Toro 3150 User Manual
Part No. 12191SL
Service Manual
(Model 04358)
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).
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR’S MANUALS FOR OPERATING,
MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. For reference, insert a copy of the Operator’s
Manuals and Parts Catalogs for your machine into
Chapter 2 of this service manual. Additional copies of
theOperator’s ManualsandParts Catalogare available
on the internet at www.Toro.com.
TheT oroCompany reservesthe right tochangeproduct
specifications or this publication without notice.
Greensmaster
This safety symbol means DANGER, WARNING
or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: ANOTE will give general information about the
correct operation, maintenance, service, testing or repair of the machine.
IMPORTANT: The IMPORTANT notice will give importantinstructionswhichmustbefollowedtoprevent damage to systems or components on the
machine.
3150
R
E The Toro Company -- 2012
This page is intentionally blank.
Greensmaster 3150
Table Of Contents
Chapter 1 -- Safety
Safety Instructions 1 -- 2..........................
Jacking Instructions 1 -- 5.........................
Safety and Instruction Decals 1 -- 5................
Chapter 2 -- Product Records and Maintenance
Product Records 2 -- 1...........................
Maintenance 2 -- 1...............................
Equivalents and Conversions 2 -- 2................
Torque Specifications 2 -- 3.......................
Chapter 3 -- Engine
General Information 3 -- 2........................
Specifications 3 -- 3..............................
Service and Repairs 3 -- 4........................
BRIGGS & STRATTON VANGUARD V-TWIN OHV
REPAIR MANUAL
Chapter 4 -- Hydraulic System
Specifications 4 -- 2..............................
General Information 4 -- 3........................
Hydraulic Schematic 4 -- 8........................
Hydraulic Flow Diagrams 4 -- 10...................
Special Tools 4 -- 18.............................
Troubleshooting 4 -- 21...........................
Testing 4 - - 26...................................
Adjustments 4 -- 49..............................
Service and Repairs 4 -- 50.......................
EATON, MEDIUM DUTY PISTON PUMP , REP AIR IN-
FORMATION, MODEL 70160 VARIABLE DISPLACEMENT PISTON PUMP
PARKER TORQMOTOR
(TC, TB, TE, TJ, TF, TG, TH and TL SERIES)
SAUER/DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
TM
SERVICE PROCEDURE
Chapter 5 -- Electrical System
General Information 5 -- 2........................
Special Tools 5 -- 3..............................
Turf Guardian Leak Detector
System Operation 5 -- 5........................
Troubleshooting 5 -- 6............................
Electrical System Quick Checks 5 -- 11.............
Component Testing 5 -- 12........................
Service and Repairs 5 -- 28.......................
Chapter 6 -- Chassis
Specifications 6 -- 2..............................
General Information 6 -- 3........................
Special Tools 6 -- 3..............................
Service and Repairs 6 -- 4........................
Chapter 7 -- DPA Cutting Units
Specifications 7 -- 2..............................
General Information 7 -- 3........................
Special Tools 7 -- 4..............................
Factors That Can Affect Cutting Performance 7 -- 6..
Set Up and Adjustments 7 -- 10....................
Service and Repairs 7 -- 12.......................
Chapter 8 -- Groomer
Specifications 8 -- 2..............................
General Information 8 -- 3........................
Troubleshooting 8 -- 4............................
Adjustments 8 -- 6...............................
Service and Repairs 8 -- 7........................
Chapter 9 -- Foldout Drawings
Hydraulic Schematic 9 -- 3........................
Electrical Schematic 9 -- 4........................
Electrical Circuit Diagrams 9 -- 5...................
Wire Harness Drawings 9 -- 12....................
SafetyDPA Cutting
Product Records
Engine
Hydraulic
Electrical
ChassisGroomer
and Maintenance
System
System
Units
Greensmaster 3150
Foldout
Drawings
This page is intentionally blank.
Greensmaster 3150
Table of Contents
SAFETY INSTRUCTIONS 2......................
Before Operating 2............................
While Operating 3............................
Maintenance and Service 4....................
JACKING INSTRUCTIONS 5.....................
SAFETY AND INSTRUCTION DECALS 5..........
Chapter 1
Safety
Safety
Greensmaster 3150 Page 1 -- 1 Safety
Safety Instructions
The Greensmaster 3150 was tested and certified by
Toro for compliancewithnationaland international standards as specified in the Operator’s Manual. Although
hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the
awareness, concern and proper training of the personnel involved in the operation, transport, maintenance
and storage of the machine. Improper use or maintenance of the machine can result in injury or death.
Before Operating
WARNING
Toreducethepotentialfor injury ordeath,comply
with the following safety instructions.
1. Read and understand thecontents of the Operator’s
Manual before starting and operating the machine. Become familiar with all controls and know how to stop
quickly. Copies of the Operator’s Manual are available
on the internet at www.Toro.com.
