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Toro Groundmaster 31900, Service Manual

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Toro Groundmaster 31900 Service Manual Download 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 – Hydraulic ................................................................................................................ 3–14
General Hydraulic System Problems ................................................................................................... 3–15
Traction System Problems................................................................................................................... 3–17
Steering System Problems .................................................................................................................. 3–19
Cutting Unit (or attachment) Lift/Lower Problems ................................................................................ 3–20
Troubleshooting – Electrical ................................................................................................................ 3–21
Starting Problems ................................................................................................................................ 3–22
General Run and Transport Problems ................................................................................................. 3–24
Cutting Unit (or attachment) Problems................................................................................................. 3–25
Factors That Can Affect Quality of Cut................................................................................................. 3–26

The information In this chapter is intended to help troubleshoot machine operation issues. Keep in mind
there can be more than one cause for a machine malfunction.

Groundsmaster

®

3200, 3300 and 3310

Page 3–1

Troubleshooting

19240SL Rev A

Summary of Contents for Groundmaster 31900

Page 1: ...Groundsmaster 3200 3300 and 3310 Models 31900 31901 31902 31903 31907 and 31909 2019 The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 Original Instructions EN Contact us at www Toro co...

Page 2: ...Revision History Revision Date Description A 2 2020 Initial release Revision History Page 2 Groundsmaster 3200 3300 and 3310 19240SL Rev A...

Page 3: ...encourage user feedback Please comment on the completeness accuracy organization usability and readability of this manual by an e mail to servicemanuals toro com or Mail to Technical Publication Mana...

Page 4: ...Reader Comments Page 4 Groundsmaster 3200 3300 and 3310 19240SL Rev A...

Page 5: ...Table of Contents for a list of the systems and the related topics covered in this manual Refer to the traction unit and cutting unit Operator s Manual for additional information about operating maint...

Page 6: ...icon is used to highlight an assembly torque requirement that is different than what is recommended in the Standard Torque Tables refer to Standard Torque for Dry Zinc Plated and Steel Fasteners Inch...

Page 7: ...s 3 24 Cutting Unit or attachment Problems 3 25 Factors That Can Affect Quality of Cut 3 26 Chapter 4 Engine 4 1 General Information 4 2 Service and Repairs 4 9 Chapter 5 Hydraulic System 5 1 General...

Page 8: ...nel A 17 Wire harness Cab HVAC Adapter A 18 Wire Harness Cab Work Light Kit optional A 19 Wire Harness Road Light Kits Lights optional A 20 Wire Harness Road Light Kit Controls optional A 21 Slope Sen...

Page 9: ...pter 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...

Page 10: ...sult in serious injury CAUTION This safety symbol means caution When you see this symbol carefully read the instructions that follow Failure to obey the instructions can result in minor to moderate in...

Page 11: ...tart Avoid burns Do not touch the engine muffler or other components which may be hot during operation while the unit is running or shortly after it has been running Allow the engine muffler and other...

Page 12: ...your body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause...

Page 13: ...es the amount of water it holds and the amount of fire it can extinguish Geometric symbol green triangle Class B fire extinguishers are for fires that involve flammable or combustible liquids such as...

Page 14: ...ge the parking brake and block the 2 rear wheels with chocks to prevent the machine from moving 3 Position the jack securely under the desired jack point Front Position the jack securely under the fra...

Page 15: ...the 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 you...

Page 16: ...Safety Safety and Instructional Decals Page 1 8 Groundsmaster 3200 3300 and 3310 19240SL Rev A...

Page 17: ...ecifications 2 7 Calculating the Torque Values When Using a Drive Adapter Wrench 2 8 Identifying the Fastener 2 9 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 2 10 Standard Torq...

Page 18: ...Specifications Overall Dimensions g301400 Figure 2 Specifications and Maintenance Specifications Page 2 2 Groundsmaster 3200 3300 and 3310 19240SL Rev A...

Page 19: ...Gear driven trochoid type Coolant capacity 6 6 L 7 US qt Alternator Regulator 12 VDC 40 A Engine weight dry 135 kg 298 lb Engine Model 31902 31903 Item Description Make Designation Yanmar Model 3TNV8...

Page 20: ...type Governor Centrifugal all speed governor Low idle no load 1 150 to 1 250 rpm High idle no load 3 200 to 3 250 rpm Engine oil API CJ 4 or higher refer to the traction unit Operator s Manual for ad...

Page 21: ...413 kPa 60 psi relief Hydraulic fluid Refer to the Traction Unit Operator s Manual Hydraulic reservoir capacity Minimum 18 9 L 5 US gallons Maximum 45 4 L 12 US gallons Chassis Item Description Front...

Page 22: ...2 and 31973 135 to 149 N m 100 to 110 ft lb Caster wheels Rotary cutting unit 8 x 3 5 4 4 ply smooth semi pneumatic F60 Flail cutting unit 8 x 3 5 4 4 ply smooth pneumatic 276 kPa 40 psi Rotary cuttin...

Page 23: ...ness of the surface underneath the head of the fastener or similar condition which affects the installation As noted in the following tables the torque values should be reduced by 25 for lubricated fa...

Page 24: ...When using a torque wrench with a drive adapter wrench the calculated torque will be lower than the listed torque recommendation Example The measured effective length of the torque wrench distance fro...

Page 25: ...to the fastener and pre applied dry thread locking compound Keep in mind a fastener with a locking feature usually means there will be friction during initial installation and during removal Toro reco...

Page 26: ...70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 6 75 8 77 8 104 11 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 11 142 15 1 2 20 UNF 32 4 53 7 72 9 85 9 115 12 120 12 163 16 5 8 11 UNC 65 10 88 12 119 16 150 15...

Page 27: ...X 2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 N m Note Reduce the torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a l...

Page 28: ...14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5 Class 8 8 80 10 ft lb 108 14 N m For steel wheels and non lubricated fasteners Thread Cutting Sc...

Page 29: ...stener installation Most thread locking compounds allow the fastener to be removed with standard tools once cured High strength thread locking compounds may require applying heat to the fastener and t...

Page 30: ...residue and previously used gaskets or gasket compounds SILICONE SEALANT Designed for a broad variety of sealing and bonding requirements silicone sealants are usually room temperature vulcanizing RTV...

Page 31: ...ts for flow and pressure capacities The tester flow measurement maximum is 57 LPM 15 GPM This tester includes the following Inlet Hose This hose connects the system circuit to the inlet side of the hy...

Page 32: ...ge rated at 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 TOR4...

Page 33: ...11 16 16 TOR4079 18 8 ORFS 13 16 16 TOR4079 19 CAP 2 each 10 ORFS 1 14 TOR4079 20 6 ORFS 11 16 16 to 8 SAE ORB 3 4 16 TOR4079 8 8 ORFS 13 16 16 to 8 SAE ORB 3 4 16 TOR4079 9 UNION 1 each 10 ORFS 1 14...

Page 34: ...t 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 re...

Page 35: ...terminal protector to the connection after you secure the battery cable ring terminal or fork terminal Dielectric Gel Toro Part No 107 0342 Use the dielectric gel to prevent corrosion of unsealed conn...

Page 36: ...Specifications and Maintenance Special Tools Page 2 20 Groundsmaster 3200 3300 and 3310 19240SL Rev A...

Page 37: ...ic System Problems 3 15 Traction System Problems 3 17 Steering System Problems 3 19 Cutting Unit or attachment Lift Lower Problems 3 20 Troubleshooting Electrical 3 21 Starting Problems 3 22 General R...

Page 38: ...n the focus of the problem 3 Assess Performance Ensure that you have all the necessary tools for testing Test all potential causes of the failure Reevaluate and create a new hypothesis if necessary 4...

Page 39: ...DERATE Engine Too Hot Engine Derate Check cooling system B2029 ENGINE RPM RESTRICTED Out Of Seat Engine Shutdown Must be seated B202F ENGINE SHUTDOWN Parking Brake Engaged Engine Shutdown Disengage p...

