Toro Greensmaster TriFlex 3300, Greensmaster TriFlex 3400, 04510, 04520 Service Manual

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Page 1

Part No. 12187SL

Service Manual

(Models 04510 and 04520)

Greensmaster

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 TriFlex 3300 and 3400.

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.T oro.com.

TheT oroCompany reservesthe right tochangeproduct specifications or this publication without notice.

TriFlex

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.

3300/3400

Greensmaster3300

E The Toro Company -- 2012

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Greensmaster 3300/3400

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Table Of Contents

Chapter 1 -- Safety

General Safety Instructions 1 -- 2..................

Jacking Instructions 1 -- 5.........................

Safety and Instruction Decals 1 -- 6................

Chapter 2 -- Product Records and Maintenance

Product Records 2 -- 1...........................

Maintenance 2 -- 1...............................

Equivalents and Conversions 2 -- 2................

Torque Specifications 2 -- 3.......................

Chapter 3 -- Gasoline Engine

Specifications 3 -- 2..............................

General Information 3 -- 3........................

Fuel Evaporative Control System 3 -- 4.............

Adjustments 3 -- 7...............................

Service and Repairs 3 -- 8........................

BRIGGS & STRATTON REPAIR MANUAL FOR

4-CYCLE V-TWIN CYLINDER OHV HEAD ENGINES

Chapter 4 -- Diesel Engine

Specifications 4 -- 2..............................

General Information 4 -- 3........................

Adjustments 4 -- 5...............................

Service and Repairs 4 -- 6........................

KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,

02--E3B SERIES

Chapter 5 -- Hydraulic System

Chapter 6 -- Electrical System

General Information 6 -- 3........................

Turf Guardian Leak Detector

System Operation 6 -- 4........................

Special Tools 6 -- 6..............................

Troubleshooting 6 -- 8............................

Electrical System Quick Checks 6 -- 23.............

Adjustments 6 -- 24..............................

Component Testing 6 -- 26........................

Service and Repairs 6 -- 54.......................

Chapter 7 -- Chassis

Specifications 7 -- 2..............................

General Information 7 -- 3........................

Special Tools 7 -- 4..............................

Adjustments 7 -- 5...............................

Service and Repairs 7 -- 6........................

Chapter 8 -- DPA Cutting Units

Specifications 8 -- 2..............................

General Information 8 -- 3........................

Special Tools 8 -- 4..............................

Factors That Can Affect Cutting Performance 8 -- 6..

Set Up and Adjustments 8 -- 10....................

Service and Repairs 8 -- 12.......................

Safety

Product Records

GasolineElectricalChassis

Diesel

Hydraulic

and Maintenance

Engine

System

Specifications 5 -- 3..............................

General Information 5 -- 4........................

Hydraulic Schematic 5 -- 10.......................

Hydraulic Flow Diagrams 5 -- 12...................

Special Tools 5 -- 22.............................

Troubleshooting 5 -- 26...........................

Testing 5 - - 32...................................

Adjustments 5 -- 54..............................

Service and Repairs 5 -- 56.......................

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

Greensmaster 3300/3400

SERVICE PROCEDURE

System

Units

DPA Cutting

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Greensmaster 3300/3400

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Table Of Contents (Continued)

Chapter 9 -- Groomer

Specifications 9 -- 2..............................

General Information 9 -- 3........................

Troubleshooting 9 -- 4............................

Adjustments 9 -- 6...............................

Service and Repairs 9 -- 7........................

Chapter 10 -- Foldout Drawings

Groomer

Hydraulic Schematic 10 -- 3.......................

Electrical Schematics 10 -- 4......................

Wire Harness Drawings 10 -- 8....................

Foldout

Drawings

Greensmaster 3300/3400

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Greensmaster 3300/3400

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Table of Contents

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

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

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

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

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

SAFETY AND INSTRUCTION DECALS 6..........

Chapter 1

Safety

Greensmaster 3300/3400 Page 1 -- 1 Safety

Page 8

General Safety Instructions

Greensmaster TriFlex 3300 and 3400 machines have been tested and certified by TORO for compliance with existing safety standards and specifications. Although hazardcontrol and accident prevention partiallyare 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 maintenanceofthemachinecan result in injury or death. Toreduce the potential for injury or death, comply with the following safety instructions.

Before Operating

WARNING

To reduce the potential for injury or death, comply with the following safety instructions.

1. Review and understand the contents of the Operator’s Manuals and Operator’s DVD before starting and operatingthe vehicle. Becomefamiliar with thecontrols and know how to stop the vehicle and engine quickly. AdditionalcopiesoftheOperator’sManualareavailable on the internet at www.Toro.com.

2. Keep all shields, safety devices and decalsin place. Ifashield,safetydevice or decal is defective,illegibleor damaged, repair or replace it before operating the machine.Alsotightenanyloosenuts,boltsorscrewstoensure machine is in safe operating condition.

3. Assure interlock switches are adjusted correctly so engine cannot be started unless traction pedal is in NEUTRAL and cutting units are DISENGAGED.

4. Since fuel is flammable, handle it carefully: A. Use an approved fuel container. B. Donotremovefuel tank capwhileengineishotor

running. C. Do not smoke while handling fuel. D. Fillfueltankoutdoorsandonlytowithinaninchof

the top of the tank, not the filler neck. Do not overfill the fuel tank.

E. Wipe up any spilled fuel.

Greensmaster 3300/3400Page 1 -- 2Safety

Page 9

While Operating

1. Sit on the seat when starting and operating the machine.

2. Before starting the engine: A. Sitontheseat,makesurecuttingunitsaredisen-

gaged. B. Verify that functional control lever is in neutral. C. Verify that parking brake is applied. D. Proceed to start engine. E. Afterengineisstarted, releaseparkingbrakeand

keepfootofftractionpedal.Machine must not move. If movement is evident, the traction pedal linkage is adjusted incorrectly; therefore, shut engine off and adjust traction pedal linkage until machine does not move when traction pedal is released.

3. Do not run engine in a confined area without ade-

quate ventilation. Exhaust fumes are hazardous and could possibly be deadly.

4. Donottouchengine,exhaustsystemcomponentsor radiator(ifequipped)while engine is running orsoonafter it is stopped. These areas could be hot enough to cause burns.

Safety

5. Before getting off the seat: A. Make sure cutting units are disengaged. B. Verify that functional control lever is in neutral. C. Apply the parking brake. D. Stop the engine and remove key from ignition

switch. E. Toro recommends that anytime the machine is

parked (short or long term), the cutting units should be lowered to the ground. This relieves pressure fromthehydraulicliftcircuitandeliminatestheriskof cutting units accidentally lowering to the ground.

F. Donotparkthemachineonslopesunlesswheels are chocked or blocked.

Greensmaster 3300/3400 Page 1 -- 3 Safety

Page 10

Maintenance and Service

1. TheTractionUnitandCuttingUnitOperator’s Manualsprovideinformationregardingtheoperation,general maintenance and maintenance intervals for your Greensmaster machine. Refer to these publications for additional information when servicing the machine.

2. Before servicing or making adjustments, lower cuttingunits, stop engine, applyparking brake and remove key from the ignition switch.

3. Make sure machine is in safe operatingcondition by keeping all nuts, bolts and screws tight.

4. Never store the machine or fuel container inside wherethereis anopenflame,such asnearawaterheater or furnace.

5. Make sure all hydraulic line connectorsare tight and all hydraulic hoses and lines are in good condition before applying pressure to the hydraulic system.

6. Keepbodyandhandsawayfrompinholeleaksinhydrauliclinesthatejecthighpressurehydraulic fluid. Use cardboard or paper to find hydraulic leaks. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Fluid accidentally injected into the skin mustbesurgicallyremovedwithin a few hours by adoctor familiar with this form of injury or gangrene may result.

7. Before disconnecting or performing any work on the hydraulic system, all pressure in system must be relieved by stopping engine and lowering cutting units to the ground.

8. If major repairsare ever neededor assistance is desired, contact an Authorized Toro Distributor.

9. To reduce potential fire hazard, keep engine area free of excessive grease, grass, leaves and dirt. Clean protective screen on machine frequently.

10.If engine must be running to perform maintenance or an adjustment, keep hands, feet, clothing and other partsofthebodyawayfromcuttingunitsandothermoving parts. Keep bystanders away.

12.Shut engine off before checking or adding oil to the engine crankcase.

13.Disconnect battery before servicing the machine. Disconnect negative battery cable first and positive cablelast.Ifbatteryvoltage is required for troubleshooting or test procedures, temporarily connect the battery. Reconnect positive battery cable first and negative cable last.

14.Battery acid is poisonous and can cause burns. Avoidcontact with skin, eyes and clothing. Protect your face, eyes and clothing when working with a battery.

15.Battery gases can explode. Keep cigarettes, sparks and flames away from the battery.

16.When welding on machine, disconnect both battery cables to prevent damage to machine electronic equipment. Disconnect negative battery cable first and positive cable last. Also, disconnect the wire harness connector from the TEC controller and the alternator connector(s). This will prevent damage to the electrical system of your Greensmaster.

17.At the time of manufacture, the machine conformed tothe safety standards forriding mowers. Toassure 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.

18.When changing attachments, tires or performing other service, use correct blocks, hoists and jacks. Make sure machine is parked on a solid level surface suchasaconcrete floor.Priorto raising themachine,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, whichmayresultinpersonal injury (seeJackingInstructions in this chapter).

11.Do not overspeed the engine by changing governor setting.Toassuresafetyandaccuracy,checkmaximum engine speed.

Greensmaster 3300/3400Page 1 -- 4Safety

Page 11

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 properraising of themachine.Always chockorblockwheels. Use jackstands to support the raised machine. If the machine is not properly supported by jack stands, the machine may move or fall, which may result in personal injury.

Front End Jacking

1. Apply parking brake and chock rear tire to prevent the machine from moving.

2. Position jack securely underthe frame jacking point: A. The left side jacking point is the frame channel

under the step behind the LH front wheel (Fig. 1). B. The right side jacking point is the frame bracket

behind the RH front wheel (Fig. 2).

3. Jack front of machine off the ground.

Safety

Figure 1

1. LH front wheel 2. Jacking point

4. Position appropriate jack stands under the frame as

close to the wheel as possible to support the machine.

Rear End Jacking

1. Applyparkingbrakeandchock both fronttirestopre-

vent the machine from moving.

2. Place jack securely under the rear jacking point on

the rear steering fork (Fig. 3).

3. Jack rear of machine off the ground.

4. Position appropriate jack stands under the frame to

support the machine.

Figure 2

1. RH front wheel 2. Jacking point

Figure 3

1. Rear steering fork 2. Rear jacking point

Greensmaster 3300/3400 Page 1 -- 5 Safety

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Safety and Instruction Decals

Numerous safety and instruction decals are affixed to the traction unit and the cutting units of Greensmaster TriFlex3300and 3400 machines.Ifany decal becomes illegible or damaged, install a new decal. Part numbers are listed in your Parts Catalog and Operator’s Manual. Order replacement decals from your Authorized Toro Distributor.

Greensmaster 3300/3400Page 1 -- 6Safety

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Product Records and Maintenance

Table of Contents

PRODUCT RECORDS 1.........................

MAINTENANCE 1...............................

EQUIVALENTS AND CONVERSIONS 2...........

Decimal and Millimeter Equivalents 2............

U.S. to Metric Conversions 2...................

TORQUE SPECIFICATIONS 3....................

Fastener Identification 3.......................

Using a Torque Wrench with an Offset Wrench 3.. Standard Torque for Dry, Zinc Plated and

Steel Fasteners (Inch Series). 4...............

Standard Torque for Dry, Zinc Plated and

Steel Fasteners (Metric Fasteners). 5..........

Other Torque Specifications 6..................

Conversion Factors 6..........................

Chapter 2

Product Records

and Maintenance

Product Records

Inserta copy ofthe TractionUnit and CuttingUnit Operator’s Manuals and Parts Catalog for your Greensmasterat the endof this chapter.Additionally,ifanyoptional equipment or accessories have been installed to your machine, insert the Installation Instructions, Operator’s ManualsandPartsCatalogsforthoseoptions at theend of this chapter.

Maintenance

Maintenanceproceduresandrecommendedserviceintervals for your Greensmaster are covered in the Traction Unit Operator’s Manual. Maintenance procedures andrecommendedserviceintervalsfortheGreensmaster Cutting Units are covered in the Cutting Unit Operator’s Manual. Refer to these publications when performing regular equipment maintenance. Refer to theEngineOperator’sManualforadditionalenginespecific maintenance procedures.

Greensmaster 3300/3400 Page 2 -- 1 Product Records and Maintenance

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Equivalents and Conversions

0.09375

Greensmaster 3300/3400Page 2 -- 2Product Records and Maintenance

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Torque Specifications

Recommended fastener torque values are listed in the followingtables.For critical applications, as determined byToro, either the recommended torque or a torquethat is unique to the application is clearly identifiedand specified in this Service Manual.

These Torque Specifications for the installation and tightening of fastenersshall apply to all fasteners which donot have aspecific requirement identifiedin this Service Manual. The following factors shall be considered when applying torque: cleanliness of the fastener, use of a thread sealant (e.g. Loctite), degree of lubrication onthe fastener,presenceof a prevailing torquefeature, hardnessofthesurfaceunderneaththefastener’s head or similar condition which affects the installation.

Fastener Identification

Asnotedinthe following tables,torquevaluesshouldbe 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. Measurethetorquerequiredtotighten the fastener until the lines match up.

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 the effective change of torquewrenchlength.Whenusingatorque wrench with 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

Torque wrenchOffset wrench

The calculated torque conversion factor for this torque wrenchwiththis offset wrench would be18/ 19 = 0.947.

Greensmaster 3300/3400 Page 2 -- 3 Product Records and Maintenance

Figure 3

Page 16

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

Thread Size

# 6 -- 32 UNC

# 6 -- 40 UNF

# 8 -- 32 UNC

# 8 -- 36 UNF

#10--24UNC

#10--32UNF

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

Grade 1, 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

17 + 2 190 + 20 25 + 2 280 + 20

29 + 3 330 + 30 41 + 4 460 + 45

31 + 3 350 + 30 43 + 4 485 + 45

42 + 4 475 + 45 60 + 6 675 + 70

48 + 4 540 + 45 68 + 6 765 + 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 -- 11UNC 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

on the fastener size, the aluminum or base material

strength, length of thread engagement, etc. are defined as threads coated with a lubricant such as 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 miniNOTE: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based

mumproof load specifiedin SAE J429.Thetolerance is

approximately +

10% of the nominal torque value. Thin

height nuts include jam nuts.

Greensmaster 3300/3400Page 2 -- 4Product Records and Maintenance

Page 17

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

Class 8.8 Bolts, Screws and Studs with

Thread Size Regular Height Nuts

(Class 8 or Stronger Nuts)

Class 10.9 Bolts, Screws and Studs with

Regular Height Nuts

(Class 10 or Stronger Nuts)

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

M6 X 1.0 96 + 9in--lb 1018 + 100 N--cm 133 + 13 in--lb 1500 + 150 N--cm M8 X 1.25 19 + 2ft--lb 26 + 3N--m 27 + 2ft--lb 36 + 3N--m M10 X 1.5 38 + 4ft--lb 52 + 5N--m 53 + 5ft--lb 72 + 7N--m

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

M16 X 2.0 166 + 15 ft--lb 225 + 20 N-- m 229 + 22 ft--lb 310 + 30 N--m M20 X 2.5 325 + 33 ft--lb 440 + 45 N--m 450 + 37 ft--lb 610 + 50 N--m

NOTE: Reduce torque values listed in the table above by 25% for lubricated fasteners. Lubricated fasteners

on the fastener size, the aluminum or base material

strength, length of thread engagement, etc. are defined as threads coated with a lubricant such as oil, graphite or thread sealant such as Loctite.

NOTE: The nominal torque values listed above are NOTE: Torque values may have to be reduced when

installing fasteners into threaded aluminum or brass. The specific torque value should be determined based

based on 75% of the minimum proof load specified in

SAEJ1199.Thetoleranceisapproximately+

nominal torque value.

10%ofthe

Product Records

and Maintenance

Greensmaster 3300/3400 Page 2 -- 5 Product Records and Maintenance

Page 18

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

*Holesize,materialstrength,material thicknessandfinish must be considered when determining specific torquevalues.Alltorque values are based onnon--lubricated fasteners.

