 − 29 DPA Cutting Units

Roller Service

1
6 7
5
4

25 to 30 ft−lb
(34 to 41 N−m) 2

4 25 to 30 ft−lb
5 (34 to 41 N−m)
6

7
3

Figure 32
1. Wiehle roller 4. Ball bearing 6. V−ring
2. Smooth roller 5. Seal 7. Bearing lock nut
3. Roller shaft

Disassembly 1 3 4 5
2
1. To hold roller shaft for bearing lock nut removal,
install a 3/8−24 UNF 2B screw into threaded end of roller 6
shaft and secure screw in place with jam nut. While re-
taining 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 secure roller assembly in bench vise and Figure 33

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
3. Seal 6. Roller shaft
bearing from roller cavity by tapping on shaft.

5. Clean bearing cavity in roller and remove any rust 3 1

2
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 Figure 34
seals have been installed. 1. Bearing lock nut 3. Bearing
2. Black assembly washer

DPA Cutting Units Page 7 − 30 Greensmaster 3150

NOTE: Special tool TOR4105 (see Special Tools) can
2 3
be used instead of washers and spacer when installing
bearings and seals in roller. 1
4
2. Position a new bearing, black assembly washer (see
Special Tools) and original lock nut onto each end of the
roller shaft (Fig. 34).

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- Figure 35

fore seal installation may result in seal damage. 1. Bearing lock nut 3. Grease nut surface
2. Seal 4. Pack with grease
5. Apply a coating of grease to the nut surface to pre-
vent seal damage during seal installation (Fig. 35).
2 1
6. Carefully install seals onto bearing lock nuts. Pack
the back of the seal 75 to 90% full with #2 grease (Fig.
35).

7. Install a nut with seal onto each end of the roller shaft.
Tighten nuts until they bottom against bearings (Fig. 36).
Remove nuts from roller shaft.

8. Position an assembly spacer and yellow assembly

washer (see Special Tools) on each end of roller shaft Figure 36
(Fig. 37). Thread nut onto each end of shaft. 1. Bearing lock nut 2. Seal

9. Tighten each nut until the yellow assembly washers

bottom out against the roller housing. Remove nuts, as- 4 3 2 1
sembly washers and assembly spacers from roller
shaft.

10.Lubricate lips of installed seals with #2 grease.

11. Carefully slide a dry V−ring onto each bearing lock

nut. The V−rings should be installed without any lubrica-
tion.

NOTE: If original bearing lock nut(s) are being used, Figure 37

DPA Cutting
apply Loctite #242 (or equivalent) to threads of lock 1. Bearing lock nut 3. Assembly spacer
2. Yellow assembly washer 4. Seal

Units
nut(s).

12.Install bearing lock nut with V−ring onto each end of

the roller shaft. Torque lock nuts from 25 to 30 ft−lb (34
to 41 N−m).

Greensmaster 3150 Page 7 − 31 DPA Cutting Units

Rear Roller Brush (Optional)

14 15
8
13

16
17
130 to 140 in−lb
(15 to 16 N−m)

13
9
14
100 ft−lb 11
8
(136 N−m) 23
10
12
22
4
18
7
20
19
12
3 6

5
2
1
12

RIGHT Antiseize
Lubricant
70 to 80 in−lb
FRONT (8 to 9 N−m)
24
25
21

Figure 38
1. Cover 10. Driven pulley 18. O−ring
2. Drive belt 11. Square key 19. Flat washer
3. Drive pulley 12. Threadlock screw (4 used) 20. Bearing spacer
4. Pulley driver 13. Roller bearing assembly (2 used) 21. Cap screw (2 used)
5. Cap screw 14. Grease fitting (2 used) 22. Cap screw
6. Idler pulley assembly 15. RH brush support 23. Bearing spacer
7. Cover plate 16. Flange head screw (4 used) 24. Hex nut (2 used)
8. Flange nut (5 used) 17. Brush assembly 25. Weight
9. Drive plate

NOTE: Drive components for the rear roller brush are NOTE: The Installation Instructions for the rear roller
located on the left side of the cutting unit (opposite from brush kit has detailed information regarding assembly
the hydraulic cutting reel motor). and adjustment. Use those Instructions along with this
Service Manual when servicing the rear roller brush.

DPA Cutting Units Page 7 − 32 Greensmaster 3150

Disassembly (Fig. 38)
20 to 25 in−lb
(2.3 to 2.8 N−m)
1. Position machine on a clean and level surface, lower
cutting units, stop engine, engage parking brake and re-
move key from the ignition switch.
4
2. To remove roller brush from brush shaft:
1
A. Loosen set screw in the bearing locking collar on
right side of brush shaft.
3
B. Using blind hole in bearing locking collar as an im- 2
pact point, unlock collar by striking it with a punch in
the opposite direction of brush rotation. Figure 39
1. Roller brush shaft 3. Roller brush
C. Remove the RH brush support (item 15), bearing 2. J−bolt 4. Lock nut
and locking collar from brush shaft and cutting unit.
2. Assemble roller brush components using Figure 38
D. Remove lock nut and J−bolt from both ends of the as a guide and the following assembly notes:
brush (Fig. 39).
A. The screws (item 12) that are used to secure the
E. While rotating brush, slide brush from the shaft. cover (item 1), driven pulley (item 10) and drive plate
(item 9) have a threadlock feature to prevent the
screws from loosening. If original screws are being
CAUTION re−used during assembly, apply Loctite #242 (or
equivalent) to threads of screws.
Contact with the reel or other cutting unit parts B. .Apply a light coating of grease to O−ring (item
can result in personal injury. Use heavy gloves
18) before installing on drive plate flange. Make sure
when handling the cutting reel.
that O−ring is correctly positioned in groove in
flange.
3. To remove roller brush drive belt (item 2):
C. Apply antiseize lubricant to threads of cap screw
A. Remove cover (item 1). (item 5) that retains drive pulley (item 3). Torque cap
screw from 70 to 80 in−lb (8 to 9 N−m) to secure
B. Loosen cap screw (item 22) and flange nut (item drive pulley to pulley driver.
8) that secure idler pulley assembly (item 6) to drive
plate. D. Secure driven pulley (item 10) to brush shaft with
threadlock screw (item 12). Torque screw from 130
C. Move idler pulley to loosen drive belt. to 140 in−lb (15 to 16 N−m).

D. Carefully remove drive belt from drive, driven and E. Secure pulley driver (item 4) and drive pulley
idler pulleys. (item 3) to cutting reel shaft with cap screw (item 5).
Torque screw to 100 ft−lb (136 N−m).

DPA Cutting
4. Disassemble roller brush components as necessary

Units
using Figure 38 as a guide. 3. If either of the bearing locking collars was loosened,
tighten locking collar onto brush shaft:
Assembly (Fig. 38)
A. Slide locking collar outward on brush shaft onto
1. If roller brush was removed from brush shaft, slide the bearing collar. Rotate locking collar by hand in
brush onto shaft while rotating brush. Secure brush to the direction of normal brush rotation until the collar
shaft with two (2) J−bolts and lock nuts. Make sure that is tight on the shaft.
the J−bolts are installed with the threaded portion on the
outside of the brush (Fig. 39). Torque lock nuts from 20 B. Using blind hole in bearing locking collar as an im-
to 25 in−lb (2.3 to 2.8 N−m). pact point, lock collar by striking it with a punch in the
normal direction of brush rotation.

C. Tighten set screw in locking collar to secure the

bearing assembly to the brush shaft.

Greensmaster 3150 Page 7 − 33 DPA Cutting Units

IMPORTANT: The brush drive belt may fail prema-
turely if the pulleys are not properly aligned.

4. Check alignment of pulleys with a straight edge

placed along the outer face of the pulleys (Fig. 40). The 1
outer faces of the drive, driven and idler pulleys should
be aligned. If necessary to align pulleys, loosen locking
collars on brush bearings and move brush assembly un-
til pulleys are aligned. Once pulleys are aligned, secure 3
brush with bearing locking collars.

