Form No. 05138SL Rev B Groundsmaster® 3280-D/3320 (Models 30307, 30308, 30309, 30343, 30344, and 30345) © 2018—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision Date - 2005 Initial Issue. A 2007 Updated Hydraulic chapter. B 2018 Updated all chapters and published in new format.
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
NOTES: Revision History Page 4 Groundsmaster® 3280-D/3320 05138SL Rev B
Preface The purpose of this publication is to provide the service technician with the information for troubleshooting, testing, and repair of the major systems and components on the Groundsmaster 3280-D and Groundsmaster 3320. Refer to the Operator’s Manuals for operating, maintenance, and adjustment instructions. Space is provided in Chapter 2 (page 2–1) of this book to insert the Operator’s Manuals and Parts Catalog for your machine.
g221829 Figure 1 Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S.
Table of Contents Preface ................................................................................................................ 5 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Jacking Instructions ..................................................................................... 1–6 Safety and Instructional Decals .
General Information ................................................................................... 11–2 Service and Repairs ................................................................................... 11–3 Appendix A ......................................................................................................A–1 Hydraulic Schematic-3280-D (Serial Numbers below 270000400) and 3320 (Serial Numbers below 280000000) .....................................................
Wire Harness Drawing-Cab Model 30298 Heat/Air Conditioning Blower.........................................................................................................A–36 Wire Harness Diagram-Cab Model 30298 Heat/Air Conditioning Blower.........................................................................................................A–37 Wire Harness Drawing-Light Kit Model 30405 (Machines without Cab) ................................................................................................
Preface Page 10 Groundsmaster® 3280-D/3320 05138SL Rev B
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Supervisor’s Responsibilities ............................................................................................................. 1–2 Before Operating the Machine ........................................................................................................... 1–2 While Operating the Machine ..........
Safety Instructions The Groundsmaster 3280-D and 3320 machines meet or exceeds safety standard specifications when weights are installed according to information in the Operator’s Manual. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
While Operating the Machine • Sit on the seat when starting and operating the machine. • Anytime you park the machine (short or long term), lower the cutting deck (or implement) to the ground. IMPORTANT When you lower the cutting deck to the ground, the pressure from the hydraulic lift circuit releases and prevents the cutting deck from accidentally lowering. • If you park the machine on a slope, block or chock the wheels.
Maintenance and Service • Before servicing or making any adjustments to the machine, lower the cutting • • • • • • • • • • • • • • • Safety: Safety Instructions deck (or implement), set the parking brake, shut off the engine, and remove the key from the key switch. Ensure that the machine is in safe operating condition by keeping all the nuts, bolts, and screws tight. Do not store the machine or a fuel container inside where there is an open flame, such as near a water heater or furnace.
Maintenance and Service (continued) • If welding on the machine is necessary, disconnect the negative battery cable to prevent electrical system damage. • Ensure to dispose of potentially harmful waste (e.g., fuel, oil, engine coolant, filters, battery) in an environmentally safe manner. Follow all local codes and regulations when recycling or disposing of waste. • At the time of manufacture, the machine conformed to the safety standards for riding mowers.
Jacking Instructions CAUTION Failing to properly support the machine with appropriate jack stands can cause the machine to move or fall and can result in personal injury. When changing the attachments, tires, or performing other services, do the following steps: • Use correct blocks, hoists, and jacks to raise and support the machine. • Park the machine on a solid level surface, such as a concrete floor.
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Decimal and Millimeter Equivalents ................................................................................................... 2–3 U.S. to Metric Conversions ................................................................................................................
Specifications Insert a copy of the Operator’s Manuals and Parts Catalogs for your machine at the end of this chapter. Additionally, if any optional equipment or accessories are installed to your machine, insert the Installation Instructions, Operator’s Manuals, and Parts Catalogs for those options at the end of this chapter. The maintenance procedures and recommended service intervals for Groundsmaster 3280-D and Groundsmaster 3320 are covered in the Operator’s Manuals.
Decimal and Millimeter Equivalents Fractions 1/64 1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 Decimals mm 0.015625 0.397 0.03125 0.794 0.046875 1.191 0.0625 1.588 0.078125 1.984 0.09375 2.381 0.109275 2.778 0.1250 3.175 0.140625 3.572 0.15625 3.969 0.171875 4.366 0.1875 4.762 0.203125 5.159 0.21875 5.556 0.234375 5.953 0.2500 6.350 0.265625 6.747 0.
U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.914 Feet Meters 0.305 Feet Centimeters 30.48 Inches Meters 0.025 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.093 Square Inches Square Centimeters 6.452 Acre Hectare 0.405 Cubic Yards Cubic Meters 0.765 Cubic Feet Cubic Meters 0.028 Cubic Inches Cubic Centimeters 16.39 Tons (Short) Metric Tons 0.
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These torque specifications for the installation and tightening of the fasteners will apply to all the fasteners which do not have a specific requirement identified in this Service Manual.
Fasteners with a Locking Feature IMPORTANT If a fastener with a locking feature or previously applied thread locking compound is reused, clean the fastener threads and apply new thread locker to the fastener during installation. Locking features are designed to create friction and prevent a fastener from loosening. Locking features can be found on externally or internally threaded fasteners. Common examples are plastic inserts incorporated into the fastener and pre-applied “dry” thread locking compound.
Calculating the Torque Values When Using a Drive-Adapter Wrench g211753 Figure 4 1. Drive-adapter wrench 3. Torque wrench 2. Effective length of torque wrench 4. Effective length of torque wrench + drive-adapter wrench Using a drive-adapter wrench (e.g., crowfoot wrench) in any position other than 90° and 270° to the frame of the torque wrench will affect the torque value measured by the torque wrench because of the effective length (lever) of the torque wrench changes.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC # 8 - 36 UNF # 10 - 24 UNC # 10 - 32 UNF Grade 1, 5 and 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in-lb in-lb N∙cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 56 18 ± 2 30 ± 5 339 ± 56 SAE Grade 5 Bolts, Screws, Studs, and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 ± 6 in-lb 644 ± 68 N∙cm 78 ± 8 in-lb 881 ± 90 N∙cm M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N∙cm 133 ± 14 in-lb 1503 ± 158 N∙cm M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N∙m 28 ± 3 ft-lb 38 ± 4 N∙m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb Thread Cutting Screws (Zinc Plated Steel) Type 1, Type 23 or Type F Thread Size Baseline Torque** No. 6 - 32 UNC 20 ± 5 in-lb No. 8 - 32 UNC 30 ± 5 in-lb No.
Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants, and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply. IMPORTANT Always follow manufacturers instructions when using or storing shop supplies.
Anti-seize lubricant Used to prevent corrosion, galling, and seizure between metal parts. Most often applied to shafts and bores during assembly. Unless otherwise specified, high viscosity regular grade lithium-graphite based anti-seize lubricant should be used. Grease Can be used to pre-fill (pack) bearings, boots, and seals before assembly, ease installation of components during assembly, or fill cavities between moving parts through grease fittings after assembly.
Special Tools You can order these special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic Pressure Testing Kit Toro Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick disconnect fittings are provided to attach directly to the mating fittings on the machine test ports without the tools. A high-pressure hose is given for remote readings.
150 LPM (40 GPM) Hydraulic Tester Toro Part No. AT40002 Use this tester to test the hydraulic circuits and components for flow and pressure capacities. The tester flow measurement maximum is 151 LPM (40 GPM). This tester includes the following: Load Valve – Turn the valve to restrict the flow to create a simulated working load in the circuit. Pressure Gauge – A glycerine filled pressure gauge 0 to 34,500 kPa (0 to 5,000 psi) to provide operating circuit pressure.
Hydraulic Test Fitting Kit Toro Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system.
High Flow Hydraulic Filter Kit Toro Part Number: TOR6011 The high flow hydraulic filter kit is designed with large flow (150 L/minute or 40 gallons/minute) and high pressure (34,500 kPa or 5,000 psi) capabilities. This kit provides for bi-directional filtration which prevents filtered unwanted material from entering into the circuit regardless of the flow direction.
Multimeter Obtain this tool locally The meter can test the electrical components and circuits for current, resistance, or voltage. Note: Use a digital multimeter when testing the electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode ensures that the excess current is not allowed through the meter. This excess current can damage the circuits that are not designed to carry it. Battery Terminal Protector Toro Part No.
Specifications and Maintenance: Special Tools Page 2–18 Groundsmaster® 3280-D/3320 05138SL Rev B
Chapter 3 Gasoline Engine Table of Contents Specifications ....................................................................................................................................... 3–2 Engine - Groundsmaster 3320-G ....................................................................................................... 3–2 General Information .............................................................................................................................. 3–4 Adding Oil to Engine ..
Specifications Groundsmaster 3320-G g243929 Figure 5 1. Engine cooling fan 3. Engine oil filter 2. Alternator 4. Flywheel Engine - Groundsmaster 3320-G Item Description Make/Designation Briggs and Stratton/Daihatsu, 4−stroke, Liquid Cooled, OHV, Gasoline 3 Number of Cylinders Bore x Stroke mm (inches) 72 x 78 (2.834 x 3.07) Total Displacement cm3 (in3) 952 (58.1) 8.
Engine - Groundsmaster 3320-G (continued) Item Description Water Pump Belt driven centrifugal type Cooling System Capacity (including reserve tank) L (US qt) Starter 12 VDC 1.2 KW Alternator/Regulator Groundsmaster® 3280-D/3320 05138SL Rev B 4.3 (4.
General Information This Chapter gives information about specifications, troubleshooting, testing, and repair of the Briggs and Stratton/Daihatsu gasoline engine used in the Groundsmaster 3320. Most repairs and adjustments require tools which are commonly available in many service shops. The use of some specialized test equipment is explained in the engine service manual found at the end of this chapter.
Adding Oil to Engine g230306 Figure 6 1. Note clearance When adding oil to the engine, maintain clearance between the oil fill device and the oil fill opening in the valve cover (Figure 6). This clearance is necessary to allow venting when adding engine oil which will prevent oil from running into the breather tube and intake system.
Adjustments Adjust Throttle Control g230313 Figure 7 1. Speed control lever 3. Cable clamp screw 2. Throttle control cable 4. High speed screw Proper throttle operation is dependent upon proper adjustment of throttle control. Ensure that the throttle control is operating properly. 1. Move remote throttle control lever to FAST position. 2. Check position of speed control lever on governor bracket.
Adjust Choke Control (continued) 1. Move choke control lever to START position. 2. Check position of choke lever on carburetor. Choke lever should be fully closed when choke lever is in START position. 3. If necessary, choke control can be adjusted by loosening cable clamp screw and repositioning choke cable until carburetor choke lever is fully closed when choke control lever is in START position.
Adjust Engine Speed 1. Allow engine to reach operating temperature before checking or adjusting engine speed. Ensure that the throttle control is adjusted properly before adjusting engine speed; refer to Adjust Throttle Control (page 3–6). 2. Park machine on a level surface, lower cutting deck (or implement), and engage parking brake. Ensure that the PTO switch is OFF. Raise hood to gain access to engine controls. 3. With engine running, move remote throttle control lever to FAST position. 4.
Service and Repairs Fuel System g230317 Figure 11 1. Fuel tank 12. Hose clamp 23. Grommet 2. Seat plate 13. Fuel hose (tank venting) 24. Fuel gauge 3. Flange-head screw (2 each) 14. Fuel hose (fuel pump to carburetor) 25. Control panel 4. Grommet 15. Hose clamp 26. Thumb screw (4 each) 5. Knob 16. Fuel hose (fuel supply) 27. Retaining ring 6. Bypass cover 17. Carriage screw (2 each) 28. Bolt 7. Threaded insert 18. Fuel cap 29. Flat washer 8.
DANGER Because gasoline is highly flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled fuel before starting the engine. Store fuel in a clean, safety−approved container and keep cap in place. Use gasoline for the engine only; not for any other purpose.
Removing the Fuel Tank (continued) g230318 Figure 12 1. Knob 4. Lower control panel 2. Flange-head screw 5. Throttle control 3. Choke control 6. Lift control lever 7. Flange nut 6. Remove flange-head screws and flange nut that secure lower control panel to machine (Figure 12). 7. Remove locknut (item 31 in Figure 11) and flat washer from left fender. 8. Use a fuel transfer pump to remove fuel from the fuel tank and into a suitable container. 9.
Air Cleaner Removing the Air Cleaner 1. Remove air cleaner components as necessary (Figure 13). 2. Refer to the Traction Unit Operator’s Manual for air cleaner service procedures. g230319 Figure 13 1. Air cleaner assembly 5. Hose clamp 9. Air inlet hose 2. Flat washer (2 each) 6. Bolt (2 each) 10. Bolt (2 each) 3. Locknut 7. Lock washer (2 each) 11. Mounting bracket 4. Air inlet hose 8.
Radiator g230307 Figure 14 1. Radiator 13. Hose clamp 25. Coolant reservoir 2. Hydraulic hose 14. Vent tube 26. Hose 3. Screw (8 each) 15. Clamp (2 each) 27. Reservoir cap 4. 5. Radiator shield Intake cover 16. 17. Lower radiator hose Hose clamp 28. 29. Overflow hose Radiator cap 6. Flange nut (8 each) 18. Upper radiator hose 30. Locknut (4 each) 7. 8. Screen Radiator support 19. 20. Fan shroud Bolt (4 each) 31. 32. Radiator shim Foam strip 9. Pop rivet (5 each) 21.
Removing the Radiator (continued) CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Ethylene-glycol antifreeze is poisonous. Dispose of coolant properly, or store it in a properly labeled container away from children and pets. 3. Drain coolant from radiator; refer to the Traction Unit Operator’s Manual. 4. Remove screen from machine; refer to the Traction Unit Operator’s Manual.
Engine g230308 Figure 15 1. Engine 11. Hex nut (4 each) 21. Spacer (4 each) 2. Muffler bracket 12. Frame trim 22. Rebound washer (4 each) 3. Lock washer 13. Spacer 23. Bolt (4 each) 4. Negative battery cable 14. Bolt (2 each per mount) 24. Locknut (2 each per mount) 5. Flat washer 15. Engine shock mount (red patch) 25. Lock washer (2 each per mount) 6. Bolt 16. Air cleaner mounting bracket 26. Bolt (2 each per mount) 7. Flange-head screw 17. Locknut (3 each) 27.
Removing the Engine 1. Park machine on a level surface, lower cutting deck (or implement), shut off the engine, and remove key from the key switch. Chock wheels to keep the machine from moving. 2. Open hood; refer to the Traction Unit Operator’s Manual. 3. Disconnect negative (-) and then positive (+) battery cables at the battery. 4. Remove battery from machine; refer to Servicing the Battery (page 6–80). g230309 Figure 16 1. Battery 3. Battery base 5. Lock washer 2. Bolt (3 each) 4.
Removing the Engine (continued) g230310 Figure 17 1. 2. 3. Radiator Locknut Hose clamp 4. 5. 6. Overflow hose Coolant reservoir Flat washer 7. 8. Bolt Fan shroud 7. Loosen hose clamp and remove overflow hose from radiator fill opening (Figure 17). Remove coolant reservoir from bracket on radiator fan shroud. 8. Remove 4 bolts, 4 flat washers, and 4 locknuts that secure fan shroud to radiator (Figure 17). Position fan shroud away from the radiator. 9.
Removing the Engine (continued) 12. Disconnect hoses from engine. A. Loosen clamps and disconnect upper and lower radiator hoses from the engine. B. At carburetor, loosen hose clamp and disconnect fuel hose. Plug hose to prevent leakage and contamination. 13. Disconnect transmission driveshaft from engine pulley; refer to Removing the Transmission Driveshaft (page 5–87). 14. Remove cotter pin and clevis pin that secure hood cable to muffler bracket on rear of engine. Support hood in the open position. 15.
Removing the Engine (continued) g230312 Figure 19 1. Gasoline engine 4. Bolt 2. Engine bracket 5. Pivot plate 3. Flat washer 6. Engine bracket 7. Engine bracket 17. If necessary, remove engine brackets from engine (Figure 19). Installing the Engine 1. Locate machine on a level surface with cutting deck (or implement) lowered and key removed from the key switch. Chock wheels to keep the machine from moving. 2.
Installing the Engine (continued) CAUTION One person should operate lift or hoist while the other person guides the engine into the machine. IMPORTANT Ensure not to damage the engine, fuel hoses, hydraulic lines, electrical harness, or other parts while installing the engine. C. Lower engine to the machine frame. Ensure that the engine bracket holes are aligned with the holes in the engine shock mounts. D. Secure engine to the engine mounts. 7.
Installing the Engine (continued) 18. Install battery to machine; refer to Servicing the Battery (page 6–80). 19. Check engine oil level; refer to the Traction Unit Operator’s Manual. 20. Connect positive (+) and then negative (-) battery cables to the battery. 21. Close hood; refer to the Traction Unit Operator’s Manual.
Gasoline Engine: Service and Repairs Page 3–22 Groundsmaster® 3280-D/3320 05138SL Rev B
Chapter 4 Diesel Engine Table of Contents Specifications ....................................................................................................................................... 4–2 Engine - Groundsmaster 3280-D ....................................................................................................... 4–2 General Information ..............................................................................................................................
Specifications Groundsmaster 3280-D g243928 Figure 20 1. Starter motor 3. Engine oil filter 5. Fuel injection pump 2. Alternator 4. Flywheel 6. Engine cooling fan Engine - Groundsmaster 3280-D Item Description Kubota D1105: 4-cycle, 3 cylinder water cooled diesel. EPA Tier 4 compliant. Make/Designation Bore 78 mm (3.07 inches) Stroke 78.4 mm (3.09 inches) Total displacement 1123 cm3 (68.
Engine - Groundsmaster 3280-D (continued) Item Description Oil pump Gear driven trochoid type Coolant capacity Groundsmaster® 3280-D/3320 05138SL Rev B 7.
General Information This chapter gives information about specifications and repair of the Kubota D1105 diesel engine used in the Groundsmaster 3280-D machine. The general maintenance procedures are described in the Operator’s Manual. Detailed information on engine troubleshooting, testing, disassembly, and assembly is identified in the Kubota Engine Workshop Manual. Additionally, some engine repair procedures are described in this manual.
Kubota Engine Workshop Manuals The engine that powers your Groundsmaster 3280-D is a Kubota D1105 Tier 4 compliant engine. Kubota Engine Workshop Manuals are available for these engines. To ensure the correct engine workshop manual is used when servicing the engine on your machine, refer to the engine group code on the emission control information label to identify the "E" (emission) level; refer to Engine Group Code (page 4–5).
Adjustments Adjusting the Throttle Control g221634 Figure 21 1. Speed control lever 2. High speed screw 3. Throttle cable Proper throttle operation is dependent upon proper adjustment of the throttle control. Ensure that the throttle control is operating properly. 1. Move the remote throttle control lever to the FAST position 2. Check the position of speed control lever on the engine fuel injection pump.
Service and Repairs Air Cleaner System g221635 Figure 22 1. Hose clamp (3 each) 4. Flat washer (2 each) 7. Air cleaner inlet hose 2. Air cleaner outlet hose 5. Locknut (2 each) 8. Air cleaner mount 3. Bolt (2 each) 6. Air cleaner assembly Removing the Air Cleaner System Note: Refer to the Operator's Manual for maintenance procedures and intervals of the air cleaner. 1.
Installing the Air Cleaner System IMPORTANT Leaks in the air filter system will allow dirt to enter into the engine and can cause serious engine damage. Ensure that all the air cleaner components are in good condition and are properly secured during installation. 1. Assemble the air cleaner system as shown in Figure 22. A. If the service indicator and adapter were removed, install the adapter and service indicator (Figure 23). Torque the adapter to 3.3 to 3.5 N·m (29 to 31 in-lb).
Exhaust System g222270 Figure 24 1. Gasket 4. Exhaust muffler 7. Bolt (2 each) 2. Upper alternator brace 5. Flange nut (2 each) 8. Muffler mount 3. Flange nut (4 each) 6. Hardened washer (4 each) 9. Engine Removing the Exhaust System CAUTION A hot engine and exhaust system can cause burns. Allow the engine and the exhaust system to cool before working on or near them. 1.
Removing the Exhaust System (continued) 3. Remove the 2 bolts (item 7 in Figure 24), 4 hardened washers, and 2 flange nuts that secure the exhaust muffler to the muffler mount. 4. Remove the 4 flange nuts (item 3 in Figure 24) from the exhaust manifold studs. 5. Loosen the alternator bolt, and move the upper alternator brace away from the muffler. 6. Remove the exhaust muffler from the machine. 7. Remove and discard the gasket (item 1 in Figure 24).
Radiator g221637 Figure 25 1. Swell latch (2 each) 13. Radiator cap 25. Flange-head screw (4 each) 2. Flange nut (6 each) 14. Hose clamp (3 each) 26. Pop rivet (4 each) 38. Hex nut (6 each) Vent hose 37. Lock washer (6 each) 3. Flange nut (4 each) 15. Locknut (8 each) 27. Back washer (2 each) 39. 4. Radiator frame 16. Flat washer (10 each) 28. Bottom radiator shield 40. Vent tube 5. Locknut (2 each) 17. Foam strip (2 each) 29. Bulkhead locknut (2 each) 41.
Removing the Radiator 1. Park the machine on a level surface, lower the cutting deck (or implement), shut off the engine, set the parking brake, and remove the key from the key switch. 2. Unlatch the hood and raise it. DANGER If the radiator or engine is hot, pressurized hot coolant can escape and cause burns. Do not open the radiator cap or drain the radiator when the coolant is hot. WARNING Ethylene-glycol antifreeze is poisonous. Keep the coolant away from children and pets.
Removing the Radiator (continued) 12. Remove the 2 bolts, 2 flat washers, and 2 locknuts that secure the coolant reservoir assembly (item 20 in Figure 25) to the fan shroud. Carefully position the coolant reservoir away from the fan shroud. 13. Remove the 4 fasteners, 6 flat washers, and 4 locknuts that secure the fan shroud (item 21 in Figure 25) to the radiator. Position the fan shroud away from the radiator. 14. Support the radiator assembly before loosening the mounting fasteners. 15.
Installing the Radiator (continued) 4. Position the fan shroud (item 21 in Figure 25) to the radiator. Secure the fan shroud to the radiator with the 4 fasteners, 6 flat washers, and 4 locknuts. Ensure that at least 6.4 mm (0.250 inch) clearance exists at all points between the fan shroud and the fan. 5. Position the coolant reservoir assembly (item 20 in Figure 25) to the fan shroud. Secure the coolant reservoir to the fan shroud with the 2 bolts, 2 flat washers, and 2 locknuts. 6.
Fuel System g221626 Figure 26 1. Fuel gauge 9. Radiator frame 17. Fuel cap 25. 26. Locknut 2. Thumb screw (4 each) 10. Clamp 18. Hose clamp (6 each) 3. Control panel 11. Hose clamp 19. Fuel hose (separator to 27. injector) Flat washer 4. Flange-head screw (2 each) 12. Vent hose 20. Fuel hose (fuel pump to 28. separator) Bolt 21. 5. Seat plate 13. Vent tube 6. Rubber grommet 14. Carriage screw (2 each) 22. Fuel pump 29.
DANGER Diesel fuel is highly 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 filling the fuel tank. • Do not fill the fuel tank while the engine is running, while the engine is hot, or when the machine is in an enclosed area. • Always fill the fuel tank outside and wipe up any spilled diesel fuel before starting the engine.
