Page 1: Service Manual
Groundsmaster 328-D Preface Use this book along with the Toro Operator’s Manual and Parts Catalog for the specific model and serial number of the machine, and the Kubota 05 Series Workshop Manual This publication will provide the service technician with...
Page 3 Table Of Contents Chapter 1 - Safety Chapter 6 - Electrical System Safety Instructions ......1 - 1 Wiring Schematics .
Page 4 Chapter 11 - 72″ Cutting Units Specifications ......11 - 2 General Information..... . 11 - 3 Troubleshooting .
Page 5: Safety Instructions
While Operating......2 Safety Instructions The Groundsmaster 300 Series was tested and certified by TORO for compliance with the B71.4 1984 specifica- tions of the American National Standards Institute.
Page 6 10. Sit on the seat when starting the engine and oper- If movement is evident, the neutral return mecha- ating the machine. nism is adjusted incorrectly. Shut engine off and adjust until machine does not move when traction 11. On machines equipped with roll-over protection pedal is released.
Page 7 If major repairs are ever needed or before applying pressure to the system. assistance is desired, contact an Authorized TORO Distributor. 36. Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure.
Page 8 Replacement parts and accessories ence to perform the job. Have it done by your Toro made by other manufacturers may result in non confor- Distributor or a qualified tire service.
Page 9 Chapter 2 Product Records and Manuals Table of Contents PRODUCT RECORD FORM ....1 TORQUE SPECIFICATIONS ....3 EQUIVALENTS AND CONVERSIONS .
Page 10: Equivalents And Conversions
Equivalents and Conversions Decimal and Millimeter Equivalents ___________________________________________________________________________________________________ Fractions Decimals Fractions Decimals ___________________________________________________________________________________________________ 1/64 0.015625 — 0.397 33/64 0.515625 — 13.097 1/32 ––––– 0.03125 — 0.794 17/32 –––– 0.53125 — 13.494 3/64 0.046875 — 1.191 35/64 0.546875 — 13.891 1/16 –––––––––––– 0.0625 —...
Page 11: Torque Specifications
Torque Specifications Use these torque values when specific torque values specified values. Torque values listed are for lubricated are not given. DO NOT use these values in place of threads. Plated threads are considered to be lubricated. Capscrew Markings and Torque Values - U.S. Customary SAE Grade Number ___________________________________________________________ __________...
Page 12 ® Torque Specifications Page 2 - 4 Rev. A Groundsmaster 300 Series...
Page 13 Drive Axle(s) Numbers: ____________________ Date Purchased: ____________________ Warranty Expires__________ Purchased From: ____________________ ____________________ ____________________ Contacts: Parts ____________________ Phone __________________ Service ____________________ Phone __________________ Sales ____________________ Phone __________________ See your TORO Distributor/Dealer for other Publications, Manuals, and Videos from The TORO Company.
Page 14 ® GROUNDSMASTER 345 Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Maintenance Interval & Service Every Every Every Check Battery Fluid Level Every 400hrs 200hrs 100hrs 50hrs Check Battery Cable Connections Lubricate All Grease Fittings Lubricate Brake Cables Check Cutting Unit Gear Box Oil Level Clean Under Cutting Unit Belt Covers Check Cutting Unit Drive Belt Adjustment Check PTO Belt Adjustment...
Page 15 GROUNDSMASTER® 345 Daily Maintenance Check List Unit Designation:__________ Daily Maintenance: TORO ID#:_______-_______ (duplicate this page for routine use) Daily Maintenance Check For Week Of _____________ TUES THURS _____ _____ _____ _____ _____ _____ _____ Maintenance Check Item Safety Interlock Operation...
Page 17 Drive Axle(s) Numbers: ____________________ Date Purchased: ____________________ Warranty Expires__________ Purchased From: ____________________ ____________________ ____________________ Contacts: Parts ____________________ Phone __________________ Service ____________________ Phone __________________ Sales ____________________ Phone __________________ See your TORO Distributor/Dealer for other Publications, Manuals, and Videos from The TORO Company.
Page 18 ® GROUNDSMASTER 322-D and 325-D Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Maintenance Interval & Service Every Every Every Check Battery Fluid and Cable Connections Every 400hrs 200hrs 100hrs 50hrs Lubricate Grease Fittings Lubricate Brake Cables Check Cutting Unit Gear Box Oil Level Clean Under Cutting Unit Belt Covers Check Cutting Unit Drive Belt Adjustment Change Engine Oil...
Page 19 ® GROUNDSMASTER 322-D and 325-D Daily Maintenance Check List Unit Designation:__________ Daily Maintenance: TORO ID#:_______-_______ (duplicate this page for routine use) Daily Maintenance Check For Week Of _____________ TUES THURS _____ _____ _____ _____ _____ _____ _____ Maintenance Check Item...
Page 21: Table Of Contents
Chapter 3 (For Groundsmaster 345 only) Ford VSG-411 Engine Table of Contents SPECIFICATIONS ......1 REPAIRS .
Page 22: Spark Plug Inspection And Replacement
General Information Spark Plug Inspection and Replacement Since air gap between center and side electrodes in- creases gradually during normal engine operation, check condition of electrodes at 100 hour intervals. The correct spark plugs to use in the engine are Motor- craft AGSF22C or AGRF22 or equivalent.
Page 23: Adjustments
Adjustments Alternator Belt Adjustment (Fig. 1) A new alternator belt is to be tensioned to 65 lbs. A used belt is to be re-tensioned to 40 lbs. 1. To adjustable tension, loosen bolt securing brace to engine, bolt securing alternator to brace and alternator mounting bolts.
Page 24: Governor Adjustment
Governor Adjustment (Fig. 3, 4) 1. With engine shut off, move throttle contro to FAST position and open hood. Check between throttle arm and stop on carburetor base to make sure there is a 1/32 in. (0.8 mm) gap. If gap s not correct, adjust throttle rod by turning ball joint ends until gap is 1/32 in.
Page 25 5. Release throttle arm, loosen jam nut on governor low idle stop screw and adjust it to get 1500 ± 100 rpm. Tighten jam nut. 6. Slowly move throttle to FAST position until engine speed reaches 3200 ± 100 rpm. Shut off engine. Adjust high idle stop screw until it contacts speed control lever.
Page 26: Repairs
Repairs Crankshaft Pulley Installation 1. Insert three of four locking rings into crankshaft pulley. NOTE: Outside locking rings have tapered I.D. and flat O.D. Inside locking rings have flat I.D. and tapered O.D. A. Install first outside ring seated against small inter- nal shoulder of pulley, flat edge of ring touching small pulley shoulder.
Page 27: Engine Removal And Installation
Engine Removal and Installation Removing the Engine 14. Remove fuel line from inlet side of fuel pump. 1. Put machine on a level surface, stop engine, remove NOTE: Be prepared to insert a plug into fuel line to key from ignition switch and engage parking brake. prevent fuel spill.
Page 28: Engine Repair Information
Engine Repair Information Ford VSG-411 Component Changes Ford VSG-411 engines with a date code of 2D21 or later have five (5) main bearings, which is the same design used on the VSG-413 engine. VSG-411 engines pro- duced before this date have four (4) main bearings (see Page 1-01, under IDENTIFICATION in the Ford VSG-411/413 Engine Service Manual for an explana- tion of Ford corporate date system).
Page 29 Table of Contents along with the Kubota 05 Series Workshop Manual (Toro Part No. 01090SL). INTRODUCTION ......2 Stop Solenoid Replacement .
Page 30: Introduction
Limited. Service and repair parts for Mitsubishi engines are supplied through TORO Distributors. Repair parts may be ordered by TORO Part Number. If no parts list is available be sure to provide your dealer or distributor with the TORO Model Number and Serial Number.
Page 31: Specifications
Specifications The illustrations (Figs. 2a and 2b) give information about Refer to the specifications listed in this section when the general construction of the engine. performing tests on the engine or examining parts for wear. Some specifications are included in the service procedures later in this chapter.
Page 32: General
General ________________________________________________________________________________________________________________________________________________________ Item Specification ________________________________________________________________________________________________________________________________________________________ Make/Designation Mitsubishi K3D-61TG, overhead valve, vertical in-line, 4 cycle diesel ________________________________________________________________________________________________________________________________________________________ Rotation Counterclockwise at flywheel side ________________________________________________________________________________________________________________________________________________________ Combustion Chamber Swirl chamber type ________________________________________________________________________________________________________________________________________________________ Number of Cylinders ________________________________________________________________________________________________________________________________________________________ Bore x Stroke 73 x 78 mm (2.9 x 3.1 in.) ________________________________________________________________________________________________________________________________________________________ Total Displacement 0.979 liter (59.7 in.
