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

E The Toro Company -- 2012

This page is intentionally blank.

Greensmaster 3150

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

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

Units

Greensmaster 3150

Foldout

Drawings

This page is intentionally blank.

Greensmaster 3150

SAFETY INSTRUCTIONS 2......................

Before Operating 2............................

While Operating 3............................

Maintenance and Service 4....................

JACKING INSTRUCTIONS 5.....................

SAFETY AND INSTRUCTION DECALS 5..........

Chapter 1

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.

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

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)

(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

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

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

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

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

RIGHT

FRONT

Antiseize

Lubricant

30 to 60 in--lb

(3.4 to 6.7 N--m)

6 7

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

25 to 38 ft--lb

(34to51N--m)

18 to 23 ft--lb

(25to31N--m)

Antiseize

Lubricant

170 to 200 in--lb

(20 to 22 N--m)

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

3. Close fuel shut--off valve on fuel tank.

1. Engine assembly

2. Fuel supply hose

3. Cap screw

4. Support clamp

25 to 38 ft--lb

(34to51N--m)

Figure 3

5. Hose clamp

6. Spacer screw

7. Washer

Engine

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).

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.

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)

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

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

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........................

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

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

(20.3 cc)

(9.5 cc)

(5.4 cc)

(169 cc)

(337 cc)

(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

General Information

Operator’s Manual

The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervalsforyourGreensmaster3150.Refer to thatpublication for additional information when servicing the machine.

Check Hydraulic System Fluid

The hydraulic system on the Greensmaster 3150 is designed to operate on high quality hydraulic fluid. Refer to the Operator’s Manual for hydraulic fluid recommendations.

IMPORTANT: Check level of hydraulic fluid before engine is first started and daily thereafter. Do not overfill hydraulic reservoir.

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.

IMPORTANT: Use only types of hydraulic fluids specifiedintheOperator’sManual. Otherfluidsmay cause system damage.

NOTE: Ared dyeadditive for the hydraulicsystem fluid

is available in 2/3 oz bottles. One bottle is sufficient for 4 to 6gallons of hydraulicfluid. Order PartNo. 44--2500 from your Authorized Toro Distributor.

Figure 1

1. Sight window 2. Hydraulic oil cap

System

Hydraulic

Greensmaster 3150 Hydraulic SystemPage 4 -- 3

Towing Traction Unit

In case of emergency, the Greensmaster 3150 can be towed for a short distance. However,Toro does not recommend 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.Rotatevalve90

2. Before starting engine,close by--pass valve byrotating it back 90 not start engine when the valve is open.

so the slot in the valve is horizontal. Do

sotheslotinthevalveisvertical.

Hydraulic Hoses

Hydraulichoses a re subject to extreme conditions such aspressure differentialsduring operation and exposure to weather, sun, chemicals, very warm storage conditionsormishandlingduringoperationandmaintenance. These conditions can cause hose damage and deterioration. Some hoses are more susceptible to these conditions than others. Inspect all machine hydraulic hoses frequently for signs of deterioration or damage:

Hard, cracked, cut, abraded, charred, leaking or otherwise damaged hose.

Kinked, crushed, flattened or twisted hose. Blistered, soft, degraded or loose hose cover. Cracked, damaged or badly corroded hose fittings.

When replacing a hydraulic hose, be sure that the hose is straight (not twisted) before tightening the fittings. This can be done by observing the imprint (layline) on thehose. Usetwo wrenches; hold the hosestraight with one wrench and tighten the hose swivel nut onto the fitting with the other wrench (see Hydraulic Hose and Tube Installation in this section). If the hose has an elbowatoneend,tightentheswivelnut on that end before tightening the nut on the straight end of the hose.

Figure 2

1. Piston pump 2. By--pass valve

WARNING

Beforedisconnecting or performing any work on hydraulic system, relieve all pressure in system (seeRelieving Hydraulic System Pressure in this section).

Keepbodyand handsawayfrompin holeleaksor nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar withthistypeofinjury.Gangrenemayresultfrom such an injury.

For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).

Greensmaster 3150Hydraulic System Page 4 -- 4

Hydraulic Hose and Tube Installation (O --Ring Face Seal Fitting)

1. Make sure threads andsealing surfaces ofthe hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material.

2. Asa preventative measure againstleakage,it is recommended that the face seal O--ring be replaced any time the connection is opened. Make sure the O--ring is installedandproperly seatedinthefittinggroove.Lightly lubricate the O--ring with clean hydraulic oil.

3. Place the hose/tube against the fitting body so that theflatfaceof the hose/tubesleevefullycontactstheO-ring in the fitting.

4. Thread the swivel nut onto the fitting by hand. While holding the hose/tube with a wrench, use a torque wrench to tighten the swivel nut to the recommended installation torque shown in Figure 5. This tightening process will require the use of an offset wrench (e.g. crowfoot wrench). Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench. Tightening torque when usingatorque wrenchwithanoffsetwrenchwillbelower than the listed installation torque (see Using a Torque Wrench with an Offset Wrench in the Torque Specificationssection of Chapter 2 -- Product Records and Maintenance).

C. Useasecondwrenchtotightenthenuttothecorrect Flats From Wrench Resistance (F.F.W.R.). The markingsonthenutandfittingbody willverifythatthe connection has been properly tightened.

Size F.F.W.R.

4 (1/4 in. nominal hose or tubing) 1/2 to 3/4 6 (3/8 in.) 1/2 to 3/4 8 (1/2 in.) 1/2 to 3/4 10 (5/8 in.) 1/2 to 3/4 12 (3/4 in.) 1/3 to 1/2 16 (1 in.) 1/3 to 1/2

Swivel Nut

Tubeor Hose

O--ring

Fitting Body

Figure 3

System

Hydraulic

5. If a torque wrench is not available or if space at the swivelnutpreventsuseof a torque wrench, an alternate method of assembly is the Flats From Wrench Resist-

Mark Nut

and Fitting

Body

Final

Position

ance (F.F.W.R.) method (Fig. 2).

A. Usingawrench,tightenthe swivel nut onto the fittinguntillight wrench resistance is reached(approximately 30 in--lb).

B. Mark the swivel nut and fitting body. Hold the hose/tube with a wrench to prevent it from turning.

AT WRENCH RESISTANCE

Extend Line

Figure 4

Fitting Dash Size Hose/Tube Side Thread Size Installation Torque

4 9/16 -- 18 18to22ft--lb(25to29N--m) 6 11/16 -- 16 27to33ft--lb(37to44N--m)

8 13/16 -- 16 37to47ft--lb(51to63N--m) 10 1--14 60 to 74 ft--lb (82 to 100 N--m) 12 13/16--12 85to105ft--lb(116to142N--m) 16 17/16--12 110to136ft--lb(150to184N--m)

Initial Position

AFTER TIGHTENING

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

Figure 5

Greensmaster 3150 Hydraulic SystemPage 4 -- 5

Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port)

Non--Adjustable Fitting (Fig. 6)

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 isrecommended that the O--ring be replaced any time the connection is opened.

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

IMPORTANT: Before installing fitting into port, determine port material. If fitting is to be installed into an aluminum port, installation torque is reduced.

4. Install the fitting into the port. Then, use a torque wrench and socket to tighten the fitting to the recommended installation torque shown in Figure 7.

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 UsingaTorqueWrenchwithanOffsetWrenchinthe Torque Specifications section of Chapter 2 -- Product RecordsandMaintenancetodeterminenecessaryconversion information.

5. If a torque wrench is not available, or if space at the portprevents use of a torque wrench,analternatemethod of assembly is the Flats From Finger Tight (F.F.F.T.) method.

A. Install the fitting into the port and tighten it down full length until finger tight.

B. If port material is steel, tighten the fitting to the listed F.F.F.T. If port material is aluminum, tighten fitting to 60% of listed F.F.F.T.

Size F.F.F.T.

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

Fitting

O--ring

0.25

Figure 6

Fitting

Dash Size

Fitting Port Side

Thread Size

Installation Torque Into

Steel Port

Installation Torque Into

Aluminum Port

4 7/16 -- 20 15to19ft--lb(21to25N--m) 9to11ft--lb(13to15N--m) 5 1/2 -- 20 18to22ft--lb(25to29N--m) 11 to 15 ft--lb (15 to 20 N--m) 6 9/16 -- 18 34to42ft--lb(47to56N--m) 20to26ft--lb(28to35N--m)

8 3/4 -- 16 58to72ft--lb(79to97N--m) 35to43ft--lb(48to58N--m) 10 7/8 -- 14 99to121ft--lb(135to164N--m) 60 to 74 ft--lb (82 to 100 N--m) 12 11/16--12 134to164ft--lb(182to222N--m) 81 to 99 ft--lb (110 to 134 N--m) 14 13/16--12 160to196ft--lb(217to265N--m) 96to118ft--lb(131to160N--m) 16 15/16--12 202to248ft--lb(274to336N--m) 121to149ft--lb(165to202N--m) 20 15/8--12 247to303ft--lb(335to410N--m) 149to183ft--lb(202to248N--m)

Figure 7

Greensmaster 3150Hydraulic System Page 4 -- 6

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. Asa preventative measure againstleakage,it is recommended that the O--ring be replaced any time the connection is opened.

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

4. Turnback the lock nut as far aspossible. Make sure the back up washer is not loose and is pushed up as far aspossible(Step1inFigure9).

IMPORTANT: Before installing fitting into port, determine port material. If fitting is to be installed into an aluminum port, installation torque is reduced.

Lock Nut

Back--up Washer

O--ring

Figure 8

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

6. Toputthefittingin the desired position, unscrew it by the required amount, but no more than one full turn (Step 3).

7. Hold the fitting in the desired position with a wrench and use a torque wrench to tighten the fitting to the recommended 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 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 portpreventsuseofatorquewrench, an alternatemethod of assembly is the Flats From Finger Tight (F.F.F.T.) method.Holdthefittinginthedesiredpositionwitha wrench and, if port material is steel, tighten the lock nut withasecondwrenchtothelistedF.F.F.T(Step4).Ifport material is aluminum, tighten fitting to 60% of listed F.F.F.T.

Step 3Step 1

Step 2 Step 4

Figure 9

System

Hydraulic

Size F.F.F.T.

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

0.25

Greensmaster 3150 Hydraulic SystemPage 4 -- 7

Hydraulic Schematic

VALVE

STEERING

Right

Motor

10.3

Left

Motor

3WD KIT

OPTIONAL

20.6

Steering Cylinder

L3A L3BL2B L1B

L2A

4.5

0.055

0.030

FC2

1.5” Bore

0.75” Rod

6.19” Stroke

Raise

CU #3

2.0” Bore

0.75” Rod

1.88” Stroke

CU #1

0.75” Rod

1.50” Bore

3.38” Stroke

Lower

1160 PSI

400 PSI

PET

2850/1650

ENGINE RPM

BYPASS

VALVE

TOP

PORT

TRANSPORT = 14.1 GPM

4.0 GPM

TRACTION PUMP

7.0 GPM

3000

PSI

3000

PSI

1.24

.33 .58

PUMP

GEAR

BOTTOM

PORT

70 to

100 PSI

110 to

150 PSI

MA L1A

0.055

550 PSI

PRV

(SW)

SWITCH

BACKLAP

OR1

FC1

0.013

S1R1

OR2

0.060

CU #2

2.0” Bore

0.75” Rod

1.88” Stroke

Center

Reel (#1)

.73

Right Front

Reel (#3)

de--energized

All solenoids are shown as

Hydraulic Schematic

Greensmaster 3150

.73

Reel (#2)

Left Front

25 PSI

FILTER

OPTIONAL

OIL COOLER

SUCTION

STRAINER

LEAK DETECTOR

LEAK

OUT

VOLUME

DETECTOR

TANK

EXPANSION

BREATHER

Greensmaster 3150Hydraulic System Page 4 -- 8

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System

Hydraulic

Greensmaster 3150 Hydraulic SystemPage 4 -- 9

Hydraulic Flow Diagrams

Steering Cylinder

1.5” Bore

0.75” Rod

6.19” Stroke

4.5

1160 PSI

PET

VALVE

STEERING

TOP

Motor

Right

10.3

Left

Motor

2850/1650

ENGINE RPM

BYPASS

VALVE

PORT

3WD KIT

OPTIONAL

20.6

BOTTOM

PORT

70 to

100 PSI

TRANSPORT = 14.1 GPM

Raise

Lower

L3A L3BL2B L1B

L2A

MA L1A

0.055

0.030

FC2

0.055

BACKLAP

550 PSI

SWITCH

400 PSI

PRV

(SW)

CU #3

2.0” Bore

0.75” Rod

1.88” Stroke

CU #1

0.75” Rod

1.50” Bore

3.38” Stroke

de--energized.

All solenoids are shown as

Right Front

Reel (#3)

CU #2

2.0” Bore

0.75” Rod

1.88” Stroke

Center

Reel (#1)

.73

Reel (#2)

Left Front

4.0 GPM

TRACTION PUMP

0.013

OR2

S1R1

0.060

OR1

FC1

7.0 GPM

25 PSI

FILTER

3000

PSI

3000

PSI

110 to

150 PSI

1.24

.33 .58

PUMP

GEAR

OPTIONAL

OIL COOLER

SUCTION

STRAINER

Greensmaster 3150

Traction Forward

OUT

LEAK

VOLUME

DETECTOR

High Pressure

Low Pressure (Charge)

Return or Suction

Flow

LEAK DETECTOR

TANK

EXPANSION

BREATHER

Greensmaster 3150Hydraulic System Page 4 -- 10

Traction Forward a nd Reverse

Forward

The piston (traction) pump is driven directly by the engine.Thetractioncircuitofthe hydraulic system acts essentiallyasaclosedloop.Takingitssuctiondirectlyfrom thereturnsideofthewheelmotorsofthetractioncircuit, the piston pump supplies oil flow to the wheel motors through the supply side of the traction circuit.