2. Never allow children to operate the machine. Never
allow adults to operate it without proper instructions.
3. Become familiar with the controls and know how to
stop the engine quickly.
4. Keep all shields, safety devices and decals in place.
Ifa shield, safety deviceordecal is defective, illegibleor
damaged: repair or replace it before operating the machine.
5. Always wear substantial shoes. Do not operate machine while wearing sandals, tennis shoes or sneakers.
Donotwearloosefittingclothingwhichcouldgetcaught
in moving parts and cause personal injury.
6. Wearing safety glasses, safety shoes, long pants
and a helmet is advisable and required by some local
safety and insurance regulations.
7. Make sure work area is clear of objects which might
be picked up and thrown by the reels.
8. Do not carry passengers on the machine. Keep everyone, especially children and pets, away from the
areas of operation.
9. Gasoline(fuel) is highly flammable; handle itcarefully.
A. Store fuel in containers specifically designed for
this purpose.
B. Add fuel before starting the engine. Never removethecapofthefueltankoraddfuelwhiletheengine is running or when the engine is hot.
C. Refuel outdoors only and do not smoke while
refuelling.
D. Fillfueltanktoalevelnohigherthantothebottom
of fuel tank filler neck. Do not overfill.
E. Replaceallfueltanksandcontainercaps securely.
F. If fuel is spilled,do notattempt tostart the engine
butmovethemachineawayfromthearea of spillage
andavoidcreatingany sourceofignitionuntilfuelvapors have dissipated.
G. Wipe up any spilled fuel.
Greensmaster 3150Page 1 -- 2Safety
While Operating
1. Donotruntheengineinaconfinedareawithoutadequate ventilation. Exhaust fumes are hazardous and
couldbedeadly.
2. Sit on the seat when starting and operating the machine.
3. Check the safety interlockswitchdaily for properoperation; see VerifyInterlockSystem Operation in Chapter 5 -- Electrical System. Replace any malfunctioning
switches before operating the machine.
4. To start the engine:
A. Sitontheseat,makesure cutting units are disengaged.
B. Verify that functional control lever is in neutral.
C. Verify that parking brake is set.
D. Proceed to start engine.
5. Using the machine demands attention. To prevent
loss of machine control:
A. Mow only in daylight or when there is good artificial light.
B. Watch for holes or other hidden hazards.
C. Do not drive close to sand traps, ditches, creeks
or other hazards.
D. Reduce speed when making sharp turns. Avoid
sudden stops and starts.
E. Before backing up, look to the rear to be sure no
one is behind the machine.
F. Watchoutfor traffic when near orcrossingroads.
Always yield the right--of--way.
G. Apply the service brakes when going downhill to
keep forward speed slow and to maintain control of
the machine.
6. Keep hands, feet and clothing away from moving
parts and the reel discharge area. The grass baskets
must be in place during operation of the reels or thatchersformaximumsafety.Shuttheengineoffbefore emptying the baskets.
7. Wearappropriateclothingincluding substantial footwear, hard hat, safety glasses and ear protection.
8. Raise the cutting units when driving from one work
area to another.
9. Do not touch engine, muffler or exhaust pipe while
engine is running or soon after it is stopped because
these areas could be hot enough to cause burns.
10.If a cutting unit strikes a solid object or vibrates abnormally, stop immediately, turn engine off, wait for all
motionto stop and inspect for damage.A damaged reel
or bedknife must be repaired or replaced before operation is continued.
11.Before getting off the seat:
A. Make sure cutting units are disengaged.
B. Verify that functional control lever is in neutral.
C. Set the parking brake.
D. Stop the engine and remove key from ignition
switch.
12.Traverse slopes carefully. Do not start or stop sud-
denly when traveling uphill or downhill.
13.Operator must be skilled and trained in how to drive
on hillsides. Avoid wet slopes. Failure to use caution on
slopes or hills may cause loss of control and vehicle to
tip or roll possibly resulting in personal injury or death.
14.If engine stalls or loses headway and cannot make
it to the top of a slope, do not turn machine around. Always back slowly straight down the slope.
15.DON’T TAKE AN INJURY RISK! Whenapersonor
pet appears unexpectedly in or near the mowing area,
STOP MOWING. Careless operation, combined with
terrain angles, ricochets or improperly positioned
guardscanlead to thrownobjectinjuries.Donotresume
mowing until area is cleared.
16.Whenever machine is left unattended, make sure
cutting units are fully raised and reels are not spinning,
key is removed from ignition switch and parking brake
is set.
Safety
Greensmaster 3150 Page 1 -- 3 Safety
Maintenance and Service
1. Before servicing or making adjustments to the machine, stop the engine, remove key from switch to prevent accidental starting of the engine.
2. Be sure entire machine is in good operating condition. Keep all nuts, bolts, screws and hydraulic fittings
tight.
