Toro Groundmaster Series User manual

FormNo.19240SLRevA
Groundsmaster®3200,3300and
3310
(Models31900,31901,31902,31903,31907
and31909)
©2019—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
OriginalInstructions(EN)
Contactusatwww.Toro.com.
AllRightsReserved

RevisionHistory
RevisionDateDescription
A
2/2020Initialrelease
RevisionHistoryPage2Groundsmaster®3200,3300and3310
19240SLRevA

ReaderComments
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efforttoimprovethequalityandusefulnessofitspublications.T odothis
effectively,weencourageuserfeedback.Pleasecommentonthecompleteness,
accuracy,organization,usability,andreadabilityofthismanualbyane-mail
orMailto:
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8111LyndaleAvenueSouth
Bloomington,MN55420-1196
Phone:+1952-887-8495
Groundsmaster®3200,3300and3310Page3ReaderComments
19240SLRevA

Preface
Thisservicemanualwaswrittenexpresslyforservicetechnicians.Basicshop
safetyknowledgeandmechanical/electricalskillsareassumed.TheToro
Companyhasmadeeveryefforttomaketheinformationinthismanualcomplete
andcorrect.
Thepurposeofthispublicationistoprovidetheservicetechnicianwith
informationabouttroubleshooting,testing,andrepairingmajorsystemsand
components.Thismanualmayalsobespeciedforuseonnumerousproducts.
RefertotheT ableofContentsforalistofthesystemsandtherelatedtopics
coveredinthismanual.
RefertothetractionunitandcuttingunitOperator’sManualforadditional
informationaboutoperating,maintaining,andadjustingthemachine.Keepa
copyoftheOperator’sManuals,InstallationInstructions,andPartsCatalogs
foryourmachineanditsaccessorieswiththisServiceManualforreference.
AdditionalcopiesoftheOperator’sManuals,InstallationInstructionsandParts
Catalogsareavailableatwww.toro.com.
TheToroCompanyreservestherighttochangetheproductspecicationsor
thispublicationwithoutnotice.
Groundsmaster®3200,3300and3310Page5Preface
19240SLRevA

ServiceProcedureIcons
ThefollowingiconsappearthroughoutthisServiceManualtobringattentionto
specicimportantdetailsofaserviceprocedure.
CriticalProcess
Thisiconisusedtohighlight:
•installingsafetyequipment(shields,guards,seatbelts,brakesandR.O.P .S.
components)thatmayhavebeenremoved
•dimensionsorsettingsthatmustbemaintainedforpropermachineoperation
•aspecicfastenertighteningsequence
•componentorientationthatmaynotbeobvious
CriticalTorque
Thisiconisusedtohighlightanassemblytorquerequirementthatisdifferentthan
whatisrecommendedintheStandardT orqueTables;refertoStandardT orque
forDry,ZincPlated,andSteelFasteners(InchSeries)(page2–10)andStandard
TorqueforDry,ZincPlated,andSteelFasteners(MetricFasteners)(page2–11).
FluidSpecications
Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless
common,andmaynotappearonthemachineservicedecalorinthemachine
Operator’sManual.
Note:RefertotheservicedecalonthemachineandthemachineOperator’s
Manualforcommonlyuseduidspecicationsandcapacities.
PrefacePage6Groundsmaster®3200,3300and3310
19240SLRevA