Withtheengine runningandtraction pedal intheneutral position, the piston pump supplies no flow to the wheel motors. When the traction pedal is pressed to the forward position, the linkage from the pedal positions the swash plate in the piston pump so oil flows out the top port of the pump. Oil flow out of the top port goes to the wheel motors and turns them in the forward direction.

Oilflowing out of thewheel motors returns to thebottom port of the piston pumpand is continuously pumped out the top port as long as the traction pedal is pressed for the forward direction.

Hydraulic oil is supplied to the traction charge circuit from the rear gear pump section though the steering valve,control manifold and backthroughthe charge circuit check valves in the piston (traction) pump. This oil replaces oil losses f rom flow through the internal case drain, shuttle valve andsmall amounts of traction circuit leakage. Charge circuit pressure is maintained by the charge relief valve that is attached to the piston pump back plate.

Reverse

The traction circuit operates essentially the same in reverse as it does in the forward direction. However, the flow through the circuit is reversed.

Withtheenginerunningandtractionpedalintheneutral position, the piston pump supplies no flow to the wheel motors. When the traction pedal is pressed to t he reverse position, the linkage from the pedal positions the swashplateinthepistonpumpsooilflowsoutthebottomportofthepump. Oilflowoutofthebottomportgoes tothe wheel motors andturnsthem in the reversedirection.

Oilflowingoutofthewheelmotorsreturns to the top port of the piston pump and is continuously pumped out the bottom port as long as the traction pedal is pressed for the reverse direction.

Thechargecircuitfunctions the same in reverse as it does in the forward direction.

Traction Circuit Cooling

The piston pump includes a shuttle valve that bleeds off asmallamountof hydraulicfluidforcoolingoftheclosed looptraction circuit. This valve allowsa small amountof hydraulic oil to pass from the low pressure side of the traction circuit while operating the traction unit in either direction. A relief valve in the piston pump back plate prevents shuttle valve bleed off until the relief valve opens(70 to100 PSI / 5to 7 bar). The charge circuit replenishes oil that is bled from the traction circuit by the shuttle valve.

System

Hydraulic

NOTE: Theshuttlevalveassemblyislocatedinthepiston pump back plate. Access to the shuttle valve requires removal of the back plate from the piston pump.

Greensmaster 3150 Hydraulic SystemPage 4 -- 11

Motor

Right

10.3

1.5” Bore

0.75” Rod

6.19” Stroke

Steering Cylinder

4.5

1160PSI

PET

Left

Motor

2850/1650

ENGINE RPM

BYPASS

VALVE

TOP

PORT

3WD KIT

OPTIONAL

20.6

BOTTOM

PORT

SolenoidsS2andS3areshown

in the energized position.

Right Front

VALVE

STEERING

TRANSPORT = 14.1 GPM

All other solenoids are shown

Reel (#3)

as de--energized.

CU #3

2.0” Bore

0.75” Rod

1.88” Stroke

CU #1

0.75” Rod

1.50” Bore

3.38” Stroke

CU #2

2.0” Bore

0.75” Rod

1.88” Stroke

.73

Raise

Lower

0.055

L3A L3BL2B L1B

0.030

FC2

L2A

0.055

Center

Reel (#1)

.73

Reel (#2)

Left Front

MA L1A

BACKLAP

550 PSI

SWITCH

400 PSI

PRV

(SW)

OR1

FC1

0.013

OR2

4.0 GPM

TRACTION PUMP

S1R1

0.060

7.0 GPM

3000

25 PSI

FILTER

70 to

100 PSI

3000

PSI

110 to

150 PSI

1.24

.33 .58

PUMP

GEAR

OPTIONAL

OIL COOLER

SUCTION

STRAINER

Greensmaster 3150

High Pressure

Raise Cutting Units

Low Pressure (Charge)

OUT

LEAK

VOLUME

DETECTOR

Return or Suction

Flow

LEAK DETECTOR

TANK

EXPANSION

BREATHER

Greensmaster 3150Hydraulic System Page 4 -- 12

Raise and Lower Cutting Units

The t andem gear pump is directly coupled to the piston (traction) pump. The rear gear pump section supplies hydraulic flow for the steering circuit (priority flow), for raisingand lowering thecutting units andfor the traction charge circuit. The gear pumptakes itssuction from the hydraulic reservoir. Maximum circuit pressure of 1160 PSI (80 bar) is limited by the relief valve located in the steering valve.

During cutting unit hold (not raising or lowering) conditions,flowfromthereargearpumpsectionisby--passed through the steering valve and de--energized solenoid valve (S2) in the hydraulic manifold directly to the traction charge circuit. Flow in excess of charge circuit requirements then returns to the gear pump inlet.

Raise Cutting Units

When the cutting units are to be raised, hydraulic manifoldsolenoidvalve (S2) is energized andblocksflowdirectly to the traction charge circuit. Flow is directed to energizedsolenoidvalve (S3), whichdirects flow tode-energized solenoid valve (S4) and the lift cylinders. Hydraulic pressure against the cylinder pistons moves their shafts causing the cutting units to raise. At the sametime,thepistonspushthehydraulicfluidoutofthe lift cylinders and back through energized solenoidvalve (S3) to the charge circuit. Raise speed for the front cutting units is controlled by a 0.055 orifice.A 0.030 orifice inthereturn line for the centercutting unit allows a slight delay in raising that cutting unit.

Lower Cutting Units

Circuit operation for lowering the lift cylinders is similar to raising them. However, the solenoid valve (S3) remains de--energized and solenoid valve (S4) is energized. Flow is reversed to and from the lift cylinders, lowering the cutting units.

Whenthecuttingunits are to belowered,solenoidvalve (S2) is energized and blocks flow directly to the traction charge circuit. Flow is directed to de--energized solenoid valve (S3), which directs flow to the lift cylinders. Hydraulic pressure against the cylinder pistons moves their shafts causing the cutting units to lower. At the sametime,thepistonspushthehydraulicfluidoutofthe liftcylindersto energized solenoid valve (S4).Flowcontinues back through solenoid valve (S3) to the charge circuit. Lower speed for the front cutting units is controlled by the 0.055 orifice. A 0.030 orifice and adjustable flow control valve for the center cutting unit allows a slight delay in lowering that cutting unit.

To control pressure while lowering the cutting units, the system is equipped with adjustable relief valve (R2) in the hydraulic manifold.

When solenoid valves (S2) and (S4) de--energize, spring action returns the valves to their original position and by--passes flow back to the traction charge circuit stopping lift cylinder movement.

System

Hydraulic

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 stoppingliftcylindermovement.Theliftcylinderposition is locked in place since there is no complete circuit of flow to and from the lift cylinders.

Greensmaster 3150 Hydraulic SystemPage 4 -- 13

Motor

Right

VALVE

STEERING

10.3

Left

Motor

3WD KIT

OPTIONAL

20.6

Steering Cylinder

Solenoid S1R1 is shown

in the energized position.

Lower

L3A L3BL2B L1B

L2A

MA L1A

4.5

0.055

0.030

FC2

0.055

550 PSI

BACKLAP

1.5” Bore

0.75” Rod

6.19” Stroke

All other solenoids are shown

as de--energized.

.73

Right Front

Reel (#3)

Raise

CU #3

2.0” Bore

0.75” Rod

1.88” Stroke

CU #1

0.75” Rod

1.50” Bore

3.38” Stroke

CU #2

2.0” Bore

0.75” Rod

1.88” Stroke

Center

Reel (#1)

.73

Left Front

Reel (#2)

SWITCH

1160 PSI

PET

4.0 GPM

400 PSI

OR1

PRV

(SW)

0.013

OR2

0.060

FC1

S1R1

TRACTION PUMP

7.0 GPM

TOP

BYPASS

PORT

TRANSPORT = 14.1 GPM

25 PSI

FILTER

2850/1650

ENGINE RPM

VALVE

3000

PSI

OPTIONAL

3000

1.24

.33 .58

GEAR

OIL COOLER

PSI

PUMP

BOTTOM

PORT

70 to

100 PSI

110 to

150 PSI

SUCTION

STRAINER

Greensmaster 3150

High Pressure

Mow

Low Pressure (Charge)

Return or Suction

Flow

LEAK DETECTOR

OUT

LEAK

VOLUME

DETECTOR

TANK

EXPANSION

BREATHER

Greensmaster 3150Hydraulic System Page 4 -- 14

Mow and Backlap

The t andem gear pump is directly coupled to the piston (traction) pump. The front gear pump section supplies oil flow tothe hydraulic manifold block and to the cutting reel motors. The gear pump takes its suction directly from the hydraulic reservoir. Maximum circuit pressure islimitedbysolenoid relief valve(S1R1)whichislocated in the hydraulic manifold.

With the engine running and the functional control and joystick levers positioned so the reels will not turn (see Operator’s Manual), solenoid relief valve (S1R1) in the hydraulic manifold is de--energized. The de--energized (S1R1) by--passes flow from the front gear pump section to the oil filter and hydraulic reservoir. Additionally, the manifold pressure reducing valve (PRV) will remain seatedto prevent the reelmotors (and reels)from rotating.

Mow

With the engine running and the functional control and joystick levers positionedso thereels will turn (see Operator’s Manual), solenoid relief valve (S1R1) is energized.Intheenergizedposition,thisvalvedirectsoilflow to the reel motors and also functions as the mow circuit relief valve.

Oil flow from manifold port (P1) flows through the reel speed control valve (FC1). Flow across the speed controlvalveis pressurecompensatedbythelogiccartridge valve (LC). The logic cartridge valve maintains a pressure differential of 75 PSI (5.2 bar) across the speed control valve. Any excess flow above t he speed control valve setting is by--passed to the reservoir through the logiccartridge valve. With the backlap valve (MR) in the mow position, oil flows through the backlap valve, out manifold port (MA) and to the reel motors that are connected in series. Oil flows through the left front reel motor, right front motor and then center motor to turn the reel motors in the mow direction.

When in the mow position, mow circuit pressure will cause the hydraulic manifold pilot piston to shift and open the pressure reducing valve ( PRV). The shifted pressurereducing valve allows circuit oil to returnto the reservoir through the manifold block, oil filter and oil cooler (if equipped).

Backlap

Backlapping operation is the same as mowing operation, except for the position of the backlap valve (MR). Whenthebacklapvalve(MR) is in the backlap position, oil flows through the backlap valve, out manifold port (MB)andtothereelmotorsthatareconnected in series. Oil flows through the center reel motor,right front motor andthen left front motoras it turns thereel motors inthe backlap direction.

System

Hydraulic

Greensmaster 3150 Hydraulic SystemPage 4 -- 15

Steering C ylinder

Motor

Right

10.3

Left

Motor

1.5” Bore

0.75” Rod

6.19” Stroke

4.5

1160PSI

PET

VALVE

STEERING

2850/1650

ENGINE RPM

BYPASS

VALVE

TOP

PORT

3WD KIT

OPTIONAL

20.6

BOTTOM

PORT

70 to

100 PSI

All solenoids are shown

TRANSPORT = 14.1 GPM

OR1

FC1

0.013

OR2

4.0 GPM

TRACTION PUMP

S1R1

0.060

7.0 GPM

25 PSI

FILTER

Raise

Lower

L3A L3BL2B L1B

L2A

MA L1A

0.055

0.030

FC2

0.055

550 PSI

SWITCH

BACKLAP

400 PSI

PRV

(SW)

CU #3

2.0” Bore

0.75” Rod

1.88” Stroke

as de--energized.

Power steering valve is

positioned for a right turn.

CU #1

0.75” Rod

1.50” Bore

3.38” Stroke

CU #2

2.0” Bore

0.75” Rod

1.88” Stroke

Center

Reel (#1)

.73

Right Front

.73

Reel (#3)

.73

Reel (#2)

Left Front

3000

PSI

110 to

150 PSI

1.24

.33 .58

PUMP

GEAR

OPTIONAL

OIL COOLER

SUCTION

STRAINER

Greensmaster 3150

Right Turn

OUT

LEAK

VOLUME

DETECTOR

High Pressure

Low Pressure (Charge)

Return or Suction

Flow

LEAK DETECTOR

TANK

EXPANSION

BREATHER

Greensmaster 3150Hydraulic System Page 4 -- 16

Right and Left Turn

With the steering wheel in the neutral position and the engine running, the spool valve in the steering valve is in the center position. Flow enters the steering control valve at Port (P) and goes through the spool valve, by-passing the steering cylinder. Flow leaves the control valve out port (E) to be available for the raise/lower and traction charge circuits.

Right Turn

When a right turn is made with the engine running, the turningofthesteering wheel positions the spoolvalvein the steering valve so that flow goes through the bottom of the spool. Flow entering the steering valve at Port (P) goesthroughthespool andisroutedtotwoplaces.First, most of the flow through the valve is by--passed out steering valve port (E) and is available for raising and loweringthe cutting unitsand for the traction chargecircuit.Second,the remainder of theflowis drawn through the steering valve rotary meter and out steering valve port (R). Pressure moves the steering cylinder piston to extend the cylinder for a right turn. The rotary meter ensuresthattheoilflowtothecylinderisproportionaltothe amount of turning on the steering wheel. Fluid leaving the cylinder flowsback through the spool valve then out steering valve port (T) and then to the traction charge circuit.