3. Make sure allhydraulic line connectorsare tight,and
all hydraulic hoses and lines are in good condition before applying pressure to the system.
4. Keep body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pressure.
Use paper or cardboard, not hands, to search for leaks.
Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and do serious damage. If
fluidisejectedintotheskinitmustbesurgically removed
within a few hours by a doctor familiar with this form of
injury or gangrene may result.
5. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be relievedbystoppingengineandloweringcuttingunitsand
attachments to the ground.
6. Toreducepotential fire hazard, keeptheenginearea
free of excessive grease, grass, leaves and accumulation of dirt.Never wash a warm engineor electrical connections with water.
7. Check all fuel linesfor tightness andwear on aregular basis. Tighten or repair fuel lines as needed.
9. Do not overspeed the engine by changing governor
settings.Toassuresafetyandaccuracy,have an Authorized Toro Distributor check maximum engine speed
with a tachometer. Maximum governed engine speed
should be 2850 +
10.Enginemustbeshutoffbeforechecking oiloradding
oil to the crankcase.
11.If major repairs are ever needed or if assistance is
desired, contact your Authorized Toro Distributor.
12.At the time of manufacture, the machine conformed
tothe safety standards for ridingmowers. To assure optimumperformanceandcontinuedsafetycertificationof
the machine, use genuine Toro replacement parts and
accessories.Replacementpartsandaccessoriesmade
by other manufacturers may result in non-conformance
with the safety standards and the warranty may be
voided.
13.When changing attachments, tires or performing
other service, use correct blocks, hoists and jacks.
Make sure machine is parkedonasolidlevelsurface
suchasaconcretefloor.Priortoraisingthemachine,remove any attachments that may interfere with the safe
and proper raising of the machine. Always chock or
block wheels. Use appropriate 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.
50 RPM.
8. If the engine must be running to perform a maintenance adjustment, keep hands, feet, clothing and any
other parts of the body away from the cutting units, attachmentsandany moving parts.Keep everyone away.
Greensmaster 3150Page 1 -- 4Safety
Jacking Instructions
CAUTION
When changing attachments, tires or performing other service, use correct jacks and supports. Make sure machine is parked on a solid,
level surface such as a concrete floor. Prior to
raising machine, remove any attachments that
may interfere with the safe and proper raising of
themachine.Always chockorblockwheels.Use
jack stands to supportthe 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.
2. Position jack securelyunder the framejacking point:
Rear End Jacking
1. Applyparkingbrakeandchock both front tirestopre-
vent the machine from moving. Make sure that cutting
units are fully lowered.
2. Place jack securely below the rear castor fork.
3. Jack rear of machine off the ground.
4. Position appropriate jack stands under the frame to
support the machine.
1
Safety
A. The left side jacking point is the frame channel
under the step behind the LH front wheel.
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 Greensmaster 3150. If any decal becomes illegible or damaged, install a new decal. Part numbers are listed in your Parts
CatalogandOperator’s Manual. Order replacement decals from your Authorized Toro Distributor.
Figure 1
1. ROPS support bracket
Greensmaster 3150 Page 1 -- 5 Safety
This page is intentionally blank.
Greensmaster 3150Page 1 -- 6Safety
Product Records and Maintenance
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.........................
Chapter 2
Product Records
and Maintenance
Product Records
Insert a copy of the Operator’s Manual and Parts Catalog for your Greensmaster 3150 at the end of this chapter. Additionally, if any optional equipment or
accessorieshavebeen installed to yourmachine, insert
the Installation Instructions, Operator’s Manuals and
PartsCatalogs for thoseoptions at theend of thischapter.
Maintenance
Maintenanceproceduresandrecommendedserviceintervals for the Greensmaster 3150 are covered in the
Traction Unit Operator’s Manual. Maintenance procedures 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. Refer to the Engine Operator’s Manual for additional engine specific maintenance procedures.
Greensmaster 3150 Page 2 -- 1 Product Records and Maintenance
Equivalents and Conversions
0.09375
Greensmaster 3150Page 2 -- 2Product Records and Maintenance
Torque Specifications
Recommended fastener torque values are listed in the
following tables. For critical applications, as determined
byToro,eithertherecommendedtorque or atorquethat
is unique to the application is clearly identified and specified in this Service Manual.
Thesetorquespecificationsfortheinstallationandtightening of fasteners shall apply to all fasteners which do
nothave a specific requirement identifiedinthis Service
Manual.The following factors shall beconsideredwhen
applying t orque: cleanliness of the fastener, use of a
threadsealant(e.g.L octite), degree oflubricationonthe
fastener,presence of a prevailing torque feature, hardness of the surface underneath the fastener’s head or
similar condition which affects the installation.
Fastener Identification
Asnotedinthefollowingtables, torque valuesshouldbe
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread engagement, etc.
The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measurethetorque required to tightenthefasteneruntil
thelinesmatchup.
