Toro Groundsmaster 3280-D, 3320 Service Repair Manual

Manuals: Service Repair Manual

Table of Content – Groundsmaster 3280-D, 3320

Title Page
Revision History
Reader Comments
Preface
Service Procedure Icons

Chapter 1 : Safety

Safety Instructions
Supervisor’s Responsibilities
Before Operating the Machine
While Operating the Machine
Before starting the machine
Before stopping the machine
Maintenance and Service
Jacking Instructions
Raising the Front of the Machine
Raising the Rear of the Machine
Safety and Instructional Decals

Chapter 2 : Specifications and Maintenance

Specifications
Decimal and Millimeter Equivalents
U.S. to Metric Conversions
Torque Specifications
Identifying the Fastener
Fasteners with a Locking Feature
Calculating the Torque Values When Using a Drive-Adapter Wrench
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
Other Torque Specifications
Conversion Factors
Shop Supplies
Special Tools
Hydraulic Pressure Testing Kit
57 LPM (15 GPM) Hydraulic Tester Kit
150 LPM (40 GPM) Hydraulic Tester
Hydraulic O-Ring Kit
Hydraulic Hose Kit
Hydraulic Test Fitting Kit
High Flow Hydraulic Filter Kit
Remote Starter Switch
Multimeter
Battery Terminal Protector

Chapter 3 : Gasoline Engine

1 Specifications
Engine – Groundsmaster 3320-G
General Information
Adding Oil to Engine
Adjustments
Adjust Throttle Control
Adjust Choke Control
Adjust Engine Speed
Service and Repairs
Fuel System
Check Fuel Lines and Connections
Drain and Clean Fuel Tank
Removing the Fuel Tank
Installing the Fuel Tank
Air Cleaner
Removing the Air Cleaner
Installing the Air Cleaner
Radiator
Removing the Radiator
Installing the Radiator
Engine
Removing the Engine
Installing the Engine
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Chapter 4 : Diesel Engine

1 Specifications
Engine – Groundsmaster 3280-D
General Information
Traction Unit Operator’s Manual
Engine Identification
Kubota Engine Workshop Manuals
Engine Group Code
Adjustments
Adjusting the Throttle Control
Service and Repairs
Air Cleaner System
Removing the Air Cleaner System
Installing the Air Cleaner System
Exhaust System
Removing the Exhaust System
Installing the Exhaust System
Radiator
Removing the Radiator
Installing the Radiator
Fuel System
Checking the Fuel Lines and Connections
Draining and Cleaning the Fuel Tank
Priming the Fuel System
Removing the Fuel Tank
Installing the Fuel Tank
Engine
Removing the Engine
Installing the Engine
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Chapter 5 : Hydraulic System