Left Turn

When a left turn is made with the engine running, the turningofthe steering wheel positions the spoolvalvein the steering valve so that flow goes through the top of the spool (Fig. 10). 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 valve port(E)andisavailablefor raisingandloweringthecutting units and for thetraction charge circuit. Second, the remainder of the flow is drawn through the steering valve rotary meter and out steeringvalveport(L).Pressuremovesthesteeringcylinder piston to retract the cylinder for a left turn. The rotary meter ensures 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 thetractionchargecircuit.

The steering valve returns to the neutral position when turning is complete.

Steering Cylinder

1.5” Bore

0.75” Rod

6.19” Stroke

4.5

System

Hydraulic

The steering valve returns to the neutral position when turning is complete.

Greensmaster 3150 Hydraulic SystemPage 4 -- 17

STEERING

VALVE

To Manifold

Port ST

To Manifold

Port P2

From Gear Pump

1160PSI

PET

Figure 10

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

Hydraulic Tester (Pressure and Flow)

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

Figure 11

1. INLET HOSE: Hose connected from the system circuit 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 provide operating circuit pressure.

4. FLOW METER: This meter measures actual oil flow intheoperatingcircuitwithagaugeratedat15GPM.

5. OUTLET HOSE: A hose from the outlet side of the hydraulictesterconnectstothehydraulicsystemcircuit.

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 recommended that O--rings be replaced whenever a hydraulic connection is loosened.

Toro Part Number: 117- -2727

Figure 12

Figure 13

Greensmaster 3150Hydraulic System Page 4 -- 18

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--directional filtration which prevents filtered debris from being allowedbackinto the circuit regardlessofflow direction.

If a component failure occurs in the closed looptraction 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 orafterreplacinga failedtractioncircuitcomponent(e.g. piston(traction)pump or wheelmotor),the high flow hydraulic filter can be installed in the traction circuit. The filterwillensurethatcontaminates are removed fromthe closed loop and thus, do not cause additional component damage.

Toro Part Number: TOR6011 NOTE: This kit does not include hydraulic hoses (see

Hydraulic Hose Kit TOR6007 above). NOTE: Replacementfilter element is Toro part n umber

TOR6012. Filter element cannister tightening torque is 2 5 f t -- l b ( 3 4 N -- m ) .

Figure 14

System

Hydraulic

Hydraulic Hose Kit

This kit includes hydraulic fittings and hoses needed to connect40GPMhydraulictester(AT40002)orhighflow hydraulic filter kit (TOR6011)to machine hydraulic traction system components.

Toro Part Number: TOR6007

Figure 15

Greensmaster 3150 Hydraulic SystemPage 4 -- 19

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.

The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings.

Toro Part Number: TOR4079

Measuring Container

Use this container for doing hydraulic motor e fficiency testing(motors with case drainlinesonly). Measure efficiency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drainlinewhilethemotorispressurizedby the hydraulic system.

TORO TEST FITTING KIT (NO. TOR4079)

Figure 16

Toro Part Number: TOR4077

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 17

Figure 18

Greensmaster 3150Hydraulic System Page 4 -- 20

Troubleshooting

The charts that follow contain information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction.

Refer to the Testing section of this Chapter for precautions and specific test procedures.

General Hydraulic System Problems

Problem Possible Cause

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

O--r ing(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.

Suction screen in reservoir is loose or clogged. Oil is contaminated or too light. Brakes are applied or are incorrectly adjusted.

System

Hydraulic

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 Hydraulic SystemPage 4 -- 21

Traction Circuit Problems

Problem Possible Cause

Neutral is difficult to find or machine operates in one direction only.

Traction response is sluggish. Hydraulic oil is very cold.

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

External control linkage is misadjusted, disconnected, binding or damaged.

Piston (traction) pump is worn or damaged (see Piston (Traction) Pump Flow Test in the Testing section of this chapter).

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).

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 neutral.

NOTE: The piston (traction) pump used on Greensmaster 3150 machines is equipped with relief valves forboththeforwardandreversedirection.Due toengine output,itisunlikely thattractionpressurewillreachrelief valve settings. If, however,a piston pump relief valve is leaking or otherwise faulty, traction performance would be affected.

Make up fluid from charge pump is not available. Piston (traction) pump relief valves are leaking or damaged.

Greensmaster 3150Hydraulic System Page 4 -- 22

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

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).

System

Hydraulic

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 Hydraulic SystemPage 4 -- 23

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 (seeChargeReliefValvePressure

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.

Cutting units raise, but will not stay up.

Spoolinsteeringcontrolvalveishungup(seeSteeringControl Valve Test in the Testing section of this chapter).

Gear pump (rear section) is worn or damaged (see Gear Pump (Rear Section) Flow Testin the Testing section of this chapter).

Hydraulic manifold solenoid valve (S4) leaks or is damaged. Lift cylinders leak internally.

Greensmaster 3150Hydraulic System Page 4 -- 24

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 wheel are necessary because of difficulty of driving in a straight line.

Steering wheel will not return to the neutral position.

Steering wheel can turn on its own. Leaf springs in steering control valve are broken or stuck.

Backlash results when turning steering wheel.

Rear wheel shimmies when the steering wheel is turned.

Thesteeringwheelcanbeturned without the rear wheel turning.

Leaf springs in steering control valve are worn or broken. 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). Spool and sleeve are sticking to steering control housing assembly

(see Steering Control Valve Test in the Testing section of this chapter).

Spool and sleeve are sticking to steering control housing assembly (see Steering Control Valve Test in the Testing section of this chapter).

Cardan shaft fork is worn or broken. Leaf springs in steering control valve are worn or broken.

Air is in the steering cylinder. Mechanical connections to the wheel or wheel bearing are worn.

The steering cylinder is worn. The gear set in the steering control valve is worn.

System

Hydraulic

Steering response is too slow and heavywhentryingtoturnquickly.

Turning steering wheel turns machine in the opposite direction.

Steering force (possibly to one side only) is insufficient.

Greensmaster 3150 Hydraulic SystemPage 4 -- 25

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

Hoses to the steering cylinder are reversed.

Hydraulic flow to steering control valve is low (traction charge and 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).

Testing

The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressuregauges and flowmeters in the circuits during various operational checks (see the Special Tools section in this Chapter).

Before Performing Hydraulic Tests IMPORTANT: All obvious areas such as oil supply,

filter, binding linkages, loose fasteners, improper adjustments, solenoid valve operation or electrical connections/circuits must be checked before assuming that a hydraulic component is the source of the problem.

Precautions for Hydraulic Testing

CAUTION

Failure to use gauges with recommended pressure (psi) rating as listed in test procedures couldresultin damage tothegaugeandpossible personal injury from leaking hot oil.

All testing should be performed by two (2) people.Onepersonshouldbein the seat to operate the machine and the other should read testing tools (e.g. pressure gauge) and record test results.

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the ignitionswitchinOFF.Removekey from the ignition switch.

1. Clean machine thoroughly before disconnecting or disassemblinganyhydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. Contamination will cause excessive wear of components.

2. Topreventhydraulicsystem contamination, put metal caps or plugs on any hydraulic lines left open or exposed during testing or removal of components.

3. Theengine must be ingoodoperatingcondition. Enginespeed will affecttest accuracy.Check pump speed with a phototac when performing hydraulic tests.

4. When using tester with pressure and flow capabilities,the inlet and theoutlethoses must be properly connected and not reversed to prevent damage to the hydraulic tester or components.

5. When using tester with pressure and flow capabilities, completely open load valve in the hydraulic tester to minimize the possibility of damaging components.

6. Install fittings finger tight and far enough to make sure that they are not cross--threaded before tightening them with a wrench.

7. Position tester hoses to prevent rotating machine partsfromcontactinganddamagingthehoses or tester.

8. Check oil level in the hydraulic reservoir. After connecting test equipment, make sure tank is full.

9. Check control linkages for improper adjustment, binding,or broken parts.

10.All hydraulic testsshouldbe made with the hydraulic oil at normal operating temperature.

WARNING

Beforedisconnectingor performinganyworkon the hydraulic system, all pressure in the system must be relieved and all rotating machine parts must be stopped. Stop engine; lower or support attachments.

Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Do not use hands to search for leaks; use paper or cardboard. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into theskin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury.

11.Record the results of all performed hydraulic tests.

Hydraulic Testing

1. Use the Hydraulic Schematic, Hydraulic Flow Diagrams and the Troubleshooting section found in this Chapter to assist in problem identification and solution.

2. Hydraulic system problems (e.g. low hydraulic oil level, contaminated oil, incorrect engine speed) will affect the entire hydraulic system.

3. For traction related problems (e.g. machine will not go up an incline), consider performing the following hydraulic tests:

Charge Pressure Relief Valve Pressure Test Wheel Motor Efficiency Test Piston (Traction) Pump Flow Test

Greensmaster 3150Hydraulic System Page 4 -- 26

4. For problems with steering or cutting unit lift/lower, consider performing the following hydraulic tests:

Charge Pressure Relief Valve Pressure Test Lower Cutting Units Relief Valve (R2) Pressure Test Implement Relief Valve Pressure Test Gear Pump (Rear Section) Flow Test Steering Valve Test

5. Forissueswiththe cuttingsystem,considerperforming the following hydraulic tests:

Mow Circuit Relief Valve (S1R1) Pressure Test Reel Motor Case Drain Flow Test Gear Pump (Front Section) Flow Test

System

Hydraulic

Greensmaster 3150 Hydraulic SystemPage 4 -- 27

Charge Relief Valve Pressure Test (Using Pressure Gauge)

VALVE

STEERING

Right

Left

Motor

10.3

3WD KIT

OPTIONAL

20.6

Motor

1.5” Bore

0.75” Rod

6.19” Stroke

Steering Cylinder

4.5

1160 PSI

PET

TOP

2850/1650

ENGINE RPM

BYPASS

VALVE

PORT

BOTTOM

PORT

70 to

100 PSI

PRESSURE

GAUGE

Raise

Lower

CU #3

2.0” Bore

0.75” Rod

1.88” Stroke

CU #1

0.75” Rod

1.50” Bore

3.38” Stroke

0.055

L3A L3BL2B L1B

0.030

FC2

400 PSI

L2A

4.0 GPM

7.0 GPM

TRANSPORT= 14.1 GPM

3000

PSI

3000

PSI

110 to

150 PSI

1.24

TRACTION PUMP

.33 .58

PUMP

GEAR

Right Front

CU #2

2.0” Bore

0.75” Rod

1.88” Stroke

0.055

25 PSI

0.013

OR2

FILTER

S1R1

0.060

OPTIONAL

OIL COOLER

SUCTION

STRAINER

Center

Reel (#1)

.73

Reel (#3)

.73

Reel (#2)

Left Front

550 PSI

OR1

PRV

FC1

MA L1A

(SW)

SWITCH

BACKLAP

LEAK DETECTOR

LEAK

DETECTOR

OUT

VOLUME

TANK

BREATHER

EXPANSION

Greensmaster 3150Hydraulic System Page 4 -- 28

Procedure for Charge Relief Valve Pressure

1. Make sure hydraulic oil is at normal operating temperaturebyoperating themachineforapproximatelyten (10) minutes.

2. Parkmachineonalevelsurface withthecuttingunits lowered. Make sure engine is off and the parking brake is engaged. Make sure the hydraulic reservoir is full.

Test

CAUTION

Before continuing further, read and become familiar with Precautions for Hydraulic Testing.

3. Install 1000 PSI (70 bar) pressure gauge with hydraulic hose attached to test port in the tee fitting on the bottom of the control m anifold (Fig. 19).

4. Make sure that traction pedal, steering wheel and joystick control are in the neutral position.

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

C. While monitoring the pressure gauge, push the traction pedal to allow traction system load.

D.Thechargepressureshoulddropnomorethan 20% from no --load charge pressure measured in step 6 above(e.g. if charge pressure in step 6 is 125 PSI (9 bar), charge pressure in forward or reverse under load should be more than 100 PSI (7 bar).

E. If charge pressure is good under no load, but drops below specification when under traction load, the piston (traction) pump and/or wheel motors should be suspected of wear and inefficiency.When thepumpand/ortractionmotor(s)arewornordamaged,thechargepumpis not able tokeepupwith internalleakagein tractioncircuitcomponents.Further testing of the traction circuit should be completed (see Piston (Traction) Pump Flow and Wheel Motor Efficiency Tests in this section).

10.When charge pressure testing is complete, disconnect pressure gauge from the test port and install dust cap on test port.

System

Hydraulic

6. Pressure gauge should read approximately 100 to 150PSI(7to10bar).

7. Shut off engine. Record test results.

8. If specification is not met, remove piston pump back plateassemblythatcontainsthechargereliefvalve(see Piston (Traction) Pump Service in the Service and Repairs section of this chapter). Repair or replace relief valve components as necessary.

9. Adynamicchargepressure test canbeperformedas follows:

A. Positionmachine so that a loadcan be placedon thetractionsystem.For example, chain the machine to an immovable object or chock all drive wheels to prevent the machine from moving.

B. With pressure gauge still connected to control manifold test port, sit in the operator seat, start the engineandmovethrottleso engine is running at high idlespeed.Movefunctionalcontrollevertothetransport position.