Page 33: Engine
Engine ________________________________________________________________________________________________________________________________________________________ Item Standard Specification Repair Limit Service Limit ________________________________________________________________________________________________________________________________________________________ Governor Mechanical/Centrifugal ________________________________________________________________________________________________________________________________________________________ ± 50 rpm Operating Speed (no load) 3200 rpm ________________________________________________________________________________________________________________________________________________________ ± 50 rpm Idle Speed (no load) 1500 rpm ________________________________________________________________________________________________________________________________________________________ Compression 32 kg/cm (455 psi) at 280 rpm 26 kg/cm (370 psi) 22 kg/cm...
Page 34 Engine (cont.) ________________________________________________________________________________________________________________________________________________________ Item Standard Specification Repair Limit Service Limit ________________________________________________________________________________________________________________________________________________________ Piston Type Solid Material Aluminum alloy Piston Outside Diameter (skirt end) 73 mm (2.874 in.) Piston to Cylinder Wall Clearance 0.3 mm (0.012 in.) Oversize 0.25, 0.50, 0.75 mm (0.01, 0.02, 0.03 in.) ________________________________________________________________________________________________________________________________________________________ Piston Pin...
Page 35: Lubrication System
Engine (cont.) ________________________________________________________________________________________________________________________________________________________ Item Standard Specification Repair Limit Service Limit ________________________________________________________________________________________________________________________________________________________ Main Bearings Oil Clearance 0.10 mm (0.004 in.) Undersize 0.25, 0.50, 0.75 mm (0.01, 0.02, 0.03 in.) ________________________________________________________________________________________________________________________________________________________ Camshaft Drive System Gear Journal to Cylinder Block Hole Clearance 0.15 mm (0.006 in.) Cam Lobe Height 35.76 mm (1.401 in.) –...
Page 36: Fuel System
Fuel System ________________________________________________________________________________________________________________________________________________________ Item Standard Specification Repair Limit Service Limit ________________________________________________________________________________________________________________________________________________________ Fuel Pump Delivery Rate 225 cc (13.73 in ) or more (15 sec., 12V) ________________________________________________________________________________________________________________________________________________________ Fuel Injection Pump Model MD-PER3M ± 2 Injection Timing (B.T.D.C.) B.T.D.C. (at smoke set position ________________________________________________________________________________________________________________________________________________________ Nozzles Type...
Page 37: Electrical System
Electrical System ________________________________________________________________________________________________________________________________________________________ Item Standard Specification Repair Limit Service Limit ________________________________________________________________________________________________________________________________________________________ Starter Type Solenoid shift type Nominal Output 2.0 kW - 12V Direction of Rotation Clockwise as viewed from pinion side No-load Characteristics (Cold) Terminal Voltage/Current 11V/130A max. at 20°C (68°F) Speed 3850 rpm min.
Page 38: Tightening Torque
Tightening Torque The Mitsubishi diesel engine has many bolts and cap- the engine. The torque specifications in American screws of special materials and sizes. It is very impor- Standard and Metric as listed below MUST be followed tant that special care be used to replace all bolts and in order to have the assembled engine conform to the capscrews in their proper location during assembly of original specifications.
Page 39: Special Tools
Special Tools Order special tools from T O R O S P E C IA L T O O L S A N D A P P L IC AT IO N S G U ID E (C o m m e rcial P ro d u c ts). Some tools may be available from a local supplier.
Page 40 Nozzle Tester (Fig. 7) Nozzle tester tests condition and opening pressure of fuel injector nozzles. Figure 7 Nozzle Tester Adapter (Fig. 8) Nozzle tester adapter is required to test the fuel injection nozzles. Figure 8 Camshaft Bushing Tool (Fig. 9) The camshaft bushing removal and installation tool is used in conjunction with a soft metal hammer to remove or install the camshaft bushing in the Mitsubishi K3D...
Page 41: Adjustments
Adjustments Valve Clearance (Fig. 10, 11, 12) Check the valve clearance after the first 50 hours of operation and every 400 hours of operation after that. 1. The engine must be cold when the valve clearance is checked. 2. Remove the air breather hose from the rocker cover. 3.
Page 42: Engine Speed Adjustments
Engine Speed Adjustments (Fig. 13, 14) Adjustments to the engine speed settings are not nor- Idle Speed Adjustment mally necessary unless the throttle linkage, injection pump, or governor mechanism have been repaired, NOTE: Specified engine rpm is with no load on engine. rebuilt, replaced or are not operating correctly.
Page 43: Throttle Linkage Adjustment
Throttle Linkage Adjustment (Fig. 15) 1. Loosen the capscrew and nut securing the throttle cable to throttle lever. 2. Push the governor lever all the way back so it is contacting the high speed set screw. 3. Move the throttle lever to the maximum speed posi- tion (all the way forward).
Page 44 ® Troubleshooting Page 4 - 16 Groundsmaster 300 Series...
Page 45 ® Groundsmaster 300 Series Page 4 - 17 Troubleshooting...
Page 46: Testing
Testing Glow Plug Test (Fig. 16) Be careful while handling or testing glow plugs. Glow plugs become extremely hot. Ac- cidental contact with the heated plug tip could cause personal in ury. 1. Disconnect the wire lead(s) to the glow plug. 2.
Page 47: Compression Test
Compression Test (Fig. 17) Normal cylinder compression is 32 kg/cm (455 psi) at 280 rpm (normal cranking speed). The engine should be warm - coolant temperature of 50 C (120 IMPORTANT: DO NOT put oil into the combustion chamber before performing a compression test. Damage may result because of “hydraulic”...
Page 48: Nozzle Tests
Nozzle Tests (Fig. 18, 19) There are several tests to examine the condition of the 3. Allow pressure to dissipate before performing the test. injection nozzles. These tests require the use of a nozzle tester and nozzle tester adapter. (See the Spe- 4.
Page 49 6. While pressure is being applied, watch for an accu- mulation of fuel at the tip of the nozzle (Fig. 18). A small amount of fuel may be present due to a previous chat- tering test - this would be normal. If the fuel accumulates and drips down during the test (about ten seconds) the nozzle assembly is defective and must be replaced.
Page 50: Injection Pump Test
Injection Pump Test Calibration of fuel delivery volumes, pressure and dis- D. Put the throttle control in the FAST position. Turn tribution between pump barrels should be performed by the ignition key to the START position to crank the a professional diesel engine service shop. Special test engine.
Page 51: Injection Timing Test
Injection Timing Test (Fig. 20, 21) Injection timing can be adjusted by installing shims 7. Standard injection timing can be confirmed by the IT under the pump body. The timing is important because marks on the crankshaft pulley and the stationary it determines when the fuel enters the combustion pointer on the crankcase (Fig.
Page 52: Fuel Pump Test
Fuel Pump Test (Fig. 22) 1. Turn the ignition switch to the ON position. Test for pump operation by listening for the pump oscillating sound, or by feeling for vibration which indicates the pump is operating. 2. If no pumping action occurs when the ignition switch is turned on, connect a 12 volt DC battery directly to the pump (Fig.
Page 53: Preparation For Engine Repair
Preparation for Engine Repair 1. Before cleaning and disassembly, carefully check for engine oil to disassembled parts, as necessary to pre- problems that cannot be found after the engine has vent rust. been cleaned or disassembled (e.g. oil leaks from cracked components, gaskets or loose fittings, dam- 5.
Page 54: External Engine Component Repair
External Engine Component Repair In this section, repairs to the external engine compo- Crankcase Breather nents will be outlined. These are repairs which can be Fan, Pulley, Bearing and Shaft Repair or Replacement accomplished without removing the engine from the Oil Pressure Switch Replacement mower frame.
Page 55: Alternator Belt Service
Alternator Belt Service (Fig. 25) 1. Unlatch and open hood. 2. Check tension by depressing belt midway between alternator and crankshaft pulleys. Belt should deflect 7/16 in. (11 mm). If deflection is incorrect, proceed to step 3. If correct, continue operation. 3.
Page 56: Fan, Fan Pulley And Fan Shaft Service
Fan, Fan Pulley and Fan Shaft Service (Fig. 27) Fan Assembly Removal Fan Assembly Inspection 1. Park the machine on a level surface, turn engine off, 1. Inspect fan for cracks; replace fan if damaged. remove key from switch, and apply the parking brake. 2.
Page 57 6. Install new cotter pins through slotted nut and fan shaft to retain both pulley and fan hub. 7. Reinstall fan assembly onto engine by performing re - moval steps 1 through 8 in reverse order. Groundsmaster 300 Series External Engine Component Repair Page 4 – 28.1 Rev. D...
Page 58 This page is intentionally blank. External Engine Components Repair Groundsmaster 300 Series Page 4 – 28.2 Rev. D...
Page 59: Glow Plug Replacement
Glow Plug Replacement If a glow plug has been determined to be defective by 3. Remove the defective glow plug from its mounting failing the glow plug test, it should be replaced. hole. 1. Remove the nut and lead wire. 4.
