Toro Groundmaster Series Service Manual

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8111 Lyndale Avenue South

Bloomington, MN 55420

Groundsmaster

3310

(Models 31900, 31901, 31902, 31903, 31907

and 31909)

Form No. 19240SL Rev A

3200, 3300 and

Original Instructions (EN)

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Toro Groundmaster Series

Page 1 Form No. 19240SL Rev A Groundsmaster ® 3200, 3300 and 3310 (Models 31900, 31901, 31902, 31903, 31907 and 31909) © 2019—The Toro® Company Original Instructions (EN) 8111 Lyndale Avenue South Contact us at www.Toro.com. Bloomington, MN 55420 All Rights Reserved...
Page 2 Revision History Revision Date Description 2/2020 Initial release Revision History Page 2 Groundsmaster ® 3200, 3300 and 3310 19240SL Rev A...
Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail servicemanuals@toro.com...
Page 4 Reader Comments Page 4 Groundsmaster ® 3200, 3300 and 3310 19240SL Rev A...
Page 5 Service Manual for reference. Additional copies of the Operator’s Manuals, Installation Instructions and Parts Catalogs are available at www.toro.com. The Toro Company reserves the right to change the product specifications or this publication without notice. Groundsmaster ®...
Page 6 Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S. components) that may have been removed •...
Page 7: Table Of Contents
Table of Contents Preface ........................ 5 Chapter 1: Safety .................... 1–1 Safety Instructions ..................1–2 Jacking Instructions ..................1–6 Safety and Instructional Decals ..............1–7 Chapter 2: Specifications and Maintenance ............ 2–1 Specifications ....................2–2 Torque Specifications ................... 2–7 Shop Supplies .................... 2–13 Special Tools ....................
Page 8 Hydraulic Schematic – 3200 4WD..............A–4 Hydraulic Schematic – 3300/3310..............A–5 Electrical Schematic – 3200/3300/3310 ............A–6 Electrical Schematic – 3300/3310 ..............A–7 Electrical Schematic – 3300/3310 (continued) ..........A–8 Electrical Schematic-Operator Cab...............A–9 Wire Harness Drawing – 3200/3300/3310...........A–10 Wire Harness Diagram – 3320/3300/3310 ..........A–11 Wire Harness Drawing – Main 3300/3310 ...........A–12 Wire Harness Diagram –...
Page 9 Chapter 1 Safety Table of Contents Safety Instructions ..........................1–2 Think Safety First ..........................1–3 Jacking Instructions ..........................1–6 Safety and Instructional Decals ......................1–7 Groundsmaster ® 3200, 3300 and 3310 Page 1–1 Safety 19240SL Rev A...
Page 10: Safety Instructions
Safety Instructions DANGER This safety symbol means danger. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions could cause serious permanent injury, disability, or death. WARNING This safety symbol means warning. When you see this symbol, carefully read the instructions that follow.
Page 11: Think Safety First
Think Safety First Toro Products are evaluated for compliance with existing safety standards and specifications. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, hazard control and accident prevention are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
Page 12 Think Safety First (continued) Use only original equipment parts to ensure that important safety criteria are met. • Avoid injury to bystanders… Always clear the area of bystanders before starting or testing powered equipment. • Avoid injury due to projectiles… Always clear the area of any debris that could be picked up and thrown by the powered equipment.
Page 13 Think Safety First (continued) – Ensure that chock blocks are used on equipment that can move. – Use lifts or jacks and jack stands that are rated to support the total weight of the machine and any attachments. – Do not rely on jacks to support the machine. –...
Page 14: Jacking Instructions
Jacking Instructions DANGER Mechanical or hydraulic jacks may fail to support the machine and cause a serious injury. • Use jack stands to support the raised machine. • Use only mechanical or hydraulic jacks to lift the machine. • Do not use the cutting unit or implement as a jacking point. 1.
Page 15: Safety And Instructional Decals
Groundsmaster 3200/3300. If any decal becomes illegible or damaged, replace it with a new decal. Part numbers are listed in your Parts Catalog and Operator’s Manual. Order replacement decals from your Authorized Toro Distributor. Groundsmaster ®...
Page 16 Safety: Safety and Instructional Decals Page 1–8 Groundsmaster ® 3200, 3300 and 3310 19240SL Rev A...
Page 17 Chapter 2 Specifications and Maintenance Table of Contents Specifications ............................2–2 Overall Dimensions..........................2–2 Engine (Model 31900 & 31901)......................2–3 Engine (Model 31902 & 31903)......................2–3 Engine (Model 31907 & 31909)......................2–4 Hydraulic System ..........................2–4 Chassis .............................. 2–5 Cutting Unit ............................2–6 Torque Specifications ...........................
Page 18: Specifications
Specifications Overall Dimensions g301400 Figure 2 Specifications and Maintenance: Specifications Page 2–2 Groundsmaster ® 3200, 3300 and 3310 19240SL Rev A...
Page 19: Engine (Model 31900 & 31901)
Engine (Model 31900 & 31901) Item Description Make/Designation Yanmar 3TNV80F: 4-cycle, 3 cylinder water cooled diesel. EPA Tier 4 compliant. Bore 80 mm (3.15 inches) Stroke 84 mm (3.31 inches) Total displacement 1,267 cm (77.31 in Firing order 1 (flywheel end) - 3 (fan end) - 2 19:1 Compression Ratio Fuel...
Page 20: Engine (Model 31907 & 31909)
Engine (Model 31902 & 31903) (continued) Item Description Crankcase-oil capacity 5.2 L (5.5 US qt) with Filter Oil pump Gear driven trochoid type Coolant capacity 7.6 L (8 US qt) Alternator/Regulator 12 VDC 55 A Engine weight (dry) 188 kg (414 lb) Engine (Model 31907 &...
Page 21: Chassis
Hydraulic System (continued) Item Description Charge circuit relief 896 kPa (130 psi) Front Wheel Motor Parker Torqmotor TG Series Displacement (per revolution) Model 31900/31901 – 280 cm (17.1 in Model 31902/31903/31907/31909 – 240 (14.5 in Rear Wheel Motor Parker Torqmotor TL Series Displacement (per revolution) Model 31901 –...
Page 22: Cutting Unit
Cutting Unit Item Description Rotary blade bolt torque Standard series cutting unit (models 68 to 81 N∙m (50 to 60 ft-lb) 31974, and 31975) Groundsmaster series cutting unit 135 to 149 N∙m (100 to 110 ft-lb) (models 31970, 31971, 31972, and 31973) Caster wheels Rotary cutting unit...
Page 23: Torque Specifications
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual.
Page 24: Calculating The Torque Values When Using A Drive-Adapter Wrench
Calculating the Torque Values When Using a Drive-Adapter Wrench g205924 Figure 3 Torque Conversion Factor = A / B Torque wrench A (effective length of torque wrench) Drive-adapter wrench (crowsfoot) B (effective length of torque wrench and drive-adapter wrench) Using a drive-adapter wrench (e.g., crowfoot wrench) in any position other than 90°...
Page 25: Identifying The Fastener
Toro recommends replacing fasteners with a locking feature once they have been removed because the effectiveness of the locking feature diminishes with each reuse. If it is necessary to reuse a fastener with a locking feature; apply a thread locking compound (Loctite for example) to the fastener during installation.
Page 26: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch Series)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, and 8 with Studs, and Sems with Studs, and Sems with Studs, and Sems with Thin Height Regular Height Nuts...
Page 27: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Metric Fasteners)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Class 10.9 Bolts, Screws, and Thread Size Studs with Regular Height Nuts Studs with Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8 57 ±...
Page 28: Other Torque Specifications
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 ±...
Page 29: Shop Supplies
Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants, and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply.
Page 30 Shop Supplies (continued) GASKET COMPOUND Used to create a seal between mating parts. Gasket compounds may be used with or without the presence of a pre-formed gasket. Gasket compounds may be solvent or silicone based, and cure when exposed to air or designed to cure in an air-less environment (anaerobic). Most gasket compounds are designed to be applied to clean surfaces free of oil, chemical residue and previously used gaskets or gasket compounds.
Page 31: Special Tools
Special Tools You can order these special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic Pressure Testing Kit Toro Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick...
Page 32 20 to 150 LPM (4 to 40 GPM). Note: This tester does not include any hydraulic hoses or fittings; refer to Hydraulic Hose Kit Toro Part No. TOR6007 and Hydraulic Test Fitting Kit Tor Part No. TOR4079. Hydraulic O-Ring Kit Toro Part No.
Page 33 Hydraulic Test Fitting Kit Toro Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system. FITTING TYPE SIZE PART NUMBER 4 ORFS (9/16–18) TOR4079–3 6 ORFS (11/16–16) TOR4079–12...
Page 34 Note: This kit does not include the hydraulic hoses; refer to Hydraulic Hose Kit (page 2–16). Note: The replacement filter element is Toro Part No. TOR6012. The filter element canister tightening torque is 34 N∙m (25 ft-lb). Remote Starter Switch After flushing the hydraulic system or replacing a hydraulic component (e.g.
Page 35 This excess current can damage the circuits that are not designed to carry it. Battery Terminal Protector Toro Part No. 107-0392 Use this aerosol spray on the battery terminals, ring terminals, and fork terminals to reduce corrosion problems. Apply the...
Page 36 Specifications and Maintenance: Special Tools Page 2–20 Groundsmaster ® 3200, 3300 and 3310 19240SL Rev A...
Page 37 Chapter 3 Troubleshooting Table of Contents GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems ......3–2 Operator Advisories..........................3–3 Machine and Engine Faults ........................3–5 Machine Faults........................... 3–5 Engine Faults (Models 31902 and 31903)..................3–11 Using the TDM Display/Controller Screens for Troubleshooting ............3–12 Troubleshooting –...
Page 38: Chapter 3: Troubleshooting
GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems 1. Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue 2. Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis •...
Page 39: Operator Advisories
Operator Advisories Operator advisories are automatically displayed by the TDM display/controller when a machine function is prevented and additional action is required. Typically, an advisory can be eliminated with a change in machine controls by the operator. For example; if the operator attempts to drive the machine when the parking brake is engaged, an advisory is identified on the TDM display/controller that the parking brake needs to be in disengaged.
Page 40 Note: If “Unknown Cause” appears as an advisory description, a controller software issue may exist. If you are unable to clear this type of advisory, contact an Authorized Toro Distributor. Troubleshooting: Cutting Unit (or attachment) Problems Page 3–4 Groundsmaster ®...
Page 41: Machine And Engine Faults
• Model 31902/03 (start interlock relay, fuel pump, alternator) Swap the TDM controller with a known-good unit (contact an Authorized Toro Distributor for assistance). Groundsmaster ® 3200, 3300 and 3310 Page 3–5 Troubleshooting: Cutting Unit (or attachment) Problems...
Page 42 • Model 31902/03 (start interlock relay, fuel pump, alternator) Swap the TDM controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1015 Engine Run Output - Open circuit Check the wire harness connectors for...
Page 43 Test the SV1 valve solenoid and cartridge valve. Swap the TDM controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1415 Solenoid Valve 1 (SV1) Open circuit Check the wire harness connectors - Open Circuit...
Page 44 Test the PTO output circuit wiring. Test the PTO clutch and TVS diode. Swap the TDM controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C14C4 PTO - Short to Overcurrent Check the wire harness connectors for...
Page 45 Machine Faults (continued) Machine Faults (continued) Fault Fault Fault Title Condition/Circuit Additional Notes Service Actions Description P06E9 Starter Timeout Starter has Starter is disabled. Verify the key switch is not stuck in the been engaged start position. continuously for Check the wire harness connector (P26) more than 30 for damage or corrosion and clean or seconds.
Page 46 U1117 Source Address TDM controller Machine is disabled. Update machine software (contact your Contention Fault received a Authorized Toro Distributor for assistance). Note: Most often, message from this fault is caused another controller by installing a on the CAN bus...
Page 47: Engine Faults (Models 31902 And 31903)
Engine Faults (Models 31902 and 31903) Engine faults are generated by the by the Yanmar engine Electronic Control Unit (ECU) to identify an electrical system malfunction (fault) pertaining to the engine during operation. The fault IDs conform to SAE J2012 standards. When a fault occurs a code for the active fault will appear along the bottom of the TDM display/controller screen.
Page 48: Using The Tdm Display/Controller Screens For Troubleshooting
Using the TDM Display/Controller Screens for Troubleshooting The TDM display/controller Main Information Screens can be used to check the operation of various components. The neutral, parking brake, cutting unit lift/lower, seat, and glow plug (model 31902 and 31903) icons represent the switch activity and can be used to verify the switch and its circuit wiring integrity.
Page 49 OFF (empty box), the controller software may require reloading or replacement. Contact your Authorized Toro Distributor for assistance with controller reprogramming or replacement.
Page 50: Troubleshooting - Hydraulic
Troubleshooting – Hydraulic The following tables contain suggestions that can be used to solve performance issues specific to the hydraulic system. The suggestions are not all-inclusive. There can be more than 1 cause for a machine malfunction. Review the hydraulic schematic found in Appendix A (page A–1) and information on the hydraulic system operation in the...
Page 51: General Hydraulic System Problems
General Hydraulic System Problems Problem Possible Cause Corrective Action Hydraulic fluid is leaking from the The fitting(s), hose(s), or tube(s) are Secure or replace loose or damaged system. loose or damaged. hydraulic connections. The O-ring(s) or seal(s) are missing or Install a new O-ring(s) or seal(s).