Figure 19

1. Hydraulic manifold 2. Test port

Greensmaster 3150 Hydraulic SystemPage 4 -- 29

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

TO MANIFOLD

PORT P1

GEAR PUMP

RESERVOIR

WHEEL MOTOR EFFICIENCY TEST FOR

LEFT FRONT WHEEL MOTOR SHOWN

FROM MANIFOLD PORT PT

110 to

150 PSI

.33 .58

FROM

TO STEERING VALVE

TRACTION PUMP

1.24

TRANSPORT = 14.1 GPM

3000 PSI

ASSEMBLY

HOSE

70 to

100 PSI

PUMP

TOP PORT

BOTTOM PORT

TESTER

BYPASS VALVE

ENGINE RPM

2850/1650

UPPER FITTING

FRONT

CAP

Left

Motor

10.3

CAP

20.6

OPTIONAL

3WD KIT

Right Motor

Procedure for Wheel Motor Efficiency

Test

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

internally.Aworn motormayby--passoiltoits case drain causing the motor to be less efficient. Eventually, enoughoil loss will cause thewheel motor to stall under heavyloadconditions. Continuedoperationwithaworn, inefficient motor can generate excessive heat, cause damageto seals andother components inthe hydraulic system and affect overall machine performance.

1. Make sure hydraulic oil is at normal operating temperaturebyoperatingthemachineforapproximatelyten (10) minutes. Make sure the hydraulic tank is full.

2. Parkmachineonalevelsurface with the cuttingunits lowered and off. Make sure engine is off.

CAUTION

Before continuing further, read and become familiar with Precautions for Hydraulic Testing.

3. Make sure that traction pedal is adjusted to the neutral position (see Traction Unit Operator’s Manual).

4. Attachaheavychaintotherearofthemachineframe and an immovable object to prevent the machine from moving during testing.

5. Ifmachinehas3wheeldrive,blockuptherearwheel offthe groundtoallowflowthroughtherearwheelmotor.

Greensmaster 3150Hydraulic System Page 4 -- 30

6. Chock front wheel beingtested to preventrotationof the wheel.

7. Thoroughly clean junction of hydraulic lines and fittings at the front wheel motor that is not being tested. Disconnect hydraulic lines from front wheel motor that is not being tested. Cap the disconnected hydraulic lines and plug ports in wheel motor.

8. Thoroughly c lean junction of hydraulic hose and hydraulic tube that connects to the upper hydraulic fitting onthefrontside ofthepistonpump(Fig. 20).Disconnect hose from the tube.

17.If machine has 3 wheel drive, test rear wheel motor: A. Both front wheel motors should have hydraulic

lines connected. Block up both front wheels off the ground to allow flow through the rear wheel motors.

B. Attach a heavy chain to the rear of the machine frame and an immovable object to prevent the machine from moving during testing.

C. Position rear wheel on thegroundandchockrear wheel to prevent it from turning.

9. Install tester with pressure gauge and flow meter in series with the pump and the disconnected hose(same tester connections as Piston (Traction) Pump Flow Test). Make sure the tester flow control valve is fully

open.

CAUTION

Use extreme caution when performing test. The wheel being tested will be trying to move the machine.

10.Start engine and move throttle to high idle speed

(2850 +

11.Slowly push traction pedal in forward direction until 1000 PSI (69 bar) is displayed on the tester pressure

gauge.Makesurethat wheeldoesnotrotateduringtest.

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.

50 RPM).

CAUTION

Use extreme caution when performing test. The rear wheel will be trying to move the machine.

D. Complete steps 10 to 15 for rear wheel motor testing.

18.When testingiscomplete, disconnecttester from hy-

draulic tube and hose. Reconnect hose to hydraulic tube. Reconnect hydraulic lines to rear wheel motor.

System

Hydraulic

13.Release traction pedal, rotate wheel being tested and retest. Testing of wheel motor leakage in three (3) differentwheel positions will provide most accurate test results.

14.Release traction pedal and shut engine off. Record results of flow test.

15.If specification is not met, the tested wheel motor needs to be repaired or replaced as necessary.

16.Test second front wheel motor.Reconnect hydraulic linesto untested frontwheel motor.Disconnect and cap hydraulic lines to previously tested front wheel motor. Completesteps10to15forthesecondfrontwheelmotor.

Greensmaster 3150 Hydraulic SystemPage 4 -- 31

1. Piston pump

2. Upper fitting

FRONT

Figure 20

3. Hydraulic tube

4. Hydraulic hose

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

TO MANIFOLD

PORT P1

GEAR

PUMP

RESERVOIR

FROM

TO STEERING VALVE

.33 .58

TRACTION PUMP

1.24

110 to

150 PSI

FROM MANIFOLD PORT PT

3000 PSI

TRANSPORT = 14.1 GPM

ASSEMBLY

HOSE

70 to

100 PSI

PUMP

TOP PORT

BOTTOM PORT

TESTER

BYPASS VALVE

ENGINE RPM

2850/1650

UPPER FITTING

FRONT

Left

Motor

10.3

20.6

OPTIONAL

3WD KIT

Right Motor

Procedure for Piston (Traction) Pump Flow Test

Thistest measurespiston (traction) pump output (flow). During this test, pump load is created at the flowmeter using the adjustable load valve on the tester.

1. Make sure hydraulic oil is at normal operating temperaturebyoperatingthemachineforapproximatelyten (10) minutes.

2. Parkmachineonalevelsurface with the cuttingunits loweredand off. Make sure engine is off.Make sure the hydraulic reservoir is full.

CAUTION

Before continuing further, read and become familiar with Precautions for Hydraulic Testing.

3. Make sure the traction assembly is adjusted to the neutral position. Also, make sure that transport speed adjustment allows the piston pump to reach full stroke (refer to Traction Unit Operator’s manual).

Greensmaster 3150Hydraulic System Page 4 -- 32

4. Blockup front wheels offtheground(alsorear wheel if machine is equipped with 3WD) to allow flow through the traction circuit.

5. Disconnect hydraulic hose from the hydraulic tube that connects to the upper hydraulic fitting on the front side of the piston pump (Fig. 21).

6. Install tester in series with the pump and the disconnected hose. Make sure flow control valve on the

tester is fully open.

7. Start engine and move throttle to high idle speed

(2850 +

50 RPM) position.

8. Move functional control lever to the transport position.

CAUTION

The drive wheels will be offthe ground and rotating during this test. Make sure machine is well supported so it will not move and accidentally fall to prevent injuring anyone nearthe machine.

13.Ifflowislessthan12.3 GPM (46.6 LPM), consider

the following:

A. The traction pedal and/or traction speed may need adjustment (see the Traction Unit Operator’s Manual).

B.Thepistonpumpneedstoberepairedorreplaced as necessary.

C. Make necessary repairs before performing additional tests.

14.If piston pumpflowtestresults are met and atraction

problem exists with machine, check wheel motor efficiency(seeWheelMotorEfficiencyTestinthischapter).

15.If testing iscomplete,disconnect tester from hydrau-

lic tube and hose. Reconnect hose to tube.

System

Hydraulic

9. Slowly push traction pedal intofully forward position.

10.Havesecondpersoncarefullywatchpressuregauge on tester while slowly closingthe flowcontrol valve until 1000PSI(69 bar) isobtained.Verifywithaphototacthat the engine speed has not changed.

NOTE: Ifengine speed drops,piston pumpflow will decrease.

11.Observe flowgauge.If piston pump isin good condition, flow indication should be approximately 14.5 GPM (54.9 LPM).

12.Release traction pedal, open control valve on tester and turn off engine.

1. Piston pump

2. Upper fitting

FRONT

Figure 21

3. Hydraulic tube

4. Hydraulic hose

Greensmaster 3150 Hydraulic SystemPage 4 -- 33

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

Motor

Right

VALVE

STEERING

10.3

Left

Motor

3WD KIT

OPTIONAL

20.6

1.5” Bore

0.75” Rod

6.19” Stroke

Steering Cylinder

Raise

CU #3

2.0” Bore

0.75” Rod

1.88” Stroke

CU #1

0.75” Rod

1.50” Bore

3.38” Stroke

Lower

4.5

0.055

L3A L3BL2B L1B

0.030

FC2

L2A

1160PSI

400 PSI

PET

2850/1650

ENGINE RPM

BYPASS

VALVE

TOP

PORT

TRANSPORT = 14.1 GPM

3000

PSI

3000

BOTTOM

PORT

70 to

100 PSI

PSI

110 to

150 PSI

4.0 GPM

TRACTION PUMP

1.24

.33 .58

TESTER

7.0 GPM

GEAR

PUMP

Right Front

Reel (#3)

CU #2

2.0” Bore

0.75” Rod

1.88” Stroke

0.055

25 PSI

0.013

OR2

FILTER

S1R1

0.060

OPTIONAL

OIL COOLER

SUCTION

STRAINER

Center

Reel (#1)

.73

Reel (#2)

Left Front

550 PSI

OR1

PRV

FC1

MA L1A

(SW)

SWITCH

BACKLAP

LEAK DETECTOR

LEAK

DETECTOR

OUT

VOLUME

TANK

BREATHER

EXPANSION

Greensmaster 3150Hydraulic System Page 4 -- 34

Procedure for Gear Pump (Rear Section) Flow

1. Make sure hydraulic oil is at normal operating temperaturebyoperating themachineforapproximatelyten (10) minutes.

Test

9. Flow gauge reading for a rear gear pump section in

good condition should be approximately 3.8 GPM (14.4 LPM). Record test results.

10.Open control valve on tester and shut off engine.

2. Parkmachineonalevelsurface withthecuttingunits lowered. Make sure engine is off and the parking brake is engaged. Make sure the hydraulic tank is full.

CAUTION

Before continuing further, read and become familiar with Precautions for Hydraulic Testing.

3. Thoroughly clean junction of hydraulic hose and the hydraulic fitting in the rear gear pump section (Fig. 22). This hose leads to port P in the steering valve.

4. Disconnect the hose from the fitting in the rear gear pump section.

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

fully open.

6. Makesurethattractionpedaland joystick controlare in neutral and the parking brake is engaged.

11.If flow was less than 3.3 GPM (12.5 LPM) or a pres-

sure of 800PSI(55bar)cannot be obtained, check for restrictionin the pump intakeline. If line is notrestricted, remove gear pump and repair or replace as necessary.

NOTE: Implement Relief Valve Pressure and Lower Cutting Units Relief Valve (R2) Pressure can be measured with tester positioned as described in this check (see Implement Relief Valve Pressure Test and Lower CuttingUnitsReliefValve(R2)PressureTestinthissection).

12.After testing is complete, disconnect tester from the

gearpump fitting and hose.Reconnect hose tothe gear pump fitting.

System

Hydraulic

7. Start engine and operate at high idle speed (2850 + 50 RPM).

IMPORTANT: Do not fully restrict oil flow through tester. In this t est, the flow tester is positioned before the circuit relief valve. Gear pump damage can occur if the oil flow is fully restricted.

8. Watchflowandpressuregaugecarefullywhile slowly closing the flow control valve on the tester until the pressure gauge reads 800PSI(55bar).

Figure 22

1. Gear pump 2. Rear section fitting

Greensmaster 3150 Hydraulic SystemPage 4 -- 35

Implement Relief Valve Pressure Test (Using Tester with Flowmeter and Pressure Gauge)

Motor

Right

VALVE

STEERING

10.3

Left

Motor

3WD KIT

OPTIONAL

20.6

Steering Cylinder

1.5” Bore

0.75” Rod

6.19” Stroke

.73

Right Front

Reel (#3)

CU #3

2.0” Bore

0.75” Rod

1.88” Stroke

CU #1

0.75” Rod

1.50” Bore

3.38” Stroke

CU #2

2.0” Bore

0.75” Rod

1.88” Stroke

Center

Reel (#1)

.73

Raise

Reel (#2)

Left Front

4.5

Lower

0.055

L3A L3BL2B L1B

0.030

FC2

L2A

0.055

550 PSI

MA L1A

BACKLAP

1160PSI

TRACTION PUMP

BYPASS

TOP

PORT

TRANSPORT = 14.1 GPM

25 PSI

FILTER

PET

4.0 GPM

400 PSI

OR1

PRV

(SW)

SWITCH

0.013

OR2

0.060

FC1

S1R1

TESTER

7.0 GPM

2850/1650

ENGINE RPM

VALVE

3000

PSI

OPTIONAL

3000

PSI

1.24

.33 .58

PUMP

GEAR

OIL COOLER

BOTTOM

PORT

70 to

100 PSI

110 to

150 PSI

SUCTION

STRAINER

OUT

LEAK

VOLUME

DETECTOR

LEAK DETECTOR

TANK

EXPANSION

BREATHER

Greensmaster 3150Hydraulic System Page 4 -- 36

Procedure for Implement Relief ValvePressure

1. Make sure hydraulic oil is at normal operating temperaturebyoperating themachineforapproximatelyten (10) minutes.

Test

10.Implement relief valve pressure should be 1050 to

1250 PSI (73 to 86 bar) higher than the charge relief valve pressure (e.g. if the charge relief valve pressure

is 100 PSI (7 bar), the implement relief valve pressure shouldbefrom1150to1350PSI(80to93bar)).

2. Parkmachineonalevelsurface withthecuttingunits lowered.Makesureengineisoff.Makesurethehydraulic tank is full.

CAUTION

Before continuing further, read and become familiar with Precautions for Hydraulic Testing.