TableofContents
Preface................................................................................................................5
Chapter1:Safety............................................................................................1–1
SafetyInstructions.......................................................................................1–2
JackingInstructions.....................................................................................1–6
SafetyandInstructionalDecals....................................................................1–7
Chapter2:SpecicationsandMaintenance....................................................2–1
Specications...............................................................................................2–2
TorqueSpecications...................................................................................2–7
ShopSupplies............................................................................................2–13
SpecialT ools..............................................................................................2–15
Chapter3:Troubleshooting.............................................................................3–1
GEARS–TheSystematicApproachtoDening,DiagnosingandSolving
Problems......................................................................................................3–2
OperatorAdvisories......................................................................................3–3
MachineandEngineFaults...........................................................................3–5
UsingtheTDMDisplay/ControllerScreensforTroubleshooting..................3–12
Troubleshooting–Hydraulic.......................................................................3–14
GeneralHydraulicSystemProblems..........................................................3–15
TractionSystemProblems..........................................................................3–17
SteeringSystemProblems.........................................................................3–19
CuttingUnit(orattachment)Lift/LowerProblems........................................3–20
Troubleshooting–Electrical........................................................................3–21
StartingProblems.......................................................................................3–22
GeneralRunandTransportProblems.........................................................3–24
CuttingUnit(orattachment)Problems........................................................3–25
FactorsThatCanAffectQualityofCut........................................................3–26
Chapter4:Engine...........................................................................................4–1
GeneralInformation.....................................................................................4–2
ServiceandRepairs.....................................................................................4–9
Chapter5:HydraulicSystem...........................................................................5–1
GeneralInformation.....................................................................................5–3
HydraulicSchematics.................................................................................5–12
HydraulicFlowDiagrams............................................................................5–13
TestingtheHydraulicSystem......................................................................5–22
Adjustments...............................................................................................5–50
ServiceandRepairs...................................................................................5–52
Chapter6:ElectricalSystem...........................................................................6–1
GeneralInformation.....................................................................................6–2
ElectricalSchematicsandWireHarnessDrawings/Diagrams.......................6–6
ElectricalSystemQuickChecks....................................................................6–7
TestingtheElectricalComponents................................................................6–9
ServiceandRepairs...................................................................................6–61
Chapter7:Chassis..........................................................................................7–1
GeneralInformation.....................................................................................7–2
Adjustments.................................................................................................7–3
ServiceandRepairs.....................................................................................7–5
Chapter8:CuttingUnits..................................................................................8–1
GeneralInformation.....................................................................................8–2
ServiceandRepairs.....................................................................................8–3
Chapter9:OperatorCab.................................................................................9–1
GeneralInformation.....................................................................................9–2
Adjustments.................................................................................................9–7
ServiceandRepairs.....................................................................................9–9
AppendixA......................................................................................................A–1
ElectricalDrawingDesignations....................................................................A–2
HydraulicSchematic–32002WD.................................................................A–3
Groundsmaster®3200,3300and3310Page7Preface
19240SLRevA

HydraulicSchematic–32004WD.................................................................A–4
HydraulicSchematic–3300/3310.................................................................A–5
ElectricalSchematic–3200/3300/3310........................................................A–6
ElectricalSchematic–3300/3310.................................................................A–7
ElectricalSchematic–3300/3310(continued)..............................................A–8
ElectricalSchematic-OperatorCab...............................................................A–9
WireHarnessDrawing–3200/3300/3310...................................................A–10
WireHarnessDiagram–3320/3300/3310..................................................A–11
WireHarnessDrawing–Main3300/3310...................................................A–12
WireHarnessDiagram–Main3300/3310...................................................A–13
WireHarnessDiagram–Main3300/3310(continued)................................A–14
WireHarness–CabPower.........................................................................A–15
WireHarness–CabRooftop......................................................................A–16
WireHarness–CabControlPanel..............................................................A–17
Wireharness–CabHVACAdapter.............................................................A–18
WireHarness–CabWorkLightKit(optional)..............................................A–19
WireHarness–RoadLightKits,Lights(optional)........................................A–20
WireHarness–RoadLightKit,Controls(optional)......................................A–21
SlopeSensorKit(optional).........................................................................A–22
AdditionalReferenceMaterials
YanmarServiceManualfor3TNV80Fengines
YanmarServiceManualfor3TNV88engines
YanmarServiceManualfor3TNV88Cengines
YanmarTroubleshootingManualfor3TNV88Cengines
DanfossLPVAxialPistonPumpServiceManual
DanfossLPVAxialPistonPumpRepairManual
ParkerTorqmotor™ServiceProcedure(TC,TB,TE,TJ,TF ,TG,TH,andTL
Series)
DanfossOSPMSteeringUnitServiceManual
SandenSDCompressorServiceGuide
PrefacePage8Groundsmaster®3200,3300and3310
19240SLRevA