Page 52 General Hydraulic System Problems (continued) Problem Possible Cause Corrective Action The hydraulic system operates hot The traction system pressure is high Inspect brake operation and service or (exceeds 95° C (203° F). due to load or dragging brakes. adjust if necessary. The hydraulic fluid level in the hydraulic Adjust the hydraulic fluid level.
Page 53: Traction System Problems
Traction System Problems Problem Possible Cause Corrective Action The traction response is sluggish. The hydraulic fluid is very cold. Allow the hydraulic fluid to warm by safely operating the machine at rest. The hydraulic fluid level in the hydraulic Adjust the hydraulic fluid level. tank is low.
Page 54 Traction System Problems (continued) Problem Possible Cause Corrective Action No traction exists in either direction. The hydraulic fluid level in the hydraulic Adjust the hydraulic fluid level. tank is low (other hydraulic circuit performance is affected as well). The traction pump bypass valve is open Close or replace the traction pump or damaged.
Page 55: Steering System Problems
Steering System Problems Problem Possible Cause Corrective Action Steering is sluggish, operates poorly or Steering components (e.g. rod ends, Inspect steering components and repair or replace if necessary. is inoperative. steering cylinder, steering stops) are worn or binding. Verify and adjust rod end and steering stop lengths and adjust if necessary.
Page 56: Cutting Unit (Or Attachment) Lift/Lower Problems
Cutting Unit (or attachment) Lift/Lower Problems Problem Possible Cause Corrective Action Lift cylinders will not raise or raise Engine speed is too low. Increase engine speed. slowly. Lift arms are binding, worn or damaged. Inspect lift components and repair or replace if necessary.
Page 57: Troubleshooting - Electrical
Troubleshooting – Electrical CAUTION Remove all the jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. Pay attention to the TDM display/controller screens. Use the main information screen icons and the operator’s advisories to help troubleshoot electrical issues.
Page 58: Starting Problems
31902 and 31903). harness connector for corrosion or damaged pins. Reprogram or replace the Engine ECU; contact an Authorized Toro Distributor for assistance. The starter solenoid “Clicks”, but the The battery is discharged. Charge and test the battery or replace engine does not crank.
Page 59 31902 and 31903). harness connector for corrosion or damaged pins. Reprogram or replace the Engine ECU; contact an Authorized Toro Distributor for assistance. The engine cranks (but should not) The switch is out of adjustment or Adjust the switch position when when the engine control inputs (neutral damaged.
Page 60: General Run And Transport Problems
31902 and 31903). harness connector for corrosion or damaged pins. Reprogram or replace the Engine ECU; contact an Authorized Toro Distributor for assistance. The battery does not charge. The engine alternator belt is loose or Adjust the alternator belt tension or damaged.
Page 61: Cutting Unit (Or Attachment) Problems
Cutting Unit (or attachment) Problems Problem Possible Cause Corrective Action The PTO shaft will not engage (or An electrical problem exists in the Check the TDM display/controller electric PTO clutch circuit. disengage). Diagnostics>PTO>Inputs and Outputs while operating the machine. Test the PTO switch and replace if necessary.
Page 62: Factors That Can Affect Quality Of Cut
Factors That Can Affect Quality of Cut There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. The turf conditions such as the excessive thatch, sponginess, or attempting to cut off too much grass height may not always be overcome by adjusting the cutting unit or machine.
Page 63 Chapter 4 Engine Table of Contents General Information ..........................4–2 Traction Unit Operator’s Manual ......................4–2 Yanmar Service and Troubleshooting Manuals .................. 4–2 Engine Electronic Control Unit (ECU) (Models 31902 and 31903)............4–3 Yanmar Engines..........................4–5 Diesel Particulate Filter ........................4–5 Service and Repairs ..........................
Page 64: General Information
Service and repair parts for the Yanmar engines are supplied through your Authorized Toro Distributor. If the parts list is not available, provide your distributor with the Toro model and serial number of your machine as well as the Yanmar engine model and serial numbers.
Page 65: Chapter 4: Engine
Engine Electronic Control Unit (ECU) (Models 31902 and 31903) g295739 Figure 8 Operator’s platform Engine ECU ground wire Engine ECU Yanmar SA-D connector The Yanmar engine that powers the Groundsmaster 3300/3310 (model 31902 and 31903) uses an Electronic Control Unit (ECU) for engine management. The TDM display/controller and the Yanmar Engine Control Unit (ECU) used on the Groundsmaster 3300/3310 machine communicate with each other on a Controller Area Network (CAN) bus system.
Page 66 Yanmar SmartAssist–Direct tool (SA-D) should be used to provide assistance in identifying the cause of the problem and the repairs that may be necessary. Contact your Toro distributor for assistance in Yanmar engine troubleshooting. IMPORTANT Do not disconnect the engine ECU for 60 seconds after the machine key switch is turned off.
Page 67: Yanmar Engines
The ECU combines numerous engine sensors, monitor and control the engine operation for optimum performance. During the operation of the engine, if conditions warrant, the engine ECU may generate an engine fault. Use the Toro Display Module (TDM display/controller) to identify the engine fault; refer to the Yanmar Troubleshooting Manual, or contact an Authorized Toro Distributor for assistance.
Page 68 Regeneration (continued) normal engine operation, the pressure differential will increase. The increase in pressure will signal the engine to begin a process called regeneration. Regeneration increases the exhaust temperature and the length of time the engine operates at a higher than normal exhaust temperature, incinerating the built up soot and turning it into ash.
Page 69 Regeneration (continued) Types of regeneration that are performed manually (while the machine is stationary) Type Conditions Description Parked Occurs when exhaust back pressure in the DPF increases due to The display screen displays continued soot buildup. the stationary regeneration icon. May occur because the Manually initiate a parked regeneration InfoCenter was set to...
Page 70 Ash Accumulation (continued) engine fault to prompt servicing the DPF. In addition to an engine fault appearing on the TDM display/controller screen, the engine output power will be reduced. Engine: General Information Page 4–8 Groundsmaster ® 3200, 3300 and 3310 19240SL Rev A...
Page 71: Service And Repairs
Service and Repairs Air Cleaner Assembly g295904 Figure 11 Air intake hose Cap screw (2 each) Cap screw (3 each) Hose clamp (3 each) Flange nut (2 each) Cap screw Air cleaner assembly Carriage bolt (2 each) Cap screw (2 each) Intake hose Cap screw (3 each) Hose clamp...
Page 72 Installing the Air Cleaner Assembly (continued) IMPORTANT Any leaks in the air cleaner system will allow the dirt into the engine and will cause serious engine damage. Ensure that all air cleaner components are in good condition and are properly secured during assembly.
Page 73: Exhaust System
Reconditioning of Soot Filter (SF) may be necessary over the life of the machine which will require exhaust system disassembly. Soot filter reconditioning should be done by a company that has the necessary equipment. Contact your Toro Distributor for information on reconditioning the soot filter.
Page 74 Removing and Installing the Exhaust System (continued) CAUTION A hot engine and exhaust system can cause burns. Allow the exhaust system components to cool before working on or near them. 1. Park the machine on a level surface, lower the cutting unit (or attachment), engage the parking brake, set the key switch to the Off position and remove the key from the key switch.
Page 75: Radiator
Radiator g296183 Figure 14 Air cleaner intake hose Foam seal (2 each) Radiator hose (lower) Radiator/hydraulic fluid cooler Foam seal (2 each) Radiator hose (upper) (radiator) Coolant drain valve Fuel cooler (31902/31903) Fan shroud Radiator/hydraulic fluid cooler (fluid Fuel hoses (31902/31903) Shroud retainer bracket cooler) Support bracket –...
Page 76 Removing the Radiator and Hydraulic Fluid Cooler DANGER If the radiator or engine is hot, pressurized hot coolant can escape and cause burns. Do not open the radiator cap or drain the coolant when the radiator or engine is hot. WARNING Ethylene-glycol antifreeze is poisonous.
Page 77 Installing the Radiator and Hydraulic Fluid Cooler Refer to Figure 14 for this procedure. 1. Lubricate new O-rings and place them onto the hydraulic fittings. If previously removed, install the fittings into the cooler ports using alignment marks made during removal; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–9).
Page 78: Fuel System
Fuel System g296817 Figure 15 Fuel tank Fuel hose, supply Cap screw Stand pipe Lock washer Fuel hose, return Flat washer Barb fitting (2 used) Bumper (4 used) Grommet (3 used) Fuel cap Fuel hose, vent Bracket, hold down Clamp (2 used) Seal Tube, vent Fuel level gauge...
Page 79 g296816 Figure 16 Fuel hose, return Elbow fitting (2 each) Clamp (3 each) Fuel hose, pump to filter Fuel hose, supply Clamp Fuel pump Fuel hose, separator to pump Fuel cooler Separator head Separator element Fuel hose, filter to cooler The fuel system includes a fuel tank with a mechanical fuel level gauge on the left side of the machine, a fuel/water separator, a low pressure electric fuel pump, and a fuel filter and mechanical high pressure fuel injection pump located on the...
Page 80 Priming the Fuel System The fuel system needs to be primed before starting the engine for the first time, after running out of fuel, or after fuel system maintenance (e.g., draining the fuel/water separator, replacing the fuel filter or disconnecting a fuel hose). IMPORTANT Do not turn the key switch to the START position to prime the fuel system.
Page 81: Engine
Engine g297765 Figure 17 (model 31900 and 31901 shown) Cap screw Flange nut (2 each) Cap screw (8 each) Negative (-) battery cable PTO clutch stop strap Cap screw (3 each) Wire harness ground Cap screw Flat washer (3 each) Throttle cable (model 31900 and PTO clutch Spacer (3 each)
Page 82 Removing the Engine (continued) 5. On model 31900 and 31901 machines; disconnect the throttle cable at the engine. IMPORTANT Mark or tag the various electrical connections during removal if necessary to assure proper assembly. To prevent damage to the electrical wire harnesses, cable ties and clamps may be used to secure wire harnesses to the machine.
Page 83 Removing the Engine (continued) 11. Connect a suitable hoist or lift to the front and rear lift tabs on the engine. On model 31902 and 31903 machines, do not allow the lift chains or straps to contact the DPF. 12. Remove the 3 lock nuts, snubbing washers, spacers and cap screws securing the engine mounts to the engine brackets.
Page 84 Installing the Engine (continued) CAUTION Make sure that the hoist or lift used to install the engine can properly support the engine. The engine assembly weighs approximately: • Model 31900 and 31901 = 150 kg (330 lbs) • Model 31902 and 31903 = 204 kg (450 lbs) •...
Page 85 Installing the Engine (continued) 19. Prime the fuel system; refer to Priming the Fuel System (page 4–18). 20. Start the engine and check for coolant and hydraulic fluid leaks. Repair any leaks as required. 21. Continue to run the engine to obtain the operating temperature. Check the coolant and hydraulic fluid levels and adjust if necessary before returning the machine to service.
Page 86 Engine: Service and Repairs Page 4–24 Groundsmaster ® 3200, 3300 and 3310 19240SL Rev A...
Page 87 Chapter 5 Hydraulic System Table of Contents General Information ..........................5–3 Traction Unit Operator’s Manual and Accessory Installation Instructions..........5–3 Relieving Pressure from the Hydraulic System .................. 5–3 Towing the Traction Unit........................5–4 Traction Circuit Component Failure....................5–5 Hydraulic Hoses..........................5–6 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fitting)............
Page 88: Additional Reference Materials
Lift Cylinder ............................ 5–102 Lift Cylinder Service ........................5–104 Auxiliary Hydraulic Valve Manifold (optional).................. 5–105 Additional Reference Materials Danfoss LPV Axial Piston Pump Service Manual Danfoss LPV Axial Piston Pump Repair Manual Parker Torqmotor™ Service Procedure (TC, TB, TE, TJ, TF, TG, TH, and TL Series) Danfoss OSPM Steering Unit Service Manual Hydraulic System: Service and Repairs Page 5–2...
Page 89: General Information
General Information Traction Unit Operator’s Manual and Accessory Installation Instructions The traction unit Operator’s Manual and accessory Installation Instructions provide information regarding the operation, general maintenance and maintenance intervals for the machine and its accessories. Refer to the traction unit Operator’s Manual and accessory Installation Instructions for additional information.
Page 90: Towing The Traction Unit
Towing the Traction Unit IMPORTANT If towing limits are exceeded, severe damage to the hydraulic pump may occur. If it becomes necessary to tow or push the machine, the traction pump must be set to bypass hydraulic fluid. Move the machine at a speed below 4.8 kph (3 mph), and for a very short distance.
Page 91: Traction Circuit Component Failure
Note: If traction circuit contamination exists, the traction pump case drain could allow contaminates to enter the hydraulic tank. The alternative to using the Toro high flow hydraulic filter kit after a traction circuit component failure would be to disassemble, drain and thoroughly clean all the components, the hydraulic tank, and the hydraulic tubes and hoses in the traction circuit.
Page 92: Hydraulic Hoses
Note: If the hose has an elbow at one end, tighten the swivel nut on the elbow end before you tighten the nut on the straight end of the hose. For more hydraulic hose information, refer to the Toro Basics Series Training Book Hydraulic Hose Servicing (Part No. 94813SL).
Page 93: Installing Hydraulic Hoses And Tubes (O-Ring Face Seal Fitting)
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fitting) g212099 Figure 19 Tube or hose Swivel nut O-ring Fitting body 1. Ensure that all the threads, the sealing surfaces of the hose/tube, and the fitting are free of burrs, nicks, scratches, or unwanted material. 2.