3. Measure and record charge relief valve pressure (see Charge Relief Valve Pressure Testin this section).

4. Thoroughly clean junction of hydraulic hose and the hydraulic fitting in the rear gear pump section (Fig. 23). 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) FlowTest).Makesure flow controlvalveonthetester

is fully open.

IMPORTANT: Hold steering wheel at full lock only long enough to get a system pressure reading.

11.The implement relief valve is also activated by the

steering system. With tester still connected to gear pump outlet, start engine and watch the pressure gauge.Turnthesteering wheel completelyin one direction and hold. Relief valve should open just after rear wheelgets to the fulllockposition.Relief pressure measured with the steering system should be similar to resultsinstep10above.

12.If implement relief valve pressure is incorrect, in-

spect relief valve located in the steering valve (see Steering Valve Service in the Service and Repairs section of this Chapter). Clean relief valve or service steering valve as needed.

NOTE: Gear Pump (Rear Section) Flow Test and LowerCuttingUnits Relief ValvePressurecanbe measured with tester positioned as described in this check (see GearPump(RearSection)FlowTestandLowerCutting Units Relief Valve Pressure Test in this section).

13.After testing is complete, remove tester from gear

pump fitting. Reconnect hose to the gear pump fitting.

System

Hydraulic

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

50 RPM).

CAUTION

When performing test, do not allow system pressure 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 causing 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.

NOTE: The implement relief valve is in series with chargerelief valve. Charge reliefpressure will affect the implement relief pressure.

Figure 23

1. Gear pump 2. Rear section fitting

Greensmaster 3150 Hydraulic SystemPage 4 -- 37

Lower Cutting Units Relief Valve (R2) Pressure Test (Using Tester with Flowmeter and Pressure Gauge)

Motor

Right

VALVE

STEERING

10.3

Left

Motor

3WD KIT

OPTIONAL

20.6

Steering C ylinder

1.5” Bore

0.75” Rod

6.19” Stroke

.73

Right Front

Reel (#3)

CU #3

2.0” Bore

0.75” Rod

1.88” Stroke

CU #1

0.75” Rod

1.50” Bore

3.38” Stroke

CU #2

2.0” Bore

0.75” Rod

1.88” Stroke

Center

Reel (#1)

.73

Raise

Reel (#2)

Left Front

4.5

Lower

0.055

L3A L3BL2B L1B

0.030

FC2

L2A

0.055

550 PSI

MA L1A

BACKLAP

SWITCH

1160PSI

TRACTION PUMP

BYPASS

TOP

PORT

TRANSPORT = 14.1 GPM

25 PSI

FILTER

PET

4.0 GPM

400 PSI

OR1

PRV

(SW)

0.013

OR2

0.060

FC1

S1R1

TESTER

7.0 GPM

2850/1650

ENGINE RPM

VALVE

3000

PSI

OPTIONAL

3000

PSI

1.24

.33 .58

PUMP

GEAR

OIL COOLER

BOTTOM

PORT

70 to

100 PSI

110 to

150 PSI

SUCTION

STRAINER

OUT

LEAK

VOLUME

DETECTOR

LEAK DETECTOR

TANK

EXPANSION

BREATHER

Greensmaster 3150Hydraulic System Page 4 -- 38

Procedure for Lower Cutting Units Relief Valve Pressure

Test

(R2)

1. Make sure hydraulic oil is at normal operating temperaturebyoperating themachineforapproximatelyten (10) minutes.

2. Parkmachineonalevelsurface withthecuttingunits lowered.Makesureengineisoff.Makesurethehydraulic tank is full.

10.If lowercuttingunitsreliefvalvepressureisincorrect,

adjust control manifold relief valve (R2) (see Adjust ManifoldReliefValvesin theAdjustmentssectionof this Chapter). Retest relief valve pressure if adjustment is performed.

NOTE: Gear Pump (Rear Section) Flow Test and Implement Relief Valve Pressure can be measured with tester positioned as described in this check (see Gear Pump (Rear Section) Flow Test and Implement Relief ValvePressureTestinthissection).

CAUTION

Before continuing further, read and become familiar with Precautions for Hydraulic Testing.

3. Measure and record charge relief valve pressure (see Charge Relief Valve Pressure Testin this section).

4. Thoroughly clean junction of hydraulic hose and the hydraulic fitting in the rear gear pump section (Fig. 24). This hose leads to port P in the steering valve.

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

is fully open.

7. Start engine and move throttle to full speed (2850 + 50 RPM). Make sure that cutting units are fully lowered

and then engage the cutting units.

11.Aftertestingiscomplete,disconnecttesterfromgear

pump and hose. Reconnect hose to hydraulic fitting on pump.

Figure 24

1. Gear pump 2. Rear section fitting

System

Hydraulic

NOTE: The LOWER function is electrically timed and automatically turns off after approximately six (6) seconds.

8. Watch pressure gauge carefully while moving the joystick control lever to the LOWER position and note pressurethat relief valve opens. Shutoffengine and record test results.

NOTE: While performing this hydraulic test, if relief pressurecannotbedetermined withintheLOWERfunction six (6) second timeframe, repeat this test procedure.

NOTE: The lower cutting units relief valve is in series with the charge relief valve. Charge relief pressure will affect the lower cutting units relief pressure.

9. The lower cutting units relief valve pressure should be approximately 400 PSI (28 b ar) higherthan 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 Hydraulic SystemPage 4 -- 39

RELIEF

VALVE (R2)

S1R1

FRONT

Figure 25

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

Motor

Right

VALVE

STEERING

10.3

Left

Motor

3WD KIT

OPTIONAL

20.6

Steering Cylinder

1.5” Bore

0.75” Rod

6.19” Stroke

.73

Right Front

Reel (#3)

CU #3

2.0” Bore

0.75” Rod

1.88” Stroke

CU #1

0.75” Rod

1.50” Bore

3.38” Stroke

CU #2

2.0” Bore

0.75” Rod

1.88” Stroke

Center

Reel (#1)

.73

Raise

Reel (#2)

Left Front

4.5

Lower

0.055

L3A L3BL2B L1B

0.030

FC2

L2A

0.055

550 PSI

MA L1A

BACKLAP

SWITCH

1160PSI

PET

4.0 GPM

400 PSI

OR1

FC1

0.013

OR2

0.060

PRV

(SW)

TESTER

S1R1

7.0 GPM

BYPASS

TOP

PORT

TRANSPORT = 14.1 GPM

TRACTION PUMP

25 PSI

FILTER

2850/1650

ENGINE RPM

VALVE

3000

PSI

OPTIONAL

BOTTOM

PORT

70 to

100 PSI

3000

PSI

110 to

150 PSI

1.24

.33 .58

PUMP

GEAR

OIL COOLER

SUCTION

STRAINER

OUT

LEAK

VOLUME

DETECTOR

LEAK DETECTOR

TANK

EXPANSION

BREATHER

Greensmaster 3150Hydraulic System Page 4 -- 40

Procedure for Gear Pump (Front Section) Flow

1. Make sure hydraulic oil is at normal operating temperaturebyoperating themachineforapproximatelyten (10) minutes.

2. Parkmachineonalevelsurface withthecuttingunits lowered. Make sure engine is off and the parking brake is engaged. Make sure the hydraulic tank is full.

Test

7. Watchpressure gauge carefullywhile slowlyclosing

the flow control valve on the tester until 2000 PSI (138 bar) is obtained.

8. Flow gauge readingfor a gear pump sectionin good

condition should be approximately 6.7 GPM (25.3 LPM). Record test results.

9. Oncegearpumpflowisrecorded,opencontrolvalve

on tester and shut off engine.

CAUTION

Before continuing further, read and become familiar with Precautions for Hydraulic Testing.

3. Disconnect the hose from the fitting in the front gear pumpsection(Fig.26).This hose leadstoportP1onthe hydraulic manifold.

4. Install tester with pressure gauge and flow meter in series with front gear pump section fitting and the disconnectedhose. Make sure the flow control valve on

the tester is fully open.

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

CAUTION

Donotengagethe cutting units when performing this test.

10.If flow was less than 5.7 GPM (21.6 LPM) or a pres-

sure of 2000 PSI (138 bar) cannot be obtained, check for restriction in the gear pump intake line. If line is not restricted, remove gear pump and repair or replace as necessary.

11.When testing is complete, disconnect tester from

gear pump fitting and hydraulic hose. Connect hose to pump fitting.

12.Adjust reel speed knob on mow control manifold to

original setting.

System

Hydraulic

6. Start engine and operate at high idle speed (2850 + 50 RPM).

IMPORTANT: Do not fully restrict oil flow through tester. In this t est, the flow tester is positioned before the circuit relief valve. Gear pump damage can occur if the oil flow is fully restricted.

Greensmaster 3150 Hydraulic SystemPage 4 -- 41

Figure 26

1. Gear pump 2. Front section fitting

Mow Circuit Relief Valve (S1R1) Pressure Test (Using Tester with Flowmeter and Pressure Gauge)

Motor

Right

STEERING

VALVE

10.3

Left

Motor

3WD KIT

OPTIONAL

20.6

Right Front

Reel (#3)

1.5” Bore

0.75” Rod

6.19” Stroke

Steering Cylinder

Center

Reel (#1)

.73

CU #3

2.0” Bore

0.75” Rod

1.88” Stroke

CU #1

0.75” Rod

1.50” Bore

3.38” Stroke

CU #2

2.0” Bore

0.75” Rod

1.88” Stroke

Reel (#2)

Left Front

Raise

4.5

Lower

0.055

L3A L3BL2B L1B

0.030

FC2

L2A

0.055

550 PSI

MA L1A

BACKLAP

1160PSI

TRACTION PUMP

TOP

BYPASS

PORT

TRANSPORT = 14.1 GPM

25 PSI

FILTER

PET

4.0 GPM

400 PSI

OR1

PRV

(SW)

SWITCH

0.013

OR2

0.060

FC1

S1R1

7.0 GPM

2850/1650

ENGINE RPM

VALVE

3000

PSI

OPTIONAL

3000

PSI

1.24

.33 .58

PUMP

GEAR

OIL COOLER

BOTTOM

PORT

70 to

100 PSI

110 to

150 PSI

SUCTION

STRAINER

TESTER

LEAK DETECTOR

LEAK

DETECTOR

OUT

VOLUME

TANK

EXPANSION

BREATHER

Greensmaster 3150Hydraulic System Page 4 -- 42

Procedure for Mow Circuit Relief Valve (S1R1)

Test

sure

1. Make sure hydraulic oil is at normal operating temperaturebyoperating themachineforapproximatelyten (10) minutes.

Pres-

B. Ifrelief valve pressure is not correct, remove solenoid relief valve (S1R1) on hydraulic control manifold (Fig. 28). Clean or replace valve (see Hydraulic Manifold Service in the Service and Repairs section ofthischapter).Aftervalveservice,retestreliefvalve (S1R1) pressure.

2. Parkmachineonalevelsurface withthecuttingunits lowered.Makesureengineisoff.Makesurethehydraulic tank is full.

CAUTION

Before continuing further, read and become familiar with Precautions for Hydraulic Testing.

3. Disconnecthydraulichosefromthefrontfittingofthe left front cutting reel motor (Fig. 27).

4. Install tester with pressure gauge and flow meter in series with the disconnected hose and front reel motor fitting. Make sure the flow controlvalve on the tester

is fully open.

5. Topreventreel damage, temporarilyadjustbedknife to allow clearance between bedknife and reel (no contact).

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

11.When testing is complete, disconnect tester from

reelmotorfittingandhydraulichose.Reconnecthoseto the front motor fitting.

12.Correctly adjust cutting unit bedknife.

LH REEL MOTOR

FRONT

1. LH reel motor

2. Front fitting

FRONT

Figure 27

3. Hydraulic hose

System

Hydraulic

CAUTION

Keep away from reels during test to prevent personal injury from the rotating reel blades.

7. Start engine and move throttle to high idle speed

(2850 +

8. Watchpressure gauge carefullywhile slowly closing the flow control valve on the tester to fully closed.

9. System pressure should be from 2700to3300PSI (186 to 228 bar) as manifold relief valve (S1R1) opens. Record test results.

10.After recording mow circuit relief pressure, disengagecuttingunits.Open controlvalveontesterandshut off engine.

50 RPM). Engage the cutting units.

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

S1R1

Figure 28

Greensmaster 3150 Hydraulic SystemPage 4 -- 43

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

FRONT

CENTER RETURN

LH CASE

DRAIN

LH RETURN

RH CASE

DRAIN

RH RETURN

CENTER

MEASURING

CONTAINER

CASE DRAIN FLOW TEST FOR

RIGHT FRONT REEL MOTOR SHOWN

CASE

DRAIN

PLUG

Right Front Reel (#3)

.73

Left Front Reel (#2)

FROM MANIFOLD PORT MA

TESTER

.73

Center Reel (#1)

.73

TO HYDRAULIC

RESERVOIR

TO MANIFOLD PORT MB

Greensmaster 3150Hydraulic System Page 4 -- 44

Procedure for Reel Motor Case Drain Flow

1. Make sure hydraulic oil is at normal operating temperaturebyoperating themachineforapproximatelyten (10) minutes. Make sure the hydraulic reservoir is full.