Chapter1
Safety
TableofContents
SafetyInstructions................................................................................................................................1–2
ThinkSafetyFirst...............................................................................................................................1–3
JackingInstructions..............................................................................................................................1–6
SafetyandInstructionalDecals............................................................................................................1–7
Groundsmaster®3200,3300and3310Page1–1Safety
19240SLRevA

SafetyInstructions
DANGER
Thissafetysymbolmeansdanger.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscouldcauseseriouspermanentinjury,disability,or
death.
WARNING
Thissafetysymbolmeanswarning.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinseriousinjury.
CAUTION
Thissafetysymbolmeanscaution.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinminortomoderateinjury.
IMPORTANT
TheImportantnoticewillgivetheimportantinstructionswhichyou
mustfollowtopreventdamagetothesystemsorcomponentson
themachine.
Note:ANotewillgivethegeneralinformationaboutthecorrectoperation,
maintenance,service,testing,orrepairofthemachine.
Safety:SafetyInstructionsPage1–2Groundsmaster®3200,3300and3310
19240SLRevA

ThinkSafetyFirst
ToroProductsareevaluatedforcompliancewithexistingsafetystandardsand
specications.Althoughhazardcontrolandaccidentpreventionarepartially
dependentuponthedesignandcongurationofthemachine,hazardcontrol
andaccidentpreventionarealsodependentupontheawareness,concern
andpropertrainingofthepersonnelinvolvedintheoperation,transport,
maintenance,andstorageofthemachine.Improperuseormaintenanceofthe
machinecanresultininjuryordeath.
WARNING
Toreducethepotentialofinjuryordeath,complywiththesafety
instructionsinthismanual,aswellasinformationfoundinthe
Operator’sManualsandtheOperatorandSafetyTrainingMaterials
foundonwww.toro.com.
•Avoidunexpectedstartingoftheengine…
Alwaysturnofftheengine,removethekeyandunplugthe48Vbattery
disconnectbeforecleaning,adjusting,orrepair.
•Avoidlacerationsandamputations…
Stayclearofallmovingpartswhenevertheengineisrunning.Treatall
normallymovingpartsasiftheyweremovingwhenevertheengineis
runningorhasthepotentialtostart.
•Avoidburns…
Donottouchtheengine,mufer,orothercomponents,whichmaybehot
duringoperation,whiletheunitisrunningorshortlyafterithasbeen
running.Allowtheengine,mufer,andothercomponentstocoolbefore
workingnearthem.
•Avoidresandexplosions…
Useextremecareinhandlingfuel.Fuelisammableanditsvaporsare
explosive.
–Extinguishallcigarettes,cigars,pipes,andothersourcesofignition.
–Avoidspillingfuelandneversmokewhileworkingwithanytypeoffuel
orlubricant.
–Wipeupanyspilledfueloroilimmediately.
–Neverremovethefuelcaporaddfuelwhentheengineisrunning.
–Alwaysuseapproved,labeledcontainersforstoringortransportingfuel
andlubricants.
–Donotaddordrainfuelinanenclosedspace.
–Donotstorethemachineorfuelcontainerwherethereisanopename,
spark,orpilotlight,suchasonawaterheaterorotherappliance.
•Avoidasphyxiation…
Donotoperateanengineinaconnedareawithoutproperventilation.
•Avoidinjuryfrombatteries…
–Batteryacidispoisonousandcancauseburns.Avoidcontactwithskin,
eyesandclothing.
–Batterygasescanexplode.Keepcigarettes,sparksandamesaway
fromthebattery.
•Avoidinjuryduetoinferiorparts…
Groundsmaster®3200,3300and3310Page1–3Safety:SafetyInstructions
19240SLRevA