IMPORTANT: Make sure that idler pulley is loos-

ened before installing brush drive belt.
2
5. To install brush drive belt (item 2):

A. Make sure that idler pulley (item 6) is loose on

Figure 40
drive plate.
1. Drive pulley 3. Idler pulley
2. Driven pulley
B. Carefully install drive belt around drive, driven
and idler pulleys.

C. After belt installation, make sure that belt and

pulley grooves are aligned and that belt is centered in
pulleys.
1
6. To tension the drive belt: 2

A. Push down on the idler pulley and secure with cap

screw (item 22) and flange nut (item 8). Make sure
that cover plate (item 7) is covering the slot in the
drive plate to prevent debris from entering the brush
drive area.

B. After idler pulley is secured, check that drive belt

has approximately 1/4” (6 mm) deflection at the cen-
ter of the belt with 2 lb (1 kg) of force applied to the Figure 41
belt (Fig. 41). 1. 2 lb (1 kg) of force 2. 1/4” (6 mm) deflection

7. Check that roller brush is parallel to rear roller with

0.010” (0.25 mm) clearance to light contact with roller.
If contact is incorrect, brush operation will be adversely
affected.

8. Lubricate grease fittings on brush support and drive

plate until grease is visible. Wipe up excess grease.

DPA Cutting Units Page 7 − 34 Greensmaster 3150

 Chapter 8

Belt Driven Groomer (Optional)

Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4
Factors Affecting Grooming . . . . . . . . . . . . . . . . . . . 4
Grooming Reel Mechanical Problems . . . . . . . . . . 5
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Height/Depth of Groomer Adjustment . . . . . . . . . . 6
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 7
Groomer Belt Replacement . . . . . . . . . . . . . . . . . . . 7
Grooming Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Grooming Reel Service . . . . . . . . . . . . . . . . . . . . . 11
Grooming Reel Bearing Replacement . . . . . . . . . 12
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lift Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Groomer Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Groomer (Optional)
Belt Driven

Greensmaster 3150 Page 8 − 1 Belt Driven Groomer (Optional)

Specifications
MOUNTING: The groomer is mounted to the DPA cut- GROOMER HEIGHT SETTING: From 0.030 to 0.620
ting unit side plates. The drive assembly for the groom- inch (0.8 to 15.7 mm) at mowing HOC range of 0.060 to
ing reel is located on the opposite side of the cutting unit 0.750 inch (1.5 to 19.1 mm).
from the hydraulic cutting reel motor.
WIDTH−OF−GROOMER: 19.380 inches (49.2 cm).
GROOMING REEL CONSTRUCTION: 2.375 inch (6
cm) diameter, 41 steel blades with 1/2 inch blade spac- HEIGHT ADJUSTMENT KNOB: Allows a 0.003 inch
ing. Blade spacing can be adjusted to 1/4 inch or 3/4 inch (0.08 mm) increment of height adjustment for each click
by altering the number and position of blade spacers on of the adjuster.
the groomer. Groomer brush can be installed in place of
grooming reel. UP−DOWN FEATURE: Allows grooming reel to be
raised above the height/depth adjustment for no groom-
ing reel action while cutting.

Belt Driven Groomer (Optional) Page 8 − 2 Greensmaster 3150

General Information

Installation Instructions
The Installation Instructions for the groomer provide in-
formation regarding the operation, general mainte-
nance procedures and maintenance intervals for the
groomer assembly on your Greensmaster 3150 ma-
chine. Refer to this publication for additional information
when servicing the groomer assembly.

Groomer (Optional)
Belt Driven

Greensmaster 3150 Page 8 − 3 Belt Driven Groomer (Optional)

Troubleshooting

Factors Affecting Grooming

There are a number of factors that can affect the perfor- IMPORTANT: Improper or overaggressive use of
mance of grooming. These factors vary for different golf the grooming reel, such as too deep or frequent
courses and from green to green. It is important to in- grooming, may cause unnecessary stress on the
spect the turf frequently and vary the grooming practice turf leading to severe turf damage. Use the groomer
with turf needs. carefully. READ AND UNDERSTAND THE GROOM-
ER INSTALLATION INSTRUCTIONS BEFORE OPER-
It is important to remember that factors affecting quality ATING OR TESTING GROOMER PERFORMANCE.
of cut also affect grooming performance.

Variables That Affect the Use and Performance of Grooming Reels:

1. The growing season and weather conditions. 8. The amount of time that a grooming reel has been in
use on a particular turf area.
2. General turf conditions.
9. The amount of traffic on the turf.
3. The frequency of grooming/cutting − number of cut-
tings per week and how many passes per cutting. 10.The overall turf management program (e.g. irriga-
tion, fertilizing, weed control, coring, overseeding, dis-
4. The blade spacing on the grooming reel. ease control, sand dressing and pest control).

5. The height−of−cut. 11. Stress periods for turf (e.g. high temperatures, high
humidity, unusually high traffic).
6. The grooming depth.

7. The type of grass on the green.

Belt Driven Groomer (Optional) Page 8 − 4 Greensmaster 3150

Grooming Reel Mechanical Problems

Problem Possible Causes Correction

The grooming reel rotates when it is The grooming reel should rotate Normal operation.
in the raised, transport position. whenever the cutting reel is en-
gaged.

No rotation of the grooming reel. Seized grooming reel or idler bear- Identify and replace faulty bear-
ing(s) in groomer side plate(s). ing(s).

Broken or damaged drive belt idler Replace idler spring.

spring.

The groomer drive belt is worn, bro- If the belt slips, it probably is worn
ken or damaged. 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 The groomer is set too aggressive- Refer to groomer Installation In-
grooming. ly. structions for groomer set−up infor-
mation.

The grooming reel blades are bent, Repair or replace blades if neces-
damaged or missing. sary.

The grooming reel shaft is bent or Replace grooming reel shaft.

damaged.

Grooming depth is not equal on Adjust depth if necessary. Check

both ends of grooming reel. and adjust cutting unit set up (level
bedknife to reel, level rear roller to
reel, set height−of−cut, etc.).

Groomer (Optional)
Belt Driven

Greensmaster 3150 Page 8 − 5 Belt Driven Groomer (Optional)

Adjustments

CAUTION
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 the Groomer Installation Instructions for

adjustment procedures for the groomer on your
Greensmaster.

Height/Depth of Groomer Adjustment

NOTE: Grooming is performed above the soil level.
When adjusting groomer height/depth, groomer blades
should never penetrate the soil.

1. Park machine on a clean and level surface, lower

cutting units completely to the ground, stop engine, en-
gage parking brake and remove key from the ignition
switch.

2. Make sure rollers are clean and cutting reel is set to

the desired height−of−cut (see Cutting Unit Operator’s
Manual for cutting unit adjustment procedures).
2
3. Position the grooming reel to the lowered, grooming 1
position (Fig. 1).
Figure 1
NOTE: Improper or over−aggressive use of the groom- 1. Height adjustment knob 2. Lock screw
ing 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 grooming 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. 1). 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.

Belt Driven Groomer (Optional) Page 8 − 6 Greensmaster 3150

Service and Repairs

Groomer Belt Replacement

1. Park machine on a clean and level surface, lower
cutting units completely to the ground, stop engine, en-
gage parking brake and remove key from the ignition 1
switch.

2. If equipped, remove rear roller brush from cutting

unit (see Rear Roller Brush Removal in the Service and
Repairs section of Chapter 7 − DPA Cutting Units).

3. Remove three (3) lock nuts that secure groomer

drive cover, then remove cover (Fig. 2).

4. Pivot idler pulley by placing a 12mm wrench on 2

pulley nut and rotating idler bracket to relax belt tension.
Slip groomer drive belt off pulleys (Fig. 3). Carefully re- Figure 2
lease idler bracket.
1. Groomer drive cover 2. Lock nut (3 used)
IMPORTANT: Make sure that the drive belt is cen-
tered on the pulleys and correctly aligned with
pulley grooves after installation. 3 2 5 1
5. Install new drive belt to drive pulley, idler pulley and
driven pulley observing correct belt routing (Fig. 3).