2. Parkmachineonalevelsurface withthecuttingunits lowered. Make sure engine is off.

Test:

10.After achieving 1000PSI(69bar), place discon-

nected motor case drain hose into a container graduated in ounces or milliliters (Tool TOR4077: see SpecialTools) and collect hydraulic fluidfor 15 seconds (Fig.29).After15seconds,removehoseendfromcon tainer.

11.Disengage cutting units. Open control valve on test-

er and stop the engine.

CAUTION

Before continuing further, read and become familiar with Precautions for Hydraulic Testing.

3. Forthesuspectedbad cutting reel motor,disconnect returnhosefromthe motor.Thereturnhoseconnectsto the fitting at the rear of the motor.

4. Install testerin series withthe reel motorand the disconnected return hose. Make sure the flow control

valve on the tester is fully open.

5. Make sure backlap knobonthe hydraulic manifold is in the mow position and reel speed is set to maximum.

6. Disconnect hose from case drain of the motor to be tested at the bulkhead fitting.

A. Plug the bulkhead port 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.

12.Measure theamount of oil collected inthe container.

Record test results.

13.If casedrainflowwasgreaterthan16.0ounces (473

milliliters) (0.5 GPM/1.9 LPM)in15 seconds,repairor replace the reel motor as necessary.

14.When testingof the reel motor is completed, discon-

nect tester from reel motor and return hose. Reconnect return hose to the motor.

15.Remove plug from bulkhead fitting. Reconnect case

drain hose to the bulkhead fitting.

16.Test other cutting reel motors as needed.

System

Hydraulic

7. One person should sit on the seat and operate the machinewhileasecondpersonreadsthetesterand measures case drain leakage.

8. Make sure functional control lever is in NEUTRAL. Startengineandmovethethrottletohighidlespeed

(2850 +

50 RPM).

CAUTION

Keep away from reels during test to prevent personal injury from the rotating reel blades.

9. Move the functional control lever to the MOW position and engage the cutting reels with the joystick control. While watching pressure gauge, slowly close flow control valve on the tester until a pressure of 1000 PSI (69 bar) is obtained.

Figure 29

Figure 30

Greensmaster 3150 Hydraulic SystemPage 4 -- 45

Steering Control Valve Test

TURNED FOR

RIGHT TURN

Steering Cylinder

(CYLINDER ROD

FULLY EXTENDED)

PLUG

4.5

TO CONTROL

MANIFOLD

PORT ST

TO CONTROL

MANIFOLD

PORT P2

FROM GEAR

PUMP

Procedure for Steering Control Valve Test:

1. Make sure the hydraulic reservoir is full.

1 160PSI

PET

STEERING VALVE

B. Steering wheel movements should be followed immediately by a corresponding rear wheel movement without the steering wheel continuing to turn.

2. Make sure hydraulic oil is at normal operating temperaturebyoperatingthemachineforapproximatelyten (10) minutes.

3. Drive machine slowly in a figure eight on a flat level surface.

A. There should be no shaking or vibration in the steering wheel or rear wheel.

4. Stop the machine with the engine running. Turn steering wheel with small quick movements in both directions.Letgoofthesteeringwheelafter each movement.

A. The steering wheel must go back immediately to the neutral position.

B. The steering wheel should not continue to turn.

Greensmaster 3150Hydraulic System Page 4 -- 46

NOTE: Thesteering 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 surethat 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 theseitemsarecheckedbeforeproceedingwithanyhydraulic testing procedure.

6. If either of these performance tests indicate a steering 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.

B. Turn the steering wheel all the way to the right (clockwise) so the steering cylinder rod is fully extended.

C. Turn engine off.

CAUTION

Before continuing further, read and become familiar with Precautions for Hydraulic Testing.

D. Read Precautions for Hydraulic Testing.

E. Removehydraulichosefromthe90 rodend of the steeringcylinder(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 cylinder fully extended. Observe the open fitting on the steeringcylinderasthe steering wheel is turned.Ifoil 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. Reconnect hose to the steering cylinder fitting.

fittingonthe

FRONT

1. Steering cylinder

2. Hydraulic hose

Figure 31

3. Rod end

4. Castor fork

System

Hydraulic

7. If steering problem exists and steering cylinder tested acceptably, steering control valve requires service (see Steering Control Valve and Steering Control Valve Service in the Service and Repairs section of this chapter).

Greensmaster 3150 Hydraulic SystemPage 4 -- 47

This page is intentionally blank.

Greensmaster 3150Hydraulic System Page 4 -- 48

Adjustments

Adjust Manifold Relief Valve (R2)

The hydraulic manifold includes an adjustable relief valveinthe lift circuit (Fig.32). If adjustmenttothisvalve 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 pressurizing the system.

FRONT

1. Locate relief valve on control manifold.

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 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.

Figure 32

1. Hydraulic manifold 2. Relief valve (R2)

CAP

ADJUSTMENT HEX SOCKET

Figure 33

System

Hydraulic

Greensmaster 3150 Hydraulic SystemPage 4 -- 49

Service and Repairs

General Precautions for Removing and Installing Hydraulic System Components

Before Repair or Replacement of Components

1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting units or attachments and stop engine. Remove key from the ignition switch

2. Clean machine before disconnecting, removing or disassembling any hydraulic components. Make sure hydraulic components, hoses connections and fittings are cleaned thoroughly. Always keep in mind the need for cleanliness when working on hydraulic equipment.

CAUTION

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the ignition switch in RUN and the engine OFF.Make sure all electrically operated control valves are actuated. Return ignition switch to OFF when pressure has been relieved. Remove key from the ignition switch.

After Repair or Replacement of Components

1. Checkoillevelinthehydraulicreservoirand add correct oil if necessary. Drain and refill hydraulic system reservoir and change oil filter if component failure was severe or system is contaminated (see Flush Hydraulic System).

2. Lubricate O-- rings and seals with clean hydraulic oil before installing hydraulic components.

3. Make sure caps or plugs are removed from the hydraulic tubes, hydraulic fittings and components before reconnecting.

4. Use proper tightening methods when installing hydraulichoses and fittings (see Hydraulic Fitting Installation).

5. After repairs, check control linkages or cables for proper adjustment, binding or broken parts.

6. After disconnecting or replacing any hydraulic components, operate machine functions slowly until air is out of system (see Charge Hydraulic in this section).

3. Putcapsorplugson any hydrauliclines,hydraulicfittings and components left open or exposed to prevent contamination.

4. Put labels on disconnected h ydraulic lines and hosesforproperinstallation afterrepairsarecompleted.

5. Note the position of hydraulic fittings (especially elbow fittings) on hydraulic components before removal. Markpartsifnecessary to makesuretheywillbealigned properly when reinstalling hydraulic hoses and tubes.

7. Checkforhydraulic oilleaks.Shutoffengineandcorrectleaksifnecessary.Checkoillevelinhydraulicreservoir and add correct oil if necessary.

Greensmaster 3150Hydraulic System Page 4 -- 50

Flush Hydraulic System

IMPORTANT: Flush the hydraulic system any time thereis a severecomponent failure or the system is contaminated (oil appears milky or black or contains metal particles).

IMPORTANT: Flush hydraulic system when changIng from petroleum base hydraulic fluid. Operate machine under normal operating conditions for at least four (4) hours before draining.

1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove key from the ignition switch.

CAUTION

Before continuing further, read and become familiar with General Precautions for Removing and Installing Hydraulic System Components.

2. Clean area around gear pump and pump inlet hose (Fig. 34). Clamp pump inlet hose. Remove hose from gearpump,releaseclampanddrainreservoirintoasuitable container. Drain hydraulic system while making sure lift cylinders, hydraulic hoses, hydraulic tubes and all other components are drained from low points while the system is warm.

3. Clean hydraulic oil filter mounting area. Remove filter and drain into a suitable container. Discard filter.

4. Inspect and clean hydraulic reservoir (see Hydraulic Reservoir in the Service and Repairs section of this chapter).

7. Disconnect both spark plug wires from spark plugs

to prevent the engine from starting.

8. Turn ignition key switch; engage starter for ten (10)

seconds to primethe hydraulic pumps. Allow the starter to cool for one (1) minute and then repeat this step again.

9. Reconnect both spark plug wires to spark plugs.

10.Startengineandletitidleatlowspeedforaminimum

oftwo(2)minutes. Increaseenginespeedtohigh idlefor minimum of one (1) minute under no load.

11.Raise and lower cutting units several times. Rotate

steering wheel in both directions several times.

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

Check oil level in hydraulic reservoir and add correct oil if necessary.

13.Operate the machine for two (2) hours under normal

operating conditions.

14.Check condition of hydraulic oil. If the new hydraulic

oil shows any signs of contamination, or if you are changingto biodegradable fluid, repeat steps 1through 13 again.

15.Assume normal operation and follow recommended

maintenance intervals.

PUMP INLET HOSE

System

Hydraulic

5. Make sure filter mounting surface is clean.Apply hydraulic oil togasket 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 biodegradable) 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.

Greensmaster 3150 Hydraulic SystemPage 4 -- 51

Figure 34

Filtering Closed--Loop Traction Circuit

Filteringof a closed--loop hydraulicsystemafter a major component failure (e.g. piston (traction) pump or wheel motor) is a requirement to prevent debris from transmitting throughout the system. If a closed--loop hydraulic systemfilteringtoolisnotused to ensure system cleanliness, repeat failures, as well as subsequent damage to other hydraulic components in the affected system, will occur. To effectively remove contamination from closed--loop traction circuit, useoftheTorohighflowhydraulic filter and hydraulic hose kits are recommended (see Special Tools in this chapter).

1. Parkmachineonalevelsurfacewithenginestopped and key removed from ignition switch.

2. Raise machine so all driven wheels are off the ground. Support raised machine with appropriate jackstands.

NOTE: Ifwheelmotorwasreplaced, install high flowfiltertotheinletof new motor instead of to piston (traction) pump fitting. This will prevent system contamination from entering and damaging the new motor.

3. Thoroughly clean junction of hydraulic hose and lowerfittingon sideofpistonpump (Fig.35).Disconnect hose from lower pump fitting.

4. Connect Toro high flow hydraulic filter in series betweenlower piston pump fittingand disconnected hose. Usehydraulichosekit (seeSpecialToolsin thischapter) to connect filter to machine. Make sure that fitting and hose connections are properly tightened.

IMPORTANT: Use only hydraulic fluids specified in Traction Unit Operator’s Manual. Other fluids could cause system damage.

IMPORTANT: While engaging the traction circuit, monitor the indicator on the high flow hydraulic filter. If the indicator should show red, either reduce pressure on the traction pedal or reduce engine speed to decrease hydraulic flow through the filter.

7. With engine running at low idle speed, slowly move thetractionpedaltotheforward direction to allow flow throughthetractioncircuitandhigh flow filter.Keeptraction circuit engaged for five (5) minutes while gradually increasing both forward pressure on traction pedal and engine speed. Monitor filter indicator to make sure that green color is showing during operation.

IMPORTANT: If using a filterthat is not the bi--directional Toro high flow filter, do not press the traction pedal in the reverse direction. If flow is reversed when using a filter that is not bi--directional, debris from the filter will re--enter the traction circuit.

8. With engine running at high idle speed, alternately movetractionpedal fromforwardtoreverse.Whilemonitoring filter indicator,continue this process for an additional five (5) minutes.

9. Shut engine off andremove key fromignition switch.

10.Remove highflow hydraulic filterand hydraulichose kit from machine. Connect hydraulic hose to lower pistonpumpfitting.Makesuretoproperlytightenhose(see Hydraulic Hose and Tube Installation in the General Information section of this chapter).

11.Lowermachinetoground.

12.Check oil levelin hydraulic reservoir andadd correct oil if necessary.

5. After installing high flow filter to machine, check and fillhydraulicreservoir with new hydraulic oilas required.

6. Start engineand run atidle speed.Check for any hydraulic leakage from filter and hose connections. Correct any leaks before proceeding.

CAUTION

Alldrivenwheelswillbeoff the ground and rotating during this operation. Make sure machine is wellsupportedsoitwillnotmove andaccidentally fall.

Figure 35

1. Piston pump 2. Lower pump fitting

Greensmaster 3150Hydraulic System Page 4 -- 52

Hydraulic System Start--up

NOTE: Wheninitially starting thehydraulic system with

neworrebuiltcomponents such as motors, pumpsorlift cylinders, it is important that this start--up procedure be used. This procedure reduces the chance of damaging the system or its components from not purging the system of air.

1. After the hydraulic system components have been properly installed and if thetractionpumpwasrebuiltor replaced, make sure traction pump housing is at least half full of clean hydraulic oil.

2. Makesureallhydraulic connectionsandlinesaresecured tightly.

CAUTION

Be careful when operating the cutting unit reels. Contact with the reel or other moving parts can result in personal injury.

10.After the hydraulic system starts to show signs of fill,

accomplish the following:

A. Ifareelmotorwasreplacedorrebuilt,runthecutting units at the minimum speed setting (under no load) for ten (10) minutes in both directions.

3. Make sure hydraulic reservoir is full. Add correct oil ifnecessary.Drain,flushand refill hydraulicsystem reservoir and change oil filter if component failure was severe or system is contaminated.

4. Afterrepairs,checkcontrollinkageforproperadjustment, binding or broken parts.

5. Make sure functional control lever is in neutral.

6. Disconnect both spark plug wires from spark plugs to prevent the engine from starting.

7. Turn ignition key switch and engage starter for ten (10)secondstoprime pump.Returnignitionswitchtooff 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 cuttingunit switch is off.Start engine and runat 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 anddeterminethe cause.