ThinkSafetyFirst(continued)
Useonlyoriginalequipmentpartstoensurethatimportantsafetycriteria
aremet.
•Avoidinjurytobystanders…
Alwayscleartheareaofbystandersbeforestartingortestingpowered
equipment.
•Avoidinjuryduetoprojectiles…
Alwayscleartheareaofanydebristhatcouldbepickedupandthrown
bythepoweredequipment.
•Avoidmodications…
Donotalterormodifyanypartunlessitisafactoryapprovedprocedure.
•Avoidunsafemachineoperation…
Alwaystestthesafetyinterlocksystemaftermakingadjustmentsor
repairsonthemachine.RefertotheElectricalsectioninthismanual
formoreinformation.
•Avoidelectricalshock…
–Nevertouchelectricalwiresorcomponentswhiletheengineisrunning.
Theycanbesourcesofshock.
–De-energizethesystemifyouarehavingtodorepairs.
–Iftestingelectricalcomponentsensurethatyouareworkinginadry
environment.
–Donotwearmetaljewelrywhenworkingonornearelectricalcomponents
orwiring.
•Avoidcontactwithpressurizedhydraulicuid...
–Releaseallpressureinthehydraulicsystembeforeperforminganywork
onthesystem.
–Keepyourbodyandhandsawayfrompin-holeleaksornozzlesthat
ejecthydraulicuidunderhighpressure.Hydraulicuidescapingunder
pressurecanhavesufcientforcetopenetratetheskinandcauseserious
injury.Usecardboardorpapertondhydraulicleaks;neveruseyour
hands.Ifhydraulicuidisinjectedintoyourskin,theuiddamage
toyourbodymustbesurgicallyremovedwithinafewhoursbya
doctorfamiliarwiththisformofinjuryorgangrenemayresult.
•Usepersonalprotectiveequipment…
–Tiebacklonghair,anddonotwearlooseclothingorjewelry.
–Useappropriatepersonalprotectiveequipment(PPE)forprotecting
yourselffrompotentialhazardsintheenvironmentinwhichyouwillwork.
–EachprocessoutlinedinthismanualmayneeddifferentPPEtoprotect
theserviceperson.UsetheproperPPEforthetaskathand.
•Usingtools…
–Alltoolsshouldbeinproperworkingorder.Donotusetoolsthatare
brokenorindisrepair.
–Usethepropertoolfortheproperapplication.
•Usinglifts,hoists,andjacks…
–Alllifts,hoists,andjacksshouldbeusedinaccordancewiththe
manufacturerinformation.
–Inspectlifts,hoists,andjackspriortouse.
–Donotoverloadlifts,hoists,andjacks.
–Donotworkunderasuspendedload.
Safety:SafetyInstructionsPage1–4Groundsmaster®3200,3300and3310
19240SLRevA

ThinkSafetyFirst(continued)
–Ensurethatchockblocksareusedonequipmentthatcanmove.
–Useliftsorjacksandjackstandsthatareratedtosupportthetotalweight
ofthemachineandanyattachments.
–Donotrelyonjackstosupportthemachine.
–Ifyouareunfamiliarwithanylifts,hoistsorjacks,donotusethemuntil
youknowhowtooperatethemcorrectly.
•Usingreextinguishers…
Usetheproperclassofreextinguisherincaseofre.
Ensurethatreextinguishersareservicedregularly,andreplaceanyre
extinguishersthataredischargedorinusebeyondtheirexpirationdates.
–ClassAreextinguishersareforordinarycombustiblematerialssuch
aspaper,wood,cardboard,andmostplastics.Thenumericalratingon
thesetypesofextinguishersindicatestheamountofwateritholdsand
theamountofreitcanextinguish.Geometricsymbol(greentriangle).
–ClassBreextinguishersareforresthatinvolveammableor
combustibleliquidssuchasgasoline,kerosene,greaseandoil.The
numericalratingforclassBextinguishersindicatestheapproximate
numberofsquarefeetofreitcanextinguish.Geometricsymbol(red
square).
–ClassCreextinguishersareforresthatinvolveelectricalequipment
suchasappliances,wiring,circuitbreakersandoutlets.Neverusewater
toextinguishclassCres-theriskofelectricalshockisfartoogreat!
ClassCextinguishersdonothaveanumericalrating.TheCclassication
meanstheextinguishingagentisnon-conductive.Geometricsymbol
(bluecircle).
–ClassABCreextinguishersareadrychemicaltypeusedformultiple
purposes.Seeabovedescriptionsforadditionalinformation.
Groundsmaster®3200,3300and3310Page1–5Safety:SafetyInstructions
19240SLRevA