Page 60: Oil Pump Servicing
Oil Pump Servicing The oil pump is a trochoid gear type pump, mounted to the rear of the fuel injection pump, and driven by the fuel injection pump camshaft. The pump houses a check valve which opens to the oil pan when the pump delivery pressure exceeds 57 psi (393 kPa), thereby preventing excessive oil pressure.
Page 61 Oil Pump Reassembly (Fig. 33) 1. Install the Plunger, Spring, Gasket and Plug of the Oil Relief Valve into the Pump Cover. 2. Verify that the dowel pins are in place, and install the 0-ring in the pump body (if replaced or removed). 3.
Page 62: Stop Solenoid Replacement
Stop Solenoid Replacement (Fig. 34) The Mitsubishi engine uses an electrical solenoid to shut off the fuel supply and stop the engine. An emer- gency stop lever is provided in case the stop solenoid fails. If a solenoid failure is suspected, it can be checked by attaching 12 VDC battery leads to the solenoid terminals.
Page 63: Water Pump Servicing
Water Pump Servicing The water pump is a centrifugal impeller type pump Water Pump Inspection which is mounted on the front upper part of the cylinder block. The pump bearings and seals are not service- 1. Inspect all hoses for cracks or leaks. able.
Page 64: Bleeding The Fuel System
Fuel System Service When cleaning the engine, DO NOT spray water onto a tolerance parts of the fuel system can be easily dam- hot injection pump. This could cause the fuel pump to aged by dirt. seize and be damaged. Wash fuel system parts in clean fresh diesel fuel.
Page 65: Bleeding Air From The Injectors
Bleeding Air From the Injectors (Fig. 37) This procedure should only be used if the fuel system has been purged of air. (See Bleeding the Fuel System in this section of the book.) 1. Loosen the pipe connection at the number 1 nozzle and holder assembly on the cylinder head .
Page 66 5. Carefully remove the spring retainer from the end of the plunger tube. Remove the washer, o-ring, valve, plunger spring and plunger. IMPORTANT: Be careful not to bend or deform the plunger tube while disassembling the fuel pump. If the plunger tube is bent, the fuel pump plunger will bind and the pump will need to be replaced.
Page 67: Governor Mechanism Operation
Governor Mechanism Operation Operation of the governor keeps the engine speed through the tie rod, in the direction that decreases the constant as the centrifugal force acting on the governor amount of fuel delivered by the injection pump. A leaf weights balances with the tension of the governor spring on the tie rod cover is used to prevent stalling spring.
Page 68: Injection Pump Servicing
Injection Pump Servicing (Fig. 41) A built-in three-cylinder injection pump is mounted on the right-hand side of the cylinder block. It consists of a pump element (plunger and barrel assem- bly), a delivery valve, a tappet and a smoke set unit. As the pump cam rotates, the plunger is moved up and down through a prescribed stroke, delivering fuel to the engine cylinders.
Page 69 Control Rack Smoke Set and Ungleich Device (Fig. 42, 43, 44) The injection pump on the is equipped with a mecha- nism that allows for over injection of fuel during starting, and thereafter limits the amount of fuel delivered during operation to reduce excessive exhaust smoke.
Page 70 Delivery Valve Operation (Fig. 45) The delivery valve serves two functions. First, the valve opens to deliver fuel to the delivery pipe when the pressure generated by the stroke of the plunger within the barrel is sufficiently high. The pressure must be high enough to cause the injector nozzle to open.
Page 71 Injection Pump Disassembly (Fig. 47) The injection pump may be disassembled to replace worn, damaged or defective components according to the following procedures: IMPORTANT: Clean external engine area near injec- tion pump before disassembly. Do not spray water on a hot injection pump. Do not remove Inter-cylin- der adjusting plates unless necessary.
Page 72 Injection Pump Inspection (Fig. 48) 1. Inspect the contact surfaces of the delivery valve seat. Replace the Delivery Valve Assembly if defective. 2. Inspect the plunger and barrel for wear, damage or rust. Check to see that the plunger slides smoothly in the barrel.
Page 73 6. Install the upper spring seat and spring. 7. Assemble the lower spring seat to the plunger. Insert the plunger into the barrel with the side of the plunger collar marked “L” towards the control rack. NOTE: the collar and pinion are designed to prevent incorrect installation.
Page 74 Injection Pump Pressure and Delivery Rate Injection pump pressure and the delivery rate of the pump, as well as inter-cylinder delivery rates must be determined by the use of specialized equipment. If difficulties with the injection pump are suspected the help of a competent diesel engine service shop should be sought.
Page 75: Nozzle Servicing
Nozzle Servicing (Fig. 51) The fuel from the injection pump flows through the 2. Remove carbon or lacquer deposits from the nozzle injection pipes to the nozzle. During the injection stroke by cleaning in clean diesel fuel. Stubborn deposits may of the pump, pressurized fuel builds up in the nozzle.
Page 76: Removing And Installing The Engine
Removing and Installing the Engine Removing the Engine 1. Put machine on a level surface, stop engine, remove NOTE: Be prepared to insert a plug into fuel line to key from ignition switch and engage parking brake. prevent fuel spill. 2.
Page 77: Cylinder Head Overhaul
Cylinder Head Overhaul This section explains disassembly, inspection, repair, IMPORTANT: When overhauling the cylinder head and reassembly of the cylinder head and its compo- and cylinder block it is important that many of the nents as outlined below: components be reinstalled in the exact location from where they were removed.
Page 78: Cylinder Head Servicing
Cylinder Head Servicing (Fig. 54) 1. Use a spring compressor to compress the valve springs. Remove the retainer locks (keepers), retainers, and valve springs. Place each part in a holder or rack so that they can be replaced in their original position. 2.
Page 79: Valve Guides
Valve Guides (Fig. 55) If the valve guide clearance, after cleaning, exceeds the specifications in step 6 above, they must be replaced. 1. Remove the existing valve guide by pressing it up- ward using a valve guide removing mandrel with a pilot section.
Page 80: Valve Seats
Valve Seats (Fig. 57, 58) 1. Check the valve seat for damage and signs of incor- rect contact. 2. If the valve seat is defective, the seat can be re-cut to the dimensions shown. 3. After cutting new valve seats, lap the valve to the seat using the lapping compound.
Page 81: Valve Springs
Valve Springs (Fig. 59) 1. Check the valve springs for rust, pitting, cracks or other damage. 2. Check the squareness of the valve spring by placing it upright on a level surface. Springs may be out of square by 1.5 degrees. Springs that are out of square by 3 degrees or more must be replaced.
Page 82: Cylinder Head Reassembly And Installation
Cylinder Head Reassembly and Installation (Fig. 61, 62, 63) 1. Ensure that the valve guides are properly installed. 2. Install the valve stem seal onto the valve guide securely. 3. Apply a coating of oil to the valve stems and insert them in proper order, into the valve guides.
Page 83: Cylinder Block Overhaul
Cylinder Block Overhaul This section outlines procedures for disassembly, in- spection, repair and reassembly of the cylinder block and its components, as outlined below: Cylinder Block Disassembly Camshaft Service Injection Pump Camshaft Service Crankshaft Bearings Timing Gears Connecting Rods and Bearings Cylinders Oversized Pistons, Cylinder Bore and Rings Piston and Pin Replacement...
Page 84 14. Remove the ring ridge from each cylinder using a ridge removing tool. This will prevent damage to the rings and pistons. Remove the connecting rod cap nuts and then remove the bearing caps. Place these parts in cylinder number order. Remove the pistons and con- necting rods by pushing them up from the bottom of the block.
Page 85: Camshaft And Bearing
Camshaft and Bearing (Fig. 65, 66) 1. Inspect the camshaft for evidence of severe wear. 2. Using a micrometer and a hole gauge, measure the clearance between the camshaft journals and the cylin- der block. If the clearance is greater than 0.0059 inch (0.15 mm) the camshaft or the camshaft bushing must be replaced.
Page 86: Crankshaft Bearings
Crankshaft Bearings (Fig. 68, 69) 1. Measure the crankshaft for “run-out” (bend). Mount the crankshaft in a pair of V-blocks (or live centers) and use a dial indicator to measure the run-out in the crank- shaft. The maximum allowable crankshaft run-out is .0012 inch (0.03 mm).
Page 87: Connecting Rod And Connecting Rod Bearings
Connecting Rod and Connecting Rod Bearings (Fig. 71) 1. Check for bending or distortion of the connecting rod. If excessive, replace the rod (0.002 inch or 0.05 mm max.). 2. Assemble each connecting rod to the crankshaft in their proper order. Use a feeler gauge to measure the connecting rod thrust clearance between the connect- ing rod and crankshaft.
Page 88: Oversized Pistons, Cylinder Bore And Rings
Oversized Pistons, Cylinder Bore and Rings (Fig. 73, 74, 75) 1. Check the piston for wear, signs of seizure or nicks. Replace it if it is defective. 2. Measure the piston outside diameter. If the clearance between the piston and the cylinder exceeds 0.01 18 in. (.3 mm), replace the piston.