1 Specifications
Groundsmaster 3280-D and 3320-G
General Information
Checking the Hydraulic Fluid
Pushing or Towing the Traction Unit
Releasing Pressure from the Hydraulic System
Releasing the Hydraulic Pressure from the Traction Circuit
Releasing the Hydraulic Pressure from the Lift Circuit
Releasing the Hydraulic Pressure from the Steering Circuit
Traction Circuit Component Failure
Hydraulic Hoses
Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting)
Hose, Tube Installation Torque Table
Flats From Wrench Resistance Table
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port)
Installing the Non-Adjustable Fittings
Fitting Installation Torque Table
Flat From Finger Tight Table
Installing an Adjustable Fitting
Flat From Finger Tight Table
Hydraulic Schematics
Hydraulic Flow Diagrams
Traction Circuit (Machine Serial Number below 316000000)
Forward Direction
Reverse Direction
Traction Circuit (Machine Serial Number above 316000000)
Forward Direction
Reverse Direction
Lift Circuit (Machine Serial Number below 311000000)
Raise Cutting Deck (or Implement)
Lower Cutting Deck (or Implement)
Counterbalance
Lift Circuit (Machine Serial Number above 311000000)
Raise the Cutting Deck (or Implement)
Lower the Cutting Deck (or Implement)
Steering Circuit (Machine Serial Number below 316000000)
Left Turn
Right Turn
Steering Circuit (Machine Serial Number above 316000000)
Left Turn
Right Turn
Special Tools
Hydraulic Pressure Testing Kit
15 GPM Hydraulic Tester Kit (Pressure and Flow)
40 GPM Hydraulic Tester (Pressure and Flow)
Hydraulic Hose Kit
Hydraulic Test Fitting Kit
O-Ring Kit
High Flow Hydraulic Filter Kit
Remote Starter Switch
Troubleshooting
General Hydraulic System Problems
Traction Circuit Problems
Lift, Lower Circuit Problems
Steering Circuit Problems
Testing the Hydraulic System
Charge Pressure Test (Using Pressure Gauge) (Machine Serial Numbers below 316000000)
Implement Relief Pressure Test (Using Pressure Gauge) (Machine Serial Numbers below 316000000)
Lift Cylinder Internal Leakage Test (Machine Serial Numbers below 316000000)
Test Procedure
Steering Cylinder Internal Leakage Test (Machine Serial Numbers below 316000000)
Test Procedure
Charge Pump Flow Test (Using Tester With Pressure Gauges and Flow Meter) (Machine Serial Numbers below 316000000)
Testing the Traction Circuit–Charge Pressure (Machine Serial Numbers above 316000000)
Test Procedure
Testing the Traction Circuit–Hydraulic Pump Flow and Relief Pressure (Machine Serial Numbers above 316000000)
Test Procedure
Testing the Steering Circuit–Steering Control Valve, Relief Valve Pressure, and Steering Cylinder (Machine Serial Numbers above 316000000)
Test Procedure
Testing the Steering Circuit–Charge Pump Flow (Machine Serial Numbers above 316000000)
Test Procedure
Testing the Lift Circuit–Lift Cylinder Internal Leakage (Machine Serial Numbers above 316000000)
Test Procedure
Adjustments
Traction Pedal Friction Wheel (Machine Serial Number below 316000000)
Adjusting the Traction Pedal Friction Wheel
Service and Repairs
General Precautions for Removing and Installing the Hydraulic System Components
Before Repairing or Replacing the Components
After Repairing or Replacing the Components
Checking the Hydraulic Lines and Hoses
Priming the Hydraulic Pump