Removing the Fuel Tank (continued) g221627 Figure 27 1. Flange nut 4. Washer-head screw (2 each) 2. Flange-head screw 5. Flange-head screw (3 each) 3. Console 6. Throttle control 7. Locknut (2 each) 9. Remove the flange-head screws and flange nut that secure the lower control panel to the machine (Figure 27). 10. Remove the locknut (item 25 in Figure 26) from the left fender. 11. Use a fuel transfer pump to remove the fuel from the fuel tank and into a suitable container. 12.
Installing the Fuel Tank (continued) 8. Connect the seat switch to the machine wire harness. 9. Connect the negative battery cable to the negative battery post. 10. Fill the fuel tank with clean fuel; refer to the Operator’s Manual. 11. Prime the fuel system; refer to Priming the Fuel System (page 4–16). 12. Check the fuel hoses and fittings for leaks. Note: Repair all fuel leaks before returning the machine to service. 13. Lower the hood and secure it with the latches.
Engine g222271 Figure 28 1. Driveshaft assembly 2. Upper engine shock mount (4 each) 10. Lock washer (2 each) 17. Bolt (4 each) Flat washer 18. 3. Flat washer (3 each) Rebound washer (4 each) 11. Battery retainer 19. Lower engine shock mount (4 each) 4. 5. Locknut (3 each) 12. Bolt (3 each) 20. Flat washer (3 each) Engine 13. Threaded insert 21. Bolt (3 each) 6. Lift tabs 14. Battery base 22. Flange-head screw (8 each) 7. Battery 15. Flange nut (3 each) 8. Bolt 16.
Removing the Engine 1. Park the machine on a level surface, lower the cutting deck (or implement), shut off the engine, set the parking brake, and remove the key from the key switch. 2. Unlatch the hood and raise it. 3. Disconnect both the battery cables at the battery. Disconnect the negative battery cable and then the positive battery cable. 4. Remove the battery from the machine; refer to Servicing the Battery (page 6–80). 5.
Removing the Engine (continued) g221629 Figure 29 1. Hose clamp 5. Coolant reservoir assembly 9. Upper radiator hose 2. Flat washer (8 each) 6. Locknut (6 each) 10. Hose clamp (4 each) 3. Bolt (4 each) 7. Fan shroud 11. Lower radiator hose 4. Reservoir hose 8. Carriage bolt (2 each) 12. Radiator 7. Loosen the hose clamp and remove the reservoir hose from the radiator fill opening (Figure 29), and remove the coolant reservoir assembly from the radiator fan shroud. 8.
Removing the Engine (continued) g221630 Figure 30 1. Cable end 2. Cable clamp 12. Remove the throttle cable from the injector pump (Figure 30) as follows: A. Remove the retaining ring that secures the throttle cable end to the injector pump control arm. B. Loosen the throttle cable clamp and remove the throttle cable from the injector pump. C. Position the throttle cable away from the engine. 13. Disconnect the hoses from the engine as follows: A.
Removing the Engine (continued) C. Cover or plug the fuel hoses and pump fittings openings to prevent contamination. Position the disconnected hoses away from the engine. 14. Remove the hydraulic pump/transmission driveshaft; refer to Removing the Hydraulic Pump Driveshaft (page 5–97) or Removing the Transmission Driveshaft (page 5–87). 15. Remove the cotter pin and clevis pin that secure the hood cable to the muffler mount. Support the hood in open position.
Removing the Engine (continued) IMPORTANT When removing the engine ensure that you do not damage the engine, fuel hoses, hydraulic lines, electrical harness or other parts. 19. Carefully raise the engine and remove from the machine. 20. If necessary, remove the engine brackets from the engine (Figure 32 and Figure 33). Installing the Engine IMPORTANT Ensure that all parts are removed from the engine during maintenance or overhaul are correctly installed on the engine. 1.
Installing the Engine (continued) g221633 Figure 33 1. Left rear engine bracket 4. Left front engine bracket 2. Lock washer (8 each) 5. Engine 3. Bolt (8 each) 2. If the engine brackets were removed from the engine, install the brackets to the engine (Figure 32 and Figure 33). 3. If the engine mount brackets (item 16 in Figure 28) were removed from the frame, secure the mount brackets to the frame with the bolts. Torque the bolts to 68 to 81 N∙m (50 to 60 ft−lb). 4.
Installing the Engine (continued) IMPORTANT When installing the engine ensure that you do not damage the engine, fuel hoses, hydraulic lines, electrical harness, radiator or other parts. 6. Carefully lower the engine to the machine frame. Ensure that the fastener holes of the engine brackets are aligned with the holes in the upper and lower engine shock mounts (items 2 and 19 in Figure 28). 7. Secure the engine to the engine mount brackets (item 16 in Figure 28). 8.
Installing the Engine (continued) IMPORTANT Ensure that the clutch pulley and PTO pulley are aligned during PTO shaft installation. 16. Install the PTO shaft to the machine; refer to Installing the PTO Shaft (page 9–9). 17. Position the fan shroud to the radiator. Ensure that a minimum of 6.4 mm (0.25 inch) clearance exists at all points between the shroud and the fan. Secure the fan shroud to the radiator with the 4 fasteners, 6 flat washers, and 4 locknuts (Figure 29). 18.
Diesel Engine: Service and Repairs Page 4–28 Groundsmaster® 3280-D/3320 05138SL Rev B
Chapter 5 Hydraulic System Table of Contents Specifications ....................................................................................................................................... 5–3 Groundsmaster 3280-D and 3320-G.................................................................................................. 5–3 General Information ..............................................................................................................................
Testing the Steering Circuit–Charge Pump Flow (Machine Serial Numbers above 316000000)...................................................................................................................................... 5–69 Testing the Lift Circuit–Lift Cylinder Internal Leakage (Machine Serial Numbers above 316000000)...................................................................................................................................... 5–72 Adjustments ......................................
Specifications Groundsmaster 3280-D and 3320-G Item Description Danfoss Series 15 U Style Axial Piston Transmission Hydrostatic transmission (Machine Serial Number below 316000000) Gerotor Pump in Hydrostat Charge pump (Machine Serial Number below 316000000) Hydraulic pump (Machine Serial Number above 316000000) Danfoss, DDC20 Axial Piston Pump Eaton 74118 Fixed Axial Piston Motor Hydraulic motor (Machine Serial Number above 316000000) Maximum pump displacement (per revolution) For Machine Serial Numb
General Information The Operator's Manual provides information regarding the operation, general maintenance procedures, and maintenance intervals for your machine. Refer to the Operator's Manual for additional information when servicing the machine. Checking the Hydraulic Fluid g224909 Figure 34 1. Hydraulic reservoir dipstick The hydraulic system on your machine is designed to operate on high quality hydraulic fluid.
Pushing or Towing the Traction Unit IMPORTANT If towing limits are exceeded, severe damage to the hydraulic pump may occur. g230813 Figure 35 1. Check valve location g224908 Figure 36 1. Hydraulic pump (for Models 30344 and 30345) 2. Bypass valve If it becomes necessary to tow or push the machine, tow or push at a speed below 4.8 km/h (3mph), and for a very short distance. If you must move the machine a considerable distance (more than a few feet), transport it on a truck or trailer.
Releasing Pressure from the Hydraulic System Release all the pressure in the hydraulic system before you work on the hydraulic system. System pressure in the cutting circuit is released when the cutting deck is disengaged. Releasing the Hydraulic Pressure from the Traction Circuit Note: If you park the machine on an incline or slope, the pressure in the traction circuit does not release. 1. Park the machine on a level surface. 2. Lower the cutting deck. 3.
Traction Circuit Component Failure The traction circuit of the Groundsmaster 3280-D and 3320 machines is a closed loop system that includes the hydraulic pump and hydraulic motor. If a component failure occurs in the traction circuit (e.g., hydraulic pump or hydraulic motor), unwanted material and contamination from the damaged component will circulate throughout the traction circuit.
Hydraulic Hoses The hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions, in addition to mishandling during operation and maintenance. These conditions can cause damage to the hose or deterioration to the hose material. Some hoses are more susceptible to these conditions than others.
Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) 1. Ensure that all the threads, the sealing surfaces of the hose/tube, and the fitting are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the face seal O-ring when you open the connection. Ensure that the O-ring is installed and correctly seated in the groove of the fitting. Lightly lubricate the O-ring with clean hydraulic fluid. g221221 Figure 37 1. Tube or hose 2. Swivel nut 3.
Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (continued) C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (FFWR); refer to the Flats From Wrench Resistance Table (page 5–10). Note: The markings on the nut and body of the fitting show that the connection is correctly tightened.
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port) Installing the Non-Adjustable Fittings 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the O-ring when you open the connection. g221223 Figure 39 1. Fitting 2. O-ring 3. Lightly lubricate the O-ring with clean hydraulic fluid.
Installing the Non-Adjustable Fittings (continued) Fitting Installation Torque Table Fitting Dash Size Fitting Port Side Thread Size (inch(es) - threads per inch) Installation Torque Into Steel Port Installation Torque Into Aluminum Port 4 7/16—20 21 to 25 N∙m (15 to 19 ft-lb) 13 to 15 N∙m (9 to 11 ft-lb) 5 1/2—20 25 to 29 N∙m (18 to 22 ft-lb) 15 to 20 N∙m (11 to 15 ft-lb) 6 9/16—18 47 to 56 N∙m (34 to 42 ft-lb) 28 to 35 N∙m (20 to 26 ft-lb) 8 3/4—16 79 to 97 N∙m (58 to 72 ft-lb) 48 to 58
Installing an Adjustable Fitting 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the O-ring when you open the connection. g221224 Figure 40 1. Locknut 2. Back-up washer 3. O-ring 3. Lightly lubricate the O-ring with clean hydraulic fluid. Ensure that the threads of the fitting are clean with no lubricant applied. g221225 Figure 41 4.
Installing an Adjustable Fitting (continued) 7. Hold the fitting in the correct alignment with a wrench and use a torque wrench and tighten the fitting to the recommended torque value within the specified range of torque values; refer to the Fitting Installation Torque Table (page 5–12). This tightening procedure requires a drive-adapter wrench (e.g., crowfoot wrench). Note: It may be necessary to use a drive-adapter wrench (e.g.
Hydraulic Schematics g243932 Figure 42 Groundsmaster® 3280-D/3320 05138SL Rev B Page 5–15 Hydraulic System: Hydraulic Schematics
g229581 Figure 43 Hydraulic System: Hydraulic Schematics Page 5–16 Groundsmaster® 3280-D/3320 05138SL Rev B
g243934 Figure 44 Groundsmaster® 3280-D/3320 05138SL Rev B Page 5–17 Hydraulic System: Hydraulic Schematics
g224768 Figure 45 Hydraulic System: Hydraulic Schematics Page 5–18 Groundsmaster® 3280-D/3320 05138SL Rev B
Hydraulic Flow Diagrams Traction Circuit (Machine Serial Number below 316000000) Forward Direction The hydrostatic transmission input shaft is rotated by a driveshaft off the front of the engine crankshaft. Pushing the top of the traction pedal rotates the variable displacement pump swash plate in the transmission to create a flow of fluid. This fluid is directed to the fixed displacement motor in the transmission which turns the front axle input shaft to drive the front wheels in the forward direction.
Forward Direction (continued) g229585 Figure 46 Hydraulic System: Hydraulic Flow Diagrams Page 5–20 Groundsmaster® 3280-D/3320 05138SL Rev B
Forward Direction (continued) g246024 Figure 47 Groundsmaster® 3280-D/3320 05138SL Rev B Page 5–21 Hydraulic System: Hydraulic Flow Diagrams
Forward Direction (continued) g246025 Figure 48 Hydraulic System: Hydraulic Flow Diagrams Page 5–22 Groundsmaster® 3280-D/3320 05138SL Rev B
Reverse Direction The traction circuit operates essentially the same in reverse as it does in the forward direction. However, the flow through the circuit is reversed. Pushing the bottom of the traction pedal rotates the variable displacement pump swash plate in the transmission to create a flow of fluid. This fluid is directed to the fixed displacement motor in the transmission which turns the differential input shaft to drive the front wheels in a reverse direction.
Traction Circuit (Machine Serial Number above 316000000) The hydraulic traction circuit is a closed loop system consisting of a variable displacement hydraulic pump and a hydraulic drive axle motor. The hydraulic pump is driven by a drive shaft connected to the engine crankshaft. Forward Direction Pressing the top of traction pedal, angles the hydraulic pump swash plate to create a flow of fluid.
Forward Direction (continued) g224777 Figure 49 Groundsmaster® 3280-D/3320 05138SL Rev B Page 5–25 Hydraulic System: Hydraulic Flow Diagrams
Reverse Direction The traction circuit operates essentially the same in reverse as it does in the forward direction. However, the flow through the circuit is reversed. Pushing the bottom of the traction pedal rotates the variable displacement pump swash plate in the hydraulic pump to create a flow of fluid. This fluid is directed to the fixed displacement motor which turns the differential input shaft to drive the front wheels in a reverse direction.
Lift Circuit (Machine Serial Number below 311000000) The hydrostatic transmission charge pump supplies charge oil for the closed loop traction circuit in addition to supplying flow for the steering circuit and the lift circuit. The charge pump takes its suction through a filter from the reservoir (front axle). Pump output flows to the steering control valve before reaching the lift valve so the steering circuit has priority.
Raise Cutting Deck (or Implement) (continued) g246023 Figure 51 When the cutting deck (or implement) is to be raised, the control valve spool is positioned rearward and flow is directed out the B port of the control valve to the cap (upper) end of the lift cylinders. Hydraulic pressure against the cylinder pistons extends the lift cylinders. At the same time, the pistons push the hydraulic fluid in the lower portion of the lift cylinders out and to the reservoir (front axle).
LIFT CYLINDERS (RETRACTING) Lower Cutting Deck (or Implement) g229582 Figure 52 g246022 Figure 53 Groundsmaster® 3280-D/3320 05138SL Rev B Page 5–29 Hydraulic System: Hydraulic Flow Diagrams
Lower Cutting Deck (or Implement) (continued) When the cutting deck (or implement) is to be lowered, the control valve spool is moved forward causing the pilot valve to shift open. This shifted valve allows a return path from the lift cylinders to the reservoir (front axle) (Figure 52). The weight of the cutting deck (or implement) causes the cylinders to retract thus lowering the cutting deck (or implement).
Lift Circuit (Machine Serial Number above 311000000) The charge pump supplies charge fluid for the closed loop traction circuit in addition to supplying flow for the steering circuit and the lift circuit. The charge pump takes its suction through a filter from the transaxle reservoir (front axle). The pump output flows to the steering control valve before reaching the lift manifold so that the steering circuit has priority.
Raise the Cutting Deck (or Implement) (continued) g224770 Figure 54 Hydraulic System: Hydraulic Flow Diagrams Page 5–32 Groundsmaster® 3280-D/3320 05138SL Rev B
Lower the Cutting Deck (or Implement) As previously described, when the lift switch is neither in the RAISE or LOWER position, fluid pressure shifts the logic cartridge LC open to provide a fluid path to the tank. When the lift switch is set to the LOWER position, solenoid valve SV2 is energized to open a path for fluid trapped behind the lift cylinder pistons to escape through the open logic cartridge LC as well.
Lower the Cutting Deck (or Implement) (continued) g224769 Figure 55 Hydraulic System: Hydraulic Flow Diagrams Page 5–34 Groundsmaster® 3280-D/3320 05138SL Rev B
Steering Circuit (Machine Serial Number below 316000000) g229584 Figure 56 The charge pump in the transmission supplies flow for the steering circuit and for the lift circuit. Charge pump output flows to the steering control valve before reaching the lift valve so that the steering circuit has priority. Steering circuit pressure is limited to 5,515 kPa (800 psi) by the implement relief valve located in the transmission.
Right Turn When a right turn is made with the engine running, the turning of the steering wheel positions the steering control spool valve so that flow goes through the top of the spool. 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 the fluid flow to the cylinder is proportional to the amount of the turning on the steering wheel.
Steering Circuit (Machine Serial Number above 316000000) The charge pump supplies flow for the steering circuit and for the lift circuit. The pump output flows to the steering control valve before reaching the lift manifold so that the steering circuit has priority. The steering circuit pressure is limited to 7,239 kPa (1,050 psi) by a relief valve located in the steering control valve.
Right Turn (continued) g224774 Figure 57 Hydraulic System: Hydraulic Flow Diagrams Page 5–38 Groundsmaster® 3280-D/3320 05138SL Rev B
Special Tools You can order these special tools from your Toro Distributor. Some tools are also available from a local tool supplier. Hydraulic Pressure Testing Kit Toro Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick disconnect fittings are provided to attach directly to the mating fittings on the machine test ports without the tools. A high-pressure hose is given for remote readings.
40 GPM Hydraulic Tester (Pressure and Flow) Toro Part No. AT40002 Use this tester to test the hydraulic circuits and components for flow and pressure capacities as recommended in Testing the Hydraulic System (page 5–47). This tester includes the following: •Load Valve: Turn the valve to restrict the flow to create a simulated working load in the circuit. •Load Valve: Turn the valve to restrict the flow to create a simulated working load in the circuit.
Hydraulic Test Fitting Kit Toro Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system.
O-Ring Kit Toro Part No. 117-2727 This kit includes O-rings in a variety of sizes for the face seal and port seal hydraulic connections. To help prevent a hydraulic leak, replace the O-rings when you open the hydraulic connection. High Flow Hydraulic Filter Kit Toro Part No. TOR6011 The high flow hydraulic filter kit is designed with large flow (150 L/minute or 40 gallons/minute) and high pressure (34,500 kPa or 5,000 psi) capabilities.
Remote Starter Switch After flushing the hydraulic system or replacing a hydraulic component (e.g. gear pump, piston pump, drive motor), it is necessary to prime the hydraulic pumps. A remote starter switch can be used for this purpose. A remote starter switch can be purchased locally or fabricated as follows. IMPORTANT: When using a remote starter switch, it is highly recommended to include a 20 amp in−line fuse between the battery and switch connector for circuit protection.
Troubleshooting The following chart contains suggestions that can be used to solve performance issues specific to the hydraulic system. The suggestions are not all-inclusive. There can be more than 1 cause for a machine malfunction. Review the hydraulic schematic found in Appendix A (page A–1) and information on the hydraulic system operation in the Hydraulic Flow Diagrams (page 5–19). This information will be useful during the hydraulic troubleshooting process.
Traction Circuit Problems Problem Possible Causes Traction jerky when starting. • Friction wheel on traction pedal out of adjustment or worn (except 3280-D Models 30344 and 30345). • The traction control linkage is incorrectly adjusted, disconnected, binding, or damaged. • The hydrostat/hydraulic pump check valve is not seating or is damaged. The traction response is sluggish. • The hydraulic pump bypass valve is open or damaged (3280-D Models 30344 and 30345). • The brake is dragging or binding.
Lift/Lower Circuit Problems Problem Possible Causes • Engine RPM is too low. The cutting deck (or implement) will not lift or lifts slowly. • The cutting deck has excessive unwanted elements in cutting chambers. • The lift arm or lift cylinder is binding. • The lift valve control linkage is binding or broken (except 3280-D Models 30344 and 30345). • The hydraulic-fluid level in the reservoir (front axle) is low. • The charge pump pressure or flow is insufficient.
Testing the Hydraulic System The most effective procedure to isolate the problems in the hydraulic system is to use hydraulic test equipment, such as pressure gauges and flow meters in the circuits during different operational checks; refer to Special Tools (page 5–39). WARNING Opening the hydraulic system without releasing pressure from the system will cause the hydraulic fluid to escape, causing possible injury.
IMPORTANT Use 2 people to perform all the tests, with 1 person in the seat and the other to read and record the test results. 1. Clean the machine fully before you disconnect or disassemble the hydraulic components. Note: Cleanliness is required whenever you work on the hydraulic equipment. Contamination causes too much wear on hydraulic components. 2. When you perform tests on the hydraulic system, wear eye protection. 3.
Charge Pressure Test (Using Pressure Gauge) (Machine Serial Numbers below 316000000) A charge pressure test should be performed to identify if a worn or damaged hydrostatic transmission is causing a hydraulic system problem. Note: Before conducting charge pressure test, determine counterbalance pressure setting for the machine; refer to the Traction Unit Operator’s Manual. 1. Ensure that the hydraulic fluid is at normal operating temperature. 2.
Charge Pressure Test (Using Pressure Gauge) (Machine Serial Numbers below 316000000) (continued) 4. Clean the area around the 1/8 inch pipe plug located on the top of the transmission between the 2 check valves (Figure 59 and Figure 60). Remove the plug from the transmission. 5. Connect a 6,900 kPa (1,000 psi) hydraulic pressure gauge to the transmission opening. 6. After installing pressure gauge, start engine, and run at idle speed.
Implement Relief Pressure Test (Using Pressure Gauge) (Machine Serial Numbers below 316000000) g230803 Figure 61 1. Seat base opening 3. Pipe plug 2. Check valve 4. Implement relief valve g230804 Figure 62 1. Relief valve The implement relief pressure test should be done if a problem is suspected with the implement relief valve. Note: When conducting the Implement Relief Pressure Test, use a 34,500 kPa (5,000 psi) Pressure Gauge. 1.
Implement Relief Pressure Test (Using Pressure Gauge) (Machine Serial Numbers below 316000000) (continued) Note: If the implement relief pressure is 4,820 to 6,900 kPa (700 to 1,000 psi) and a steering or lift problem occurs, inspect for a problem unrelated to the hydraulic circuit (e.g., binding steering or lift system components, debris build-up on/under the cutting deck). Check and repair other items before continuing with hydraulic tests. 4.
Lift Cylinder Internal Leakage Test (Machine Serial Numbers below 316000000) g230805 Figure 63 Test Procedure The lift cylinder internal leakage test should be performed if a cutting deck (or implement) raise and lower problem is identified. This test will determine if the lift cylinders are damaged. Note: Cutting deck raise/lower circuit operation will be affected by lift cylinder binding, extra weight on the cutting deck (or implement), and/or binding of lift components.
Test Procedure (continued) 2. With the engine running, raise the cutting deck (or implement) completely. Using blocking or a hoist, support the cutting deck (or implement) to keep it in the fully raised position. Shut off the engine. 3. Place a drain pan under the lift cylinder that is to be tested for internal leakage. Clean the area around the cylinder return hose at the bottom of the lift cylinder. g230806 Figure 64 1. 2. Lift cylinder Return hose 4.
Steering Cylinder Internal Leakage Test (Machine Serial Numbers below 316000000) g230807 Figure 65 Test Procedure The steering cylinder internal leakage test should be performed if a steering problem is identified. This test will determine if the steering cylinder is damaged. Note: Steering circuit operation will be affected by rear tire pressure, steering cylinder binding, extra weight on the vehicle, and/or binding of rear axle steering components.
Test Procedure (continued) 6. With the engine shut off, continue turning the steering wheel for a right turn (clockwise) with the steering cylinder fully extended. Observe the open fitting on the steering cylinder as the wheel is turned. If fluid comes out of the fitting while turning the steering wheel to the right, the steering cylinder has internal leakage and must be repaired or replaced. 7. Remove plug from the hydraulic hose. Reconnect hose to the steering cylinder fitting. 8.
Charge Pump Flow Test (Using Tester With Pressure Gauges and Flow Meter) (Machine Serial Numbers below 316000000) The charge pump flow test should be performed if a hydraulic problem is identified that affects both the steering and lift circuits. Note: The charge pump provides make-up fluid for internal hydrostat components before flow is available for the steering and lift circuits. Flow measured in this test will be less than total charge pump output. 1.