Page 89: Piston And Pin Replacement
Piston and Pin Replacement (Fig. 76) To remove a piston from its connecting rod, use the piston pin tool (see Special Tools section) to press the pin from the connecting rod. IMPORTANT: Do not attempt to remove the piston pins by driving them out with a hammer. A stuck piston pin, requiring excessive pressure to remove, should be replaced.
Page 90 Engine Reassembly Procedures Follow the procedures listed below in reassembling the engine. 1. Install the camshaft bushing. Figure 77 Installing camshaft bushing 2. Install the main bearings to the cylinder block and main bearing cap. Ensure that these are in proper position.
Page 91 6. Apply sealant to the outside surface of the front and rear side seals. The side seals are installed with the radius towards the outside of the engine. Figure 80 Installing bearing side cap seals Figure 81 Direction of side seal installation 7.
Page 92 NOTE: Before insertion apply engine oil to the piston pin O.D. and the connecting rod small end inside diameter. 10. To assemble the piston to the connecting rod, press the piston pin into the set position. Use the piston pin setting tool.
Page 93 12. Insert the piston and connecting rod assembly into the cylinder block using a ring compressor and a wooden block. After insertion into the cylinder, properly install the connecting rod bearings and rod caps and tighten the bolts to the specified torque. NOTE: The bearing assembly grooves in the connecting rod cap should be on the same side when assembled.
Page 94 29. Install the front gear case and gasket, using PER- MATEX No. 2 on gasket surfaces. When installing the gear case insert the tie rod and tie rod stopper spring into the hole in the cylinder block under injection pump. Install the crankshaft pulley and key.
Page 95 TORO Distributors. bleshooting, testing, disassembly and assembly is iden- Repair parts may be ordered by TORO part number. If tified in the Kubota 05 Series Service Manual (Toro part no parts list is available be sure to provide your Distribu- 01090SL).
Page 96 Engine Oil See Operator’s Manual Oil Capacity 4 U.S. quart (3.8 liter) with filter Starter 12 VDC, 1.4 KW Alternator/Regulator 12 VDC, 40 AMP Dry Weight 205.0 lbs (93.0 kg) Page 4A – 2 Rev. G Specifications Groundsmaster 300 Series...
Page 97 Chapter 5 Hydraulic System Table of Contents SPECIFICATIONS ......2 REPAIRS ....... . 26 Hydraulic Oil .
Page 98: Specifications
Specifications Item Description Standard ________________________________________________________________________________________________________________________ ________________________________ Transmission Sauer-Sundstrand 15 Series In-line Operating Pressure 500 to 5200 PSI Charge pressure 70 - 150 PSI Implement relief pressure 700 to 900 PSI Forward traction relief pressure (4WD only) 5200 PSI ________________________________________________________________________________________________________________________ ________________________________ Oil filter 25 micron rated, screw-on type ________________________________________________________________________________________________________________________ ________________________________...
Page 99: Hydraulic Hoses
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as, pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage condi- WARNING tions or mishandling during operation or maintenance. These conditions can cause damage or premature Before disconnecting or performing any work deterioration.
Page 100 SAE Straight Thread O-Ring Port (Non-adjustable) 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O-ring seal when this type of fitting shows signs of leakage. 3. Lubricate the O-ring with a light coating of oil. O-Ring 4.
Page 101 Pushing or Towing (Fig. 6) In an emergency, the traction unit can be pushed or towed for a very short distance. However, Toro does not recommend this as a standard procedure. IMPORTANT: Do not push to tow the traction unit faster than 2 to 3 mph because the transmission may be damaged.
Page 102: Hydraulic Schematics
Hydraulic Schematics 2 Wheel Drive Traction Unit 4 Wheel Drive Traction Unit ® Hydraulic Schematics Page 5 - 6 Groundsmaster 300 Series...
Page 103: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams Forward Traction Operation The hydrostatic transmission consists of a charge pump, variable dis- placement pump and a fixed displacement motor. The diagram shows flow of the hydraulic oil during forward operation. ® Groundsmaster 300 Series Page 5 - 7 Hydraulic Flow Diagrams...
Page 104: Raising The Cutting Unit
Raising the Cutting Unit The charge pump supplies oil through the “AUX” port of the steering valve to the lift valve. When the lift lever is actuated to raise the cutting unit, oil supplied by the charge pump is directed out the work port of the lift valve to the barrel end of the lift cylinder. Oil displaced from the rod end of the cylinders goes through the oil cooler and back to reservoir.
Page 105: Turning Steering Wheel To Right
Turning Steering Wheel to Right When the steering wheel is turned to the right the control valve within the steering valve shifts to close the “AUX” port. This directs oil supplied by the charge pump to the metering section of the steering valve. As the steering wheel turns, oil is metered out port “RT” to the steering cylinder.
Page 106: Special Tools
Special Tools NOTE: Order special tools from the TORO SPECIAL Catalog for your Toro equipment. Some tools may also TOOLS AND APPLICATIONS GUIDE (COMMERCIAL be available from a local supplier. PRODUCTS) . Some tools may be listed in the Parts Hydraulic Pressure Gauges (Fig.
Page 107 4. HIGH PRESSURE GAUGE: High range gauge to for this tester to use it on current models of the accommodate pressure beyond the capacity of the low Groundsmaster 300 Series. pressure gauge, 0 - 5000. 1. INLET HOSE: Hose connected from the system 5.
Page 108: Troubleshooting
Troubleshooting The cause of an improperly functioning hydraulic sys- The charts that follow contain detailed information to tem is best diagnosed with the use of proper testing assist in troubleshooting. There may possibly be more equipment and a thorough understanding of the com- than one cause for a machine malfunction.
Page 109 System Operates Hot Check Check Check radiator, Inspect Inspect lift Check for kinked Inspect engine hydraulic screen, fan, by-pass lever latch or severely bent acceleration oil level fan belt and valve position hose or tubing valves coolant level Defective Incorrect Kinked or bent Defective Open or defective...
Page 110 Loss Of Power Or Unit Will Not Operate In Either Direction Check Check Check Inspect Inspect Inspect traction Check charge engine engine to hydraulic by-pass inlet control linkage pump transmission oil level valve filter pressure/flow coupler Disconnected or damaged Open or defective Loose or clogged Loose or defective Adjust,...
Page 111 Inspect lift Inspect Check Inspect Check lift arm valve control engine underside of hydraulic linkage pivots cutting unit oil level Binding, broken Excess debris Binding or out of adjustment Adjust, Lubricate Lubricate Fill to Clean proper tachometer repair repair level Check charge Inspect pump...
Page 112 Check steering Check High Steering Effort linkage for binding hydraulic or damage oil level Defective Fill to Repair proper level Check charge Inspect pump transmission pressure/flow inlet filter Loose or clogged Repair or replace Inspect Inspect Test Tighten transmission charge implement steering (pump &...
Page 113 Steering Wander or Shimmy Inspect for loose Air in hydraulic Inspect steering or worn steering system cylinder for internal linkage leakage Defective Defective Defective Repair linkage and Bleed air from Replace steering adjust toe-in hydraulic system cylinder ® Groundsmaster 300 Series Page 5 - 17 Troubleshooting...
Page 114: Testing
Testing The most effective method for isolating problems in the 1. Thoroughly clean the machine before disconnecting hydraulic system is by using hydraulic test equipment or disassembling any hydraulic components. Always such as pressure gauges and flow meters in the circuits keep in mind the need for cleanliness when working on during various operational checks.
Page 115: Test No. 1: Charge Pressure
TEST NO. 1: Charge Pressure (Fig. 9) Using a low pressure gauge: 0 - 1000 psi NOTE: If adding shims to the relief valve does not increase the pressure, inspect the condition of the 1. Engage the parking brake, and block the front wheels charge pump gerotor and internal housing.
Page 116: Test No. 2: Implement Relief Pressure
TEST NO. 2: Implement Relief Pressure (Fig. 9) Using a low pressure gauge: 0 - 1000 psi hydraulic circuit. This is can be caused by parts that are binding or build up of debris under the cutting unit. This 1. Perform steps 1 - 7 under Charge Pressure Test. adds to the amount of force that the hydraulic cylinder must overcome.
Page 117: Test No. 3: Traction Pressure
TEST NO. 3: Traction Pressure (Fig. 10) Using a high pressure gauge: 0 - 5000 psi CAUTION Failure to use a high pressure gauge 0 - 5000 psi during this traction pressure test could result in damage to the gauge and possible personal in ury due to leaking, hot oil.
Page 118: Test No. 4: Charge Pump Flow And Implement Relief Pressure
TEST NO. 4: Charge Pump Flow and Implement Relief Pressure (Fig. 11) Using a hydraulic tester with flow meter If adding shims to the relief valve does not increase the pressure, inspect the condition of the charge pump 1. Engage the parking brake and block the front wheels gerotor and internal housing.