6. Secure belt cover to machine with three (3) lock nuts

(Fig. 2).

7. If equipped, install rear roller brush to cutting unit

(see Rear Roller Brush Installation in the Service and
Repairs section of Chapter 7 − DPA Cutting Units).
4

Figure 3
1. Drive pulley 4. Driven pulley
2. Idler pulley 5. Groomer drive belt
3. Idler pulley nut

Groomer (Optional)
Belt Driven

Greensmaster 3150 Page 8 − 7 Belt Driven Groomer (Optional)

Grooming Reel

21
16
9 14 17
20

22 100 ft−lb
(135 N−m)
23 18
11 22 20
10 12
13
26
8

Antiseize 7
Lubricant 6
24 5
4
3

13

12
11 16
19
RIGHT 1

FRONT 15 2
1
10 21 17 to 21 ft−lb
25 (24 to 28 N−m)

Figure 4
1. Lock nut (4 used) 10. Cap screw (2 used) 19. Driven pulley
2. Drive cover 11. Bushing (2 used) 20. HOC screw (2 used)
3. Groomer drive belt 12. Spring washer (2 used) 21. HOC nut (2 used)
4. Drive pulley 13. Lock nut (2 used) 22. Plow bolt (2 used)
5. Shoulder bolt (2 used) 14. Support plate 23. Grooming reel assembly
6. Spring 15. LH groomer arm assembly 24. Front roller assembly
7. Drive plate assembly 16. HOC washer (2 used) 25. Ball stud (2 used per roller)
8. Groomer shim 17. RH cutting unit sideplate 26. O−ring
9. RH groomer arm assembly 18. LH cutting unit sideplate

Remove the grooming reel to replace individual blades, Removal (Fig. 4)

to replace worn groomer components, to reverse the
blades on the shaft or to replace the grooming shaft. 1. Park machine on a clean and level surface, lower
cutting units completely to the ground, stop engine, en-
NOTE: The drive assembly for the grooming reel is lo- gage parking brake and remove key from the ignition
cated on the left side of the cutting unit (opposite from switch.
the hydraulic cutting reel motor).
2. Remove the cutting unit from the machine and place
cutting unit on a flat work area.

Belt Driven Groomer (Optional) Page 8 − 8 Greensmaster 3150

3. If equipped, remove rear roller brush from cutting
unit (see Rear Roller Brush Removal in the Service and 5
2
Repairs section of Chapter 7 − DPA Cutting Units).

4. Remove groomer drive cover (item 2) and groomer

drive belt (item 3) from groomer drive (see Groomer Belt
Replacement in this section).

5. Loosen cap screws (item 10) that secure front roller

shaft to groomer arms.

6. Remove lock nut (item 13) and spring washer (item

12) that secure LH groomer arm lift rod to drive plate as- 1
3 4
sembly (shown in Fig. 5).

7. Remove HOC nut (item 21), HOC washer (item 16) Figure 5
and plow bolt (item 22) that secure LH groomer arm as- 1. Roller cap screw 4. Spring washer
sembly to drive plate assembly. Do not change height− 2. Grooming reel assembly 5. Groomer arm lift rod
of−cut screw adjustment. Remove LH groomer arm 3. Lock nut
assembly from cutting unit.

8. Remove front roller assembly from cutting unit. 4 5 1

2
NOTE: To prevent grooming reel shaft from turning
when removing driven pulley, use wrench on shaft flats
to hold shaft.

9. Remove the lock nut (item 1) that secures driven

pulley (item 19) to grooming reel shaft. Remove driven
pulley from shaft.

NOTE: To prevent cutting reel from turning when re-

moving drive pulley, block reel with piece of wood. 3

10.Loosen and remove drive pulley (item 4) from the Figure 6

cutting reel shaft. 1. Drive pulley 4. Drive plate assembly
2. Idler pulley 5. Groomer drive belt
11. Remove two (2) shoulder bolts (item 5) that secure 3. Driven pulley
the drive plate assembly (item 7) to the cutting unit
frame. Remove the groomer drive plate assembly from 3. Carefully place grooming reel assembly into the sup-
grooming shaft and cutting unit. Locate and retrieve port plate taking care to not damage seal in support plate
groomer shim (item 8). or O−ring on shaft.

12.Carefully pull the grooming reel from the support 4. Apply light coating of grease to O−ring on drive plate
plate on the right side of the cutting unit. assembly pivot hub and pilot bore of cutting unit side
plate.
13.Inspect seals, bushings and bearings in drive side
plate, support plate and groomer arms for wear or dam- 5. Position groomer shim (item 8) to drive plate assem-
age. Replace components as needed. bly.
Groomer (Optional)
Installation (Fig. 4) 6. Carefully place drive plate assembly onto groomer
Belt Driven

shaft taking care not to damage seals in drive plate.

1. Apply a light coating of grease to ends of grooming Position drive plate to the cutting unit frame and secure
shaft and also to seal lips in drive and support plates. with two (2) shoulder bolts (item 5). Make sure that drive
Make sure that all bearings, bushings and seals are plate rotates freely after installation.
properly installed.
7. Apply light coating of grease to hub on driven pulley
2. Make sure that O−ring (item 26) is installed on (item 19) taking care to not get grease on belt surface of
grooming shaft. Apply light coating of grease to O−ring. pulley. Slide driven pulley onto the grooming reel shaft
taking care to not damage seal in drive plate.

Greensmaster 3150 Page 8 − 9 Belt Driven Groomer (Optional)

NOTE: To prevent grooming reel shaft from turning 14.Secure LH groomer arm assembly to drive plate with
when installing driven pulley, use wrench on shaft flats spring washer (item 12) and lock nut (item 13).
to hold shaft.
15.Center front roller to cutting unit and tighten cap
8. Secure driven pulley to grooming reel shaft with lock screws (item 10) to secure roller.
nut (item 1). Torque lock nut from 17 to 21 ft−lb (24 to
28 N−m). 16.Install groomer drive belt (item 3) and groomer drive
cover (item 2) to drive plate (see Groomer Belt Replace-
NOTE: To prevent cutting reel from turning when instal- ment in this section).
ling drive pulley, block reel with piece of wood.
17.If equipped, install rear roller brush to cutting unit
9. Secure drive pulley (item 4) to cutting reel shaft. (see Rear Roller Brush Installation in the Service and
Torque pulley to 100 ft−lb (135 N−m). Repairs section of Chapter 7 − DPA Cutting Units).

10.Insert front roller into RH groomer arm assembly. 18.Check grooming reel height and mower height−of−
cut settings. Adjust as needed.
11. Make sure that bushing (item 11) is installed in drive
plate assembly. 19.Install cutting unit to the machine.

12.Apply antiseize lubricant to threads of LH groomer 20.Lubricate groomer bearings (see Groomer Installa-
arm lift rod. tion Instructions).

13.Position LH groomer arm assembly to front roller, NOTE: After greasing groomer bearings, operate
groomer drive plate and cutting unit frame. Secure groomer for 30 seconds, stop machine and wipe excess
groomer arm to cutting unit with plow bolt (item 22), HOC grease from groomer shaft and seals.
washer (item 16) and HOC nut (item 21).