Greensmaster 3300/3400Page 2 -- 6Product Records and Maintenance

Page 19

Table of Contents

SPECIFICATIONS 2.............................

GENERAL INFORMATION 3.....................

Operator’s Manual 3..........................

FUEL EVAPORATIVE CONTROL SYSTEM 4.......

ADJUSTMENTS 7..............................

Choke Cable Adjustment 7.....................

Throttle Cable Adjustment 7....................

SERVICE AND REPAIRS 8......................

Fuel Evaporative Control System (Serial Number

Below 312000000) 8.........................

Fuel Evaporative Control System (Serial Number

Above 312000000) 10.......................

Fuel Tank 12.................................

Engine 14....................................

Engine Removal 14..........................

Engine Installation 16........................

BRIGGS & STRATTON VANGUARD V--TWIN OHV

REPAIR MANUAL

Chapter 3

Gasoline Engine

Engine

Gasoline

Greensmaster 3300 Page 3 -- 1 Gasoline Engine

Page 20

Specifications

Item Description

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

Bore x Stroke 2.97” x 2.76” (75.5 mm x 70 mm)

Total Displacement 38.3 in3(627 cc)

Governor Mechanical Governor

Carburetor Float Feed, Two Barrel

Fuel Pump Pulsating Crankcase Vacuum

Fuel Unleaded, regular grade gasoline

Fuel Tank Capacity 6.0 U.S. gallons (22.7 liters)

Low Idle (no load) 1650 + 100 RPM

High Idle (no load) 2920 + 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

OHV, Air Cooled, Gasoline Engine -- Model 385447

Ignition System Flywheel magneto, twin electronic armatures

Spark Plugs Champion RC 14YC (or equivalent)

Spark Plug Gap 0.030” (0.76 mm)

Alternator 20/50 Amp

Dry Weight (approximate) 85 lb (39 kg)

Greensmaster 3300Page 3 -- 2Gasoline Engine

Page 21

General Information

Informationaboutspecifications, maintenance, troubleshooting,testing and repair ofthegasoline engine used in the Greensmaster TriFlex 3300 is included in this chapter and the Briggs & Stratton Vanguard V--Twin OHV Repair Manual.

Most engine repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Briggs & Stratton 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 Traction Unit Operator’s Manual provides information regarding the operation, general maintenance and maintenanceintervals for your Greensmastermachine. Refer to the Operator’s Manual for additional information when servicing the machine.

Service and repair parts for Briggs &Stratton Vanguard V-Twin OHV enginesare supplied through yourlocal localToro distributor.If noparts list is available,besure to provide your distributor with the Toro model and serial numberalongwith the engine modelandserialnumber.

Engine

Gasoline

Greensmaster 3300 Page 3 -- 3 Gasoline Engine

Page 22

Fuel Evaporative Control System

SERIAL NUMBER BELOW 312000000

FUEL TANK

CARBON

CANNISTER

CHECK VALVE

TO INTAKE MANIFOLD

ENGINE

FUEL

TANK

FRESH AIR

FILTER

SERIAL NUMBER ABOVE 312000000

CARBON

CANNISTER

TO INTAKE MANIFOLD

CHECK

VALVE

CHECK

VALVE

FRESH AIR

FILTER

TO AIR

CLEANER

ENGINE

Figure 1

Greensmaster 3300Page 3 -- 4Gasoline Engine

Page 23

The function of the fuel evaporative control system is to collect and store evaporative emissions from the fuel tankandengine.Theevaporatecontrolsystem used on Greensmaster 3300 machines uses a carbon cannister to collect these evaporative emissions. Fuel vapors fromthefueltankareventedtothecanisterwhentheengine is not running. Vapors from the canister are consumed when the engine is running.

Machines With Serial Number Below 312000000

Onmachines with serial number below 312000000, the carbon canister is mounted under the fuel tank mount plate. One fitting at the engine intake manifold is used toconnect the evaporative systemtothe engine. These machinesuseaninlinecheckvalvebetweenthecarbon cannister and the engine intake manifold fitting.

The fuel tank on Greensmaster 3300 machines uses a non--vented fuel cap. To connect the tank to the evaporative control system, a fuel vent valve is positioned in the top of the tank that allows tank venting through the carbon cannister.

NOTE: Ifthereisrestrictioninthefreshairfilter,thecarbon cannister or the fuel vent valve, the fuel tank may distortduetoventing issues.Ifthefueltank returns toit’s normal shape when the fuel cap is removed, restriction in the evaporative control system is likely.

Components used in the evaporative controlsystem on Greensmaster 3300 machines changed at serial number 312000000. Figure 1 illustrates the components used in the evaporative control system.

Machines With Serial Number Above 312000000

Onmachines with serial numberabove312000000, the carbon canister is mounted between the hydraulic reservoir and leak detector tank. The evaporative system includestwo(2)connectionsto theengine:onetotheintake manifold and the second to the air cleaner base. Venting hose assemblies include a check valve in two (2) locations as shown in Figure 1.

NOTE: Thecheckvalves used onmachines with serial numberabove312000000areincludedasacomponent of the hose assembly and are not available as a separatepart.Toensureproperoperationofcheckvalves,do not attempt to remove them from the hose assembly. If either of these hose assemblies are removed, make surethattheyare correctlyinstalledtoinsurecorrectoperation of the evaporative control system.

Engine

Gasoline

Greensmaster 3300 Page 3 -- 5 Gasoline Engine

Page 24

This page is intentionally blank.

Greensmaster 3300Page 3 -- 6Gasoline Engine

Page 25

Adjustments

Choke Cable Adjustment

1. Parkmachineonalevelsurface,disengageand lower cutting units, move functional control lever to neutral (N),engage parking brake, stoptheengine and remove the key from the ignition switch. Wait for all machine movement to stop.

2. Remove air cleaner cover and air filter from engine.

3. Move choke control on control panel while watching choke plate in carburetor.

A. Choke plate should be fully open when choke control is pushed in.

B. Choke plate should be fully closed when choke control is pulled out.

Throttle Cable Adjustment

4. Ifcableadjustmentis needed, loosen cap screw and nut that secure choke cable clamp. Reposition cable to allow correct choke operation. Secure choke cable clamp.

5. After adjustment, move choke control several times to make sure that choke operation is correct.

6. Assemble air cleaner.

Engine

Gasoline

2. Adjustthrottle control onconsoleto the fast position. Inspectgovernorlever onenginetomakesure thatlever is fully rotated and against stop on governor control.

3. If throttle cable adjustment is needed (Fig. 2): A. Loosen cap screw that secures throttle cable

clamp on engine bracket. B. Reposition cable to allow correct governor rota-

tion. C. Tighten screw to secure throttle cable clamp.

4. After adjustment, move throttle control on console

from low idle to high idle to make sure that cable travel is correct.

1. Throttle cable

2. Cable clamp

Figure 2

3. Governor control lever

Greensmaster 3300 Page 3 -- 7 Gasoline Engine

Page 26

Service and Repairs

Fuel Evaporative Control System (Serial Number Below 312000000)

RIGHT

FRONT

1. Flange head screw (2 used)

2. Tank mount plate

3. Fuel hose (to engine intake manifold)

4. Grommet (2 used)

5. Fuel hose (cannister to tank vent)

6. Hose clamp (3 used)

7. Carbon canister

Figure 3

8. Bracket

9. Flange nut (2 used)

10. Fuel hose (cannister to check valve)

11. Fuel hose

12. Fresh air filter

13. R--clamp

14. Washer head screw

15. Check valve

16. Cap screw

17. R--clamp

18. Spacer screw (attached to engine)

19. Worm clamp (4 used)

Greensmaster 3300Page 3 -- 8Gasoline Engine

Page 27

Removal (Fig. 3)

1. Parkmachineonalevelsurface,disengageand low-

er cutting units, move functional control lever to neutral (N),engage parking brake, stoptheengine and remove the key from the ignition switch. Wait for all machine movement to stop.

DANGER

Gasolineisflammable. Use cautionwhenstoring or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running or in an enclosed area. Always fill fuel tank out side and wipe up any spilled fuel before starting the engine. Store fuel in a clean, safety--approved container and keep the cap in place. Use gasoline for the engine only; not for any other purpose.

2. Access the carboncannister under thefuel tank and

betweentherearframesections. Ifnecessary,raiseand supporttankmountplateassembly(hydraulicreservoir, fuel tank and tank mount plate) to reach the cannister (seeTank Mount PlateAssemblyinthe Service and Repairs section of Chapter 7 -- Chassis).

3. Inspect carbon cannister and attached for damage

or obvious leaks. A damaged or leaking cannister should be replaced.

4. Remove components as needed using Figure 3 as

a guide.

FRONT

1. Carbon cannister

2. Hose to tank vent

Figure 4

3. Hose to engine

Engine

Gasoline

A. Ifcheckvalve (item15)isremoved,notedirection of arrow on valve body for assembly purposes.

Installation (Fig. 3)

1. Install all removed components using Figure 3 as a

guide.

A. Ifcheckvalve(item 15) was removed,makesure that arrow on valve body points toward engine.

B. Make sure that fuel hoses are not kinked after installation.Also,secureallhoseswithhoseclamps.

2. If tank mount plate assembly (hydraulic reservoir,

fueltankandtankmountplate)wasraisedtoaccessthe cannister,lowerand secure tank mount plate assembly (seeTank Mount PlateAssemblyinthe Service and Repairs section of Chapter 7 -- Chassis).

Greensmaster 3300 Page 3 -- 9 Gasoline Engine

Page 28

Fuel Evaporative Control System (Serial Number Above 312000000)

RIGHT

FRONT

29 32

14 15

25 26

16 14

25 19

17 14

1. Flange head screw (2 used)

2. Tank mount plate

3. Washer head screw (2 used)

4. Grommet (2 used)

5. Washer head screw

6. Hose clamp (2 used)

7. Carbon cannister

8. Cannister bracket

9. Flange nut

10. Worm clamp

11. Cap screw

12. R--clamp

The function of the fuel evaporative control system is to collect and store evaporative emissions from the fuel tankandengine.Onmachineswithserialnumberabove 312000000, a carbon canister mounted above the hydraulicreservoirisused tocollectcollecttheseevaporative emissions. Fuel vapors from the engine and fuel tank are vented to the canister when the engine is not running. Vaporsfrom the canister are consumed when the engine is running.

Figure 5

13. Fuel hose (fuel supply)

14. Hose clamp (5 used)

15. R--clamp

16. Fuel filter (fuel supply)

17. Fuel hose (fuel supply)

18. Label (air cleaner)

19. R--clamp

20. Hose clamp (2 used)

21. Fuel hose (to vent valve on fuel tank)

22. R--clamp

23. Cap screw

24. Clip (2 used)

NOTE: The purge hose assembly (item 27) and tee

hose assembly (item 28) both include a check valve as a component of the assembly. The check valve is not available as a separate part. If either of these hose assembliesareremoved,makesurethattheyarecorrectly installed to insure correct operation of the evaporative control system.

25. Flat washer (3 used)

26. Flange head screw (2 used)

27. Purge hose assembly (see NOTE)

28. Tee hose assembly (see NOTE)

29. Hose clamp (4 used)

30. Fresh air filter

31. Fuel hose

32. Fuel hose

33. Barbed fitting

34. Engine hose (to air cleaner)

35. Engine hose (to intake manifold)

Greensmaster 3300Page 3 -- 10Gasoline Engine

Page 29

Removal (Fig. 5)

Installation (Fig. 5)

1. Parkmachineonalevelsurface,disengageand low-

er cutting units, move functional control lever to neutral (N),engage parking brake, stoptheengine and remove the key from the ignition switch. Wait for all machine movement to stop.

DANGER

2. Remove leak detector tank (machines with Turf

Guardian voircover(machineswithoutTurfGuardian tector System) to gain access to carbon cannister (see Service and Repairs section of Chapter 5 -- Hydraulic System).

Leak Detector System) or hydraulic reser-

LeakDe-

1. Install all removed components using Figure 5 as a guide.

A. If either purge hose assembly (item 27) or tee hose assembly (item 28) was removed, make sure that installation is correct.

B. Make sure that fuel hoses are not kinked after installation.Also,secureallhoseswithhoseclamps.

2. Install leak detector tank (machines with Turf Guar-

dian cover (machines without Turf Guardian

Leak Detector System) or hydraulic reservoir

Leak Detector System) (see Service and Repairs section of Chapter 5 -- Hydraulic System).

Engine

Gasoline

3. Inspect carbon cannister and attached hoses for damageorobvious leaks.Adamagedorleakingcannister should be replaced.

4. Remove components as needed using Figure 5 as a guide.

A. If either purge hose assembly (item 27) or tee hoseassembly(item28)istoberemoved,labelends of hose for assembly purposes. Both of these assembliesincludea check valve sodirectionofinstallation is important for correct operation of the evaporative control system. The check valve is not available as a separate part so hose assembly replacement is necessary if the check valve or hose is faulty. To ensure proper operation of check valves, donotattempttoremovethemfromthehose assembly.

FRONT

1. Carbon cannister

2. Screw (2 used)

Figure 6

3. Cannister bracket

4. Leak detector tank

Greensmaster 3300 Page 3 -- 11 Gasoline Engine

Page 30

Fuel Tank

Illustration from machine with serial

number below 312000000 shown

Antiseize Lubricant

30 to 50 in--lb

(3.4 to 5.6 N--m)

RIGHT

FRONT

1. Flange head screw (2 used)

2. Tank mount plate

3. Washer head screw (2 used)

4. Grommet (2 used)

5. Fuel hose (2 used)

6. Hose clamp (3 used)

7. Carbon cannister

8. Bracket

9. Flange nut (2 used)

10. Worm clamp (5 used)

11. Fuel hose

12. Fresh air filter

Figure 7

13. Fuel supply hose

14. Hose clamp (3 used)

15. R--clamp

16. Fuel filter

17. Fuel hose

18. Clamp

19. Washer head screw

20. Check valve

21. Fuel hose

22. Fuel tank

23. Fuel tank cap

24. Clip (2 used)

25. Flat washer (2 used)

26. Flange head screw (2 used)

27. Fitting (LH thread)

28. O--ring

29. Shut--off valve

30. Nut (LH thread)

31. Fuel vent valve

32. Grommet

33. Flange bushing (4 used)

34. Washer (4 used)

35. Cap screw (4 used)

Greensmaster 3300Page 3 -- 12Gasoline Engine

Page 31

Fuel Tank Removal (Fig. 7)

Fuel Tank Installation (Fig. 7)

CAUTION

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

DANGER

2. Drain fuel tank:

1. Install fitting assembly and shut--off valve into fuel tankiftheywere removedfromtank(Fig.8). Thenutand fitting have left hand threads.

2. Position fuel tank on the tank mount plate.

3. Secure fuel tank to tank mount plate:

A. Applyantiseizelubricantto the threadsofthefour (4) cap screws (item 35).

B. Securefuel tank tothe tank mountplate with four (4) cap screws (item 35), flat washers (item 34) and flange bushings (item 33).

C. Torque cap screws from 30 to 50in--lb(3.4to5.6 N--m).

4. Install fuel supply hose (item 13) to fuel shut--off valve and fuel filter. Secure supply hose with hose clamps.

5. Connectfuelhose(item5)tofuelventvalve(item31) and secure with hose clamp.

6. Fill fuel tank with fuel.

7. Open fuel shut--off valve. Check all fuel hoses and fuel tank for leaks.

Engine

Gasoline

A. Close fuel shut--off valve (item 29). B. Disconnect fuel supply hose (item 13) at the fuel

filter (item 16) and drain any fuel trapped in the fuel filter and fuel hose into a suitable container.

C. Placeendoffuel hoseintoasuitablecontainerfor draining the tank.

D. Drain fuel tank by opening the fuel shutoff valve.

3. Remove fuel hose (item 5) from fuel vent valve (item

31).

4. Remove four (4) cap screws (item 35), flat washers (item 34) and flange bushings (item 33) that secure the fuel tank to the tank mount plate (item 2). Remove the fuel tank from the machine.

5. Ifnecessary,remove fuel supplyhose(item13) from fuel shut--off valve.

6. If necessary, remove shut--off valve and fitting assembly from fuel tank (Fig. 8). The nut and fitting have left hand threads.