Page 94 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fitting) (continued) Hose/Tube Installation Torque Table (continued) Hose/Tube Side Thread Size Fitting Dash Size Installation Torque (inch)—threads per inch) 1–3/16—12 116 to 142 N∙m (85 to 105 ft-lb) 1–7/16—12 150 to 184 N∙m (110 to 136 ft-lb) 1–11/16—12 190 to 233 N∙m (140 to 172 ft-lb) Flats From Wrench Resistance Table...
Page 95: Installing The Hydraulic Fittings (Sae Straight Thread O-Ring Fittings)
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) Installing a Non-Adjustable Fitting g212226 Figure 21 Fitting O-ring 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2.
Page 96 Installing an Adjustable Fitting g212224 Figure 22 Locknut Back-up washer O-ring g212225 Figure 23 Step 1: clearance the lock nut Step 3: align the fitting Step 2: seat the back-up washer Step 4: tighten the lock nut 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material.
Page 97 Installing an Adjustable Fitting (continued) A. Hold the fitting in the correct alignment with a wrench and use a torque wrench and tighten the lock nut to the recommended torque value within the specified range of torque values; refer to the Fitting Installation Torque Table (page 5–11).
Page 98: Hydraulic Schematics
Hydraulic Schematics The hydraulic schematics for the Groundsmaster 3200/3300 machines are located in Appendix A (page A–1). Hydraulic System: Hydraulic Schematics Page 5–12 Groundsmaster ® 3200, 3300 and 3310 19240SL Rev A...
Page 99: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams Traction Circuit g298101 Figure 24 Traction Circuit Diagram (Forward) Groundsmaster ® 3200, 3300 and 3310 Page 5–13 Hydraulic System: Hydraulic Flow Diagrams 19240SL Rev A...
Page 100 The hydraulic traction circuit is a closed loop system consisting of a variable displacement hydraulic piston (traction) pump and a series of hydraulic wheel motors. The hydraulic fluid passes through the hydraulic manifold on its way to and from the wheel motors. The traction pump is driven by the engine via a multi-row V-belt.
Page 101 Reverse Direction The traction circuit operates essentially the same in reverse as it does in the forward direction. However, the flow through the circuit is reversed. Pushing the bottom of the traction pedal rotates the piston (traction) pump swash plate to create a flow of oil.
Page 102: Steering Circuit
Steering Circuit g298128 Figure 25 Steering Circuit Diagram Gear pump (P2) supplies oil flow for the steering circuit and lift circuit, and also provides a constant supply of charge oil to the closed loop traction circuit. The pump output flows to the steering control valve before supplying the lift and charge circuit needs so that the steering circuit has priority.
Page 103 Left Turn (continued) steering cylinder flows back through the spool valve, then out the T port, through the hydraulic manifold, and back to the gear pump (P2). Right Turn When a right turn is made with the engine running, the turning of the steering wheel positions the steering control spool valve so that the flow goes through the top of the spool.
Page 104: Lift Circuit
Lift Circuit g298562 Figure 26 Lift Circuit Diagram Gear pump (P2) supplies oil flow for the steering circuit and lift circuit, and also provides a constant supply of charge oil to the closed loop traction circuit. The Hydraulic System: Hydraulic Flow Diagrams Page 5–18 Groundsmaster ®...
Page 105 pump output flows to the steering control valve before supplying the lift and charge circuit needs so that the steering circuit has priority. Cutting Unit (or Implement) Idle When the lift system is not actively raising, lowering, or floating (idle), fluid flow enters the hydraulic manifold at the P port.
Page 106: Auxiliary Valve Circuit (Optional)
Auxiliary Valve Circuit (Optional) g298934 Figure 27 Auxiliary Valve Circuit Diagram An auxiliary valve kit is available to support the hydraulic needs of various attachments. The kit includes a 3 position cartridge style solenoid valve (SV) in a separate manifold. The valve has 2 coils (S1 and S2). The auxiliary valve manifold is located near the front of the machine under the operator floor plate.
Page 107 Auxiliary Valve Circuit (Optional) (continued) When the auxiliary valve control switch is in the idle position, the valve allows hydraulic fluid to pass through the auxiliary valve manifold, out port P2, and on to the main hydraulic manifold. When the auxiliary valve control switch is set to the left position, solenoid S1 is energized and fluid flow is directed to the A port of the auxiliary valve manifold (male quick disconnect fitting).
Page 108: Testing The Hydraulic System
Testing the Hydraulic System The most effective procedure to isolate the problems in the hydraulic system is to use hydraulic test equipment, such as pressure gauges and flow meters in the circuits during different operational checks; refer to Special Tools (page 2–15).
Page 109 IMPORTANT Use 2 people to perform all the tests, with 1 person in the seat and the other to read and record the test results. 1. Use the following resources to assist with hydraulic system troubleshooting. • The Hydraulic Schematic in Appendix A (page A–1) •...
Page 110: Hydraulic Test Selection
Hydraulic Test Selection Before beginning any hydraulic test, identify if the problem is related to the traction circuit, steering circuit, or lift circuit. Once the faulty system has been identified, perform tests that relate to that circuit. If a traction circuit problem exists, consider performing one or more of the following tests: Charge Pressure, Wheel Motor Efficiency, and/or Traction Pump (P1) Flow and Relief Valve.
Page 111: Testing The Traction Circuit - Charge Pressure
Testing the Traction Circuit – Charge Pressure g299123 Figure 28 Traction Circuit – Charge Pressure Groundsmaster ® 3200, 3300 and 3310 Page 5–25 Hydraulic System: Testing the Hydraulic System 19240SL Rev A...
Page 112 Test Procedure The charge pressure test is the first in a series of tests recommended to determine traction circuit performance. A charge pressure drop of more than 20% when a moderate load is placed on the piston (traction) pump indicates an internal leak in the piston (traction) pump.
Page 113 Test Procedure (continued) 5. Clean the fittings and the hydraulic tube shown; refer to Figure 6. Remove the hydraulic tube and use 2 hydraulic hoses to install the tester to the exposed fittings. Make sure the tester is installed in the correct flow direction (toward the wheel motors) and the tester flow control valve is fully open.
Page 114 Test Procedure (continued) E. Start the engine and check for any hydraulic fluid leaks. Repair hydraulic leaks if necessary before returning the machine to service. Hydraulic System: Testing the Hydraulic System Page 5–28 Groundsmaster ® 3200, 3300 and 3310 19240SL Rev A...
Page 115: Testing The Traction Circuit - Wheel Motor Efficiency
Testing the Traction Circuit – Wheel Motor Efficiency g299737 Figure 30 Traction Circuit – Wheel Motor Efficiency Groundsmaster ® 3200, 3300 and 3310 Page 5–29 Hydraulic System: Testing the Hydraulic System 19240SL Rev A...
Page 116 Wheel motor efficiency is the second in a series of tests recommended to determine traction circuit performance. Too much hydraulic fluid flow through a single stationary wheel motor under load indicates an internal leak in the wheel motor. A worn wheel motor is less efficient. Eventually, enough fluid by−pass will cause the wheel motor to stall under heavy load conditions.
Page 117 Test Procedure – Front Wheel Motor (continued) g299124 Figure 31 Hydraulic pump (P1) Hydraulic tube 2. Remove the hydraulic tube and use 2 hydraulic hoses to install the tester to the exposed fittings. Make sure the tester is installed in the correct flow direction (toward the wheel motors) and the tester flow control valve is fully open.
Page 118 Test Procedure – Front Wheel Motor (continued) g301210 Figure 32 Front left wheel motor Front right wheel motor A port 4. Cap the disconnected hydraulic line with a hydraulic ORFS cap, and plug the port of the disconnected wheel motor with a hydraulic ORFS plug. 5.
Page 119 Test Procedure – Front Wheel Motor (continued) g299968 Figure 33 Left side bulkhead fitting Right side bulkhead fitting Left rear wheel motor hydraulic hoses Right rear wheel motor hydraulic hoses A. Disconnect both hydraulic hoses from the bulkhead fitting. B. Plug the disconnected motor hoses with hydraulic ORFS plugs. C.
Page 120 Test Procedure – Front Wheel Motor (continued) 10. Slowly press the traction pedal in the forward direction until 6,900 kPa (1,000 psi) is displayed on the tester pressure gauge. Ensure that the front wheel is not rotating and record the flow meter reading. 11.
Page 121 Test Procedure – Rear Wheel Motor (continued) g299738 Figure 34 Left side bulkhead fitting Right side bulkhead fitting Left rear wheel motor supply hose Right rear wheel motor supply hose 4. Disconnect the rear wheel motor supply hose for the motor being tested and install a hydraulic tester with a pressure gauge and flow meter in series between the disconnected hydraulic hose and the rear wheel motor.
Page 122 Test Procedure – Rear Wheel Motor (continued) 8. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10 minutes. 9. Use the TDM controller/display screen to verify the engine speed. 10. Slowly press the traction pedal in the forward direction until 6,900 kPa (1,000 psi) is displayed on the tester pressure gauge.
Page 123: Testing The Traction Circuit - Piston (Traction) Pump (P1) Flow And Relief Pressure
Testing the Traction Circuit – Piston (traction) Pump (P1) Flow and Relief Pressure g299804 Figure 35 Traction Circuit – Piston (traction) Pump (P1) Flow and Relief Pressure The hydraulic pump (P1) flow test is the third in a series of tests recommended to determine the traction circuit performance.
Page 124 Test Procedure (continued) that the hydraulic pump is at full stroke when traction pedal is pressed fully in forward position. 4. Clean the fittings and the hydraulic tube shown; refer to Figure g299564 Figure 36 Hydraulic pump (P1) Hydraulic tube 5.
Page 125 Test Procedure (continued) C. Record the tester pressure and flow readings. 11. Verify the pump flow Under Load as follows: A. Slowly press the traction pedal to fully F position. ORWARD B. Apply an additional load of 8,274 to 12,410 kPa (1,200 to 1,800 psi) by slowly closing the flow meter.
Page 126: Testing The Steering And Lift Circuit - Gear Pump (P2) Flow And Circuit Relief Valve
Testing the Steering and Lift Circuit – Gear Pump (P2) Flow and Circuit Relief Valve g299871 Figure 37 Gear Pump (P2) Flow and Circuit Relief Valve Gear pump (P2) is designed to satisfy both steering cylinder and lift cylinder needs simultaneously (at full speed throttle). The Gear Pump (P2) Flow Test compares fluid flow at No Load with fluid flow Under Load.
Page 127 If cutting unit lift operation is unsatisfactory, check lift control cartridge valve (SV2) and/or lift cylinders; refer to Cartridge Valve Service (page 5–93) and/or Testing the Steering and Lift Circuit – Lift Cylinder Internal Leakage (page 5–47). Special Equipment Required: •...
Page 128 Test Procedure (continued) g299958 Figure 39 (steering cover raised) Steering control valve Hydraulic tube – P port 7. Remove the hydraulic tube and use 2 hydraulic hoses to install the tester to the exposed fittings. Make sure the tester is installed in the correct flow direction (toward the steering control valve) and the tester flow control valve is fully open.
Page 129 Test Procedure (continued) CAUTION Do not close tester valve fully when performing this test. In this test, the hydraulic tester is positioned before the circuit relief valve. Pump damage can occur if the fluid flow is completely restricted by fully closing the tester flow control valve. A.
Page 130 Test Procedure (continued) B. Install the hydraulic tube previously removed. C. Check and adjust the level of the hydraulic fluid in the hydraulic reservoir; refer to the traction unit Operator’s Manual. D. Start the engine and check for any hydraulic fluid leaks. Repair hydraulic leaks if necessary before returning the machine to service.
Page 131: Testing The Steering And Lift Circuit - Steering Cylinder And Circuit Relief Valve
Testing the Steering and Lift Circuit – Steering Cylinder and Circuit Relief Valve g301301 Figure 40 Steering Cylinder and Circuit Relief Valve Unit steering performance 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 linkage or spindles.
Page 132 Test Procedure (continued) B. When steering wheel is released, steering control valve should return to the neutral position with no additional turning. 4. If a steering problem is suspect, determine if the steering cylinder or circuit relief valve is damaged using the following procedure: A.
Page 133: Testing The Steering And Lift Circuit - Lift Cylinder Internal Leakage
Testing the Steering and Lift Circuit – Lift Cylinder Internal Leakage g299978 Figure 41 Lift Cylinder Internal Leakage Perform the lift cylinder internal leakage test if you identify a cutting unit lift or lower problem. This test determines if the lift cylinder being tested is damaged. When performing the lift cylinder internal leakage test, the cutting unit should be attached to the lift arms.
Page 134 Test Procedure (continued) 3. Raise the front of the operator platform to access the lift cylinder hydraulic fittings: refer to Figure A. Remove the steering cover fasteners and raise the steering cover. B. Remove the front tie-down bracket. C. Raise the hood and remove the hood support bracket (item 4). D.
Page 135 Test Procedure (continued) 4. Clean and disconnect the hydraulic hose fitting at the elbow fitting near the barrel end (front) of the lift cylinder being tested. 5. Cap the disconnected fitting with a hydraulic ORFS cap, and plug the disconnected hose with a hydraulic ORFS plug. 6.
Page 136: Adjustments
Adjustments Adjusting the Traction System for Neutral The traction pedal must return to the N position when released from either EUTRAL the forward or reverse position. The machine must not creep in either direction on level ground when in the traction pedal is in the N position.
Page 137 Adjusting the Traction System for Neutral (continued) 5. Tighten the locknut to secure the adjustment. 6. Set the key switch to the O position. 7. With the traction pedal in the N position, measure the air gap between EUTRAL the face of the neutral switch and the pump lever and adjust if necessary; refer to Adjusting the Traction Neutral Switch (page 6–29).