Charge Pump Flow Test (Using Tester With Pressure Gauges and Flow Meter) (Machine Serial Numbers below 316000000) (continued) 6. Ensure that the flow control valve on the tester is fully open. Also, ensure that the traction pedal and lift valve are in neutral and that the parking brake is engaged. 7. Start engine and run at idle speed. Check for any hydraulic leakage from test connections and correct before proceeding with test. 8. Run engine at full speed (3,150 to 3,250 rpm).
Testing the Traction Circuit–Charge Pressure (Machine Serial Numbers above 316000000) g224775 Figure 67 Test Procedure The charge pressure test is the first in a series of tests recommended to determine traction circuit performance. A charge pressure drop of more than 20% indicates an internal leak in the hydraulic pump. Continued unit operation can generate excessive heat, cause damage to seals and other components in the hydraulic system, and affect overall machine performance.
Test Procedure (continued) 3. Read all Warning, Cautions, and precautions listed at the beginning of this section. 4. Raise and support the operator seat, remove the seat plate to get access to the hydraulic pump assembly. 5. Ensure that the traction pedal is in the NEUTRAL position, the steering wheel is stationary and parking brake is set. g226949 Figure 68 1. 2. 90° hydraulic fitting Hydraulic tube 6. Clean the fitting and hydraulic tube (Figure 68). Loosen and remove the tube from the fitting.
Test Procedure (continued) 12. Record the reading on the pressure gauge (under load). The charge pressure (under load) should not drop more than 20% when compared to charge pressure (without load) recorded in step 10. If specifications are not met, perform the hydraulic pump flow and traction relief pressure test; refer to Testing the Traction Circuit–Hydraulic Pump Flow and Relief Pressure (Machine Serial Numbers above 316000000) (page 5–62). 13.
Testing the Traction Circuit–Hydraulic Pump Flow and Relief Pressure (Machine Serial Numbers above 316000000) g224776 Figure 69 The hydraulic pump flow test is the second in a series of tests recommended to determine the traction circuit performance. This test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 12% indicates an internal leak or malfunctioning relief valve in the hydraulic pump.
Test Procedure (continued) CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–6). 2. Park the machine on a level surface, lower the cutting deck, shut off the engine, and set the parking brake. 3. Read all Warning, Cautions, and precautions listed at the beginning of this section. 4.
Test Procedure (continued) 9. Use the hydraulic hose kit to connect tester to the machine; refer to Hydraulic Hose Kit (page 5–40). Ensure that the fitting and hose connections are properly tightened. Also, ensure that the flow control valve on tester is fully open. CAUTION During this procedure, all the wheels will be off the ground and rotating. Ensure that the machine is well supported so it will not move and accidentally fall to prevent injuring anyone around the machine. 10.
Test Procedure (continued) 18. Install the seat plate, lower and secure the operator seat. 19. Start the engine, check for hydraulic-fluid leaks, repair any leaks as required, and fill the hydraulic reservoir (front axle) with the correct quantity of new hydraulic fluid before returning the machine to service.
Testing the Steering Circuit–Steering Control Valve, Relief Valve Pressure, and Steering Cylinder (Machine Serial Numbers above 316000000) g224913 Figure 71 Unit steering performance will be affected by incorrect rear tire pressure, binding in the hydraulic steering cylinder, extra weight on the vehicle, and/or binding of the steering forks. Ensure that these conditions are checked and functioning properly before proceeding with any steering system hydraulic testing.
Test Procedure (continued) A. There should be no shaking or vibration in the steering wheel or rear wheels. B. The steering wheel movements should be followed immediately by a corresponding rear wheel movement without the steering wheel continuing to turn. 3. Stop unit with the engine running. Turn the steering wheel with small quick movements in both directions. Let go of the steering wheel after each movement. A. The steering control valve should respond to each steering wheel movement. B.
Test Procedure (continued) 6. If the specification is not met, repair or replace the steering control valve; refer to Servicing the Steering Control Valve (page 5–116). 7. After you complete the testing, shut off the engine, and then release hydraulic system pressure; refer to Releasing Pressure from the Hydraulic System (page 5–6). Disconnect the pressure gauge, and connect removed hydraulic hose to the steering cylinder. 8.
Testing the Steering Circuit–Charge Pump Flow (Machine Serial Numbers above 316000000) g226658 Figure 72 The charge pump is designed to satisfy the steering cylinder needs (at full speed). The charge pump flow test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 15% indicates the gears and wear plates in the pump have worn.
Test Procedure (continued) 3. Raise and support the operator seat, remove the seat plate to get access to the hydraulic pump assembly. 4. Clean the junction of the hydraulic tube and left side elbow fitting on the charge pump. Disconnect the hydraulic tube from the left side of the pump fitting. IMPORTANT Ensure that the fluid flow indicator arrow on the flow meter is showing that the fluid will flow from the hydraulic tube, through the tester, and into the charge pump. 5.
Test Procedure (continued) B. The charge pump is worn and should be repaired or replaced; refer to Servicing the Hydraulic Pump (Machine Serial Number above 316000000) (page 5–103). 14. After you complete the testing, shut off the engine, and then release pressure from the hydraulic system; refer to Releasing Pressure from the Hydraulic System (page 5–6). 15. Disconnect the tester, and connect the removed hydraulic tube. 16. Install the seat plate, lower and secure the operator seat. 17.
Testing the Lift Circuit–Lift Cylinder Internal Leakage (Machine Serial Numbers above 316000000) g225190 Figure 73 Perform a lift cylinder internal leakage test if you identify a cutting deck raise and lower problem. This test determines if the lift cylinder being tested is damaged. The lift cylinders must be tested individually. Note: The raise/lower circuit operation can be affected by the lift cylinder binding, extra weight on the cutting deck, and/or binding of the lift components.
Test Procedure Note: When performing the lift cylinder internal leakage test, the cutting deck should be attached to the lift arms. g225791 Figure 74 1. Cylinder barrel end fitting 3. Hydraulic hose 2. Hydraulic hose 4. Lift cylinder 1. Park the machine on a level surface with the PTO switch off, shut off the engine, and set the parking brake. 2. For the lift cylinder that is to be tested, use a jack to raise the lift arm slightly.
Test Procedure (continued) 11. Remove the cap from the cylinder fitting and the plug from the hydraulic hose. 12. Connect the hydraulic hose to the lift cylinder fitting. 13. Carefully remove the jack from under the lift arm. Start the engine and operate the lift cylinders through several up and down cycles. Shut off the engine and check for any leakage. 14. If necessary, repeat the steps 2 through 13 for other lift cylinders. 15.
Adjustments Traction Pedal Friction Wheel (Machine Serial Number below 316000000) g230809 Figure 75 1. Traction pedal 2. Friction wheel 3. Inspection point The traction pedal friction wheel is designed to reduce transmission oscillation caused by rapid back and forth foot movements against the traction pedal. This is most noticeable when operating over bumpy terrain. Occasionally inspect the friction wheel surface that contacts the traction pedal (Figure 75).
Adjusting the Traction Pedal Friction Wheel (continued) 2. Rotate the shaft to move the worn friction wheel section away from the traction pedal. 3. Tighten the flange nuts to secure traction pedal shaft and friction wheel in position.
Service and Repairs General Precautions for Removing and Installing the Hydraulic System Components Before Repairing or Replacing the Components 1. Before removing any parts from the hydraulic system, park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Clean the machine before you disconnect, remove, or disassemble the hydraulic components.
After Repairing or Replacing the Components (continued) 4. Remove all the caps or plugs from the hydraulic tubes, hydraulic fittings, and components before connecting them again. 5. Use proper tightening procedures when installing the hydraulic hoses and fittings; refer to Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (page 5–9) and Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port) (page 5–11). 6.
Priming the Hydraulic Pump When the hydraulic system is flushed, the hydraulic system is charged, or the hydraulic components are installed, it is important to properly prime the hydraulic pumps. The hydraulic pump priming ensures that the hydraulic pump have sufficient fluid during initial start-up and running. The pump can be primed by using a remote starter switch (refer to Remote Starter Switch (page 5–43)) to crank the engine which allows the pump to prime.
Flushing the Hydraulic System IMPORTANT Flush the hydraulic system whenever there is a severe component failure or the system is contaminated (for example, the fluid appears milky, black, or contains metal particles). IMPORTANT If a component failure occurs in the traction circuit; refer to the Traction Circuit Component Failure (page 5–7) for information regarding the importance of removing contamination from the traction circuit. 1.
Flushing the Hydraulic System (continued) 8. Perform the following to prevent engine from starting: A. Disconnect the electrical connector to the fuel stop solenoid on Groundsmaster 3280-D machines. B. Disconnect and ground all engine spark plug wires on Groundsmaster 3320 machines. 9. Prime the hydraulic pump; refer to Priming the Hydraulic Pump (page 5–79). 10. Connect the fuel stop solenoid (Groundsmaster 3280-D) or spark plug wires (Groundsmaster 3320) to allow the engine to start. 11.
Filtering the Closed-Loop Traction Circuit (Machine Serial Number above 316000000) g225778 Figure 78 1. Right elbow fitting 4. Left elbow fitting 2. Hydraulic tube (forward) 5. Hydraulic pump 3. Hydraulic hose (reverse) Filtering a closed-loop hydraulic system after a major component failure (e.g., hydraulic pump or hydraulic motor) is necessary to prevent unwanted material from transmitting throughout the system.
Filtering the Closed-Loop Traction Circuit (Machine Serial Number above 316000000) (continued) IMPORTANT Using other hydraulic fluids could damage the hydraulic system. Use the hydraulic fluids that are specified in the Operator’s Manual. 5. After you install the high-flow filter to the machine, check and fill the hydraulic reservoir (front axle) with the correct quantity of new hydraulic fluid. 6. Start the engine and run it at low-idle speed.
Filtering the Closed-Loop Traction Circuit (Machine Serial Number above 316000000) (continued) 11. Remove the high flow hydraulic filter and hydraulic hose kit from the machine. Connect the hydraulic hose to the left pump fitting. Ensure that you properly tighten the hoses; refer to Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (page 5–9). 12. Lower the machine to the ground. 13.
Charging the Hydraulic System Note: When initially starting the hydraulic system with new or rebuilt components such as hydraulic pump, hydraulic motor, or lift cylinders, it is important that the hydraulic system is charged properly. Remove the air from the system and its components to reduce the chance of damage. IMPORTANT Change the hydraulic-fluid filter when you repair or replace the hydraulic components. 1. Park the machine on a level surface and shut off the engine. 2.
Charging the Hydraulic System (continued) 13. Turn the steering wheel in both directions so that the steering cylinders move in and out several times. 14. Operate the traction pedal in the forward and reverse directions. The drive wheels should rotate in the proper direction. If the wheels rotate in the wrong direction, shut off the engine, inspect the hydraulic line placement at the hydraulic pump and hydraulic motor. Correct the hydraulic line installation before you proceed. 15.
Transmission Driveshaft (Machine Serial Numbers below 316000000) g230811 Figure 79 1. 2. Driveshaft Conelock nut 6. 7. Bolt Square-head screw (2 each) 11. 12. Transmission Bolt 3. Flat washer 8. Coupling spacer 13. Lock washer 4. Rubber coupling 9. Pump hub 5. Coupling spacer 10. Bolt Removing the Transmission Driveshaft 1. Park the machine on a level surface, engage parking brake, lower cutting deck (or implement), and shut off the engine. Remove key from the key switch. 2.
Aligning the Transmission Driveshaft The engine crankshaft and the transmission input shaft must be aligned within 3 mm (0.125 inch) of each other. 1. Verify that the driveshaft is straight and that the flanges are perpendicular to the tube and are not bent. 2. Attach the driveshaft directly to the engine hub to allow verification of driveshaft alignment. 3. Loosen square-head screws (item 7 in Figure 79) that secure pump hub to transmission input shaft.
Aligning the Transmission Driveshaft (continued) 7. When driveshaft alignment is correct, tighten fasteners to secure front axle to frame. IMPORTANT Do not overtighten jam nut for transmission anchor as driveshaft alignment will be affected. 8. Tighten upper jam nut (item 8 in Figure 80) until it contacts top of transmission anchor and then tighten locknut below transmission anchor.
Hydrostatic Transmission (Machine Serial Numbers below 316000000) g230835 Figure 81 1. Bolt 2. Bolt (3 each) 3. Lock washer (4 each) 4. Flat washer 5. Spacer 18. Pump lever 35. Adapter 19. Cotter pin 36. Plug 20. Flat washer 37. O-ring 21. Rubber bushing 38. Filter adapter 22. Hydraulic tee fitting 39. Jam nut 6. Mounting spacer (4 each) 23. Hydraulic hose 40. Hydraulic filter 7. Pinion gear 24. Hydraulic hose 41. Hose clamp 8. Snap ring 25. Hose clamp 42.
Removing the Hydrostatic Transmission 1. Park the machine on a level surface, engage parking brake, lower cutting deck (or implement), and shut off the engine. Remove key from the key switch. 2. To prevent contamination of the hydraulic system, clean transmission and front axle. CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic fluid. 3. Label hydraulic hoses to assist in assembly. Disconnect all hydraulic hoses from the transmission assembly.
Installing the Hydrostatic Transmission 1. Coat new hydraulic fitting O-rings lightly with clean hydraulic fluid. Install fittings with new O-rings to the transmission. Orientate the fittings as noted during disassembly. 2. If pump lever (item 18 in Figure 81) was removed, clean pump shaft and apply Loctite #680 Retaining Compound (or equivalent) to pump shaft. Slide pump lever onto shaft and secure with bolts and locknuts. 3. Apply non-hardening gasket sealant to both sides of gasket (item 9 in Figure 81).
Servicing the Hydrostatic Transmission (Machine Serial Numbers below 316000000) g230836 Figure 82 1. Retaining ring 20. Piston (pump) (9 each per block) 39. Center section 2. Trunnion shaft 21. O-ring 40. Pipe plug (4 each) 3. Flat washer 22. Check valve 41. O-ring 4. Roller bearing 23. Plug 42. Threaded plug 5. Needle bearing 24. O-ring 43. Bolt (4 each) 6. Transmission housing 25. Shim pack 44. Expansion plug 7. Lip seal 26. Relief valve spring 45.
Servicing the Hydrostatic Transmission (Machine Serial Numbers below 316000000) (continued) Note: For transmission repair information; refer to the Danfoss 15 Series Axial Piston Pumps, Motors and Transmission Repair Manual and Service Manual.
Hydrostatic Transmission Neutral Arm Assembly (Machine Serial Number below 316000000) g230837 Figure 83 1. Transmission housing 2. Bolt 8. Eccentric pin 14. Socket-head screw (4 each) 3. Mounting plate 9. Retaining ring 15. Socket-head screw 7. 13. Grease fitting Bearing 4. Neutral return spring 10. Jam nut 16. Neutral proximity switch 5. 6. Neutral return arm Bushing 11. 12. Socket-head screw Pin 17. 18. Trunnion cam Seal g230838 Figure 84 1. Eccentric pin 2.
Assembling the Hydrostatic Transmission Neutral Arm Assembly 1. Assemble neutral arm components to hydrostatic transmission (Figure 83). If eccentric pin was removed, ensure that the mark on eccentric pin is orientated to top of transmission. Note fastener torque specifications. 2. Lubricate grease fitting on eccentric pin; refer to the Traction Unit Operator’s Manual. 3. Check and adjust neutral position; refer to the Traction Unit Operator’s Manual. 4.
Hydraulic Pump Driveshaft (Machine Serial Number above 316000000) g224766 Figure 85 1. Hydraulic pump 5. Flange-head screw (2 each) 2. Flange nut (2 each) 6. Locknut (2 each) 10. Bolt (3 each) 3. Flat washer (2 each) 7. Driveshaft assembly 11. Bolt (2 each) 4. Pump bracket 8. Kubota diesel engine 9. Flat washer (3 each) Removing the Hydraulic Pump Driveshaft 1.
Servicing the Driveshaft Cross and Bearing g224767 Figure 86 1. End yoke 4. Shaft yoke 2. Cross and bearing kit 5. Grease fitting 3. Snap ring (4 each) 1. Remove the snap rings that secure the bearings in the yokes. IMPORTANT Support the yokes when removing and installing the bearings to prevent damage. 2. Use a press to remove the cross and bearings from the yokes. Clean the driveshaft yokes. 3. Install new cross and bearings as follows: A.
Installing the Hydraulic Pump Driveshaft (continued) 4. Slide the driveshaft end yoke on the pump input shaft so that the yoke is flush with end of the input shaft. Secure the driveshaft end yoke to the pump input shaft with the 2 bolts (item 11 in Figure 85) and 2 locknuts. 5. Position the driveshaft loop to the radiator frame and secure with the 2 flat washers and 2 locknuts. 6. Lubricate the grease fittings on the driveshaft.
Hydraulic Pump (Machine Serial Number above 316000000) g224765 Figure 87 1. Hydraulic tube 10. O-ring (2 each) 19. Hydraulic tube 2. Hydraulic tube 11. 90° hydraulic fitting (2 each) 20. Hydraulic hose 3. Flange-head screw (2 each) 12. O-ring (2 each) 21. Hydraulic pump 4. Pump Bracket 13. Hydraulic tube 22. Flange nut (2 each) 5. Flange-head screw (4 each) 14. Suction hose 23. Flat washer (2 each) 6. Hardened washer 15. O-ring (3 each) 24.
Removing the Hydraulic Pump CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–6). 1. Park the machine on a level surface, set the parking brake, lower the cutting deck (or implement), shut off the engine, and remove the key from the key switch. 2. Remove the operator seat; refer to Removing the Operator Seat (page 7–20). 3.
Installing the Hydraulic Pump (continued) IMPORTANT Ensure that you do not damage the machine components while installing the hydraulic pump. 2. Carefully lower the hydraulic pump into the machine. 3. Secure the hydraulic pump to the pump bracket with the 2 flange-head screws (item 3 in Figure 87), 2 washers, and 2 flange nuts. 4.
Servicing the Hydraulic Pump (Machine Serial Number above 316000000) g224915 Figure 88 Groundsmaster® 3280-D/3320 05138SL Rev B Page 5–103 Hydraulic System: Service and Repairs
Servicing the Hydraulic Pump (Machine Serial Number above 316000000) (continued) Figure 88 (continued) 1. Retaining ring (2 each) 14. Needle bearing 27. Relief cone valve 2. O-ring (2 each) 15. Swash plate 28. Slotted pin 3. Body (2 each) 16. Thrust plate 29. End cap 4. Inner race (2 each) 17. End cap gasket 30. O-ring 5. Seal lip 18. Cylinder block kit 31. Back-up ring 6. Plug (3 each) 19. Valve plate 32. O-ring 7. Hydraulic pump housing 20. Plug (2 each) 33.
Traction Neutral Arm Assembly (Machine Serial Number above 316000000) g225054 Figure 89 1. Flat washer (2 each) 10. Sensor bracket 19. 2. Traction rod 11. Carriage screw (2 each) 20. Thrust washer Traction stud 3. Neutral cam 12. Hydraulic pump 21. Locknut (2 each) 4. Bolt 13. Lock washer (2 each) 22. Bearing spacer 5. Traction neutral sensor 14. Jam nut (2 each) 23. Ball bearing 6. Cable tie 15. Carriage bolt 24. Extension spring 7. Thread eyebolt (right) 16.
Assembling the Traction Neutral Arm Assembly 1. Assemble the neutral arm components to the hydraulic pump (Figure 89). 2. Check and adjust the neutral position; refer to the Operator's Manual. 3. Check for correct operation of the neutral sensor and adjust if necessary; refer to the Traction Neutral Sensor (Machine Serial Number above 316000000) (page 6–16).
Front Axle Drive Motor (Machine Serial Number above 316000000) g224764 Figure 90 1. Hydraulic tube 6. Flange-head screw (6 each) 11. Hardened washer 2. Hydraulic tube 7. Hydraulic motor 12. Pump bracket 3. O-ring (2 each) 8. O-ring 13. Front axle 4. 90° hydraulic fitting (2 each) 9. Snap ring (2 each) 5. O-ring (2 each) Groundsmaster® 3280-D/3320 05138SL Rev B 10.
Removing the Front Axle Drive Motor CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–6). 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Block the wheels with chocks to prevent the machine from moving. 3.
Servicing the Front Axle Drive Motor (Machine Serial Number above 316000000) g224914 Figure 91 1. Retaining ring 6. Thrust bearing 11. Valve plate 2. Spacer 7. Splined driveshaft 12. O-ring 3. Washer 8. Housing assembly 13. Backplate assembly 4. Retaining ring (2 each) 9. Camplate insert 14. Plug assembly 5. Bearing race (2 each) 10. Rotating kit assembly 15.
Lift Cylinder g224916 Figure 92 3280-D Models 30344 and 30345 1. O-ring (2 each) 7. Tee fitting 13. Cotter pin (4 each) 2. Straight hydraulic fitting 8. Locknut (2 each) 14. Lift cylinder (2 each) 3. O-ring (7 each) 9. Hydraulic hose 15. Bolt (2 each) 16. Lift arm (left) 4. Hydraulic hose 10. O-ring (2 each) 5. Lift control valve 11. Adapter (2 each) 6. Hydraulic hose 12.
g230839 Figure 93 1. Lift cylinder 7. Hose clamp 13. Hydraulic tee fitting 2. Bolt 8. Hose stem 14. Hydraulic hose 3. O-ring 9. Cotter pin 15. Hydraulic tee fitting 4. Hydraulic fitting 10. Cylinder pin 16. O-ring 5. O-ring 11. Hydraulic hose 17. Test port 6. Hydraulic hose 12. Hydraulic hose 18. Lift control valve Note: If the lift cylinder wear or damage occurs, the lift cylinder replacement is necessary. The lift cylinders are not rebuildable.
Removing the Lift Cylinder (continued) 7. Remove the locknut (item 8 in Figure 92) from the bolt that retains the lift cylinder to the frame. 8. Support the lift cylinder and slide the bolt (item 15 in Figure 92) from the lift cylinder and frame. 9. Lower the lift cylinder from the frame. 10. If the hydraulic fittings are to be removed from the lift cylinder, mark the fitting orientation for assembly purposes. Remove the fittings from the lift cylinder and discard the O-rings from the fittings.
Steering Control Valve g223612 Figure 94 1. Steering wheel cover 11. Compression spring 21. Socket-head screw (4 each) 2. Locknut 12. Knob 22. Flange nut (2 each) 3. Flat washer 13. Tilt steering lever 23. Friction disc 4. Steering wheel 14. Grip 24. Pivot plate 5. Foam collar 15. Steering control valve 25. Friction disc 6. Tower panel 16. Spacer 26. Tilt bracket 7. Retainer nut (6 each) 17. Flange nut (3 each 27. Flat washer 8. Flange-head screw 18.
Removing the Steering Control Valve 1. Park the machine on a level surface, set the parking brake, lower the cutting deck (or implement), shut off the engine, and remove the key from the key switch. 2. Remove the knob (item 12 in Figure 94) from the end of the parking brake rod. 3. Remove the 6 phillips-head screws (item 9 in Figure 94) that secure the tower panel to the machine, and remove the tower panel. 4.
Installing the Steering Control Valve 1. If the hydraulic fittings were removed from the steering control valve, lubricate new O-rings with clean hydraulic fluid, position the O-rings to the fittings, and install the fittings to the steering control valve; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port) (page 5–11). 2. Slide the steering control valve onto the steering column.