1. Shut--off valve

2. Nut (LH thread)

2 1

Figure 8

3. Fitting (LH thread)

4. O--ring

Greensmaster 3300 Page 3 -- 13 Gasoline Engine

Page 32

Engine

20 to 25 in--lb

(2.3 to 2.8 N--m)

90 to 110 in--lb

Antiseize

Lubricant

(10.2 to 12.4 N--m)

25 to 38 ft--lb

(34to51N--m)

170 to 200 in--lb

(19.3 to 22.6 N--m)

FRONT

RIGHT

1. Engine assembly

2. Spacer screw

3. Muffler

4. Muffler mount

5. Cap screw (4 used)

6. Flange nut (4 used)

7. Muffler shield

8. Hardened washer (8 used)

9. Cap screw (4 used)

10. Muffler clamp

11. Lock nut (4 used)

12. Pump mount

13. Cap screw (4 used)

14. Exhaust manifold

15. Gasket (2 used)

16. Flange head screw (4 used)

17. Engine frame

18. Flange head screw (3 used)

Engine Removal (Fig. 9)

CAUTION

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

Figure 9

19. Square key

20. Engine hub

21. Square head screw (2 used)

22. Rubber coupling

23. Coupling spacer (2 used)

24. Flange head screw (2 used)

25. Lock washer

26. Flat washer (4 used)

DANGER

Greensmaster 3300Page 3 -- 14Gasoline Engine

Page 33

2. Disconnect the negative (--) battery cable at the battery.

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

4. Disconnect fuel hoses from the fuel filter outlet and thecheckvalve nearrearenginecylinderhead (Fig.10). Drainany fuel trappedin the fuel filterand fuel hoseinto a suitable container.

5. Disconnect choke and throttle control cables from engine.

6. Loosen and remove cap screw (item 5), flat washer (item 26), lock washer (item 25) and flange nut (item 6) that secure wire harness ground connectors to engine assembly (Fig. 11).

7. Disconnect wire harness connectors from engine components:

NOTE: Beforedisconnectingwireharnessconnectors, label all electrical leads for assembly purposes.

A. Alternator (from regulator/rectifier) (Fig. 11) B. Fuel solenoid (Fig. 11) C. Magneto (Fig. 11) D. Oil pressure switch (next to oil filter) E. Starter motor (Fig. 11) F. Ground wire at rear muffler mount screw

1. Fuel filter

2. Check valve

Figure 10

3. Rear cylinder head

4. Fuel pump

Engine

Gasoline

8. Loosen the two (2) square head screws (item 21) thatsecuretheenginehub(item20)totheenginecrankshaft.

9. Supportthe engine assembly topreventit from shifting or falling.

10.Remove four (4) cap screws (item 13) that secure engine assembly to pump mount (item 12).

IMPORTANT: Make sure to not damage the engine, fuel lines, hydraulic hoses, electrical harness, controlcablesorother parts whileremovingtheengine.

11.Carefully move the engine assembly away from the pumpmounttoslidetheengine crankshaft out oftheenginehub(item 20). Once thecrankshafthas cleared the hub, remove the engine from the machine.

12.Locateandretrievesquare key(item19)fromengine crankshaft.

13.If necessary, remove exhaust system components from engine using Figure 9 as a guide.

1. Ground connectors

2. Alternator wire

3. Fuel solenoid wire

1. Piston (traction) pump

2. Pump mount

Figure 11

4. Magneto wire

5. Starter motor cable

Figure 12

3. Engine hub

4. Rubber coupling

Greensmaster 3300 Page 3 -- 15 Gasoline Engine

Page 34

Engine Installation (Fig. 9)

1. Make sure that all removed engine components are correctly installed to the engine.

2. If exhaust system components were removed from engine, attach removed components using Figure 9 as a guide.

3. Apply antiseize lubricantto engine crankshaft. Position square key (item 19) to crankshaft.

IMPORTANT: Make sure to not damage the engine, fuel hose, hydraulic hoses, electrical harness, controlcablesorotherpartswhileinstallingtheengine.

4. Aligntheenginehub(item20)withtheenginecrankshaft and square key.

5. While supporting the engine to prevent damaging thepump coupling, carefullymove the engineso crankshaftslidesintotheenginehub(item20)and toward the pump mount. Once the engine contacts the pump mount,alignmounting holesandsecureengineto pump mount with four (4) cap screws (item 13). Torque cap screws from 25 to 38 ft--lb (34 to 51 N--m).

7. Securewireharnessgroundconnectortoengine assembly with cap screw (item 5), flat washer (item 26), lock washer (item 25) and flange nut (item 6) (Fig. 11). Make sure that lock washer is positioned between ground connector and engine flange to ensure ground connection to engine.

8. Connect all wire harness connectors to correct engine components.

9. Connectandadjustthechoke control cable (see Adjusting the Choke Control in the Adjustments section of this chapter).

10.Connect and adjust the throttle control cable (see Adjusting the Throttle Control in the Adjustments section of this chapter).

11.Connect fuel hoses to the fuel filter outlet and check valve near rear engine cylinder head (Fig. 10). Secure hoses with hose clamps.

12.Openfueltankshut--offvalveandcheck fuelhosefor leaks.

13.Check engine oil level and adjust if necessary.

6. Make sure that rubber coupling (item 22) is not distorted.Secureenginehubto engine crankshaft with two (2) square head screws (item 21). Torque screws from 90 to 110 in--lb (10.2 to 12.4 N--m).

14.Start the engine and check for proper operation.

Greensmaster 3300Page 3 -- 16Gasoline Engine

Page 35

Table of Contents

SPECIFICATIONS 2.............................

GENERAL INFORMATION 3.....................

Operator’s Manual 3..........................

ADJUSTMENTS 5..............................

Adjust Throttle Control 5.......................

SERVICE AND REPAIRS 6......................

Air Cleaner Assembly 6........................

Exhaust System 8............................

Fuel Tank 10.................................

Radiator 12..................................

Engine 14....................................

Engine Removal 14..........................

Engine Installation 16........................

Engine Bell Housing 18........................

KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,

SM--E3B SERIES

Chapter 4

Diesel Engine

Diesel

Engine

Greensmaster 3400 Page 4 -- 1 Diesel Engine

Page 36

Specifications

Item Description

Make / Designation Kubota water--cooled, Diesel,

Number of Cylinders 3

Bore x Stroke 2.83” x 2.9” (72mm x 73.6mm)

Total Displacement 54.8 in3(898 cc)

Compression Ratio 24.0:1

Firing Order 1 (closest to gear case end) -- 2 -- 3 (closest to flywheel end)

Direction of Rotation Counterclockwise (viewed from flywheel)

Fuel Diesel or Biodiesel (up to B20) Fuel with

Low or Ultra Low Sulfur Content

Fuel Injector Pump Bosch MD Type Mini

Fuel Injection Nozzle Bosch Throttle Type

Fuel Capacity 6.0 U.S. gallons (22.7 liters)

Governor Centrifugal Mechanical

Model D902--E3B

Low Idle (no load) 1500+150/--100 RPM

High Idle (no load) 2880 + 50 RPM

Engine Oil API CH--4, CI--4 or higher

Engine Oil Viscosity See Operator’s Manual

Oil Pump Gear Driven Trochoid Type

Crankcase Oil Capacity 3.9 U.S. quarts (3.7 liters) with filter

Cooling System Capacity (including reserve tank) 4.9 U.S. quarts (4.6 liters)

Starter 12 VDC 1.2 KW

Alternator/Regulator 12 VDC 60 AMP

Dry Weight (approximate) 159 lbs (72 kg)

Greensmaster 3400Page 4 -- 2Diesel Engine

Page 37

General Information

Informationaboutspecifications, maintenance, troubleshooting, testing andrepair ofthe diesel engine used in theGreensmaster TriFlex 3400 is included in this chapter and the Kubota Workshop Manual, Diesel Engine, SM--E3B Series.

Most engine repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Kubota Workshop 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

Service and repair parts for Kubota engines are supplied through yourlocal localToro distributor.Ifno parts list is available, be sure to provide your distributor with the Toro model and serial number.

Diesel

Engine

Greensmaster 3400 Page 4 -- 3 Diesel Engine

Page 38

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Greensmaster 3400Page 4 -- 4Diesel Engine

Page 39

Adjustments

Adjust Throttle Control

Proper throttle operation is dependent upon proper adjustment of throttle control. Make sure throttle control is operating properly.

NOTE: The throttle cable swivel should be positioned in the lowest hole in the speed control lever.

1. Move throttle control lever on control console to FAST position.

2. Check position of the engine speed control lever on fuel injection pump (Fig. 1). The speed control lever should be contacting the high speed screw when the throttle control lever is in the FAST position.

3. Ifnecessary,throttlecontrolcanbeadjustedbylooseningcablejamnutsandrepositioningcontrolcableuntil speed control lever contacts high speed screw when the throttle control lever is in the FAST position (Fig. 2). Tightencable jam nuts after adjustment has been completed.

1. High speed screw

2. Speed control lever

1. Throttle cable

2. Speed control lever

Figure 1

Figure 2

3. Fuel solenoid

3. Cable jam nut

4. Throttle cable swivel

Diesel

Engine

Greensmaster 3400 Page 4 -- 5 Diesel Engine

Page 40

Service and Repairs

Air Cleaner Assembly

RIGHT

FRONT

1. Air inlet hood

2. Flat washer (2 used)

3. Cap screw (2 used)

Figure 3

4. Mounting bracket

5. Air cleaner assembly

6. Hose clamp (2 used)

7. Flange nut (2 used)

8. Air intake hose

9. R--clamp

Greensmaster 3400Page 4 -- 6Diesel Engine

Page 41

Air Cleaner Removal (Fig. 3)

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

2. Remove air cleaner components as needed using Figure 3 as a guide.

3. Check air intake hose (item 8) for damage or wear. Replace hose if damage is found.

4. Disassemble air cleaner as necessary (Fig. 4).

5. Checkaircleaner housingandcoverfordamagethat could cause possible air leaks.

Air Cleaner Installation (Fig. 3) IMPORTANT: Any leaks in the air cleaner system

will allow dirt into engine and will cause serious engine damage. Make sure that all air cleaner components are in good condition and are properly secured during assembly.

1. Assemble air cleaner system using Figures 3 and 4 as guides.

A. Ifplugwasremoved from aircleanerhousing,apply sealant to threads of plug before assembly.

B. Make sure that vacuator valve on air cleaner assembly is pointed down after assembly.

C. Make sure thatair intake hose(item 8) has clearance around it at all points after air cleaner installation is completed.

1. Housing

2. Filter element

3. Cover

Figure 4

4. Vacuator valve

5. Plug

Diesel

Engine

Greensmaster 3400 Page 4 -- 7 Diesel Engine

Page 42

Exhaust System

FRONT

RIGHT

1. Engine assembly

2. Muffler assembly

3. Lock nut (4 used)

4. Exhaust pipe

5. Flange head screw

6. Flange nut (4 used)

Figure 5

7. Lock washer (3 used)

8. Exhaust plate

9. Exhaust gasket

10. Flange nut

11. Flange nut

12. Brace

13. Flat washer (8 used)

14. Cap screw (4 used)

15. Brace

16. Spring (4 used)

17. Muffler shield

18. Flange head screw

Greensmaster 3400Page 4 -- 8Diesel Engine

Page 43

Exhaust System Removal (Fig. 5)

Exhaust System Installation (Fig. 5)

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

CAUTION

The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before workingon the muffler.

2. Removeexhaustsystemcomponentsasneededusing Figure 5 as a guide.

NOTE: Mufflerassemblyis secured tobrackets on piston(traction)pumpwith lock nuts (item 3)andflatwashers (item 13).

1. Make sure the engine is off.

IMPORTANT: If exhaust studs were removed from engine cylinder head, thoroughly clean threads in head and apply Loctite #277 (or equivalent) to stud threads before installing studs into head.

NOTE: Make sure exhaust plate and engine exhaust

manifold sealing surfaces are free of debris or damage that may prevent a tight seal.

2. If exhaust gasket (item 9) was removed, place new exhaust gasket on the engine exhaust manifold.

NOTE: To ensure proper exhaust system sealing, mount all exhaust system components loosely before fully tightening any fastener.

3. Assemble all removed exhaust system components using Figure 5 as a guide.

4. Afterallexhaustcomponentshavebeenassembled, make sure that all fasteners are properly tightened.

Diesel

Engine

Greensmaster 3400 Page 4 -- 9 Diesel Engine

Page 44

Fuel Tank

RIGHT

FRONT

1. Fuel tank

2. Tank mount plate

3. Flange head screw (4 used)

4. Clip (2 used)

5. Fuel cap

6. Fuel vent valve

12 13

Antiseize

Lubricant

30 to 50 in--lb

(3.4 to 5.6 N--m)

Figure 6

7. Grommet

8. Bushing

9. Elbow fitting

10. Vent hose

11. Hose clamp

12. Flange bushing (4 used)

13. Flat washer (4 used)

14. Cap screw (4 used)

15. Return hose

16. Hose clamp

17. Fuel supply hose

Fuel Tank Removal (Fig. 6)

CAUTION

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

Greensmaster 3400Page 4 -- 10Diesel Engine

Page 45

2. Position fuel tank on the tank mount plate.

DANGER

Diesel fuel is flammable. Use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running or in an enclosed area. Always fill fuel tank outsideand wipe up any spilledfuel before starting the engine. Store fuel in a clean, safety--approved container and keep the cap in place.

2. Drain fuel tank: A. Close fuel shut--off valve on bottom of fuel tank. B. Disconnect fuel supply hose (item 17) at the fuel

filter and drain any fuel trapped in the fuel filter and fuel hose into a suitable container.

C. Placeendoffuel hoseintoasuitablecontainerfor draining the tank.

D. Drain fuel tank by opening the fuel shutoff valve.

3. To allow easier access to fasteners that secure fuel

tank, raise and support tank mount plate assembly (hydraulic reservoir, fuel tank and tank mount plate) (see Tank Mount Plate Assembly in the Service andRepairs section of Chapter 7 -- Chassis).

3. Move fuel tank towards the rear of the machine and install return hose (item 15) to elbow fitting on front of tank. Secure hose with hose clamp.

4. Secure fuel tank to tank mount plate: A. Applyantiseizelubricantto the threadsofthefour

(4) cap screws (item 14). B. Securefuel tank tothe tank mountplate with four

(4) cap screws (item 14), flat washers (item 13) and flange bushings (item 12).

C. Torque cap screws from 30 to 50in--lb(3.4to5.6 N--m).

5. Lower and secure tank mount plate assembly (hy-

draulic reservoir, fuel tank and tank mount plate) (see Tank Mount Plate Assembly in the Service andRepairs section of Chapter 7 -- Chassis).

6. Connect fuel supply hose (item 17) to the fuel shut--

off valve and fuel filter. Secure supply hose with hose clamps.

7. Connect vent hose (item 10) to fuel vent valve (item

6) and secure with hose clamp.

8. Fill fuel tank with fuel.

Diesel

Engine

4. Remove vent hose (item 10) from fuel vent valve (item 6).

5. Remove four (4) cap screws (item 14), flat washers (item 13) and flange bushings (item 12) that secure the fuel tank to the tank mount plate (item 2).

6. Move fuel tank towards the rear of the machine to gainaccessto fuelreturnhose(item15). Removereturn hose from elbow fitting on front of tank.

7. Remove the fuel tank from the machine.

8. If necessary, remove fuel supply hose from shut--off valve.

9. If necessary, remove shut--off valve and fitting assembly from fuel tank (Fig. 7). The nut and fitting have left hand threads.

Fuel Tank Installation (Fig. 6)

1. Install fitting assembly and shut--off valve into fuel tankiftheywere removedfromtank(Fig.7). Thenutand fitting have left hand threads.

9. Open fuel shut--off valve. Check all fuel hoses and

fuel tank for leaks.

2 1

Figure 7

1. Shut--off valve

2. Nut (LH thread)

3. Fitting (LH thread)

4. O--ring

Greensmaster 3400 Page 4 -- 11 Diesel Engine

Page 46

Radiator

RIGHT FRONT

1. Seal panel

2. Radiator shroud

3. Trim seal

4. Fan assembly

5. Radiator assembly

6. Hose clamp (2 used)

7. R--clamp (2 used)

8. Clip (8 used)

9. Stud (2 used)

Figure 8

10. Stud retainer (2 used)

11. Receptacle (2 used)

12. Cap screw (4 used)

13. Flat washer (4 used)

14. R--clamp

15. Screen

16. Flange head screw (12 used)

17. Lock nut (4 used)

18. Flange head screw (4 used)

19. Front shroud

20. Flange nut (12 used)

21. Lower radiator hose

22. Upper radiator hose

23. Breather hose (to thermostat)

24. Overflow hose (to overflow tank)

25. Fuel pump assembly

Greensmaster 3400Page 4 -- 12Diesel Engine

Page 47

Radiator Removal (Fig. 8)

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

10.Disconnect fan wire connector from machine wire

harness.