Page 138: Service And Repairs
Service and Repairs General Precautions for Removing and Installing the Hydraulic System Components Before Repairing or Replacing the Components 1. Before removing any parts from the hydraulic system, park the machine on a level surface, lower the cutting unit (or attachment), engage the parking brake, set the key switch to the O position and remove the key from the key switch.
Page 139 After Repairing or Replacing the Components (continued) Fitting) (page 5–7) Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–9). 5. After you complete the repairs, check the control linkages or cables for proper adjustment, binding, or broken parts. 6.
Page 140: Checking The Hydraulic Lines And Hoses
Checking the Hydraulic Lines and Hoses WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. •...
Page 141: Flushing The Hydraulic System
Flushing the Hydraulic System IMPORTANT If a component failure occurs in the traction circuit; refer to Filtering the Closed-loop Traction Circuit (page 5–57) for additional information. IMPORTANT Flush the hydraulic system whenever there is a severe component failure or the system is contaminated (for example, the fluid appears milky, black, or contains metal particles).
Page 142 Flushing the Hydraulic System (continued) 8. Fill the hydraulic tank with the correct type and quantity of new hydraulic fluid; refer to the traction unit Operator’s Manual. 9. Prime the hydraulic pumps; refer to Priming the Hydraulic Pumps (page 5–60). 10.
Page 143: Filtering The Closed-Loop Traction Circuit
To effectively remove contamination from the closed−loop traction circuit, use of a Toro bidirectional high flow hydraulic filter and hydraulic hose kit is recommended; refer to...
Page 144 5. Connect the Toro high flow hydraulic filter in series between the disconnected fittings and tube or hose. Use the hydraulic hose kit to connect the filter to the machine if necessary;...
Page 145 IMPORTANT If you are using a filter that is not the Toro high flow filter that is bi-directional, do not press the traction pedal in the opposite direction.
Page 146: Priming The Hydraulic Pumps
Priming the Hydraulic Pumps Whenever hydraulic fluid has been drained from the pumps (system drain, flush, or pump removal/installation) it is important to properly prime the hydraulic pumps. Priming the hydraulic pumps ensures that the gear pumps and piston (traction) pump have sufficient fluid while charging the hydraulic system. The pumps can be primed by using a remote starter switch to crank the engine which allows the pump to prime;...
Page 147 Priming the Hydraulic Pumps (continued) 7. Engage the remote starter switch and crank the starter for 15 seconds to prime the hydraulic pump. Wait for 30 seconds to allow the starter motor and starter solenoid to cool. Repeat the cranking procedure for the second time. 8.
Page 148: Charging The Hydraulic System
Charging the Hydraulic System IMPORTANT Air must be purged from the hydraulic system to reduce the chance of component damage. When initially starting the hydraulic system with new or rebuilt components such as wheel motors, pumps, or cylinders, it is important that the hydraulic system is charged properly to remove air from the system.
Page 149 Charging the Hydraulic System (continued) F. Test gear pump (P2) for damage. 9. Turn the steering wheel in both directions so that the steering cylinder moves in and out several times. 10. Operate the traction pedal in the forward and reverse directions. Make sure the wheels are turning in the proper direction.
Page 150: Hydraulic Tank
Hydraulic Tank g301600 Figure 47 Hose – suction Tube – vent Dipstick Hose clamp Hose Hydraulic tank Suction filter Hose clamp (2 each) Drop tube Rubber bumper (4 each) Drain plug w/o-ring Flat washer Hold down bracket Grommet Lock washer Plug w/o-ring Grommet Cap screw...
Page 151 Removing and installing the Hydraulic Tank (continued) 4. Remove the cap screw (item 7) from under the front of the hydraulic tank. IMPORTANT To prevent damage to the hydraulic hoses and tubes, cable ties and clamps may be used to secure the hoses and tubes to the machine components.
Page 152: Hydraulic Fluid Cooler
Hydraulic Fluid Cooler g296183 Figure 48 Air cleaner intake hose Foam seal (2 each) Radiator hose (lower) Radiator/hydraulic fluid cooler Foam seal (2 each) Radiator hose (upper) (radiator) Coolant drain valve Fuel cooler (31902/31903) Fan shroud Radiator/hydraulic fluid cooler (fluid Fuel hoses (31902/31903) Shroud retainer bracket cooler)
Page 153: Traction Pump Drive
Traction Pump Drive Replacing the Traction Pump Drive Belt g316420 Figure 49 Idler arm Pump pulley Drive belt 1. Park the machine on a level surface, lower the cutting unit (or attachment), engage the parking brake, set the key switch to the O position and remove the key from the key switch.
Page 154 Removing and Installing the Traction Pump Drive Assembly g301635 Figure 50 Idler pulley Grease fitting Flange bushing (2 each) Retaining ring Flange lock nut (5 each) Torsion spring Drive belt Cap screw Shoulder bolt Square head set screw (2 each) Pump shaft Cap screw (3 each) Pump pulley...
Page 155 Removing and Installing the Traction Pump Drive Assembly (continued) 8. Grease the idler pivot shaft with Mobil high-temp XHP-222 grease or equivalent before and after assembly. Groundsmaster ® 3200, 3300 and 3310 Page 5–69 Hydraulic System: Service and Repairs 19240SL Rev A...
Page 156: Piston (Traction) Pump (P1)
Piston (traction) Pump (P1) g302934 Figure 51 Pump pulley Neutral switch Bracket Square head set screw (2 each) Hose clamp Straight fitting Cap screw (2 each) Suction hose Straight fitting Washer (2 each) Return tube Flange nut (2 each) Cap screw (2 each) Damper Straight fitting (2 each) Gear pump...
Page 157 Removing the Traction (piston) Pump (continued) 3. Remove the hydraulic tank; refer to Removing and installing the Hydraulic Tank (page 5–64). 4. Remove the traction pump drive belt from the pump pulley and remove the pump pulley from the pump; refer to Traction Pump Drive (page 5–67).
Page 158 Installing the Traction (piston) Pump (continued) 5. Apply a thin layer of anti-seize lubricant to the traction pump drive shaft and keyway. Install the key and pump drive pulley. Align the pump pulley with the engine pulley. 6. Apply medium strength thread locking compound to the pulley set screws and tighten the set screws from 15 to 16 N·m (135 to 145 in-lb).
Page 159: Servicing The Traction (Piston) Pump (P1)
Servicing the Traction (piston) Pump (P1) g213710 Figure 52 Relief valve (2 each) O-ring (2 each) Neutral return pivot Seal kit (2 each) Bearing (2 each) Spring Charge relief poppet Plug (2 each) Cylinder block kit Spring O-ring (2 each) Valve plate Shim kit Traction pump housing...
Page 160 Servicing the Traction (piston) Pump (P1) (continued) IMPORTANT If a traction (piston) pump failure occurs, refer to Traction Circuit Component Failure (page 5–5)for information regarding the importance of removing contamination from the traction circuit. Hydraulic System: Service and Repairs Page 5–74 Groundsmaster ®...
Page 161: Gear Pump (P2)
Gear Pump (P2) g302898 Figure 53 O-ring Straight fitting Gear pump Barb fitting – suction Washer (2 each) Hose clamp Cap screw (2 each) Removing the Gear Pump Note: The gear pump (P2) can be removed separately or with the traction (piston) pump;...
Page 162 Removing the Gear Pump (continued) A case drain exists in the traction (piston) pump and a suction port is near the input shaft of the gear pump. When the gear pump is removed from the traction pump, install plugs into the case drain and suction ports to prevent the pumps from draining.
Page 163 Installing the Gear Pump (continued) 7. Charge the hydraulic system; refer to Charging the Hydraulic System (page 5–62). Groundsmaster ® 3200, 3300 and 3310 Page 5–77 Hydraulic System: Service and Repairs 19240SL Rev A...
Page 164: Gear Pump (P2) Service
Gear Pump (P2) Service g303051 Figure 55 Shaft seal (2 each) Thrust plate (2 each) Seal Retaining ring Driven gear Rear cover Backup washer Drive shaft Washer (4 each) Front cover Dowel pin (4 each) Cap screw (4 each) Uni-ring (2 each) Seal Pressure seal (2 each) Body...
Page 165 Disassembling the Gear Pump (continued) g303052 Figure 56 Marker line IMPORTANT Use caution when clamping gear pump in a vise to avoid distorting any pump components. 3. Secure the front cover of the pump in a vise with the drive shaft pointing down. 4.
Page 166 Inspecting the Gear Pump (continued) CAUTION Use eye protection such as goggles when using compressed air. 2. Clean all parts with solvent. Dry all parts with compressed air. 3. Inspect the drive gear and driven gear for the following: A. The gear shafts should be free of rough surfaces and excessive wear at the thrust plate points and sealing areas.
Page 167 Assembling the Gear Pump (continued) 3. Place the front flange, seal side down, on a flat surface. 4. Assemble the gear pump as follows: A. Install the pressure seals, flat side outward, into the grooves in the thrust plates. Follow by carefully placing the uni-rings, flat side outward, between the pressure seals and the grooves in the thrust plate.
Page 168: Wheel Motors
Wheel Motors Front Wheel Motors g303210 Figure 58 Front wheel motor Brake drum Clevis pin Elbow fitting Wheel hub nut Return spring Elbow fitting Brake plate assembly Cotter pin Woodruff key Cap screw (4 each) Spring clip Cap screw (4 each) Brake adapter Lock nut (4 each) Wheel hub...
Page 169 Front Wheel Motors (continued) 8. Clean the hydraulic tube ends and fittings on the wheel motor to prevent contaminants from entering into the hydraulic system. 9. Label and remove the hydraulic tubes from the fittings on the wheel motor. Allow the tubes to drain into a suitable container. 10.
Page 170 Front Wheel Motors (continued) 6. Clean the tapers of the wheel hub and wheel motor shaft and install the woodruff key and wheel hub. 7. Install a new wheel hub nut. Use a torque multiplier and tighten the nut from 475 to 540 N·m (350 to 400 ft-lb).
Page 171 Rear Wheel Motors (4WD models) (continued) 2. Use a wheel hub puller for a 108 mm (4.25 inch) bolt circle and remove the wheel hub and woodruff key. 3. Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 5–52).
Page 172: Wheel Motor Service
Wheel Motor Service g186199 Figure 60 Dirt and water seal Thrust bearing Commutator ring Outer bearing Coupling shaft Manifold Housing Thrust bearing Stator Back-up ring Drive link Vane (7 each) Back-up washer Bolt (7 each) Wear plate Shaft seal End cover Rotor Inner bearing Body seal (5 each)
Page 173 Wheel Motor Service (continued) IMPORTANT If a wheel motor fails; refer to Traction Circuit Component Failure (page 5–5) for information regarding the importance of removing contamination from the traction circuit. Groundsmaster ® 3200, 3300 and 3310 Page 5–87 Hydraulic System: Service and Repairs 19240SL Rev A...
Page 174: Hydraulic Manifold
Hydraulic Manifold g303280 Figure 61 Cap screw (3 each) Hydraulic fluid filter Hydraulic manifold assembly Removing the Hydraulic Manifold Refer to Figure 61 for this procedure. 1. Park the machine on a level surface, lower the cutting unit (or attachment), engage the parking brake, set the key switch to the O position and remove the key from the key switch.
Page 175 Removing the Hydraulic Manifold (continued) 7. Label and remove the hydraulic tubes and hoses from the fittings on the manifold. Allow the tubes and hoses to drain into a suitable container. 8. Install clean caps and plugs on the hydraulic tubes, hoses, and fittings to prevent system contamination.
Page 176: Hydraulic Manifold Service
Hydraulic Manifold Service g297318 Figure 62 (2WD Manifold – Model 31900) Manifold block Check valve – CV1 Check orifice – 0.100 inch – C1 Straight fitting #6 zero-leak plug with O-ring (3 Straight fitting each) Straight fitting (2 each) #10 zero-leak plug with O-ring (6 Elbow fitting each) Check valve –...
Page 177 Hydraulic Manifold Service (continued) g297319 Figure 63 (4WD Manifold – Models 31901/31902/31903/31907/31909) Manifold block Check valve – CV1 Straight fitting Straight fitting #6 zero-leak plug with O-ring (3 Check orifice – 0.100 inch – C1 each) Straight fitting (5 each) Check valve –...
Page 178 Hydraulic Manifold Service (continued) IMPORTANT A removable check orifice exists under the fitting in the C1 port, and a removable control orifice exists under the plug in the OR port of the hydraulic manifold. If the fitting or plug is removed, remove the orifice for cleaning and label its position for assembly purposes.
Page 179: Cartridge Valve Service
Cartridge Valve Service Note: For solenoid style cartridge valve coil testing information; refer to Hydraulic Solenoid Valve Coils (page 6–59). Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 5–52) prior to removing hydraulic system components.
Page 180 Cartridge Valve Service (continued) while energized procedure 5 or 6 times. Remove the solenoid from the cartridge. 7. Install the cartridge valve: A. Lubricate the new O-rings and the backup rings of the seal kit with clean hydraulic fluid and install them on the cartridge valve. The O-rings and the backup rings must be arranged correctly on the cartridge valve for proper operation and sealing;...
Page 181: Steering Control Valve
Steering Control Valve g303304 Figure 64 Steering cover Steering control valve Rubber boot Elbow fitting Cap screw (4 each) Straight fitting (4 each) Removing the Steering Control Valve 1. Park the machine on a level surface, lower the cutting unit (or implement), engage the parking brake, set the key switch to the O position and remove the key from the key switch.