Page 119: Adjustments
1. Loosen two nuts securing traction pedal shaft on right 3. Tighten nuts to secure shaft and wheel in position. side of pedal. 2. Rotate shaft to relocate worn surface of friction wheel away from underside of traction pedal. Groundsmaster 300 Series Page 5 – 23 Rev. G Adjustments...
Page 120: Traction Control Neutral Adjustment
A. Ball bearing is loose or worn. B. Plunger on interlock switch is sticking. C. Fasteners on pump control assembly are loose or missing. Page 5 - - 24 Adjustments Rev. I Groundsmaster 300 Series...
Page 121: Lift Lever Latch Adjustment
Lift Lever Latch Adjustment (Fig. 14) A lift lever latch that is positioned incorrectly can cause the lift lever to hold the spool in an actuated position when the implement is in the FLOAT position. This causes oil in the hydraulic system to overheat. When lift lever latch is adjusted correctly, the lift lever should just clear the rounded part of the latch as lever is moved into FLOAT position.
Page 122: Repairs
Repairs Transmission Trunnion Seal Replacement (Fig. 15) 1. Remove the control lever and the interlock switch assembly from the trunnion shaft on the right side of the transmission. 2. Remove the snap ring from the end of trunnion shaft and slide the flat washer off of the shaft. Using a seal puller;...
Page 123: Transmission By-Pass Valve
Transmission By-Pass Valve (Fig. 16) 1. Place a drain pan below the by-pass valve. 2. Remove the by-pass valve assembly from the center section by turning it counterclockwise. Some oil may flow into the drain pan. 3. Inspect the threads on the by-pass valve. Replace the valve if the threads are damaged.
Page 124: Transmission Acceleration Valves
Transmission Acceleration Valves (Fig. 17) 1 . Place a drain pan below the acceleration valves. 2. Remove both acceleration valve plugs and O-rings from the sides of the center section. Some oil may flow into the drain pan. 3. Slide the acceleration valve and spring out of the center section.
Page 125: Transmission Implement Relief Valve
Transmission Implement Relief Valve (Fig. 18) 1. Place a drain pan below the implement relief valve. 2. Remove the implement relief plug and O-ring from the side of the pump housing. Slide the shim pack, spring and cone out of the pump housing. Some oil may flow out of the transmission.
Page 126: Transmission Charge Relief Valve
Transmission Charge Relief Valve (Fig. 19) 1 . Place a drain pan below the charge relief valve. 2. Remove the charge relief plug and O-ring from the side of the pump housing. Slide the shim pack, spring and ball or cone out of the housing. Some oil may flow out of the transmission.
Page 127: Transmission Charge Pump
Transmission Charge Pump (Fig. 20, 21) 1. Remove the drive coupling from between the engine pulley and the transmission hub; refer to "Removing Drive Coupling" in Chapter 10. 2. Remove the taper lock (if applicable) and the hub from the transmission shaft. 3.
Page 128 8. Examine the bearing in the charge pump housing for damage and free rotation. If the bearing is damaged, replace the bearing and seal. 9. To assemble the charge pump, install a new O-ring into the groove in charge pump housing. 10.
Page 129: Transmission Removal And Installation
Transmission Removal and Installation 1. Position the machine on a level surface in a clean 7. Loosen and remove the engine to transmission area of the workshop.Block all four wheels of the unit to coupler; refer to "Removing Drive Coupling" of Chapter prevent it from moving.
Page 130: Transmission Overhaul
Transmission Overhaul As the transmission components are removed for ser- by a minimum amount of polishing or touch lapping; vice and inspection, it should be noted that nominal rework and use them again. wear to the components is acceptable. Critical contact surfaces (i.e.
Page 131: Transmission Pump Section
Transmission Pump Section (Fig. 24, 25, 26, 27) 1. Separate the pump housing from the center section; refer to "Separating Transmission Into Sections,". 2. Lift the cylinder block assembly out of the pump housing. Do not be concerned if the pistons come out of the cylinder block because they do not have a special order in the cylinder block NOTE: Since the entire cylinder block assembly must...
Page 132 10. Clean and inspect the following parts: be 1/4 inch below the surface of the swash plate. Make sure the swash plate swings freely; 15 A. Thrust Plate - Check both sides for damage and degrees to each side of center. flatness.
Page 133: Transmission Center Section
Transmission Center Section (Fig. 28) 1 . Separate the center section from the motor and pump NOTE: Replace any defective parts. The slotted plugs, housings; refer to "Separating Transmission Into valve springs, and check balls are interchangeable. Sections". 6. If the needle bearings were removed, press new 2.
Page 134: Transmission Motor Section
Transmission Motor Section (Fig. 29, 30) 1. Separate the motor housing from the center section; NOTE: Make sure the splines at the end of the motor refer to "Separating Transmission Into Sections". shaft are toward the flange side of the motor housing. 2.
Page 135: Assembling Transmission Sections
Assembling Transmission Sections (Fig. 31, 32) 1. Apply transmission oil on both sides of the center section. Place the gaskets in position against the pump and motor sides of the center section. NOTE: The transmission oil should hold the gaskets against the sides of the center section.
Page 136: Priming After Transmission Overhaul Or Replacement
Priming After Transmission Overhaul Or Replacement Use the following procedures to prime the hydraulic 4. Start the engine and operate the traction and lift system whenever the Sundstrand Transmission is over- system controls for approximately five minutes. Then hauled or replaced: turn the engine off.
Page 137: Lift Cylinder Removal And Installation
9. NOTE: The hydraulic fitting elbow located at the back of the lift cylinder has a special orifice size to determine the actuation speed of the cylinder. Always use the proper Toro replacement part for this fitting to prevent damage to the hydraulic system. ®...
Page 138: Lift Cylinder Repair
Lift Cylinder Repair (Fig. 34) Pump the oil out of the cylinder into a drain pan by 10. Use a new seal kit (Items 3, 6 - 10) to replace all moving the piston back and forth. O-rings, seals and back-up rings. 1.
Page 139: Lift Valve Removal And Installation
Lift Valve Removal and Installation (Fig. 35) 1. Unscrew the ball from the lift lever. 2. Remove the self-tapping screws and lift the cover off of the lift lever to expose the valve. 3. Loosen and remove the hydraulic lines that are attached to the valve.
Page 140: Lift Valve Repair
Lift Valve Repair (Fig. 36) 1. After removing the control valve assembly, wash the valve in solvent and dry it thoroughly. 2. Carefully mount the control valve into a vise so that the control valve mounting pads are against the jaws of the vise.
Page 141 Chapter 6 Electrical System Table of Contents WIRING SCHEMATICS ..... . 2 Glow Plugs ..22 (Groundsmaster 322-D/325-D only) Groundsmaster 345.
Page 142: Wiring Schematics
Wiring Schematics Groundmaster 345 (Serial Number less than 40000) Rev. E Groundsmaster 300 Series Page 6 − 2 Wiring Schematics...
Page 143: Groundsmaster 345
Groundmaster 345 (Serial Number 40001 to 200999999) Rev. E Groundsmaster 300 Series Page 6 − 2.1 Wiring Schematics...
Page 144 Groundmaster 345 (Serial Number higher than 21000000) Rev. E Groundsmaster 300 Series Page 6 − 2.2 Wiring Schematics...
Page 145: Groundsmaster 322-D/325-D
Groundmaster 322−D/325−D (Serial Number less than 20000000) Groundsmaster 300 Series Rev. E Page 6 − 3 Wiring Schematics...
Page 146 Groundmaster 345 (Serial Number higher than 21000000) Groundsmaster 300 Series Rev. E Page 6 − 3.1 Wiring Schematics...
Page 147 Groundmaster 322−D/325−D (Serial Number less than 20000000) Groundsmaster 300 Series Rev. E Page 6 − 3.2 Wiring Schematics...
Page 148 Groundmaster 322−D/325−D (Serial Number more than 20000000) Groundsmaster 300 Series Rev. E Page 6 − 3.3 Wiring Schematics...
Page 149 Groundmaster 328−D Groundsmaster 300 Series Rev. E Page 6 − 3.4 Wiring Schematics...
Page 150: Special Tools
Special Tools NOTE: Order special tools from the TO R O S P E C IA L TO O L S A N D A P P L IC AT IO N S G U ID E (C O M M E R C IA L P R O D U C T S ).
Page 151 Skin-Over Grease (Fig. 3) Special non-conductive grease which forms a light pro- tective skin to help waterproof electrical switches and contacts. Figure 3 ® Groundsmaster 300 Series Page 6 - 5 Special Tools...
Page 152: Troubleshooting (Groundsmaster 345)
Troubleshooting (Groundsmaster 345) Study the operating characteristics preceding the elec- trical failure to help identify the area of difficulty. Try to isolate the failure to a specific functional system; then CAUTION check that area, repairing one component at a time. Attempting to repair more than one system at one time Remove all jewelry, especially rings and will lead to confusion.