11.Support radiator assembly to prevent it from falling.

12.Remove four (4) flangenutsthatsecurefrontshroud

to machine. Remove radiator assembly from machine.

CAUTION

DO NOT open radiator cap or drain coolant if the engineorradiatorishot. Pressurized hot coolant can escape and cause burns.

Ethylene--gycol antifreeze is poisonous. Disposeofitproperlyorstoreitinaproperlylabeled container away from children and pets.

2. Remove the radiator cap.

3. Drain radiator into a suitable container by disconnecting lower radiator hose from the radiator.

4. Remove screen (item 15) from radiator shroud.

5. Remove four (4) flange head screws (item 16) that secure radiator shroud (item 2) to radiator assembly. Remove radiator shroud.

6. Remove flange head screw that secures R--clamp (item 14) to bottom of front shroud (item 19).

7. Remove the following hoses from the radiator: A. Loosen hose clamps and disconnect breather

hose (item 23) and overflow hose (item 24) from radiator filler neck.

13.Removecomponentsfromr adiator asnecessaryusing Figure 8 as a guide.

Radiator Installation (Fig. 8)

1. Assembleall removed components toradiatorusing Figure 8 as a guide.

2. Position radiator assembly to machine.Secure front shroud to machine with four (4) flange nuts.

3. Position fuel pump assembly to radiator assembly and secure with flange head screw and flange nut.

4. Connect fan wire connector to machine wire harness.

5. Slidefuelreturnhosethroughbothr--clamps(item7) onfront shroud (item19). Connect return hose sections at splice fitting and secure with hose clamp.

6. Connect the following hoses to the radiator and secure with hose clamps:

A. Upper and lower radiator hoses (items 22 and

21). B. Breather hose (item 23) and overflow hose (item

24) to radiator filler neck.

Diesel

Engine

B. Loosenhose clamps (item6) and disconnectupper and lower radiator hoses (items 22 and 21).

8. Locate splice fitting in fuel return hose near fuel

pump. Disconnect one of the return hose sections from splicefittingandremovereturnhose frombothr--clamps (item 7) on front shroud (item 19).

9. Remove flange head screw and flange nut that se-

cure fuel pump assembly to front shroud. Position fuel pump assembly away from radiator assembly.

Greensmaster 3400 Page 4 -- 13 Diesel Engine

7. Secure R--clamp (item 14) to bottom of front shroud (item 19).

8. Secureradiatorshroud (item 2) to radiatorassembly with four (4) flange head screws (item 16).

9. Install screen (item 15) to radiator shroud.

10.Fill radiator with coolant. Check radiator and hoses for leaks.

Page 48

Engine

FRONT

RIGHT

1. Engine assembly

2. Muffler assembly

3. Lock nut (4 used)

4. Exhaust pipe

5. Flange head screw

6. Flange nut (4 used)

7. Lock washer (3 used)

8. Exhaust plate

9. Exhaust gasket

10. Flange nut

11. Flange nut

12. Brace

13. Flat washer (8 used)

14. Cap screw (4 used)

15. Brace

16. Spring (4 used)

17. Muffler shield

18. Flange head screw

19. Alternator assembly

Engine Removal (Fig. 9)

Figure 9

20. V--belt

21. Fuel/water separator

22. Cap screw (2 used)

23. Engine support

24. Cap screw (4 used)

25. Lock washer (4 used)

26. Lock washer (ground connection)

27. Rear engine mount

28. R--clamp (air intake hose)

CAUTION

The engine, radiator, exhaust system and hydraulic system may be hot. T oavoid possible injury,allowmachinetocoolbefore working on the engine.

Greensmaster 3400Page 4 -- 14Diesel Engine

Page 49

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

3. Remove air cleaner and air intake hose from ma-

chine (see Air Cleaner Removal in this section).

4. Remove radiator from machine (see Radiator Re-

moval in this section).

5. Remove exhaust system from machine (see Ex-

haust System Removal in this section).

6. Disconnect fuel supply hose from the injector pump

and fuel return hose from the #3 injector. Drain any fuel trapped in the hoses into a suitable container.Remove hoses from grommets in engine support on front of engine. Plug hoses and position them away from engine assembly.

7. Loosenscrewthat secures the throttle cable to swiv-

el on injector pump speed control lever. Disconnect cable from swivel and cable bracket (Fig. 10). Position cable away from engine.

8. Disconnect wire harness connectors from engine

components: NOTE: Beforedisconnectingwireharnessconnectors,

label all electrical leads for assembly purposes.

A. Negative battery cable and wire harness ground from lower engine mount fastener (Fig. 11).

1. Throttle cable

2. Speed control lever

Figure 10

3. Cable jam nut

4. Throttle cable swivel

Diesel

Engine

B. Fuel stop solenoid (Fig. 12). C. Glow plug bus (Fig. 12). D. Temperature sender (Fig. 12). E. Alternator connector and stud (Fig. 13). F. Starter motor solenoid and fusible link harness

(Fig. 13). G. Oil pressure switch (near oil filter) (Fig. 13).

CAUTION

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

9. Support hydraulic pump assembly to prevent it from

moving during engine removal.

10.Removetwo(2)capscrewsandflat washersthatse-

cure hydraulic pump assembly to bell housing on engine.

1. Engine mount

2. Negative cable

1. Fuel return hose

2. Throttle cable swivel

3. Fuel stop solenoid

Figure 11

3. Wire harness ground

Figure 12

4. Glow plug bus

5. Temperature sender

Greensmaster 3400 Page 4 -- 15 Diesel Engine

Page 50

CAUTION

When removing engine assembly, make sure lift or hoist can safely support 190 lbs (86 kg).

11.Attach a suitable lift or hoist to engine. Support engine with lift or hoist to prevent engine from shifting or moving.

12.Remove fasteners that secure engine to machine: A. Remove cap screw, spacer, snubbing washer

and flange nut that secure engine support to engine mount (Fig. 14).

B. Remove two (2) cap screws, washers and lock nuts that secure rear engine plate to rear engine mount (Fig. 15).

IMPORTANT: Make sure to not damage the engine, fuel hoses, hydraulic lines, electrical harness or other parts while removing the engine. Also, make sure that hydraulic pump assembly does not shift location during engine removal.

13.Slowly move the engine assembly away from the hy-

draulic pump assembly to allow the pump coupling to slide out of the engine coupling flange (Fig. 16). Once the engine has cleared the pump coupling, carefully remove the engine from the machine.

14.If necessary, remove engine support (item 23) from

engine.

Engine Installation (Fig. 9)

1. Alternator stud

2. Alternator connector

3. Starter motor solenoid

FRONT

Figure 13

4. Fusible link harness

5. Oil pressure switch

1. Make sure that all removed engine components are

correctly installed to the engine.

2. If engine support (item 23) was removed from en-

gine, secure supportto enginewith removedfasteners.

3. Makesurethathydraulicpump assemblyiswellsup-

ported to prevent it from moving during engine Installation.

CAUTION

When installing engine assembly, make sure lift or hoist can safely support 190 lbs (86 kg).

4. Attach a suitable lift or hoist to engine.

1. Engine

2. Engine support

3. Cap screw

FRONT

1. Rear engine mount

2. Cap screw (2 used)

Figure 14

4. Spacer

5. Rebound washer

6. Flange nut

Figure 15

3. Washer (2 used)

4. Lock nut (2 used)

Greensmaster 3400Page 4 -- 16Diesel Engine

Page 51

IMPORTANT: Make sure to not damage the engine, fuel hoses, hydraulic lines, electrical harness or other parts while installing the engine. Also, make sure that hydraulic pump assembly does not shift location during engine installation.

5. Slowly move the engine assembly toward the hydraulic pump assembly to allow the pump coupling to slide into the engine coupling flange (Fig. 16).

13.Insert fuel supply hose and fuel return hose through grommetsinenginesupportonfrontofengine.Remove plugs placed during engine removal from hoses. Connectfuelsupplyhosetotheinjectorpumpfittingandfuel return hose to the #3 injector fitting. Secure fuel hoses with hose clamps.

14.Open fuelshutoffvalve on fueltank. Check tankand hoses for leaks.

6. Secure hydraulic pump assembly to bell housing on engine with two (2) cap screws and flat washers (Fig.

16).

7. Secure engine to machine: A. Secureenginesupport(item23)toenginemount

withcapscrew,spacer,snubbing washerandflange nut (Fig. 14).

B. Secure engine rear plate to rear engine mount withtwo (2) cap screws, washers and lock nuts(Fig.

15).

8. Connect all electrical harness connectors to engine

using labels placed during engine removal.

9. Connectthrottle cable to the swivelon injector pump

speed control lever (Fig. 10). Adjust cable (see Adjust ThrottleControl in the Adjustmentssection of thischapter).

10.Installexhaustsystemtomachine(seeExhaustSys-

tem Installation in this section).

11.Install radiator to machine (see Radiator Installation

in this section).

12.Install air cleaner tomachine(seeAirCleaner Instal-

lationinthis section).Makesurethatallhoseclampsare properly tightened.

15.Fill cooling system with coolant. Check radiator and hoses for leaks.

16.Make sure thatalternator belt tension isproperly adjusted.

17.Bleed fuel system.

18.Make sure that engine oil level is correct.

Loctite #242

27 to 33 ft--lb

(37to44N--m)

FRONT

Figure 16

1. Piston pump

2. Cap screw (2 used)

3. Flat washer (2 used)

4. Coupling

5. Cap screw

6. Spacer

7. Engine coupling flange

8. Bell housing

9. Key

Diesel

Engine

Greensmaster 3400 Page 4 -- 17 Diesel Engine

Page 52

Engine Bell Housing

1. Engine

2. Flange head screw (5 used)

Removal (Fig. 17)

FRONT

RIGHT

Figure 17

3. Bell housing

4. Coupling flange

5. Flange head screw (5 used)

6. Dowel pin (2 used)

Installation (Fig. 17)

NOTE: The hydraulic pump assembly needs to be re-

moved from engine before bell housing and coupling flange can be removed.

1. Ifengineisinmachine,supportenginefrombelowto preventitfrom shifting. Removehydraulicpumpassembly(see Piston (Traction)PumpRemoval in theService and Repairs section of Chapter 4 -- Hydraulic System).

2. As necessary, remove bell housing and coupling flange from engine using Figure 17 as a guide.

1. If coupling flange was removed from engine flywheel, position flange to flywheel and align mounting holes.Secureflange toflywheelwithfive(5) flangehead screws. Tighten screws in a star pattern.

2. Ifbell housing was removedfromengine,make sure that spring pin is secure in upper hole of bell housing. Position bell housing to flywheel plate and secure with five(5)flangeheadscrews. Tightenscrewsinastar pattern.

3. If engine is in machine, install hydraulic pump assembly (see Piston (Traction) Pump Installation in the Service and Repairs section of Chapter 5 -- Hydraulic System).

Greensmaster 3400Page 4 -- 18Diesel Engine

Page 53

Table of Contents

Chapter 5

Hydraulic System

SPECIFICATIONS 3.............................

GENERAL INFORMATION 4.....................

Operator’s Manuals 4.........................

Check Hydraulic Fluid Level 4..................

Pushing Traction Unit 4........................

Relieving Hydraulic System Pressure 5..........

Traction Circuit Component Failure 5............

Hydraulic Hoses 6............................

Hydraulic Hose and Tube Installation (O--Ring

Face Seal Fitting) 7..........................

Hydraulic Fitting Installation (SAE Straight Thread

O--Ring Fitting into Component Port) 8.........

HYDRAULIC SCHEMATIC 10....................

HYDRAULIC FLOW DIAGRAMS 12...............

Traction Circuit 12.............................

Lower Cutting Units 14.........................

Raise Cutting Units 16.........................

Mow and Backlap 18..........................

Right and Left Turn 20.........................

SPECIAL TOOLS 22............................

TROUBLESHOOTING 26........................

General Hydraulic System Problems 26..........

Traction Circuit Problems 27....................

Mow Circuit Problems 28.......................

Lift/Lower Circuit Problems 29..................

Steering Circuit Problems 30...................

TESTING 32...................................

Charge Relief Valve Pressure Test 34............

Piston (Traction) Pump Flow Test 36.............

Wheel Motor Efficiency Test 38.................

Steering/Lift Relief Valve Pressure Test 40........

Lower Cutting Units Relief Valve (RV)

Pressure Test 42............................

Steering/Lift Circuit Gear Pump Flow Test 44.....

Power Steering Valve Test 46...................

Mow Circuit Gear Pump Flow Test 48............

Mow Circuit Relief Pressure Test 50.............

Reel Motor Case Drain Flow Test 52.............

ADJUSTMENTS 54.............................

Adjust Manifold Relief Valves 54................

Adjust Traction Control Assembly 55.............

SERVICE AND REPAIRS 56.....................

General Precautions for Removing and

Installing Hydraulic System Components 56....

Flush Hydraulic System 57.....................

Filtering Closed--Loop Traction Circuit 58.........

Hydraulic System Start--up 59..................

Gear Pump 60................................

Gear Pump Service 62.........................

Piston (Traction) Pump Neutral System 64.......

Piston (Traction) Pump 66......................

Piston (Traction) Pump Service 70..............

Piston Pump Crush Ring Replacement 72

Wheel Motors 74........................

Front

Rear Wheel Motor (Optional 3WD) 76...........

Wheel Motor Service 78.......................

Cutting Reel Motors 80........................

Cutting Reel Motor Service 82..................

Mow Control Manifold 86.......................

Mow Control Manifold Service 88...............

Control Manifold Cartridge Valve Service 91......

Lift Cylinders 92..............................

Lift Cylinder Service 94........................

Lift Control Manifold 96........................

Lift Control Manifold Service 98.................

Power Steering Valve 100......................

Power Steering Valve Service 102...............

Steering Cylinder 104..........................

Steering Cylinder Service 106..................

Hydraulic Reservoir (Machines Equipped with

Turf Guardiant Leak Detector System) 108....

Hydraulic Reservoir (Machines Not Equipped with

Turf Guardiant Leak Detector System) 110....

Leak Detector Tank (Machines Equipped with Turf

Guardiant Leak Detector System) 112........

Leak Detector Solenoid Valve Assembly (Machines

Equipped with Turf Guardiant Leak Detector

System) 116................................

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 3300/3400 Hydraulic SystemPage 5 -- 1

Page 54

This page is intentionally blank.

Greensmaster 3300/3400Hydraulic System Page 5 -- 2

Page 55

Specifications

Item Description

Piston (Traction) Pump Variabledisplacement piston pump (Eaton model 70160)

Maximum Pump Displacement (per revolution) 1.44 in

Gear Pump 2 section, positive displacement gear pump (Casappa)

Front Section Displacement (per revolution) 0.58 in Rear Section Displacement (per revolution) 0.33 in

Charge Circuit Relief Pressure 110to 150 PSI (7.6 to 10.3 bar)

Traction Circuit Relief Pressure

Forward 3000 PSI (207 bar) Reverse 3000PSI (207 bar)

Front Wheel Motors Orbital rotor motor (Parker TF Series)

Displacement (per revolution) 10.3 in

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

Displacement (per revolution) 20.6 in

Mow Circuit Relief Pressure 2700 to 3300 PSI (186 to 227 bar)

Cutting Reel Motor Gear motor (Casappa)

Maximum Pump Displacement (per revolution) 0.73 in

Power Steering Valve Hydrostatic Steering Unit (Sauer--Danfoss Type OSPMS)

Displacement (per revolution) 4.5 in

(23.6 cc)

(9.5 cc)

(5.4 cc)

(169 cc)

(337 cc)

(12 cc)

(74 cc)

Steering/Lift Circuit Relief Pressure 1160PSI (80 bar)

Hydraulic Filter Spin--on cartridge type

Hydraulic Oil See Operator’s Manual

Hydraulic Reservoir Capacity

Machines with Turf Defender Machines without Turf Defender

Leak Detector 6.8 gal. U.S. (25.7 L)

Leak Detector 5.5gal. U.S. (20.8 L)

System

Hydraulic

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 3

Page 56

General Information

Operator’s Manuals

The Traction Unit and Cutting Unit Operator’s Manuals provide information regarding the operation, general maintenanceproceduresandmaintenanceintervalsfor your Greensmaster machine. Refer to these publications for additional information when servicing the machine.