Page 182 Removing the Steering Control Valve (continued) 7. Support the steering control valve to prevent it from falling during removal. 8. Raise the rubber boot at the base of the steering column, then loosen and remove the 4 fasteners securing the steering control valve to the steering column.
Page 183: Steering Control Valve Service
Steering Control Valve Service g303292 Figure 65 Relief valve assembly Cross pin End cover Dust seal ring Sleeve Tube (2 each) Steering valve housing Spool Washer (5 each) Shaft seal Cardan shaft Pin bolt Thrust washer O-ring Cap screw (4 each) Bearing race Distributor plate Ball...
Page 184: Steering Cylinder
Steering Cylinder g303392 Figure 66 (shown with rear bumper removed) Retaining ring Ball joint – rod end Washer Elbow fitting (2 each) Grease fitting (2 each) Slotted nut Steering cylinder Lock nut Cotter pin Cap screw Lock nut Ball joint – barrel end Removing the Steering Cylinder Refer to Figure 66...
Page 185 Removing the Steering Cylinder (continued) 8. If the hydraulic fittings are to be removed from the cylinder, mark the fitting orientation for assembly purposes and remove the fittings from the cylinder. Discard the O-rings from the fittings. Installing the Steering Cylinder Refer to Figure 66 for this procedure.
Page 186 Installing the Steering Cylinder (continued) g314861 Figure 68 D. Start the engine and turn the steering wheel to full right turn. Set the key switch to the O position. E. Adjust the right steering stop bolt until it contacts the right drag link. F.
Page 187: Steering Cylinder Service
Steering Cylinder Service g303568 Figure 69 Barrel Rod seal External retaining ring Lock nut Rod wear ring Piston wear ring Rod wiper Wiper seal mask Rod seal Dual seal Repair kit Piston seal Internal retaining ring Piston Cylinder head If items other than the cylinder seals are worn or damaged, the cylinder must be replaced as a complete assembly.
Page 188 Lift Cylinder g303516 Figure 70 Flange nut (2 each) Cap screw Grease fitting Flange nut (3 each) Grease fitting Elbow fitting (2 each) Step Lift cylinder Lock nut Pivot pin Pivot bolt Nylon washer (2 each) Removing the Lift Cylinder Refer to Figure 70 for this procedure.
Page 189 Removing the Lift Cylinder (continued) 9. If the hydraulic fittings are to be removed from the cylinder, mark the fitting orientation for assembly purposes and remove the fittings from the cylinder. Discard the O-rings from the fittings. Installing the Lift Cylinder Refer to Figure 70 for this procedure.
Page 190 Lift Cylinder Service g303569 Figure 71 Barrel Dual seal Wiper seal mask Lock nut Rod wear ring Piston wear ring Cylinder head Grease fitting Piston Rod seal Grease fitting Piston seal Rod wiper Repair kit Internal retaining ring External retaining ring If items other than the cylinder seals are worn or damaged, the cylinder must be replaced as a complete assembly.
Page 191 Auxiliary Hydraulic Valve Manifold (optional) g303669 Figure 72 Valve manifold assembly Cap screw (3 each) Lock nut (2 each) Bracket Quick disconnect fitting – female Carriage bolt (2 each) Quick disconnect fitting – male An optional auxiliary hydraulic valve kit is available. The kit is intended to expand the hydraulic capability for front mounted attachments.
Page 192 Removing and Installing the Auxiliary Hydraulic Valve Manifold (continued) 9. Operate the auxiliary valve. Check for hydraulic leaks and correct if necessary. 10. Check the hydraulic fluid level and adjust if necessary before returning the machine to service. Servicing the Auxiliary Hydraulic Valve Manifold g303601 Figure 73 Manifold...
Page 193 Chapter 6 Electrical System Table of Contents General Information ..........................6–2 Traction Unit Operator’s Manual and Accessory Installation Instructions..........6–2 Yanmar Engine Electrical Components....................6–2 TDM Display/Controller........................6–3 CAN bus Communications ......................... 6–5 Electrical Schematics and Wire Harness Drawings/Diagrams ............... 6–6 Electrical System Quick Checks ......................
Page 194: General Information
31900, 31901, 31907 and 31909 machines), use the correct engine service manual and troubleshooting manual. Yanmar engine service and troubleshooting manuals are available online, on the Toro Service Reference flash drive, and in print from your authorized Toro Distributor.
Page 195: Tdm Display/Controller
Groundsmaster 3200/3300/3310 machines communicate with each other on a Controller Area Network (CAN) bus system. Note: If the TDM display/controller is replaced for any reason, system software needs to be reloaded (contact an Authorized Toro Distributor for assistance). Groundsmaster ®...
Page 196 TDM Display/Controller (continued) g307390 Figure 75 TDM Display/Controller Screens Electrical System: General Information Page 6–4 Groundsmaster ® 3200, 3300 and 3310 19240SL Rev A...
Page 197: Can Bus Communications
The Toro DIAG electronic control diagnostics service system is available to Authorized Toro Distributors to support machine fault diagnosis and maintenance services of the machine electrical control devices. The Toro DIAG connector is located at the rear of the operator’s console.
Page 198: Electrical Schematics And Wire Harness Drawings/Diagrams
Electrical Schematics and Wire Harness Drawings/Diagrams The electrical schematics and wire harness drawings for the Groundsmaster 3200/3300/3310 machine are located in Appendix A (page A–1). Electrical System: Electrical Schematics and Wire Page 6–6 Groundsmaster ® 3200, 3300 and 3310 Harness Drawings/Diagrams 19240SL Rev A...
Page 199: Electrical System Quick Checks
Electrical System Quick Checks Testing the Charging System The Groundsmaster 3200/3300/3310 machines use a single 12 Volt maintenance free battery mounted on the left side of the machine behind the fuel tank. The battery is charged by either a 40 Amp (models 31900/31901) or 55 Amp (Models 31902/31903/31907/31909) 12 volt alternator mounted to the engine, which is driven by a single row V-belt.
Page 200: Checking The Operation Of The Interlock Switches
Checking the Operation of the Interlock Switches CAUTION Do not disconnect safety switches. They are for the operator’s protection. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before operating the machine. The Groundsmaster 3200/3300/3310 machines are equipped with a TDM controller that monitors interlock switch operation.
Page 201: Testing The Electrical Components
Testing the Electrical Components For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g., unplug the key switch connector before doing a continuity check of the switch). Always check the item being tested and the harness connector for damage or corrosion and clean or repair if necessary.
Page 202: Fusible Link Harness
Fusible Link Harness g304898 Figure 77 Fusible link harness Fusible link harness connector The Groundsmaster 3200/3300/3310 machines use 3 fusible links for circuit protection. These fusible links are located in a harness that connects the battery positive cable to the machine wire harness. If any of these links fail, current to the protected circuit stops;...
Page 203 Testing the Fusible Link Harness (continued) Note: Do not replace individual fusible link conductors of the fusible link harness. If any of the harness links are open (failed), replace the entire fusible link harness. 6. After you complete the testing, ensure that the fusible link harness connectors are correctly attached to the starter and machine wire harness.
Page 204: Fuses
Fuses g305067 Figure 78 Operator’s control console Fuse FB1-F3 Access cover Fuse FB1-F4 Fuse block 1 Fuse FB2-F1 Fuse block 2 Fuse FB2-F2 Fuse FB1-F1 Fuse FB2-F3 Fuse FB1-F2 Fuse FB2-F4 Most of the individual control circuits are protected by a variety of fuses found in the main fuse blocks located in the operator’s control console.
Page 205 Fuse Identification and Function (continued) connector, the optional wireless hour meter and the optional USB charger port. • FB2–F2: (15 Amp) supplies switched power to the optional air ride seat. • FB2–F3: (open slot) available to supply power to accessories. •...
Page 206 Fuse Identification and Function (continued) g307136 Figure 80 Frame crossmember Fuse – hazard lights (optional) Maxi fuse – main cab power circuits Fuse – radio (optional) (models 31903 and 31909) • Located along the frame crossmember in front of the engine: (60 Amp Maxi fuse) supplies unswitched power to the cab power circuits via the cab power relay.
Page 207 Fuse Identification and Function (continued) • Fuse F-1 (open slot) supplies switched power available for optional equipment. • Fuse F-2 (40 Amp) supplies switched power to the mixing box blower, the defroster blower and the dome light. • Fuse F-3 (20 Amp) supplies switched power to the windshield wipers and washer pump.
Page 208 Fuse Identification and Function (continued) g305189 Figure 83 Right side frame rail Fuse – LH brake/turn Fuse – RH tail light Fuse – LH tail light Fuse – RH brake/turn Four (5 Amp) fuses are integrated into the optional turn signal/hazard wire harness.
Page 209: Can Bus
2. The Toro DIAG connector is part of the CAN bus and is located at the rear of the operator’s console. Remove the connector cover from the machine wire harness and use a multimeter (ohms setting) to check the Toro DIAG connector.
Page 210 CAN bus Terminator Resistors (page 6–56) and/or Appendix A (page A–1) for additional information. If necessary, contact an Authorized Toro Distributor for assistance. 3. Install the connector cover after testing. Electrical System: Testing the Electrical Components Page 6–18 Groundsmaster ®...
Page 211: Tdm Display/Controller
TDM Display/Controller g305621 Figure 85 TDM display/controller Display screen select button LED fault active indicator The TDM display/controller is an LCD device located on the operator’s console that presents operating hours, engine coolant temperature, electrical system voltage, engine RPM, and active faults. The display screen button located next to the TDM is used to select the various display screens.
Page 212 TDM Display/Controller (continued) TDM Display/Controller Inputs (continued) INPUT NUMBER DESCRIPTION INPUT NUMBER DESCRIPTION IN 1 Key Switch – Start IN 7 Traction Neutral Switch IN 2 PTO Switch AIN 1 Cutting Unit High Trim Height Switch IN 3 Cutting Unit Lift AIN 2 Model 31900, 31901, Lower Switch –...
Page 213 A controller may be damaged if an attempt is made to test it with an electrical test device (e.g. digital multimeter or test light). Note: If the TDM display/controller is replaced for any reason, system software needs to be reloaded (contact an Authorized Toro Distributor for assistance). Groundsmaster ®...
Page 214: Key Switch
Key Switch POSITION CLOSED CIRCUITS 1 + 6, 4 + 5 1 + 3 + 4 + 5 + 6 START 1 + 2 + 4 + 5 + 6 The key switch is located on the operator’s console and has 3 positions: O , and S .
Page 215: Pto Switch
PTO Switch POSITION CLOSED CIRCUITS COM B + NC B (DOWN) COM C+ NC C ON (UP) COM B + NO B COM C+ NO C The power take off (PTO) switch is located on the operator’s console. This switch is pulled up to engage the PTO shaft and pushed down to disengage the PTO shaft.
Page 216: Lift/Lower Switch
Lift/Lower Switch POSITION CLOSED CIRCUITS 2 + 3, 5 + 6 INCREASE SPEED NEUTRAL NONE DECREASE 2 + 1, 5 + 4 SPEED The lift/lower switch is located on the operator’s console. When the front of the switch is depressed, the lift arms will lower. When the rear of the switch is depressed, the lift arms will lift.
Page 217: Glow Plug Switch (Model 31900, 31901, 31907 And 31909)
Glow Plug Switch (Model 31900, 31901, 31907 and 31909) POSITION CLOSED CIRCUITS 2 + 3, 5 + 6 2 + 1, 5 + 4 The glow plug switch is located on the operator’s console. The glow relay and the glow plugs are energized as long as the front of the switch is depressed. Testing the Glow Plug Switch 1.
Page 218: Throttle Switch (Model 31902 And 31903)
Throttle Switch (Model 31902 and 31903) POSITION CLOSED CIRCUITS 2 + 3, 5 + 6 INCREASE SPEED NEUTRAL NONE DECREASE 2 + 1, 5 + 4 SPEED The throttle switch is located on the operator’s console. When the front of the switch is depressed, the engine speed (RPM) will increase.
Page 219: Seat Switch
Seat Switch g306072 Figure 87 Seat switch harness connector The seat switch is normally open and closes when the operator is on the seat. The seat switch is located directly under the seat cushion. Testing the switch can be done without removing the seat by disconnecting the seat switch wire harness from the machine wire harness.
Page 220 Testing the Seat Switch (continued) B. Disconnect the seat switch harness from the seat switch. Check the switch and the harness connectors for damage or corrosion and clean or repair if necessary. C. Use a multimeter (ohms setting) and check the continuity of the switch harness.
Page 221: Traction Neutral Switch
Traction Neutral Switch g304274 Figure 88 Pump lever Cap screw (2 each) Neutral switch Pinch bolt Jam nut (2 each) Cap screw (2 each) Lock washer (2 each) Cap screw Lock nut Ball joint Support bracket Spacer – 5 mm (0.21 inch) Damper Traction cable The traction neutral switch is a normally open proximity switch that closes when...
Page 222 Adjusting the Traction Neutral Switch (continued) IMPORTANT To prevent damage to the traction neutral switch, make sure that nothing contacts the switch face during operation or adjustment. Do not scratch the face of the neutral switch. 2. When the traction lever is in the N position, the clearance between the EUTRAL face of the neutral switch and the pump lever should be from 2.4 to 2.5 mm...
Page 223 Testing the Traction Neutral Switch (continued) 3. Disconnect the traction neutral switch from the machine wire harness. Check the harness connectors for damage or corrosion and clean or repair if necessary. Use a multimeter (ohms setting) to check the machine wire harness connector.