Flushing the Hydraulic System
Filtering the Closed-Loop Traction Circuit (Machine Serial Number above 316000000)
Charging the Hydraulic System
Transmission Driveshaft (Machine Serial Numbers below 316000000)
Removing the Transmission Driveshaft
Aligning the Transmission Driveshaft
Installing the Transmission Driveshaft
Hydrostatic Transmission (Machine Serial Numbers below 316000000)
Removing the Hydrostatic Transmission
Installing the Hydrostatic Transmission
Servicing the Hydrostatic Transmission (Machine Serial Numbers below 316000000)
Hydrostatic Transmission Neutral Arm Assembly (Machine Serial Number below 316000000)
Disassembling the Hydrostatic Transmission Neutral Arm Assembly
Assembling the Hydrostatic Transmission Neutral Arm Assembly
Hydraulic Pump Driveshaft (Machine Serial Number above 316000000)
Removing the Hydraulic Pump Driveshaft
Servicing the Driveshaft Cross and Bearing
Installing the Hydraulic Pump Driveshaft
Hydraulic Pump (Machine Serial Number above 316000000)
Removing the Hydraulic Pump
Installing the Hydraulic Pump
Servicing the Hydraulic Pump (Machine Serial Number above 316000000)
Traction Neutral Arm Assembly (Machine Serial Number above 316000000)
Disassembling the Traction Neutral Arm Assembly
Assembling the Traction Neutral Arm Assembly
Front Axle Drive Motor (Machine Serial Number above 316000000)
Removing the Front Axle Drive Motor
Installing the Front Axle Drive Motor
Servicing the Front Axle Drive Motor (Machine Serial Number above 316000000)
Lift Cylinder
Removing the Lift Cylinder
Installing the Lift Cylinder
Steering Control Valve
Removing the Steering Control Valve
Installing the Steering Control Valve
Servicing the Steering Control Valve
Steering Cylinder (2-Wheel Drive)
Removing the Steering Cylinder (2-Wheel Drive)
Installing the Steering Cylinder (2-Wheel Drive)
Servicing the Steering Cylinder (2-Wheel Drive)
Disassembling the Steering Cylinder (2-Wheel Drive)
Inspecting the Steering Cylinder
Assembling the Steering Cylinder (2-Wheel Drive)
Steering Cylinder (4-Wheel Drive)
Removing the Steering Cylinder (4-Wheel Drive)
Installing the Steering Cylinder (4-Wheel Drive)
Servicing the Steering Cylinder (4-Wheel Drive)
Disassembling the Steering Cylinder (4-Wheel Drive)
Inspecting the Steering Cylinder
Assembling the Steering Cylinder (4-Wheel Drive)
Lift Control Valve (Machine Serial Numbers below 316000000)
Removing the Lift Control Valve
Installing the Lift Control Valve
Servicing the Lift Control Valve (Machine Serial Numbers below 311000000)
Disassembly the Lift Control Valve
Inspecting the Lift Control Valve
Assembling the Lift Control Valve
Counterbalance Valve Manifold (Machine Serial Numbers below 311000000) (If Equipped)
Removing the Counterbalance Valve Manifold
Servicing the Manifold
Installing the Counterbalance Valve Manifold
Lift Control Valve (Machine Serial Number above 311000000)
Removing the Lift Control Valve
Installing the Lift Control Valve
Servicing the Lift Control Valve (Machine Serial Number above 311000000)
Servicing the Control Manifold Cartridge Valve
Oil Cooler (Groundsmaster 3280-D)
Removing the Oil Cooler
Inspecting the Oil Cooler
Installing the Oil Cooler
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Chapter 6 : Electrical System