B. If the gear pump was replaced or rebuilt, run the cuttingunitsat the minimum speedsetting(underno load) for ten (10) minutes.

C. If the pistonpump or a wheelmotor was replaced or rebuilt, run the traction unit so the wheels turn slowly for ten (10) minutes.

11.Operate the traction unit and cutting units by gradu-

allyincreasing their workload to fullover a ten (10) min ute period.

12.Stop the machine. Check reservoir and fill if neces-

sary.Check hydraulic componentsfor leaks and tighten any loose connections.

System

Hydraulic

Greensmaster 3150 Hydraulic SystemPage 4 -- 53

Gear Pump

RIGHT

FRONT

1. Pump inlet hose

2. Gear pump

3. Hydraulic fitting

4. Hydraulic fitting

5. O--ring

6. O--ring

Figure 36

7. Hose clamp (2 used)

8. O--ring

9. O--ring

10. Hydraulic hose

11. O- -ring

12. Piston pump

13. Socket head screw (2 used)

14. Flat washer (2 used)

15. Hydraulic hose

16. Hose connector

17. O--ring

Greensmaster 3150Hydraulic System Page 4 -- 54

Removal (Fig. 36)

4. Secure gear pump to the piston pump with two (2)

socket head screws and flat washers.

CAUTION

Before continuing further, read and become familiar with General Precautions for Removing and Installing Hydraulic System Components.

1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake,lower cutting unitsand stop engine.Remove key from the ignition switch.

2. Label all hose connections for assembly purposes.

3. Clamp pump inlet hose to prevent draining the hydraulic reservoir.

4. Loosen hose clamp and remove pump inlet hose from the gear pump. Allow clamped hose to drain into a suitable container.

5. Disconnect hydraulic hoses from fittings on bottom of the gear pump. Allow hoses to drain into a suitable container. Plug hoses to prevent contamination.

IMPORTANT: Note position of hydraulic fittings for assembly purposes.

6. Mark hydraulic fitting orientation to allow correct assembly. Remove hydraulic fittings and O--rings from gear pump.

7. Support gear pump to prevent it from shifting. Separate gear pump from the piston pump by removing both socket head screws and flat washers. Remove O--ring from between the gear pump and piston pump.

5. Inspect threads and sealing surfaces of hydraulicfit-

tingsandhydraulichose connectors. Replace a ny damaged or worn fittings or hoses.

6. Lubricate and place new O--rings onto gear pump

hydraulic fittings. Install fittings into pump openings makingsure that fittingorientationis as notedduring removal.Tightenfittings (see Hydraulic Fitting Installation in the General Information section of this chapter).

7. Remove plugs that were placed during disassembly

from hydraulic hoses.

8. Usinglabelsplacedduringgearpump removal,lubri-

cate new O--rings and connect hydraulic hoses to lower gear pump fittings. Tighten hose connections (see Hydraulic Hose and Tube Installation in the General Information section of this chapter).

9. Installpumpinlethosetothe hose connector ongear

pump.Securehosewithhoseclamp.

10.Remove clamp from pump inlet hose to allow hy-

draulic oil flow to the gear pump.

11.Check oil levelin hydraulic reservoirand add correct

oil if necessary.

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

Hydraulic System Start--up in this section).

Remove plugs

before installing gear pump to piston pump

System

Hydraulic

NOTE: Acasedrainexists in thepiston (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. Makesure mounting andO--ringsealing surfaces on the gear pump and piston pump are clean.

2. Lubricateandplacenew O--ring(item11)onthegear pump.

3. Position gear pump to the piston pump so that the pump inlet is facing up.

Greensmaster 3150 Hydraulic SystemPage 4 -- 55

Figure 37

1. Piston pump case drain 2. Gear pump suction port

Gear Pump Service

Figure 38

1. O--ring

2. Front cover

3. Back--up seal

4. Pressure seal

5. Thrust plate

6. Drive shaft

7. Idler gear

8. Thrust plate

9. Dowel pin

10. O--ring

11. Housing

12. Coupler

13. Back--up seal

14. Pressure seal

15. Thrust plate

Gear Pump Disassembly (Fig. 38) NOTE: Disassemble gear pump for cleaning, inspec-

tion and seal replacement only.Individual gears, housings 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.

33 ft--lb

(45 N--m)

16. Drive gear

17. Idler gear

18. Thrust plate

19. O--ring

20. End cover

21. Socket head screw (4 used)

22. Washer (4 used)

MARKER LINES

1. Plug pump ports and thoroughly clean exterior of pump with cleaning solvent. Make sure work area is clean.

2. Useamarkertomakea“V”acrossthefrontcover, housing and endcover for assemblypurposes (Fig.39).

IMPORTANT: Use caution when clamping gear pumpinaviseto avoid distorting any pump components. Also, use a vise with soft jaws.

3. Secure the front cover of the pump in a vise with soft jaws with the drive shaft pointing down.

Figure 39

4. Loosen the four (4) socket head screws that secure pump assembly.

5. Remove pump from vise and remove fasteners.

Greensmaster 3150Hydraulic System Page 4 -- 56

6. Support the pump assembly and gently tap the pump housing with a soft face hammer to loosen the pump sections. Be careful to not drop parts or disengage gear mesh.

Gear Pump Assembly (Fig. 38)

1. Apply clean hydraulic oil to all parts before assem-

bling.

IMPORTANT: Mark therelative positions of thegear teeth and the thrust plates so they can be assembledinthesameposition.Donottouchthegear surfaces as residue on hands may be corrosive to gear finish.

7. Remove the thrust platesand seals from eachpump section. Before removing each gear set, apply marking dye to mating teeth to retain ”timing”. Pump efficiency maybe affected if theteeth are notinstalled in the same positionduringassembly.Keepthepartsfor each pump section together; do not mix parts between sections.

8. Clean all parts. Check all components for burrs, scoring, nicks and other damage.

9. Replacetheentirepumpassemblyifanypumpcomponents are excessively worn or scored.

NOTE: Pressure and back--up seals fit in grooves machinedintothrustplates.BodyO--ringsfitingroovesmachined in housing.

2. Assemble pump sectionsstarting atfront cover end.

Apply grease or petroleum jelly to new section seals to hold them in position during gear pump assembly.

3. After pump has been assembled, tighten socket

headscrewsbyhand.Rotatethedriveshaft to check for binding.Protect the shaft if usinga pliers to rotate shaft.

4. Tightenthe socket headscrews evenly in a crossing

patterntoatorqueof33 ft--lb (45 N--m).

System

Hydraulic

Greensmaster 3150 Hydraulic SystemPage 4 -- 57

Piston (Traction) Pump Neutral Assembly

25 to 38 ft--lb

(34to51N--m)

Antiseize

Lubricant

RIGHT

FRONT

1. Lock nut

2. Pivot tube

3. Cap screw

4. Damper lever

5. Pivot spacer

6. Pump lever

7. Flat washer

8. Cap screw

9. Cable support

10. Flat washer (2 used)

11. Neutral arm

12. Thrust washer

13. Traction stud

14. Bearing spacer

15. Ball bearing

16. Extension spring

17. Cap screw (2 used)

18. Flange nut (3 used)

19. Cap screw

20. Cap screw

21. Lock washer (2 used)

22. Cable ball joint

23. Flange nut

24. Cap screw

25. Flat washer (2 used)

26. Dampener hose

Figure 40

27. Traction control cable

28. Flat washer (2 used)

29. Pivot plate

30. Mount (3 used)

31. Cap screw (3 used)

32. Lock nut (3 used)

33. Washer (3 used)

34. Nylon washer (2 used)

35. Spring bracket

36. Mount plate

37. Piston pump assembly

38. Cap screw (2 used)

39. Key

Greensmaster 3150Hydraulic System Page 4 -- 58

Disassembly (Fig. 40)

1. Park machine on a level surface, engage parking brake,lower cutting unitsand stop engine.Remove key from the ignition switch.

CAUTION

The extension spring (item 16) is under tension and may cause personal injury during removal. Use caution when removing the spring from the pump neutral assembly.

2. Removecomponentsfromtractionneutralassembly as needed using Figure 40 as a guide.

Assembly (Fig. 40)

1. Install removed components to traction neutral assemblyusing Figure 40 asaguide along with thefollowing:

CAUTION

The extension spring (item 16) is under tension and may cause personal injury during installation. 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 installing plate to shaft.

1. Piston pump

2. Neutral arm

3. Cap screw

Figure 41

4. Pump lever

5. Cable support

6. Traction cable

System

Hydraulic

B. Ifdamperlever (item 4)was removed, applyantiseize 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 thatthe transmission isadjusted for theneutralposition so thatthe machine doesnot move orcreep when the traction pedal is in neutral.

Greensmaster 3150 Hydraulic SystemPage 4 -- 59

Piston (Traction) Pump

81 to 99 ft--lb

(110 to 134 N--m)

81 to 99 ft--lb

(110 to 134 N--m)

RIGHT

FRONT

Loctite #242

27 to 33 ft--lb

(37to44N--m)

Loctite #242

90 to 110 in--lb

(10.2to12.4N--m)

Antiseize

Lubricant

Figure 42

1. Pump hub

2. Piston pump

3. Flat washer (4 used)

4. Pump inlet hose

5. Gear pump

6. Lock nut (4 used)

7. Coupling spacer (4 used)

8. Rubber coupling

9. Flat washer (4 used)

10. Cap screw (4 used)

11. Square head set screw (2 used)

12. Square key

13. Engine hub

14. Flat washer

15. Hose clamp (2 used)

16. Lock washer (2 used)

17. Cap screw (2 used)

18. Hydraulic fitting

19. 90

hydraulic fitting

20. Hydraulic tube

21. Support clamp

22. Cap screw

23. 90

hydraulic fitting (2 used)

24. 90

hydraulic fitting

25. O--ring

26. Socket head screw (2 used)

NOTE: The complete piston (traction) and gear pump

assembly can be removed from the machine with the neutral assembly attached to the pistonpump. See Piston(Traction)Pump Neutral Assembly inthis section for information regarding servicing the neutral assembly.

27. Hose connector

28. Spacer

29. Cap screw

30. O--ring

31. Hydraulic hose

32. Hydraulic hose

33. O--ring

34. O--ring

35. O--ring

36. O--ring

37. Hydraulic hose

38. O--ring

39. Key

Greensmaster 3150Hydraulic System Page 4 -- 60

Piston Pump Removal (Fig. 42)

1. Park machine on a level surface, engage parking brake,lower cutting unitsand stop engine.Remove key from the ignition switch.

CAUTION

Before continuing further, read and become familiar with General Precautions for Removing and Installing Hydraulic System Components.

2. Disconnect the traction control cable ball joint and jamnuts from the neutralarm(Fig. 43). Position traction cable away from the pump assembly.

CAUTION

The extension spring attached to theneutralarm is under tension and may cause personal injury during removal. Use caution when removing the spring from the pump neutral arm.

1. Piston pump

2. Traction cable

Figure 43

3. Jam nut (2 used)

4. Cable ball joint

System

Hydraulic

3. Disconnect one end oftheextensionspring attached to the neutral arm (Fig. 44).

4. Remove two (2) cap screws (item 10), flat washers (item 9), coupling spacers (item 7) and lock nuts (item

6) that secure pump hub to rubber coupling (item 8).

5. Thoroughlycleanhydraulichose endsandfittingson gear and piston (traction) pumps to prevent hydraulic system contamination.

6. Label all hydraulic hose connections on gear and piston pumps for assembly purposes.

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.Allowhosesto drain into asuitablecontainer. Plug hoses and fittings to prevent contamination.

1. Extension spring

2. Dampener hose

3. Spring bracket

Figure 44

4. Mount plate

5. Neutral arm

Remove plugs before installing gear pump to piston pump

CAUTION

Support the pump assembly when removing its supporting fasteners to prevent it from falling and causing personal injury.

10.Support pump assembly to prevent it from falling. Greensmaster 3150 Hydraulic SystemPage 4 -- 61

Figure 45

1. Piston pump case drain port

2. Gear pump suction port

11.Remove two (2) cap screws (item 17), lock washers (item16)and flat washers (item3)thatsecure pump assembly to pump adapter mounted to engine. Separate pump assembly from the pump adapter and remove from machine.

6. Lubricate and place new O--rings onto all removed hydraulic fittings. Install fittings into pump openings makingsure that fittingorientation is asnoted during removal. Tighten fittings (seeHydraulic FittingInstallation in the General Information section of this chapter).

12.If necessary, remove pump hub (item 1) from pump input shaft. Locate and retrieve key (item 39).

13.Separategearpumpfromthepistonpump(seeGear Pump in this section).

IMPORTANT: If fittings are going to be removed from piston pump, note position of fittings for assembly purposes.

14.If fitting removal from piston pump is necessary, markhydraulicfittingorientationtoallowcorrectassembly. Remove hydraulic fittings and O--rings from piston pump. Discard removed O--rings.

15.If necessary, remove the neutral assembly attached to the piston pump (see Piston (Traction) Pump Neutral Assembly in this section).

Piston Pump Installation (Fig. 42)

1. If any neutral assembly components were removed from piston pump, install them to pump (see Piston (Traction) Pump Neutral Assembly in this section).

2. Make sure theflange surfaces ofthe gear pumpand piston pump are thoroughly clean.

7. Position pump assembly to pump adapteron engine and align pump hub with rubber coupling (item 8). Secure pump assembly to pump adapter with two (2) cap screws (item 17), lock washers (item 16) and flat washers (item 3).