Servicing the Steering Control Valve g224771 Figure 96 1. Dust seal ring 2. Ball 11. Housing 20. Special screw (3 each) 3. Ball stop 12. Piston 21. O-ring (5 each) 4. Shaft seal 13. Compression spring 22. End cover 5. Bearing assembly 14. Adjusting spring with O-ring 23. Gearwheel set 6. Spool 15. Plug 24. Distributor plate 7. Ring 16. O-ring (3 each) 25. Cardan shaft 8. Cross pin 17. Special screw (2 each) 9. Sleeve 18. O-ring (2 each) 10. Spring set 19.
Steering Cylinder (2-Wheel Drive) g224773 Figure 97 1. Bolt 5. O-ring (2 each) 9. 2. Spacer ring 6. O-ring (2 each) 10. Thrust washer Flange nut (2 each) 3. Steering cylinder 7. Straight hydraulic fitting 11. Steering pivot plate 4. 45° hydraulic fitting 8. Bolt 12.
Removing the Steering Cylinder (2-Wheel Drive) 1. Park the machine on a level surface, lower cutting deck (or implement), shut off the engine, set the parking brake, and remove the key from the key switch. 2. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 5–77).
Installing the Steering Cylinder (2-Wheel Drive) 1. If the hydraulic fittings were removed from the steering cylinder, lubricate new O-rings with clean hydraulic fluid, position the O-rings to the fittings, and install the fittings to the steering cylinder ports; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port) (page 5–11). 2. Position the steering cylinder to the machine.
Servicing the Steering Cylinder (2-Wheel Drive) g225169 Figure 99 1. 2. Barrel BP seal 5. 6. Internal collar Shaft 9. 10. BS seal Back-up washer 3. Piston 7. Dust seal 11. O-ring 4. O-ring 8. Head 12. Locknut Disassembling the Steering Cylinder (2-Wheel Drive) 1. Slowly pump the cylinder shaft to remove the hydraulic fluid from the steering cylinder into a drain pan. Plug both the ports and clean the outer surface of the cylinder.
Disassembling the Steering Cylinder (2-Wheel Drive) (continued) IMPORTANT Clamping the vise jaws against the shaft surface could damage the shaft. When securing the shaft in a vise, protect the shaft surface. 5. Mount the shaft in a vise. Remove the locknut and piston from the shaft. Carefully slide the head and internal collar off the shaft. 6. Remove and discard the BP seal (item 2 in Figure 99) and O-rings from the piston. Remove and discard the O-ring, dust seal, and BS seal from the head.
Assembling the Steering Cylinder (2-Wheel Drive) (continued) Note: Do not damage the seals during installation. 7. Coat all the internal cylinder components with clean hydraulic fluid. Slide the shaft assembly into the barrel. 8. Use a spanner wrench, secure the internal collar in the barrel.
Steering Cylinder (4-Wheel Drive) g225055 Figure 100 1. Thrust washer 8. Retaining ring (2 each) 15. 90° hydraulic fitting 2. Jam nut 9. Grease fitting 16. 45° lube fitting 3. Rear axle pin 10. 45° hydraulic fitting 17. Steering cylinder support bracket 4. 90° grease fitting 11. Hydraulic hose 18. Bolt (4 each) 5. Washer-head screw 12. Hydraulic hose 19. Washer (4 each) 6. Ball joint (2 each) 13. O-ring (2 each) 20. Jam nut (4 each) 7. Steering cylinder 14.
Removing the Steering Cylinder (4-Wheel Drive) (continued) CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–6). 3. For assembly purposes, label all the hydraulic hoses that are connected to the fittings on the steering cylinder. 4. Clean the hydraulic hose ends before you disconnect the hoses from the steering cylinder. 5.
Servicing the Steering Cylinder (4-Wheel Drive) g225059 Figure 101 1. Barrel 5. Head 2. 3. Locknut Piston 6. 7. Internal collar Dust seal 10. 11. Rod seal O-ring 4. Shaft 8. Back-up washer 12. U-ring 9. O-ring Disassembling the Steering Cylinder (4-Wheel Drive) 1. Slowly pump the cylinder shaft to remove the hydraulic fluid from the steering cylinder into a drain pan. Plug both the ports and clean the outer surface of the cylinder.
Disassembling the Steering Cylinder (4-Wheel Drive) (continued) 5. Mount the shaft in a vise. Remove the locknut and piston from the shaft. Carefully slide the head and internal collar off the shaft. 6. Remove and discard the U-ring (item 12 in Figure 101) and O-ring from the piston. Remove and discard the dust seal, back-up washer, O-ring, and rod seal from the head. Inspecting the Steering Cylinder CAUTION Use eye protection such as goggles when using compressed air. 1.
Lift Control Valve (Machine Serial Numbers below 316000000) g230840 Figure 102 Hydraulic hose 17. Spacer 10. Flat washer (2 each) 18. Bolt 11. Bolt (2 each) 19. Knob O-ring 12. Lock washer (2 each) 20. Link tube Hydraulic hose 13. Pin 21. Hydraulic hose 6. Hydraulic hose 14. Cotter pin 22. Check valve 7. Hydraulic fitting 15. Lift lever 8. O-ring 16. Flange nut 1. Lift control valve 2. O-ring 3. Hydraulic adapter 4. 5. Groundsmaster® 3280-D/3320 05138SL Rev B 9.
g230841 Figure 103 1. Lift control valve 4. Counterbalance manifold 7. Lock washer (2 each) 2. Hydraulic adapter 5. Hydraulic fitting 8. Flat washer (2 each) 3. Hydraulic tube 6. Bolt (2 each) Note: Early machines came fitted with a lift control valve that incorporated the counterbalance valve (Figure 102). On later machines (machine serial numbers below 311000000) or early machines that have been updated), the counterbalance valve is located in a separate manifold (Figure 103).
Installing the Lift Control Valve 1. Coat new O-rings lightly with clean hydraulic fluid. Install all removed hydraulic fittings with new O-rings to the lift control valve. 2. Position lift control valve to machine frame. Secure control valve to machine with 2 bolts (item 11 in Figure 102), 2 lock washers, and 2 flat washers. 3. Secure link tube (item 20 in Figure 102) to control valve with pin and cotter pin. 4. Remove all caps or plugs from hydraulic hoses and fittings. 5.
Servicing the Lift Control Valve (Machine Serial Numbers below 311000000) g230842 Figure 104 1. Detent ball 10. Poppet stop 19. Detent plunger 2. 3. Spring 11. Poppet 20. Spring Gasket 12. End cap 21. O-ring 4. O-ring 13. Spacer 22. Lockout seat (black) 5. Screw 14. Adapter plug 23. O-ring 6. Washer 15. O-ring 24. O-ring 7. Screw and lock washer (2 each) 16. Detent plug 25. Lockout seat (silver) 8. Spool 17. Spring 9. Plug 18.
Disassembly the Lift Control Valve (continued) 5. Carefully remove O-rings (item 4 in Figure 104) from spool bore. Take care not to damage spool bore or O-ring cavities during O-ring removal. 6. Remove detent plug (item 16 in Figure 104), O-ring, spring, and detent ball. 7. Remove plug (item 9 in Figure 104) with O-ring, and lockout seat with O-ring from valve body. 8. Remove adapter plug (item 14 in Figure 104) with O-ring, poppet stop, spring, and poppet from control valve body. 9.
Assembling the Lift Control Valve (continued) CAUTION Use eye protection such as goggles when using compressed air. 1. Clean all control valve components with clean solvent and blow dry with compressed air. 2. Replace all removed O-rings. Lightly lubricate new O-rings with clean hydraulic fluid before assembly. 3. Install new O-rings into control valve spool bore. 4. Lubricate spool liberally with clean hydraulic fluid and carefully install into control valve bore. 5.
Counterbalance Valve Manifold (Machine Serial Numbers below 311000000) (If Equipped) g230845 Figure 106 9. Hydraulic hose 1. Lift control valve 5. O-Ring 2. Hydraulic adapter 6. Counterbalance manifold 10. Flange nut (2 each) 11. Mounting bracket 3. Hydraulic tube 7. Bolt (2 each) 4. O-Ring 8. Hydraulic hose Removing the Counterbalance Valve Manifold 1. Park the machine on a level surface, engage the parking brake, lower the cutting deck (or implement), and shut off the engine.
Servicing the Manifold g230846 Figure 107 1. 2. Manifold Counterbalance valve 3. 4. Check valve Plug 1. Ensure that the manifold is cleaned before removing either of the valves. IMPORTANT Use care when handling the hydraulic valve. Slight bending or distortion of the stem tube can cause binding and malfunction. 2. Using a deep socket, remove valves from manifold. Note correct location of O-rings, sealing rings, and back-up rings. Remove and discard seal kit from valves. 3.
Servicing the Manifold (continued) 5. Lubricate new valve seal kit components with clean hydraulic fluid and install on valves. The O-rings, sealing rings, and backup rings must be arranged properly on the valves for proper operation and sealing. 6. Thread valves carefully into correct manifold port. The valves should go in easily without binding. Using a deep socket, torque valves to values identified in Figure 107. Installing the Counterbalance Valve Manifold 1.
Lift Control Valve (Machine Serial Number above 311000000) g225057 Figure 108 1. Lift control valve 4. Flat washer (2 each) 7. Hydraulic hose 2. O-ring (4 each) 5. Lock washer (2 each) 8. Hydraulic hose 3. Hydraulic tube 6. Bolt (2 each) 9. Hydraulic tube Note: For testing the solenoid valve coils; refer to Lift Control Valve Solenoid Valve Coil (Machine Serial Number above 311000000) (page 6–62). Removing the Lift Control Valve 1.
Removing the Lift Control Valve (continued) CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–6). WARNING Ensure that the cutting deck is fully lowered and supported before loosening the hydraulic lines, cartridge valves, or plugs from the lift control valve.
Removing the Lift Control Valve (continued) IMPORTANT A flow control orifice (item 5 in Figure 109) is placed below the hydraulic fitting on the lift control valve. If the fitting is removed from the manifold and a flow control orifice is in the manifold block, ensure that you remove the orifice and label its position for assembly purposes. 12. If necessary, remove the hydraulic fittings from the manifold block (item 1 in Figure 109), and discard the O-rings. 13.
Servicing the Lift Control Valve (Machine Serial Number above 311000000) g225058 Figure 110 5. Expander plug 1. Nut (2 each) 9. Check valve 2. Coil 6. O-ring 10. Solenoid valve (SV1) 3. Logic valve 7. 90° elbow fitting 11. Solenoid valve (SV2) 4. Manifold block 8. Dust cap 12. Solenoid coil Note: The ports on the lift control valve are marked for easy identification of the components.
WARNING Ensure that the cutting deck is fully lowered and supported before loosening the hydraulic lines, cartridge valves, or plugs from the lift control valve. If the deck is not fully lowered as the lift control valve components are loosened, the deck may drop unexpectedly.
Servicing the Control Manifold Cartridge Valve (continued) CAUTION Sudden movement of the internal valve spools can release the stored fluid suddenly. 6. Use clean-mineral spirits and clean the cartridge valve. Put the valve in the clean-mineral spirits to flush out contamination. IMPORTANT Particles as fine as talcum powder can affect the operation of high-pressure hydraulic valves.
Oil Cooler (Groundsmaster 3280-D) g221637 Figure 111 1. Swell latch (2 each) 13. Radiator cap 25. Flange-head screw (4 each) 37. Lock washer (6 each) 2. Flange nut (6 each) 14. Hose clamp (3 each) 26. Pop rivet (4 each) 38. Hex nut (6 each) 3. Flange nut (4 each) 15. Locknut (8 each) 27. Back washer (2 each) 39. Vent hose 4. Radiator frame 16. Flat washer (10 each) 28. Bottom radiator shield 40. Vent tube 5. Locknut (2 each) 17. Foam strip (2 each) 29.
Inspecting the Oil Cooler 1. Back flush the oil cooler with cleaning solvent. After cleaning the cooler, ensure that all the solvent is drained from the cooler WARNING Use eye protection such as goggles when using compressed air to dry the oil cooler. 2. Use compressed air in the opposite direction of the fluid flow and dry the interiors of the oil cooler. 3. Install clean plugs on the oil cooler ports. Clean the outer surface of the cooler.
Hydraulic System: Service and Repairs Page 5–144 Groundsmaster® 3280-D/3320 05138SL Rev B
Chapter 6 Electrical System Table of Contents General Information .............................................................................................................................. 6–3 Electrical Schematics and Wire Harness Drawings/Diagrams............................................................ 6–3 Standard Control Module (SCM) ........................................................................................................ 6–3 Standard Control Module Logic Chart ..................
Lift Control Valve Solenoid Valve Coils (Machine Serial Number above 311000000) ........................ 6–76 PTO Electric Clutch.......................................................................................................................... 6–78 Battery Storage ................................................................................................................................ 6–80 Battery Care.............................................................................................
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine. Electrical Schematics and Wire Harness Drawings/Diagrams Refer to the Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A (page A–1). Standard Control Module (SCM) g226810 Figure 112 1. Standard Control Module (SCM) 2.
SCM Inputs The power input LED should be illuminated when the key switch is in the ON position. The power input LED should also be illuminated when the key switch is in the START position. The start input LED should be illuminated when the key switch is in the START position. The neutral input LED should be illuminated when the traction pedal is in the neutral position. The parking brake off input LED should be illuminated when you do not set the parking brake.
SCM Outputs (continued) The PTO output LED should be illuminated when the key switch is in the ON position and the PTO switch is ON (pulled out). Note: If the SCM high-temperature warning input LED is illuminated, the PTO output LED does not illuminate, and the PTO disengages regardless of the PTO switch position.
Standard Control Module Logic Chart (continued) g226938 Figure 114 Electrical System: General Information Page 6–6 Groundsmaster® 3280-D/3320 05138SL Rev B
Special Tools You can order these special tools from your Authorized Toro Distributor. Some tools are also available from a local supplier. Multimeter The meter can test the electrical components and circuits for current, resistance, or voltage. You can get the digital multimeter locally. Note: Use a digital multimeter when testing the electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode ensures that the excess current is not allowed through the meter.
Dielectric Gel Toro Part No. 107-0342 Use the dielectric gel to prevent corrosion of unsealed connection terminals. To ensure complete coating of the terminals, liberally apply the gel to the component and wire harness connector, plug the connector into the component, unplug the connector, apply the gel to both surfaces again, and connect the harness connector to the component again. The connectors must be fully packed with gel for effective results.
Troubleshooting CAUTION Remove all the jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. For the effective 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 Drawings/Diagrams in Appendix A (page A–1).
Starting Problems Problem Possible Causes All the electrical power is dead. • The battery is discharged. • The battery cables are loose or corroded. • The fuse F1-1 (15 A) to the key switch is damaged; refer to Fuses (Machine Serial Number below 400000000) (page 6–22) or Fuses (Machine Serial Number above 400000000) (page 6–23). • The ground connection is loose or corroded. • The key switch or circuit wiring is damaged. The starter solenoid clicks, but the starter does not crank.
Starting Problems (continued) The engine cranks, but should not, when the PTO switch is in the ON (up) position. • The PTO switch or circuit wiring is damaged. The engine starts, but stops when the key switch is released from the START position. • The circuit wiring is damaged. Nothing happens when you attempt to start the engine. • The traction pedal is not in the neutral position. • The Standard Control Module is damaged. • The key switch is damaged. • Interlock system has problem.
General Run and Transport Problems Problem Possible Causes The engine continues to run, but should not, when the key switch is turned to the OFF position. • The battery is discharged. • The battery cables are loose or corroded. • The fuse F1-1 (15 A) to the key switch is damaged; refer to Fuses (Machine Serial Number below 400000000) (page 6–22) or Fuses (Machine Serial Number above 400000000) (page 6–23). • The key switch or circuit wiring is damaged.
General Run and Transport Problems (continued) Problem Possible Causes The engine shuts off during the operation (the operator sitting on the seat). • The operator is not in the center of the seat (the seat switch is not pressed). • The engine temperature is excessive (above 115°C /240°F). • The engine high temperature shutdown switch is damaged. • The machine is operated on a slope with a low fuel level. • The parking brake is engaged or the parking brake switch is damaged. • The key switch is damaged.
Cutting Deck Operating Problems Problem Possible Causes The cutting deck remains engaged, but should not, with no operator in the seat. The cutting deck run, but should not, with the PTO switch in the OFF (disengage) position. The cutting deck does not operate with the PTO switch in the ON (up) position. • The seat switch or circuit wiring is damaged. • A loose, corroded, or broken wire(s) exist in the PTO clutch circuit; refer to the Electrical Schematics in Appendix A (page A–1).
Electrical System Quick Checks Testing the Battery (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals; refer to Battery Test Table (page 6–15). Set the multimeter to the DC volts settings. The battery must be at a temperature of 16°C to 38°C (60°F to 100°F). Ensure that the key is in the OFF position and all the accessories are turned off.
Testing the Charging System (continued) Battery Voltage Table At least 0.50 V over the initial battery voltage. Initial battery voltage = 12.30 V Battery voltage after 3 minutes charge = 12.85 V Difference = +0.55 V Testing the Glow Plug System (Groundsmaster 3280-D) This is a fast, simple test that helps to determine the integrity and operation of the Groundsmaster 3280-D glow plug system. Perform this test when you find hard starting (cold engine) on a diesel engine equipped with a glow plug system.
Adjustments Traction Neutral Sensor (Machine Serial Number above 316000000) g226812 Figure 115 1. Traction neutral sensor 3. Neutral arm 2. Sensor bracket 4. Jam nut (2 each) 5. Lock washer (2 each) The traction neutral sensor is a normally open proximity sensor that closes when the traction pedal is in the neutral position. The sensor is located under the seat and mounted to a sensor bracket over the hydraulic pump (Figure 115).
Adjusting the Traction Neutral Sensor (continued) 3. If the gap is incorrect, adjust the traction neutral sensor; refer to Adjusting the Proximity Sensor in the Traction Unit Operator’s Manual. 4. Check that the LED on the cable end of the traction neutral sensor is illuminated when the traction pedal is in the neutral position.
Parking Brake Switch g227534 Figure 117 1. Steering tower cover 3. Phillips-head screw (2 each) 2. Parking brake knob 4. Phillips-head screw (6 each) The switch used for the parking brake is a normally open switch. The switch closes when the parking brake is disengaged. The parking brake switch is located under the steering tower cover (Figure 117). The sensing plate for the parking brake switch is the parking brake rod tab (Figure 118). Adjusting the Parking Brake Switch g226937 Figure 118 1.
Testing the Electrical Components For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g., unplug the key switch connector before doing a continuity check of the switch). Note: Electrical troubleshooting of any 12 Volt power connection can be performed through voltage drop tests without disconnecting the component.
g223020 Figure 120 The Groundsmaster 3280-D and 3320 machines use 3 fusible links for the circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the wire harness (Figure 119 and Figure 120). If any of these links fail, current to the protected circuit stops; refer to the Electrical Schematics in Appendix A (page A–1) for additional circuit information. Testing the Fusible Link Harness 1.
Fuses (Machine Serial Number below 400000000) g230995 Figure 121 1. Fuse block The fuse block is located under the control panel (Figure 121). g230996 Figure 122 Identification and Function The fuses are held in the fuse block. Use Figure 122 to identify each individual fuse and its correct amperage. Each fuse holder has the following function. Fuse 1 (15 A): Protects main power circuit to key switch terminal B. Fuse 2 (10 A): Protects power circuit from key switch terminal S.
Fuses (Machine Serial Number above 400000000) g225175 Figure 123 1. SCM 2. Fuse block 3. Throttle control lever The fuse blocks are located under the control panel (Figure 123). Identification and Function g225176 Figure 124 The fuses are held in the fuse blocks. Use Figure 124 to identify each individual fuse and its correct amperage. Each fuse holder has the following function. F1-1 (15 A): Protects main power circuit to the key switch terminal B.
Identification and Function (continued) F2-2 (20 A) (If equipped): Protects power supply to the optional accessory. F2-3 (20 A) (if equipped): Protects power supply to the optional accessory. F2-4 (20 A) (if equipped): Protects power supply to the optional accessory. Testing the Fuses 1. Turn the key switch to the ON position (do not start the engine) and remove the control panel.
Operator Cab Fuses (Machines with Operator Cab) g243422 Figure 125 1. Fuse blocks location g243782 Figure 126 1. 10 A fuse 2. 60 A maxi-fuse 3. Battery The operator cab fuse blocks are located in the cab headliner (Figure 125). In addition to the cab fuses in the fuse blocks, there are 2 additional fuses included in the cab wire harness. These fuses plug into the fuse holders near the battery (Figure 126).
Identification and Function g244181 Figure 127 Refer to Figure 127 to identify each individual fuse and its correct amperage. The fuses have the following functions. Fuse F1-1 (20 A): Protects the cab work light circuit. Fuse F1-2 (25 A): Protects the blower fan circuit. Fuse F1-3 (30 A): Protects the air conditioner compressor clutch circuit. Fuse F2-1 (15 A): Protects the windshield wiper/washer circuit. Fuse F2-2 (15 A): Protects the cab dome light circuit.
Key Switch g226806 Figure 128 1. Control panel 2. Key switch 3. Thumb screw (4 each) g190999 Figure 129 The key switch (item 2 in Figure 128) is located on the control panel and has 3 positions: OFF, RUN, and START (Figure 129). The Standard Control Module (SCM) monitors the operation of the key switch. When the key switch is in the ON position, the SCM power input LED must be illuminated. If the key switch is in the START position, both the power input and start input LEDs should be illuminated.
Testing the Key Switch (continued) 4. If the SCM determines that the key switch and circuit wiring are not functioning correctly, then test the key switch as follows: A. Remove the 4 thumb screws (item 3 in Figure 128) that secure the control panel to the fuel tank. B. Ensure that the key switch is in the OFF position. Disconnect the wire harness connector from the key switch. C.
Indicator Lights g226805 Figure 130 1. 2. Charge indicator 3. High temperature warning Glow plug indicator 4. Engine oil pressure Charge Indicator Light The charge indicator light should come on when the key switch is in the ON position with the engine not running. Also, it should illuminate with an improperly operating charging circuit while the engine is running.
Glow Plug Indicator Light The glow plug light on Groundsmaster 3280-D machines should come on when the key switch is placed in the ON position before placing the key switch in the START position. The light should stay lit for approximately 6 seconds while the key switch is left in the ON position. Testing the Indicator Lights g226816 Figure 131 1. Glow plug indicator 2. High temperature warning 4. 3. Warning light front 5. Charge indicator Engine oil pressure 6. Warning light back 1.
Hour Meter g225181 Figure 132 1. Hour meter The hour meter records and displays accumulated hours of engine operation (Figure 132). Testing the Hour Meter 1. Park the machine on a level surface, lower the cutting deck, set the parking brake, and shut off the engine. 2. Ensure that the key switch is in the OFF position. Locate the hour meter and disconnect the wire harness electrical connector from the hour meter. 3.
PTO Switch g226809 Figure 133 1. PTO switch 2. Control panel 3. Thumb screw (4 each) 5. 6. NO C terminal NC C terminal g227536 Figure 134 1. 2. COM B terminal NO B terminal 3. 4. NC B terminal COM C terminal The PTO switch is located on the control panel (Figure 133). Pull up the PTO switch to engage the PTO electric clutch. The Standard Control Module (SCM) monitors the position of the PTO switch (up or down).
IMPORTANT During the operation of the machine, if the PTO shuts down and the console temperature warning light is illuminated because of excessive engine coolant temperature, avoid shutting off the engine. Under this condition, push the PTO knob down, slowly drive to a safe flat area, move the throttle lever to the SLOW position, press the traction pedal, and set the parking brake.