Product Records
and Maintenance
Grade 1 Grade 5 Grade 8
Inch Series Bolts and Screws
Figure 1
Using a Torque Wrench with an Offset Wrench
Useofanoffsetwrench(e.g.crowfootwrench)willaffect
torquewrench calibration dueto theeffectivechange of
torque wrench length. When usinga torque wrenchwith
an offset wrench, multiply the listed torque recommendation by the calculated torque conversion factor (Fig.
3) to determine proper tightening torque. Tightening
torque when using a torque wrench with an offset
wrench will be lower than the listed torque recommendation.
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”.
Themeasuredeffectivelengthofthetorquewrenchwith
the offset wrench installed (distance from the center of
the handle to the center of the offset wrench) is 19”.
Class 8.8 Class 10.9
Metric Bolts and Screws
Figure 2
If the listed torque recommendation for a fastener is
from 76 to 94 ft--lb, the proper torque when using this
torque wrench with an offset wrench would be from 72
to 89 ft--lb.
(effective length of
torque wrench)
A
B
(effective length of torque
wrench + offset wrench)
TORQUE CONVERSION FACTOR = A / B
T orque wrenchOffset wrench
The calculated t orque conversion factor for this torque
wrenchwith this offsetwrench would be18 / 19 = 0.947.
Greensmaster 3150 Page 2 -- 3 Product Records and Maintenance
Figure 3
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Grade1,5,&
Thread Size
#6--32UNC
#6--40UNF 17 + 2 190 + 20 25 + 2 280 + 20
#8--32UNC
#8--36UNF 31 + 3 350 + 30 43 + 4 485 + 45
#10--24UNC
#10--32UNF 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
3/8 -- 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 4 58 + 5
8withThin
Height Nuts
in--lb in--lb N--cm in--lb N--cm in--lb N--cm
10 + 2 13 + 2 147 + 23
13 + 2 25 + 5 282 + 30
18 + 2 30 + 5 339 + 56
ft--lb ft--lb N--m ft--lb N--m ft--lb N--m
SAE Grade 1 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
15 + 2 170 + 20 23 + 2 260 + 20
29 + 3 330 + 30 41 + 4 460 + 45
42 + 4 475 + 45 60 + 6 675 + 70
SAE Grade 8 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
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
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such a s
oil, graphite or thread sealant such as Loctite.
NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAEJ429. The tolerance is
approximately +
10% of t he 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.
Greensmaster 3150Page 2 -- 4Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws and Studs with
Thread Size
M5 X 0.8 57 + 5in--lb 640 + 60 N--cm 78 + 7in--lb 885 + 80 N--cm
M6 X 1.0 96 + 9in--lb 1018 + 100 N--cm 133 + 13 in--lb 1500 + 150 N--cm
M8 X 1.25 19 + 2ft--lb 26 + 3N--m 27 + 2ft--lb 36 + 3N--m
M10 X 1.5 38 + 4ft--lb 52 + 5N--m 53 + 5ft--lb 72 + 7N--m
M12 X 1.75 66 + 7ft--lb 90 + 10 N--m 92 + 9ft--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
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite or thread sealant such as Loctite.
NOTE: Torque values may have to be reduced when
installing fasteners into 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.
Regular Height Nuts
(Class 8 or Stronger Nuts)
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAEJ1199.Thetoleranceisapproximately+
nominal torque value.
Class 10.9 Bolts, Screws and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)
10%ofthe
Product Records
and Maintenance
Greensmaster 3150 Page 2 -- 5 Product Records and Maintenance
Other Torque Specifications
SAE Grade 8 Steel Set Screws
Recommended Torque
Thread Size
Square Head Hex Socket
1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb
5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb
3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3ft--lb
1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Size Baseline Torque*
No. 6 -- 32 UNC 20 + 5in--lb
Wheel Bolts and Lug Nuts
Thread Size
7/16 -- 20 UNF
Grade 5
1/2 -- 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
* For steel wheels and non--lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
No. 6 18 20 20 + 5in--lb
Threads per Inch
Type A Type B
Recommended Torque*
65 + 10 ft--lb 88 + 14 N--m
80 + 10 ft--lb 108 + 14 N--m
80 + 10 ft--lb 108 + 14 N--m
80 + 10 ft--lb 108 + 14 N--m
Baseline Torque**
No. 8 -- 32 UNC 30 + 5in--lb
No. 10 -- 24 UNC 38 + 7in--lb
1/4 -- 20 UNC 85 + 15 in--lb
5/16 -- 18 UNC 110 + 20 in--lb
3/8 -- 16 UNC 200 + 100 in--lb
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
No. 8 15 18 30 + 5in--lb
No. 10 12 16 38 + 7in--lb
No. 12 11 14 85 + 15 in--lb
** Hole size, material strength, material thickness & finish must be considered when determining specific
torquevalues.Alltorquevaluesarebasedonnon--lubricated fasteners.
