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Toro
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30403
Toro 30403 Service Manual
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Service
and
Repairs
PT
O
Drive
Belt
g220804
Figure
289
1.
Bolt
6.
Muf
er
mount
bracket
1
1.
Bolt
2.
Flat
washer
(2
each)
7.
Kubota
diesel
engine
12.
Lock
washer
3.
Compression
spring
8.
Electric
clutch
13.
Flat
washer
4.
Spacer
9.
Locknut
14.
PT
O
pulley
5.
PT
O
shaft
10.
PTO
drive
belt
15.
PTO
tension
shaft
Note:
Refer
to
the
T
raction
Unit
Operator
’s
Manual
for
information
regarding
PTO
Belt
Adjustment
and
Installation.
Groundsmaster
®
3280-D/3320
Page
9–3
PTO
System:
Service
and
Repairs
05138SL
Rev
B
420
422
Table of Contents
Table of Contents
7
Chapter 1: Safety
11
Safety Instructions
12
Jacking Instructions
16
Safety and Instructional Decals
16
Chapter 2: Specifications and Maintenance
17
Specifications
18
Torque Specifications
21
Shop Supplies
27
Special Tools
29
Specifications
31
Specifications
33
Chapter 3: Gasoline Engine
35
Specifications
36
General Information
38
Adjustments
40
Service and Repairs
43
Chapter 4: Diesel Engine
57
Specifications
58
General Information
60
Adjustments
62
Service and Repairs
63
Table of Contents
85
Default Chapter
86
Service and Repairs
86
Chapter 5 :Hydraulicsystem
87
Specifications
87
Groundsmaster 3280-D and 3320-G
87
General Information
88
Checking the Hydraulic Fluid
88
Pushing or Towing the Traction Unit
89
Releasing Pressure from the Hydraulic System
90
Traction Circuit Component Failure
91
Hydraulic Hoses
92
Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting)
93
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port)
95
Hydraulic Schematics
99
Hydraulic Flow Diagrams
103
Traction Circuit (Machine Serial Number below 316000000)
103
Traction Circuit (Machine Serial Number above 316000000)
108
Lift Circuit (Machine Serial Number below 311000000)
111
Lift Circuit (Machine Serial Number above 311000000)
115
Steering Circuit (Machine Serial Number below 316000000)
119
Steering Circuit (Machine Serial Number above 316000000)
121
Special Tools
123
Hydraulic Pressure Testing Kit
123
GPM Hydraulic Tester Kit (Pressure and Flow)
123
GPM Hydraulic Tester (Pressure and Flow)
124
Hydraulic Hose Kit
124
Hydraulic Test Fitting Kit
125
O-Ring Kit
126
High Flow Hydraulic Filter Kit
126
Remote Starter Switch
127
Troubleshooting
128
General Hydraulic System Problems
128
Traction Circuit Problems
129
Lift/Lower Circuit Problems
130
Steering Circuit Problems
130
Testing the Hydraulic System
131
Charge Pressure Test (Using Pressure Gauge) (Machine Serial Numbers below 316000000)
133
Implement Relief Pressure Test (Using Pressure Gauge) (Machine Serial Numbers below 316000000)
135
Lift Cylinder Internal Leakage Test (Machine Serial Numbers below 316000000)
137
Steering Cylinder Internal Leakage Test (Machine Serial Numbers below 316000000)
139
Charge Pump Flow Test (Using Tester with Pressure Gauges and Flow Meter) (Machine Serial Numbers below 316000000)
141
Testing the Traction Circuit-Charge Pressure (Machine Serial Numbers above 316000000)
143
Testing the Traction Circuit-Hydraulic Pump Flow and Relief Pressure (Machine Serial Numbers above 316000000)
146
Testing the Steering Circuit-Steering Control Valve, Relief Valve Pressure, and Steering Cylinder (Machine Serial Numbers above 316000000)
150
Testing the Steering Circuit-Charge Pump Flow (Machine Serial Numbers above 316000000)
153
Testing the Lift Circuit-Lift Cylinder Internal Leakage (Machine Serial Numbers above 316000000)
156
Adjustments
159
Traction Pedal Friction Wheel (Machine Serial Number below 316000000)
159
Service and Repairs
161
General Precautions for Removing and Installing the Hydraulic System Components
161
Checking the Hydraulic Lines and Hoses
162
Priming the Hydraulic Pump
163
Flushing the Hydraulic System
164
Filtering the Closed-Loop Traction Circuit (Machine Serial Number above 316000000)
166
Charging the Hydraulic System
169
Transmission Driveshaft (Machine Serial Numbers below 316000000)
171