Deck Lift Switch (Machine Serial Numbers above 311000000) g225172 Figure 135 1. Deck lift switch 2. Thumb screw (4 each) The deck lift/lower switch is used to raise and lower the cutting deck on later machines. The switch is located on the control panel (Figure 135). The engine must be running to allow the cutting deck to be raised or lowered. When the front of the lift switch is pressed, the deck will lower fully. When the rear of the lift switch is pressed and held, the deck will raise.
Testing the Deck Lift Switch (continued) g223017 Figure 136 5. The deck lift switch terminals are identified in Figure 136 and the circuitry of the switch is shown in the Circuit Logic Table (page 6–35). With the use of a multimeter (ohms setting), test the switch functions to determine if continuity exists between the various terminals for each switch position. Check the continuity between the switch terminals.
Seat Switch g190803 Figure 137 1. Seat 3. Washer-head screw (2 each) 2. Machine wire harness 4. Seat switch The seat switch is normally open and closes when the operator is on the seat. If the traction system or PTO switch is engaged when the operator raises out of the seat, the engine shuts off. The seat switch and its electrical connector are located directly under the seat (Figure 137).
Testing the Seat Switch (continued) 8. Replace the seat switch if testing determines that the switch is damaged. 9. If the seat switch testing is correct and the circuit problem still exists, check the machine wire harness; refer to the Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A (page A–1). 10. After you complete the seat switch testing, connect the machine wire harness connector to the seat switch. Check the operation of the seat switch.
Windshield Washer/Wiper Switch (Machines with Operator Cab) g243779 Figure 138 Center roof switch installation view 1. Switch panel 2. Washer/wiper switch The windshield washer/wiper switch controls the operation of the windshield wiper and washer pump. The switch is located in the cab headliner (Figure 138). Testing the Windshield Washer/Wiper Switch 1. Park the machine on a level surface, lower the cutting deck, set the parking brake, and shut off the engine. 2.
Testing the Windshield Washer/Wiper Switch (continued) Circuit Logic Table Switch Position Normal Circuits Other Circuits OFF 2+1 None WIPER ON 2+3 None WASHER ON 2+3 5+6 6. Replace the windshield wiper/washer switch if testing determines that the switch is damaged. 7. If the windshield wiper/washer switch testing is correct and a circuit problem still exists, check the wire harness; refer to the Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A (page A–1). 8.
Accessory Power Switch (Machines with Operator Cab) g243784 Figure 140 1. 2. Switch panel Accessory power switch The accessory power switch controls the power supply to the accessory power outlet. The switch is located in the cab headliner (Figure 140). Testing the Accessory Power Switch 1. Park the machine on a level surface, lower the cutting deck, set the parking brake, and shut off the engine. 2.
Testing the Accessory Power Switch (continued) Circuit Logic Table Switch Position Normal Circuits Other Circuits DECREASE 2+1 5+4 OFF None None INCREASE 2+3 5+6 Note: The accessory power switch terminals 4, 5, and 6 are not used on the Groundsmaster 3280-D machines. 6. Replace the accessory power switch if testing determines that the switch is damaged. 7.
Fan Speed Switch (Machines with Operator Cab) g243778 Figure 142 1. Cab headliner (air/heat panel) 2. Fan speed switch The fan speed switch is located in the cab headliner (Figure 142). The switch is used to select the fan speed (off, low, medium, or high). Testing the Fan Speed Switch 1. Park the machine on a level surface, lower the cutting deck, and shut off the engine. Remove the key from the key switch. 2.
Testing the Fan Speed Switch (continued) Circuit Logic Table Switch Position Closed Circuits OFF L+H LOW B+C+L MEDIUM B+C+M HIGH B+C+H 6. Replace the fan speed switch if testing determines that the switch is damaged. 7. If the fan speed switch testing is correct and a circuit problem still exists, check the wire harness; refer to the Electrical Schematics and Wire Harness Drawings and Diagrams in Appendix A (page A–1). 8.
Work Light Switch (Machines with Operator Cab–Optional) g243426 Figure 144 1. Work light switch (optional) 2. Beacon switch (optional) 3. Cab headliner (lights switch panel) The switches are located in the cab headliner (Figure 144). The switches are used to turn the optional light kits on and off. Testing the Work Light Switch 1. Park the machine on a level surface, lower the cutting deck, and shut off the engine. Remove the key from the key switch. 2.
Testing the Work Light Switch (continued) 7. If the switch testing is correct and a circuit problem still exists, check the wire harnesses; refer to the Electrical Schematics and Wire Harness Drawings and Diagrams in Appendix A (page A–1). 8. After you complete the testing, connect the machine wire harness connector to the switch and install the lights switch panel. 9. Install the cab roof; refer to Roof Assembly (page 11–3).
Traction Neutral Switch (Machine Serial Numbers below 316000000) g231017 Figure 146 1. Traction neutral switch 2. Neutral return arm The traction neutral switch is a normally open proximity switch that closes when the traction pedal is in the neutral position. A socket-head screw threaded into the hydrostat neutral return arm acts as the sensing plate for the switch (Figure 146). The Standard Control Module monitors the operation of the traction neutral switch.
Adjusting the Traction Neutral Switch (continued) g230994 Figure 147 1. Traction neutral switch 2. Socket-head screw 3. Neutral return arm 3. Rotate socket-head screw so that the clearance between end of the socket-head screw and neutral switch is 3.2 mm (0.125 inch) (Figure 147). 4. Torque jam nut to 8 to 10 N∙m (71 to 89 in-lb) to secure adjustment. After jam nut is tightened, ensure that the clearance between the socket-head screw and the traction neutral switch has not changed. 5.
Traction Neutral Sensor (Machine Serial Number above 316000000) g226812 Figure 148 1. Traction neutral sensor 3. Neutral arm 2. Sensor bracket 4. Jam nut (2 each) 5. Lock washer (2 each) The traction neutral sensor is a normally open proximity switch that closes when the traction pedal is in the neutral position. The sensor is located under the seat and mounts to a sensor bracket over the hydraulic pump (Figure 148). The sensing plate for the traction neutral sensor is the neutral arm.
Testing the Traction Neutral Sensor (continued) 9. If the traction neutral sensor LED did not function correctly, do the following: A. Ensure that the traction neutral sensor is correctly adjusted; refer to adjusting the traction neutral sensor. B. Ensure that the key switch is in the OFF position and disconnect the traction neutral sensor connector from the machine wire harness. C.
Parking Brake Switch g227534 Figure 149 1. Steering tower cover 3. Phillips-head screw (2 each) 2. Parking brake knob 4. Phillips-head screw (6 each) g226808 Figure 150 1. Parking brake switch 2. Connector The switch used for the parking brake is a normally open switch. The switch closes when the parking brake is not set. The parking brake switch is located under the steering tower cover (Figure 149). The Standard Control Module (SCM) monitors the operation of the parking brake switch.
Testing the Parking Brake Switch (continued) 3. If the SCM verifies that the sensor and circuit wiring are functioning correctly, then no more switch testing is necessary. 4. If the SCM determines that the parking brake switch and circuit wiring are not functioning correctly, proceed with the test. 5. Remove the knob from the parking brake rod and the screws from the steering tower cover (Figure 149). 6. Slide the steering tower cover up the steering column. 7. Locate the parking brake switch (Figure 150).
High Temperature Warning Switch g227147 Figure 151 1. High temperature warning switch (diesel engine) g230991 Figure 152 1. High temperature warning switch (gasoline engine) The high temperature warning switch (Figure 151 and Figure 152) is attached to the water pump housing on the engine and has a yellow wire attached to it. This switch is normally open and closes when the engine coolant temperature reaches approximately 105°C (220°F).
Testing the High Temperature Warning Switch (continued) DANGER If the radiator or engine is hot, pressurized hot coolant can escape and cause burns. Do not open the radiator cap or drain the radiator when the coolant is hot. Ensure that the engine is cool before removing the high temperature warning switch from the engine. 3. Lower the coolant level in the engine. 4. Remove the wire harness connector from the high temperature warning switch, and remove the switch from the engine. g226814 Figure 153 5.
Testing the High Temperature Warning Switch (continued) 8. After you complete the testing, install the temperature switch to the engine housing, do the following steps: A. Clean the threads of the housing and switch. Apply thread sealant to the threads of the switch. B. Thread the switch into the housing; torque the switch to 29.4 to 39.2 N∙m (22 to 28 ft-lb). C. Connect the harness wires to the temperature switch. 9. Fill the engine cooling system; refer to the Traction Unit Operator’s Manual. 10.
High Temperature Shutdown Switch g226811 Figure 154 1. High temperature shutdown switch (diesel engine) g230992 Figure 155 1. High temperature shutdown switch (gasoline engine) The high temperature shutdown switch (Figure 154 or Figure 155) is attached to the water pump housing on the engine and has a blue/white wire attached to it. This switch is normally open and closes when engine coolant temperature reaches approximately 115°C (240°F).
Testing the High Temperature Shutdown Switch (continued) DANGER If the radiator or engine is hot, pressurized hot coolant can escape and cause burns. Do not open the radiator cap or drain the radiator when the coolant is hot. Ensure that the engine is cool before removing the high temperature shutdown switch from the engine. 3. Lower the coolant level in the engine. 4. Remove the wire harness connector from the high temperature shutdown switch, and remove the switch from the engine.
Testing the High Temperature Shutdown Switch (continued) 9. After you complete the testing, install the temperature switch to the engine housing, do the following steps: A. Clean the threads of the housing and switch. Apply thread sealant to the threads of the switch. B. Thread the switch into the housing; torque the switch to 29.4 to 39.2 N∙m (22 to 28 ft-lb). C. Connect the harness wires to the temperature switch. 10. Fill the engine cooling system; refer to the Traction Unit Operator’s Manual. 11.
Engine Oil Pressure Switch g226807 Figure 157 1. Oil pressure switch (diesel engine) g230993 Figure 158 1. Oil pressure switch (gasoline engine) The engine oil pressure switch is located on the engine near the oil filter (Figure 157 or Figure 158). The oil pressure switch is a normally closed switch that opens with oil pressure. On the Groundsmaster 3280-D (diesel engine), the oil pressure switch should open at approximately 55 kPa (8 psi).
IMPORTANT If the oil pressure indicator light is illuminated with the engine running, shut off the engine immediately. Check the indicator light, circuit wiring, pressure switch, and engine lubrication system to identify the cause of the illuminated indicator light. Testing the Engine Oil Pressure Switch Note: Refer to engine service manual for information regarding engine lubrication system and testing. 1.
Relays (Groundsmaster 3280-D) The Groundsmaster 3280-D machine uses 3 identical electrical relays that have 4 terminals. A tag near the wire harness relay connector can be used to identify each relay. g225179 Figure 159 1. Glow relay 2. Fuel/water separator The glow relay used is attached to the support bracket inside the right side frame near the fuel/water separator (Figure 159). When energized, the glow relay allows electrical current to the engine glow plugs. g225178 Figure 160 1.
g244180 Figure 161 1. 2. Cab power relay Battery The cab power relay (on the machines with operator cab) is attached near the battery (Figure 161). The cab power relay is used to provide current to the operator cab electrical circuits. Testing the Relays 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. To get access to the glow relay, remove the control panel.
Testing the Relays (continued) g214499 Figure 162 5. Check the coil resistance between terminals the 85 and 86 with a multimeter (ohms setting). The resistance should be approximately 72 ohms (Figure 162). 6. Connect the multimeter (ohms setting) leads to relay terminals 30 and 87. The ground terminal 85 and apply +12 VDC to terminal 86. The relay should make and break continuity between the terminals 30 and 87 as +12 VDC is applied and removed from terminal 86. 7.
Lift Control Valve Solenoid Valve Coil (Machine Serial Number above 311000000) g227680 Figure 163 1. 2. Lift control valve SV2 solenoid 3. SV1 solenoid The hydraulic lift control valve is located on the right side of the machine, near the front right wheel (Figure 163). When the solenoid coils are energized, the valve shift occurs to control the hydraulic fluid flow. The electrical testing of the coils can be done with the coil installed on the hydraulic valve.
Testing the Lift Control Valve Solenoid Valve Coil (continued) 4. Use a multimeter (ohms setting), measure the resistance between the 2 connector terminals on the solenoid valve coil. The correct resistance for the solenoid coil is identified in the Solenoid Valve Coil Specifications Table (page 6–64). Solenoid Valve Coil Specifications Table Solenoid Valve Coil Diameter Height Resistance SV1 35.8 mm (1.41 inches) 36.3 mm (1.43 inches) 8.8 ohms SV2 46.7 mm (1.84 inches) 49.9 mm (1.96 inches) 7.
PTO Electric Clutch An electric clutch is used to engage the PTO. The electric clutch is mounted on the engine crankshaft and engages when current is applied to the clutch. The clutch also incorporates a magnetic brake to stop clutch rotation when the clutch is de-energized. Testing the PTO Electric Clutch 1. Park the machine on a level surface, lower the cutting deck, set the parking brake, shut off the engine, and remove the key from the key switch. 2. Unlatch the hood and raise it.
Fuel Stop Solenoid (Groundsmaster 3280-D) g225174 Figure 166 1. Fuel stop solenoid The fuel stop solenoid used on the Groundsmaster 3280-D machine must be energized for the diesel engine to run. The solenoid is mounted to the injection pump on the engine (Figure 166). Testing the Fuel Stop Solenoid (In Place) Note: Before taking the small resistance readings with a digital multimeter, short the multimeter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less).
Testing the Fuel Stop Solenoid (In Place) (continued) 4. Use a digital multimeter, touch 1 test lead to the pull coil terminal and the other test lead to the fuel stop solenoid frame (ground) (Figure 167). The resistance of the pull coil should be less than 1 ohm (but not zero). 5. Use a digital multimeter, touch 1 test lead to the hold coil terminal and the other test lead to the fuel stop solenoid frame (ground) (Figure 167). The resistance of the hold coil should be approximately 15 ohms. 6.
Glow Controller (Groundsmaster 3280-D) g227149 Figure 168 1. Throttle control lever 2. Glow controller 3. SCM 3. Slide view g227537 Figure 169 1. Top view 2. Glow controller end view The glow controller used on the Groundsmaster 3280-D machine is located under the control panel (Figure 168). Note: Refer to the Electrical Schematics in Appendix A (page A–1) when troubleshooting the glow controller circuit. Controller Operation 1.
Controller Checks 1. Ensure that there is power from the battery. 2. Disconnect the electrical connector to the fuel stop solenoid to prevent the engine from starting. 3. Turn the key switch to the RUN position. Check the following while in the RUN position: A. Glow indicator lamp is on. B. Glow relay is energized. C. Glow plugs are energized. D. Glow indicator lamp goes out and glow plugs de-energize after approximately 6 seconds. 4. Turn the key switch to the START position.
Fuel Pump (Groundsmaster 3280-D) g225173 Figure 170 1. Fuel hose (from tank) 3. Fuel hose (from engine) 5. Inlet fitting 2. Fuel pump 4. Pump discharge hose 6. Fuel/water separator 7. Fuel/water filter g230997 Figure 171 1. Fuel hose (from tank) 4. Pump discharge hose 2. Fuel filter 5. Fuel hose (to engine) 3. Fuel pump 6.
DANGER Diesel fuel is highly flammable. • Use caution whenever you handle diesel fuel. • Do not smoke while testing the fuel pump. • Do not test the fuel pump while the engine is hot. • Ensure that there is adequate ventilation when testing. • Always wipe up any spilled diesel fuel before starting the engine. Testing the Fuel Pump Capacity 1. Park the machine on a level surface, lower the cutting deck, set the parking brake, and shut off the engine. Ensure that the key switch is in the OFF position. 2.
Testing the Fuel Pump Capacity (continued) Fuel Pump Specifications (except Models 30344 and 30345) Pump Capacity 0.7 L/minute (23.5 fl oz/minute) Pressure 22.8 kPa (3.3 psi) Maximum Current Draw 0.9 A 10. Lower the hood and secure it with the latches.
Fuel Pump (Groundsmaster 3320) g230998 Figure 172 1. Fuel hose (from tank) 3. Fuel hose 2. Fuel filter 4. Fuel pump 5. Fuel hose (to engine) The fuel pump used on the Groundsmaster 3320 (gasoline engine) is attached to the support bracket inside the right side frame near the fuel filter (Figure 172). IMPORTANT When testing fuel pump, ensure that the pump is not operated without fuel. DANGER Because gasoline is highly flammable, use caution when handling it.
Testing the Fuel Pump Capacity (continued) 6. The amount of fuel collected in the graduated cylinder should be approximately 400 ml (13.5 fl oz) after 30 seconds. 7. Replace fuel pump if necessary. Install fuel hose to carburetor inlet. Fuel Pump Specifications Pump Capacity 800 ml/minute (27 fl oz/minute) Pressure 19.6 to 29.4 kPa (2.8 to 4.
Fuel Pump Relay (Groundsmaster 3320) g223021 Figure 173 1. Coil terminal 3. Normally open term 2. Normally closed term 4. Common terminal The Groundsmaster 3320 uses a relay to energize the fuel pump. The fuel pump relay is attached to the support bracket inside the right side frame near the fuel filter. Testing the Fuel Pump Relay Note: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together.
Service and Repairs Note: Refer to the Kubota Workshop Manual: 05 Series Engine (Groundsmaster 3280-D) or the Briggs and Stratton/Daihatsu Engine Repair Manual (Groundsmaster 3320) for additional component repair information. Lift Control Valve Solenoid Valve Coils (Machine Serial Number above 311000000) g227288 Figure 174 1. Nut (2 each) 3. Solenoid valve (SV1) 2. Coil 4. Solenoid valve (SV2) 5.
Installing the Lift Control Valve Solenoid Valve Coils 1. Slide the coil assembly onto the hydraulic valve. 2. Install the nut onto the valve and torque the nut to 6.7 N∙m (5 in-lb). Note: Do not overtighten the nut. 3. Connect the machine wire harness connector to the solenoid coil.
PTO Electric Clutch g227287 Figure 175 1. Kubota diesel engine 5. Stub shaft 2. Flange nut (2 each) 6. Electric clutch 10. PTO shaft pulley 3. Flange-head screw (2 each) 7. Bolt 11. Square key 4. Clutch stop 8. Spacer 9. PTO drive belt g230999 Figure 176 1. Bolt 4. Stub shaft 7. Square key 2. Spacer 5. Gasoline engine 8. Clutch stop 3. Electric clutch 6. Mounting bracket 9. Flange-head screw Removing the PTO Electric Clutch 1.
Removing the PTO Electric Clutch (continued) 3. Remove the PTO belt from the clutch and PTO shaft pulley; refer to the Traction Unit Operator’s Manual. 4. Remove the clutch stop components (Figure 175 or Figure 176). Note: Hold the coupler on the front of the engine to prevent crankshaft from turning when removing the bolt that secures the clutch to the stub shaft. 5. Remove the bolt and spacer that secure the clutch to the stub shaft.
Battery Storage If you store the machine for more than 30 days: 1. Ensure that the key switch is in the OFF position. Remove the battery and charge it fully; refer to Servicing the Battery (page 6–81). 2. Either store the battery on a shelf or on the machine. 3. Disconnect the cables if the battery is kept on the machine. 4. Store the battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5.
Battery Care (continued) WARNING Connecting the cables to the wrong battery post could result in personal injury and/or damage to the electrical system. Ensure that the cables are properly connected to the correct battery posts before operating the machine. 4. If corrosion occurs at the battery terminals, disconnect the cables. Always disconnect the negative (-) cable first. Clean the cable clamps and terminals separately. Connect the cables with the positive (+) cable first.
Removing and Installing the Battery g227290 Figure 177 1. Negative cable 4. Battery retainer 7. Bolt 2. Battery base 5. Flat washer 8. Battery 3. Threaded insert 6. Lock washer 9. Positive cable IMPORTANT Be careful when removing the battery cables and ensure that you do not damage the terminal posts or cable connectors. 1. Unlatch, raise the hood and support it. 2. Loosen and remove the negative (-) cable from the battery.
Inspecting, Maintaining, and Testing the Battery 1. Do the following inspections and maintenance: A. Check for cracks. Replace the battery if cracked or leaking. B. Check the battery terminal posts for corrosion. Use the wire brush to clean corrosion from the posts. IMPORTANT Before cleaning the battery, tape or block the vent holes of the filler caps and ensure that the caps are tight. C.
Inspecting, Maintaining, and Testing the Battery (continued) C. If the difference between the highest and lowest cell specific gravity is 0.050 or more or the lowest cell specific gravity is less than 1.225, charge the battery. D. Charge at the rate and time given in Charging the Battery (page 6–85) or until all cells specific gravity is 1.225 or greater with the difference in specific gravity between the highest and lowest cell is less than 0.050.
Charging the Battery To minimize damage to the battery and allow the battery to charge fully, do the following slow charging procedure. You can do this charging procedure with a constant current battery charger that is locally available. IMPORTANT Follow the manufacturer's instructions when using a battery charger. Note: Use specific gravity of the battery cells is the most accurate procedure of determining the battery condition. 1.
Charging the Battery (continued) CAUTION Charging a frozen battery can cause explosion and can cause personal injury. Let the battery warm to 15.5°C (60°F) before connecting to a charger. • Charge the battery in a well-ventilated place to dissipate the gases produced from the charging. • These gases are explosive; keep open flame and electrical spark away from the battery. Do not smoke. • Inhaling the battery gases can cause nausea.
Chapter 7 Chassis Table of Contents Specifications ....................................................................................................................................... 7–2 General Information .............................................................................................................................. 7–3 Service and Repairs ............................................................................................................................. 7–4 Wheels ............
Specifications Item Description Front tire pressure (23 x 9.50 − 12, 4 ply, tubeless) 138 kPa (20 psi) Rear tire pressure ( 2-wheel drive machines) 138 kPa (20 psi) (16 x 6.50 − 8, 4 ply, tubeless) Rear tire pressure (4-wheel drive machines) 138 kPa (20 psi) (18 x 6.
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your Groundsmaster 3280-D and 3320 machines. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and Repairs Wheels g223611 Figure 178 1. Rear wheel hub 3. Wheel-lug nut (5 each per wheel) 5. Front axle 2. Rear wheel assembly 4. Front wheel assembly 6. Rear axle (2-wheel drive) Removing the Wheel 1. Park the machine on a level surface, lower the cutting deck (or implement), shut off the engine, set the parking brake, and remove the key from the key switch. 2. Block the wheels that are not removed with chocks to prevent the machine from moving. 3.
Removing the Wheel (continued) 4. Lift the machine with a jack until the wheel to be removed is off the ground. Support the machine with appropriate jack stands. 5. Remove the 5 wheel-lug nuts that attach the wheel to the machine, and remove the wheel. Installing the Wheel 1. Install the wheel to the machine with the 5 wheel-lug nuts. 2. Lower the machine to the ground. WARNING Failure to maintain proper torque could result in failure or loss of wheel and may result in personal injury.
Steering Column g223612 Figure 179 1. Steering wheel cover 11. Compression spring 21. Socket-head screw (4 each) 2. Locknut 12. Knob 22. Flange nut (2 each) 3. Flat washer 13. Tilt steering lever 23. Friction disc 4. Steering wheel 14. Grip 24. Pivot plate 5. Foam collar 15. Steering control valve 25. Friction disc 6. Tower panel 16. Spacer 26. Tilt bracket 7. Retainer nut (6 each) 17. Flange nut (3 each) 27. Flat washer 8. Flange-head screw 18.
Removing the Steering Column 1. Park the machine on a level surface, set the parking brake, lower the cutting deck (or implement), shut off the engine, and remove the key from the key switch. 2. Carefully remove the steering wheel cover (item 1 in Figure 179) from the steering wheel. 3. Remove the locknut (item 2 in Figure 179) and flat washer that secure the steering wheel to the steering column. 4. Remove the steering wheel and foam collar from the steering column (item 29 in Figure 179). 5.