Page 153: Starting Problems
Starting Problems (continued) Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Nothing happens when start Battery is dead. Charge battery. Replace battery if attempt is made. it will not hold a charge. Loose or corroded battery cables. Clean and tighten or repair as Loose or corroded ground.
Page 154 Starting Problems (continued) Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Engine cranks, but does not start. Engine wiring connector or wires Repair wiring. loose, corroded or damaged. Temp. gauge switch faulty. Test temp. gauge switch and replace if faulty. Temp. relay faulty. Test temp.
Page 155: Operation Problems
Operation Problems Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Engine continues to run (but Seat switch plunger depressed Check for seat support spring should not) when traction pedal is with no operator on seat. that is broken, missing or stuck in depressed with no operator on down position.
Page 156 Operation Problems (continued) Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Engine continues to run (but Seat switch plunger depressed Check for seat support spring should not) when PTO is ON with with no operator on seat. that is broken, missing or stuck in no operator on the seat.
Page 157: Verify Interlock Operation
Verify Interlock System Operation The machine has interlock switches in the electrical 2. Sit on seat. Move PTO lever to ON position. With the system. These switches are designed to stop the engine traction pedal in neutral position, try to start the engine. when operator gets off the seat while either the PTO The engine should not crank.
Page 158: Troubleshooting (Groundsmaster 322-D/325-D)
Troubleshooting (Groundsmaster 322-D/325-D) Study the operating characteristics preceding the elec- trical failure to help identify the area of difficulty. Try to isolate the failure to a specific functional system; then CAUTION check that area, repairing one component at a time. Attempting to repair more than one system at one time Remove all jewelry, especially rings and will lead to confusion.
Page 159 Starting Problems (continued) Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Nothing happens when start Battery is dead. Charge battery. Replace battery if attempt is made. it will not hold a charge. Loose or corroded battery cables. Clean and tighten or repair as Loose or corroded ground.
Page 160 Starting Problems (continued) Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Engine cranks, but does not start Glow plugs not used properly Use glow plugs to pre-heat (if engine cranks, cause of before starting. engine cylinders before and problem is not in interlock during cold starting.
Page 161: Operation Problems
Operation Problems Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Engine continues to run (but Seat switch plunger depressed Check for seat support spring should not) when traction pedal is with no operator on seat. that is broken, missing or stuck in depressed with no operator on down position.
Page 162 Operation Problems (continued) Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Engine continues to run (but Seat switch plunger depressed Check for seat support spring should not) when PTO is ON with with no operator on seat. that is broken, missing or stuck in no operator on the seat.
Page 163: Verify Interlock Operation
Verify Interlock System Operation The machine has interlock switches in the electrical 2. Sit on seat. Move PTO lever to ON position. With the system. These switches are designed to stop the engine traction pedal in neutral position, try to start the engine. when operator gets off the seat while either the PTO The engine should not crank.
Page 164: Testing
Testing This section will define components, and the tests that can be performed on those components, when those parts are disconnected from the electrical system. CAUTION For accurate resistance and/or continuity checks, elec- When testing electrical components for con trically disconnect the component being tested from the tinuity with a volt-ohm meter or continuity circuit (e.g.
Page 165: Seat Switch
Seat Switch (Fig. 6, 7) The seat switch is a normally open (N.O.) switch that closes when the operator is on the seat. If the PTO switch or traction switch is open and the operator raises off the seat, the engine will stop. 1.
Page 166: Traction Neutral Switch
Traction (Neutral) Switch (Fig. 8) The traction switch is normally open and closes when traction pedal is in neutral. TRACTION NEUTRAL SWITCH IMPORTANT: The traction switch has three (3) ter minals. Make sure the wires are connected to the “COMMON”...
Page 167: Starter Interlock Relay
Starter Interlock Relay (Fig. 11, 12, 13) To test the relay (Fig. 11, Item 22 or Fig. 12, Item 42), disconnect the relay wire connector and install a conti- nuity tester between the relay terminals (terminals 30 and 87). The relay should make and break continuity at terminals 30 and 87 as 12 V.D.C.
Page 168: Glow Plugs (Groundsmaster 322-D/325-D Only)
Glow Plugs (Groundsmaster 322-D/325-D only) See Chapter 4 - Diesel Engine. Battery (Fig. 14, 15) Use a hydrometer to test the battery. Charge the battery if necessary (see Battery Service). Electrolyte specific gravity Fully charged: 1.250 - 1.280 Discharged: less than 1.240 Figure 14 (Groundsmaster 345) 1.
Page 169: Fuel Stop Solenoid (Groundsmaster 322-D/325-D Only)
Fuel Stop Solenoid (Fig. 16) (Groundsmaster 322-D/325-D only) Test the fuel stop solenoid by connecting the two sole- noid lead wires to a 12 volt battery (fused at 10 AMPS). When the battery is connected, the plunger of the sole- noid should be activated (for replacement instructions see Chapter 4 - Diesel Engine).
Page 170: Fuel Stop Control Unit
Fuel Stop Control Unit (Fig. 17) (Groundsmaster 322-D/325-D only) The control unit (Fig. 17, Item 27) is a solid-state timing device that controls a fuel stop solenoid for shutting the engine off with the ignition key switch. To check operation of the control unit and fuel stop solenoid, listen for an audible “click”...
Page 171 ® Groundsmaster 300 Series Page 6 - 25 Testing...
Page 172: (Groundsmaster 322-D/325-D Only)
Indicator Lights, Buzzers and Gauges Oil Pressure Light and Buzzer Test the indicator by disconnecting the wires and check- ing for continuity across the terminals. Oil pressure lamp and buzzer should come on when the ignition key switch is in the RUN position with the engine Hourmeter not running or if the oil pressure switch closes during operation - oil pressure below 7 psi (0.5 kg/cm...
Page 173: Temperature Relay
Temperature Relay (Fig. 18) The temperature relay (Fig. 18, Item 18) works with the temperature gauge to disconnect battery voltage to the ignition system (gas engine) or fuel shut stop control unit (diesel engine) if the engine temperature gets too hot. The B &...
Page 174: Engine Oil Pressure Switch
Engine Oil Pressure Switch (Fig. 20) The oil pressure switch is located on the cylinder block and has a brown wire attached. The switch is normally closed (NC) and opens with pressure. Turn ignition key switch ON. Oil pressure lamp and buzzer should be on.
Page 175: Fuel Gauge Sending Unit
Fuel Gauge Sending Unit (Fig. 21) 1. Remove the two wires from top of sending unity. 2. Loosen and remove screws securing sending unit to fuel tank. DANGER Because fuel is flammable, caution must be used when the sending unit is removed. Va pors may build up and be ignited by a spark or flame source many feet away.
Page 176: Repairs
Repairs IMPORTANT: Before welding on the machine, dis connect both battery cables from the battery and disconnect the terminal connector from the alterna tor to prevent damage to the electrical system. Battery Service (Fig. 22) IMPORTANT: To prevent damage to electrical com Reelmaster 345 Battery Specifications ponents, do not operate the engine with the battery...
Page 177 Fuses and Circuit Breaker (Fig. Figure 23, 24) Groundsmaster 345 An engine temperature reset relay fuse – SFE 14 AMP – is located behind the reset relay. An inline fuse – SFE 14 AMP – protects the entire electrical system. Get access to the fuses by removing the instrument panel cover.
Page 178: Traction (Neutral) Switch Replacement
Traction (Neutral) Switch Replacement (Fig. 25) 1. Remove the two wires that are connected to the traction switch. TRACTION NEUTRAL SWITCH 2. Loosen two (2) screws and remove the switch. 3. Install new switch. DO NOT over-tighten screws as the switch case could break. NOTE: Apply “Loctite 271”...
Page 179 PTO Switch Replacement (Fig. 26, 27) Lever Type Switch (S/N Below 30001) (Fig. 26) 1. Disengage latches and remove instrument cover. 2. Disconnect negative battery cable from battery and separate wire harness connectors. 3. Move PTO lever to the ON position and remove capscrew and locknut holding switch against mounting bracket.
Page 180 Plunger Type Switch (S/N 30001 and UP) (Fig. 27) 1. Disengage latches and remove instrument cover. 2. Disconnect negative battery cable from battery. 3. Move PTO lever forward to ON position. 4. Disconnect PTO switch electrical connector. 5. Remove boot from button end of switch. Keep boot for installation later.
Page 181: Seat Switch Replacement
Seat Switch Replacement (Fig. 28, 29) Lever Type Switch (S/N Below 30001) (Fig. 28) 1. Remove instrument cover and disconnect nega- tive (–) battery cable from battery. 2. Pivot seat forward and secure with support rod to prevent it from falling. 3.
Page 182 Plunger Type Switch (S/N 30001 and UP) (Fig. 29) 1. Remove instrument cover and disconnect nega- tive (–) battery cable from battery. 2. Pivot seat forward and secure with support rod to prevent it from falling. 3. (4WD units only) Remove (4) flange screws and (2) locknuts securing sealing plate to frame above fuel tank.