Belt Driven Groomer (Optional) Page 8 − 10 Greensmaster 3150

Grooming Reel Service
Inspect grooming reel blades frequently for damage and
200 to 250 in−lb
wear. Straighten bent blades with a pliers. Replace
(23 to 28 N−m)
blades that are worn or damaged.
6
Grooming blades (Fig. 8) should be replaced if worn or
damaged. Blades that are rounded to the midpoint of the
1 2
blade tip can be reversed on the grooming shaft to ex-
tend the life of the blade. 4 5

Disassembly (Fig. 7)
3
1. Remove grooming reel from cutting unit (see Groom-
ing Reel Removal in this section). Figure 7
1. Grooming reel shaft 4. Thick spacer (2 used)
2. Remove lock nut from either end of the shaft (Fig. 7). 2. Groomer blade 5. Lock nut (2 used)
3. Blade spacer 6. O−ring
3. Remove spacers and blades from groomer shaft as
necessary.
2
3
Assembly (Fig. 7) 1
1. Start by placing thick spacer against the lock nut
installed on one end of groomer shaft. Then, place first
blade against installed spacer (Fig. 7).

2. For 1/2 inch (1.3 cm) blade spacing, make sure there
are two (2) blade spacers between blades (Fig. 7).
ROTATION
3. When all blades have been installed, place second
thick spacer on shaft and then thread second lock nut Figure 8
onto the shaft. 1. Grooming blade 3. Dull (rounded) edge
2. Sharp edge
4. Position lock nuts to allow blades and spacers to be
centered on the shaft (Fig. 9). Torque lock nuts from 200
to 250 in−lb (23 to 28 N−m) so spacers are not free to CENTER BLADES ON SHAFT
rotate. 1 2

5. Install grooming reel back onto cutting unit (see

Grooming Reel Installation in this section).

Figure 9
1. Lock nut 2. Grooming shaft

Groomer (Optional)
Belt Driven

Greensmaster 3150 Page 8 − 11 Belt Driven Groomer (Optional)

Grooming Reel Bearing Replacement

16

15

6
7

5
8

9
4

10
3

Seal lip 2
10
(toward center of
cutting unit) 9 1
Seal lip
(toward center of
cutting unit)

9
10

RIGHT
Seal lip
(toward center of 11
FRONT cutting unit)
13
14
12

Figure 10
1. Pivot hub 7. Retaining ring 12. Lock nut
2. Spacer 8. Grease fitting 13. Bearing
3. Idler bracket 9. Bearing 14. Retaining ring
4. Spacer 10. Seal 15. Support plate (cutting unit RH side)
5. Drive plate (cutting unit LH side) 11. Idler pulley 16. Plug
6. O−ring

NOTE: The groomer reel drive is located on the left side 3. Remove groomer support plate assembly from the
of the cutting unit, opposite from the hydraulic cutting right side of cutting unit:
reel motor.
A. Remove two (2) socket head screws and lock
Bearing Removal nuts that secure motor mount to cutting unit (Fig. 11).
Remove motor mount from cutting unit.
1. Remove the cutting unit from the machine and place
cutting unit on a flat work area. B. Remove lock nut and spring washer that secure
RH groomer arm lift rod to support plate (Fig. 12). Re-
2. Remove front roller, grooming reel and drive plate move support plate from cutting unit.
assembly from left side of cutting unit (see Grooming
Reel Removal in this section).

Belt Driven Groomer (Optional) Page 8 − 12 Greensmaster 3150

4. Remove grooming reel bearings and seals from
drive plate and support plate assemblies (Fig. 10): 4
5
A. Remove seals from groomer plates. Discard re-
moved seals.

B. Press bearings out of side plate housings. Dis-

card removed bearings.

Bearing Installation
3
1. Install new grooming reel bearings and seals into 2
drive plate and support plate assemblies (Fig. 13):
1 1
IMPORTANT: Bearings should be installed with ex-
tended inner races toward center of housing. Also,
apply pressure equally to inner and outer bearing Figure 11
races when installing bearings. 1. Socket head screw 4. Cutting unit
2. Motor mount 5. Lock nut (2 used)
A. Press new outer bearing fully to shoulder of drive 3. Groomer side plate (RH)
plate bore. Then, install new inner bearing until inner
race contacts outer bearing race.
5 2
B. Press new bearing into support plate until it is
flush with shoulder of bearing bore.

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 support plate to right side of cutting unit:

1 4
A. Apply antiseize lubricant to threads of RH groom- 3
er arm lift rod.
Figure 12
B. Position support plate to cutting unit making sure 1. Front roller cap screw 4. Spring washer
that RH groomer arm lift rod is positioned through 2. Grooming reel assembly 5. Groomer arm lift rod
bushing in support plate. 3. Lock nut

C. Place spring washer and lock nut on lift rod

threads (Fig. 12). Tighten lock nut. 2
1
3 6 4
D. Position motor mount to groomer support plate 5
(Fig. 11). Secure motor mount and support plate to
cutting unit with two (2) socket head screws and lock
nuts.

3. Install grooming reel, front roller and drive plate to left

side of cutting unit (see Grooming Reel Installation in Groomer (Optional)
this section).
Belt Driven

4. Check and adjust grooming reel height and mower

5 5
height−of−cut settings.

5. Install cutting unit to the machine. 7 8

6. Lubricate groomer bearings. Figure 13

NOTE: After greasing groomer bearings, operate 1. Outer bearing 5. Seal lip
2. Drive plate shoulder 6. Support plate bearing
groomer for 30 seconds, stop machine and wipe any ex- 3. Inner bearing 7. Drive plate
cess grease from groomer shaft and seals. 4. Inner race 8. Support plate

Greensmaster 3150 Page 8 − 13 Belt Driven Groomer (Optional)

Idler Assembly

6
7
5

8 3

11

9
10
12

Figure 14
1. Pivot hub 5. Drive plate assembly 9. Bearing (2 used)
2. Spacer 6. O−ring 10. Retaining ring
3. Idler bracket 7. Retaining ring 11. Idler pulley
4. Spacer 8. Grease fitting 12. Lock nut

Belt Driven Groomer (Optional) Page 8 − 14 Greensmaster 3150

The groomer drive side plate assembly incorporates the
idler system for tensioning the groomer drive belt. The 3 2 5 1
idler system uses a spring to maintain proper belt ten-
sion.

Removal

1. Remove groomer belt cover, drive belt and drive

pulley from groomer drive side of cutting unit (see
Grooming Reel Removal in this section).

2. Using Figures 14 and 15 as guides, remove idler

4
bracket, idler pulley and/or idler bearings as needed.

3. If idler bracket (item 3 in Figure 14) needs to be re- Figure 15

moved, remove drive plate from cutting unit (see 1. Drive pulley 4. Drive plate assembly
Grooming Reel in this section). Remove idler bracket 2. Idler pulley assembly 5. Groomer drive belt
3. Driven pulley
from drive plate using Figure 14 as a guide.

Installation

1. Assemble components using Figures 14 and 15 as

guides.

NOTE: When properly installed, the idler pulley should

move freely from side to side on the idler bracket pin.

2. If idler bracket (item 3 in Figure 14) was removed, in-

stall drive plate to cutting unit (see Grooming Reel in this
section).

3. Install drive pulley, drive belt and belt cover to left

side of cutting unit (see Grooming Reel Installation in
this section).

4. Check and adjust grooming reel height and mower

height−of−cut settings.

Groomer (Optional)
Belt Driven

Greensmaster 3150 Page 8 − 15 Belt Driven Groomer (Optional)

Lift Arm Assembly

1
14
2

13

11
15
7 12
16

10

8
9
Antiseize
Lubricant
7
6
3

17 4
Antiseize
Lubricant

18

Antiseize 5
Lubricant

Figure 16
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

Belt Driven Groomer (Optional) Page 8 − 16 Greensmaster 3150

Disassembly (Fig. 16) Assembly (Fig. 16)

1. Remove flange nut (item 2) that secures lift arm to 1. Assemble lift arm using Figure 16 as a guide.
HOC groomer arm. Remove lock nut (item 16) and
spring washer (item 17) that secure lift arm to side plate. 2. Apply antiseize lubricant to threads of groomer lift
Loosen lock screw (item 6) completely. rod (item 5) and lift arm assembly stud (item 8).

2. Remove lift arm from cutting unit. 3. Install lift arm onto cutting unit. Secure with flange nut
(item 2) and lock nut (item 16) with spring washer (item
3. Disassemble lift arm using Figure 16 as a guide. 17).