Installing the Steering Column (continued) 8. Position the tower panel to the machine and secure the panel with the 6 phillips-head screws. 9. Install the knob on the end of the parking brake rod. 10. Slide the foam collar onto the steering column. 11. Slide the steering wheel onto the steering column and secure the steering wheel with the flat washer and locknut; torque the locknut to 27 to 35 N·m (20 to 26 ft-lb). 12. Install the steering wheel cover (item 1 in Figure 179) onto the steering wheel.
Rear Frame and Axle Assembly g223992 Figure 180 1. Rear weight 7. Socket-head screw (6 each) 13. Flat washer (4 each) 2. Flange-head screw (4 each) 8. Driveshaft 14. Lock washer (4 each) 3. Rear bumper 9. Flange-head screw (4 each) 15. Bolt (4 each) 4. Rear frame and axle assembly (4-wheel drive) 10. Locknut (2 each) 16. Rear frame and axle assembly (2-wheel drive) 5. Bi-directional clutch 11. Bolt (2 each) 6. Lock washer (6 each) 12.
Removing the Rear Frame and Axle Assembly (continued) 8. Remove the 4 flange-head screws (item 9 in Figure 180) that secure the rear frame and axle assembly to the machine frame. 9. Carefully move the rear frame and axle assembly from the machine. Installing the Rear Frame and Axle Assembly 1. Carefully position the rear frame and axle assembly to the machine frame.
Rear Axle (2-Wheel Drive) g223700 Figure 181 1. Bolt 4. Locknut 7. Rear axle 2. Flat washer 5. Flat washer 8. Thrust washer (0.766 inch inner diameter) 3. Pivot pin 6. Thrust washer (1.030 inch inner diameter) 9. Locknut 10. Steering cylinder Note: For repair information regarding the rear axle on 4-wheel drive machines; refer to Chapter 8: Drive Axles (page 8–1). Removing the Rear Axle 1.
Removing the Rear Axle (continued) Note: Several washers (items 5, 6, and 8 in Figure 181) are installed between the axle pivot tube and the rear frame to adjust clearance between the axle pivot tube and rear frame. Before removing the axle pivot pin, note the location of the washers. 6. Pull the axle pivot pin out. This will release the rear axle and washer(s) from the frame. Carefully pull the entire axle and wheel assembly out from under the machine. 7.
Servicing the Rear Axle (2-Wheel Drive) g223802 Figure 182 1. Rear axle 9. Grease fitting (4 each) 17. Jam nut (2 each) 2. Flange-head screw 10. Thrust washer 18. Tie rod (2 each) 3. Spindle cap 11. Right spindle 19. Retaining ring 4. Retaining ring 12. Flat washer (2 each) 20. Thrust washer 5. Thrust washer (0.060 inch thick) (2 13. each) Jam nut (8 each) 21. Steering pivot bushing (2 each) 6. Flat washer (0.018 inch thick) 14. Jam nut (left-hand thread) (2 each) 22.
Axle Pivot Bushings The rear axle must be held in place snugly by the axle pivot pin. Excessive movement of the axle, which is characterized by erratic steering, can indicate worn axle pivot bushings. To correct the problem, replace the axle pivot bushings (item 24 in Figure 182). 1. Remove the rear axle from the machine; refer to Removing the Rear Axle (page 7–11). 2. Use a drift punch and hammer to drive both axle pivot bushings out of the axle pivot tube.
Steering Pivot Bushings (continued) 5. Use a drift punch and hammer to drive both the steering pivot bushings out of the steering pivot. Clean the inside of the steering pivot to remove any dirt or unwanted material. Also, clean the mounting pin at the bottom of the rear axle. 6. Apply grease to the inner and outer surfaces of new bushings. Use an arbor press to install the bushings into the top and bottom of the steering pivot. The bushings must be flush with the pivot plate. 7.
Rear Axle Spindle Bushings (continued) 12. Lubricate the steering spindles through the grease fittings on the rear axle; refer to the Traction Unit Operator’s Manual. 13. Check the rear wheel toe-in; refer to the Traction Unit Operator’s Manual. 14. After all adjustments have been made, ensure that there is no contact between any steering components as the wheels move from lock to lock. Adjust if necessary.
Rear Wheel Bearings (2-Wheel Drive) g224228 Figure 184 Oil seal 5. Cotter pin 9. 2. Bearing cup (2 each) 6. Dust cap 10. 3. 4. Rear wheel Tab washer 7. 8. Retainer Jam nut 1. Bearing cone (2 each) Wheel hub Note: For repair information regarding the rear axle on 4-wheel drive machines; refer to Chapter 8: Drive Axles (page 8–1). Disassembling the Rear Wheel Bearings 1. Raise the rear of the machine until the wheel is off the ground.
Assembling the Rear Wheel Bearings (continued) 2. Pack both the bearings with grease. Install 1 bearing into the cup on inboard side of the wheel hub. Lubricate the inner surface of the new seal and press it into the wheel hub. 3. Pack inside of the wheel hub with some grease (not full). Position remaining bearing into the outer bearing cup. 4. Slide the wheel hub assembly onto the spindle shaft and secure it in place with the tab washer and jam nut. Do not tighten the nut or install the cotter pin. 5.
Operator Seat g223702 Figure 185 1. Seat 8. Flange nut (2 each) 15. Wire cap (4 each) 2. Seat switch 9. Carriage screw (2 each) 16. Socket-head screw (4 each) 3. Washer-head screw (2 each) 10. Flange nut (12 each) 17. Flat washer (4 each) 4. Seat bracket (left) 11. Seat base 18. Seat adjuster 5. Seat adjuster with latch 12. Flange-head screw (2 each) 19. Seat bracket (right) 6. Seat suspension 13. Flange-head screw (4 each) 7. Lower seat bracket (2 each) 14.
Removing the Operator Seat 1. Park the machine on a level surface, lower the cutting deck (or implement), shut off the engine, set the parking brake, and remove the key from the key switch. 2. Disconnect the negative battery cable from the battery; refer to Servicing the Battery (page 6–80). 3. Disconnect the electrical connector from the seat switch. On pneumatic seat suspension systems, disconnect the electrical connector from the suspension. 4.
Mechanical Seat Suspension g243926 Figure 186 1. Rivet (2 each) 13. Roll pin 25. Lower shock bolt (2 each) 37. Flat washer 2. Cotter pin 14. Weight adjust spacer 26. Lower housing 38. Spring shaft 3. Roll pin 15. Weight adjust shaft 27. Shaft block (4 each) 39. Extension spring (2 each) 4. Up-stop bumper block 16. Weight adjuster 28. Scissor assembly 40. Spring bushing (2 each) 5. Flat washer 17. Weight adjust nut 29. Lower shock bushing (2 each) 41. Flat washer 6.
Removing the Mechanical Seat Suspension g223699 Figure 187 1. Seat bracket (right) 5. Wire cap (4 each) 9. Flat washer (8 each) 2. Seat bracket (left) 6. Lower seat bracket (2 each) 10. Seat adjuster 3. Flange-head screw (8 each) 7. Flange-head screw (4 each) 11. Socket-head screw (4 each) 4. Flange nut (12 each) 8. Mechanical suspension assembly 12. Seat adjuster with latch 1.
Installing the Mechanical Seat Suspension (continued) 2. Install the seat and seat suspension to the machine; refer to Operator Seat (page 7–19). Ensure to connect the harness electrical connector to the seat switch.
Pneumatic Seat Suspension g223803 Figure 188 1. Upper housing 15. Bumper spacer (2 each) 29. Thread forming screw (8 each) 2. Convoluted tubing 16. Scissor pivot block (2 each) 30. Lower housing 3. Nylon tubing 17. Hex nut (2 each) 31. Wire harness 4. Air control valve 18. Flange-head screw (2 each) 32. Bolt 5. Connector 19. Retaining ring 33. 90° elbow stud 6. Weight tape guide 20. Flat washer (2 each) 34. Shaft block (2 each) 7. Cable tie (9 each) 21.
g224018 Figure 189 1. Pneumatic suspension assembly 2. Flange-head screw (4 each) 3. Lower seat bracket (2 each) Removing the Pneumatic Seat Suspension 1. Park the machine on a level surface, lower the cutting deck (or implement), shut off the engine, set the parking brake, and remove the key from the key switch. IMPORTANT Do not damage the electrical harness when removing the seat suspension from the machine. 2.
Lift Arms g223996 Figure 190 9. Jam nut 17. Clevis pin 10. Locknut 18. Height-of-cut collar Cylinder pin 11. Bolt 19. Flat washer Cotter pin 12. Hairpin cotter 20. Bolt 1. Lift cylinder 2. Cotter pin (2 each) 3. 4. 5. Pivot pin 13. Clevis pin 21. Hairpin cotter 6. Roll pin 14. Thrust washer (2 each) 22. Carrier bracket 7. Roll pin 15. Rod end 8. Height-of-cut tube 16.
Removing the Lift Arms g224019 Figure 191 1. Lift arm (left) 4. Rivet (3 each) 7. Plain washer (3 each) 2. Flange bushing (2 each) 5. Plastic pad 8. Spherical bearing 3. Grease fitting (2 each) 6. Rubber pad 9. Retaining ring g224020 Figure 192 1. Inner roll pin split 2. outer roll pin split 3. Roll pin ends flush with pivot pin surface 1.
Installing the Lift Arms 1. If the lift arm was disassembled, install the lift arm components (Figure 191). 2. Install the lift arm components to the machine (Figure 190). A. If the roll pins (items 6 and 7 in Figure 190) were removed from the pivot pin, install the roll pins so that one end is flush with the pivot pin and the inner roll pin split should be opposite to the outer roll pin split (Figure 192). 3. Connect the brake return spring to the lift arm. 4.
Chapter 8 Drive Axles Table of Contents Specifications ....................................................................................................................................... 8–2 General Information .............................................................................................................................. 8–3 Front Axle...........................................................................................................................................
Specifications Item Description Front axle (hydraulic reservoir) fluid Front axle (hydraulic reservoir) capacity Refer to the Traction Unit Operator’s Manual 5.7 L (1.5 US gallons) Refer to the Traction Unit Operator’s Manual for checking the procedure 4-wheel drive rear axle lubricant 4-wheel drive rear axle lubricant capacity GL-5 API, SAE 80W−90 gear lube 2.9 L (0.
General Information Front Axle g225887 Figure 193 The Groundsmaster 3280-D (for models 30344 and 30345) use a Schafer axle, model A20AA150-1. The Groundsmaster 3280-D (except models 30344 and 30345) and 3320 use a Dana axle, model GT-20. The differential and axle form the final drive of the power train (Figure 193). The differential has a heavy duty case with automotive type, cut gears that rotate on tapered roller bearings.
4-Wheel Drive Rear Axle (continued) The 4-wheel drive rear axle used on the Groundsmaster 3280-D is a steerable, mechanical drive axle. A driveshaft connected to the front axle output shaft provides power to the 4-wheel drive rear axle. The driveshaft incorporates a bi-directional clutch that transfers power from the driveshaft to the 4-wheel drive rear axle input shaft (Figure 194). g225899 Figure 195 1. Forward clutch engagement 2. Neutral (freewheeling) 3.
Special Tools You can order the special tools from your Toro Distributor. Differential Gear Holder Toro Part No. TOR4027 Remove the gear cover from right hand side of the differential and bolt this tool in place to lock spur gear in position when removing the nut that secures the pinion coupler.
Service and Repairs Servicing the Brake g225901 Figure 196 1. Brake cable link 7. Return spring (right) 13. Adjuster spring Brake lever retainer 2. Brake return spring 8. Star wheel socket 14. 3. Cotter pin 9. Star wheel adjuster 15. Return spring (left) 4. Clevis pin 10. Pivot nut 16. Brake spider 5. 6. Brake cable Dust shield 11. 12. Brake shoe set Brake drum 17. Brake lever Disassembling the Brake 1.
Disassembling the Brake (continued) 6. Remove the adjuster spring (item 13 in Figure 196). 7. Spread the upper ends of the brake shoes (item 11 in Figure 196), and remove the star wheel socket, star wheel adjuster, and pivot nut. 8. Remove the brake lever retainers (item 14 in Figure 196). 9. Pull the brake lever from the brake shoes. 10. Remove the return springs (items 7 and 15 in Figure 196) and brake shoe by prying the end of the spring up and out of the brake shoe.
Front Axle Shafts and Bearings g225902 Figure 197 1. Front axle housing 10. Star wheel adjuster 19. Adjuster spring 2. Socket-head screw (4 each per wheel) 11. Pivot nut 20. Return spring (right) 3. Axle shaft 12. Hardened washer (4 each per wheel) 21. Return spring (left) 4. Inner axle oil seal 13. Wheel stud (5 each per wheel) 22. Brake lever 5. Bearing retainer 14. Brake drum 23. Brake cable link 6. Bearing 15. Locknut (4 each per wheel) 24. Brake return spring 7.
Disassembling the Front Axle Shafts and Bearings 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the brake return spring (item 24 in Figure 197) from the brake cable link. Remove the cotter pin and clevis pin, and disconnect the brake cable from the brake lever. 3. Remove the wheel assembly from the front axle; refer to Removing the Wheel (page 7–4). g225903 Figure 198 4.
Disassembling the Front Axle Shafts and Bearings (continued) IMPORTANT Hold the socket-head screws with a wrench to prevent the screw head from rotating and damaging the axle tube. g225905 Figure 200 6. Pull the axle shaft and brake assembly out of the axle housing (Figure 200). Note: If necessary, remove the bearing race from the axle housing with a bearing puller. g225888 Figure 201 7. Remove and discard the inner axle shaft seal (Figure 201).
Disassembling the Front Axle Shafts and Bearings (continued) g225889 Figure 202 8. Center punch and drill a 6 mm (1/4 inch) hole (approximate) into the outside of the bearing retainer to a depth of about 3/4 the thickness of the retainer (Figure 202). IMPORTANT Drilling completely through the retainer ring will damage the axle shaft. g225890 Figure 203 WARNING Wear protective safety goggles when breaking the retaining ring. Personal injury could result from flying metal particles.
Disassembling the Front Axle Shafts and Bearings (continued) 11. Remove and discard the outer seal plate. g225891 Figure 204 12. Inspect all the components for wear and damage (Figure 204). Replace the axle shaft if the seal has grooved the axle surface more than 0.40 mm (1/64 inch). Assembling the Front Axle Shafts and Bearings 1. Coat a new outer seal plate with a thin layer of fluid and place the outer seal plate, brake assembly, and dust shield in position on the axle shaft. g225892 Figure 205 2.
Assembling the Front Axle Shafts and Bearings (continued) g225893 Figure 206 3. Slide a new bearing retainer on the axle shaft. Support the shaft and retainer in a suitable press and press the bearing retainer firmly against the bearing (Figure 206). IMPORTANT Do not heat the bearing retainer to install. Heat will destroy the close tolerance press fit. g225894 Figure 207 4. Prepare a new inner shaft seal for assembly. Put a light coat of No.
Assembling the Front Axle Shafts and Bearings (continued) g225895 Figure 208 5. Apply a 1.60 mm (1/16 inch) bead of Loctite Ultra Gray Silicone (gasket eliminator) to the axle housing flange. Align the dust shield and brake assembly with the axle housing flange and push the axle shaft assembly all the way into the axle housing. Ensure that you do not damage the oil seal and bearing (Figure 208). Note: Liquid gasket kit (Toro Part No.
Assembling the Front Axle Shafts and Bearings (continued) 7. Slide the brake drum onto the wheel studs. 8. Secure the brake cable to the brake lever with the clevis pin (item 26 in Figure 197) and cotter pin. Attach the brake return spring to the brake cable link. 9. Install the wheel assembly to the front axle; refer to Installing the Wheel (page 7–5). 10. Check and adjust the brakes; refer to the Traction Unit Operator’s Manual.
Front Axle (Machine Serial Number before 316000000) g230990 Figure 210 1. Bolt 10. Front axle assembly 19. Axle shim (as necessary) 2. Bolt (3 each) 11. Jam nut 20. Hydraulic fitting 3. Lock washer (4 each) 12. Transmission anchor 21. Hose clamp 4. Flat washer 13. Locknut 22. Hydraulic hose 5. Spacer 14. Carrier bracket (2 each) 23. Transmission 6. Mounting spacer (4 each) 15. Wheel-lug nut (5 each per wheel) 24. Locknut (4 each) 7. Pinion gear 16.
Removing the Front Axle 1. Park machine on a level surface, lower cutting deck (or implement), shut off the engine, engage parking brake and remove key from the key switch. 2. Remove the cutting deck (or implement); refer to the Cutting Unit Operator’s Manual. 3. To prevent contamination of the hydraulic system, clean transmission and front axle. 4. Drain oil from front axle; refer to the Traction Unit Operator’s Manual. 5.
Removing the Front Axle (continued) 13. Put a jack or blocking under front axle to prevent it from falling. Remove bolts, flat washers, and locknuts that secure axle mounting pads to frame. Retrieve and note location of axle shims (item 19 in Figure 210). 14. Carefully lower front axle and remove from machine. Installing the Front Axle 1. Position front axle to machine frame and support axle in place. 2. Place axle shims in location noted during disassembly.
Front Axle (Machine Serial Number after 316000000) g225897 Figure 212 1. Socket-head screw (4 each) 2. Lock washer (4 each) 3. Hydraulic pump 4. 5. 8. 15. O-ring (2 each) Flange-head screw (4 each) 16. Flat washer (4 each) 10. 90° hydraulic fitting 17. Bolt (4 each) Pump bracket 11. O-ring 18. Front wheel assembly Hydraulic motor 12. Straight thread fitting 19. Front axle 6. Flange-head screw (4 each) 13. Locknut (4 each) 20. Carrier bracket (2 each) 7.
Removing the Front Axle 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the cutting deck (or implement); refer to the Cutting Unit Operator’s Manual. 3. Clean the hydraulic components and front axle to prevent contamination. 4. Drain the hydraulic fluid from the hydraulic reservoir (front axle); refer to the Operator’s Manual.
Removing the Front Axle (continued) 13. Carefully lower the front axle and remove the axle from the machine. Installing the Front Axle 1. Position the front axle to the machine frame and support the axle in place. 2. Place the axle shims in the location that you noted during disassembly. Install the 4 bolts (item 17 in Figure 212), 4 flat washers, and 4 locknuts that secure the axle mounting pads to the frame. Leave the fasteners loose to allow alignment of hydraulic motor. 3.
Servicing the Front Axle g226662 Figure 214 1. Hex nut (8 each) 14. Spur gear 27. Differential bearing cup (2 each) 2. Lock washer (8 each) 15. Shim 28. Differential bearing cone (2 each) 3. Dowel pin (2 each) 16. Bolt (8 each) 29. Ring gear 4. Thrust washer (2 each) 17. Washer 30. Lock pin 5. Side bevel gear (2 each) 18. Nut 31. Bolt (5 each) 6. Pinion mate bevel gear (2 each) 19. Flange coupler 32. Differential case 7. Spherical thrust washer (2 each) 20. Seal 33.
Disassembling the Front Axle 1. Remove the right and left-hand axle assemblies; refer to Disassembling the Front Axle Shafts and Bearings (page 8–9). g225906 Figure 215 2. Remove the 8 housing bolts, 8 hex nuts, and 8 lock washers that secure the axle housings. Separate the front and rear axle housings (Figure 215). Clean all gasket material from the housing mating surfaces. g225907 Figure 216 3. Remove the 4 bearing bolts, and remove the caps.
Disassembling the Front Axle (continued) g225908 Figure 217 4. To remove the differential assembly, place 2 wooden devices (e.g., hammer handles) under the differential case and pry firmly upward. Mark the bearing cups and cones, they must be installed in matched sets (Figure 217). g225909 Figure 218 Note: Protect the ring gear when removing it from the differential case; this will avoid damage of the ring gear teeth. 5. Remove the ring gear bolts.
Disassembling the Front Axle (continued) g225910 Figure 219 6. Do not remove the bearings from the differential case unless there is a bearing failure. Whenever the bearings are removed (regardless of usage) they must be replaced with new ones. Remove the case side bearing with a puller as shown in Figure 219. If the bearings are removed from the differential case, locate and retrieve the shims from the case. For assembly purposes, note the location of the shim.
Disassembling the Front Axle (continued) g225912 Figure 221 8. While supporting the differential in a vise, drive the pinion mate shaft from the differential with a long drift punch (Figure 221). g225913 Figure 222 9. To remove the side gears and pinion mate gears, rotate the side gears. This will allow the pinion mate gears to turn to the opening of the case (Figure 222). Remove the pinion mate gears and spherical washers behind the gears.
Disassembling the Front Axle (continued) g225914 Figure 223 10. Remove the 8 side cover bolts, and remove the side cover from the carrier assembly (Figure 223). Clean the gasket material from the mating surfaces before assembly. g226660 Figure 224 1. Bearing spacer 4. Shim 7. Washer 2. Outer bearing cup 5. Seal 8. Nut 3. Outer bearing cone 6. Flange coupler 11. Install the differential gear holder to carrier to retain the spur gear; refer to the Differential Gear Holder (page 8–5).
Disassembling the Front Axle (continued) g225915 Figure 225 12. Position the housing assembly on a suitable press. Place a 3 mm (1/8 inch) piece of steel or a screwdriver blade under the edge of the spur gear. This will prevent the spur gear from cocking and possibly cracking the housing (Figure 225). IMPORTANT Do not allow the pinion shaft to drop on the floor during removal as damage will result. Carefully press the drive pinion shaft from the housing.
Disassembling the Front Axle (continued) g225917 Figure 227 15. Clamp the inner pinion bearing with a universal bearing remover (Figure 227). Position the unit in a press and carefully push the drive pinion out of the bearing. IMPORTANT Do not allow the pinion to drop on the floor during removal as damage will result. g225918 Figure 228 16. To remove the outer pinion bearing cup, position the housing in a press. Place a press plate of the proper size against the cup.
Disassembling the Front Axle (continued) g225919 Figure 229 Insert a press plate of the proper size and press the inner bearing cup toward the inside of the housing. Retain the shims located under the bearing cup (Figure 229). If the shims are damaged, replace with new shims of the same thickness. Assembling the Front Axle 1. Inspect the differential parts for damage before assembling. A. If any bearings are damaged they must be replaced with new ones. Replace all the bearings that were removed. B.
Assembling the Front Axle (continued) g225921 Figure 231 3. Put the front housing on a press. Use a press plate, push new pinion outer bearing cup into the housing until it bottoms in the housing (Figure 231). IMPORTANT Correct engagement between the ring gear and pinion gear is critical to axle performance and durability. Note: A complete upper housing assembly for differential repairs is available.
Assembling the Front Axle (continued) B. When you install new ring and pinion gears (supplied in matched sets only) ensure that the numbers etched on both the pinion and ring gear match (Figure 232). Compare the +, -, or 0 markings of the old and new pinions. Adjust the thickness of a new shim pack to compensate for the difference in these 2 numbers. For example: If the old pinion reads +2 and the new pinion reads -2, add 0.004 inch of bearing shims to the original shim pack thickness.
Assembling the Front Axle (continued) g225924 Figure 234 6. Insert the spur gear into the front housing with the chamfered area of the center spline toward the pinion gear. Tap the pinion gear with a soft mallet to engage the splines in the spur gear (Figure 234). g225925 Figure 235 7. Support the drive pinion in a suitable press (Figure 235).