Page 40: ...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 G...

Page 41: ...e speed increase decrease switch 2 Check the wire harness connectors P100 P106 for damage or corrosion and clean or repair if necessary 3 Check the circuit wiring B105D Cutting unit Raise Lower Switch...

Page 42: ...connectors for damage or corrosion and clean or repair if necessary Model 31900 01 P100 P19 P202 P203 Model 31902 03 P100 P19 P53 P55 P01 2 Test the engine run output circuit wiring 3 Test the engine...

Page 43: ...t could be to battery voltage or to another signal that is in a high state 1 Check the wire harness connectors P100 P32 for damage or corrosion and clean or repair if necessary 2 Test the SV2 output c...

Page 44: ...known good unit contact an Authorized Toro Distributor for assistance C14C5 PTO Open Circuit Open circuit detected on PTO output circuit 1 Check the wire harness connectors for damage or corrosion an...

Page 45: ...emperature sender and replace if necessary P100D Engine Coolant Temperature Above Threshold Engine Shut Down Engine coolant temperature has exceeded 115 C 239 F Engine is shut down 1 Allow the engine...

Page 46: ...rness connector P86 10A B Test engine ECU supply and ground circuit wiring 2 Test the CAN bus U1117 Source Address Contention Fault TDM controller received a message from another controller on the CAN...

Page 47: ...s active their codes will scroll across the bottom of the TDM display controller screen one by one Depending on the severity of the fault a STOP icon may also be displayed Recent faults can be viewed...

Page 48: ...the cutting unit or attachments and all moving parts while troubleshooting to prevent personal injury If a machine operation is malfunctioning the following procedure can help identify the component o...

Page 49: ...the OK Run output display ON the engine is allowed to crank when the key switch is set to the START position refer to Figure 7 g307543 Figure 7 Note If the Oil Pressure input does not display ON withi...

Page 50: ...Review the hydraulic schematic found in Appendix A page A 1 and information on the hydraulic system operation in the Hydraulic Flow Diagrams page 5 13 This information will be useful during the hydrau...

Page 51: ...level The hydraulic system has a wrong type of fluid Replace the hydraulic fluid Note Refer to the traction unit Operator s Manual for hydraulic fluid specifications The incompatible hydraulic fluids...

Page 52: ...around the fluid cooler The traction pump bypass valve is open or damaged Close or replace the traction pump bypass valve The charge pressure is low steering and lift circuit performance is also affec...

Page 53: ...essure Test in the Hydraulic System chapter of this manual The wheel motor s is worn or damaged Verify wheel motor operation refer to Testing the Traction Circuit Wheel Motor Efficiency in the Hydraul...

Page 54: ...is also affected Verify charge pressure refer to Testing the Traction Circuit Charge Pressure in the Hydraulic System chapter of this manual The traction pump is worn or damaged Verify traction pump...

Page 55: ...ef valve R4 operation refer to Testing the Steering and Lift Circuit Steering Cylinder and Circuit Relief Valve in the Hydraulic System chapter of this manual Steering is sluggish operates poorly or i...

Page 56: ...ure refer to Testing the Traction Circuit Charge Pressure in the Hydraulic System chapter of this manual Lift cylinders will not raise or raise slowly Verify gear pump P2 performance refer to Testing...

Page 57: ...fective troubleshooting and repairs you must have a good understanding of the electrical circuits and components that are used on this machine refer to the Electrical Schematics and Wire Harness Drawi...

Page 58: ...r corrosion or damaged pins Reprogram or replace the TDM display controller contact an Authorized Toro Distributor for assistance Engine ECU is damaged models 31902 and 31903 Check the engine ECU and...

Page 59: ...ne The engine or fuel system is malfunctioning Test the engine fuel system refer to the Yanmar Service Manual and Troubleshooting Manual for the engine Engine ECU is damaged models 31902 and 31903 Che...

Page 60: ...Distributor for assistance Engine ECU is damaged models 31902 and 31903 Check the engine ECU and wire harness connector for corrosion or damaged pins The engine shuts off during operation but it is ab...

Page 61: ...achine Test the solenoid valve coil SV1 and replace if necessary Test the machine wire harness solenoid valve SV1 circuit The cutting unit or attachment does not lift A hydraulic issue exists in the l...

Page 62: ...del 02835 flail mower check the air pressure of the pneumatic caster wheel tires Adjust to the pressure specified in the flail mower Operator s Manual Blade condition Sharpen the blades if their cutti...

Page 63: ...s 4 5 Diesel Particulate Filter 4 5 Service and Repairs 4 9 Air Cleaner Assembly 4 9 Exhaust System 4 11 Radiator 4 13 Fuel System 4 16 Engine 4 19 Additional Reference Materials Yanmar Service Manual...

Page 64: ...ributor 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 Traction Unit Operator s...

Page 65: ...trical connectors should be plugged into the ECU before the machine key switch is moved from the OFF position to either the ON or START position The engine ECU is attached to the underside of the oper...

Page 66: ...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 e...

Page 67: ...e 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 Troubles...

Page 68: ...harmful emissions and incinerating soot to ash Passive regeneration occurs as part of normal engine operation The display screen does not display an icon during passive regeneration While operating t...

Page 69: ...ing more soot to the DPF after a parked regeneration was requested Can only be initiated when prompted by the engine ECU The display screen displays the stationary regeneration icon Manually initiate...

Page 70: ...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 Groundsmaste...

Page 71: ...t or attachment engage the parking brake set the key switch to the Off position and remove the key from the key switch 2 Raise the hood 3 Remove the air cleaner components if necessary 4 Refer to Trac...

Page 72: ...ner housing 7 Vacuator valve 4 Flange nut 2 each 8 Air cleaner cover A If the service indicator or pipe nipple were replaced Apply sealant to the threads of the nipple and install the nipple in the ai...

Page 73: ...ssary 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 f...

Page 74: ...h 2 Raise the hood and allow the exhaust system to cool before servicing the exhaust system components 3 Remove and install the exhaust system components if necessary Do not reuse exhaust gaskets Clea...

Page 75: ...c tube assembly 6 Radiator foam 2 each 14 Coolant reservoir hose 22 Hydraulic fitting straight 7 Radiator foam 2 each 15 Coolant reservoir 23 Hydraulic fitting elbow 8 Radiator shroud assembly 16 Supp...

Page 76: ...from radiator 7 Remove the support bracket from the left side of the radiator assembly 8 For model 31902 31903 machines disconnect the fuel hoses from the fuel cooler and pass the hoses out through th...

Page 77: ...side of the radiator assembly 7 Connect the upper and lower radiator hoses to the radiator and secure the hoses with the hose clamps 8 Install the support bracket to the left side of the radiator ass...

Page 78: ...Lock washer 12 Fuel hose return 4 Flat washer 13 Barb fitting 2 used 5 Bumper 4 used 14 Grommet 3 used 6 Fuel cap 15 Fuel hose vent 7 Bracket hold down 16 Clamp 2 used 8 Seal 17 Tube vent 9 Fuel level...

Page 79: ...y flammable and explosive A fire or an explosion from the fuel can burn you burn other people and damage property Use caution whenever you store or handle diesel fuel Do not smoke while handling diese...

Page 80: ...ld down bracket from the ROPS 4 Remove the battery cover 5 Remove the cap screw item 2 from under the front of the fuel tank IMPORTANT To prevent damage to the fuel hoses cable ties and clamps may be...

Page 81: ...nut 3 each 7 Cap screw 14 Stub shaft 21 Engine lift lugs Removing the Engine Refer to Figure 17 for this procedure 1 Remove the radiator and hydraulic fluid cooler refer to Removing the Radiator and...

Page 82: ...nd 31909 only 2 DPF temperature sensors model 31902 31903 31907 and 31909 only 4 engine wire harness connectors model 31902 31903 31907 and 31909 only On the right side of the engine Fusible link conn...