NOTE: Right and left side HOC groomer arms (item 1) 4. Secure groomer in raised or lowered position with
and lift arm assemblies (item 8) are different; other com- lock screw (item 6).
ponents shown in Figure 16 are the same on both sides
of cutting unit. 5. Check and adjust grooming reel height and mower
height−of−cut settings.
NOTE: Grooved pin (item 3) is used to retain lock screw
(item 6) to lift arm assembly.

Groomer (Optional)
Belt Driven

Greensmaster 3150 Page 8 − 17 Belt Driven Groomer (Optional)

Groomer Brush

1
2

20 to 25 in−lb
(2.3 to 2.8 N−m)

4 20 to 25 in−lb
(2.3 to 2.8 N−m)
2

Figure 17
1. Groomer brush shaft 3. J−bolt 5. O−ring
2. Lock nut 4. Groomer brush

The groomer brush attaches to the groomer drive in

place of the grooming reel. Removal and installation of
the groomer brush uses the same procedure as removal
1
and installation of the grooming reel (see Grooming
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
2
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. 18). Figure 18
Torque lock nuts from 20 to 25 in−lb (2.3 to 2.8 N−m). 1. J−bolt 2. Lock nut

Belt Driven Groomer (Optional) Page 8 − 18 Greensmaster 3150

 Chapter 9

Universal Groomer (Optional)

Table of Contents
Specifications ....................................................................................................................................... 9–2
Universal Groomer............................................................................................................................. 9–2
General Information .............................................................................................................................. 9–3
Installation Instructions ...................................................................................................................... 9–3
Grooming Performance...................................................................................................................... 9–3
Troubleshooting ................................................................................................................................. 9–4
Service and Repairs ............................................................................................................................. 9–5
The Gear Box Assembly .................................................................................................................... 9–6
The Idler Assembly .......................................................................................................................... 9–10
The Groomer Reel ........................................................................................................................... 9–12
The Height Adjuster Assembly ......................................................................................................... 9–15
The Grooming Brush (Optional) ....................................................................................................... 9–17

Greensmaster® 3150 Page 9–1 Universal Groomer (Optional)

12191SL Rev B
Specifications
Universal Groomer
Item Description
Grooming reel diameter 6 cm (2.375 inches)
Groomer blade type Spring Steel: 40 steel blades with 1/2 inch blade
spacing.
Carbide: 40 steel blades with 1/2 inch blade
spacing.
Thin blade: 81 steel blades with 1/4 inch blade
spacing.
The groomer brush can be installed in place of
grooming reel.
Groomer mounting The groomer is mounted to the cutting unit side
plates. The drive assembly for the grooming reel is
located on the opposite side of the cutting unit from
the hydraulic cutting reel motor.
Groomer height setting Mowing: 0.8 to 15.7 mm (0.030 to 0.620 inch).
HOC range: 1.5 to 19.1 mm (0.060 to 0.750 inch).
Width-of-groomer 54.6 cm (21.5 inches).
Height adjustment knob Allows a 0.003 inch (0.08 mm) increment of height
adjustment for each click of the adjuster.
Quick-up feature Allows grooming reel to be raised above the
height/depth adjustment for no grooming reel action
while mowing.
Groomer drive The groomer drive assembly is attached to the right
side of the cutting unit.

Universal Groomer (Optional): Specifications Page 9–2 Greensmaster® 3150

12191SL Rev B
General Information
Installation Instructions
The Installation Instructions for the groomer provides information regarding
the set-up, operation, general maintenance procedures, and maintenance
intervals for the groomer assembly on your Greensmaster machine. Refer to the
Installation Instructions for additional information when servicing the groomer
assembly.

Grooming Performance
There are a number of factors that can affect the performance of grooming.
These factors vary for different golf courses and from fairway to fairway. It
is important to inspect the turf frequently and vary the grooming practice with
turf needs.

IMPORTANT

Improper or overaggressive use of the groomer (e.g., too deep or

too frequent grooming) may cause unnecessary stress on the turf
leading to severe turf damage. Use the groomer carefully. Read and
understand the groomer operation instructions before operating or
testing the groomer performance.

It is important to remember that the same factors that affect quality of cut also
affect grooming performance.
Variables that Affect the Use and Performance of the Groomer:
1. The growing season and weather conditions.
2. General turf conditions.
3. The frequency of grooming/cutting–number of cuttings per week and how
many passes per cutting.
4. The height-of-cut.
5. The grooming depth.
6. The type of grass.
7. The amount of time that a groomer reel has been in use on a particular turf
area.
8. The amount of traffic on the turf.
9. The overall turf management program–irrigation, fertilizing, weed control,
coring, over-seeding, sand dressing, disease control, and pest control.
10. Stress periods for turf–high temperatures, high humidity, and unusually
high traffic.

Greensmaster® 3150 Page 9–3 Universal Groomer (Optional): General Information

12191SL Rev B
Troubleshooting
Problem Possible Causes Correction
The groomer reel does not The groomer drive is in Engage the groomer drive to
rotate. neutral. forward or reverse.
The groomer drive gears are Repair the groomer drive.
damaged or seized.
The turf is damaged or has The groomer is set too Refer to groomer Installation
uneven grooming. aggressively. Instructions for groomer set-up
information.
The groomer reel blades are Repair or replace the blades if
bent, damaged, or missing. necessary.
The groomer reel shaft is bent Replace the groomer reel
or damaged. shaft.
Grooming depth is not equal Adjust the depth if necessary.
on both ends of the groomer Check and adjust the cutting
reel. unit set up (level bed knife to
reel, level rear roller to reel,
set the height-of-cut, etc.).

Universal Groomer (Optional): General Information Page 9–4 Greensmaster® 3150

12191SL Rev B
Service and Repairs

g227930

Figure 1
1. Gear box assembly 3. Groomer reel 5. Weight
2. Idler assembly 4. Height adjuster assembly (2 each) 6. Flat head screw (2 each)

CAUTION
Never work on the groomer with the engine running. Always stop
the engine, remove the key from the ignition switch and wait for all
machine movement to stop before working on the groomer.

Greensmaster® 3150 Page 9–5 Universal Groomer (Optional): Service and Repairs
12191SL Rev B
The Gear Box Assembly

g251181

Figure 2
1. Gear box assembly 4. Clevis pin
2. Drive shield 5. Input shaft
3. Cotter pin 6. Shim

The groomer gear box assembly is located on the opposite side of the cutting
unit from the cutting unit hydraulic motor.

Removing the Gear Box Assembly

1. Park the machine on a clean and level surface, lower the cutting units
completely to the ground, set the parking brake, and remove the key from the
key switch.
2. Remove the groomer reel assembly; refer to Removing the Groomer Reel
(page 9–12).
3. Remove the drive shield, or, if the cutting unit is equipped with an optional
powered rear roller brush, remove the rear roller brush drive assembly to
service the groomer drive.
4. Safely prevent the reel from rotating by blocking the cutting reel with a piece
of wood near one of the reel spiders.

IMPORTANT

All of the groomer gear boxes for this machine are installed on the
left side of the cutting unit. Groomer gear boxes installed on the left
side of the cutting unit use a left hand thread. Turn the input shaft
(rear roller brush drive shaft) clockwise to remove the gear box.

5. Remove the gear box from the cutting unit as follows:

A. Turn the input shaft clockwise to loosen it from the reel.
B. Remove the cotter pin and clevis pin from the height adjustment rod at
the front of the groomer gear box. Discard the cotter pin.

Universal Groomer (Optional): Service and Repairs Page 9–6 Greensmaster® 3150
12191SL Rev B
Removing the Gear Box Assembly (continued)
C. Continue to unscrew the input shaft and remove the gear box from the
cutting unit.
D. Retrieve the shim (item 6 in Figure 2).