Assembling the Front Axle (continued) g225926 Figure 236 8. Install the outer bearing spacer with the chamfer toward the pinion splines and position new outer bearing cone on the pinion shaft (Figure 236). g225927 Figure 237 9. With a hollow press sleeve of proper diameter, press on the outer bearing cone race until the drive pinion seats in the carrier and a slight drag is felt when the gear is rotated by hand (Figure 237). If more than 0.2 to 1.
Assembling the Front Axle (continued) g226661 Figure 238 1. Bearing spacer 4. Shim 7. Washer 2. Outer bearing cup 5. Seal 8. Nut 3. Outer bearing cone 6. Flange coupler 11. Install the seal into the housing. Install the shim, flange coupler, washer, and nut onto end of the pinion shaft (Figure 238). Torque the nut that secures the pinion coupler to 95 to 122 N·m (70 to 90 ft-lb). 12. Check the pinion shaft end-play. Pinion shaft end-play: 0.00 to 0.13 mm. (0.000 to 0.
Assembling the Front Axle (continued) Install the spur gear cover (Figure 239). Torque the bolts to 3 to 4.5 N·m (25 to 40 in-lb). g225929 Figure 240 15. Place the differential case in a vise (Figure 240). Apply grease to new side gear thrust washers and hubs of the side gears. Apply grease to new pinion mate spherical washers and pinion mate gears. Place the side gears and thrust washers in the case. Install the pinion gears while holding the side gears in place.
Assembling the Front Axle (continued) g225931 Figure 242 17. Assemble the lock pin. Drive the pin to the approximate center location of the pinion mate shaft. Peen the metal of the case to lock the pin in place (Figure 242). g226482 Figure 243 18. Position the ring gear onto the differential case and thread new bolts into the ring gear. Tighten the bolts, alternating back and forth across the gear to allow the gear to be pulled evenly into place.
Assembling the Front Axle (continued) g225933 Figure 244 19. When you install new differential bearings, use the original shims or use new shims of the same thickness. Press new differential bearings onto the differential case. If a new differential case is being installed, start with a 0.50 mm (0.020 inch) pack of shims under each differential bearing (Figure 244). Note: Shims are available in 0.08 mm (0.003 inch), 0.13 mm (0.005 inch), 0.25 mm (0.010 inch), and 0.76 mm (0.030 inch) thickness. 20.
Assembling the Front Axle (continued) g225935 Figure 246 22. Use a dial indicator, check the ring gear backlash in 3 equally spaced points. The ring gear backlash should be 0.076 to 0.178 mm (0.003 to 0.007 inch) and must not vary more than 0.05 mm (0.002 inch) between the points checked (Figure 246). If the backlash is not in this range, move the shims which are located below the differential bearings, from one side to the other until the correct backlash is attained. 23.
Ring to Pinion Gear Engagement (Front Axle) Final position of the front axle pinion is verified by using the gear contact pattern method as described in the following procedure. g226484 Figure 248 1. Top land 3. Toe 5. Lengthwise bearing arc 2. Profile 4. Heel 6. Root Gear tooth definitions (Figure 248): • Toe - the portion of the tooth surface at the end toward the center. • Heel - the portion of the gear tooth at the outer end. • Top Land - top surface of tooth. 1.
Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as the gear location is changed. When making pinion position changes, shims should be changed in the range of 0.05 to 0.10 mm (0.002 to 0.004 inch) until a correct pattern has been obtained. When a change in backlash is required, backlash shims should be changed in the range of 1-1/2 times the amount of backlash necessary to bring the gears into specification.
g226457 Figure 252 1. 2. Heel Drive side 3. 4. Toe Coast side Example 3: Backlash incorrect. Thinner pinion position shim necessary. Adjust backlash to match (Figure 252). Gear Pattern Movement Summary 1. Decreasing backlash moves the ring gear closer to the pinion. Drive pattern (convex side of gear) moves lower and toward the toe. Coast pattern (concave side of gear) moves slightly higher and toward the heel. 2. Increasing backlash moves the ring gear away from the pinion.
Rear Axle Driveshaft (4-Wheel Drive) g226458 Figure 253 1. Bi-directional clutch 5. Grease fitting (2 each) 2. Lock washer (6 each per flange) 6. Yoke and shaft 3. Socket-head screw (6 each per flange) 7. Grease fitting 4. Cross and bearing kit (2 each) 8. Front axle flange 9. 10. Yoke flange (2 each) Yoke and tube Removing the Rear Axle Driveshaft (4-Wheel Drive) 1.
Installing the Rear Axle Driveshaft (4-Wheel Drive) IMPORTANT If the driveshaft tube and shaft were separated, ensure that the driveshaft yokes are aligned when the tube and shaft are assembled (Figure 253). Misalignment of the yokes will result in shortened driveshaft life and will cause unnecessary vibration. 1. Position the rear axle driveshaft to the machine. Ensure that the driveshaft tube (item 10 in Figure 253) is toward the rear axle. 2.
Servicing the Rear Axle Driveshaft Cross and Bearing (4-Wheel Drive) g226486 Figure 254 1. End yoke 3. Snap ring (4 each) 2. Cross and bearing kit 4. Shaft yoke 1. Remove the rear axle driveshaft from the machine; refer to Removing the Rear Axle Driveshaft (4-Wheel Drive) (page 8–43). 2. Remove the snap rings that secure the bearings in the yokes. IMPORTANT Support the yokes when removing and installing the bearings to prevent damage. 3.
Rear Axle (4-Wheel Drive) g226663 Figure 255 1. Clutch locator adapter 16. Oscillation stop 31. Thrust washer (as necessary) 2. Bolt (2 each) 17. Thrust washer 32. Thrust washer (as necessary) 3. Bi-directional clutch 18. Jam nut 33. Steering cylinder support bracket 4. Spacer 19. Locknut 34. Steering cylinder ball joint (2 each) 5. Flat washer 20. Flange-head screw (4 each) 35. Retaining ring (2 each) 6. Lock washer 21. Axle support 36. Grease fitting 7. Bolt 22.
Note: For repair information regarding the rear axle on 2-wheel drive machines; refer to Chapter 7: Chassis (page 7–1). Removing the Rear Axle (4-Wheel Drive) 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Drain the hydraulic fluid from the rear axle; refer to the Traction Unit Operator’s Manual. 3. Remove the 2 rear wheels from the rear axle; refer to Removing the Wheel (page 7–4). 4.
Installing the Rear Axle (4-Wheel Drive) (continued) 10. Start the engine and check for component interference as the steering wheel is turned from lock to lock. 11. Check the rear wheel toe-in and adjust if necessary; refer to the Traction Unit Operator’s Manual. 12. Check the steering stop bolt adjustment on both sides of the axle. At full right and left turns, a gap of 2.2 mm (0.088 inch) should exist between the bevel gear case casting and the stop bolt on the axle case.
Bevel Gear Case and Axle Case (4-Wheel Drive Axle) The following procedures assume the 4-wheel drive rear axle assembly has been removed from the machine. Removing the Bevel Gear Case and Axle Case (4-Wheel Drive Axle) g226459 Figure 256 1. Mounting screw 3. Bevel gear case/axle case 5. assembly Locknut 2. O-ring 4. Lock washer Axle support 6. 1. Remove the mounting screws, nuts, and lock washers, and remove the bevel gear case/axle case assembly and O-ring from the axle support (Figure 256).
Removing the Bevel Gear Case and Axle Case (4-Wheel Drive Axle) (continued) g226460 Figure 258 1. Axle case 3. Mounting screw 2. Axle case support 4. Support shim 4. Remove the axle case support mounting screws, axle case support, and support shims (Figure 258).
Removing the Bevel Gear Case and Axle Case (4-Wheel Drive Axle) (continued) g226461 Figure 259 1. Knuckle pin 7. Axle case cover 13. 2. O-ring 8. Mounting screws 14. Upper bevel gear 3. Bevel gear case 9. Lower bearing 15. Collar 16. Upper bearing 4. Shaft seal (2 each) 10. Lower bevel gear 5. Axle case 11. Bevel gear shaft 6. O-ring 12. Thrust washer Spacer 5. Remove the knuckle pin mounting screws and knuckle pin. Remove and discard the O-ring (Figure 259). 6.
Inspecting the Bevel Gear Case and Axle Case g226462 Figure 260 1. Knuckle pin 2. Axle case support 1. Measure the knuckle pin outer diameter and the axle case support bushing inner diameter to determine the bushing to pin clearance (Figure 260). Replace the components as necessary. Bushing to pin clearance: 0.05 to 0.40 mm (0.002 to 0.016 inch) Knuckle pin outer diameter (factory specification): 24.95 to 24.98 mm (0.982 to 0.
Installing the Bevel Gear Case and Axle Case (4-Wheel Drive Axle) (continued) g226464 Figure 262 1. Axle case cover 5. Spacer 2. Lower bearing 6. Upper bevel gear 3. Lower bevel gear 7. Collar 4. Thrust washer 8. Knuckle pin 9. 10. Upper bearing Bevel gear shaft 2. Install the lower bevel gear and bevel gear shaft in the axle case cover. Coat a new O-ring with grease and install the axle case cover (Figure 262). Tighten the cover screws to 23 to 27 N·m (17 to 20 ft-lb). 3.
Installing the Bevel Gear Case and Axle Case (4-Wheel Drive Axle) (continued) g226465 Figure 263 1. Dial indicator 4. Axle case 2. Axle case support 5. Bevel gear case 3. Support shim location 6. Knuckle pin 7. Vertical end-play C. Use a dial indicator to measure vertical end-play of the axle case (Figure 263). Axle case assembly end-play: 0.02 to 0.20 mm (0.001 to 0.008 inch) D. Adjust end-play by increasing or reducing the number of axle case support shims.
Installing the Bevel Gear Case and Axle Case (4-Wheel Drive Axle) (continued) g226466 Figure 264 1. Axle support 3. Upper bevel gear 2. Differential shaft gear 4. Dial indicator 5. Axle bearing shims 7. Temporarily install the bevel gear case/axle case assembly on the axle support. Position a dial indicator at the tooths center. Prevent the axle from turning and measure the upper bevel gear to the differential shaft gear backlash (Figure 264). Upper bevel gear backlash: 0.10 to 0.40 mm (0.
Installing the Bevel Gear Case and Axle Case (4-Wheel Drive Axle) (continued) Position a dial indicator at the tooths center. Prevent the axle from turning and measure the lower bevel gear to the axle gear backlash (Figure 265). Lower bevel gear backlash: 0.10 to 0.40 mm (0.004 to 0.016 inch) 10. Adjust backlash by increasing or reducing the axle bearing shim thickness; refer to the Axle Shafts (4-Wheel Drive Axle) (page 8–59). Note: Axle bearing shims are available in 0.20 mm (0.008 inch), 0.30 mm. (0.
Differential Shafts (4-Wheel Drive Axle) The following procedures assume the 4-wheel drive rear axle assembly has been removed from the machine. Removing the Differential Shaft (4-Wheel Drive Axle) IMPORTANT Do not interchange the right and left differential shafts assemblies. Mark the right and left shafts before disassembly. g226459 Figure 266 1. Mounting screw 3. Bevel gear case/axle case 5. assembly Locknut 2. O-ring 4. Lock washer Axle support 6. 1.
Removing the Differential Shaft (4-Wheel Drive Axle) (continued) 5. Inspect all gears, shafts, bearings, and cases for damage and wear. Replace the components as necessary. Installing the Differential Shaft (4-Wheel Drive Axle) 1. Press the bearings onto the differential shaft. Place correct combination of bearing shims in the axle support and drive the differential shaft and bearing assembly into the axle support. 2. Install the bevel gear and retaining ring. 3. Coat new O-ring with grease.
Axle Shafts (4-Wheel Drive Axle) The following procedures assume the 4-wheel drive rear axle assembly has been removed from the machine. Removing the Axle Shaft (4-Wheel Drive Axle) g226470 Figure 268 1. Axle case 3. Mounting screw 2. O-ring 4. Axle cover assembly 1. Remove the axle cover mounting screws, and remove the axle cover from the axle case as an assembly (Figure 268). g226471 Figure 269 1. Bearing 3. Shims 2. Bevel gear 4. Retaining ring 5. Spacer 2.
Installing the Axle Shaft (4-Wheel Drive Axle) g226488 Figure 270 1. 2. Axle cover Bearing 3. 4. Axle shaft Axle shaft seal 1. Coat new axle shaft seal with grease and install the shaft seal in the axle cover (Figure 270). 2. Press the axle cover and bearing assembly onto the axle shaft. Press only on the inner race of the cover bearing (Figure 270). 3. Install the retaining ring, spacer, and correct combination of bearing shims. Install the bevel gear and bearing. 4.
Input Shaft/Pinion Gear (4-Wheel Drive Axle) The following procedures assume the 4-wheel drive rear axle assembly has been removed from the machine. Removing the Input Shaft/Pinion Gear (4-Wheel Drive Axle) g226489 Figure 271 1. Input shaft/pinion gear 5. Bearing case 9. 2. Inner bearing 6. Outer bearing 10. Stake washer 3. Bearing case O-ring 7. Seal collar 11. Locknut 4. Bearing case shims 8. O-ring Oil seal 1.
Installing the Input Shaft/Pinion Gear (4-Wheel Drive Axle) (continued) 1. If the inner bearing cone was removed, press a new bearing cone all the way onto the input shaft/pinion gear. 2. Place the shaft and bearing assembly in the bearing case and install the outer bearing cone. Note: The bearings must be completely seated. There should be no input shaft/pinion gear end-play. g226490 Figure 272 1. Bearing case 2. Oil seal 3. Coat a new oil seal with grease and install the seal as shown in Figure 272.
Installing the Input Shaft/Pinion Gear (4-Wheel Drive Axle) (continued) 9. Use a depth gauge to measure the distance from the end face of the input shaft/pinion gear to the mating surface of the bearing case. Subtract the design cone center distance from this distance to determine initial shim thickness (Figure 273). Design cone center distance (distance from mating surface of the axle support to the end face of the pinion gear): 47.50 ± 0.05 mm (1.870 ± 0.
Differential Gear Assembly (4-Wheel Drive Axle) The following procedures assume the 4-wheel drive rear axle assembly has been removed from the machine. Removing the Differential Gear Assembly (4-Wheel Drive Axle) 1. Remove the bevel gear case/axle case assemblies; refer to Bevel Gear Case and Axle Case (4-Wheel Drive Axle) (page 8–49). IMPORTANT Do not interchange the right and left differential shafts assemblies. 2. For assembly purposes, mark the differential shaft assemblies.
Removing the Differential Gear Assembly (4-Wheel Drive Axle) (continued) g226494 Figure 276 1. Spring pin 2. Differential case 6. Drive the spring pin from the differential case with a punch and hammer. Discard the spring pin (Figure 276). Note: Mark and arrange all components so that they can be assembled in their original position. g226495 Figure 277 1. Differential pinion shaft 4. Side gear (2 each) 2. Pinion washer (2 each) 5. Side gear shims 3. Pinion gear (2 each) 6. Ring gear 7.
Inspecting the Differential Gear Assembly g226496 Figure 278 1. Side gear 2. Differential case 1. Measure the differential side gear outer diameter and the differential case inner diameter to determine the side gear to case clearance (Figure 278). Replace the components as necessary. Side gear to case clearance: 0.05 to 0.30 mm (0.002 to 0.012 inch) Side gear outer diameter (factory specification): 33.91 to 33.95 mm (1.335 to 1.337 inch) Differential case inner diameter (factory specification): 34.
Inspecting the Differential Gear Assembly (continued) g226497 Figure 279 1. 2. Pinion shaft Pinion gear 2. Measure the differential pinion shaft outer diameter and the pinion gear inner diameter to determine the pinion shaft to pinion gear clearance (Figure 279). Replace the components as necessary. Pinion shaft to pinion gear clearance: 0.03 to 0.25 mm (0.001 to 0.010 inch) Pinion shaft outer diameter (factory specification): 13.97 to 13.98 mm (0.550 to 0.
Installing the Differential Gear Assembly (4-Wheel Drive Axle) (continued) 1. If the ring gear was removed from the differential case, use medium strength Loctite threadlocker and tighten the mounting screws to 30 to 34 N·m (22 to 25 ft-lb). 2. Apply molybdenum disulfide lubricant (Threebond 1901 or equivalent) to the splines and bearing surfaces of the differential pinion gears, pinion washers, and side gears. 3.
Installing the Differential Gear Assembly (4-Wheel Drive Axle) (continued) 15. Coat new O-rings with grease, align the differential shaft splines with the differential gear assembly and slide the differential shaft assemblies onto the axle support. 16. Install the bevel gear case/axle case assemblies; refer to Bevel Gear Case and Axle Case (4-Wheel Drive Axle) (page 8–49).
Pinion Gear to Ring Gear Engagement (4-Wheel Drive Axle) The final position of the pinion gear is verified by using the gear contact pattern method as described in the following procedure. g226500 Figure 282 1. Top land 3. Toe 5. Heel 2. Profile 4. Lengthwise bearing arc 6. Root Gear tooth definitions (Figure 282): • Toe - the portion of the tooth surface at the end toward the center. • Heel - the portion of the gear tooth at the outer end. • Top Land - top surface of tooth. 1.
g226502 Figure 284 1. Input shaft/pinion gear 3. Differential bearing shims 2. Bearing case shims 4. Differential gear case Adjustments to the gear contact position are made by moving the input shaft/pinion gear (bearing case shims) or by moving the differential gear case (differential bearing shims) (Figure 284). Note: Bearing case shims are available in 0.10 mm (0.004 inch) and 0.20 mm (0.008 inch) thickness. Note: Differential bearing shims are available in 0.10 mm (0.004 inch), 0.20 mm (0.
Gear Pattern Movement Summary (continued) g226503 Figure 285 1. Heel contact 2. Base contact 1. If contact is toward the heel or base of the gear (Figure 285), do as follows: A. Install the thicker or additional bearing case shim(s) to move the pinion shaft toward the ring gear. B. Install the thinner or remove differential bearing shim(s) to move the ring gear backward. C. Repeat until proper tooth contact and pinion gear to ring gear backlash are correct. g226504 Figure 286 1. Toe contact 2.
Bi-Directional Clutch (4-Wheel Drive) g226505 Figure 287 1. Rear axle assembly 5. Spacer 2. Clutch locator adapter 6. Flat washer 3. Bolt (2 each) 7. 4. Bi-directional clutch 8. 9. Lock washer (6 each) 10. Socket-head screw (6 each) Lock washer 11. Driveshaft assembly Bolt 12. Bolt (2 each) Removing the Bi-Directional Clutch (4-Wheel Drive) 1.
Installing the Bi-Directional Clutch (4-Wheel Drive) (continued) 6. Fill the clutch with oil to the correct level; refer to the Traction Unit Operator’s Manual.
Servicing the Bi-Directional Clutch (4-Wheel Drive) g226506 Figure 288 1. Oil seal 7. Snap ring 13. Hub 2. Snap ring 8. End plate 14. Needle bearing 3. Bearing housing 9. 4. Roller cage assembly 5. 6. Socket-head screw (6 each) 15. Wave spring 10. Oil seal 16. Oil seal Thrust washer 11. Bearing 17. Bearing Housing 12. Phillips-head screw with O-ring 18. Retaining ring Disassembling the Bi-Directional Clutch (4-Wheel Drive) 1.
Assembling the Bi-Directional Clutch (4-Wheel Drive) (continued) 5. Secure the end plate with the 6 socket-head screws; torque the screws to 19 N·m (14 ft-lb).
Chapter 9 PTO System Table of Contents General Information .............................................................................................................................. 9–2 Service and Repairs ............................................................................................................................. 9–3 PTO Drive Belt ................................................................................................................................... 9–3 PTO Driveshaft .....
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and Repairs PTO Drive Belt g220804 Figure 289 1. 2. Bolt Flat washer (2 each) 6. 7. Muffler mount bracket Kubota diesel engine 11. 12. Bolt Lock washer 3. Compression spring 8. Electric clutch 13. Flat washer 4. Spacer 9. Locknut 14. PTO pulley 5. PTO shaft PTO drive belt 15. PTO tension shaft 10. Note: Refer to the Traction Unit Operator’s Manual for information regarding PTO Belt Adjustment and Installation.
PTO Driveshaft g220803 Figure 290 1. PTO shaft 4. Cutting deck gearbox 7. Cotter pin 2. Bolt (4 each) 5. Roll pin 8. PTO bearing bracket 3. PTO driveshaft 6. Locknut (4 each) WARNING Do not start the engine and engage the PTO switch when the PTO driveshaft is disconnected from the cutting deck (or implement). If you start the engine and the PTO shaft is allowed to rotate, serious personal injury and machine damage could result.
Removing the PTO Driveshaft 1. Park the machine on a level surface, lower the cutting deck (or implement), shut off the engine, set the parking brake, and remove the key from the key switch. 2. Disconnect the end yoke of the PTO driveshaft (item 3 in Figure 290) from the PTO shaft as follows: A. Straighten the cotter pin and remove the cotter pin from the end yoke and PTO shaft. B. Loosen the 2 bolts and 2 locknuts. C. Slide the driveshaft end yoke from the PTO shaft. 3.
Installing the PTO Driveshaft (continued) 3. Secure the end yokes of the PTO driveshaft as follows: A. Install a cotter pin (item 7 in Figure 290) in the end yoke and PTO shaft. B. Install a roll pin (item 5 in Figure 290) in the end yoke and gearbox shaft. C. Install the 4 bolts in the driveshaft end yokes. Alternate direction that the bolt is installed on each yoke. D. Install and tighten the 4 locknuts to secure the end yokes to the gearbox shaft and PTO shaft. 4.
Servicing the PTO Driveshaft Cross and Bearing g221216 Figure 292 1. End yoke 4. Shaft yoke 2. Cross and bearing kit 5. Grease fitting 3. Snap ring (4 each) 1. Remove the PTO driveshaft from the machine; refer to Removing the PTO Driveshaft (page 9–5). 2. Remove the snap rings that secure the bearings in the yokes. IMPORTANT Support the yokes when removing and installing the bearings to prevent damage. 3. Use a press to remove the cross and bearings from the yokes. Clean the driveshaft yokes.
PTO Shaft g220805 Figure 293 1. Bolt 7. PTO tension shaft 13. Flange bearing (2 each) 2. Lock washer 8. Flange nut (8 each) 14. Bolt (2 each) 3. Flat washer 9. Woodruff key 15. Flat washer (4 each) 4. PTO drive belt PTO shaft 16. Rubber mount (2 each) 10. 5. PTO pulley 11. PTO bearing bracket 17. Bolt (4 each) 6. Carriage screw (4 each) 12. Bushing support plate 18.
Removing the PTO Shaft (continued) 4. Remove the rear frame and axle assembly from the machine; refer to Removing the Rear Frame and Axle Assembly (page 7–9). 5. Remove the bolt (item 1 in Figure 293), lock washer, and flat washer that secure the pulley to the PTO shaft. Use a puller, remove the pulley from the PTO shaft. Locate and retrieve the woodruff key. 6. Loosen the set screws that secure the front and rear flange bearing locking collars to the PTO shaft.
Installing the PTO Shaft (continued) 3. Carefully raise the PTO shaft to the machine. 4. Secure the PTO bearing bracket to the frame with the 4 bolts (item 17 in Figure 293) and 4 flange nuts. 5. Secure the rear flange bearing to the PTO tension shaft with the 2 carriage screws (item 6 in Figure 293) and 2 locknuts. 6. Clean the tapers of the PTO shaft and pulley. Apply anti-seize lubricant to the PTO shaft taper. Position the woodruff key into the shaft slot. Install the pulley onto the PTO shaft. 7.