Check Hydraulic Fluid Level

Thehydraulicsystemon yourGreensmastermachineis designed to operate on high quality hydraulic fluid. Check level of hydraulic fluid daily. Refer to Traction Unit Operator’s Manual for fluid level checking procedure and hydraulic oil recommendations.

Pushing Traction Unit

In case of emergency, your Greensmaster can be pushed for a very short distance. However, Toro does not recommend this as a standard procedure.

1. Make sure that engine is not running.

2. Locateby--pass valve on piston(traction)pump(Fig.

2). Rotate by--pass valve so slot is vertical.

IMPORTANT: Do not push the machine faster than 2mph(3.2kph) because the traction system may be damaged.Ifmachinemust be movedaconsiderable distance (more than a few feet), transport it on a truck or trailer.

3. Slowly push machine.

4. Before starting engine, rotate piston (traction) pump by--pass valve so slot is horizontal. Do not start engine when by--pass valve is in the vertical position.

Figure 1

1. Hydraulic reservoir 2. Fuel tank

Figure 2

1. Piston (traction) pump 2. By--pass valve

Greensmaster 3300/3400Hydraulic System Page 5 -- 4

Page 57

Relieving Hydraulic System Pressure

Before disconnecting or performing any work on your Greensmaster hydraulic system, all pressure in the hydraulic system must be relieved.

To relievehydraulic pressure in the traction circuit, park machineona levelsurfacewiththecutting unitslowered and off. Turnignition switch to OFF and allow engine to stop. If machine is parked on an incline or slope, pressure in the traction circuit WILL NOT be relieved.

To relieve hydraulicpressure in liftcircuit, fully lower the cutting units to the ground. Turn ignition switch to OFF and allow engine to stop.Make surethat after lowering, none of the cutting units are not being supported by the lift cylinders.

Traction Circuit Component Failure

The traction circuit on your Greensmaster machine is a closed loop system that includes the piston (traction) pumpand two (2)wheel motors (three(3) wheel motors are included if machine is equipped with optional 3WD kit). If a component in the traction circuit should fail, debris and contamination from the failed component will circulatethroughoutthetractioncircuit.Thiscontamination can damage other components in the circuit so it must be removed to prevent additional component failure.

The recommended method of removing traction circuit contamination would be to temporarily install the Toro high flow hydraulic filter (see Special Tools in thischapter) into the circuit. This filtershould beused when connecting hydraulic test gauges in order to test traction circuitcomponentsorafter replacing afailedtractioncircuit component (e.g. piston (traction) pump or wheel motor). The filter will ensure that contaminates are removedfromtheclosedloopandthus,donotcauseadditional component damage.

To relieve hydraulic pressure in the steeringcircuit,park machineona levelsurfacewiththecutting unitslowered and off. Turn ignition switch to OFF. After engine has come to a complete stop, rotate steering wheel in both directions.

Hydraulic pressure in the mow circuit is relieved when the ignition switch is turned to OFF.

Once the Toro high flow hydraulic filter kit has been placedin the circuit,raise and support themachine with all drive wheels off the ground. Then, operate the tractioncircuit to allow oilflow throughout thecircuit. The filter will remove contamination from the traction circuit duringoperation. Because the Toro high flow filter is bi-directional, the traction circuit can be operated in both the forward and reverse direction. The filter should be removed from the machine after contamination has been removed from the traction circuit. See Filtering Closed--LoopTractionCircuitintheServiceandRepairs section of this chapter for additional information on using the Toro high flow hydraulic filter.

Thealternativetousing the Torohighflowhydraulic filter kit after a traction circuit component failure would be to disassemble, drain and thoroughly clean all components, tubes and hoses in the traction circuit. If any debris remains in the traction circuit and the machine is operated,thedebris cancauseadditionalcircuitcomponent failure.

System

Hydraulic

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 5

Page 58

Hydraulic Hoses

Hydraulichoses are subjecttoextreme conditions such aspressuredifferentialsduring operation and exposure to weather, sun, chemicals, very warm storage conditionsormishandlingduring operation andmaintenance. 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:

WARNING

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

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.Usetwowrenches; hold the hose straightwith 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,tightenthe swivel nut onthatendbefore tightening the nut on the straight end of the hose.

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

Keepbodyandhandsawayfrompinholeleaksor 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.Gangrenemay result from such an injury.

Greensmaster 3300/3400Hydraulic System Page 5 -- 6

Page 59

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

1. Makesurethreads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratchesor any foreign material.

2. Asapreventative measure against leakage, it is recommended that the face seal O--ring be replaced any time the connection is opened. Make sure the O--ringis installedandproperlyseatedinthefittinggroove.Lightly lubricate the O--ring with clean hydraulic oil.

3. Place the hose/tube against the fitting body so that theflatface ofthehose/tubesleevefullycontacts theO-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 usingatorquewrenchwithanoffsetwrenchwillbelower than the listed installation torque (see Using a Torque Wrench with an Offset Wrench in the TorqueSpecificationssection of C hapter 2 --Product Records and Maintenance).

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

Fitting 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

Tube or Hose

O--ring

Fitting Body

Figure 3

5. If a torque wrench is not available or if space at the swivelnutpreventsuseofatorquewrench,analternate 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,tighten the swivel nutontothefittinguntillightwrench resistanceisreached(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 85 to 105 ft--lb (116 to 142 N--m) 16 17/16--12 110 to 136 ft--lb (150 to 184 N--m)

Initial Position

AFTER TIGHTENING

System

Hydraulic

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

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 7

Figure 5

Page 60

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. Asapreventative measure against leakage, 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. 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: Useof an offset wrench (e.g. crowfoot wrench) will affect torque wrench c alibration 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 Using a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 -- Product RecordsandMaintenancetodetermine necessary conversion information.

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

Fitting 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 +

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) 11to15ft--lb(15to20N--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 99 to 121 ft--lb (135 to 164 N--m) 60 to 74 ft--lb (82 to 100 N--m) 12 11/16--12 134 to 164 ft--lb (182 to 222 N--m) 81 to 99 ft--lb (110 to 134 N--m) 14 13/16--12 160 to 196 ft--lb (217 to 265 N--m) 96 to 118 ft--lb (131 to 160 N--m) 16 15/16--12 202 to 248 ft--lb (274 to 336 N--m) 121 to 149 ft--lb (165 to 202 N--m) 20 15/8--12 247 to 303 ft--lb (335 to 410 N--m) 149 to 183 ft--lb (202 to 248 N--m)

Figure 7

Greensmaster 3300/3400Hydraulic System Page 5 -- 8

Page 61

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. Asapreventative measure against leakage, 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. Fittingthreadsshould becleanwithnolubricantapplied.

4. Turnback the lock nut as far as possible. Make sure the back up washer is not loose and is pushed up as far as possible (Step 1 in Figure 9).

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. To put the fittinginthedesiredposition,unscrewitby 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 fittingto the recommended installation torque shown in Figure 7. This tightening process will require the use of an offset wrench (e.g. crowfootwrench). Use of an offsetwrench will affect torque wrench c alibration 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 portpreventsuseof atorquewrench,analternatemethod of assembly is the Flats From Finger Tight (F.F.F.T.) method. Hold the fitting in the desired position with a wrench and, if port material is steel, tighten the lock nut withasecondwrenchtothe listed F.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

Fitting 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 +

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 9

0.25

Page 62

Hydraulic Schematic

PORT BACK

FORWARD

TOP

PORT

3000

GEAR

70 to

PSI

PUMP

PORT FRONT

PSI

100

PSI

110 -- 150

JOINT END

PORT BALL

STEERING CYLINDER

RIGHT FRONT (#3)

(Extend to Lower)

CENTER (#1)

(Extend to Raise)

4.5

OR3

.028

C6C1C4

OR2

.028

1160

POWER

PSI

VALVE

STEERING

OR1

.037

400

PSI

HYDROSTAT

4.0 GPM

10.3

ENGINE

1.9 GPM

1.44

.58

.33

MOTOR

RIGHT

MOTOR

LEFT

20.6

BA B

BOTTOM

PSI

3000

MOW = 6.7 GPM AT3.8 MPH

PORT

BYPASS

OPTIONAL 3WD

VALVE

TRANSPORT = 17.5 GPM AT10 MPH

LEFT FRONT (#2)

RIGHT FRONT

7.0 GPM

PORV

COOLER

OPTIONAL OIL

OR1

OR2

MOW

CONTROL

MANIFOLD

PRV

OUT

SUCTION

STRAINER

BREATHER

LIFT

CONTROL

MANIFOLD

(ExtendtoLower)

REEL (#3)

.73

FRONT

PORT

CENTER REEL

FRONT

PORT

(#1)

.73

FRONT

REEL (#2)

LEFT FRONT

PORT

NOTE: A larger hydraulic schematic is

included in Chapter 9 -- Foldout Drawings

LEAK DETECTOR KIT

LEAK

DETECTOR

VOLUME

TANK

EXPANSION

Greensmaster 3300/3400Hydraulic System Page 5 -- 10

Page 63

This page is intentionally blank.

System

Hydraulic

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 11

Page 64

Hydraulic Flow Diagrams

PORT BACK

FORWARD

TOP

3000

PORT

70 to

PSI

GEAR

PUMP

PORT FRONT

PSI

100

PSI

110 -- 150

JOINT END

PORT BALL

STEERING CYLINDER

RIGHT FRONT (#3)

(Extend to Lower)

CENTER (#1)

(Extend to Raise)

4.5

OR3

.028

C6C1C4

OR2

.028

1160

POWER

PSI

VALVE

STEERING

OR1

.037

400

PSI

HYDROSTAT

4.0 GPM

10.3

ENGINE

1.9 GPM

1.44

.58

.33

MOTOR RIGHT

MOTOR

LEFT

20.6

BA B

PSI

3000

OPTIONAL 3WD

PORT

BOTTOM

VALVE

BYPASS

MOW = 6.7 GPM AT3.8 MPH

TRANSPORT = 17.5 GPM AT10 MPH

All solenoids are shown

as de--energized.

Traction Circuit (Forward Direction Shown)

Greensmaster 3300/3400

LEFT FRONT(#2)

Traction pedal is pressed for

the forward direction.

(Extend to Lower)

REEL (#3)

RIGHT FRONT

High Pressure

Low Pressure (Charge)

Return or Suction

.73

Flow

FRONT

PORT

CENTER REEL

FRONT

PORT

(#1)

.73

LEFT FRONT

REEL (#2)

FRONT

PORT

LIFT

CONTROL

MANIFOLD

M2 M1

7.0 GPM

PORV

COOLER

OPTIONAL OIL

LEAK DETECTOR KIT

OR1

OR2

LEAK

DETECTOR

MOW

CONTROL

MANIFOLD

PRV

OUT

VOLUME

SUCTION

STRAINER

BREATHER

TANK

EXPANSION

Greensmaster 3300/3400Hydraulic System Page 5 -- 12

Page 65

Traction Circuit

The traction circuit piston pump is a variable displacement pump that is directly coupled to the engine. Pushingthetractionpedalcontrolsthevariabledisplacement piston pump swash plate to create a flow of oil. This oil is directed to the wheel motors. Operating pressure on the high pressure side of the closed traction circuit loop is determined by the amount of load developed at the fixed displacement wheel motors. As the load increases,circuitpressurecanincreasetoreliefvalvesettings: 3000 PSI (207 bar) in both forward and reverse. If pressure exceeds the relief setting, oil flows through the relief valve to the low pressure side of the closed loop traction circuit.

The traction circuit pump and wheel motors use a small amount of hydraulic fluid for internal lubrication. Fluid is designed to leak across traction pump and motor components into the case drain. This leakage results in the lossofhydraulic fluidfromtheclosedloop tractioncircuit thatmust be replaced.The charge circuit is designedto replace this traction circuit leakage.

The gear pump section that supplies oil to the steering andliftcircuitsalso provides charge circuit oil.Thisgear pump is driven directly off the piston (traction) pump. It provides a constant supply of charge oil to the traction circuit to make up for oil that is lost due to internal leakage in the traction pump and wheel motors.

Charge pump flow is directed to the low pressure side of the closed loop traction circuit. Charge circuit pressure (110 to 150 PSI / 7.6 to 10.3 bar) is maintained by the charge relief valve that is attached to the piston pump back plate.

The functional control lever on TriFlex Greensmaster machines has positions for neutral, mow and transport. When the functional control lever is in the neutral position,thetraction pedal is secured intheneutralposition. The mow position allows traction pedal inputs that are appropriateformowspeedsby limitingthemovementof the piston pump swash plate. The transport position allows full movement of the traction pedal so complete pump swash rotation is possible.

Forward

The piston (traction) pump is driven directly by the engine. The hydraulic traction circuit acts essentially as a closed loop. Taking its suction directly from the return sideofthewheelmotorsofthetractioncircuit,thepiston pump supplies oil flow to the wheel motors through the supply side of the traction circuit.

Withtheenginerunningandtractionpedalintheneutral 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.

Oilflowingout of the wheelmotorsreturns to the bottom portof the piston pump and is continuously pumpedout the top port.

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 the reverse position, the linkage from the pedal positions the swash plate in the piston pump so oil flows out the bottomportofthepump. Oilflowoutofthebottomportgoes tothewheel motors and turnstheminthe reverse direction.

Oilflowingoutofthewheel motors returns to thetopport of the piston pump and is continuously pumped out the bottom port.

Traction Circuit Cooling

Thepiston pump includesa shuttle valvethat bleeds off asmallamountofhydraulicfluidforcoolingof theclosed looptraction circuit. Thisvalve allows asmall amount of 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(70to 100 PSI / 4.9to6.8 bar). The chargecircuit replenishesoilthatisbledfromthetractioncircuitbythe shuttle valve.

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

System

Hydraulic

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 13

Page 66

PORT BACK

FORWARD

TOP

PORT

3000

GEAR

70 to

PSI

PUMP

PORT FRONT

PSI

100

PSI

110 -- 150

JOINT END

PORT BALL

STEERING CYLINDER

RIGHT FRONT (#3)

(Extend to Lower)

CENTER (#1)

(Extend to Raise)

4.5

OR3

.028

C6C1C4

OR2

.028

1160

POWER

PSI

VALVE

STEERING

OR1

.037

400

PSI

HYDROSTAT

4.0 GPM

10.3

ENGINE

1.9 GPM

1.44

.58

.33

MOTOR

RIGHT

MOTOR

LEFT

20.6

BA B

BOTTOM

PSI

3000

MOW = 6.7 GPM AT3.8 MPH

PORT

BYPASS

OPTIONAL 3WD

VALVE

TRANSPORT = 17.5 GPM AT10 MPH

(Extend to Lower)

LEFT FRONT (#2)

Solenoids S1, S2, S3 and S4 in

lift control manifold are shown in

Lower Cutting Units

Greensmaster 3300/3400

High Pressure

energized position.

.73

REEL (#3)

RIGHT FRONT

Low Pressure (Charge)

Return or Suction

Flow

FRONT

PORT

CENTER REEL

FRONT

PORT

(#1)

.73

LEFT FRONT

REEL (#2)

FRONT

PORT

LIFT

CONTROL

MANIFOLD

M2 M1

7.0 GPM

PORV

COOLER

OPTIONAL OIL

LEAK DETECTOR KIT

OR1

OR2

LEAK

DETECTOR

MOW

CONTROL

MANIFOLD

PRV

OUT

VOLUME

SUCTION

STRAINER

BREATHER

TANK

EXPANSION

Greensmaster 3300/3400Hydraulic System Page 5 -- 14

Page 67

Lower Cutting Units

The tandem 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 raisingandloweringthecuttingunits and for the traction chargecircuit. The gearpump takes its suctionfrom the hydraulic reservoir. Maximum circuit pressure of 1160 PSI (80 bar) is limited by the relief valve located in the power steering valve.