Greensmaster 3150Page 2 -- 6Product Records and Maintenance
Table of Contents
GENERAL INFORMATION 2.....................
Operator’s Manual 2..........................
SPECIFICATIONS 3............................
SERVICE AND REPAIRS 4......................
Fuel Tank 4..................................
Engine 6.....................................
Engine Removal 7...........................
Engine Installation 7.........................
Fuel Evaporative Control System 10.............
BRIGGS&STRATTONVANGUARDV--TWIN OHVRE-
PAIR MANUAL
Chapter 3
Engine
Engine
Greensmaster 3150 Page 3 -- 1 Engine
General Information
This Chapter gives information about specifications,
maintenance, troubleshooting, testing and repair of the
engine used in the Greensmaster 3150.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
tools are described in the Briggs & Stratton Vanguard
V-Twin OHV Repair Manual. The use of some specialized 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 TractionUnit Operator’s Manual provides information regarding the operation, general maintenance and
maintenanceintervalsfor your Greensmaster 3150 machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and repair parts for Briggs& Stratton Vanguard
V-Twin OHV engines are suppliedthrough your locallocalTorodistributor.Ifno parts list is available, be sure to
provide your distributor with the Toro model and serial
numberalongwith the enginemodeland serial number.
Greensmaster 3150Page 3 -- 2Engine
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
Fuel Pump Pulsating Crankcase Vacuum
Fuel Unleaded, regular grade gasoline
Fuel TankCapacity 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
Engine
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
15
RIGHT
FRONT
1
2
14
2
Antiseize
Lubricant
30 to 60 in--lb
(3.4 to 6.7 N--m)
18
16
13
4
20
21
22
5
3
12
16
6
17
6
7
9
7
8
9
10
6
11
7
18
8
19
1. Fuel filter
2. Hose clamp
3. Fuel hose (filter to engine)
4. Fuel cap
5. Fuel tank
6. Grommet (4 used)
7. Flat washer (4 used)
8. Hose support clamp
Figure 1
9. Cap screw (4 used)
10. Cap screw
11. Hose support clamp
12. Vehicle frame
13. Fuel tank vent fitting
14. Fuel hose (shut--off valve to filter)
15. Fuelshut--off valve
16. Hose clamp
17. Fuel hose (tank to shut--off valve)
18. Hose clamp
19. Spacer
20. Hose clamp
21. Fuel vent hose (fitting to cannister)
22. Grommet
Greensmaster 3150Page 3 -- 4Engine
Fuel Tank Removal (Fig. 1)
Fuel Tank installation (Fig. 1)
1. Park machine on a level surface, lower cutting units,
stop the engine, engage parking brake and remove the
key from the ignition switch.
CAUTION
The muffler and exhaust manifold may be hot.
Avoid possible burns, allow exhaust system to
cool before working on the engine.
DANGER
Gasolineisflammable.Use caution whenstoring
or handling it. Do not smoke while filling the fuel
tank. Do not fill fuel tank while engine is running
or in an enclosed area. Always fill fuel tank outside and wipe up any spilled fuel before starting
the engine. Store fuel in a clean, safety--approved container and keep the cap in place. Use
gasoline for the engine only; not for any other
purpose.
IMPORTANT: After fuel tank is installed, make sure
that clearance between hydraulic reservoir and fuel
tank if from 0.125” to 0.375” (3.2 to 9.5 mm).
1. Position fuel tank on the vehicle frame.
A. Applyantiseizelubricantto the threads ofthefour
(4) cap screws (item 9).
B. Securethe fuel tanktothe vehicle framewith four
(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 fuelhose support clamps (item 8) are positioned correctly.
C. Torquecapscrewsfrom30to60in--lb(3.4 to6.7
N--m).
2. Connect vent hose (item 21) to fuel tank vent fitting
(item 13) on top of tank and secure with hose clamp.
Make sure that hose is not kinked or obstructed.
3. Connectfuelhose (item 14) to thefuelshut--off valve
(item15)andsecurewithhoseclamp.
Engine
2. Drain fuel tank as follows:
A. Close fuel shut--off valve (item 15).
B. Disconnectfuelhose(item14) atthe fuelshut--off
valve and drain any fuel trapped in the fuel filter and
fuel hose into a suitable container.
C. Installoneendofasparelengthoffuelhoseto 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. Disconnectventhose(item21)fromfueltankventfit-
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 vehicle frame.
4. Open fuel shut--off valve and fill fuel tank with fuel.
Check all fuel hoses and tank for leaks.