Hydrostatic Transmission (Machine Serial Numbers below 316000000)
174
Servicing the Hydrostatic Transmission (Machine Serial Numbers below 316000000)
177
Hydrostatic Transmission Neutral Arm Assembly (Machine Serial Number below 316000000)
179
Hydraulic Pump Driveshaft (Machine Serial Number above 316000000)
181
Hydraulic Pump (Machine Serial Number above 316000000)
184
Servicing the Hydraulic Pump (Machine Serial Number above 316000000)
187
Traction Neutral Arm Assembly (Machine Serial Number above 316000000)
189
Front Axle Drive Motor (Machine Serial Number above 316000000)
191
Servicing the Front Axle Drive Motor (Machine Serial Number above 316000000)
193
Lift Cylinder
194
Steering Control Valve
197
Servicing the Steering Control Valve
200
Steering Cylinder (2-Wheel Drive)
201
Servicing the Steering Cylinder (2-Wheel Drive)
204
Steering Cylinder (4-Wheel Drive)
207
Servicing the Steering Cylinder (4-Wheel Drive)
209
Lift Control Valve (Machine Serial Numbers below 316000000)
211
Servicing the Lift Control Valve (Machine Serial Numbers below 311000000)
214
Counterbalance Valve Manifold (Machine Serial Numbers below 311000000) (if Equipped)
217
Lift Control Valve (Machine Serial Number above 311000000)
220
Servicing the Lift Control Valve (Machine Serial Number above 311000000)
223
Oil Cooler (Groundsmaster 3280-D)
226
Table of Contents
229
Chapter 6: Electrical System
230
General Information
231
Electrical Schematics and Wire Harness Drawings/Diagrams
231
Standard Control Module (SCM)
231
Standard Control Module Logic Chart
233
Special Tools
235
Multimeter
235
Terminal Protector
235
Battery Hydrometer
235
Dielectric Gel
236
Troubleshooting
237
Electrical System Quick Checks
243
Testing the Battery (Open Circuit Test)
243
Testing the Charging System
243
Testing the Glow Plug System (Groundsmaster 3280-D)
244
Checking the Operation of the Interlock Switches
244
Adjustments
245
Parking Brake Switch
247
Testing the Electrical Components
248
Fusible Link Harness
248
Fuses (Machine Serial Number below 400000000)
250
Fuses (Machine Serial Number above 400000000)
251
Operator Cab Fuses (Machines with Operator Cab)
253
Key Switch
255
Indicator Lights
257
Hour Meter
259
PTO Switch
260
Deck Lift Switch (Machine Serial Numbers above 311000000)
262
Seat Switch
264
Windshield Washer/Wiper Switch (Machines with Operator Cab)
266
Fan Speed Switch (Machines with Operator Cab)
270
Work Light Switch (Machines with Operator Cab-Optional)
272
Traction Neutral Switch (Machine Serial Numbers below 316000000)
274
Traction Neutral Sensor (Machine Serial Number above 316000000)
276
High Temperature Warning Switch
280
High Temperature Shutdown Switch
283
Engine Oil Pressure Switch
286
Relays (Groundsmaster 3280-D)
288
Lift Control Valve Solenoid Valve Coil (Machine Serial Number above 311000000)
291
PTO Electric Clutch
293
Fuel Stop Solenoid (Groundsmaster 3280-D)
294
Glow Controller (Groundsmaster 3280-D)
296
Fuel Pump (Groundsmaster 3280-D)
298
Fuel Pump (Groundsmaster 3320)
301
Fuel Pump Relay (Groundsmaster 3320)
303
Service and Repairs
304
Table of Contents
315
Chapter 7 :Chassis
316
Specifications
316
General Information
317
Service and Repairs
318
Wheels
318
Steering Column
320
Rear Frame and Axle Assembly
323
Chapter 8: Drive Axles
325
Rear Axle (2-Wheel Drive)
325
Servicing the Rear Axle (2-Wheel Drive)
327
Rear Wheel Bearings (2-Wheel Drive)
331
Operator Seat
333
Mechanical Seat Suspension
335
Pneumatic Seat Suspension
338
Lift Arms
340
Table of Contents
343
Specifications
344
General Information
345
Front Axle
345
4-Wheel Drive Rear Axle
345
Special Tools
347
Differential Gear Holder
347
Service and Repairs
348
Servicing the Brake
348
Front Axle Shafts and Bearings
350
Front Axle (Machine Serial Number before 316000000)
358
Front Axle (Machine Serial Number after 316000000)
361
Servicing the Front Axle
364
Ring to Pinion Gear Engagement (Front Axle)
382
Rear Axle Driveshaft (4-Wheel Drive)
385
Servicing the Rear Axle Driveshaft Cross and Bearing (4-Wheel Drive)
387
Rear Axle (4-Wheel Drive)
388
Bevel Gear Case and Axle Case (4-Wheel Drive Axle)