The lift controlmanifold includes four (4) electrically operatedsolenoidvalves.SolenoidvalveS1causescircuit flow to by--pass the lift cylinders when de--energized anddirects flow tothe cylinders whenenergized. Directionalsolenoid valve S2 is used to directoil flow to raise the cutting units when de--energized and lower them whenenergized.Whenenergized,solenoid valve S3 allows hydraulic flow to and from the front cutting unit lift cylinders (#2 and #3) and prevents oil passage to and from the lift cylinders when de--energized. When energized, solenoid valve S4 allows hydraulic flow to and fromthecentercutting unit liftcylinder(#1)andprevents oil passage to and from the lift cylinder when de--energized.

The console arm joystick is used to raise and lower the cutting units. The joystick acts as an input to the TEC controller to send electrical outputs to appropriate lift control manifold solenoid coils in order to raise or lower the cutting units.

While operating the machine during conditions of not raising or lowering the cutting units (joystick in the neutral (center) position), all of the lift manifold solenoid valves(S1,S2, S3andS4)arede--energized.Flowfrom therear gear pump section isdirected through thepowersteeringvalve,de--energizedsolenoidvalveS1inthe lift control manifold, oil filter and to the traction charge circuit. Flow in excess of charge circuit needs then returns to the gear pump input.

Lower Cutting Units

When the joystick is moved to the lower position, the Toro Electronic Controller (TEC) energizes all of the lift controlmanifoldsolenoidvalvesforapproximatelythree (3) seconds. This time frame ensures that the cutting unitswillbefully loweredtoallowthemtofloat duringoperation.Thecontroller also provides ashortdelay in energizing solenoid valve S4 which delays the lowering of the center cutting unit (#1).

Energizedliftmanifold solenoidsS1andS2directcircuit flow toward the lift cylinders in the correct direction to lower the cutting units. The front lift cylinders extend to lower the cutting units while the center lift cylinder retracts to lower the cutting unit. Hydraulic pressure againstthe lift cylinder pistons moves their shafts causingthecutting unitstolower.Atthesametime,theliftcylinderpistonspushthehydraulicfluidoutofthecylinders toenergized solenoid valvesS3 (front liftcylinders) and S4 (center lift cylinder). Return flow continues through energized solenoid valve S2, to the oil filter and then to the traction charge circuit.

Lowering speed for each of the front cutting units (#2 and #3) is controlled by a 0.028 orifice (OR2 and OR3) intheliftcontrolmanifold. A 0.037 orifice (OR1) controls lowering speed for the center cutting unit (#1).

If the lift cylinders should reach the end of their stroke whiletheliftmanifoldsolenoidsarestillenergized,liftcircuit pressure will increase. The lift circuit lower relief valve (RV) in the lift control manifold allows lift circuit pressureto be limitedto 400 PSI(27.6 bar) whilelowering the cutting units.

NOTE: Adjustment of the lift control manifold lift circuit lower relief valve (RV) is not recommended.

When the lift control manifold solenoid valves are de-energized by the TEC controller, spring action returns the valves to their original position stopping lift cylinder movement. The lift cylinder position is locked in place sincethere is no complete circuit of flow to and from the lift cylinders. Hydraulic flow by--passes the lift cylinders and is routed to the oil filter and charge circuit.

System

Hydraulic

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 15

Page 68

PORT BACK

FORWARD

TOP

PORT

3000

GEAR

70 to

PSI

PUMP

PORT FRONT

PSI

100

PSI

110 -- 150

JOINT END

PORT BALL

STEERING CYLINDER

RIGHT FRONT (#3)

(Extend to Lower)

CENTER (#1)

(Extend to Raise)

4.5

OR3

.028

C6C1C4

OR2

.028

1160

POWER

PSI

VALVE

STEERING

OR1

.037

400

PSI

HYDROSTAT

4.0 GPM

10.3

ENGINE

1.9 GPM

1.44

.58

.33

MOTOR

RIGHT

MOTOR

LEFT

20.6

B BA

BOTTOM

PSI

3000

MOW = 6.7 GPM AT3.8 MPH

PORT

BYPASS

OPTIONAL 3WD

VALVE

TRANSPORT = 17.5 GPM AT10 MPH

(Extend to Lower)

LEFT FRONT (#2)

Solenoids S1, S3 and S4 in lift

control manifold are shown in

Raise Cutting Units

Greensmaster 3300/3400

High Pressure

energized position.

.73

REEL (#3)

RIGHT FRONT

Low Pressure (Charge)

Return or Suction

Flow

FRONT

PORT

CENTER REEL

FRONT

PORT

(#1)

.73

FRONT

REEL (#2)

LEFT FRONT

7.0 GPM

PORV

COOLER

OPTIONAL OIL

LEAK DETECTOR KIT

OR1

OR2

LEAK

DETECTOR

MOW

CONTROL

MANIFOLD

PRV

OUT

VOLUME

SUCTION

STRAINER

BREATHER

TANK

EXPANSION

LIFT

CONTROL

MANIFOLD

PORT

Greensmaster 3300/3400Hydraulic System Page 5 -- 16

Page 69

Raise Cutting Units

Whenthejoystickismovedtotheraiseposition,theToro Electronic Controller (TEC) energizes lift control manifold solenoid valves S1, S3 and S4 for approximately three(3) seconds. Thistime frame ensures thatthe cutting units will be fully raised. The controller provides a shortdelayinenergizingsolenoidvalveS4whichdelays the raising of the center cutting unit (#1).

Energized lift manifold solenoids S1, S3 (front lift cylinders) and S4 (center lift cylinder) direct circuit flow towardthe lift cylindersin the correct direction to raise the cutting units. The front lift cylinders retract to raise the cuttingunitswhilethe center liftcylinderextendstoraise the cutting unit.Hydraulic pressure against the lift cylinder pistons moves their shafts causing the cutting units to raise. At the same time, the lift cylinder pistons push the hydraulic fluid out of the cylinders to de--energized solenoid valve S2. Return flow continues to the oil filter and then to the traction charge circuit.

A0.037orifice(OR1) controls raising speed forthecentercuttingunit(#1). Flowtothefrontliftcylinders(cutting units#2and#3)bypassestheliftmanifold orifices (OR2 and OR3) when the front cutting units are being raised.

System

Hydraulic

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 17

Page 70

PORT BACK

FORWARD

TOP

3000

PORT

70 to

PSI

GEAR

PUMP

PORT FRONT

PSI

100

PSI

110 -- 150

JOINT END

PORT BALL

STEERING CYLINDER

RIGHT FRONT (#3)

(Extend to Lower)

CENTER (#1)

(Extend to Raise)

4.5

OR3

.028

C6C1C4

OR2

.028

1160

POWER

PSI

VALVE

STEERING

OR1

.037

400

PSI

HYDROSTAT

4.0 GPM

10.3

ENGINE

1.9 GPM

1.44

.58

.33

MOTOR

RIGHT

MOTOR

LEFT

20.6

BA B

BOTTOM

PSI

3000

MOW = 6.7 GPM AT3.8 MPH

PORT

BYPASS

OPTIONAL 3WD

VALVE

TRANSPORT = 17.5 GPM AT10 MPH

LEFT FRONT (#2)

(Extend to Lower)

REEL (#3)

RIGHT FRONT

.73

FRONT

PORT

CENTER REEL

FRONT

PORT

(#1)

.73

LEFT FRONT

REEL (#2)

FRONT

PORT

LIFT

CONTROL

MANIFOLD

M2 M1

7.0 GPM

PORV

COOLER

OPTIONAL OIL

OR1

OR2

MOW

CONTROL

MANIFOLD

PRV

OUT

SUCTION

STRAINER

BREATHER

High Pressure

Low Pressure (Charge)

Return or Suction

Flow

Pressure Reducing Valve (PRV)

in mow control manifold is shown

Mow

Greensmaster 3300/3400

in energized position.

LEAK DETECTOR KIT

LEAK

DETECTOR

VOLUME

TANK

EXPANSION

Greensmaster 3300/3400Hydraulic System Page 5 -- 18

Page 71

Mow and Backlap

The tandem gear pump is directly coupled to the piston (traction) pump. The front gear pump section supplies hydraulic flow for the mow circuit. The gear pump takes its suction from the hydraulic reservoir and supplies oil flow to the mow control manifold and to the cutting reel motors. Maximum circuit pressure is limited by the proportional relief valve (PRV) located in the mow control manifold.

With the functional control lever and joystick not in the mowposition,proportionalreliefvalve (PRV)inthemow control manifold is de--energized. The de--energized PRVroutesgearpump flow directly tothehydraulicreservoir by--passing the cutting reel motors. Additionally, manifold pressure reducing valve (PORV) will remain seatedto prevent thereel motors (and reels)from rotating.

Mow

With the engine running, the functional control lever in MOWandthejoystickmovedtothe reels lower position, proportional relief valve (PRV) is energized by the TEC controller.In the energized position, this valve directs oil flow toward the reel motors and also functions as the mow circuit relief valve.

Oilflow from manifold portP flows through theflow control valve (FC) used to adjust reel speed. Flow across the flow control valve is pressure compensated by the logic cartridge 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 the speed control valve setting is by--passed to the reservoirthroughthe logiccartridgevalve.Withthebacklap valve(MV)inthemow position, oil flows through the backlapvalve,outmanifold port(M1)andtothereelmotors that are connected in series. Oil flows through the left (#2), right (#3) and then center reel motor (#1) as it turns the motors in the mow direction.

When in the mow position, mow circuit pressure will cause the mow control manifold pilot piston to shift and open the pressure reducing valve (PORV). The shifted pressurereducing valve allows circuitoil to returntothe reservoir through the manifold block.

Backlap

Backlapping operation is the same as mowing operation, except forthe position of the backlap valve (MV) in themowcontrolmanifold.Whenthebacklapvalve(MV) is in the backlap position, oil flows through the center (#1),right(#3)andthen left (#2) reelmotorasitturnsthe motors in the backlap direction.

System

Hydraulic

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 19

Page 72

STEERING CYLINDER

PORT BACK

FORWARD

TOP

3000

PORT

70 to

PSI

GEAR

100

PUMP

PORT FRONT

PSI

110 -- 150

JOINT END

PORT BALL

RIGHT FRONT (#3)

(Extend to Lower)

CENTER (#1)

(Extend to Raise)

4.5

OR3

.028

C6C1C4

OR2

.028

1160

POWER

PSI

VALVE

STEERING

OR1

.037

400

PSI

HYDROSTAT

4.0 GPM

10.3

ENGINE

1.9 GPM

1.44

.58

.33

MOTOR

RIGHT

MOTOR

LEFT

20.6

BA B

BOTTOM

PSI

3000

MOW = 6.7 GPM AT3.8 MPH

PORT

BYPASS

OPTIONAL 3WD

VALVE

TRANSPORT = 17.5 GPM AT10 MPH

LEFT FRONT (#2)

(Extend to Lower)

REEL (#3)

RIGHT FRONT

.73

FRONT

PORT

CENTER REEL

FRONT

PORT

(#1)

.73

FRONT

REEL (#2)

LEFT FRONT

7.0 GPM

PORV

COOLER

OPTIONAL OIL

OR1

OR2

MOW

CONTROL

MANIFOLD

PRV

OUT

SUCTION

STRAINER

BREATHER

LIFT

CONTROL

MANIFOLD

PORT

High Pressure

Low Pressure (Charge)

Return or Suction

Flow

All solenoids are shown

as de--energized.

Power steering valve is

Right Turn

Greensmaster 3300/3400

positioned for a right turn.

LEAK DETECTOR KIT

LEAK

DETECTOR

VOLUME

TANK

EXPANSION

Greensmaster 3300/3400Hydraulic System Page 5 -- 20

Page 73

Right and Left Turn

With the steering wheel in the neutral position (not turned) and the engine running, the power steering valvespoolisin the center position. Gear pumpflowenters the power steering valve at port (P) and goes through the spool valve, by--passing the steering cylinder. Flow leaves the steering valve from port (E) to be availablefortheraise/lowerandtractioncharge circuits.

Right Turn

When a right turn is made with the engine running, the turning of the steering wheel positions the power steeringvalvespool so that gear pumpflowgoes through the top of thespool. Flow entering the power 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-passedoutport(E)andbecomesavailablefortheraise/ lower and traction charge circuits. Second, the remainder of the flow is drawn through the steering valverotarymeter and out steeringvalveport (R). Pressure retracts the steering cylinder for a right turn. The

rotary meter ensures that the oil flow to the cylinder is proportionalto the amount ofthe turning on the steering wheel.Fluid leaving the cylinder flows back throughthe spool valve, out steering valve port (T) and then to the traction charge circuit.

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

Left Turn

When a left turn is made with the engine running, the turning of the steering wheel positions the power steeringvalvespool so that gear pumpflowgoes through the bottom of the spool. Flow entering the power steering valveat port (P) goes through the spooland is routed to two places. First, most of the flow through the valve is by--passed out port (E) and becomes available for the raise/lowerand traction chargecircuits. Second, the remainder of the flow is drawn through the steering valve rotary meter and out steering valve port (L). Pressure extends the steering cylinder for a left turn. The rotary meter ensures that the oil flow to the cylinder is proportionaltotheamountoftheturningonthesteeringwheel. Fluid leaving the cylinder flows back through the spool valve,outsteering valve port (T) andthento the traction charge circuit.

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

NO CYLINDER

MOVEMENT

POWER

STEERING

VALVE

TO CHARGE

CIRCUIT

FROM GEAR

PUMP

NEUTRAL POSITION

STEERING CYLINDER

PORT BALL JOINT END

4.5

1160

PSI

TO LIFT CONTROL

VALVE

POWER

STEERING

VALVE

TO CHARGE

CIRCUIT

FROM GEAR

PUMP

RIGHT TURN

STEERING CYLINDER

4.5

1160

PSI

TO LIFT CONTROL

VALVE

Figure 10

PORT BALL JOINT END

POWER

STEERING

VALVE

TO CHARGE

CIRCUIT

FROM GEAR

STEERING CYLINDER

PUMP

LEFT TURN

4.5

1160

PSI

TO LIFT CONTROL

VALVE

PORT BALL JOINT END

System

Hydraulic

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 21

Page 74

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)

Figure 11

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

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 in the operating circuit with a gauge rated at 15 GPM.

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

Toro Part Number: TOR214678

Figure 12

Greensmaster 3300/3400Hydraulic System Page 5 -- 22

Page 75

40 GPM Hydraulic Tester (Pressure and Flow)

Use to test hydraulic circuits and components for flow andpressurecapacitiesas recommendedintheTesting sectionofthischapter.Thistesterincludesthefollowing:

1. LOAD VALVE: A simulated working load is created in the circuit by turning the valve to restrict flow.

2. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure.

3. FLOW METER: This meter measures actual oil flow in the operating circuit with a gauge rated from 4 to 40 GPM (20 to 150 LPM).

Toro Part Number: AT40002 NOTE: This tester does not include hydraulic hoses

(see Hydraulic Hose Kit TOR6007 below).

Hydraulic Hose Kit

This kit includes hydraulic fittings and hoses needed to connect40GPMhydraulictester (AT40002)or high flow hydraulic filter kit (TOR6011)tomachine hydraulic traction system components.

Toro Part Number: TOR6007

O --ring Kit

Figure 13

Figure 14

System

Hydraulic

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

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 23

Figure 15

Page 76

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--directionalfiltration whichprevents filtered debris from being allowedbackintothecircuitregardless of flow direction.

If a component failure occurs in the closed loop traction circuit, contamination from the failed part will remain in the circuit until removed. When connecting hydraulic test gauges in order to test traction circuit components orafterreplacingafailedtractioncircuitcomponent(e.g. piston(traction)pump or wheel motor), thehighflowhydraulic filter can be installed in the traction circuit. The filterwillensure thatcontaminatesareremovedfromthe 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: Replacementfilterelement is Toro partnumber

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

Figure 16

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

TORO TEST FITTING KIT (NO. TOR4079)

Figure 17

Greensmaster 3300/3400Hydraulic System Page 5 -- 24

Page 77

Measuring Container

Use this container for doing hydraulic motor efficiency testing(motorswithcasedrainlinesonly).Measureefficiency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drainlinewhilethemotorispressurizedbythehydraulic system.

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 18

Figure 19

System

Hydraulic

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 25

Page 78

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

Hydraulic fluid foams. Oil level in reservoir is low.

Hydraulic system has wrong type of oil. The pump suction line has an air leak.

Hydraulic system operates hot. Oil level in reservoir is low or inlet filter is loose or clogged.