Page 83: ...heck the condition of the motor mounts and replace if necessary Ensure that the battery negative cable is secured to one of the front left motor mount fasteners 15 Continue to disassemble the engine i...

Page 84: ...kets 7 Install the PTO clutch stop strap 8 Connect the cutting unit drive shaft at the PTO clutch 9 Use a 1 2 inch square drive on the hydraulic pump drive belt idler arm and install the pump drive be...

Page 85: ...k 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 necess...

Page 86: ...Engine Service and Repairs Page 4 24 Groundsmaster 3200 3300 and 3310 19240SL Rev A...

Page 87: ...p P2 Flow and Circuit Relief Valve 5 40 Testing the Steering and Lift Circuit Steering Cylinder and Circuit Relief Valve 5 45 Testing the Steering and Lift Circuit Lift Cylinder Internal Leakage 5 47...

Page 88: ...ference 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 U...

Page 89: ...ng Pressure from the Hydraulic System Release all the pressure in the hydraulic system before you work on the hydraulic system Note If you park the machine on an incline or slope the pressure in the t...

Page 90: ...than a short distance the machine should be transported on a trailer 1 Access the bypass valve from under the machine g296244 Figure 18 1 Traction pump 2 Bypass valve 2 Use an 11 16 box end wrench to...

Page 91: ...g hydraulic test gauges to test traction circuit components or after replacing a failed traction circuit component The filter will ensure that contaminates are removed from the closed loop traction ci...

Page 92: ...on the system Keep your body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Do not use your hands to search for leaks use a piece of paper or cardboard Hy...

Page 93: ...e in alignment with a wrench use a torque wrench to tighten the swivel nut to the recommended torque value within the specified range of torque values refer to the Hose Tube Installation Torque Table...

Page 94: ...1 2 16 1 inch 1 3 to 1 2 5 If a torque wrench is not available or if space at the swivel nut prevents the use of a torque wrench use the alternative procedure Flats From Wrench Resistance FFWR given...

Page 95: ...ocket to tighten the fitting to the recommended torque value within the specified range of torque values refer to the Fitting Installation Torque Table page 5 11 Note It may be necessary to use a driv...

Page 96: ...possible Ensure that the back up washer is not loose and it is pushed up as far as possible Step 1 in Figure 23 5 Install the adjustable fitting into the port by hand until the washer contacts the fa...

Page 97: ...FFFT Table page 5 11 Fitting Installation Torque Table Fitting Dash Size Fitting Port Side Thread Size inch threads per inch Installation Torque Into Steel Port Installation Torque Into Aluminum Port...

Page 98: ...c 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 19240...

Page 99: ...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: ...e hydraulic manifold equalize traction system pressure to reduce tire scuffing when turning Check valves in the hydraulic manifold allow the rear wheel motors to over run during tight turns Hydraulic...

Page 101: ...Pa 3625 psi by the reverse traction relief valve R2 located in the piston traction pump For 4WD machines check valves in the hydraulic manifold allow the hydraulic fluid to bypass the rear wheel motor...

Page 102: ...rs the steering control valve at the P port and by passes the rotary meter and steering cylinder Flow leaves the steering control valve through the E port and is directed to the lift manifold to suppl...

Page 103: ...Flow entering the steering control valve at the P port passes through the rotary meter and is directed out port R Pressure extends the steering cylinder for a right turn The rotary meter ensures that...

Page 104: ...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 105: ...ow through the manifold and back to the gear pump P2 until the lift switch is released The lift circuit pressure is limited to 7 000 to 7 500 kPa 1 015 to 1 088 psi A check valve in solenoid valve SV2...

Page 106: ...is located near the front of the machine under the operator floor plate Gear pump P2 supplies oil flow for the steering circuit optional auxiliary valve circuit lift circuit and also provides a const...

Page 107: ...et to the right position solenoid S2 is energized and fluid flow is directed to the B port of the auxiliary valve manifold female quick disconnect fitting When the hydraulic component controlled by th...

Page 108: ...essure Do not use your hands to search for leaks use a piece of paper or cardboard Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If h...

Page 109: ...ed hydraulic performance parameters aprox 3 per 100 engine rpm at full throttle IMPORTANT Hydraulic component output volume relates directly to engine RPM For every 100 engine rpm the following compon...

Page 110: ...r Efficiency and or Traction Pump P1 Flow and Relief Valve If a steering optional auxiliary valve or lift circuit problem exists consider performing one or more of the following tests Steering Relief...

Page 111: ...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: ...sure gauge that has at least a 114 L minute 30 gallons minute capacity 2 Hydraulic Hoses 1 Park the machine on a level surface lower the cutting unit or attachment and set the key switch to the OFF po...

Page 113: ...place or repair the hydraulic pump charge relief valve refer to Servicing the Traction piston Pump P1 page 5 73 B Gear pump P2 is faulty steering and lift circuit performance will also be affected Tes...

Page 114: ...t 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 3...

Page 115: ...g 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...

Page 116: ...n regarding the importance of removing contamination from the traction circuit 1 Park the machine on a level surface lower the cutting unit or attachment and set the key switch to the OFF position 2 R...

Page 117: ...installed in the correct flow direction toward the wheel motors and the tester flow control valve is fully open Note Remove and reinstall the wheel to access the wheel motor hydraulic connections if...

Page 118: ...ulic ORFS cap and plug the port of the disconnected wheel motor with a hydraulic ORFS plug 5 Disconnect the rear wheel motor on the opposite side of the front motor being tested from the traction circ...

Page 119: ...ame hose to the remaining exposed bulkhead fitting 6 Start the engine and run it at low idle speed Correct any hydraulic fluid leaks at the test connections before continuing the test 7 Start the engi...

Page 120: ...4 L minute 1 gallons minute Model 31902 31903 31907 and 31909 less than 3 4 L minute 0 9 gallons minute 14 If specifications are not met replace or repair the worn wheel motor refer to Wheel Motors pa...

Page 121: ...the tester flow control valve is fully open 5 Disconnect the rear wheel motor supply hose for the motor not being tested Cap the disconnected bulkhead fitting with a hydraulic ORFS cap and plug the di...

Page 122: ...nce Testing of wheel motor leakage in the 3 different wheel positions will provide the most accurate test results The flow through a stationary front wheel motor should be Model 31901 less than 3 4 L...

Page 123: ...Eventually enough fluid bypass will cause the unit to stall under heavy load conditions Continued operation can generate excessive heat cause damage to seals and other components in the hydraulic syst...

Page 124: ...before continuing the test 7 Start the engine and move the throttle to the full speed Model 31900 and 31901 3235 rpm Model 31902 and 31903 3150 rpm Model 31907 and 31909 3235 rpm 8 Make sure hydrauli...

Page 125: ...e flow control valve fully move the throttle to low speed and set the key switch to the OFF position 13 If the relief pressure can not be met or is greater than specified the traction relief valve is...

Page 126: ...mp have worn Continued operation with a worn pump can generate excessive heat and cause damage to the seals and other components in the hydraulic system The relief valve for the steering and lift circ...

Page 127: ...and set the key switch to the OFF position 2 Read and adhere to the information provided in Testing the Hydraulic System page 5 22 3 Ensure that the traction pedal is correctly adjusted for the NEUTRA...

Page 128: ...eed Model 31900 and 31901 3235 rpm Model 31902 and 31903 3150 rpm Model 31907 and 31909 3235 rpm 10 Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximat...

Page 129: ...ck position Record the pressure at which the relief valve opens C Open the circuit relief valve via the lift system Watch the pressure gauge on the tester and set the lift lower switch to the LIFT pos...

Page 130: ...c 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 mach...

Page 131: ...t Procedure 1 Ensure that the hydraulic fluid is at normal operating temperature by operating the machine for at least 10 minutes 2 Drive the machine slowly in a figure eight on a flat level surface A...

Page 132: ...eck that the engine speed is correct IMPORTANT Turn the steering wheel to the left only long enough to get a system pressure reading Turning the steering wheel to the left for an extended period may d...