Page 224: Parking Brake Switch
Parking Brake Switch g306071 Figure 90 POSITION CLOSED CIRCUITS ENGAGED (brake 1 + 3 lever up) 1 + 2 DISENGAGED (brake lever down) The parking brake switch is located under the brake lever cover on the left side of the brake lever. A set of normally closed contacts in the switch are opened when the parking brake is disengaged (brake lever down).
Page 225 Testing the Parking Brake Switch (continued) 5. Replace the switch if necessary. 6. If the parking brake switch testing is correct and a circuit problem still exists, check the main wire harness; refer to Appendix A (page A–1). 7. Connect the wire harness connector and test the parking brake switch operation before returning the machine to service.
Page 226: Cutting Unit High Trim Height Switch
Cutting Unit High Trim Height Switch g306357 Figure 91 Cutting unit high trim height switch Sensing plate Jam nut (2 each) Wire harness connector Switch bracket The cutting unit high trim height switch is a normally open proximity switch that closes when the lift arms are lowered.
Page 227 Adjusting the Cutting Unit High Trim Height Switch (continued) g306186 Figure 92 Switch bracket (on frame) Sensing plate (on lift arm) High trim height switch Jam nut (2 each) 3. If necessary, loosen the lock nuts securing the switch to the switch bracket and set the switch so the correct clearance exists between the target eye and the sensing plate.
Page 228 Testing the Cutting Unit High Trim Height Switch (continued) Main P102 Pink 12 VDC with key switch in the R position Chassis Ground (do not start engine) 4. If the harness wires test correctly and the switch LED does not function, replace the high trim height switch.
Page 229: Windshield Washer/Wiper Switch (Model 31903 And 31909)
Windshield Washer/Wiper Switch (Model 31903 and 31909) POSITION CLOSED CIRCUITS 1 + 2 WIPER 2 + 3 WASHER 2 + 3, 5 + 6 The windshield washer/wiper switch is located in the cab control panel cover. The windshield washer/wiper switch controls the operation of the windshield wiper and the washer pump.
Page 230: Air Conditioning On/Off Switch (Model 31903 And 31909)
Air Conditioning On/Off Switch (Model 31903 and 31909) POSITION CLOSED CIRCUITS NONE 1+ 2 + 3 Testing the Air Conditioning On/Off Switch 1. Park the machine on a level surface, lower the cutting unit (or attachment), engage the parking brake, set the key switch to the O position and remove the key from the key switch.
Page 231: Fan Speed Switch (Model 31903 And 31909)
Fan Speed Switch (Model 31903 and 31909) POSITION CLOSED CIRCUITS NONE B + C + L B + C + M HIGH B + C + H The fan speed switch is located in the cab headliner. The switch is used to select the fan speed (off, low, medium, or high).
Page 232: Multifunction Switch (Optional)
Multifunction Switch (Optional) POSITION CLOSED CIRCUITS ALL OFF NONE HORN 4 + 8 ROAD 1 + 9 LIGHTS WORK 3 + 9 LIGHTS ROAD and 1 + 3 + 9 WORK LIGHTS TURN 2 + 6 SIGNALS (Turn Right) TURN 2 + 7 SIGNALS (Turn Left)
Page 233: Hazard Switch (Optional)
Hazard Switch (Optional) POSITION CLOSED CIRCUITS 2 + 3, 5 + 6 2 + 1, 5 + 4 The optional hazard switch is located on the steering column control pod. When the forward end of the hazard switch is depressed, power is sent to the flasher module to illuminate the hazard lights (switch light illuminated).
Page 234: Relays With 4 Terminals
Relays with 4 Terminals g304775 Figure 93 Washer Relay – glow plug Operator’s console Relay – fuel solenoid pull coil Relay – main power Panel fastener g306841 Figure 94 Frame crossmember Steering column control pod (optional) Cab power relay Horn relay (optional) The Groundsmaster 3200 machine uses 3 identical relays that have 4 terminals.
Page 235 • The main power relay supplies power to the fuses (and all of the circuits protected by the fuses) in fuse block 2; refer to Fuse Identification and Function (page 6–12). The main power relay is energized when the key switch is in the R or S position.
Page 236 Testing Relays with 4 Terminals (continued) 6. Connect the multimeter (ohms setting) leads to relay terminals 30 and 87. The ground terminal 85 and apply +12 VDC to terminal 86. The relay should make and break continuity between the terminals 30 and 87 as +12 VDC is applied and removed from terminal 86.
Page 237: Relays With 5 Terminals
Relays with 5 Terminals g316378 Figure 96 Relay – start Operator’s console Panel fastener Relay – start interlock Relay – EGR valve g316076 Figure 97 AC/Heat assembly AC switch signal relay AC condenser fans relay AC clutch relay The Groundsmaster 3200 machine uses one relay that has 5 terminals. The Groundsmaster 3300/3310 machines use 3 identical relays that have 5 terminals.
Page 238 to the engine starter solenoid and the engine fuel solenoid via the delay timer. For model 31902 and 31903 machines, the start interlock relay sends power to the engine ECU. The start interlock relay is energized by the TDM. • The Exhaust Gas Recirculation (EGR) relay is used to provide current to the engine EGR valve (models 31902 and 31903 only).
Page 239 Testing Relays with 5 Terminals (continued) Note: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads.
Page 240: Pto Clutch
PTO Clutch g306981 Figure 99 PTO clutch Wire harness connector Access slot (3 each) An electric clutch is used to engage the PTO. The electric clutch is mounted on the engine crankshaft and engages when current is applied to the clutch coil. The clutch also incorporates a magnetic brake to stop clutch rotation when the clutch is de-energized.
Page 241 Testing the PTO Clutch (continued) 5. Replace the clutch if necessary; refer to Removing and Installing the PTO Clutch (page 7–21). 6. After testing, connect the clutch electrical connector to the machine wire harness. Groundsmaster ® 3200, 3300 and 3310 Page 6–49 Electrical System: Testing the Electrical Components 19240SL Rev A...
Page 242: Fuel Pump
Fuel Pump g304147 Figure 100 Fuel pump Fuel hose (disconnected) Fuel filter Fuel Pump Specifications Pump Capacity 700 ml (23.5 fluid ounces) per minute Pressure 22.8 kPa (3.3 psi) Current Draw 0.9 amp Testing the Fuel Pump The fuel pump used on the Groundsmaster 3200/3300/3310 machines is attached to the support bracket at the front of the engine.
Page 243 Testing the Fuel Pump (continued) IMPORTANT When testing the fuel pump output, do not turn the key switch to the S position. TART 5. Place the disconnected hose end into a 0.95 liter (1 quart) graduated cylinder and set the key switch to the R position for 30 seconds.
Page 244: Transient Voltage Suppression (Tvs) Diode
Transient Voltage Suppression (TVS) Diode g305819 Figure 101 TVS diode A transient voltage suppression (TVS) diode assembly is used to protect the electrical system components from power surges created by energizing and de-energizing the PTO clutch coil. The TVS diode plugs into the main wire harness above the right rear corner of the operator’s platform.
Page 245: Diode Assemblies (Model 31902 And 31903)
Diode Assemblies (Model 31902 and 31903) g305875 Figure 102 (shown with hydraulic tank removed) Traction pump Diode at connector P56 (EGR) Diode at connector P57 (starter) Two (2) different diodes are used on the Groundsmaster 3300/3310 (model 31902 and 31903) machines. The maximum current allowed through any of the diodes is 6 amps.
Page 246 Testing the Diode Assemblies (continued) Multimeter Multimeter Resistance Red (+) Lead Black (-) Lead DIODE DIODE VERY LOW TERMINAL A TERMINAL B DIODE DIODE VERY HIGH TERMINAL B TERMINAL A 4. If testing determines the diode is faulty, replace the diode. 5.
Page 247: Resistor Assemblies
Resistor Assemblies g305818 Figure 103 75 ohm resistor A 75 ohm resistor assembly is used for proper key switch (start circuit) operation. The resistor plugs into the main wire harness above the right rear corner of the operator’s platform. The resistor can be identified by its gray color and resistor symbol on the end of the resistor body.
Page 248: Can Bus Terminator Resistors
CAN bus Terminator Resistors System communication between various electrical components on the Groundsmaster 3200/3300/3310 machines is accomplished on a CAN bus communications network. Two specially designed, twisted wires form the CAN bus. These wires provide the data pathways between the components on the network.
Page 249 Testing the CAN bus Terminator Resistors (continued) resistor and the resistor holder for damage or corrosion and clean or repair if necessary. Note: The insulator wedge in the external termination resistor is blue for identification purposes. There also is a center keyway to prevent the termination resistor from plugging into the wrong wire harness connector.
Page 250 Black/White 5. If testing determines the integrated termination resistor is faulty, replace the engine ECU; contact an Authorized Toro Distributor for assistance. 6. After testing is complete, install the SA-D connector cap, and make sure the external terminator resistor is fully installed into the connector and secured to the wire harness.
Page 251: Hydraulic Solenoid Valve Coils
Hydraulic Solenoid Valve Coils g304231 Figure 106 Main hydraulic manifold Auxiliary hydraulic valve manifold (optional) Valve SV1 coil (raise) Auxiliary valve coil S1 Valve SV2 coil (lower) Auxiliary valve coil S2 Coil nut Coil spacer Electric coil actuated hydraulic valves are used on the main manifold and the optional Auxiliary Hydraulic Valve manifold.
Page 252 Testing the Hydraulic Solenoid Valve Coils (continued) B. The coils of solenoid valves SV1 and SV2 on the optional auxiliary hydraulic valve manifold are the same. Resistance of these coils should be approximately 7.1 ohms when tested at 20° C (68° F). 3.
Page 253: Service And Repairs
6. If corrosion occurs at the battery terminals, disconnect the battery cables. Always disconnect the negative (-) cable first. Clean the cable clamps and terminals separately. Connect the battery cables. Always connect the positive (+) cable first. Apply a coating of Toro Part No. 107-0392 battery Groundsmaster ®...
Page 254: Storing The Battery
Caring for the Battery (continued) terminal protector or a light coat of petroleum jelly to the terminals to reduce corrosion after you make the connections. 7. Check the battery-electrolyte level every 25 operating hours and every 30 days if machine is in storage. Note: Do not fill the cells above the fill line.
Page 255: Servicing The Battery
Servicing the Battery g307125 Figure 107 Battery Starter connection Battery cover Alternator cable Battery clamp Fusible link harness Negative (-) cable Engine ground connection Boot Cap screw Positive (+) cable Chassis ground connection Battery Specifications Battery-electrolyte specific gravity Fully Charged: 1.25 to 1.28 at 27°C (80°F) Discharged: less than 1.24 Battery specifications BCI Group 26...
Page 256 CAUTION Battery-electrolyte is corrosive and can burn skin and eyes and damage clothing. While working with the batteries, use extreme caution to avoid splashing or spilling of the electrolyte. Always wear the safety goggles and a face shield while working with batteries. Removing and Installing the Battery g307058 Figure 108...
Page 257 The cable clamp must be parallel to the edge of the battery before securing the clamp. 10. After you make the connections, apply battery terminal protector Toro Part No. 107-0392 or a light layer of petroleum jelly to the battery terminals and cable connectors.
Page 258 Inspecting, Maintaining, and Testing the Battery (continued) Minimum Voltage (continued) 20°F -7°C 10°F -12°C 0°F -18°C 1. Inspect the battery as follows: A. Check for cracks. Replace the battery if cracked or leaking. B. Check the battery terminals for corrosion. Use the wire brush to clean corrosion from the posts.
Page 259 Inspecting, Maintaining, and Testing the Battery (continued) D. Charge at the rate and time given in Battery Charge Rate (page 6–67) or until all cells specific gravity is 1.225 or greater with the difference in specific gravity between the highest and lowest cell being less than 0.050.
Page 260 Charging the Battery (continued) Battery Charge Rate (continued) 80 or less 3.8 hrs @ 3 A 7.5 hrs @ 3 A 11.3 hrs @ 3 A 15 hrs @ 3 A 81 to 125 5.3 hrs @ 4 A 10.5 hrs @ 4 A 15.8 hrs @ 4 A 21 hrs @ 4 A 126 to 170...
Page 261 Chapter 7 Chassis Table of Contents General Information ..........................7–2 Traction Unit Operator’s Manual and Accessory Installation Instructions..........7–2 Adjustments ............................7–3 Adjusting the Parking Brake....................... 7–3 Adjusting the Traction Cable ......................7–3 Adjusting the Tie Rod Length (Rear Wheel Toe-In)................7–3 Adjusting the PTO Clutch ........................
Page 262: General Information
General Information Traction Unit Operator’s Manual and Accessory Installation Instructions The traction unit Operator’s Manual and accessory Installation Instructions provide information regarding the operation, general maintenance and maintenance intervals for the machine and its accessories. Refer to the traction unit Operator’s Manual and accessory Installation Instructions for additional information.
Page 263: Adjustments
Adjustments Adjusting the Parking Brake Refer to the traction unit Operator’s Manual for this procedure. Adjusting the Traction Cable 1. Check the traction system for N and adjust if necessary; refer to EUTRAL Adjusting the Traction System for Neutral (page 5–50).
Page 264: Adjusting The Pto Clutch
Adjusting the PTO Clutch g314284 Figure 110 PTO clutch Access slot (3 each) Wire harness connector Locknut (3 each) 1. Use the access slots in the clutch cover to measure the gap between the clutch rotor and the armature. The gap should be 0.3 to 0.6 mm (0.012 to 0.024 inch) at all the 3 access slots.