JackingInstructions
DANGER
Mechanicalorhydraulicjacksmayfailtosupportthemachineand
causeaseriousinjury.
•Usejackstandstosupporttheraisedmachine.
•Useonlymechanicalorhydraulicjackstoliftthemachine.
•Donotusethecuttingunitorimplementasajackingpoint.
1.Parkthemachineonalevelsurface,lowerthecuttingunit(orattachment),
engagetheparkingbrake,setthekeyswitchtotheOFFpositionandremove
thekeyfromthekeyswitch.
2.engagetheparkingbrakeandblockthe2rearwheelswithchockstoprevent
themachinefrommoving.
3.Positionthejacksecurelyunderthedesiredjackpoint:
•Front=Positionthejacksecurelyundertheframetubejustbehindthe
frontwheel.
•Rear=Positionthejacksecurelyundertheframedirectlyinfrontofthe
rearaxle.
Afterraisingthemachine,useanappropriatejackstandunderthemachine
frametosupportthemachine.
g303670
Figure1
1.Jackpoint–front3.Jackpoint–rear
2.Jackstandpoint–front4.Jackstandpoint–rear
IMPORTANT
Usetwojackstandswhensupportingthemachine.
Safety:JackingInstructionsPage1–6Groundsmaster®3200,3300and3310
19240SLRevA

SafetyandInstructionalDecals
Numeroussafetyandinstructiondecalsareafxedtothetractionunitand
cuttingunitsoftheGroundsmaster3200/3300.Ifanydecalbecomesillegible
ordamaged,replaceitwithanewdecal.PartnumbersarelistedinyourParts
CatalogandOperator’sManual.OrderreplacementdecalsfromyourAuthorized
ToroDistributor.
Groundsmaster®3200,3300and3310Page1–7Safety:SafetyandInstructionalDecals
19240SLRevA

Chapter2
SpecicationsandMaintenance
TableofContents
Specications.......................................................................................................................................2–2
OverallDimensions............................................................................................................................2–2
Engine(Model31900&31901)..........................................................................................................2–3
Engine(Model31902&31903)..........................................................................................................2–3
Engine(Model31907&31909)..........................................................................................................2–4
HydraulicSystem...............................................................................................................................2–4
Chassis..............................................................................................................................................2–5
CuttingUnit........................................................................................................................................2–6
TorqueSpecications...........................................................................................................................2–7
CalculatingtheT orqueValuesWhenUsingaDrive-AdapterWrench.................................................2–8
IdentifyingtheFastener......................................................................................................................2–9
StandardT orqueforDry,ZincPlated,andSteelFasteners(InchSeries)..........................................2–10
StandardT orqueforDry,ZincPlated,andSteelFasteners(MetricFasteners).................................2–11
OtherTorqueSpecications.............................................................................................................2–12
ConversionFactors..........................................................................................................................2–12
ShopSupplies....................................................................................................................................2–13
SpecialTools......................................................................................................................................2–15
Groundsmaster®3200,3300and3310Page2–1SpecicationsandMaintenance
19240SLRevA