8. Secure pump hub to rubber coupling (item 8) with two (2) cap screws (item 10), flat washers (item 9), coupling spacers (item 7) and lock nuts (item 6).

CAUTION

The neutral arm extension spring is under tension and may cause personal injury during installation. Use caution when installing the spring to the pump neutral arm.

9. Connecttheextensionspringtotheneutralarm(Fig.

44).

10.Connect the traction control cable to the neutralarm (Fig. 43):

A. Secure traction cable ball joint to neutral arm.

IMPORTANT: A casedrain exists in the piston (traction) pump and a suctionport is near the input shaft of the gear pump (Fig. 45). Before the gear pump is installed to the piston pump, make sure that plugs placed in either of these ports are removed. Failure to remove plugs will cause excessive pressure in the piston pump and damage seals.

3. Install gear pump to the piston pump (see Gear Pump in this section).

4. Ifremoved,securehub(item1)topistonpumpshaft: A. Make sure that pump shaft and bore of hub are

thoroughly cleaned. B. Position key (item 39) to pump shaft. C. Apply Loctite #242 (or equivalent) to the threads

of the cap screw used to secure hub to pump shaft. D. Slide hub onto pump shaft and secure with

spacer (item 28) and cap screw (item 29). Torque cap screw from 27 to 33 ft--lb (37 to 44 N--m).

5. Inspect threads and sealing surfacesof hydraulic fit-

tingsandhydraulichose connectors. Replace anydamaged or worn fittings or connectors.

B. Secure control cable to neutral arm with cable jam nuts. Make sure that a washer is positioned on each side of the neutral arm.

11.Remove plugs from hydraulic fittings and hoses that were placed during pump removal.

12.Using labels placed during pump removal, lubricate newO-- rings andconnecthydraulichosestogearpump andpistonpumpfittings.Tightenhose connections(see Hydraulic Hose and Tube Installation in the General Information section of this chapter).

13.Make sure that gear pump inlet hose is installed to pump fitting and secured with hose clamp. Remove clamp from gear pump inlet hose.

14.Check oil levelin hydraulic reservoir andadd correct oil if necessary.

15.Follow Hydraulic System Start--up procedures (see Hydraulic System Start--up in this section).

16.Check neutral position of the traction pedal. If adjustmentis required, seeAdjust Transmissionfor Neutral in the Traction Unit Owner’s Manual.

Greensmaster 3150Hydraulic System Page 4 -- 62

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System

Hydraulic

Greensmaster 3150 Hydraulic SystemPage 4 -- 63

Piston (Traction) Pump Service

REAR

OF TRACTION UNIT

1. Key

2. Drive shaft

3. Bearing

4. Cap screw (3 used per plate)

5. Cover plate

6. O--ring

7. Shim kit (for crush ring replacement)

8. Bearing cone

9. Key

10. Swash plate

11. Rotating kit

12. Gasket

13. Valve plate

14. Bearing

Figure 46

15. Dowel pin

16. Back plate

17. O--ring

18. Forward relief valve

19. Bypass valve

20. O--ring

21. Cap screw (2 used)

22. Cap screw (2 used)

23. Coupler

24. Roll pin

25. Cover plate

26. Swash plate insert

27. Shaft seal

28. Washer

29. Housing

30. Retaining ring

31. Bearing race

32. Thrust bearing

33. Washer

34. Shaft seal

35. Retaining ring

36. Retaining ring

37. Plug

38. Plug with O--ring (2 used)

39. Bearing cup

40. Shuttle relief valve with O--ring

41. Reverse relief valve

Greensmaster 3150Hydraulic System Page 4 -- 64

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

NOTE: Thecharge relief valve is attached tothe piston pumpbackplate(shown in Fig.47).Thebackplatemust be removed to service the relief valve.

NOTE: The piston pump is equipped with relief valves (items18and41)for both the forward and reversedirection.Dueto engineoutput,itisunlikely thattractionpressure will reachrelief valve settings. If,however,apiston pump relief valve is leaking or otherwise faulty, traction performance would be affected.

IMPORTANT: The shimkit(item7)isusedtoreplace theoriginalcrushring (not shown) inthecoverplate (item 25). If the swash plate (item 10), cover plate (item25)orhousing(item29)is replaced during servicing, the old crush ring must be replaced. For in formation on crush ring replacement, see Piston Pump Crush Ring Replacement in this section in conjunctionwiththe piston pump service manual at the end of this chapter.

CHARGE RELIEF VALVE

1. Back plate

2. Charge relief valve

3. O--ring

4. Housing

Figure 47

5. Poppet

6. Spring

7. Washer

8. Retaining ring

System

Hydraulic

Greensmaster 3150 Hydraulic SystemPage 4 -- 65

Piston Pump Crush Ring Replacement

29 ft--lb

(39 N--m)

Figure 48

1. Crush ring

2. Shims

3. Cover plate

4. Housing

5. Swash plate (control shaft)

6. Bearing cone

7. Bearing cup

NOTE: The shims replace the crush ring in the cover

plate.Ifthecamplate, cover plate orhousingisreplaced during servicing of the pump, the old crush ring can not be used to make sure of proper preload.

1. Remove crush ring from the cover plate. Measure

thickness of crush ring.

2. Stack shims to the thickness of the crush ring.

3. Insert shims intothe cover platein the same location

that the crush ring was removed from.

4. Assemble housing sub assembly consisting of the

housing, camplate, bearing cone, bearing cup and cover plate (see Eaton, Medium Duty Piston Pump, Repair Information,Model70160 VariableDisplacementPiston Pump at the end of this chapter).

8. O--ring

9. Washer (3 used)

10. Cap screws (3 used)

5. Install washers and cap screws to the cover plate and housing. Torquecapscrews to 29 ft--lbs (39 N--m).

6. Checktorquerequired to rotate control shaft.Torque should be 5to15in--lbs(0.6to1.7N--m).

A. If torque is too low,add additional shims and repeat steps 3 through 6 until the specified torque is achieved.

B. If torque is too high, remove shims and repeat steps 3 t hrough 6 until the specified torque is achieved.

7. Complete assembly of thepump(seeEaton,Medium Duty Piston Pump, Repair Information, Model 70160VariableDisplacementPistonPumpattheendof this chapter).

Greensmaster 3150Hydraulic System Page 4 -- 66

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System

Hydraulic

Greensmaster 3150 Hydraulic SystemPage 4 -- 67

Front Wheel Motors

70 to 90 ft--lb

(95 to122 N--m)

RIGHT

FRONT

250 to 400 ft--lb

(339 to 542 N--m)

1. Lug nut (4 per wheel)

2. Wheel assembly

3. Lock nut

4. Brake lever

5. Brake drum

6. Wheel hub

7. Drive stud (4 per hub)

8. Brake assembly

9. Brake cam

Figure 49

10. Retaining ring

11. Cap screw (4 per brake)

12. Lock nut (4 per brake)

13. Woodruff key

14. Brake bracket

15. Hydraulic hose

16. Hydraulic hose

17. 45

Hydraulic fitting (2 per motor)

18. O--ring

19. O--ring

20. Hydraulic motor

21. Cap screw (4 per motor)

22. Lock nut (4 per motor)

23. Brake rod

24. Jam nut

25. Clevis pin

26. Swivel clevis

27. Cotter pin

Greensmaster 3150Hydraulic System Page 4 -- 68

Front Wheel Motor Removal (Fig. 49)

Front Wheel Motor Installation (Fig. 49)

1. Before removing any parts from the hydraulic system, park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine.

2. Remove front wheel, brake drum assembly and brake assembly from machine (see Front Wheel and Brake in the Service and Repairs section of Chapter 6

-- Chassis).

CAUTION

Before continuing further, read and become familiar with General Precautions for Removing and Installing Hydraulic System Components.

3. Label all wheel motor hydraulic connections for assembly purposes.

4. Disconnect both hose assemblies and O--rings from the hydraulic fittings on the wheel motor.Allow hosesto drain into a suitable container. Discard removed O-rings.

1. Position hydraulic wheel motor and brake bracket (item14)totheframe.Makesureportsofmotorfacethe rear of the machine. Secure motor and brake bracket to the frame with four (4) cap screws (item 21) and lock nuts (item 22).

2. Remove plugs from wheel motor ports. Lubricate and place new O--rings onto fittings. Install fittings into motor openings making sure that fitting orientation is as notedduringremoval.Tightenfittings(seeHydraulicFittingInstallationintheGeneralInformation section of this chapter).

3. Remove caps from disconnected hydraulic lines.

4. Lubricate and position new O--rings to fittings on wheel motor.Use labelsplaced duringthe removalprocessto properly installhydraulic lines towheel motorfittings (see Hydraulic Hose andTubeInstallationinthe General Information section of this chapter).

5. Install brake assembly, brake drum assembly and front wheel to machine (see Front Wheel and Brake in the Service and Repairs section of Chapter 6 -- Chassis).

System

Hydraulic

5. Mark wheel motor fitting orientation to allow correct assembly. Remove hydraulic fittings and O--rings from motor. Discard removed O--rings.

6. Put caps or plugs on disconnected hoses and motor port openings to prevent contamination.

7. Remove four (4) cap screws (item 21) and lock nuts (item 22) that secure brake bracket (item 14) and hydraulic wheel motorto machine. Remove brake bracket and motor from the frame.

WARNING

Failure to maintain proper wheel lug nut and wheel hub lock nut torque could result in failure orlossofwheeland may result in personal injury.

6. Make sure to properly torque lock nut from 250 to 400 ft--lb (339 to 542 N--m) and wheel lug nuts from 70 to 90 ft--lb (95 to 122 N -- m).

7. Check oil level inhydraulic reservoir andadd correct oil if necessary.

8. Follow Hydraulic System Start--up procedures (see Hydraulic System Start--up in this section).

Greensmaster 3150 Hydraulic SystemPage 4 -- 69

Rear Wheel Motor (Optional 3WD)

100 ft--lb

(135 N--m)

Loctite #242

80 to 100 in--lb

(9.0 to 11.3 N--m)

40 ft--lb

(55 N--m)

Figure 50

1. Lock nut (2 used)

2. Spacer (2 used)

3. Grommet (2 used)

4. Hydraulic hose assembly

5. Washer (4 used)

6. Castor fork

7. Mount spacer (2 used)

8. Grease fitting

9. Bearing flangette (lube)

10. Bearing

11. Bearing flangette

12. Cap screw (3 used)

13. Lock nut (2 used)

14. Wheel motor & hub assembly

15. Adapter (2 used)

16. Socket head screw (2 used)

17. Bulkhead bracket

18. Lug nut (4 used)

19. Hydraulic hose assembly

20. Hydraulic tube assembly

21. Washer (3 used)

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.

70 to 90 ft--lb

(95 to122 N--m)

22. Lock nut (3 used)

23. O--ring

24. O--ring

25. O--ring

26. O--ring

27. Set screw

28. Wheel assembly

29. Grease fitting

30. Hydraulic hose assembly

31. Washer head screw (2 used)

FRONT RIGHT

Greensmaster 3150Hydraulic System Page 4 -- 70

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System

Hydraulic

Greensmaster 3150 Hydraulic SystemPage 4 -- 71

Wheel Motor Service

Figure 51

1. Dirt seal

2. Bearing

3. Housing

4. Back--up washer

5. Seal ring

6. Back--up washer

7. Inner seal

8. Thrust washer

9. Thrust bearing

10. Bearing

11. Coupling shaft

12. Thrust bearing

13. Drive link

14. Cap screw

15. Commutator seal

16. Commutator

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

Torqmotor

Service Procedure (TC, TB, TE, TJ, TF,

TG, TH and TL Series) at the end of this chapter.

17. Woodruff key

18. Wear plate

19. Rotor

20. Vane

21. Stator

22. Manifold

23. Commutator ring

24. End cover

Greensmaster 3150Hydraulic System Page 4 -- 72

Toro 3150 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Table Of Contents

Table of Contents

Safety Instructions

Before Operating

While Operating

Maintenance and Service

Jacking Instructions

Safety and Instruction Decals

Table of Contents

Product Records

Maintenance

Equivalents and Conversions

Torque Specifications

Fastener Identification

Using a Torque Wrench with an Offset Wrench

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

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

Other Torque Specifications

Conversion Factors

Table of Contents

General Information

Operator’s Manual

Specifications

Service and Repairs

Fuel Tank

Engine

Fuel Evaporative Control System

Table of Contents

Specifications

General Information

Operator’s Manual

Check Hydraulic System Fluid

Towing Traction Unit

Hydraulic Hoses

Hydraulic Schematic

Hydraulic Flow Diagrams

Special Tools

Troubleshooting

General Hydraulic System Problems

Traction Circuit Problems

Mow Circuit Problems

Lift/Lower Circuit Problems

Steering Circuit Problems

Testing

Precautions for Hydraulic Testing

Steering Control Valve Test

Adjustments

Adjust Manifold Relief Valve (R2)

Service and Repairs

General Precautions for Removing and Installing Hydraulic System Components

Flush Hydraulic System

Gear Pump

Gear Pump Service

Piston (Traction) Pump Neutral Assembly

Piston (Traction) Pump

Piston (Traction) Pump Service

Piston Pump Crush Ring Replacement

Front Wheel Motors

Rear Wheel Motor (Optional 3WD)

Wheel Motor Service