Servicing the Gear Box

g251182

Figure 3
1. Drive adapter 15. Thrust washer 29. Ring gear
2. Input shaft 16. O-ring 30. Flange bushing
3. O-ring (3 each) 17. O-ring 31. Sun gear
4. V-ring 18. Dowel pin (2 each) 32. Bearing
5. Oil seal 19. Drain/fill plug (4 each) 33. Planet gear (3 each)
6. Groomer housing 20. Straight bushing (2 each) 34. Flange bushing (3 each)
7. Ball bearing (2 each) 21. Detent ball 35. Locknut
8. Retaining ring 22. Detent spring 36. Driver gear
9. Driven gear 23. Oil seal 37. Bearing (2 each)
10. Actuator shaft 24. Socket-head screw(4 each) 38. Oil seal
11. Pin 25. Groomer cover 39. Driven shaft
12. O-ring 26. Gasket 40. Shield
13. Knob 27. Thrust washer
14. Retaining ring 28. Ball bearing

Greensmaster® 3150 Page 9–7 Universal Groomer (Optional): Service and Repairs
12191SL Rev B
Servicing the Gear Box (continued)
1. Remove the drain/fill plug and drain the oil from the gear box.
2. Remove the 4 socket-head screws and separate the gear box cover and
housing. Remove and discard the cover gasket.
3. Slide the sun gear, ring gear, and planet gears from the pins on the gear
box housing.
4. Continue to disassemble the gear box as necessary.

CAUTION
Use the 1−3/8 inch flats on the input shaft to prevent the input shaft
from rotating during drive adapter removal and installation. DO NOT
use the 1/2 inch hex on the input shaft for drive adapter removal or
installation as input shaft damage may occur.

5. If the drive adapter requires replacement, apply high strength thread locker
(Loctite 243 or equivalent) to the 5/8 inch threads of the drive adapter and
tighten the adapter from 150 to 173 N∙m (110 to 120 ft-lb).
6. Carefully clean all the gasket material from the gear box housing and cover.
7. Inspect the V-ring, seals, bearings, gears, and bushings in the gear box
assembly. Replace the damaged or worn components as necessary.
8. If the sun gear, ring gear, or the gear box housing bearings are replaced,
press the bearings all the way to shoulder into the part.
9. If the flange bushings are replaced, ensure that the flange bushing is fully
seated against the part.
10. Assembly the gearbox.
• Ensure that all the retaining rings and O-rings are fully seated in the ring
groove during assembly.
• Lubricate the seal lips and O-rings before installing the shafts.
• Lubricate the planet gear and sun gear pins in the gear box housing with
the gear oil prior to installing the gears.
11. Clean the gasket surface on the gear box housing and cover with the solvent
and install new gasket.
12. Fit the gear box cover over dowel pins and install the 4 socket-head screws.
Tighten the screws from 1.7 to 4.5 N∙m (15 to 40 in-lb). In an alternating
cross pattern, tighten the screws from 8.4 to 9.6 N∙m (75 to 85 in-lb).
13. Fill the gear box with 80W−90 gear oil and tighten the drain/fill plug from
4 to 5 N∙m (32 to 42 in-lb).
The gear box oil capacity is 50 ml (1.7 fluid ounces).
14. Operate the groomer gear box by hand to check for proper operation prior to
installation.

Universal Groomer (Optional): Service and Repairs Page 9–8 Greensmaster® 3150
12191SL Rev B
Installing the Gear Box Assembly
1. Park the machine on a clean and level surface, lower the cutting units
completely to the ground, set the parking brake, and remove the key from the
key switch.
2. Safely prevent the reel from rotating by blocking the cutting reel with a piece
of wood near one of the reel spiders.

IMPORTANT

All of the groomer gear boxes for this machine are installed on the
left side of the cutting unit. Groomer gear boxes installed on the left
side of the cutting unit use a left hand thread. Turn the input shaft
(rear roller brush drive shaft) counter-clockwise to install the gear
box.

3. Install the gear box to the cutting unit as follows:

A. Fit the shim (item 6 in Figure 2) over the input shaft.
B. Apply medium strength thread locking compound to the input shaft
threads and turn the input shaft counter–clockwise until it is seated
against the reel.
C. Install the clevis pin and a new cotter pin to secure the height adjustment
rod to the front of the groomer gear box.
D. Tighten the input shaft from 136 to 149 N∙m (100 to 110 ft-lb).
4. Apply a retaining compound (Loctite 609 or equivalent) to the lip of the drive
housing and install the drive shield, or, if the cutting unit is equipped with an
optional powered rear roller brush, install the rear roller brush drive assembly.
5. Install the groomer reel assembly; refer to Installing the Groomer Reel (page
9–14).

Greensmaster® 3150 Page 9–9 Universal Groomer (Optional): Service and Repairs
12191SL Rev B
The Idler Assembly

g251183

Figure 4
1. Socket-head screw (2 each) 9. Stub shaft
2. 10. Flocked seal (2 each)
3. Motor adapter 11. Bearing
4. Bushing 12. Retaining ring
5. Idler arm 13. Flange nut
6. O-ring 14. Clevis pin
7. Lock nut (2 each) 15. Cotter pin
8. Shield 16. Collar

The groomer idler assembly is located on the opposite side of the groomer gear
box.

Removing the Idler Assembly

1. Park the machine on a clean and level surface, lower the cutting units
completely to the ground, set the parking brake, and remove the key from the
key switch.
2. Remove the reel motor from the cutting unit.
3. Remove the groomer reel assembly; refer to Removing the Groomer Reel
(page 9–12).
4. Remove the cotter pin and clevis pin from the height adjustment rod at the
front of the idler arm. Discard the cotter pin.
5. Remove the two socket-head screws that secure the motor adapter to the
cutting unit, and remove the adapter and idler assembly. Retrieve and
discard the O-ring and lock nuts.
6. Inspect the shields, bearing, and bushing in the idler assembly. Replace any
components that are worn or damaged.

Universal Groomer (Optional): Service and Repairs Page 9–10 Greensmaster® 3150
12191SL Rev B
Installing the Idler Assembly
1. If the shields, bearing, or bushing was removed from the idler arm:
A. Press the bushing into a groomer plate until the bushing is centered in
the idler arm bore.
B. Press the bearing into the idler arm so that the bearing contacts the
shoulder in idler arm bore and install the bearing retaining ring.
C. Install the bearing shields with the flocked side of the shield toward the
bearing.
D. Insert the stub shaft through the shields and bearing. Use the through
hole in the shaft to prevent the shaft from rotating and tighten the flange
nut from 37 to 45 N∙m (27 to 33 ft-lb).
E. If the collar was removed from the idler arm, install the collar and tighten
from 33 to 41 N∙m (24 to 30 ft-lb).
2. Fit a new O-ring to the motor adapter.
3. Apply anti-seize lubricant to the outside diameter of the motor adapter and
position the idler arm over the adapter.
4. Use new lock nuts and secure the motor adapter and idler arm to the cutting
unit side plate.
5. Install the clevis pin and a new cotter pin to secure the height adjustment rod
to the front of the idler arm.
6. Install the reel motor.

Greensmaster® 3150 Page 9–11 Universal Groomer (Optional): Service and Repairs
12191SL Rev B
The Groomer Reel

g228732

Figure 5
1. Shaft clamp (4 each) 3. Bolt (4 each)
2. Jam nut (4 each) 4. Groomer reel

Remove the groomer reel to replace individual groomer blades or replace the
shaft. The groomer reel can be reversed to provide additional blade life.

Removing the Groomer Reel

1. Park the machine on a clean and level surface, lower the cutting units
completely to the ground, set the parking brake, and remove the key from the
key switch.

CAUTION
Contact with the reel or other cutting unit parts can result in personal
injury.
Use heavy gloves when handling the groomer reel.