Engine(Model31900&31901)
ItemDescription
Make/DesignationYanmar3TNV80F:4-cycle,3cylinderwater
cooleddiesel.EPATier4compliant.
Bore80mm(3.15inches)
Stroke84mm(3.31inches)
Totaldisplacement1,267cm3(77.31in3)
Firingorder1(ywheelend)-3(fanend)-2
CompressionRatio19:1
FuelDieselorBiodieselfuel(uptoB7)
Fueltankcapacity45.4L(12USgallons)
FuelinjectionpumpYanmarSupplyPump
FuelinjectornozzleThrottletype
GovernorCentrifugal-allspeedgovernor
Lowidle(noload)1,150to1,250rpm
Highidle(noload)3,200to3,250rpm
EngineoilAPICJ-4orhigher;refertothetraction
unitOperator’sManualforadditional
engineoilinformation
Crankcase-oilcapacity3.4L(3.6USqt)
OilpumpGeardriventrochoidtype
Coolantcapacity6.6L(7USqt)
Alternator/Regulator12VDC,40A
Engineweight(dry)135kg(298lb)
Engine(Model31902&31903)
ItemDescription
Make/DesignationYanmarModel3TNV88C-DTR:4-Cycle,3cylinder
watercooleddiesel.EPATier4compliant.
Bore88mm(3.465inches)
Stroke90mm(3.543inches)
Totaldisplacement1,642cm3(100.2in3)
Firingorder1(ywheelend)-3(fanend)-2
CompressionRatio23:1
FuelDieselorBiodieselfuel(uptoB7)
Fueltankcapacity45.4L(12USgallons)
FuelinjectionpumpYanmarSupplyPump
FuelinjectornozzleCommonRailwithDirectInjection
GovernorElectronic-allspeed
Lowidle(noload)1,350to1,450rpm
Highidle(noload)3,100to3,200rpm
EngineoilAPICJ-4orhigher;refertothetraction
unitOperator’sManualforadditional
engineoilinformation
Groundsmaster®3200,3300and3310Page2–3SpecicationsandMaintenance:Specications
19240SLRevA

Engine(Model31902&31903)(continued)
ItemDescription
Crankcase-oilcapacity5.2L(5.5USqt)withFilter
OilpumpGeardriventrochoidtype
Coolantcapacity7.6L(8USqt)
Alternator/Regulator12VDC55A
Engineweight(dry)188kg(414lb)
Engine(Model31907&31909)
ItemDescription
Make/DesignationYanmar3TNV88-BDTR:4-Cycle,3cylinderwater
cooleddiesel.EPATier2compliant.
Bore88mm(3.465inches)
Stroke90mm(3.543inches)
Totaldisplacement1,642cm3(100.2in3)
Firingorder1(ywheelend)-3(fanend)-2
CompressionRatio23:1
FuelDieselorBiodieselfuel(uptoB7)
Fueltankcapacity45.4L(12USgallons)
FuelinjectionpumpYanmarSupplyPump
FuelinjectornozzleThrottletype
GovernorCentrifugal-allspeedgovernor
Lowidle(noload)1,150to1,250rpm
Highidle(noload)3,200to3,250rpm
EngineoilAPICJ-4orhigher;refertothetraction
unitOperator’sManualforadditional
engineoilinformation
Crankcase-oilcapacity6.6L(7USqt)
OilpumpGeardriventrochoidtype
Coolantcapacity7.6L(8USqt)
Alternator/Regulator12VDC,40A
EngineWeight(dry)161kg(355lb)
HydraulicSystem
ItemDescription
Piston(traction)pumpDanfoss,LPVvariabledisplacementclosed
circuitaxialpistonpump
Maximumpumpdisplacement(per
revolution)
34.9cm3(2.13in3)
Tractioncircuitreliefpressure(forwardand
reverse)
24,993kPa(3625psi)
ChargePump
Maximumpumpdisplacement(per
revolution)
Casappapositivedisplacementgeartypepump
5.6cm3(0.34in3)
SpecicationsandMaintenance:SpecicationsPage2–4Groundsmaster®3200,3300and3310
19240SLRevA
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