Page 183 Chapter. See Chapter 6 – Electrical System for addition - al component identification and testing information. Electrical Schematics The electrical schematics for all Groundsmaster 300 models are provided in Chapter 6 – Electrical System. Groundsmaster 300 Series Page 6A – 1 Electrical System (Rev. G)
Page 184: Special Tools
Ob- tain Digital Multimeter from a local supplier. Note: Toro recommends the use of a DIGITAL multi- meter when testing electrical circuits. The high imped- ance (internal resistance) of a digital meter will ensure that excess current is not allowed through the meter.
Page 185: Electrical System Quick Checks
27 Amps. If low current the ignition switch in the OFF position, place the amme- reading is observed, one (or more) glow plugs is faulty. Groundsmaster 300 Series Page 6A – 3 Electrical System (Rev. G)
Page 186: Component Testing
BACK OF SWITCH Verify continuity between switch terminals. Figure 4 SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS 2 + 3 5 + 6 1 + 2 4 + 5 Page 6A – 4 Electrical System (Rev. G) Groundsmaster 300 Series...
Page 187: Start Enable, Run Enable, Over Temperature And Seat Delay (Gm 328-D) Relays
30 and 87A as +12 VDC is applied and removed from terminal 85. 6. Disconnect voltage and multimeter leads from the relay terminals. Reconnect relay to machine wire har- ness. Groundsmaster 300 Series Page 6A – 5 Electrical System (Rev. G)
Page 188: Fuel Sender
240 to 260 ohms. 6. Replace sender as necessary. Reinstall sender into fuel tank. 7. Reconnect wires to fuel sender. Apply skin–over grease (Toro Part No. 505–47) to sender terminals. Page 6A – 6 Electrical System (Rev. G) Groundsmaster 300 Series...
Page 189: Fusible Link Harness
(diode test or ohms setting) and the table be- Figure 8 low. 1. Diode 3. Female terminal 2. Male terminal Multimeter Multimeter Red Lead (+) Black Lead (–) Continuity on Terminal on Terminal Female Male Male Female Groundsmaster 300 Series Page 6A – 7 Electrical System (Rev. G)
Page 190: Control Ignition Delay Module (Groundsmaster 345)
VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as +12 VDC is applied and removed from terminal 85. 3. Disconnect voltage and leads from the terminals. Page 6A – 8 Electrical System (Rev. G) Groundsmaster 300 Series...
Page 191: Glow Controller (Groundsmaster 328-D)
Step 4 again (see Groundsmaster 328–D electrical schematic in Chapter 6 – Electrical System). Groundsmaster 300 Series Page 6A – 9 Electrical System (Rev. G)
Page 192 3. Connect a positive (+) test lead from a 12 VDC source to the pins of the red/black and white wires. Page 6A – 10 Electrical System (Rev. G) Groundsmaster 300 Series...
Page 193 Note: When testing run solenoid, use test leads with at least 14 gauge wire. 3. Connect a positive (+) test lead from a 12 VDC source to the pull coil and hold coil terminals. Groundsmaster 300 Series Page 6A – 11 Electrical System (Rev. G)
Page 194: Service And Repairs
Charge at 15 to 25 amps for 15 minutes to al- low sufficient mixing of the electrolyte. Page 6A – 12 Electrical System (Rev. G) Groundsmaster 300 Series...
Page 195 I. If the test voltage is below the minimum, replace using a battery load tester. the battery. If the test voltage is at or above the mini- mum, return the battery to service. Groundsmaster 300 Series Page 6A – 13 Electrical System (Rev. G)
Page 196 17.3 hrs 23 hrs 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 10 amps 10 amps 10 amps 10 amps Page 6A – 14 Electrical System (Rev. G) Groundsmaster 300 Series...
Page 197 Chapter 7 Differential Axle Table of Contents INTRODUCTION ......1 Axle Shaft Disassembly TORQUE SPECIFICATIONS ....2 and Wheel Bearing Service .
Page 198 0.00 to 0.005 in. Special Tools NOTE: Order special tools from the TORO SPECIAL Catalog for your Toro equipment. Some tools may also TOOLS AND APPLICATIONS GUIDE (COMMERCIAL be available from a local supplier. PRODUCTS) . Some tools may be listed in the Parts...
Page 199: Repairs
Repairs Axle Removal and Installation 1. Put machine on a level surface, lower cutting unit, stop the engine and remove key from ignition switch. Block rear wheels to prevent machine from moving. 2. Remove the cutting unit. (See the Repairs section of Chapter 11 - Cutting Units.) 3.
Page 200: Axle Shaft Disassembly And Wheel Bearing Service
Axle Shaft Disassembly and Wheel Bearing Service NOTE: When servicing the bearing and seal area of the axle shaft, it is recommended that you replace hex head screws and flange nuts with socket head screws (94- 6934), washers (94-6936) and nuts (94-6935). See Figure 18.
Page 201 4. Remove the inner axle shaft seal (Fig. 8). Discard the seal and replace with a new one at the time of assembly. Figure 8 5. Center punch the outside of the retaining ring (Fig. 9). Figure 9 6. Drill a 1/4 inch hole (approximate) into the outside of the retainer ring to a depth of about 3/4 the thickness of the ring (Fig.
Page 202 7. After drilling, put a chisel in position across the hole and strike sharp y to break the ring. Replace with a new ring at time of reassembly (Fig. 11). WARNING Wear protective safety goggles when break ing the retaining ring. Personal injury could result from flying metal particles.
Page 203 11. Slide a new retaining ring on the axle shaft and support the shaft and ring in a suitable press (Fig. 14). Press the retaining ring firmly against the bearing. Figure 14 12. Put a light coating of No. 1 Permatex on the outside diameter of a new grease seal (surface that contacts the axle housing).
Page 204: Differential And Housing Disassembly
13. Assemble the bearing retainer bolts to the axle housing. Apply a 0.625 in. (16 mm) bead of gasket material to flange on end of axle housing, then install the axle shaft assembly into the axle housing. Be careful not to damage the oil seal and bearing. Line up the holes of the brake assembly and oil seal.
Page 205 2. Remove the four bearing cap screws and remove the caps. Place the caps in a safe place to avoid damaging their machined surfaces (Fig. 20). The bearing caps are marked for identification. The letters or numbers are in horizontal and vertical posi- tions.
Page 206 5. Do not remove the bearings from the differential case unless bearing failure is evident. It is recommended that whenever bearings are removed (regardless of usage) they must be replaced with new ones. Remove the case side bearing with a puller as shown (Fig. 23). Figure 23 6.
Page 207 8. 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 (Fig. 26). Remove the pinion mate gears and the spherical wash- ers behind the gears.
Page 208 11. Before pressing pinion out of housing: If unit was equipped with an expansion plug (re- moved in step 10), remove the snap ring and shim from the end of the pinion (Fig. 29). If unit is equipped with a flange for 4WD (no expan- sion plug), nut, washer and flange (Fig.
Page 209 13. Clamp the inner pinion bearing with a universal bearing remover (Fig. 32). Position the unit in a press and carefully push the drive pinion out of the bearing. DO NOT allow the pinion to drop on the floor - damage will result.
Page 210: Differential And Housing Reassembly
Differential and Housing Reassembly 1. Inspect the differential parts for damage before assembling. A. If any bearings are damaged they must be re- placed with new ones. B. Check the ring, pinion, and spur gear for abnormal wear and damage; replace worn components. C.
Page 211 Ring and Pinion Set Rings gears and pinions are supplied in matched sets only. Matching numbers are etched on both the pinion and ring gear (Fig. 37). The mounting distance from the bottom of the differen- tial bearing bores to the button end of the pinion is 1.210 in.
Page 212 4. Install a new inner bearing cup using a press plate of proper diameter. Reuse the original shims or use new shims of the same thickness. Push the bearing cup into the housing until it bottoms against the housing (Fig. 38). Figure 38 5.
Page 213 7. Support the drive pinion in a suitable press (Fig. 41). Figure 41 8. Install the outer pinion spacer with the chamfer to- wards the pinion splines and install the new outer pinion bearing cone (Fig. 42). Figure 42 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 noticed when the gear is rotated by hand (2-13 in.-lb.
Page 214 10. Install the shim and snap ring onto the end of the pinion shaft. Use the thickest shim possible which will permit installation of the snap ring (Fig. 44). Limit the end play to 0.000 - 0.005 inch (0.000 - 0.127 mm). Figure 44 11.
Page 215 13. Place the differential case in a vise as shown (Fig. 47). 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.
Page 216 Seat differential assembly with drive gear on proper side of carrier into carrier bearing cra- dles. NOTE: Groundsmaster 300 Series (S/N 90001 & up) require that the ring gear teeth face toward the spur gear Figure 51 cover.