Page 133: ...the lift cylinder binding extra weight on the cutting unit and or binding of the lift components Ensure that these items are checked before performing the lift cylinder internal leakage test Note The...

Page 134: ...item 10 securing the fire wall to the frame F Remove the 6 fasteners items 6 and 11 securing the operator platform assembly to the frame G Raise and support the front of the operator platform assembl...

Page 135: ...kly replace or repair the lift cylinder refer to Lift Cylinder page 5 102 or Lift Cylinder Service page 5 104 11 Use a jack to raise the cutting unit and lift arms slightly Support the cutting unit wi...

Page 136: ...cutting unit or attachment and set the key switch to the OFF position WARNING Review and follow the Jacking Instructions page 1 6 before lifting the machine 2 Raise both front wheels for 2WD machines...

Page 137: ...ir gap between the face of the neutral switch and the pump lever and adjust if necessary refer to Adjusting the Traction Neutral Switch page 6 29 8 When finished remove the jack stands and lower the m...

Page 138: ...pressure in the system refer to Relieving Pressure from the Hydraulic System page 5 3 5 The hydraulic fluid may be hot Be careful when you loosen and remove the hydraulic system components 6 Install c...

Page 139: ...the pumps system drain flush or pump removal installation it is important to properly prime the hydraulic pumps refer to Priming the Hydraulic Pumps page 5 60 7 After you disconnect or replace any hy...

Page 140: ...t high pressure hydraulic fluid Use a piece of cardboard or paper to find hydraulic leaks Release all pressure in the hydraulic system before performing any work on the system Seek immediate medical a...

Page 141: ...hine with contaminated hydraulic fluid to warm the fluid before draining IMPORTANT Follow all local codes and regulations when recycling or disposing the hydraulic fluid and filters 3 Drain the hydrau...

Page 142: ...ydraulic fluid refer to the traction unit Operator s Manual 9 Prime the hydraulic pumps refer to Priming the Hydraulic Pumps page 5 60 10 Charge the hydraulic system refer to Charging the Hydraulic Sy...

Page 143: ...switch to the OFF position and remove the key from the key switch 2 Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components page...

Page 144: ...PORTANT If using a hydraulic filter that is not bidirectional install the filter with the flow direction toward the traction pump for a traction pump failure and toward the wheel motors for a wheel mo...

Page 145: ...color is showing during the operation 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 If the...

Page 146: ...itch to the OFF position and remove the key from the key switch 3 Check the hydraulic fluid level in the hydraulic tank and add the correct type and quantity of fluid if necessary refer to the tractio...

Page 147: ...seconds to allow the starter motor and starter solenoid to cool Repeat the cranking procedure for the second time 8 Disconnect the remote starter switch leads from the machine 9 Charge the hydraulic...

Page 148: ...nstructions page 1 6 before lifting the machine 5 Raise the front wheels of 2WD machines or all of the wheels for 4WD machines off the floor and support the machine with jack stands 6 Make sure the tr...

Page 149: ...hen released and adjust if necessary refer to Adjusting the Traction System for Neutral page 5 50 12 Lower the machine to the ground 13 Operate the machine by gradually increasing its work load to ful...

Page 150: ...ving and installing the Hydraulic Tank Refer to Figure 47 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 t...

Page 151: ...stem 7 Remove the hydraulic tank from the machine 8 Inspect the 4 rubber bumpers that support the hydraulic tank for damage or wear and replace them if necessary 9 Inspect the 2 rubber grommets that s...

Page 152: ...ator foam 2 each 14 Coolant reservoir hose 22 Hydraulic fitting straight 7 Radiator foam 2 each 15 Coolant reservoir 23 Hydraulic fitting elbow 8 Radiator shroud assembly 16 Support bracket LH 24 Hydr...

Page 153: ...e the hood 3 Use a 1 2 inch square drive on the hydraulic pump drive belt idler arm to relieve the belt tension and remove the belt from the idler and pump pulleys 4 Disconnect the cutting unit drive...

Page 154: ...square drive on the hydraulic pump drive belt idler arm to relieve the belt tension and remove the belt from the pump pulley 4 Allow the idler arm to rest with no spring load 5 Disassembly the pump dr...

Page 155: ...on 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...

Page 156: ...ion piston pump 14 O ring Removing the Traction piston Pump Note The gear pump P2 can be removed separately or with the traction piston pump refer to Removing the Gear Pump page 5 75 Refer to Figure 5...

Page 157: ...p assembly before removing the pump mounting bolts 12 Remove the fasteners securing the pump s to the machine and carefully remove the pump s out the right side of the machine 13 If not previously rem...

Page 158: ...efer to Installing Hydraulic Hoses and Tubes O Ring Face Seal Fitting page 5 7 Tighten the gear pump suction hose clamp to 10 N m 90 in lb 9 Connect the traction cable to the cable bracket and the pum...

Page 159: ...ool 8 End cap 24 Seal 40 Spring 9 End cap gasket 25 Backup washer 41 Plug 10 Thrust plate 26 Retaining ring 2 each 42 O ring 11 Swash plate 27 Retaining ring 2 each 43 Bypass valve 12 Pin 2 each 28 Tr...

Page 160: ...on 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...

Page 161: ...system Tighten the drain plug from 18 to 19 N m 155 to 171 in lb 3 Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components page...

Page 162: ...a suction port is near the input shaft of the gear pump Figure 54 Before the gear pump is installed ensure that any plugs placed in either of these ports are removed Failure to remove the plugs will...

Page 163: ...alling 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 Re...

Page 164: ...ar pump must be replaced as a complete assembly Individual gears housings and thrust plates are not available separately Disassemble inspect and assemble the gear pump for cleaning inspection and seal...

Page 165: ...face hammer to loosen the pump section IMPORTANT Mark the relative positions of the gear teeth and the thrust plates so they can be reassembled in the same position Do not touch the gear surfaces as r...

Page 166: ...r or scoring B The face of the thrust plates that are in contact with the gears should be free of wear roughness or scoring C The thickness of the thrust plates should be equal 5 Inspect the front cov...

Page 167: ...il to the gear faces E Install the rear thrust plate with the pressure seal side up and the open side of the pressure seal pointing to the inlet side of the pump F Install the dowel pins in the body G...

Page 168: ...talling the Wheels page 7 5 2 Disengage the parking brake and remove the brake return spring cotter pin clevis pin and washer that attach the brake cable to the brake actuator lever 3 Remove the brake...

Page 169: ...n unit Parts Catalog and part number on the wheel motor to identify the right and left motors The left side wheel motors are identified with a yellow dot on the motor housing near the B port Refer to...

Page 170: ...g and Installing the Wheels page 7 5 11 Charge the hydraulic system refer to Charging the Hydraulic System page 5 62 12 Check and adjust the parking brake as necessary before returning the machine to...

Page 171: ...ne e g do not put the right motor on the left side of the machine If necessary use the traction unit Parts Catalog and part number on the wheel motor to identify the right and left motors The left sid...

Page 172: ...0 3310 machines are Parker Torqmotor motors of the same basic design with minor differences The front wheel motors are TG series motors and the rear wheel motors are TL series motors The motor displac...

Page 173: ...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...

Page 174: ...mpty the hydraulic tank through the drain plug at the bottom of the tank Use a new O ring and install the plug when finished to prevent contamination from entering the hydraulic system Tighten the dra...

Page 175: ...Hydraulic Manifold Service page 5 90 2 Fit the manifold to the machine and secure it with the previously removed fasteners Tighten the cap screws from 36 to 44 N m 27 to 33 ft lb 3 Remove the caps and...

Page 176: ...leak plug with O ring 6 each 19 Elbow fitting 4 Check valve CV2 12 Diagnostic fitting 4 each 20 Logic cartridge LC 5 Solenoid coil 2 each 13 Cap 4 each 21 8 zero leak plug with O ring 6 Coil nut 2 eac...