General Information
Electrical Schematics and Wire Harness Drawings, Diagrams
Standard Control Module (SCM)
SCM Inputs
SCM Outputs
Standard Control Module Logic Chart
Special Tools
Multimeter
Terminal Protector
Battery Hydrometer
Dielectric Gel
Troubleshooting
Starting Problems
General Run and Transport Problems
Cutting Deck Operating Problems
Cutting Deck Lift, Lower Problems
Electrical System Quick Checks
Testing the Battery (Open Circuit Test)
Battery Test Table
Testing the Charging System
Battery Voltage Table
Testing the Glow Plug System (Groundsmaster 3280-D)
Checking the Operation of the Interlock Switches
Adjustments
Traction Neutral Sensor (Machine Serial Number above 316000000)
Adjusting the Traction Neutral Sensor
Parking Brake Switch
Adjusting the Parking Brake Switch
Testing the Electrical Components
Fusible Link Harness
Testing the Fusible Link Harness
Fuses (Machine Serial Number below 400000000)
Identification and Function
Testing the Fuses
Fuses (Machine Serial Number above 400000000)
Identification and Function
Testing the Fuses
Operator Cab Fuses (Machines with Operator Cab)
Identification and Function
Testing the Fuses
Key Switch
Testing the Key Switch
Circuit Logic Table
Indicator Lights
Charge Indicator Light
Engine Oil Pressure Light
High Temperature Warning Light
Glow Plug Indicator Light
Testing the Indicator Lights
Hour Meter
Testing the Hour Meter
PTO Switch
Testing the PTO Switch
Circuit Logic Table
Deck Lift Switch (Machine Serial Numbers above 311000000)
Testing the Deck Lift Switch
Circuit Logic Table
Seat Switch
Testing the Seat Switch
Windshield Washer, Wiper Switch (Machines with Operator Cab)
Testing the Windshield Washer, Wiper Switch
Circuit Logic Table
Accessory Power Switch (Machines with Operator Cab)
Testing the Accessory Power Switch
Circuit Logic Table
Fan Speed Switch (Machines with Operator Cab)
Testing the Fan Speed Switch
Circuit Logic Table
Work Light Switch (Machines with Operator Cab–Optional)
Testing the Work Light Switch
Circuit Logic Table
Traction Neutral Switch (Machine Serial Numbers below 316000000)
Testing the Traction Neutral Switch
Adjusting the Traction Neutral Switch
Traction Neutral Sensor (Machine Serial Number above 316000000)
Testing the Traction Neutral Sensor
Parking Brake Switch
Testing the Parking Brake Switch
High Temperature Warning Switch
Testing the High Temperature Warning Switch
High Temperature Shutdown Switch
Testing the High Temperature Shutdown Switch
Engine Oil Pressure Switch
Testing the Engine Oil Pressure Switch
Relays (Groundsmaster 3280-D)
Testing the Relays
Lift Control Valve Solenoid Valve Coil (Machine Serial Number above 311000000)
Testing the Lift Control Valve Solenoid Valve Coil
Solenoid Valve Coil Specifications Table
PTO Electric Clutch
Testing the PTO Electric Clutch
Fuel Stop Solenoid (Groundsmaster 3280-D)
Testing the Fuel Stop Solenoid (In Place)
Testing the Fuel Stop Solenoid (Live)
Glow Controller (Groundsmaster 3280-D)
Controller Operation
Controller Checks
Fuel Pump (Groundsmaster 3280-D)
Testing the Fuel Pump Capacity
Fuel Pump Specifications (for Models 30344 and 30345)
Fuel Pump Specifications (except Models 30344 and 30345)
Fuel Pump (Groundsmaster 3320)
Testing the Fuel Pump Capacity
Fuel Pump Specifications
Fuel Pump Relay (Groundsmaster 3320)
Testing the Fuel Pump Relay
Service and Repairs
Lift Control Valve Solenoid Valve Coils (Machine Serial Number above 311000000)
Removing the Lift Control Valve Solenoid Valve Coils
Installing the Lift Control Valve Solenoid Valve Coils
PTO Electric Clutch
Removing the PTO Electric Clutch
Installing the PTO Electric Clutch
Battery Storage
Battery Care
Servicing the Battery
Battery Specifications
Removing and Installing the Battery
Inspecting, Maintaining, and Testing the Battery
Cell Specific Gravity Example
Minimum Voltage Table
Charging the Battery
Battery Charge Level Table