Page 265: Service And Repairs
Service and Repairs Wheels g302853 Figure 111 Front wheel and tire – all models Rear wheel and tire – 2WD models Flat washer Lug nut (as required) Cap screw Rear wheel and tire – 4WD models Washer Removing and Installing the Wheels 1.
Page 266 Removing and Installing the Wheels (continued) WARNING Failure to maintain proper torque could result in failure or loss of wheel and may result in personal injury. Maintain the proper torque of the wheel fasteners. Tighten lug nuts evenly in a crossing pattern. 7.
Page 267: Parking Brakes
Parking Brakes g313947 Figure 112 Brake drum Clevis pin Hold down pin (2 each) Wheel hub nut Brake actuator Clevis pin Wheel hub Brake actuator lever Washer Retaining ring Retainer plate Return spring Cap screw (4 each) Dust boot Cotter pin Hold down cup (2 each) Rivet (4 each) Woodruff key...
Page 268 Disassembling the Parking Brakes (continued) B. Use a wheel hub puller for a 114 mm (4.5 inch) bolt circle and remove the wheel hub and woodruff key. C. Remove the 4 fasteners securing the brake assembly to the brake adapter. 5.
Page 269 Replacing the Parking Brake Cables g313966 Figure 113 Cotter pin Brake cable – left Return spring Brake cable – right Clevis pin Brake cable bracket – brake lever Washer Jam nut Brake cable bracket – wheel motor Equalizer bracket Refer to Figure 113 for this procedure.
Page 270 Replacing the Parking Brake Cables (continued) 8. Using the notes recorded during brake cable removal, route and secure the brake cable through the machine. Note: The longer (right side) cable should pass over the top of one of the wheel motor hydraulic tubes mid way between the wheel motors. 9.
Page 271: Traction Pedal, Cable, And Control Assembly
Traction Pedal, Cable, and Control Assembly g302086 Figure 115 Pad – forward Jam nut (2 each) Clamp Pad – reverse Lock washer (2 each) Socket head screw (2 each) Plastic washer (2 each) Lock nut Spacer – 9 mm (0.35 inch) Pedal hub Support bracket Washer (2 each)
Page 272 Removing and Installing the Traction Control Components (continued) g314863 Figure 116 Pedal end Pump end B. Attach the ball joints to the pump lever and the traction pedal hub. C. Fit the cable housing into the support bracket with a flat washer and a jam nut on each side of the bracket.
Page 273: Steering Column
Steering Column g314030 Figure 117 Steering wheel cover Cap screw (4 each) Locknut Cap screw (4 each) Flat washer Rubber bellows Steering column Steering cover Foam collar Cap screw (4 each) Lock nut (4 each) Steering wheel Removing the Steering Column 1.
Page 274 Removing the Steering Column (continued) 6. Slide the rubber bellows up the steering column to get access to the fasteners that secure the steering column to the machine. Note: Do not allow the steering control valve to hang from the hydraulic lines. 7.
Page 275 Installing the Steering Column (continued) 7. Secure the steering wheel to the steering column assembly with the flat washer and lock nut. Tighten the lock nut from 28 to 35 N·m (20 to 26 ft-lb). 8. Install the steering wheel cover. Groundsmaster ®...
Page 276: Rear Axle And Spindles
Rear Axle and Spindles g314919 Figure 119 Weight Rear wheel spindle 2WD Pivot pin Weight lock Rear wheel spindle 4WD Thrust washer (2 each) Rear bumper Drag link (2 each) Sleeve bushing (2 each) Tie rod assembly Thrust washer (2 each) Rear axle Cotter pin (2 each) Flange bushing (4 each)
Page 277 Removing the Rear Axle (continued) 2. Remove any weights from the rear bumper and remove the rear bumper from the machine. 3. Remove the steering cylinder; refer to Removing the Steering Cylinder (page 5–98). 4. Raise and support the rear of the machine; refer to Jacking Instructions (page 1–6).
Page 278 Installing the Rear Axle (continued) rear of the axle and the machine frame. Slide the axle pivot pin through the frame, washers, and axle. 2. Ensure that the roll pin in the axle pivot pin is seated in the slots of the machine frame and secure the pivot pin with the thrust washer and locknut.
Page 279: Pto Shaft
PTO Shaft g314273 Figure 120 PTO shaft Cap screw (2 each) PTO clutch Lock nut (2 each) Cap screw (6 each) Alignment mark Removing and Installing the PTO Shaft IMPORTANT To maintain correct shaft balance, clearly mark the PTO shaft across the slip shaft and the slip tube prior to disassembly.
Page 280: Servicing The Pto Shaft Cross And Bearing
Servicing the PTO Shaft Cross and Bearing g221216 Figure 121 End yoke Shaft yoke Cross and bearing kit Grease fitting Snap ring (4 each) 1. Remove the PTO shaft from the machine; refer to Removing and Installing the PTO Shaft (page 7–19).
Page 281: Pto Clutch
PTO Clutch g314358 Figure 122 PTO clutch Cap screw (2 each) Lock nut (2 each) Washer Washer (2 each) Spacer Stub shaft Stop strap Spring washer Square key Spacer (2 each) Cap screw For PTO clutch testing and adjustment procedures, refer to Testing the PTO Clutch (page 6–48) Adjusting the PTO Clutch (page...
Page 282 Removing and Installing the PTO Clutch (continued) 8. Use medium strength thread locking compound and install the spacer, spring washers, and the cap screw securing the clutch to the stub shaft. Tighten the cap screw from 68 to 81 N·m (50 to 60 ft-lb). 9.
Page 283: Operator's Console
Operator’s Console g304808 Figure 123 (models 31900 and 31901 shown) Swell latch (2 each) Screw Access cover Cover – right side Cap screw (10 each) Cover – left side Removing and Installing the Operator’s Console Covers Refer to Figure 123 for this procedure.
Page 284: Hood
Hood g297644 Figure 124 Hood assembly Clevis pin (2 each) Hair pin (2 each) Removing and Installing the Hood Refer to Figure 124 for this procedure. 1. With the hood closed, remove the hair pins and clevis pins from the hood hinges.
Page 285 Removing and Installing the Hood (continued) g314859 Figure 125 Support bracket Cooling shroud Hood Groundsmaster ® 3200, 3300 and 3310 Page 7–25 Chassis: Service and Repairs 19240SL Rev A...
Page 286: Operator Seat
Operator Seat g314395 Figure 126 (standard seat shown – model 31980) Console mount kit Back cover Bracket kit Seat belt kit Lower console mount Seat track kit Seat switch harness Seat switch Cushion cover Armrest kit Standard seat (model 31980), mechanical suspension seat (model 31981), and air ride suspension seat (model 31982) are available for the Groundsmaster 3200/3300 machines.
Page 287 Removing and Installing the Operator Seat (continued) 7. Connect the electrical connector to the seat switch. On air ride seat suspension systems, connect the electrical connector to the air compressor. 8. Test the seat switch operation before returning the machine to service. Groundsmaster ®...
Page 288: Mechanical Suspension Seat (Model 31981)
Mechanical Suspension Seat (Model 31981) g314958 Figure 127 Upper console mount kit Seat belt kit Bracket kit Seat track kit Lower console mount Seat switch Back cover Weight adjust knob Cushion cover Bellows Seat switch harness Armrest kit Chassis: Service and Repairs Page 7–28 Groundsmaster ®...
Page 289: Air Ride Suspension Seat (Model 31982)
Air Ride Suspension Seat (Model 31982) g314969 Figure 128 Upper console mount kit Air bag kit Bracket kit Air valve kit Lower console mount Seat belt kit Back cover Seat track kit Cushion cover Seat switch Seat harness (2 pieces) Bellows Air compressor kit Armrest kit...
Page 290: Lift Arms
Lift Arms g314906 Figure 129 Lift arm – left Flange bushing (2 each) Spherical bearing Lift arm pivot pin U-bolt (2 each) Flange nut Bumper pad Height of cut (HOC) chain (2 each) 13. Lift arm – right Switch sensing plate Shoulder bolt Lift cylinder pivot pin Retaining ring...
Page 291 Removing the Lift Arms (continued) 4. When removing the right side lift arm, carefully remove the cutting unit high trim height switch sensing plate from the lift arm. CAUTION Each lift arm weighs approximately 27 kg (60 lbs). 5. Support the lift arm and remove the lift arm pivot pin. Remove the lift arm from the machine.
Page 292 Installing the Lift Arms (continued) 8. Grease the lift arm and lift cylinder pivots; refer to the traction unit Operator’s Manual. 9. Install the front wheel; refer to Removing and Installing the Wheels (page 7–5). 10. Install the cutting unit to the machine; refer to the cutting unit Operator’s Manual.
Page 293 Chapter 8 Cutting Units Table of Contents General Information ..........................8–2 Cutting Unit Operator's Manual ......................8–2 Blade Stopping Time.......................... 8–2 Service and Repairs ..........................8–3 Rotary Cutting Units ........................... 8–3 Flail Cutting Unit (Model 02835) Information Pending ..............8–22 Groundsmaster ®...
Page 294: General Information
General Information Several cutting units are available for the Groundsmaster 3200, 3300, and 3310 machines. This chapter gives information about service and repair of the following units: Model Description 31974 Standard Series 152 cm (60 inch) Rear Discharge Rotary Mower 31975 Standard Series 183 cm (72 inch) Rear Discharge Rotary Mower 31970...
Page 295: Service And Repairs
Service and Repairs WARNING Do not start the engine and engage the PTO switch when the PTO shaft is disconnected from the cutting unit. If you start the engine and the PTO shaft is allowed to rotate, serious personal injury and machine damage could result.
Page 296 Idler Assemblies g315036 Figure 132 (side discharge cutting unit shown) Shoulder bolt Spacer Idler lever Washer Flange bushing (2 each) Lock nut Torsion spring Retaining ring Washer Flange nut Idler pivot Dust shield Flange nut Idler pulley Cap screw Pulley spacer Idler pulley Carriage bolt Removing the Tensioning Idler Assembly...
Page 297 Idler Assemblies (continued) CAUTION The spring is under heavy load and can cause personal injury. Be careful when removing tension from the torsion spring of the idler arm. 7. Use a 3/8 inch or 1/2 inch drive ratchet or breaker bar in the idle arm to move the idler arm away from the shoulder bolt.
Page 298 Idler Assemblies (continued) CAUTION The spring is under heavy load and can cause personal injury. Be careful when removing tension from the torsion spring of the idler arm. 3. Use a 3/8 inch or 1/2 inch drive ratchet or breaker bar in the idle arm to release the drive belt tension.
Page 299 Blade Spindle Assemblies g315082 Figure 133 Spindle assembly – Standard Flange nut (6 or 8 each) Blade – Standard Blade – Groundsmaster Hex bushing – Standard Anti-scalp cup – Groundsmaster Blade bolt – Standard Blade bolt – Groundsmaster Spindle assembly – Groundsmaster Removing the Blade Spindle Assemblies Refer to Figure 133...
Page 300 Blade Spindle Assemblies (continued) B. For Groundsmaster series cutting units, align the spindle grease fitting with the decal on the cutting unit for each spindle. 2. Install the blade, hex bushing or anti-scalp cup, and blade bolt. • For standard series cutting units, tighten the blade bolt from 68 to 81 N∙m (50 to 60 ft-lb).
Page 301 Servicing the Blade Spindle (Standard Series Cutting Units) g315887 Figure 134 Lock nut Bearing spacer Disc spring washer Spindle housing Pulley Bottom guard Bearing guard Spindle shaft Ball bearing (2 each) Drive stud (6 each) Blade spindles for Standard series cutting units have cast aluminum spindle housings, sealed ball bearings, 25 mm (1 inch) spindle shafts, and are designed to use 5.1 mm (0.20 inch) thick blades.
Page 302 Servicing the Blade Spindle (Standard Series Cutting Units) (continued) Assembling the Blade Spindle Refer to Figure 134 for this procedure. 1. Install a bearing into the bottom of the spindle housing by pressing equally on the inner and outer race of the bearing. Ensure that the bearing seats against the shoulder of the bearing bore.
Page 303 Servicing the Blade Spindle (Groundsmaster Series Cutting Units) g315871 Figure 135 Spindle housing O-ring Grease fitting Bearing cone (2 each) Locknut Bearing cup (2 each) Hardened washer Spacer ring Pulley Large snap ring Spindle shaft Inner bearing spacer Spindle spacer Outer bearing spacer Seal (2 each) Drive Stud (8 each)
Page 304 Servicing the Blade Spindle (Groundsmaster Series Cutting Units) (continued) 1. Remove the locknut, hardened washer, and pulley from the top of the spindle shaft. 2. Use an arbor press to remove the spindle shaft from the spindle housing. Note: Ensure that the spindle shaft spacer remains on the spindle shaft while removing the shaft.
Page 305 Servicing the Blade Spindle (Groundsmaster Series Cutting Units) (continued) 1. If previously removed, install the large snap ring into the housing groove. Ensure that the snap ring is fully seated in the housing groove. 2. Install the outer bearing spacer from the top of the spindle housing. The spacer should contact the large snap ring.
Page 306 Servicing the Blade Spindle (Groundsmaster Series Cutting Units) (continued) IMPORTANT The upper seal must have the lip facing in (down). Also, install upper seal so it is flush to 1.5 mm (0.060 inch) below the housing surface. 6. Slide the spacer ring and inner bearing spacer into the spindle housing, then install the upper bearing cone and oil seal into the top of the housing.