Page 177: ...is the pressure connection port from the steering control valve and SV1 is the location for the lift lower solenoid valve refer to the hydraulic schematic in Appendix A page A 1 to identify the functi...

Page 178: ...position for assembly purposes If the hydraulic fittings are to be removed from the manifold 1 Mark the fitting orientation for assembly purposes 2 Remove the fittings from the manifold and discard th...

Page 179: ...nd the back up rings Remove and discard the seal kit from the cartridge valve 5 Visually inspect the manifold port and the cartridge valve A Check for damaged threads on the cartridge valve and in the...

Page 180: ...distortion of the stem tube can cause binding and malfunction Make sure that deep well socket fully engages the valve base B Lubricate the threads on the cartridge valve with clean hydraulic fluid Thr...

Page 181: ...aise the steering cover 3 Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components page 5 52 4 Clean the hydraulic tube ends and f...

Page 182: ...fittings and install the fittings to the steering control valve refer to Installing the Hydraulic Fittings SAE Straight Thread O Ring Fittings page 5 9 2 Apply anti seize lubricant to the splines of t...

Page 183: ...4 Shaft seal 12 Cardan shaft 20 Pin bolt 5 Thrust washer 13 O ring 21 Cap screw 4 each 6 Bearing race 14 Distributor plate 22 Ball 7 Ring 15 Outer gearwheel 8 Spring set 16 Inner gearwheel For the ste...

Page 184: ...and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components page 5 52 3 Clean the fitting and hydraulic hose connections before disconnec...

Page 185: ...the machine with the previously removed fasteners Secure the slotted nut with a new cotter pin 4 Remove the caps and plugs then connect the hydraulic tubes to the cylinder fittings refer to Installing...

Page 186: ...n E Adjust the right steering stop bolt until it contacts the right drag link F Tighten the steering stop bolt jam nuts and the steering cylinder rod end ball joint clamp 8 Check the hydraulic fluid l...

Page 187: ...cylinder must be replaced as a complete assembly Disassemble inspect and assemble the cylinder for inspection and seal replacement only The cylinder repair kit includes special tools required to repla...

Page 188: ...ift arm 4 Remove the nut pivot bolt and nylon washers securing the barrel end of the cylinder to the frame 5 Remove the pivot pin securing the rod end of the cylinder to the lift arm and lower the cyl...

Page 189: ...2 Remove the caps and plugs then connect the hydraulic tubes to the cylinder fittings refer to Installing Hydraulic Hoses and Tubes O Ring Face Seal Fitting page 5 7 3 Install the pivot pin securing...

Page 190: ...maged the cylinder must be replaced as a complete assembly Disassemble inspect and assemble the cylinder for inspection and seal replacement only The cylinder repair kit includes special tools require...

Page 191: ...e key switch to the OFF position and remove the key from the key switch 2 Label and disconnect wire harness connectors from the cartridge valve solenoids 3 To prevent contamination of hydraulic system...

Page 192: ...of the cartridge valve and hydraulic lines at each port For cartridge valve service procedures refer to Cartridge Valve Service page 5 93 1 Mark the fitting orientation to allow for correct assembly...

Page 193: ...09 6 25 Throttle Switch Model 31902 and 31903 6 26 Seat Switch 6 27 Traction Neutral Switch 6 29 Parking Brake Switch 6 32 Cutting Unit High Trim Height Switch 6 34 Windshield Washer Wiper Switch Mode...

Page 194: ...its accessories Refer to the traction unit Operator s Manual and accessory Installation Instructions for additional information Yanmar Engine Electrical Components When servicing or troubleshooting t...

Page 195: ...the main power relay is energized key switch is in the ON or START position A 15 Amp fuse FB1 F4 protects the TDM power circuit The TDM display controller is also a 2001 series microcontroller that mo...

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: ...nts that is controlled by the CAN bus link only needs four 4 wires to operate and communicate to the system CAN High CAN Low power and ground The key switch needs to be in the RUN or START position fo...

Page 198: ...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 Harness Drawings Diagr...

Page 199: ...1 Check to make sure each alternator drive belt is not loose worn or damaged 2 Turn the key switch to the ON position and set the TDM display controller screen to view the voltmeter battery icon 3 Re...

Page 200: ...cessary to allow a specific machine operation are not in their desired position an Operator s Advisory may appear on the TDM display controller screen refer to Operator Advisories page 3 3 The machine...

Page 201: ...ss connector for damage or corrosion and clean or repair if necessary Note Refer to the appropriate Yanmar engine Service manual or Troubleshooting Manual for your machine for additional electrical co...

Page 202: ...key switch to the OFF position and remove the key from the key switch 2 Disconnect the negative battery cable from the battery terminal and then disconnect the positive cable from the battery refer to...

Page 203: ...re 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 Connect the positive battery cab...

Page 204: ...steering column control pod and in the lighting kit wire harness Refer to Appendix A page A 1 for specific circuit information Fuse Identification and Function Main Fuse Blocks FB1 F1 models 31900 an...

Page 205: ...atics connector 3 Fuse engine ECU models 31902 and 31903 2 Fuse expansion port Located above the operator s platform in right rear corner 10 Amp supplies unswitched power to the telematics connector L...

Page 206: ...he cab power circuits via the cab power relay Located along the frame crossmember in front of the engine 15 Amp supplies unswitched power to the optional hazard light circuit Located along the frame c...

Page 207: ...switched power to the condenser fans and compressor clutch Road Light Kit Optional Fuse Block g306148 Figure 82 1 Control pod fuse block 3 Knob 2 each 2 Access panel Fuse F 1 10 Amp supplies switched...

Page 208: ...attachment engage the parking brake set the key switch to the OFF position and remove the key from the key switch 2 Remove the fuse from the fuse block or fuse holder for testing Check the fuse fuse b...

Page 209: ...nicate to the system CAN High CAN Low power and ground The key switch needs to be in the RUN or START position for the components on the network to be activated Two specially designed twisted wires fo...

Page 210: ...dicates one of the CAN bus terminator resistors is not connected or damaged Refer to CAN bus Terminator Resistors page 6 56 and or Appendix A page A 1 for additional information If necessary contact a...

Page 211: ...osition A 15 Amp fuse FB1 F4 protects the TDM power circuit The TDM display controller is also a 2001 series microcontroller that monitors the condition of various machine switches and sensors inputs...

Page 212: ...ION OUT 1 PTO Clutch OUT 2 Model 31900 31901 31907 and 31909 Start Interlock Relay coil Fuel Pump and Fuel Stop Solenoid hold coil Model 31902 and 31903 Start Interlock Relay coil and Engine ECU start...

Page 213: ...on and clean or repair if necessary Because of the solid state circuitry built into the controller there is no method to test the controller directly A controller may be damaged if an attempt is made...

Page 214: ...6 64 3 Remove the operator s console covers refer to Removing and Installing the Operator s Console Covers page 7 23 4 Disconnect the wire harness connector from the switch and remove the switch from...

Page 215: ...ake set the key switch to the OFF position and remove the key from the key switch 2 Disconnect the battery negative cable at the battery refer to Removing and Installing the Battery page 6 64 3 Remove...

Page 216: ...troller Screens for Troubleshooting page 3 12 If testing determines that the switch and circuit wiring are not functioning correctly proceed with the following test procedure 1 Park the machine on a l...

Page 217: ...g and Installing the Operator s Console Covers page 7 23 4 Disconnect the wire harness connector from the switch and remove the switch from the console if necessary Check the switch and the harness co...

Page 218: ...test 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 OFF position and remove the key from the key switch 2 Disco...

Page 219: ...ge 3 12 If testing determines that the switch and circuit wiring are not functioning correctly proceed with the following test procedure 1 Park the machine on a level surface lower the cutting unit or...

Page 220: ...eat switch A Detach the rear of the seat base fabric cover seat with suspension system B Access the top of the switch by slipping between the seat frame and the seat base foam C Release the switch fro...