Chapter 7 : Chassis

Specifications
NO TITLE
General Information
Service and Repairs
Wheels
Removing the Wheel
Installing the Wheel
Steering Column
Removing the Steering Column
Installing the Steering Column
Rear Frame and Axle Assembly
Removing the Rear Frame and Axle Assembly
Installing the Rear Frame and Axle Assembly
Rear Axle (2-Wheel Drive)
Removing the Rear Axle
Installing the Rear Axle
Servicing the Rear Axle (2-Wheel Drive)
Axle Pivot Bushings
Steering Pivot Bushings
Rear Axle Spindle Bushings
Rear Wheel Bearings (2-Wheel Drive)
Disassembling the Rear Wheel Bearings
Assembling the Rear Wheel Bearings
Operator Seat
Removing the Operator Seat
Installing the Operator Seat
Mechanical Seat Suspension
Removing the Mechanical Seat Suspension
Installing the Mechanical Seat Suspension
Pneumatic Seat Suspension
Removing the Pneumatic Seat Suspension
Installing the Pneumatic Seat Suspension
Lift Arms
Removing the Lift Arms
Installing the Lift Arms

Chapter 8 : Drive Axles

Specifications
NO TITLE
General Information
Front Axle
4-Wheel Drive Rear Axle
Special Tools
Differential Gear Holder
Service and Repairs
Servicing the Brake
Disassembling the Brake
Assembling the Brake
Front Axle Shafts and Bearings
Disassembling the Front Axle Shafts and Bearings
Assembling the Front Axle Shafts and Bearings
Front Axle (Machine Serial Number before 316000000)
Removing the Front Axle
Installing the Front Axle
Front Axle (Machine Serial Number after 316000000)
Removing the Front Axle
Installing the Front Axle
Servicing the Front Axle
Disassembling the Front Axle
Assembling the Front Axle
Ring to Pinion Gear Engagement (Front Axle)
Gear Pattern Movement Summary
Rear Axle Driveshaft (4-Wheel Drive)
Removing the Rear Axle Driveshaft (4-Wheel Drive)
Installing the Rear Axle Driveshaft (4-Wheel Drive)
Servicing the Rear Axle Driveshaft Cross and Bearing (4-Wheel Drive)
Rear Axle (4-Wheel Drive)
Removing the Rear Axle (4-Wheel Drive)
Installing the Rear Axle (4-Wheel Drive)
Bevel Gear Case and Axle Case (4-Wheel Drive Axle)
Removing the Bevel Gear Case and Axle Case (4-Wheel Drive Axle)
Inspecting the Bevel Gear Case and Axle Case
Installing the Bevel Gear Case and Axle Case (4-Wheel Drive Axle)
Differential Shafts (4-Wheel Drive Axle)
Removing the Differential Shaft (4-Wheel Drive Axle)
Installing the Differential Shaft (4-Wheel Drive Axle)
Axle Shafts (4-Wheel Drive Axle)
Removing the Axle Shaft (4-Wheel Drive Axle)
Installing the Axle Shaft (4-Wheel Drive Axle)
Input Shaft, Pinion Gear (4-Wheel Drive Axle)
Removing the Input Shaft, Pinion Gear (4-Wheel Drive Axle)
Installing the Input Shaft, Pinion Gear (4-Wheel Drive Axle)
Differential Gear Assembly (4-Wheel Drive Axle)
Removing the Differential Gear Assembly (4-Wheel Drive Axle)
Inspecting the Differential Gear Assembly
Installing the Differential Gear Assembly (4-Wheel Drive Axle)
Pinion Gear to Ring Gear Engagement (4-Wheel Drive Axle)
Gear Pattern Movement Summary
Bi-Directional Clutch (4-Wheel Drive)
Removing the Bi-Directional Clutch (4-Wheel Drive)
Installing the Bi-Directional Clutch (4-Wheel Drive)
Servicing the Bi-Directional Clutch (4-Wheel Drive)
Disassembling the Bi-Directional Clutch (4-Wheel Drive)
Assembling the Bi-Directional Clutch (4-Wheel Drive)

Chapter 9 : PTO System

General Information
Service and Repairs
PTO Drive Belt
PTO Driveshaft
Removing the PTO Driveshaft
Installing the PTO Driveshaft
Servicing the PTO Driveshaft Cross and Bearing
PTO Shaft
Removing the PTO Shaft
Installing the PTO Shaft
Aligning the PTO Pulley to the Electric Clutch Pulley
Checking the Pulley Alignment
Adjusting the Pulley Alignment

Chapter 10 : Cutting Units

General Information
Specifications
Cutting Unit Operator’s Manual
Troubleshooting
Factors That Can Affect Quality of Cut
Adjustments
Castor Wheel Tire Pressure
Service and Repairs
Cutting Deck
Idler Assembly
Removing the Idler Assembly
Installing the Idler Assembly
Blade Spindle
Removing the Blade Spindle
Installing the Blade Spindle
Servicing the Blade Spindle
Disassembling the Blade Spindle
Assembling the Blade Spindle
Gearbox
Removing the Gearbox
Installing the Gearbox
Castor Forks and Wheels
Disassembling the Castor Forks and Wheels
Assembling the Castor Forks and Wheels
Cutting Deck Rollers and Skids
Removing the Cutting Deck Rollers and Skids
Installing the Cutting Deck Rollers and Skids