Page 307 Rollers and Skids g315280 Figure 140 Lock nut Spacer Skid/bumper Roller Spanner Flange nut (2 each) Spanner Cap screw Cap screw Carriage screw (2 each) Removing and Installing the Rollers and Skids Refer to Figure 140 for this procedure. 1. Park the machine on a level surface, lower the cutting unit, engage the parking brake, set the key switch to the O position and remove the key from the key switch.
Page 308 Latch Assembly g315284 Figure 141 Latch arm Cap screw (2 each) Flange bushing (2 each) Flange nut (2 each) Spacer (2 each) Extension spring Latch mount – LH Handle Latch mount – RH Servicing the Latch Assembly Refer to Figure 141 for this procedure.
Page 309 Gearbox g315870 Figure 142 Pulley PTO guard Cap screw (4 each) Spacer (2 each) Gearbox bracket – right Gearbox bracket – left Shoulder screw (2 each) Gearbox Cap screw (4 each) Dipstick/breather Square key Copper washer Set screw (2 each) Removing the Gearbox WARNING Do not start the engine and engage the PTO switch when the PTO...
Page 310 Gearbox (continued) 3. Use a 3/8 inch or 1/2 inch drive ratchet or breaker bar in the idle arm to release the drive belt tension. 4. Slip the drive belt off the gearbox pulley then unload the idler spring tension. 5.
Page 311 Gearbox (continued) 5. Apply medium strength thread locking compound to the threads of the set screws and start the set screws in the pulley hub. 6. Fit the pulley to the output shaft with the set screws toward the gearbox and align the bottom of the pulley hub flush with the end of the output shaft.
Page 312 Castor Wheels g315376 Figure 144 Caster wheel assembly Castor fork Bearing (2 each) Spacer (7 each) Bearing spacer Thrust washer (2 each) Wheel hub Flange bushing (2 each) Wheel rim half (2 each) Height-of Cut cap assembly Tire – semi-pneumatic Retaining ring Plate Cap washer...
Page 313 Castor Wheels (continued) 3. Record the number of caster fork spacers above and below the caster arm and remove the height-of-cut cap and castor fork if necessary. A. Inspect the caster arm bushings for wear or damage and replace them if necessary.
Page 314: Flail Cutting Unit (Model 02835) Information Pending
Flail Cutting Unit (Model 02835) Information Pending Refer to the flail mower Operator’s Manual for the flail mower removal and installation procedures. Cutting Units: Service and Repairs Page 8–22 Groundsmaster ® 3200, 3300 and 3310 19240SL Rev A...
Page 315 Chapter 9 Operator Cab Table of Contents General Information ..........................9–2 Traction Unit Operator’s Manual and Accessory Installation Instructions..........9–3 Electrical Components, Schematics and Wire Harness Drawings ............9–4 Air Conditioning System........................9–5 Cab Heater System..........................9–6 Adjustments ............................9–7 Adjusting the Compressor Belt Tension....................
Page 316: General Information
General Information Operator Cab: General Information Page 9–2 Groundsmaster ® 3200, 3300 and 3310 19240SL Rev A...
Page 317: Traction Unit Operator's Manual And Accessory Installation Instructions
Traction Unit Operator’s Manual and Accessory Installation Instructions The traction unit Operator’s Manual and accessory Installation Instructions provide information regarding the operation, general maintenance and maintenance intervals for the machine and its accessories. Refer to the traction unit Operator’s Manual and accessory Installation Instructions for additional information.
Page 318: Electrical Components, Schematics And Wire Harness Drawings
Electrical Components, Schematics and Wire Harness Drawings For information regarding the operators cab electrical components (switches and relays); refer toChapter 6: Electrical System (page 6–1). The electrical schematic and wire harness drawings for the operator cab are included in Appendix A (page A–1).
Page 319: Air Conditioning System
Air Conditioning System Air Conditioning Components The air conditioning system used in the machine operator cab consists of the following components: • A compressor mounted on the left side of the engine driven by a single V−belt. • A condenser assembly with two (2) condenser fans located outside the rear of the cab roof assembly.
Page 320: Cab Heater System
Cab Heater System The cab heater system used in the machine operator cab consists of the following components: • A heater core in the mixing box mounted in the headliner of the cab. • Hoses to allow a circuit for engine coolant to circulate through the heater core. •...
Page 321: Adjustments
Adjustments Adjusting the Compressor Belt Tension g316005 Figure 145 Compressor Jam nut – right hand thread Turnbuckle V-belt Jam nut – left hand thread Compressor belt tension = 9.5 mm (0.38 inch) deflection when 4.5 kg (10 lb) is applied to the top of the belt half way between the engine and compressor pulleys.
Page 322: Adjusting The Doors
Adjusting the Doors g316080 Figure 146 Striker stud Lock nut Door seal Shim (as required) Striker guard Door panel Adjuster Frame 1. Use shims under the striker stud if necessary for proper door latch engagement. 2. Check the door adjustment to ensure that proper sealing occurs at the 2 points indicated.
Page 323: Service And Repairs
Service and Repairs General Precautions for Removing and Installing Air Conditioning System Components WARNING The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified air conditioning service technician.
Page 324 General Precautions for Removing and Installing Air Conditioning System Components (continued) 9. The air conditioning system uses R134a refrigerant. DO NOT use other refrigerants in the system. air conditioning system capacity is approximately 0.9 kg (30 oz or 1.88 lbs) of R134a refrigerant. 10.
Page 325: Air Conditioning Compressor
Air Conditioning Compressor g316096 Figure 147 Compressor bracket Ball joint Jam nut – left hand thread Flange nut (metric) Jam nut Ball joint – left hand thread Shim (as required) Spacer (3 each) Cap screw Compressor Washer (2 each) Cap screw (metric) Lock nut (2 each) Cap screw V-belt...
Page 326 Replacing the Compressor Drive Belt (continued) 6. Guide the hydraulic pump drive belt over the PTO clutch and out of the machine. 7. Guide the compressor drive belt over the PTO clutch and out of the machine. 8. To install the new drive belt, follow this procedure in reverse order. 9.
Page 327: Heating And Air Conditioning Components
Heating and Air Conditioning Components g316219 Figure 148 (shown with roof removed) Refrigerant hoses Blower Fresh air intake (2 each) Pressure switch Evaporator Condenser fans Drier – receiver Heater core Condenser Expansion valve Heat valve Thermostat – resistor Heater (engine coolant) hoses Remove the roof to access the heating and air conditioning components.
Page 328: Control Panel And Windshield Wiper Assembly
Control Panel and Windshield Wiper Assembly g316356 Figure 149 Wiper motor Flange nut (2 each) Gasket Wiper blade Mounting plate Spacer (2 each) Washer (2 each) Wiper arm assembly Lock nut (2 each) Bracket Boot (2 each) Removing the Windshield Wiper Assembly Note: If possible, operate the windshield wipers to ensure that the wiper motor shaft is in its home position prior to disassembly.
Page 329 Installing the Control Panel and Windshield Wiper Assembly (continued) 3. With the wiper motor in it’s home position, install the wiper arm assembly. The wiper blade should be approximately 7 cm (2.75 inch) from the right edge of the windshield when in the home position. Install the flange nuts and tighten from 23 to 25 N∙m (17 to 18 ft-lb).
Page 330: Doors
Doors g316367 Figure 150 (right side door shown) Door handle assembly Latch assembly Latch support plate Door panel w/ seal Neoprene flange bushing (18 each) Washer (5 each) Hinge (2 each) Shoulder screw (9 each) Door frame Gasket Lock nut CAUTION Each door assembly weighs approximately 424 kg (52 lbs).
Page 331 Doors (continued) g316230 Figure 151 Gas strut Door frame Cab frame Adjust the door fit against the frame as necessary; refer to Adjusting the Doors (page 9–8). Groundsmaster ® 3200, 3300 and 3310 Page 9–17 Operator Cab: Service and Repairs 19240SL Rev A...
Page 332 Operator Cab: Service and Repairs Page 9–18 Groundsmaster ® 3200, 3300 and 3310 19240SL Rev A...
Page 333 Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations......................A–2 Hydraulic Schematic – 3200 2WD......................A–3 Hydraulic Schematic – 3200 4WD......................A–4 Hydraulic Schematic – 3300/3310......................A–5 Electrical Schematic – 3200/3300/3310 .....................A–6 Electrical Schematic – 3300/3310 ......................A–7 Electrical Schematic – 3300/3310 (continued) ...................A–8 Electrical Schematic-Operator Cab....................A–9 Wire Harness Drawing –...
Page 334: Electrical Drawing Designations
Y or YE YELLOW Numerous harness wires used on the Toro machines include a line with an alternate color. These wires are identified with the wire color and line color with either a / or _ separating the color abbreviations listed above (e.g., R/BK is a red wire with a black line, OR_BK is an orange wire with a black line).
Page 335: Hydraulic Schematic - 3200 2Wd
Hydraulic Schematic – 3200 2WD g296996 Model 31900, Drawing 133-6540 Rev A, Sheet 1 of 1 19240SL Rev A Page A–3...
Page 336: Hydraulic Schematic - 3200 4Wd
Hydraulic Schematic – 3200 4WD g303916 Page A–4 19240SL Rev A Model 31901, Drawing 138-4500 Rev A, Sheet 1 of 1...
Page 337: Hydraulic Schematic - 3300/3310
Hydraulic Schematic – 3300/3310 g296995 Model 31902, 31903, 31907 and 31909, Drawing 133-6520 Rev A, Sheet 1 of 1 19240SL Rev A Page A–5...
Page 338: Electrical Schematic - 3200/3300/3310
Electrical Schematic – 3200/3300/3310 g296993 Page A–6 19240SL Rev A Model 31900, 31901, 31307 and 31309, Drawing 122-1226 Rev A, Sheet 1 of 1...
Page 339: Electrical Schematic - 3300/3310
Electrical Schematic – 3300/3310 g296989 Model 31902 and 31903, Drawing 122-1220 Rev A, Sheet 1 of 2 19240SL Rev A Page A–7...
Page 340: Electrical Schematic - 3300/3310 (Continued
Electrical Schematic – 3300/3310 (continued) g296968 Page A–8 19240SL Rev A Model 31902 and 31903, Drawing 122-1220 Rev A, Sheet 2 of 2...
Page 341: Electrical Schematic-Operator Cab
Electrical Schematic-Operator Cab g306863 Model 31903 and 31909, Drawing 122-1437 Rev A, Sheet 1 of 1 19240SL Rev A Page A–9...
Page 342: Wire Harness Drawing - 3200/3300/3310
Wire Harness Drawing – 3200/3300/3310 g295556 Page A–10 19240SL Rev A Model 31900, 31901, 31907 and 31909, Drawing 122-1657 Rev A, Sheet 1 of 1...
Page 343: Wire Harness Diagram - 3320/3300/3310
Wire Harness Diagram – 3320/3300/3310 g295555 Model 31900, 31901, 31907 and 31909, Drawing 122-1657 Rev A, Sheet 1 of 1 19240SL Rev A Page A–11...
Page 344: Wire Harness Drawing - Main 3300/3310
Wire Harness Drawing – Main 3300/3310 g295559 Page A–12 19240SL Rev A Model 31902 and 31903, Drawing 122-1656 Rev A, Sheet 1 of 1...
Page 345: Wire Harness Diagram - Main 3300/3310
Wire Harness Diagram – Main 3300/3310 g295557 Model 31902 and 31903, Drawing 122-1656 Rev A, Sheet 1 of 2 19240SL Rev A Page A–13...
Page 346: Wire Harness Diagram - Main 3300/3310 (Continued
Wire Harness Diagram – Main 3300/3310 (continued) g295558 Page A–14 19240SL Rev A Model 31902 and 31903, Drawing 122-1656 Rev A, Sheet 2 of 2...
Page 347: Wire Harness - Cab Power
Wire Harness – Cab Power g297520 Model 31903 and 31909, Drawing 122-1435 Rev A, Sheet 1 of 1 19240SL Rev A Page A–15...
Page 348: Wire Harness - Cab Rooftop
Wire Harness – Cab Rooftop g256477 Page A–16 19240SL Rev A Model 31903 and 31909, Drawing 122-1245 Rev D, Sheet 1 of 1...
Page 349: Wire Harness - Cab Control Panel
Wire Harness – Cab Control Panel g297533 Model 31903 and 31909, Drawing 122-1660 Rev A, Sheet 1 of 1 19240SL Rev A Page A–17...
Page 350: Wire Harness - Cab Hvac Adapter
Wire harness – Cab HVAC Adapter g297534 Page A–18 19240SL Rev A Model 31903 and 31909, Drawing 122-1678 Rev A, Sheet 1 of 1...
Page 351: Wire Harness - Cab Work Light Kit (Optional
Wire Harness – Cab Work Light Kit (optional) g260313 Model 31993, Drawing 122-1248 Rev B, Sheet 1 of 1 19240SL Rev A Page A–19...
Page 352: Wire Harness - Road Light Kits, Lights (Optional
Wire Harness – Road Light Kits, Lights (optional) g302637 Page A–20 19240SL Rev A Model 31991 and 31992, Drawing 122-1436 Rev A, Sheet 1 of 1...
Page 353: Wire Harness - Road Light Kit, Controls (Optional
Wire Harness – Road Light Kit, Controls (optional) g306840 Model 31991 and 31992, Drawing 122-1435 Rev A, Sheet 1 of 1 19240SL Rev A Page A–21...
Page 354: Slope Sensor Kit (Optional
Slope Sensor Kit (optional) g303863 Page A–22 19240SL Rev A Model 31900, 31901, 31902, 31903, 31907 and 31909, Drawing 122-1665 Rev B, Sheet 1 of 1...

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Toro Groundmaster Series Service Manual

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