Page 221: ...ed When the traction linkage moves toward Forward or Reverse the pump lever moves away from the switch face and the switch opens With the key switch in the RUN position the LED on the cable end of the...

Page 222: ...er adjusting the neutral switch use the TDM display controller screen to verify that neutral switch and circuit wiring are functioning correctly Testing the Traction Neutral Switch The traction neutra...

Page 223: ...n 2 ohms 1 Main P40 A Pink 2 Chassis Ground 12 VDC with key switch in the RUN position do not start engine 4 If the harness wires test correctly and the sensor LED does not function replace the tracti...

Page 224: ...h and its circuit wiring can be tested using the TDM display controller main information screens brake icon refer to Using the TDM Display Controller Screens for Troubleshooting page 3 12 If testing d...

Page 225: ...lem 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 8 Ins...

Page 226: ...opens With the key switch in the RUN position the LED on the cable end of the high trim height switch should be illuminated when the lift arm is in the lowered position Use a small mirror to view the...

Page 227: ...3 12 If testing determines that the switch and circuit wiring are not functioning correctly proceed with the following test procedure 1 Park the machine on a level surface lower the cutting unit or a...

Page 228: ...n replace the high trim height switch Connect the high trim height switch to the machine wire harness and adjust the switch after installation refer to Adjusting the Cutting Unit High Trim Height Swit...

Page 229: ...h 2 Remove the switch plate from the control panel cover 3 Disconnect the wire harness electrical connector from the windshield wiper washer switch Check the switch and the harness connector for damag...

Page 230: ...ch and remove the switch from the AC control panel if necessary 5 Use a multimeter ohms setting and the preceding table to determine whether continuity exists between the various terminals for each sw...

Page 231: ...he roof from the cab 4 Disconnect the wire harness connector from the switch and remove the switch from the control panel if necessary Check the switch and the harness connector for damage or corrosio...

Page 232: ...ng the Battery page 6 64 3 To access the switch remove the cover from the steering column control pod 4 Disconnect the machine wire harness connector from the multifunction switch Check the switch and...

Page 233: ...position and remove the key from the key switch 2 Disconnect the battery negative cable at the battery refer to Removing and Installing the Battery page 6 64 3 Remove the steering column control pod...

Page 234: ...es use 2 identical relays that have 4 terminals The relays are located in the operator s console A tag near the wire harness relay connector can be used to identify each relay Groundsmaster 3310 machi...

Page 235: ...e cutting unit or attachment engage the parking brake set the key switch to the OFF position and remove the key from the key switch 2 Disconnect the ground cable at the battery refer to Removing and I...

Page 236: ...Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85 9 Replace the relay if neces...

Page 237: ...have 5 terminals The relays are located in the operator s console A tag near the wire harness relay connector can be used to identify each relay Groundsmaster 3310 machines have three additional 5 te...

Page 238: ...AC clutch relay and the AC condenser fans relay must be energized to engage the compressor clutch models 31903 and 31909 only The AC clutch relay is energized by the thermostat as long as the minimum...

Page 239: ...al 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85 7 Connect multimeter ohms setting leads t...

Page 240: ...s for damage or corrosion and clean or repair if necessary Note Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small r...

Page 241: ...cessary 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 Electri...

Page 242: ...ng unit or attachment engage the parking brake set the key switch to the OFF position and remove the key from the key switch 2 Ensure that the fuel hoses attached to the fuel pump are free of obstruct...

Page 243: ...nd set the key switch to the RUN position for 30 seconds The pump should deliver approximately 350 ml 11 8 ounces in 30 seconds Replace the fuel pump if necessary 6 After testing connect the fuel hose...

Page 244: ...e Transient Voltage Suppression TVS Diode 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...

Page 245: ...nector P56 is used to protect the engine ECU from reverse polarity in the EGR relay circuit Testing the Diode Assemblies 1 Park the machine on a level surface lower the cutting unit or attachment enga...

Page 246: ...termines the diode is faulty replace the diode 5 If the diode tests correctly and a circuit problem still exists check the wire harnesses refer to Appendix A page A 1 6 After testing is complete make...

Page 247: ...Disconnect the resistor from the wire harness Check the resistor and the resistor holder for damage or corrosion and clean or repair if necessary 3 Measure the resistance across the resistor terminals...

Page 248: ...he front of the operator s console under the console cover external and is replaceable separately The second CAN bus termination resistor is part of the Yanmar engine ECU integrated and can be tested...

Page 249: ...istor 5 After testing is complete make sure the external terminator resistor is fully installed into the connector and secured to the wire harness 6 Install the operator s console covers if previously...

Page 250: ...ck White 120 ohms 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...

Page 251: ...or no resistance or open infinite resistance 1 Locate the hydraulic solenoid valve coil to be tested and disconnect the wire harness connector from the coil Check the harness connectors for damage or...

Page 252: ...hydraulic valve B Slide the solenoid coil from the valve C Clean any corrosion or dirt from the valve stem D Install the coil and the nut onto the valve and tighten nut to 7 N m 60 in lb 4 If the sol...

Page 253: ...battery condition weekly or after every 50 hours of operation Keep terminals and entire battery case clean because a dirty battery will discharge slowly IMPORTANT Do not remove fill caps while cleanin...

Page 254: ...el with the distilled or demineralized water Storing the Battery If you store the machine for more than 30 days 1 Remove the battery and charge it fully refer to Charging the Battery page 6 67 2 Store...

Page 255: ...80 F Discharged less than 1 24 Battery specifications BCI Group 26 540 CCA at 18 C 0 F Reserve Capacity of 80 minutes at 27 C 80 F Battery dimensions including terminal posts and caps Length 22 4 cm...

Page 256: ...Be careful when removing the battery cables and ensure that you do not damage the terminal posts or cable connectors 1 Ensure that the key switch and all accessories are in the OFF position 2 Open the...

Page 257: ...ct the negative cable connector to the negative battery terminal The cable clamp must be parallel to the edge of the battery before securing the clamp 10 After you make the connections apply battery t...

Page 258: ...E Check the electrolyte level in each cell If the level is below the tops of the plates in any cell fill all the cells with distilled water between the minimum and maximum fill lines Charge at 15 to 2...

Page 259: ...rer s instructions C Ensure that the battery terminals are free of corrosion D Measure the electrolyte temperature of the center cell E Connect a battery load tester to the battery terminals following...

Page 260: ...xplosion and can cause personal injury Let the battery warm to 15 C 60 F before connecting to a charger Charge the battery in a well ventilated place to dissipate the gases produced from the charging...

Page 261: ...usting the PTO Clutch 7 4 Service and Repairs 7 5 Wheels 7 5 Parking Brakes 7 7 Traction Pedal Cable and Control Assembly 7 11 Steering Column 7 13 Rear Axle and Spindles 7 16 PTO Shaft 7 19 Servicing...

Page 262: ...tallation 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 ac...

Page 263: ...the traction pedal fully forward extend the pedal stop bolt to contact the traction pedal 5 Release the traction pedal and extend the pedal stop bolt an additional 1 2 turn before locking the stop bo...

Page 264: ...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 2 If the gap is incorrect loosen or tigh...

Page 265: ...e fasteners lug nuts or cap screws that secure the wheel being removed to the machine IMPORTANT Before lifting the machine with a jack review and follow Jacking Instructions page 1 6 3 Raise the machi...

Page 266: ...pattern 7 Tighten the wheel fasteners to the specified torque refer to the specifications table for Chassis page 2 5 8 Check and adjust the tire pressures refer to the specifications table for Chassis...

Page 267: ...16 Spring pivot Disassembling the Parking Brakes Refer to Figure 112 for this procedure 1 Remove the front wheel refer to Removing and Installing the Wheels page 7 5 2 Disengage the parking brake and...

Page 268: ...e brake plate assembly with the previously removed fasteners IMPORTANT Before installing the wheel hub clean the tapers of the wheel hub and wheel motor shaft Ensure that the tapers are free of grease...