Aligning the PTO Pulley to the Electric Clutch Pulley Checking the Pulley Alignment 1. Park the machine on a level surface, lower the cutting deck (or implement), shut off the engine, set the parking brake, and remove the key from the key switch. Note: Because the clutch pulley and PTO pulley have different thicknesses, check the pulley alignment at the pulley grooves. 2. Measure at the bottom of the pulleys, check that the clutch and PTO pulley grooves are aligned within 1.5 mm (0.06 inch). 3.
PTO System: Service and Repairs Page 9–12 Groundsmaster® 3280-D/3320 05138SL Rev B
Chapter 10 Cutting Units Table of Contents General Information ............................................................................................................................ 10–2 Specifications................................................................................................................................... 10–2 Cutting Unit Operator's Manual ........................................................................................................ 10–2 Troubleshooting...........
General Information g223997 Figure 294 Specifications Several cutting units are available for the Groundsmaster 3280-D and 3320 machines. Refer to the Cutting Unit Operator's Manual for specifications and optional accessories for the cutting unit used on your machine. Note: This chapter gives information about troubleshooting and repair of 72 inch base cutting deck. The 52, 60, 62, and 72 inch side discharge cutting decks, 62 inch base cutting deck information is not covered in this chapter.
Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. The turf conditions such as the excessive thatch, sponginess, or attempting to cut off too much grass height may not always be overcome by adjusting the cutting deck or machine. It is important to remember that the lower the height-of-cut, the more critical these factors are.
Adjustments CAUTION Do not work on the cutting deck 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 deck. Refer to the Cutting Unit Operator’s Manual for adjustment procedures for the cutting unit on the Groundsmaster 3280-D and 3320. Castor Wheel Tire Pressure Castor tires on the cutting deck should be inflated to 345 kPa (50 psi).
Service and Repairs WARNING Do not start the engine and engage the PTO switch when the PTO driveshaft is disconnected from the cutting deck. If you start the engine and the PTO shaft is allowed to rotate, serious personal injury and machine damage could result. If the PTO driveshaft is disconnected from the cutting deck, disconnect the PTO electric clutch electrical connector. CAUTION Do not work on the cutting deck or lift arms with the engine running.
Idler Assembly g223995 Figure 295 1. Grease fitting 5. Torsion spring 2. Snap ring 6. Washer 3. Flange bushing (2 each) 7. 4. Idler arm 8. Cutting Units: Service and Repairs 9. Locknut 10. Idler pulley Drive belt 11. Idler spacer Cutting deck 12.
Removing the Idler Assembly 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the belt covers from the top of the cutting deck. Remove the drive belt from the deck pulleys; refer to the Cutting Unit Operator’s Manual. 3. Insert a nut driver or small piece of pipe onto the torsion spring end of the idler arm. CAUTION The spring is under heavy load and can cause personal injury.
Blade Spindle g223993 Figure 296 1. Idler pulley (2 each) 5. Left spindle assembly 9. 2. Drive pulley 6. Cutting blade (3 each) 10. Center spindle assembly Cutting deck 3. Drive belt 7. Blade bolt (3 each) 11. Right spindle assembly 4. Ribbed neck bolt (8 each per spindle) 8. Anti-scalp cup (3 each) Removing the Blade Spindle 1. Park the machine on a level surface, raise the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch.
Removing the Blade Spindle (continued) 4. Remove the 8 ribbed neck bolts and 8 flange nuts that secure the spindle assembly to the deck, and remove the spindle assembly from the deck. Installing the Blade Spindle g223662 Figure 297 1. Left spindle grease fitting 2. Center spindle grease fitting 3. Right spindle grease fitting 1. Position the spindle on the cutting deck and note the orientation of the grease fitting (Figure 297).
Servicing the Blade Spindle Disassembling the Blade Spindle g223663 Figure 298 1. Locknut 5. Oil seal (2 each) 9. Grease fitting 2. Special hardened washer 6. Bearing spacer 10. Shaft spacer 3. Pulley 7. Ribbed neck bolt (8 each) 11. Spindle shaft 4. O-ring 8. Spindle housing 12. Bearing set 1. Remove the locknut from the top of the spindle shaft. 2. Remove the special hardened washer and pulley from the shaft. 3.
Assembling the Blade Spindle g189007 Figure 299 1. Bearing 3. Large snap ring 2. Spacer ring 4. Inner spacer 5. Outer spacer Note: A replacement spindle bearing set contains 2 bearings, a spacer ring, and a large snap ring (items 1, 2, and 3 in Figure 299). You cannot purchase these parts separately. Also, do not mix the bearing set components from one deck spindle to the another. Note: A replacement bearing spacer set includes the inner spacer and outer spacer (items 4 and 5 in Figure 299).
Assembling the Blade Spindle (continued) g223664 Figure 300 1. Bearing cup 3. Outer spacer 5. Support 2. Large snap ring 4. Arbor press 6. Arbor press base 3. Use an arbor press to push the bearing cups into the top and bottom of the spindle housing (Figure 300). Note: The top bearing cup must contact the outer spacer that was previously installed, and the bottom bearing cup must contact the snap ring.
Assembling the Blade Spindle (continued) 6. Slide the spacer ring and inner bearing spacer into the spindle housing, then install the upper bearing cone and oil seal into the top of the housing. Note: The upper seal must have the lip facing in (down). Also, install upper seal so it is flush to 1.5 mm (0.060 inch) recessed to the housing surface (Figure 301). 7. Examine the spindle shaft and shaft spacer to ensure that there are no burrs or nicks that could damage the oil seals.
Gearbox g223994 Figure 303 1. Mount (4 each) 6. Right gearbox bracket 11. Taper lock bushing 2. Lock washer (4 each) 7. Gearbox 12. Set screw (2 each) 3. Bolt (4 each) 8. Left gearbox bracket 13. Carriage screw (4 each) 4. Flange nut (4 each) 9. Woodruff key 14. Cutting deck 5. Washer (4 each) 10. Drive pulley Removing the Gearbox 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch.
Removing the Gearbox (continued) WARNING Do not start the engine and engage the PTO switch when the PTO driveshaft is disconnected from the cutting deck. If you start the engine and the PTO shaft is allowed to rotate, serious personal injury and machine damage could result. If the PTO driveshaft is disconnected from the cutting deck, disconnect the PTO electric clutch electrical connector. 3. Disconnect the PTO driveshaft from the gearbox; refer to Removing the PTO Driveshaft (page 9–5). 4.
Removing the Gearbox (continued) g223658 Figure 305 1. Oil cap 4. Washer 7. Oil cap 2. Oil seal (2 each) 5. 90° elbow fitting 8. Gearbox 3. Breather plug 6. Plug 9.
Removing the Gearbox (continued) 11. If necessary, remove and replace the oil seals and oil caps in the gearbox (Figure 305). Note: If internal gearbox wear or damage occurs, gearbox replacement is necessary. The internal gearbox components are not available. Installing the Gearbox 1. If oil seals or oil caps were removed from the gearbox, install new seals and caps to the gearbox (Figure 305). 2. Clean the gearbox output shaft, pulley ID (inner diameter), and taper lock bushing. 3.
Castor Forks and Wheels g223659 Figure 306 9. Inner tube 17. Flange bushing (2 each) 10. Castor tire 18. Thrust washer (2 each) Bolt (5 each per arm) 11. Wheel rim half 19. Spacer Bolt 12. Plate 20. Retaining ring 1. Flange nut (5 each per arm) 2. Castor arm (left) 3. 4. 5. Bearing (2 each) 13. Flange nut (4 each) 21. Cap washer 6. Inner bearing spacer 14. Locknut 22. Compression spring 7. Wheel hub 15. Castor fork 23. Cap 8. Wheel rim half 16.
Disassembling the Castor Forks and Wheels 1. Disassemble the castor forks and wheels as necessary (Figure 306). Assembling the Castor Forks and Wheels 1. Assemble the castor forks and wheels. Ensure that the thrust washers (item 18 in Figure 306) are positioned directly above and below the castor arm bushings. 2. If the bearings were removed from the wheel hub, do the following steps: A. Press first bearing into the hub until it contacts the shoulder of the hub. B.
Cutting Deck Rollers and Skids g223660 Figure 307 1. Right skid 5. Carriage screw (4 each) 2. Cutting deck 6. Washer-head screw (2 each) 3. Left skid 7. 4. Flange nut (5 each) 8. 9. Bolt (2 each) 10. Roller Locknut (2 each) 11. Roller shaft Roller (2 each) 12. Flange-head screw Removing the Cutting Deck Rollers and Skids 1. Remove the skids and rollers from the cutting deck (Figure 307). Installing the Cutting Deck Rollers and Skids 1.
Chapter 11 Operator Cab Table of Contents General Information ............................................................................................................................ 11–2 Operator’s Manual ........................................................................................................................... 11–2 Electrical Components and Schematics........................................................................................... 11–2 Cab Heater System......................
General Information The information in this chapter pertains to the operator cab of the Groundsmaster 3280-D machine. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and Repairs Roof Assembly g243575 Figure 308 1. Washer-head screw (16 each) 6. Flat washer (22 each) 11. Cab strap (2 each) 2. Roof cover 7. Short roof strap (2 each) 12. Headliner assembly 3. Short side cover seal (2 each) 8. Flange nut (38 each) 13. Long side cover seal (2 each) 4. Roof 5. Shoulder screw (22 each) 9. Long roof strap (2 each) 10. Side cab strap (2 each) Get access to the heater core components by removing the roof.
Removing the Roof Assembly 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the 16 washer-head screws (item 1 in Figure 308) that secure the roof cover, cover seals, and roof straps to the roof. 3. Remove the 22 shoulder screws (item 5 in Figure 308), 22 flat washers, and 22 flange nuts that secure the roof and cab straps to the headliner. 4. Carefully lift the roof from the headliner and cab. 5.
Heating Components g243012 Figure 309 1. Right intake air filter 3. Heater valve 2. Left intake air filter 4. Mixing box assembly Groundsmaster® 3280-D/3320 05138SL Rev B Page 11–5 5.
Heating Components (continued) g243014 Figure 310 1. Heater core 2. Blower fan 3. Air diverter assembly Get access to the cab heating components by removing the cab roof; refer to Removing the Roof Assembly (page 11–4). After you remove the cab roof, refer to Figure 309 and Figure 310 to identify the components used for heating the operator cab.
Mixing Box Assembly g243574 Figure 311 1. Rivet (19 each) 8. Air diverter assembly 15. Vent hose (left) 22. Tube support (2 each) 2. Mixing box cover 9. Support plate 16. Hose clamp (2 each) 23. Vent hose (right defrost) 3. Cover insulation 10. Flange nut (4 each) 17. Mixing box inlet foam 24. Vent hose (center) 4. Flat washer (4 each) 11. Hose clamp (7 each) 18. Flat washer (2 each) 25. Vent hose (right) 5. Hairpin cotter (4 each) 12. Tube support (4 each) 19.
Removing the Mixing Box Assembly 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the roof from the top of the cab to get access to the mixing box assembly; refer to Removing the Roof Assembly (page 11–4). 3. Remove the cover from the mixing box assembly as follows: A. Carefully use a small prybar to raise the head of the pin in the center of each rivet that secures the mixing box cover. B.
Installing the Mixing Box Assembly (continued) 4. Operate the heater system to ensure that there are no coolant leaks in the cab headliner. 5. When you complete all the service in the cab headliner, secure the roof to the top of the cab; refer to Installing the Roof Assembly (page 11–4).
Heater Core g243783 Figure 313 1. Rivet (19 each) 6. Mount bracket 11. Cover gasket 2. Mixing box cover 7. Tap screw (11 each) 12. Mount bracket cover 13. Blower fan 3. Cover insulation 8. Gasket (6 each) 4. Air diverter assembly 9. Heater core 5. Mixing box 10. Heater core mount bracket (2 each) Note: The heater core can be removed and installed with the mixing box (item 5 in Figure 313) attached to the cab headliner. Removing the Heater Core 1.
Removing the Heater Core (continued) 4. Remove the mixing box cover as follows: A. Carefully use a small prybar to raise the head of the pin in the center of each rivet that secures the mixing box cover. B. Lift the rivets from the cover and mixing box. C. Remove the mixing box cover. 5. Remove the 7 tap screws (item 7 in Figure 313) that secure the mount bracket cover to the mount bracket. Lift the cover and position it away from the mount bracket. 6. Carefully lift the heater core from the mount bracket.
Blower Fan g243780 Figure 314 1. Rivet (19 each) 4. Air diverter assembly 7. Blower fan 2. Mixing box cover 5. Mixing box 8. Heater core assembly 3. Cover insulation 6. Tap screw (6 each) Note: The blower fan can be removed and installed with the mixing box (item 5 in Figure 314) attached to the cab headliner. Removing the Blower Fan 1. Park the machine on a level surface, lower the cutting deck, shut of the engine, set the parking brake, and remove the key from the key switch. 2.
Removing the Blower Fan (continued) C. Remove the mixing box cover. g243781 Figure 315 1. Terminal 3 (orange) 2. Terminal 2 (brown) 3. MIN terminal (violet) 4. Ground terminal (black) 5. Note the location of the wire harness connectors on the blower fan assembly (Figure 315), disconnect the wire harness connectors from the fan. 6. Carefully raise the heater core assembly with attached blower fan from the mixing box. 7.
Windshield Wiper Assembly g243015 Figure 316 1. Bolt 6. Wiper motor 11. Wiper arm assembly 2. Lock washer 7. Flange nut (4 each) 12. Lock washer (2 each) 3. Flange nut (2 each) 8. Cab headliner 13. Screw (2 each) Washer plate 14. Wiper blade 4. Wiper bracket 5. Washer-head screw (2 each) 9. 10. Washer-head screw (4 each) Disassembling the Windshield Wiper Assembly 1.
Assembling the Windshield Wiper Assembly 1. If necessary, install the wiper motor components that were removed (Figure 316) and do the following: A. If the wiper bracket (item 4 in Figure 316) was removed, apply bead of RTV sealant around the wiper opening on inside of the headliner before you install the bracket. B. Ensure that the wiper motor electrical connector is secured to the cab wire harness. C. Secure the roof to the top of the cab; refer to Installing the Roof Assembly (page 11–4). 2.
Operator Cab: Service and Repairs Page 11–16 Groundsmaster® 3280-D/3320 05138SL Rev B
Appendix A Foldout Drawings Table of Contents Appendix A ...........................................................................................................................................A–1 Electrical Drawing Designations ........................................................................................................A–3 Hydraulic Schematic-3280-D (Serial Numbers below 270000400) and 3320 (Serial Numbers below 280000000) .....................................................................
Wire Harness Diagram-Light Kit Model 30405 (Machines without Cab)............................................A–39 Wire Harness Drawing-North American Light Kit Model 30701 (Machines Serial Number 315000000 and Up) .........................................................................................................................A–40 Wire Harness Diagram-North American Light Kit Model 30701 (Machines Serial Number 315000000 and Up) ........................................................................
Electrical Drawing Designations Note: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire harness diagram (e.g., SP01 is splice number 1). Wire Color The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter.
Foldout Drawings Page A–4 Groundsmaster® 3280-D/3320 05138SL Rev B
Hydraulic Schematic-3280-D (Serial Numbers below 270000400) and 3320 (Serial Numbers below 280000000) g243931 Groundsmaster 3280-D/3320, Drawing 108-2091 Rev -, Sheet 1 of 1 05138SL Rev B Page A–5
Hydraulic Schematic-3280-D (Serial Numbers 270000400 to 311000000) and 3320 (Serial Numbers 280000000 to 311000000) g243930 Page A–6 05138SL Rev B Groundsmaster 3280-D/3320, Drawing 114-2878 Rev C, Sheet 1 of 1
Hydraulic Schematic-3280-D (Serial Numbers 311000001 through 316000000) g243933 Groundsmaster 3280-D, Drawing 120-6589 Rev A, Sheet 1 of 1 05138SL Rev B Page A–7
Hydraulic Schematic-3280-D (Machine Serial Numbers after 316000000) g226776 Page A–8 05138SL Rev B Groundsmaster 3280-D, Drawing 133-6390 Rev B, Sheet 1 of 1
Electrical Schematic-3320 6 5 4 3 2 1 D D C C B B A A 6 5 4 3 2 1 g231003 Groundsmaster 3320, Drawing 108-2006 Rev A, Sheet 1 of 1 05138SL Rev B Page A–9
Electrical Schematic (Machine Serial Number before 311000000) g231002 Page A–10 05138SL Rev B Groundsmaster 3280-D, Drawing 108-2007 Rev C, Sheet 1 of 1
Electrical Schematic (Machine Serial Number 311000000 and Up) g243927 Groundsmaster 3280-D, Drawing 119-5771 Rev A, Sheet 1 of 1 05138SL Rev B Page A–11
Electrical Schematic-Operator Cab g226449 Page A–12 05138SL Rev B Operator Cab, Drawing 122-0426 Rev A, Sheet 1 of 2
Electrical Schematic-Operator Cab g226450 Operator Cab, Drawing 122-0426 Rev A, Sheet 2 of 2 05138SL Rev B Page A–13
Wire Harness Drawing-Main-3320 (Serial Numbers below 260000000) g231009 Page A–14 05138SL Rev B Groundsmaster 3320, Drawing 108-2019 Rev F, Sheet 1 of 2
Wire Harness Diagram-Main-3320 (Serial Numbers below 260000000) g231010 Groundsmaster 3320, Drawing 108-2019 Rev F, Sheet 2 of 2 05138SL Rev B Page A–15
Wire Harness Drawing-Main-3320 (Serial Numbers above 260000000) 6 5 4 3 2 1 D D C C B B A A 6 5 4 3 2 1 g231011 Page A–16 05138SL Rev B Groundsmaster 3320, Drawing 110-1684 Rev F, Sheet 1 of 2
Wire Harness Diagram-Main-3320 (Serial Numbers above 260000000) g231012 Groundsmaster 3320, Drawing 110-1684 Rev F, Sheet 2 of 2 05138SL Rev B Page A–17
Wire Harness Drawing-Main-3280-D (Serial Numbers below 260000000) g231005 Page A–18 05138SL Rev B Groundsmaster 3280-D, Drawing 108-2020 Rev D, Sheet 1 of 2
Wire Harness Diagram-Main-3280-D (Serial Numbers below 260000000) g231006 Groundsmaster 3280-D, Drawing 108-2020 Rev D, Sheet 2 of 2 05138SL Rev B Page A–19
Wire Harness Drawing-Main-3280-D (Machine Serial Number 260000000 to 270000600) g231007 Page A–20 05138SL Rev B Groundsmaster 3280-D, Drawing 110-1686 Rev E, Sheet 1 of 2
Wire Harness Diagram-Main-3280-D (Machine Serial Number 260000000 to 270000600) g231008 Groundsmaster 3280-D, Drawing 110-1686 Rev E, Sheet 2 of 2 05138SL Rev B Page A–21
Wire Harness Drawing-Main-3280-D (Machine Serial Number 270000601 to 311000000) g246496 Page A–22 05138SL Rev B Groundsmaster 3280-D, Drawing 114-3398 Rev C, Sheet 1 of 2
Wire Harness Diagram-Main-3280-D (Machine Serial Number 270000601 to 311000000) g246497 Groundsmaster 3280-D, Drawing 114-3398 Rev C, Sheet 2 of 2 05138SL Rev B Page A–23
Wire Harness Drawing-Main-3280-D (Machine Serial Number 311000000 to 316000000) g243935 Page A–24 05138SL Rev B Groundsmaster 3280-D, Drawing 119-5772 Rev C, Sheet 1 of 2
Wire Harness Diagram-Main-3280-D (Machine Serial Number 311000000 to 316000000) g243936 Groundsmaster 3280-D, Drawing 119-5772 Rev C, Sheet 2 of 2 05138SL Rev B Page A–25
Wire Harness Drawing-Main-3280-D (Machine Serial Number 316000000 to 400000000) g243937 Page A–26 05138SL Rev B Groundsmaster 3280-D, Drawing 122-0703 Rev C, Sheet 1 of 2
Wire Harness Diagram-Main-3280-D (Machine Serial Number 316000000 to 400000000) g243938 Groundsmaster 3280-D, Drawing 122-0703 Rev C, Sheet 2 of 2 05138SL Rev B Page A–27
Wire Harness Drawing-Main-3280-D (Machine Serial Number 400000000 and Up) g226777 Page A–28 05138SL Rev B Groundsmaster 3280-D, Drawing 122-0987 Rev B, Sheet 1 of 2
Wire Harness Diagram-Main-3280-D (Machine Serial Number 400000000 and Up) g226778 Groundsmaster 3280-D, Drawing 122-0987 Rev B, Sheet 2 of 2 05138SL Rev B Page A–29
Wire Harness Drawing-Cab Model 30298 Power 6 5 4 3 2 1 D D C C B B A A 6 5 4 3 2 1 g243941 Page A–30 05138SL Rev B Cab Model 30298 Power, Drawing 122-0387 Rev A, Sheet 1 of 2
Wire Harness Diagram-Cab Model 30298 Power g243942 Cab Model 30298 Power, Drawing 122-0387 Rev A, Sheet 2 of 2 05138SL Rev B Page A–31
Wire Harness Drawing-Cab Model 30298 Headliner g243429 Page A–32 05138SL Rev B Cab Model 30298 Headliner, Drawing 122-0723 Rev B, Sheet 1 of 2
Wire Harness Diagram-Cab Model 30298 Headliner g243430 Cab Model 30298 Headliner, Drawing 122-0723 Rev B, Sheet 2 of 2 05138SL Rev B Page A–33
Wire Harness Drawing-Cab Model 30298 Front Mount Accessory Power Supply g243939 Page A–34 05138SL Rev B Cab Model 30298 Front Mount Accessory Power Supply, Drawing 122-0158 Rev A, Sheet 1 of 2
Wire Harness Diagram-Cab Model 30298 Front Mount Accessory Power Supply g243940 Cab Model 30298 Front Mount Accessory Power Supply, Drawing 122-0158 Rev A, Sheet 2 of 2 05138SL Rev B Page A–35
Wire Harness Drawing-Cab Model 30298 Heat/Air Conditioning Blower g243427 Page A–36 05138SL Rev B Cab Model 30298 Heat/Air Conditioning Blower, Drawing 122-0153 Rev B, Sheet 1 of 2
Wire Harness Diagram-Cab Model 30298 Heat/Air Conditioning Blower g243428 Cab Model 30298 Heat/Air Conditioning Blower, Drawing 122-0153 Rev B, Sheet 2 of 2 05138SL Rev B Page A–37
Wire Harness Drawing-Light Kit Model 30405 (Machines without Cab) g226451 Page A–38 05138SL Rev B Light Kit Model 30405, Drawing 120-3983 Rev A, Sheet 1 of 2
Wire Harness Diagram-Light Kit Model 30405 (Machines without Cab) g226452 Light Kit Model 30405, Drawing 120-3983 Rev A, Sheet 2 of 2 05138SL Rev B Page A–39
Wire Harness Drawing-North American Light Kit Model 30701 (Machines Serial Number 315000000 and Up) 6 5 4 3 2 1 D D C C B B A A 6 5 4 3 2 1 g226453 Page A–40 05138SL Rev B North American Light Kit Model 30701, Drawing 122-0668 Rev A, Sheet 1 of 2
Wire Harness Diagram-North American Light Kit Model 30701 (Machines Serial Number 315000000 and Up) g226454 North American Light Kit Model 30701, Drawing 122-0668 Rev A, Sheet 2 of 2 05138SL Rev B Page A–41
