Toro Greensmaster TriFlex 3300, Greensmaster TriFlex 3400, 04510, 04520 Service Manual
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.
R
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.
TM
3300/3400
Greensmaster3300
E The Toro Company -- 2012
This page is intentionally blank.
Greensmaster 3300/3400
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
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
TM
SERVICE PROCEDURE
System
Units
DPA Cutting
This page is intentionally blank.
Greensmaster 3300/3400
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
This page is intentionally blank.
Greensmaster 3300/3400
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
Safety
Greensmaster 3300/3400 Page 1 -- 1 Safety
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
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
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
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
2
1
Figure 1
1. LH front wheel 2. Jacking point
2
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.
1
Figure 2
1. RH front wheel 2. Jacking point
2
1
Figure 3
1. Rear steering fork 2. Rear jacking point
Greensmaster 3300/3400 Page 1 -- 5 Safety
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
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
Equivalents and Conversions
0.09375
Greensmaster 3300/3400Page 2 -- 2Product Records and Maintenance
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)
A
B
(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
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
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
Other Torque Specifications
*
SAE Grade 8 Steel Set Screws
Recommended Torque
Thread Size
Square Head Hex Socket
1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb
5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb
3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3ft--lb
1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Size Baseline Torque*
No. 6 -- 32 UNC 20 + 5in--lb
Wheel Bolts and Lug Nuts
Thread Size
7/16 -- 20 UNF
Grade 5
1/2 -- 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
** For steel wheels and non--lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
No. 6 18 20 20 + 5in--lb
Threads per Inch
Type A Type B
Recommended Torque**
65 + 10 ft--lb 88 + 14 N--m
80 + 10 ft--lb 108 + 14 N--m
80 + 10 ft--lb 108 + 14 N--m
80 + 10 ft--lb 108 + 14 N--m
Baseline Torque
No. 8 -- 32 UNC 30 + 5in--lb
No. 10 -- 24 UNC 38 + 7in--lb
1/4 -- 20 UNC 85 + 15 in--lb
5/16 -- 18 UNC 110 + 20 in--lb
3/8 -- 16 UNC 200 + 100 in--lb
Conversion Factors
in--lb X 11.2985 = N--cm N--cm X 0.08851 = in--lb
ft--lb X 1.3558 = N--m N--m X 0.7376 = ft--lb
No. 8 15 18 30 + 5in--lb
No. 10 12 16 38 + 7in--lb
No. 12 11 14 85 + 15 in--lb
*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
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
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
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
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
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
This page is intentionally blank.
Greensmaster 3300Page 3 -- 6Gasoline Engine
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
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.
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
1. Throttle cable
2. Cable clamp
2
Figure 2
3. Governor control lever
3
Greensmaster 3300 Page 3 -- 7 Gasoline Engine
Service and Repairs
Fuel Evaporative Control System (Serial Number Below 312000000)
1
2
8
RIGHT
FRONT
7
4
4
6
6
9
19
11
10
6
19
5
12
14
13
19
15
19
16
3
17
18
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
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.
2
1
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
3
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
Fuel Evaporative Control System (Serial Number Above 312000000)
RIGHT
FRONT
14
1
8
1
7
6
31
14
29
32
28
21
27
29
29
30
6
9
12
11
2
24
4
5
10
3
22
20
13
35
3
34
18
20
14
15
25
26
16
14
23
33
29
18
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
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
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. 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).
TM
Leak Detector System) or hydraulic reser-
TM
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-
TM
dian
cover (machines without Turf Guardian
Leak Detector System) or hydraulic reservoir
TM
Leak Detector System) (see Service and Repairs section of Chapter 5 -- Hydraulic System).
4
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.
2
FRONT
1. Carbon cannister
2. Screw (2 used)
3
1
Figure 6
3. Cannister bracket
4. Leak detector tank
Greensmaster 3300 Page 3 -- 11 Gasoline Engine
Fuel Tank
Illustration from machine with serial
number below 312000000 shown
5
2
3
33
34
35
Antiseize
Lubricant
30 to 50 in--lb
(3.4 to 5.6 N--m)
3
RIGHT
FRONT
31
32
27
28
23
22
30
29
1
24
8
6
9
7
10
6
10
4
5
13
14
5
18
11
10
12
15
19
25
26
14
16
10
20
10
21
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)
17
14
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
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