Chapter 11 : Operator Cab

General Information
Operator’s Manual
Electrical Components and Schematics
Cab Heater System
Service and Repairs
Roof Assembly
Removing the Roof Assembly
Installing the Roof Assembly
Heating Components
Mixing Box Assembly
Removing the Mixing Box Assembly
Installing the Mixing Box Assembly
Heater Core
Removing the Heater Core
Installing the Heater Core
Blower Fan
Removing the Blower Fan
Installing the Blower Fan
Windshield Wiper Assembly
Disassembling the Windshield Wiper Assembly
Assembling the Windshield Wiper Assembly
Appendix A: Foldout Drawings
Electrical Drawing Designations
Hydraulic Schematic-3280-D (Serial Numbers below 270000400) and 3320 (Serial Numbers below 280000000)
Hydraulic Schematic-3280-D (Serial Numbers 270000400 to 311000000) and 3320 (Serial Numbers 280000000 to 311000000)
Hydraulic Schematic-3280-D (Serial Numbers 311000001 through 316000000)
Hydraulic Schematic-3280-D (Machine Serial Numbers after 316000000)
Electrical Schematic-3320
Electrical Schematic (Machine Serial Number before 311000000)
Electrical Schematic (Machine Serial Number 311000000 and Up)
Electrical Schematic-Operator Cab
Electrical Schematic-Operator Cab
Wire Harness Drawing-Main-3320 (Serial Numbers below 260000000)
Wire Harness Diagram-Main-3320 (Serial Numbers below 260000000)
Wire Harness Drawing-Main-3320 (Serial Numbers above 260000000)
Wire Harness Diagram-Main-3320 (Serial Numbers above 260000000)
Wire Harness Drawing-Main-3280-D (Serial Numbers below 260000000)
Wire Harness Diagram-Main-3280-D (Serial Numbers below 260000000)
Wire Harness Drawing-Main-3280-D (Machine Serial Number 260000000 to 270000600)
Wire Harness Diagram-Main-3280-D (Machine Serial Number 260000000 to 270000600)
Wire Harness Drawing-Main-3280-D (Machine Serial Number 270000601 to 311000000)
Wire Harness Diagram-Main-3280-D (Machine Serial Number 270000601 to 311000000)
Wire Harness Drawing-Main-3280-D (Machine Serial Number 311000000 to 316000000)
Wire Harness Diagram-Main-3280-D (Machine Serial Number 311000000 to 316000000)
Wire Harness Drawing-Main-3280-D (Machine Serial Number 316000000 to 400000000)
Wire Harness Diagram-Main-3280-D (Machine Serial Number 316000000 to 400000000)
Wire Harness Drawing-Main-3280-D (Machine Serial Number 400000000 and Up)
Wire Harness Diagram-Main-3280-D (Machine Serial Number 400000000 and Up)
Wire Harness Drawing-Cab Model 30298 Power
Wire Harness Diagram-Cab Model 30298 Power
Wire Harness Drawing-Cab Model 30298 Headliner
Wire Harness Diagram-Cab Model 30298 Headliner
Wire Harness Drawing-Cab Model 30298 Front Mount Accessory Power Supply
Wire Harness Diagram-Cab Model 30298 Front Mount Accessory Power Supply
Wire Harness Drawing-Cab Model 30298 Heat, Air Conditioning Blower
Wire Harness Diagram-Cab Model 30298 Heat, Air Conditioning Blower
Wire Harness Drawing-Light Kit Model 30405 (Machines without Cab)
Wire Harness Diagram-Light Kit Model 30405 (Machines without Cab)
Wire Harness Drawing-North American Light Kit Model 30701 (Machines Serial Number 315000000 and Up)
Wire Harness Diagram-North American Light Kit Model 30701 (Machines Serial Number 315000000 and Up)