Greensmaster 3150 Page 3 -- 5 Engine
Engine
1
2
29
25 to 38 ft--lb
(34to51N--m)
18 to 23 ft--lb
(25to31N--m)
53
52
51
56
54
25
46
55
24
45
24
23
42
16
44
39
22
50
43
19
33
49
34
41
1
20
43
22
38
42
2
3
40
45
46
Antiseize
Lubricant
27
37
47
48
21
30
170 to 200 in--lb
(20 to 22 N--m)
4
6
29
31
7
32
17
11
16
27
8
11
28
5
27
10
28
11
12
29
26
36
35
34
13
15
9
12
14
18
Loctite #242
90 to 110 in--lb
(10.2 to 12.4 N--m)
1. Cap screw (3 used)
2. Flat washer (3 used)
3. Spacer (3 used)
4. Exhaust manifold
5. Regulator shield
6. Muffler clamp
7. Flange nut (3 used)
8. Engine assembly
9. Muffler
10. Muffler shield
11. Ground wires
12. Flat washer (8 used)
13. Muffler mount
14. Cap screw (4 used)
15. Flat washer (4 used)
16. Hex flange nut (10 used)
17. Lock washer
18. Cap screw (4 used)
19. Pump adapter
Figure 2
20. Socket head screw (2 used)
21. Engine mount plate
22. Lock washer (4 used)
23. Cap screw (2 used)
24. Engine mount (3 used)
25. Cap screw (6 used)
26. Lock nut (4 used)
27. Spring washer (3 used)
28. Washer head screw (2 used)
29. Engine wire harness
30. Flange head screw (4 used)
31. Gasket (2 used)
32. Battery cable
33. Purge hose assy (to intake manifold)
34. Hose clamp (2 used)
35. Barbed fitting
36. Hose clamp
37. Hose (to air cleaner base)
38. Hex nut
39. Cap screw (2 used)
40. Spring bracket
41. Engine hub
42. Lock nut (4 used)
43. Coupling spacer (4 used)
44. Rubber coupling
45. Flat washer (4 used)
46. Cap screw (4 used)
47. Square head set screw (2 used)
48. Key
49. Cap screw
50. Spacer
51. Hardened washer (2 used)
52. Lock washer (2 used)
53. Cap screw (2 used)
54. Pump hub
55. Piston pump assembly
56. Key
Greensmaster 3150Page 3 -- 6Engine
Engine Removal (Fig. 2)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
11.Carefully move the engine away from the piston
pump until the crankshaft clears the engine hub. Remove the engine from the machine. Locate and retrieve
key (item 48) from crankshaft.
2. Disconnect negative (--) battery cable from battery.
CAUTION
The muffler and exhaust manifold may be hot.
Avoid possible burns, allow exhaust system to
cool before working on the engine.
DANGER
Gasolineisflammable.Use caution whenstoring
or handling it. Do not smoke while filling the fuel
tank. Do not fill fuel tank while engine is running
or in an enclosed area. Always fill fuel tank outside and wipe up any spilled fuel before starting
the engine. Store fuel in a clean, safety--approved container and keep the cap in place. Use
gasoline for the engine only; not for any other
purpose.
3. Close fuel shut--off valve on fuel tank.
1
1. Engine assembly
2. Fuel supply hose
3. Cap screw
4. Support clamp
25 to 38 ft--lb
(34to51N--m)
2
Figure 3
3
6
7
5. Hose clamp
6. Spacer screw
7. Washer
4
3
4
5
Engine
2
4. Removethefuelhosesupportclampanddisconnect
fuelhoseatthefuelpump(Fig.3).Drainany fueltrapped
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 System in this section).
6. Disconnect the engine wiring harness (item 29), the
choke control cable, the throttle control cable and the
ground wires (item 11) at the engine.
7. Carefully disconnect extension spring on piston
pump control assembly from spring bracket that is a ttached to engine mount plate (Fig. 4).
8. Loosen the two(2) set screws(item 47) securing the
engine hub (item 41) to the engine shaft.
9. Support the piston pump assembly and remove the
two(2)capscrews(item 53), lockwashers(item52)and
hardened washers (item 51) securing the pump to the
pumpadapter (item 19). Do Not disconnectthe hydraulic hoses or neutral control linkage from the pump.
10.Support the engine assembly and remove the three
(3) engine mount flange nuts (item 7), cap screws (item
1), flat washers (item 2) and spacers (item 3).
5
6
7
1
Figure 4
1. Engine mount plate
2. Spring bracket
3. Lock washer (2 used)
4. Cap screw (2 used)
5. Dampener hose
6. Extension spring
7. Piston pump assembly
Engine Installation (Fig. 2)
1. Make sure that all parts removed from the engine
duringmaintenanceorrebuildingareinstalledto the engine.
2. Apply antiseize lubricant to bore of engine hub.
Place key (item 48) into slot on the engine crankshaft.
Greensmaster 3150 Page 3 -- 7 Engine
IMPORTANT: Make sure to not damage engine, fuel
hose, hydraulic hoses, electrical harness, control
cables or other parts while installing the engine.