2. Carefully remove the 4 jam nuts, 4 bolts, and 4 shaft clamps that secure the
groomer reel to the output and stub shafts.
3. Lift the groomer reel from the cutting unit.
4. Inspect the shields, stub shaft, driven shaft and shaft bearings for wear or
damage and replace components as necessary; refer to The Gear Box
Assembly (page 9–6) and The Idler Assembly (page 9–10).

Universal Groomer (Optional): Service and Repairs Page 9–12 Greensmaster® 3150
12191SL Rev B
Servicing the Groomer Reel

g251184

Figure 6
1. Groomer reel shaft 5. Rounded edge
2. Groomer blade (40 each) 6. Midpoint
3. Spacer (39 each) 7. Centered on shaft
4. Locknut (2 each)

Inspect the groomer reel blades frequently for any damage and wear. Straighten
the bent blades. Either replace the worn blades or reverse the individual
blades to put the sharpest blade edge forward. The blades that are rounded to
the midpoint of the blade tip must be reversed or replaced for best groomer
performance: refer to Figure 6.
1. Park the machine on a clean and level surface, lower the cutting units
completely to the ground, set the parking brake, and remove the key from the
key switch.
2. Remove the groomer reel from the cutting unit; refer to Removing the
Groomer Reel (page 9–12).
3. Remove the lock nut from either end of the groomer reel shaft.
4. Remove the blades and from the groomer shaft. If necessary, remove
second lock nut from the shaft.
5. Inspect and replace worn or damaged components.
6. Assemble the groomer reel as follows:
Note: New lock nuts have an adhesive patch to prevent the lock nut from
loosening. If a used lock nut is being installed, apply a medium strength
thread locker (Loctite #242 or equivalent) to the threads of the lock nut.
A. Install a lock nut on one end of the groomer reel shaft.
B. Install a groomer blade against the lock nut.
C. Install the remaining spacers and blades in an alternating manner making
sure that all blades are separated by a spacer.

Greensmaster® 3150 Page 9–13 Universal Groomer (Optional): Service and Repairs
12191SL Rev B
Servicing the Groomer Reel (continued)
D. When all the blades have been installed, install the second lock nut onto
the shaft. Center the blades and spacers on the shaft by adjusting the
lock nuts.
E. Use the through holes in shaft to prevent the shaft from rotating and
tighten the second lock nut to 42 to 48 N∙m (31 to 35 ft-lb). After
tightening the lock nut, spacers should not be free to rotate and the
groomer blades should be centered on the shaft.
7. Install the groomer reel back onto the cutting unit; refer to Installing the
Groomer Reel (page 9–14).

Installing the Groomer Reel

1. Position the cutting unit on a level surface. If the cutting unit is attached to the
traction unit, set the parking brake, and remove the key from the key switch.
2. Position the groomer reel between the groomer driven and stub shafts.
3. Secure the groomer reel to the cutting unit with the 4 jam nuts, 4 bolts, and 4
shaft clamps. Tighten the bolts from 5 to 7 N∙m (45 to 60 in-lb).
4. Check the groomer reel height and mower height-of-cut settings and adjust
as necessary.

Universal Groomer (Optional): Service and Repairs Page 9–14 Greensmaster® 3150
12191SL Rev B
The Height Adjuster Assembly

g251185

Figure 7
1. Clevis pin 11. Pinch bolt
2. Cotter pin 12. Height-of-cut bracket
3. Tabbed washer 13. Quick up lever
4. Lock nut 14. Groomer pin
5. Bumper 15. Quick up cover
6. Plow bolt 16. Detent spring
7. Height adjustment rod 17. Button-head screw
8. Flange nut 18. Height adjuster knob
9. Washer (2 each) 19. Height adjustment bolt
10. Compression spring

Note: Early universal groomers used 2 compression springs on non-adjustable

height adjustment rods. Retrofitting the assemblies on each side of the cutting
unit with new compression springs, height adjustment rods, and adding flange
nuts to enable spring adjustment is recommended; refer to Figure 7.

Disassembling the Height Adjuster

1. Park the machine on a clean and level surface, lower the cutting units
completely to the ground, set the parking brake, and remove the key from the
key switch.
2. Remove the cutting unit from the machine.
3. Remove the cotter pins and clevis pins that secure the height adjustment
rods to the groomer gear box and idler arm. Discard the cotter pins.
4. Loosen the pinch bolts that secure the front roller to the height-of-cut
brackets.
5. Remove the hex nuts, tabbed washers and plow bolts that secure the
height-of-cut brackets to the cutting unit side plates, and remove the height
adjusters and front roller from the cutting unit.

Greensmaster® 3150 Page 9–15 Universal Groomer (Optional): Service and Repairs
12191SL Rev B
Disassembling the Height Adjuster (continued)
6. Disassemble the height adjuster assembly as necessary.
7. Replace components that are worn or damaged.

Assembling the Height Adjuster

1. Apply anti-seize lubricant to the upper threads of the adjustment rod and
lower threads of the height adjusters. Assemble the height adjuster assembly.
2. If both the height adjusters are removed, fit 1 height adjuster assembly to the
cutting unit side plate and secure it with a plow bolt, tabbed washer and lock
nut. Tighten the lock nut finger tight.
3. Position front roller between the height adjuster assemblies and secure the
remaining height adjuster assembly to the cutting unit side plate with a plow
bolt, tabbed washer and lock nut. Tighten the lock nut finger tight.
4. center the front roller between the height-of-cut brackets and tighten the
front roller pinch bolts
5. Install new cotter pins and clevis pins and secure the height adjustment rods
to the groomer gear box and idler arm.
6. Adjust the cutting unit height-of-cut; refer to Cutting Unit Operators Manual.
7. Check the groomer reel height and adjust as necessary.

g229170

Figure 8

8. Adjust the flange nuts on the groomer height adjustment rods until the
springs are compressed to 16 mm (0.625 inch).

Universal Groomer (Optional): Service and Repairs Page 9–16 Greensmaster® 3150
12191SL Rev B
The Grooming Brush (Optional)

g229629

Figure 9
1. Spiral brush 4. Lock nut (2 each)
2. Brush shaft 5. Grooming brush
3. J-bolt (2 each) 6. Roll pin (2 each)

The optional grooming brush attaches to the groomer in place of the groomer
reel. The grooming brush is removed and installed from the groomer in the same
manner as the groomer reel; refer to The Groomer Reel (page 9–12).
The grooming brush element or shaft can be serviced separately.
To remove the spiral grooming brush from the shaft, remove the lock nut and
J-bolt from both ends of the brush assembly and slide the brush from the shaft.
When assembling the spiral brush to the shaft, make sure that the J-bolts are
installed with the threaded portion on the outside of the brush and tighten the
lock nuts from 2.3 to 2.8 N∙m (20 to 25 in-lb).

Greensmaster® 3150 Page 9–17 Universal Groomer (Optional): Service and Repairs
12191SL Rev B
 This page is intentionally blank

Universal Groomer (Optional) Page 9 - 18 Greensmaster® 3150

 Chapter 10

Foldout Drawings
Table of Contents
ELECTRICAL DRAWING DESIGNATIONS . . . . . . . 2
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 3
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . 4
ELECTRICAL CIRCUIT DIAGRAMS . . . . . . . . . . . . . 5
Crank Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Run Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Raise Reels Circuits . . . . . . . . . . . . . . . . . . . . . . . . . 7
Lower Reels (6 Seconds) Circuits . . . . . . . . . . . . . 8
Mow Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Backlap Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WIRE HARNESS DRAWINGS . . . . . . . . . . . . . . . . . 12
Wire Harness Drawing . . . . . . . . . . . . . . . . . . . . . . 12
Wire Harness Diagram . . . . . . . . . . . . . . . . . . . . . . 13
Engine Wire Harness Drawing . . . . . . . . . . . . . . . 14

Greensmaster 3150 Page 10 − 1 Foldout Drawings

Electrical Drawing Designations
NOTE: A splice used in a wire harness will be identified
on the wire harness diagram by SP. The manufacturing
number of the splice is also identified on the wire har-
ness diagram (e.g. SP01 is splice number 1).