Oil is contaminated or too light. Parking brake is applied or incorrectly adjusted. Piston pump by--pass valve is open or defective. Working load of machine may require use of oil cooler. Oil cooler (if installed) is damaged or plugged. Oil cooler (if installed) by--pass relief is stuck open or air flow is ob-

structed. Charge pressure is low. Wheel motor(s) or reel motor(s) are worn or damaged. Piston pump is worn or damaged (see Piston (Traction) Pump Flow

Test in the Testing section of this chapter).

Greensmaster 3300/3400Hydraulic System Page 5 -- 26

Page 79

Traction Circuit Problems

Problem Possible Cause

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

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).

Traction response is sluggish. Hydraulic oil is very cold.

Parking brake is applied or incorrectly adjusted. Piston pump by--pass valve is open or defective. Charge pressure is low (see Charge Relief Valve Pressure Test in

the Testing section of this chapter). Relief valve(s) in piston (traction) pump are leaking or damaged. Wheel motor(s) is 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).

No traction exists in either direction. Parking brake is applied or incorrectly adjusted.

Oil level in reservoir is low (other hydraulic systems also affected). Piston pump by--pass valve is open. Charge pressure is low. Relief valve(s) in piston (traction) pump are leaking or damaged. Wheel motor(s) are worn or damaged (see Wheel Motor Efficiency

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

Test in the Testing section of this chapter).

Wheel motor will not turn. Brakes are binding.

Key on wheel motor shaft is sheared or missing. Wheel motor is damaged.

Wheel motor will not hold load in

Make up fluid from charge pump is not available.

neutral.

Piston pump relief valves are faulty.

NOTE: The piston pump used on Greensmaster TriFlexmachinesisequippedwithreliefvalves for both the forward and reverse direction. Due to engine output, it is unlikely that traction pressure will reach relief valve settings. If, however, a piston pump relief valve is leaking or otherwise faulty, traction performance would be affected.

System

Hydraulic

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 27

Page 80

Mow Circuit Problems

Problem Possible Cause

Gear pump is noisy (cavitation). Reservoir oil level is low.

Gear pump suction line is restricted. Gear pump suction line has an air leak.

Reels will not turn. Proportional relief valve (PRV) in mow control manifold is stuck

open (not shifting to its energized position). An electrical problem exists that prevents correct operation of pro-

portional relief valve (PRV) in mow control manifold (see Chapter 5

-- Electrical System).

Pressure reducing valve (PORV) in mow control manifold is not shifting.

Logic cartridge valve (LC) in mow control manifold is stuck open. Front gear pump section for mow circuit is damaged (see Mow Cir-

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

Reel speed is erratic. A cutting unit problem exists (see Cutting Unit chapter).

Mow control manifold cartridge valve is leaking or damaged. Mow control manifold orifice is plugged.

Reel speed is low. Engine speed is too low.

Reel speed on mow control manifold not adjusted correctly. A cutting unit problem exists (see Cutting Unit chapter). Mow control manifold cartridge valve is leaking or damaged. Excessive internal wear in reel motor exists (see Reel Motor Case

Drain Flow Test in the Testingsection of this chapter).

Greensmaster 3300/3400Hydraulic System Page 5 -- 28

Page 81

Lift/Lower Circuit Problems

Problem Possible Cause

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

Reservoir oil level is low. Lift cylinder linkage is binding or broken. Lift cylinder bushings are binding. Relief valve in power steering valve is leaking or damaged (see

Steering/Lift Relief Valve Pressure Test in the Testing section of this chapter).

Solenoid valve (S1) in lift control manifold is leaking or damaged (not shifting to its energized position).

Lift cylinders leak internally. Spool in power steering valve is hung up (see Power Steering

Valve Test in the Testing section of this chapter). Rear gear pump section is worn or damaged (steering and charge

circuits affected as well) (see Steering/Lift Circuit Gear Pump Flow Test in the Testing section of this chapter).

Front cutting units (#2 and #3) raise, but will not stay up. (NOTE: Lift cylinders and control manifold check valves cannot provide an absolutely perfect seal. The cutting units will eventually lower if left in the raised position)

Center cutting unit (#1) raises, but will not stay up. (NOTE: Lift cylinders and control manifold valves cannot provide an absolutely perfect seal. The cutting units will eventually lower if left in the raised position)

Solenoid valve (S3) in lift control manifold is leaking or damaged. Front lift cylinders leak internally.

Solenoid valve (S4) in lift control manifold is leaking or damaged. Center lift cylinder leaks internally.

System

Hydraulic

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 29

Page 82

Steering Circuit Problems

Problem Possible Cause

Steering wheel is hard to turn. Power steering valve has insufficient oil flow (see Steering/Lift Cir-

cuit Gear Pump Flow Test in the Testing section of this chapter). Emergency steering ball in power steering valve is missing or dam-

aged.

Regular adjustments to steering

Leaf springs in power steering valve are worn or broken. wheel are necessary because of difficulty to drive in a straight line.

Gear wheel set in power steering valve is worn.

Steering cylinder is seized or its piston seals are worn (see Power

Steering Valve Test in the Testing section of this chapter). Steering wheel will not return to the

neutral position.

Spool and sleeve are sticking to power steering housing assembly

(see Power Steering Valve Test in the Testing section of this chap-

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

Spool and sleeve are sticking to power steering housing assembly

(see Power Steering Valve Test in the Testing section of this chap-

ter). Backlash results when turning steer-

Cardan shaft fork in power steering valve is worn or broken. ing wheel.

Leaf springs in power steering valve are worn or broken.

Splines on the steering column are worn. Rear wheel shimmies when the

Air is in the steering cylinder. steering wheel is turned.

Mechanical connections to the wheel or wheel bearing are worn. The steering wheel can be turned

without the rear wheel turning.

Steering response is too slow and heavy when trying to turn quickly.

Turning steering wheel turns machine in the opposite direction.

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

The steering cylinder is worn.

The gear set in the power steering valve is worn.

The rear gear pump section is worn or damaged (steering and

charge circuits affected as well) (see Steering/Lift Circuit Gear

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

Hoses to the steering cylinder are reversed.

Hoses to the power steering valve are not connected to correct

ports.

Relief valve in power steering valve is leaking or damaged (see

Steering/Lift Relief Valve Pressure Test in the Testing section of this

chapter).

Rear gear pump section is worn or damaged (steering and charge

circuits affected as well) (see Steering/Lift Circuit Gear Pump Flow

Test in the Testing section of this chapter).

Greensmaster 3300/3400Hydraulic System Page 5 -- 30

Page 83

This page is intentionally blank.

System

Hydraulic

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 31

Page 84

Testing

The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment suchas pressure gauges andflow meters inthe circuits during various operational checks (see the Special Tools section in this Chapter).

IMPORTANT: All obvious areas such as oil supply, filter, binding linkages, loose fasteners, improper adjustments, solenoid valve operation or electrical connectionsmustbe checkedbeforeassumingthat ahydrauliccomponentis the sourceoftheproblem.

WARNING

Beforedisconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved and all rotating machine parts must be stopped. See Relieving Hydraulic System Pressure in the General Information section.

CAUTION

Failure to use gauges with recommended pressure (PSI) rating as listed in test procedures couldresultindamage to thegaugeandpossible personal injury from leaking hot oil.

Precautions for Hydraulic Testing

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

2. To prevent hydraulic systemcontamination,putmetal caps or plugs on any hydraulic lines left open or exposed during testing or removal of components.

3. Theenginemust be in good operating condition.Enginespeed will affecttestaccuracy.Check pumpspeed with a phototac when performing hydraulic tests.

4. When using tester with pressure and flow capabilities,theinletandtheoutlet hoses must be properlyconnected and not reversed to prevent damage to the hydraulic tester or other 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 partsfromcontactinganddamagingthehosesortester.

CAUTION

All testing should be performed by two (2) people.Onepersonshouldbe in the seattooperate the machine and the other should monitor testing equipment and record test results.

WARNING

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 fluidisinjectedinto theskin,itmustbesurgicallyremoved within a few hoursby a doctor familiar with this type of injury.Gangrene may result from such an injury.

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 thehydraulic oil at normal operating temperature.

11.Record the results of all performed hydraulic tests.

Which Hydraulic Tests Are Necessary?

Before beginning any hydraulic test, identify if the problemisrelatedtothetraction circuit, mowcircuit,lift/lower circuit or steering circuit. Once the faulty system has been identified, perform tests that relate to that circuit.

1. Use the Hydraulic Schematic, Hydraulic Flow Diagrams and the Troubleshooting section found in this Chapterto assist in hydraulicproblemidentification and solution.

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

Greensmaster 3300/3400Hydraulic System Page 5 -- 32

Page 85

3. For traction related problems (e.g. machine will not goupanincline),considerperformingone ormoreofthe following tests:

A. Charge Relief Valve Pressure. B. Piston (Traction) Pump Flow. C. Wheel Motor Efficiency.

4. For problems with the steering and lift/lower circuit, consider performing one or more of the following tests:

A. Steering/Lift Relief Valve Pressure. B. Lower Cutting Units Relief Valve (RV) Pressure. C. Steering/Lift Circuit Gear Pump Flow.

5. For issues withthe mow circuit,consider performing one or more of the following tests:

A. Mow Circuit Gear Pump Flow. B. Mow Circuit Relief Valve Pressure. C. Reel Motor Case Drain Flow.

D. Power Steering Valve.

System

Hydraulic

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 33

Page 86

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

TO POWER STEERING VALVE

.33

FROM

HYDRAULIC

RESERVOIR

TO MOW CONTROL VALVE

GEAR PUMP

.58

FROM POWER STEERINGAND LIFT CONTROL VALVES

PRESSURE

3000

110 -- 150

PSI

1.44

MOW = 6.7 GPM AT3.8 MPH

TRANSPORT = 17.5 GPM AT10 MPH

PSI

3000

PSI

GAUGE

1.9 GPM

HYDROSTAT

BYPASS

VALVE

70 to 100 PSI

BOTTOM

PORT

TOP

PORT

ENGINE

20.6

OPTIONAL 3WD

FRONT

PORT

10.3

LEFT

MOTOR

BACK

PORT

RIGHT

MOTOR

Thetractioncharge circuit is designedtoreplace loss of hydraulic fluid from the closed loop traction circuit. The charge relief valve pressure test will identify if charge pressure is correct.

Procedure for Charge Relief Valve Pressure

Test:

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

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

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Thoroughly clean junction of hydraulic hose and hydraulictubethat runsunderpiston(traction)pump (Figs. 20or 21). Disconnect hydraulic hosefrom the hydraulic tube.

4. Install a tee fitting between the disconnected hose and tube. Install a 1000 PSI (70 bar) pressure gauge to the tee fitting.

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

6. Startengine and runatlow idle speed.Checkfor hydraulic leakage at pressure gauge and correct before proceeding with test.

7. Movethrottlesoengineisrunningathighidlespeed.

8. Pressure gauge should read approximately 110 to 150 PSI (7.6 to 10.3 bar).

9. Shut off engine. Record test results.

Greensmaster 3300/3400Hydraulic System Page 5 -- 34

Page 87

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

11.Adynamicchargepressuretestcanbeperformedas follows:

A. Positionmachinesothataloadcanbeplacedon thetractionsystem.Forexample,chainthemachine to an immovable object or chock all drive wheels to prevent the machine from moving.

B. Withpressuregaugestillconnected,sitintheoperatorseat,start the engine andmovethrottleso engine is running at high idle speed. Move functional control lever to the transport position.

C. While monitoring the pressure gauge, push the tractionpedalintheappropriatedirection(forwardor reverse) to allow traction system load.

D. The charge pressure should drop no more than 20% from no--load charge pressure measured in step8 above (e.g.if charge pressure in step 8is 125 PSI (8.6 bar), charge pressure in forward or reverse under load should be more than 100 PSI (6.9 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 shouldbe suspected of wear andinefficiency.When the pump and/or traction motor(s) are worn or damaged,thechargepumpis not able to keep upwithinternalleakageintractioncircuitcomponents.Further testing of the traction circuit should be completed (see Piston (Traction)Pump Flow and Wheel Motor Efficiency Tests in this section).

GREENSMASTER 3300 SHOWN

Figure 20

1. Piston (traction) pump 2. Hydraulic tube

GREENSMASTER 3300 SHOWN

Figure 21

1. Hydraulic tube location 2. Hose and tube junction

System

Hydraulic

12.When charge pressure testing is complete, disconnect pressure gauge and tee fitting from the hydraulic hose and hydraulic tube. Connect hose to tube.

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 35

Page 88

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

TO POWER STEERING VALVE

.33

FROM HYDRAULIC RESERVOIR

TO MOW CONTROL VALVE

GEAR PUMP

.58

FROM POWER STEERINGAND LIFT CONTROL VALVES

3000

PSI

110 -- 150

PSI

1.44

3000

PSI

MOW = 6.7 GPM AT3.8 MPH

TRANSPORT = 17.5 GPM AT10 MPH

1.9 GPM

HYDROSTAT

BYPASS

VALVE

70 to 100

PSI

BOTTOM

PORT

TESTER

TOP

PORT

ENGINE

20.6

OPTIONAL 3WD

FRONT

PORT

10.3

LEFT

MOTOR

BACK

PORT

RIGHT

MOTOR

PUMP FROM GREENSMASTER 3300 PUMP FROM GREENSMASTER 3400

PISTON

PUMP

UPPER

FITTING

FRONTFRONT

PISTON

PUMP

Greensmaster 3300/3400Hydraulic System Page 5 -- 36

Page 89

This test measures piston pump output (flow). During thistest,pumploadiscreatedatthe flowmeter using the adjustable load valve on the tester.

7. After installing tester,start engineand run atlow idle speed. Check for hydraulic leakage and correct before proceeding with test.

Procedure for Piston (Traction) Pump Flow

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

2. Parkmachineonalevel surfacewiththecuttingunits lowered and off.Make sure engineis off.Make sure the hydraulic tank is full.

Test:

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Make sure the traction pedal is adjusted to the neutral position. Also, make sure that transport s peed is properly adjusted.

4. Blockupfront wheels offthe ground (also rear wheel if machine is equipped with 3WD) to allow flow through the traction circuit.

5. Thoroughly clean junctionof hydraulic hoseand up- perhydraulicfittingonfrontsideofpistonpump(forward port). Disconnect hose from upper pump fitting.

8. Move functional lever to the transport position.

CAUTION

Wheelsoffthegroundwillberotating during this test. Make sure machine is properly supported soitwillnotmove and accidentally fall toprevent injuring anyone near the machine.

9. Movethrottlesoengineisrunningathighidlespeed.

10.Slowly push traction pedal to fully forward position. Keep pedal fully depressed in the forward position.

11.Havesecondpersoncarefullywatchpressuregauge ontester while slowly closing theflow control valveuntil 1000PSI(69bar) isobtained.Verifywithaphototacthat the engine speed has not changed.

NOTE: Ifenginespeeddrops,pistonpumpflow will decrease.

12.Observe flow gauge.Ifpistonpump is in good condition, flow indication should be approximately 17.1 GPM (64.7 LPM).

13.Release traction pedal, open control valve on tester and turn off engine. Record test results.

IMPORTANT: Traction circuit flow for Greensmaster TriFlex machines is approximately 17 GPM (65 LPM).Use40GPM Hydraulic Tester#AT40002(pressure and flow) for this test (see Special Toolsinthis chapter).

6. Install 40 GPM Hydraulic Tester #AT40002 (pressureand flow) in seriesbetween piston pump fittingand disconnected hose to allow flow from piston pump to tester.Use hydraulic hose kit (see Special Tools in this chapter)toconnecttestertomachine.Makesurethatfittingand hose connections are properly tightened. Also, make sure the flow control valve on tester is fully open.

14.If flow is less than 15.3 GPM (57.9 LPM), consider the following:

A. The traction pedal and/or traction speed may need adjustment.

B. The piston pump needs to be repaired or replaced as necessary.

C. Make necessary repairs before performing additional hydraulic traction circuit tests.

15.When piston pump flow testing is complete, disconnecttesterfrompumpfittingandhose.Connecthydraulic hose to pump fitting.