Page 269: ...in and washer that attach the brake cable to the brake actuator lever 3 Loosen the flange nuts that secure the brake cable to the brake cable bracket near the wheel motor and remove the cable from the...

Page 270: ...12 Ensure that the brake lever is completely disengaged down and fit the cable end into the equalizer bracket the cable housing into the bracket below the brake lever The cables should push the botto...

Page 271: ...p screw 2 each 32 Pedal stop bolt 9 Bearing 2 each 21 Cap screw 33 Traction pedal 10 Flange nut 12 each 22 Ball joint 2 each 34 Roll pin 11 Cap screw 2 each 23 Spacer 5 mm 0 21 inch 35 Forward pedal 1...

Page 272: ...ion cable to the cable bracket below the operator s platform E Check the traction pedal operation and adjust the traction cable before returning the machine to service refer to Adjusting the Traction...

Page 273: ...ke lower the cutting unit or attachment set the key switch to the OFF position and remove the key from the key switch 2 Carefully remove the steering wheel cover from the steering wheel 3 Remove the l...

Page 274: ...Pin 3 Lock washer 2 each 10 Pedal block 4 Release pin 11 Pedal 5 Cylinder shaft 12 Spring 6 Jam nut 13 Universal joint 7 Cylinder 14 Pin Installing the Steering Column 1 Assemble the steering column r...

Page 275: ...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 3200 3300 and 33...

Page 276: ...4 each 21 Thrust washer 6 Slotted nut 2 each 14 Retaining ring 2 each 22 Lock nut 7 Steering stop bolt 2 each 15 Cap 2 each 23 Grease fitting 8 Jam nut 2 each 16 Cap screw 2 each Removing the Rear Ax...

Page 277: ...ivot pin thrust washers Servicing the Rear Axle The rear axle must be held in place snugly by the axle pivot pin The rear wheel spindle pivot shafts must fit snugly in the rear axle Excessive movement...

Page 278: ...he tapers of the tie rod ends and the tapered sockets in the drag link arms C Fit the tie rod ends into the drag links tighten the slotted nuts and install new cotter pins 6 Install the rear wheels re...

Page 279: ...t flange at the PTO clutch apply medium strength thread locking compound to the cap screws and tighten from 18 to 21 N m 155 to 185 in lb in a star pattern 4 Install the cutting unit to the machine re...

Page 280: ...he yoke C Insert the cross into the yoke and bearing D Hold the cross in alignment and press the bearing in until it hits the yoke E Install the snap ring into the yoke groove to secure installed bear...

Page 281: ...he position of the cable ties securing the wire harness near the clutch and unplug the clutch harness connector from the machine wire harness 3 Remove the clutch stop strap Locate and retrieve the spa...

Page 282: ...N m 50 to 60 ft lb 9 Install the clutch stop strap Ensure that the spacers are in the stop strap and that the strap is tight against the clutch flange 10 Connect the PTO clutch to the machine wire har...

Page 283: ...r 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 2 Remove the access panel from the right side of the operator s...

Page 284: ...h the hood closed remove the hair pins and clevis pins from the hood hinges 2 Lift the hood assembly from the machine 3 Install the hood in the reverse order 4 Adjust the bracket to contact the front...

Page 285: ...Removing and Installing the Hood continued g314859 Figure 125 1 Support bracket 3 Cooling shroud 2 Hood Groundsmaster 3200 3300 and 3310 Page 7 25 Chassis Service and Repairs 19240SL Rev A...

Page 286: ...Model 31981 page 7 28 or Air Ride Suspension Seat Model 31982 page 7 29 Removing and Installing the Operator Seat 1 Park the machine on a level surface lower the cutting unit or attachment engage the...

Page 287: ...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 Grounds...

Page 288: ...ount kit 7 Seat belt kit 2 Bracket kit 8 Seat track kit 3 Lower console mount 9 Seat switch 4 Back cover 10 Weight adjust knob 5 Cushion cover 11 Bellows 6 Seat switch harness 12 Armrest kit Chassis S...

Page 289: ...kit 2 Bracket kit 9 Air valve kit 3 Lower console mount 10 Seat belt kit 4 Back cover 11 Seat track kit 5 Cushion cover 12 Seat switch 6 Seat harness 2 pieces 13 Bellows 7 Air compressor kit 14 Armre...

Page 290: ...ng the lift arms from the machine Removing the Lift Arms 1 Remove the cutting unit from the machine refer to the cutting unit Operator s Manual 2 Remove the front wheel next to the lift arm being remo...

Page 291: ...removed Tighten the flange nut from 114 to 135 N m 84 to 100 ft lb 3 Use an arbor press to install new flange bushings in the rear lift arm hub if necessary 4 Lightly grease the lift arm pivot pin Po...

Page 292: ...o 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 Man...

Page 293: ...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 3200 3...

Page 294: ...overs are fully seated in the retainers before returning the machine to service Cutting Unit Operator s Manual The cutting unit Operator s Manual provides information regarding the specifications oper...

Page 295: ...N Do not work on the cutting unit or lift arms with the engine running Always shut off the engine and remove the key from the key switch before working on the cutting unit Rotary Cutting Units Refer t...

Page 296: ...ower the cutting unit engage the parking brake set the key switch to the OFF position and remove the key from the key switch 2 Remove the belt covers from the cutting unit 3 Use a 3 8 inch or 1 2 inch...

Page 297: ...he idler pivot plate CAUTION The spring is under heavy load and can cause personal injury Be careful when applying tension to the torsion spring of the idler arm 5 Use a 3 8 inch or 1 2 inch drive rat...

Page 298: ...the SERVICE position refer to the traction unit Operator s Manual 6 Inspect the pulley bearing and spacer shaft for damage or wear Replace the pulley and or the spacer if necessary Note The pulley sp...

Page 299: ...t refer to the cutting unit Operator s Manual 3 Rotate the cutting unit to the SERVICE position refer to the traction unit Operator s Manual 4 Remove the blade bolt hex bushing or anti scalp cup and b...

Page 300: ...N m 50 to 60 ft lb For Groundsmaster series cutting units tighten the blade bolt from 135 to 149 N m 100 to 110 ft lb 3 Slowly rotate the cutting blades to check that the blades do not contact any de...

Page 301: ...to use 5 1 mm 0 20 inch thick blades Disassembling the Blade Spindle Refer to Figure 134 for this procedure 1 Remove the lock nut disc spring washer pulley and bearing guard from the top of the spind...

Page 302: ...gn the bearings and bearing spacer during assembly 3 Support the inner and outer race of the previously installed bearing then install a bearing into the top of the spindle housing by pressing equally...

Page 303: ...bearing spacer 7 Spindle spacer 15 Outer bearing spacer 8 Seal 2 each 16 Drive Stud 8 each Blade spindles for Groundsmaster series cutting units have cast iron spindle housings greasable roller bearin...

Page 304: ...Use an arbor press to replace any drive studs if necessary Assembling the Blade Spindle IMPORTANT Do not mix the components from one bearing set to another Replace the bearings as a complete set only...

Page 305: ...ing Ensure that the assembly is correct by supporting the first bearing cup and pressing the second bearing cup against it refer to Figure 137 g223664 Figure 137 1 Bearing cup 4 Arbor press 2 Large sn...

Page 306: ...the shaft Carefully slide the spindle shaft with the spacer up through the spindle housing The bottom oil seal and shaft spacer fit together when the spindle is fully inserted 9 Install the O ring to...

Page 307: ...ng brake set the key switch to the OFF position and remove the key from the key switch 2 To preserve the roller or skid height record the mounting hole locations and remove the rollers or skids from t...

Page 308: ...ke set the key switch to the OFF position and remove the key from the key switch 2 Remove the extension spring and disassemble the service latch as necessary 3 Inspect the latch handle bushings for da...

Page 309: ...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 If the PTO shaft is disconnected...