Makesureenginehubisinpositionbeforeinstalling
the engine mount cap screws.
3. Align the engine hub (item 41) with the engine shaft
and key (item 48). Slide crankshaft into hub and move
engine until the engine mount plate (item 21) is aligned
with the three (3) engine mounts (item 24). Takecare to
notdamage therubber coupling(item 44) duringengine
installation.
4. Install the three (3) engine mount cap screws (item
1), flat washers (item 2), spacers (item 3) and flange
nuts (item 7).
8. Carefully connect extension spring on piston pump
controlassemblytospringbracket thatisattachedtoengine mount plate (Fig. 4).
9. Connect the engine wiring harness (item 29) and
ground wires (item 11) to the engine.
10.Connect and adjust the choke and throttle control
cables.
11.Connect the f uel evaporative control system hoses
to engine (see Fuel Evaporative Control System in this
section).
12.Connect fuel hose to the fuel pump and secure with
hose clamp. Install the fuel hose support clamp.
5. Position the piston pump assembly to the pump
adapter (item 19) and secure with two (2) cap screws
(item53)lock washers (item 52)andhardenedwashers
(item 51).
6. Position engine hub on crankshaft to best align the
rubber coupling.
7. Apply Loctite #242 (or equivalent) to threads of enginehubset screws (item 47).Securehub to crankshaft
with two (2) set screws. Torque set screws from 90 to
110 in--lb (10.2 to 12.4N--m).
13.Secure negative (--) battery cable to battery.
14.Open fuel shut--off valve on fuel tank. Check fuel
hose for leaks.
15.Check engine oil level and adjust if necessary.
16.Start the engine and check for proper engine operation.
Greensmaster 3150Page 3 -- 8Engine
This page is intentionally blank.
Engine
Greensmaster 3150 Page 3 -- 9 Engine
Fuel Evaporative Control System
FUEL
TANK
CHECK
VALVE
TO INTAKE
MANIFOLD
Figure 5
CARBON
CANNISTER
CHECK
VALVE
FRESH AIR
FILTER
TO AIR
CLEANER
ENGINE
Greensmaster 3150 machines are equipped with a fuel
evaporative control system designed to collect and
store evaporative emissions from the fuel tank. The
evaporate control system uses a carbon cannister to
collect these evaporative emissions. Fuel vapors from
the fuel tank are vented to the canister. Vaporsfrom the
canister are consumed when the engine is running.
The fuel tank on Greensmaster 3150 machines uses a
non--vented fuel cap. Toconnect the tank to the evaporativecontrolsystem,afuel tankventfittingispositioned
inthetop of the tankthatallows tank ventingthroughthe
carbon cannister.
NOTE: If there is restriction in the carbon cannister or
the fuel tank vent fitting, the fuel tank may distort due to
venting issues. If the fuel tank returns to it’s normal
shape when the fuel cap is removed, restriction in the
evaporative control system is likely.
The carbon canister is mounted on the hydraulic leak
detector tank (Fig. 6). The evaporative system includes
two(2)connections totheengine:onetotheintakemanifold and the second to the air cleaner base. Venting
hose assemblies (purgehose assembly and t--hose assembly) include check valves in two (2) locations as
showninFigure5.
NOTE: The purge hose assembly (item 5 in Fig. 6) and
teehoseassembly(item10inFig.6)bothincludea
check valve asa componentof t he hose assembly.The
check valve is not available as a separate part. To ensureproperoperationof check valves, donot attempt to
remove them from the hose assembly.If either of these
hose assemblies is removed, make sure that they are
correctly installed to ensure proper operation of the
evaporative control system.
Greensmaster 3150Page 3 -- 10Engine
Disassembly (Fig. 6)
DANGER
Gasolineisflammable.Use caution whenstoring
or handling it. Wipe up any spilled fuel before
starting the engine.
1. Inspect carbon cannister and attached hoses for
damageorobviousleaks. Adamagedorleakingcannister should be replaced.
2. Remove components as needed using Figure 6 as
a guide.
A. If either purgehose assembly(item 5) or T--hose
assembly (item 10) is to be removed, label ends of
hose for assembly purposes. Both of these assembliesincludea check valve so direction ofinstallation
is important for correct operation of the evaporative
controlsystem. The check valveisnot available as a
separatepartsohose assembly replacement is necessary if the check valve or hose is faulty. To ensure
proper operation of check valves, do not attempt to
remove them from the hose assembly.
2
6
7
4
11
1. Leak detector tank
2. Carbon cannister
3. Cable tie (2 used)
4. Hose clamp
5. Purge hose assembly
6. Hose clamp
7. Hose (to fuel tank vent)
3
4
8
5
9
10
4
8
4
12
Figure 6
8. Hose clamp
9. Hose (to t--fitting)
10. T--hose assembly
11. Fresh air filter
12. Hose (to air cleaner)
13. Barbed fitting
13
1
Engine
Assembly
1. Install all removed components using Figure 6 as a
guide.