System

Hydraulic

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 37

Page 90

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

TO POWER STEERING VALVE

.33

FROM HYDRAULIC RESERVOIR

TO MOW CONTROL VALVE

GEAR PUMP

.58

FROM POWER STEERINGAND LIFT CONTROL VALVES

3000

110 -- 150

PSI

1.44

MOW = 6.7 GPM AT3.8 MPH

TRANSPORT = 17.5 GPM AT10 MPH

PSI

3000

PSI

1.9 GPM

WHEEL MOTOR EFFICIENCY TEST FOR

RIGHT FRONT WHEEL MOTOR SHOWN

HYDROSTAT

BYPASS

VALVE

70 to 100

PSI

BOTTOM

PORT

TOP

PORT

ENGINE

TESTER

CAP

20.6

OPTIONAL 3WD

FRONT

PORT

10.3

LEFT

MOTOR

BACK

PORT

RIGHT

MOTOR

PUMP FROM GREENSMASTER 3300

PISTON

PUMP

UPPER

FITTING

NOTE: Over a period of time, a wheel motor can wear internally.Aworn motormayby--passoiltoitscasedrain causing the motor to be less efficient. Eventually, enoughoil loss willcause the wheelmotor to stallunder heavyloadconditions. Continuedoperationwithaworn, inefficient motor can generate excessive heat, cause damageto seals and othercomponents in the hydraulic system and affect overall machine performance.

PUMP FROM GREENSMASTER 3400

UPPER

FITTING

FRONTFRONT

PISTON

PUMP

Procedure for Wheel Motor Efficiency

Test:

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

2. Parkmachineonalevel surfacewiththecuttingunits lowered and off.Make sure engineis off.Make sure the hydraulic tank is full.

Greensmaster 3300/3400Hydraulic System Page 5 -- 38

Page 91

CAUTION

14.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.

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Read Precautions for Hydraulic Testing in this section.

4. Makesurethetransmissionis adjusted totheneutral position.

5. Attachaheavy chaintotherearofthemachineframe and an immovable object to prevent the machine from moving during testing.

6. Ifmachinehas3wheeldrive,blockup the rear wheel offthegroundtoallowflowthroughtherear wheelmotor.

7. Chockfront wheel being tested toprevent rotation of the wheel.

8. Thoroughly clean junction of hydraulic lines and fitting on 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 fittings in wheel motor.

9. Thoroughly clean junctionof hydraulic hoseand up- perhydraulicfittingonfrontsideofpistonpump(forward port). Disconnect hose from upper pump fitting.

10.Install hydraulic tester (pressure and flow) in series between piston pump fitting and disconnected hose to allow flow from piston pump to tester (same tester connections as Piston (Traction) Pump Flow Test). Make surethatfittingandhose connections are properly tightened.Also, make sure theflow control valve ontester is fully open.

15.Release traction pedal to theneutralpositionandrelease brakes. Rotate wheel being tested and retest. Testing of wheel motor leakage in three (3) different wheel positions will provide most accurate test results.

16.Release traction and brake pedals. Shut engine off. Record results of wheel motor leakage test.

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

18.To test second front wheel motor: A. Reconnecthydrauliclinestountestedfrontwheel

motor. B. Disconnectandcaphydrauliclinestotestedfront

wheel motor. C. Complete steps 11 to 17 for the second front

wheel motor.

19.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. Front wheels need to turn freely when testing rear wheel motor.

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. Positionrearwheelon the groundand chockrear wheel to prevent it from turning.

CAUTION

System

Hydraulic

11.Start engine andrun at low idlespeed.Check for hydraulicleakageandcorrectbefore proceeding with test.

CAUTION

Use extreme caution when performing test. The wheelbeing tested will betrying to move themachine.

12.Move throttle so engine is running at high idle speed.

13.Slowly push traction pedal in forward direction until 1000 PSI (69 bar) is displayed on the tester pressure gauge. Make sure that wheel motor being tested is not rotating.

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 39

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

D. Complete steps 11to 17to test rear wheel motor leakage.

20.When testing is completed, disconnect tester from

hydraulic hose andpump fitting. Connect hose to pump fitting. Make sure that hydraulic connections at wheel motors are all secure.

Page 92

Steering/Lift Relief Valve Pressure Test (Using Pressure Gauge)

LEFT FRONT(#2)

(Extend to Lower)

CONTROL

MANIFOLD

PRESSURE

LIFT

GAUGE

CENTER (#1)

(Extend to Raise)

OR2 .028

RIGHT FRONT (#3)

(Extend to Lower)

RV 400 PSI

C6C1C4

.028

OR3

25 PSI

OR1 .037

STEERING CYLINDER

PORT BALL JOINT END

4.5

POWER

STEERING

C5 C2

VALVE

1160

PSI

TO MOW

CONTROL

MANIFOLD

.33

FROM

HYDRAULIC

RESERVOIR

GEAR PUMP

110 -- 150

PSI

1.44

.58

MOW = 6.7 GPM AT3.8 MPH

TRANSPORT = 17.5 GPM AT10 MPH

3000

PSI

3000

PSI

HYDROSTAT

1.9 GPM

BYPASS

VALVE

70 to 100

PSI

BOTTOM

PORT

TOP PORT

FORWARD

ENGINE

20.6

OPTIONAL 3WD

FRONT

PORT

10.3

MOTOR

LEFT

BACK

PORT

MOTOR

RIGHT

Greensmaster 3300/3400Hydraulic System Page 5 -- 40

Page 93

Thesteering/lift relief valve pressuretest should be performed to make sure that the relief pressure for the steering and lift circuits is correct.

Procedure for Steering/Lift Relief Valve Pressure Test:

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

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

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

NOTE: The steering/lift relief valve is in series with the

traction charge relief valve. Traction charge pressure will therefore affect steering/lift relief valve pressure.

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

9. Watch the pressure gauge and move the joystick to

theraiseposition.Momentarilyholdthejoystickwiththe cuttingunits fully raised causingtherelief valve to open. Release the joystick when the relief pressure is identified.

10.Shut off engine. Record pressure at which the relief

valve opens.

11.Steering/lift valve pressure should beapproximately

1160PSI (80 bar) higher than the charge relief valve pressure (e.g.ifthechargerelief valve pressure is 125

PSI(8.6bar),thesteering/lift relief valve pressure should be approximately 1285 PSI (88.6 bar)).

12.If steering/lift relief valve pressure is incorrect, in-

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

NOTE: The lower cutting units relief valve (RV) pressure can also be measured with pressure gauge positionedas described inthis test (seeLower Cutting Units Relief Valve (RV) Pressure Test in this section).

13.When testing is complete, disconnect pressure

gaugefromliftcontrolmanifoldtest port. Install dust cap to test port fitting. Install right side cover.

4. Remove right side cover next to operator seat to allow access to lift control manifold.

5. Install 5000 PSI (350 bar) pressure gauge with hydraulichoseattachedto lift control manifoldtestport(G) (Fig. 22).

6. Makesurethattractionpedalandjoystickareinneutral and the parking brake is engaged.

7. Start engine andrun at lowidle speed. Check for hydraulicleakage and correct beforeproceedingwithtest.

8. Movethrottlesoengineisrunningat high idle speed.

CAUTION

While measuring steering/lift relief valve pressure, do not allow circuit pressure to exceed 1400 PSI (82.8 bar).

Figure 22

1. Lift control manifold 2. Test port

System

Hydraulic

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 41

Page 94

Lower Cutting Units Relief Valve (RV) Pressure Test (Using Pressure Gauge)

LEFT FRONT(#2)

(Extend to Lower)

CONTROL

MANIFOLD

PRESSURE

LIFT

GAUGE

CENTER (#1)

(Extend to Raise)

OR2 .028

RIGHT FRONT (#3)

(Extend to Lower)

RV 400 PSI

C6C1C4

.028

OR3

25 PSI

OR1 .037

STEERING CYLINDER

PORT BALL JOINT END

4.5

POWER

STEERING

C5 C2

VALVE

1160

PSI

TO MOW

CONTROL

MANIFOLD

.33

FROM

HYDRAULIC

RESERVOIR

GEAR PUMP

110 -- 150

PSI

1.44

.58

MOW = 6.7 GPM AT3.8 MPH

TRANSPORT = 17.5 GPM AT10 MPH

3000

PSI

3000

PSI

HYDROSTAT

1.9 GPM

BYPASS

VALVE

70 to 100

PSI

BOTTOM

PORT

TOP PORT

FORWARD

ENGINE

20.6

OPTIONAL 3WD

FRONT

PORT

10.3

MOTOR

LEFT

BACK

PORT

MOTOR

RIGHT

Greensmaster 3300/3400Hydraulic System Page 5 -- 42

Page 95

The lower cutting units relief valve (RV) pressure test should be performed to make sure that the relief pressure for lowering the cutting units is correct.

Procedurefor Lower Cutting Units Relief Valve (R Pressure

Test:

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

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

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

NOTE: The lower cutting units relief valve is in series

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

9. The lower cutting units relief pressure should be

approximately 400 PSI (27.6 bar) higher than charge relief pressure (e.g. if charge relief valve pressure is 125PSI(8.6 bar), the lowerreliefvalve pressure should be approximately 525 PSI (36.2 bar)).

10.If the lower relief valve pressure is incorrect, adjust

lower cutting units relief valve on lift control manifold (Fig. 24) (see Adjust Manifold Relief Valves in the Adjustments section of this Chapter). Retest relief valve pressure after adjustment is performed.

NOTE: Thesteering/liftcircuitreliefvalve pressure can also be measured with pressure gauge positioned as described in this test (see Steering/Lift Relief Valve Pressure Test in this section).

11.When testing is complete, disconnect pressure

gaugefromliftcontrolmanifold test port. Install dust cap to test port fitting. Install right side cover.

3. Measure and record charge relief valve pressure (see Charge Relief ValvePressure Testinthis section).

4. Remove right side cover next to operator seat to allow access to lift control manifold.

5. Install 1000 PSI (70 bar) pressure gauge with hydraulichoseattachedtoliftcontrolmanifoldtestport(G) (Fig. 23).

6. After installing pressure gauge, startengine and run at low idle speed. Check for hydraulic leakage and correct before proceeding with test.

7. Movethrottlesoengineisrunningathighidlespeed. NOTE: The lower cutting units function is electrically

timed and automatically turns off after approximately three (3) seconds.

8. Watch pressure gauge carefully while moving the joystick to LOWER and note pressure that relief valve opens.Release joystick, shut offengineand record test results.

NOTE: While performing this hydraulic test, if relief pressurecannotbe determinedwithintheLOWERfunction three (3) second timeframe, repeat this test procedure.

Figure 23

1. Lift control manifold 2. Test port

RELIEF

VALVE (RV)

FRONT

LIFT CONTROL

MANIFOLD

System

Hydraulic

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 43

Figure 24

Page 96

Steering/Lift Circuit Gear Pump Flow Test (Using Tester with Flowmeter and Pressure Gauge)

LEFT FRONT(#2)

(Extend to Lower)

CONTROL

MANIFOLD

LIFT

CENTER (#1)

(Extend to Raise)

OR2 .028

RIGHT FRONT (#3)

(Extend to Lower)

TESTER

RV 400 PSI

C6C1C4

.028

OR3

25 PSI

OR1 .037

STEERING CYLINDER

PORT BALL JOINT END

4.5

POWER

STEERING

C5 C2

VALVE

1160

PSI

TO MOW

CONTROL

MANIFOLD

.33

FROM

HYDRAULIC

RESERVOIR

GEAR PUMP

110 -- 150

PSI

1.44

.58

MOW = 6.7 GPM AT3.8 MPH

TRANSPORT = 17.5 GPM AT10 MPH

3000

PSI

3000

PSI

HYDROSTAT

1.9 GPM

BYPASS

VALVE

70 to 100

PSI

BOTTOM

PORT

TOP PORT

FORWARD

ENGINE

20.6

OPTIONAL 3WD

FRONT

PORT

10.3

MOTOR

LEFT

BACK

PORT

MOTOR

RIGHT

Greensmaster 3300/3400Hydraulic System Page 5 -- 44

Page 97

The steering/lift circuit gear pump flow test should be performed to make sure that the steering, lift and traction charge circuits have adequate hydraulic flow.

Procedure for Steering/Lift Circuit Gear Pump Flow Test:

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

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

CAUTION

IMPORTANT: Do not fully restrict oil flow through tester. In this test, the flow tester is positioned beforethecircuitreliefvalve.Pumpdamagecanoccur if the oil flow is fully restricted.

8. Watchflowandpressuregaugecarefullywhileslow-

ly closing the flow control valve on the tester until the pressure gauge reads 800 PSI (55.2 bar).

9. Flow gauge reading for a gear pump in good condi-

tion should be approximately 3.9 GPM (14.8 LPM).

10.Open control valveontesterandshutoffengine.Re-

cord test results.

11.If gear pump flow is less than 3.5 GPM (13.2 LPM),

checkforrestriction in the pump intakeline.If no restriction is found, repair or replace rear gear pump section.

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Thoroughlyclean junction ofhydraulichose and discharge fitting of rear gear pump section (Fig. 25). Disconnect hose from pump fitting.

4. Install hydraulic tester (pressure and flow) in series with the rear gear pump s ection and the disconnected hose. Make sure that tester flow arrow points from the pump discharge and toward the disconnected hose.

Also, make sure flow control valve on the tester is fully open.

5. Makesurethattractionpedalandjoystickare in neutral and the parking brake is engaged.

6. Startengine and runatlow idle speed.Checkfor hydraulicleakageandcorrectbefore proceeding with test.

7. Movethrottlesoengineisrunningathighidlespeed.

12.When testing iscomplete,disconnecttesterfromthe

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

GR3300 GEAR PUMP SHOWN

Figure 25

1. Gear pump 2. Rear section fitting

System

Hydraulic

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 45

Page 98

Power Steering Valve Test

STEERING CYLINDER

(CYLINDER ROD

FULLYEXTENDED)

BALL JOINT

END PORT

PLUG

STEERING WHEEL

ROTATED FOR

LEFT TURN

POWER

STEERING

VALVE

4.5

1160

PSI

Greensmaster 3300/3400Hydraulic System Page 5 -- 46

Page 99

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 theseitemsarecheckedbeforeproceeding with any hydraulic testing procedure.

Procedure for Power Steering Valve

Test:

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

1. Make sure the hydraulic tank is full.

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

3. Perform the Steering/Lift Relief Valve Pressure and Steering/LiftCircuitGear PumpFlowTeststomakesure thatreliefvalve and gear pumparefunctioningcorrectly (see Steering/Lift Relief Valve Pressure and Steering/ Lift Circuit Gear Pump Flow Tests in this section).

4. 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.

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

5. Stop the unit with the engine running. Turn steering wheel with small quick movements in both directions. Let go of the steering wheel after each movement.

D. Read Precautions for Hydraulic Testing. E. Removehydraulichosefrom the fittingontheball

joint end of the steering cylinder.Plug the end of the hose.

F. With the engine off,continue turning the steering wheeltotheleft (counterclockwise) with the steering cylinder fully extended. Observe the open fitting on thesteering cylinder as the steeringwheel is turned. Ifoilcomesoutofthefittingwhileturning the steering wheel to the left, the steering cylinder has internal leakage and must be repaired or replaced.

G. When steering cylinder testing is completed, removeplug from the hydraulichose. Connect hose to the steering cylinder fitting.

7. If steering problem exists and steering cylinder

tested acceptably, power steering valve requires service (see Power Steering Valve and Power Steering Valve Service in the Service and Repairs section of this chapter).

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

B. The steering wheel should not continue to turn.

NOTE: Thesteeringwheel must beable to turnwith no more than 45 in--lb (5.1 N--m) of torque.

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 unitsloweredand off.Makesureengineisoffandthe parking brake is engaged.

B. Turn the steering wheel all the way to the left (counterclockwise)sothesteeringcylinderrod is fully extended.

C. Turn engine off.

Figure 26

1. Steering cylinder 2. Ball joint end hose

System

Hydraulic

Greensmaster 3300/3400 Hydraulic SystemPage 5 -- 47

Page 100

Mow Circuit Gear Pump Flow Test (Using Tester with Flowmeter and Pressure Gauge)

RIGHT FRONT

REEL (#3)

.73

LEAK DETECTOR KIT

LEAK

DETECTOR

VOLUME

EXPANSION

TANK

OUT

FRONT PORT

.73

FRONT PORT

LEFT FRONT

REEL (#2)

OPTIONAL OIL

COOLER

OR2

CENTER REEL

PORV

OR1

PRV

(#1)

FRONT PORT

.73

TO POWER STEERING VALVE

TESTER

GEAR PUMP

.58

.33

MOW CONTROL MANIFOLD

BREATHER

SUCTION

STRAINER

Greensmaster 3300/3400Hydraulic System Page 5 -- 48