Page 310: ...If necessary remove and replace the gearbox dipstick breather copper washer oil seals and oil caps Note If internal gearbox wear or damage occurs gearbox replacement is necessary The internal gearbox...

Page 311: ...to 18 N m 130 to 160 in lb 8 Secure the gearbox assembly to the cutting with the previously removed fasteners and install the drive belt 9 Tighten the drain plug from 20 to 27 N m 15 to 20 ft lb 10 Fi...

Page 312: ...asher 8 Flange nut 4 each 18 Compression spring 9 Cap screw 19 Cap 10 Locknut Servicing the Castor Wheels Refer to Figure 144 for this procedure 1 Park the machine on a level surface raise the cutting...

Page 313: ...emaining spacers and the height of cut cap Note Ensure that the thrust washers are positioned directly above and below the castor arm bushings 4 Record the caster wheel mounting hole and remove the ca...

Page 314: ...odel 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 an...

Page 315: ...ments 9 7 Adjusting the Compressor Belt Tension 9 7 Adjusting the Doors 9 8 Service and Repairs 9 9 General Precautions for Removing and Installing Air Conditioning System Components 9 9 Air Condition...

Page 316: ...General Information Operator Cab General Information Page 9 2 Groundsmaster 3200 3300 and 3310 19240SL Rev A...

Page 317: ...structions 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 Inst...

Page 318: ...ators 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...

Page 319: ...mponent of the mixing box located in the cab headliner The fan motor is also used for the cab heating system Operator controls to turn the air conditioning on to adjust the fan speed and to control th...

Page 320: ...eater core A blower fan motor that provides air movement through the heater core and into the cab The fan motor is a component of the mixing box located in the cab headliner The fan motor is also used...

Page 321: ...10 lb is applied to the top of the belt half way between the engine and compressor pulleys Note The jam nut at the bottom of the turnbuckle has left hand threads 1 Loosen the jam nuts at each end of...

Page 322: ...proper sealing occurs at the 2 points indicated The distance between the sealing surface of the frame and the outer edge of the door trim when the door is fully latched should be from 19 to 25 mm 0 8...

Page 323: ...ing system components Thorough cleaning will prevent system contamination while performing service procedures 3 Before loosening or removing any air conditioning system hose or other component have a...

Page 324: ...lways placed on the pressure hose ports These caps prevent refrigerant leakage from the system 13 The drier receiver component is used to collect moisture that will reduce air conditioning performance...

Page 325: ...laced Replacing the Compressor Drive Belt Refer to Figure 146 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...

Page 326: ...t the hoses at the compressor then cap the fittings and plug the hoses to prevent contamination from entering the air conditioning system 4 Remove the fuel tank refer to Removing and Installing the Fu...

Page 327: ...enser fans 3 Drier receiver 8 Heater core 13 Condenser 4 Expansion valve 9 Heat valve 5 Thermostat resistor 10 Heater engine coolant hoses Remove the roof to access the heating and air conditioning co...

Page 328: ...rness and remove the cover assembly 3 Remove the windshield wiper boots lock nuts and washers from outside the roof panel 4 Support the wiper motor remove the mounting plate from outside the cab and r...

Page 329: ...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 4 Connect the windshield wiper switch to the wire harness and install the c...

Page 330: ...hing 18 each 9 Washer 5 each 4 Hinge 2 each 10 Shoulder screw 9 each 5 Door frame 11 Gasket 6 Lock nut CAUTION Each door assembly weighs approximately 424 kg 52 lbs Ensure the door gas strut is proper...

Page 331: ...igure 151 1 Gas strut 3 Door frame 2 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...

Page 332: ...Operator Cab Service and Repairs Page 9 18 Groundsmaster 3200 3300 and 3310 19240SL Rev A...

Page 333: ...300 3310 A 10 Wire Harness Diagram 3320 3300 3310 A 11 Wire Harness Drawing Main 3300 3310 A 12 Wire Harness Diagram Main 3300 3310 A 13 Wire Harness Diagram Main 3300 3310 continued A 14 Wire Harness...

Page 334: ...ude 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...

Page 335: ...Model 31900 Drawing 133 6540 Rev A Sheet 1 of 1 19240SL Rev A Page A 3 Hydraulic Schematic 3200 2WD g296996...

Page 336: ...Page A 4 19240SL Rev A Model 31901 Drawing 138 4500 Rev A Sheet 1 of 1 Hydraulic Schematic 3200 4WD g303916...

Page 337: ...Model 31902 31903 31907 and 31909 Drawing 133 6520 Rev A Sheet 1 of 1 19240SL Rev A Page A 5 Hydraulic Schematic 3300 3310 g296995...

Page 338: ...Page A 6 19240SL Rev A Model 31900 31901 31307 and 31309 Drawing 122 1226 Rev A Sheet 1 of 1 Electrical Schematic 3200 3300 3310 g296993...

Page 339: ...Model 31902 and 31903 Drawing 122 1220 Rev A Sheet 1 of 2 19240SL Rev A Page A 7 Electrical Schematic 3300 3310 g296989...

Page 340: ...Page A 8 19240SL Rev A Model 31902 and 31903 Drawing 122 1220 Rev A Sheet 2 of 2 Electrical Schematic 3300 3310 continued g296968...

Page 341: ...Model 31903 and 31909 Drawing 122 1437 Rev A Sheet 1 of 1 19240SL Rev A Page A 9 Electrical Schematic Operator Cab g306863...

Page 342: ...Page A 10 19240SL Rev A Model 31900 31901 31907 and 31909 Drawing 122 1657 Rev A Sheet 1 of 1 Wire Harness Drawing 3200 3300 3310 g295556...

Page 343: ...Model 31900 31901 31907 and 31909 Drawing 122 1657 Rev A Sheet 1 of 1 19240SL Rev A Page A 11 Wire Harness Diagram 3320 3300 3310 g295555...

Page 344: ...Page A 12 19240SL Rev A Model 31902 and 31903 Drawing 122 1656 Rev A Sheet 1 of 1 Wire Harness Drawing Main 3300 3310 g295559...

Page 345: ...Model 31902 and 31903 Drawing 122 1656 Rev A Sheet 1 of 2 19240SL Rev A Page A 13 Wire Harness Diagram Main 3300 3310 g295557...

Page 346: ...Page A 14 19240SL Rev A Model 31902 and 31903 Drawing 122 1656 Rev A Sheet 2 of 2 Wire Harness Diagram Main 3300 3310 continued g295558...

Page 347: ...Model 31903 and 31909 Drawing 122 1435 Rev A Sheet 1 of 1 19240SL Rev A Page A 15 Wire Harness Cab Power g297520...

Page 348: ...Page A 16 19240SL Rev A Model 31903 and 31909 Drawing 122 1245 Rev D Sheet 1 of 1 Wire Harness Cab Rooftop g256477...

Page 349: ...Model 31903 and 31909 Drawing 122 1660 Rev A Sheet 1 of 1 19240SL Rev A Page A 17 Wire Harness Cab Control Panel g297533...

Page 350: ...Page A 18 19240SL Rev A Model 31903 and 31909 Drawing 122 1678 Rev A Sheet 1 of 1 Wire harness Cab HVAC Adapter g297534...

Page 351: ...Model 31993 Drawing 122 1248 Rev B Sheet 1 of 1 19240SL Rev A Page A 19 Wire Harness Cab Work Light Kit optional g260313...

Page 352: ...Page A 20 19240SL Rev A Model 31991 and 31992 Drawing 122 1436 Rev A Sheet 1 of 1 Wire Harness Road Light Kits Lights optional g302637...

Page 353: ...Model 31991 and 31992 Drawing 122 1435 Rev A Sheet 1 of 1 19240SL Rev A Page A 21 Wire Harness Road Light Kit Controls optional g306840...

Page 354: ...Page A 22 19240SL Rev A Model 31900 31901 31902 31903 31907 and 31909 Drawing 122 1665 Rev B Sheet 1 of 1 Slope Sensor Kit optional g303863...

Page 355: ......

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