A. If either purgehose 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,secureallhoseswithhoseclamps.
Greensmaster 3150 Page 3 -- 11 Engine
This page is intentionally blank.
Greensmaster 3150Page 3 -- 12Engine
Table of Contents
Chapter 4
Hydraulic System
SPECIFICATIONS 2............................
GENERAL INFORMATION 3.....................
Operator’s Manual 3...........................
Check Hydraulic System Fluid 3.................
Towing Traction Unit 4.........................
Hydraulic Hoses 4.............................
Hydraulic Hose and Tube Installation (O--Ring
Face Seal Fitting) 5..........................
Hydraulic Fitting Installation (SAE Straight Thread
O--Ring Fitting into Component Port) 6.........
HYDRAULIC SCHEMATIC 8.....................
HYDRAULIC FLOW DIAGRAMS 10...............
Traction Forward and Reverse 10................
Raise and Lower Cutting Units 12................
Mow and Backlap 14...........................
Right and Left Turn 16.........................
SPECIAL TOOLS 18............................
TROUBLESHOOTING 21........................
General Hydraulic System Problems 21..........
Traction Circuit Problems 22...................
Mow Circuit Problems 23......................
Lift/Lower Circuit Problems 24..................
Steering Circuit Problems 25...................
TESTING 26...................................
Precautions for Hydraulic T esting 26.............
Charge Relief Valve Pressure Test 28............
Wheel Motor Efficiency Test 30..................
Piston (Traction) Pump Flow Test 32.............
Gear Pump (Rear Section) Flow Test 34..........
Implement Relief Valve Pressure Test 36.........
Lower Cutting Units Relief Valve (R2)
Pressure Test 38.............................
Gear Pump (Front Section) Flow Test 40.........
Mow Circuit Relief Valve (S1R1) Pressure Test 42.
Reel Motor Case Drain Flow Test 44.............
Steering Control V alve Test 46..................
ADJUSTMENTS 49.............................
Adjust Manifold Relief Valves (R2) 49............
SERVICE AND REPAIRS 50.....................
General Precautions for Removing and
Installing Hydraulic System Components 50.....
Flush Hydraulic System 51......................
Filtering Closed--Loop Traction Circuit 52.........
Hydraulic System Start--up 53...................
Gear Pump 54................................
Gear Pump Service 56.........................
Piston (Traction) Pump 60......................
Piston (Traction) Pump Service 64...............
Piston Pump Crush Ring Replacement 66........
Front Wheel Motors 68.........................
Rear Wheel Motor (Optional 3WD) 70............
eel Motor Service 72........................
Wh
Cutting Reel Motors 74.........................
Cutting Reel Motor Service 78...................
Front Lift Cylinders 82..........................
Center Lift Cylinder 84.........................
Lift Cylinder Service 86.........................
Hydraulic Manifold 88..........................
Hydraulic Manifold Service 90...................
Steering Control Valve 94.......................
Steering Control Valve Service 96...............
Steering Cylinder 98...........................
Steering Cylinder Service 100...................
Leak Detector 102.............................
Hydraulic Reservoir 106........................
EATON, MEDIUM DUTY PISTON PUMP, REPAIR
INFORMATION, MODEL 70160 VARIABLE DISPLACEMENT PISTON PUMP
PARKER TORQMOTOR
(TC, TB, TE, TJ, TF, TG, TH and TL SERIES)
SAUER/DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
TM
SERVICE PROCEDURE
System
Hydraulic
Greensmaster 3150 Hydraulic SystemPage 4 -- 1
Specifications
Item Description
Piston (Traction) Pump Variabledisplacement piston pump
Maximum Pump Displacement (per revolution) 1.24 in
Charge Pressure 110to150PSI(8to10bar)
Gear Pump 2 section, positive displacement gear pump
Front Section (cutting reels) Displacement (per revolution) 0.58 in
Rear Section (steering/lift) Displacement (per revolution) 0.33 in
Front Wheel Motors Orbital rotor motor
Displacement (per revolution) 10.3 in
Rear Wheel Motor (Optional 3WD Kit) Orbital rotor motor
Displacement (per revolution) 20.6 in
Cutting Reel Motor Gear motor
Displacement (per revolution) 0.73 in
Steering Control Valve Distributor valve with rotary meter
Implement (Steering and Lift) Relief Pressure 1160PSI (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
3
(20.3 cc)
3
(9.5 cc)
3
(5.4 cc)
3
(169 cc)
3
(337 cc)
3
(12 cc)
Hydraulic Oil See Operator’s Manual
Hydraulic Reservoir Reservoir (with leak detector) capacity 8.5 gal. U.S. (32.2 L)
Greensmaster 3150Hydraulic System Page 4 -- 2
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