391
Service and Repairs
392
Differential Shafts (4-Wheel Drive Axle)
399
Axle Shafts (4-Wheel Drive Axle)
401
Input Shaft/Pinion Gear (4-Wheel Drive Axle)
403
Differential Gear Assembly (4-Wheel Drive Axle)
406
Pinion Gear to Ring Gear Engagement (4-Wheel Drive Axle)
412
Bi-Directional Clutch (4-Wheel Drive)
415
Servicing the Bi-Directional Clutch (4-Wheel Drive)
417
General Information
419
Chapter 9 :Ptosystem
420
General Information
420
Service and Repairs
421
PTO Drive Belt
421
PTO Driveshaft
422
Servicing the PTO Driveshaft Cross and Bearing
425
PTO Shaft
426
Aligning the PTO Pulley to the Electric Clutch Pulley
429
Table of Contents
431
Chapter 10 :Cuttingunits
432
General Information
432
Specifications
432
Cutting Unit Operator's Manual
432
Troubleshooting
433
Factors that Can Affect Quality of Cut
433
Adjustments
434
Castor Wheel Tire Pressure
434
Service and Repairs
435
Cutting Deck
436
Idler Assembly
436
Blade Spindle
438
Servicing the Blade Spindle
440
Gearbox
444
Castor Forks and Wheels
448
Cutting Deck Rollers and Skids
450
General Information/Service and Repairs
451
General Information
452
Operator's Manual
452
Electrical Components and Schematics
452
Cab Heater System
452
Service and Repairs
453
Roof Assembly
453
Heating Components
455
Mixing Box Assembly
457
Heater Core
458
Blower Fan
462
Windshield Wiper Assembly
464
Appendix A
467
Electrical Drawing Designations
469
Hydraulic Schematic-3280-D (Serial Numbers below 270000400) and 3320 (Serial Numbers below 280000000
471
Hydraulic Schematic-3280-D (Serial Numbers 270000400 to 311000000) and 3320 (Serial Numbers 280000000 to 311000000
472
Hydraulic Schematic-3280-D (Serial Numbers 311000001 through 316000000
473
Hydraulic Schematic-3280-D (Machine Serial Numbers after 316000000
474
Electrical Schematic-3320
475
Electrical Schematic (Machine Serial Number before 311000000
476
Electrical Schematic (Machine Serial Number 311000000 and up
477
Electrical Schematic-Operator Cab
478
Electrical Schematic-Operator Cab
479
Wire Harness Drawing-Main-3320 (Serial Numbers below 260000000
480
Wire Harness Diagram-Main-3320 (Serial Numbers below 260000000
481
Wire Harness Drawing-Main-3320 (Serial Numbers above 260000000
482
Wire Harness Diagram-Main-3320 (Serial Numbers above 260000000
483
Wire Harness Drawing-Main-3280-D (Serial Numbers below 260000000)
484
Wire Harness Diagram-Main-3280-D (Serial Numbers below 260000000
485
Wire Harness Drawing-Main-3280-D (Machine Serial Number 260000000 to 270000600
486
Wire Harness Diagram-Main-3280-D (Machine Serial Number 260000000 to 270000600
487
Wire Harness Drawing-Main-3280-D (Machine Serial Number 270000601 to 311000000
488
Wire Harness Diagram-Main-3280-D (Machine Serial Number 270000601 to 311000000
489
Wire Harness Drawing-Main-3280-D (Machine Serial Number 311000000 to 316000000
490
Wire Harness Diagram-Main-3280-D (Machine Serial Number 311000000 to 316000000
491
Wire Harness Drawing-Main-3280-D (Machine Serial Number 316000000 to 400000000
492
Wire Harness Diagram-Main-3280-D (Machine Serial Number 316000000 to 400000000
493
Wire Harness Drawing-Main-3280-D (Machine Serial Number 400000000 and up
494
Wire Harness Diagram-Main-3280-D (Machine Serial Number 400000000 and up
495
Wire Harness Drawing-Cab Model 30298 Power
496
Wire Harness Diagram-Cab Model 30298 Power
497
Wire Harness Drawing-Cab Model 30298 Headliner
498
Wire Harness Diagram-Cab Model 30298 Headliner
499
Wire Harness Drawing-Cab Model 30298 Front Mount Accessory Power Supply
500
Wire Harness Diagram-Cab Model 30298 Front Mount Accessory Power Supply
501
Wire Harness Drawing-Cab Model 30298 Heat/Air Conditioning Blower
502
Wire Harness Diagram-Cab Model 30298 Heat/Air Conditioning Blower
503
Wire Harness Drawing-Light Kit Model 30405 (Machines Without Cab
504
Other manuals for Toro 30403
Operator's Manual
72 pages
Installation Instructions
2 pages
4
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Toro 30403 Specifications
General
Brand
Toro
Model
30403
Category
Lawn Mower
Language
English
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