Wire Color
The following abbreviations are used for wire harness
colors on the electrical schematics and wire harness
drawings in this chapter.

ABBREVIATION COLOR

BK BLACK

BR or BN BROWN

BU BLUE

GN GREEN

GY GRAY

OR ORANGE

PK PINK

R or RD RED

T TAN

VIO VIOLET

W or WH WHITE

Y or YE YELLOW

Numerous harness wires used on Toro machines in-

clude a line with an alternate color. These wires are iden-
tified with the wire color and line color with either a / or
_ separating the color abbreviations listed above (e.g.
R/BK is a red wire with a black line, OR_BK is an orange
wire with a black line).

Wire Size
The individual wires of the electrical harness diagrams AWG EQUIVALENTS FOR METRIC WIRE
in this chapter identify both the wire color and the wire
size. DIAGRAM LABEL METRIC SIZE AWG EQUIVALENT

050 0.5 mm 20 GA
Examples:
175 0.75 mm 18 GA
16 BK = 16 AWG (American Wire Gauge) wire that
has a black insulator 100 1.0 mm 16 GA
050 R = 0.5 mm metric wire that has a red insulator 150 1.5 mm 14 GA
(AWG equivalents for metric wire appear in the fol-
lowing table)

Foldout Drawings Page 10 − 2 Greensmaster 3150

 Steering Cylinder
RIGHT FRONT 1.5” Bore
REEL (#3) 0.75” Rod
.73
6.19” Stroke

.73
CENTER CU #2 CU #1 CU #3
REEL (#1) 2.0” Bore 1.50” Bore 2.0” Bore
0.75” Rod 0.75” Rod 0.75” Rod
1.88” Stroke 3.38” Stroke 1.88” Stroke
.73 L R
Raise
LEFT FRONT
REEL (#2)

Lower

MA MB L2B L2A L1B L1A L3A L3B

FC2 STEERING
0.055 0.030 0.055
VALVE
MR 4.5
BACKLAP
SWITCH 550 PSI
(SW)

PRV

R2
400 PSI S4 1160 PSI

FC1 OR1
0.013
OR2 P E T
0.060
S3
ST
LC

S2

G1

S1R1

P1 T G2 P2 PT

4.0 GPM

7.0 GPM

TRACTION PUMP
TOP
PORT
TRANSPORT = 14.1 GPM
25 PSI A
FILTER

LEAK DETECTOR BYPASS

VALVE LEFT 10.3 10.3 RIGHT
MOTOR MOTOR
3000 PSI
LEAK OPTIONAL
DETECTOR IN
ENGINE RPM
VOLUME OIL COOLER GEAR .33 .58 1.24 2850/1650
PUMP 3000 PSI
OUT 20.6
110 to 150 70 to 100
PSI PSI
EXPANSION B
TANK OPTIONAL
BOTTOM 3WD KIT
PORT

BREATHER
SUCTION
STRAINER Greensmaster 3150
Hydraulic Schematic

Page 10 − 3
 (IN NEUTRAL)

(NOT OCCUPIED)

Greensmaster 3150
Electrical Schematic
All relays and solenoids
are shown as de−energized.

Page 10 − 4
 (ENERGIZED)
(IN NEUTRAL)
(ENERGIZED)
(ENERGIZED)

(NOT OCCUPIED)

(ENERGIZED)

(ENERGIZED)

Greensmaster 3150
Crank Circuits
Power Current
Control Current
Indication Current

Page 10 − 5
 (NOT IN NEUTRAL)

(OCCUPIED)
(OFF POSITION)
(ENERGIZED)

(ENERGIZED)

Greensmaster 3150
Run Circuits
Power Current
Control Current
Indication Current

Page 10 − 6
 (NOT IN NEUTRAL)

(OCCUPIED)
(OFF POSITION)

(ENERGIZED)

(ENERGIZED)

(ENERGIZED)

Greensmaster 3150
Raise Reels Circuits
Power Current
Control Current
Indication Current

Page 10 − 7
 (NOT IN NEUTRAL)

(OCCUPIED)
(OFF POSITION)

(ENERGIZED)
(ENERGIZED)

NOTE: TIME DELAY KEEPS THE LOWER

RELAY ENERGIZED FOR SIX (6) SECONDS

(ENERGIZED)

(ENERGIZED)

Greensmaster 3150
Lower Reels (6 Seconds) Circuits
Power Current
Control Current
Indication Current

Page 10 − 8
 (NOT IN NEUTRAL)

NOTE: JOYSTICK RELAY INITIALLY ENERGIZED (ENERGIZED)

(OCCUPIED) WHEN JOYSTICK IS MOVED TO LOWER

(OFF POSITION)

(MOW POSITION)

(ENERGIZED)
NOTE: DIODE D1−C ALLOWS
CURRENT FLOW TO KEEP
JOYSTICK RELAY ENERGIZED
AFTER JOYSTICK IS
(ENERGIZED)

RELEASED FROM LOWER

(ENERGIZED)

Greensmaster 3150
Mow Circuits
Power Current
Control Current
Indication Current

Page 10 − 9
 (IN NEUTRAL)

(BACKLAP
POSITION)

NOTE: JOYSTICK RELAY INITIALLY ENERGIZED (ENERGIZED)

(NOT OCCUPIED) WHEN JOYSTICK IS MOVED TO LOWER

(ON POSITION)

(ENERGIZED)
NOTE: DIODE D1−C ALLOWS
CURRENT FLOW TO KEEP
JOYSTICK RELAY ENERGIZED
AFTER JOYSTICK IS
(ENERGIZED)

RELEASED FROM LOWER

(ENERGIZED)

Greensmaster 3150
Backlap Circuits
Power Current
Control Current
Indication Current

Page 10 − 10
This page is intentionally blank.

Page 10 − 11
 SEAT WIRE
HARNESS

Greensmaster 3150
Wire Harness Drawing

Page 10 − 12
 SEAT WIRE
HARNESS

WHITE/BLACK
ORANGE/BLACK
GREEN/BLACK

BLUE/BLACK
YELLOW
GRAY/BLACK

YELLOW

BLUE/RED
BLACK

ORANGE
BLACK

BLACK

BLACK
BLACK

VIOLET
GRAY

VIOLET
BLUE/BLACK GRAY/BLACK
ORANGE/BLACK
WHITE/BLACK

GREEN/BLACK
VIOLET/BLACK

VIOLET VIOLET
PINK/BLACK
BLUE/RED BLUE/RED

PINK
VIOLET/BLACK

GREEN
BLUE
ORANGE/BLACK GREEN/GRAY
GREEN/RED
BLACK GREEN/BLACK

YELLOW

GREEN/GRAY
WHITE
BLACK GREEN/BLACK

BLACK
GREEN/BLACK
WHITE/BLUE
GRAY/BLACK
BLACK BLUE/BLACK

BLACK
BLACK
BLUE/BLACK
BLACK
WHITE/BLUE WHITE/BLUE
BLACK

YELLOW
BLACK PINK/BLUE

BLACK
BLACK

WHITE

BLACK
BLACK
BLACK BLACK
BLACK

FUSIBLE LINK
BLACK
BLUE
BLACK

BLACK YELLOW
WHITE/BLUE

VIOLET
RED
PINK WHITE
PINK
TAN ORANGE/BLACK
ORANGE YELLOW
YELLOW
GREEN
BLUE BLUE/BLACK
WHITE BLUE

YELLOW
GRAY
GRAY
WHITE WHITE
GRAY/BLACK
YELLOW

BLUE
BLUE
WHITE

BLUE

(TO ENGINE HARNESS) (TO SEAT HARNESS) (TO SEAT HARNESS)

Greensmaster 3150
Wire Harness Diagram

Page 10 − 13
 YELLOW
VIOLET
WHITE FUSIBLE LINK
BLACK

Greensmaster 3150
Engine Wire Harness Drawing

Page 10 − 14