Page 217 19. Using a dial indicator, check the ring gear backlash in three equally spaced points. Ring gear backlash should be .003 - .007 inch (.076 - .178 mm) and must not vary more than .002 in. between points checked (Fig. 53). If the backlash is not in this range, move the shims which are located beneath the differential bearings, from one side to the other until the correct backlash is attained.
Page 218 Drive Side Coast Side Heel Heel Backlash correct. Thicker pinion position shims required. Figure 55 Drive Side Coast Side Heel Heel Backlash correct. Thinner pinion position shims required. Figure 56 Drive Side Coast Side Heel Heel Backlash incorrect. Thinner pinion position shim re- quired.
Page 219 Gear Pattern Movements 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.
Page 220 ® Repairs Page 7 - 24 Groundsmaster 300 Series...
Page 221 Chapter 8 Steering and Brakes Table of Contents INTRODUCTION ......2 REPAIRS ....... . 11 SCHEMATICS .
Page 222: Introduction
Introduction Power Steering ® The Groundsmaster 300 Series traction units are equipped with power steering. The power steering valve is enclosed in the steering tower at the front of the traction unit. As the steering wheel is turned, the steer- ing valve meters hydraulic fluid to the double-acting steering cylinder on the rear axle and turns the wheels.
Page 223 Power Steering Schematics FROM PUMP When the steering wheel is turned to the right (Fig. 3), STEERING VALVE the control valve within the steering valve shifts to close the “AUX” port. This directs oil supplied by the steering pump to the metering section of the steering valve. As the steering wheel is turned, system oil is metered out port “RT”...
Page 224: Specifications
Specifications Item Specification __________________________________________________________________________________________ Front wheel lug nut torque 45 to 55 ft-lb ________________________________________________________________________________________________________________________________________________________ Rear wheel lug nut torque 30 to 35 ft-lb ________________________________________________________________________________________________________________________________________________________ Steering cylinder bolt torque 130 to 150 ft-lb ________________________________________________________________________________________________________________________________________________________ Rear wheel toe-in 0 to 1/8 in. ________________________________________________________________________________________________________________________________________________________ Tire pressure 10 to 15 psi, front and rear...
Page 225: Troubleshooting
Troubleshooting Problem Possible Causes ___________________________________________________________________________________________ Steering Wander Tire pressure incorrect or unequal left to right. Loose or worn steering linkage. Improperly adjusted or worn rear wheel bearings. Rear wheels out of alignment; toe-in / toe-out. Internal leakage of steering cylinder. ________________________________________________________________________________________________________________________________________________________ Poor or No Returnability (Recovery) Improper rear wheel alignment;...
Page 226 Problem Possible Causes __________________________________________________________________________________________ Steering Wheel Lash (Free Movement) Steering wheel loose on column. Steering linkage loose or worn. Steering valve loose at mounting. Air in hydraulic system. Internal leakage in hydraulic cylinder. ________________________________________________________________________________________________________________________________________________________ Excessive Heat in Hydraulic System Undersized replacement hose or tube line. Kinked or severely bent hose or tube line.
Page 227: Testing
Testing Steering Valve Test (Control Valve Section) Using Hydraulic Tester With Flow Meter 1. Engage the parking brake and block the front wheels to prevent movement of the machine. Lower the cutting unit or implement to the floor and turn the engine OFF. 2.
Page 228: Steering Cylinder Internal Leakage Test
Steering Cylinder Internal Leakage Test 1. Engage the parking brake, and lower the cutting unit to the floor. 2. Turn the steering wheel all the way to the left (coun- terclockwise) on a 2WD machine or to the right (clock- wise) on a 4WD machine, so the steering cylinder rod is extended all the way.
Page 229: Adjustments
Adjustments Rear Wheel Toe-in Adjustment The rear wheels should have 0 to 1/8 of an inch toe-in when they are pointed straight ahead. To check toe-in, measure the center-to-center distance, at axle height, in front and rear of steering tires. If toe-in is not within specifications, an adjustment is required.
Page 230: Brake Adjustment
Brake Adjustment Adjust the service brakes when there is more that one inch of “free travel” of the brake pedals. Free travel is the distance the brake pedal moves before braking resistance is felt. Adjust where brake cables connect to brake pedal mount.
Page 231: Repairs
Repairs Steering Wheel Removal and Installation Removing the Steering Wheel Remove the cover from the steering wheel hub. Re- move the locknut that secures the steering wheel to the shaft (Fig. 15). Pull the steering wheel off the shaft. NOTE: It may be necessary to use a jaw-type puller to remove the steering wheel from the steering shaft.
Page 232: Rear Axle Bushing Service
Rear Axle Bushing Service (2WD Units) The rear axle must be held in place snugly by the axle 5. Use a drift punch and hammer to drive both bushings pin. Excessive movement of the axle, which is charac- (Item 4) out of the axle pivot tube. Clean the inside of terized by erratic steering, usually indicates worn bush- the axle pivot tube to remove dirt and foreign material.
Page 233 7. Connect the tie rod end to the spindle bracket with 8. Install the lock nut and cap screw to secure the one (1) nut. Tighten the nut to a torque of 25 - 33 ft-lb. steering cylinder rod end to the steering pivot. Tighten Install the jam nut and tighten against the other nut to the nut to 130 to 150 ft-lb.
Page 234: Rear Wheel Spindle Bushing Service
Rear Wheel Spindle Bushing Service (2WD Units) The rear wheel spindles must fit snugly in the rear axle. 7. Apply grease to the inside and outside of the new Excessive movement of the spindle in the axle indicates bushings. Use an arbor press to install the bushings into that the bushings are probably worn and must be re- the top and bottom of the axle tube.
Page 235: Front Wheel Bearing Service
Figure 17 Front Wheel Bearing Service See Axle Shaft Disassembly and Wheel Bearing Serv- ice in the Repairs section of Chapter 6 - Differential. ® Groundsmaster 300 Series Page 8 - 15 Repairs...
Page 236: Rear Wheel Bearing Service
Rear Wheel Bearing Service (2WD Units) Disassemble, clean, repack and adjust the rear wheel wear, pitting or other noticeable damage. Replace worn bearings after each 500 hours of operation or once a or damaged parts. year. Use No. 2 general purpose lithium base grease containing E.P.
Page 237 Adjusting Rear Wheel Bearings 1. Remove dust cap from end of wheel spindle. Also remove cotter pin retaining slotted nut in place (Fig. 18). 2. Rotate the wheel by hand and tighten the slotted nut (Fig. 19) until the bearing binds SLIGHTLY. Then, loosen the nut until the nearest slot and hole in the spindle line up.
Page 238: Steering Cylinder Removal And Installation
Steering Cylinder Removal and Installation 1. Engage the parking brakes, lower the cutting units to the ground, turn the engine OFF and remove the key from the ignition switch. 2. Disconnect the hydraulic hoses from the steering cylinder. Put caps or plugs on all the fittings and hoses to prevent contamination.
Page 239: Steering Cylinder Service
Steering Cylinder Service 8. Remove all seals and O-rings (Item 2). IMPORTANT: To prevent damage to rod or barrel, clamp vise on pivot ends only. DO NOT clamp against smooth rod surface. 9. Wash parts in a safe solvent. Dry parts with com- pressed air.
Page 240: Brake Shoe Replacement
Brake Shoe Replacement CAUTION CAUTION The brake linings contain asbestos fibers. Wear a face shield when removing brake re Breathing dust containing asbestos fibers turn spring (Fig. 22). The spring is under ten may be hazardous to your health and may sion and could possibly slip during removal.
Page 241: Steering Valve Removal And Installation
Steering Valve Removal and Installation 1. Engage the parking brakes, lower the cutting units to the ground, turn the engine OFF and remove the key from the ignition switch. 2. Remove the cutting unit or other implement. 3. Remove the steering wheel. 4.
Page 242: Steering Valve Service
Steering Valve Service Before Disassembly When disassembling any of the parts, use a clean work bench. Wash all parts in solvent and dry them with compressed air. DO NOT wipe them dry with a cloth of paper as lint and dirt may remain. Keep each part separate to prevent nicks and burrs.
Page 243 Disassembly of Steering Valve 1. To avoid distorting or damaging the steering valve, do not clamp it directly into a vise. Clamp a service assem- bly fixture securely in a vise (Fig. 25). Put the steering valve, input shaft first, into the service assembly fixture. Attache the steering valve to the fixture with four (4) 5/16-24 UNF nuts (Fig.
Page 244 4. Grasp the port cover assembly (four plates bonded together) and lift it from the unit. Remove and discard the four o-rings and seal ring (Fig. 29). Figure 29 5. Remove the loosened plug and o-ring assembly from the port cover. Be ready to catch the steel check ball as it falls from its cavity (Fig.
Page 245 11. Remove the valve ring (Fig. 32). Remove and dis- card the two seal rings (Fig. 33). The valve ring should be free of nicks and scoring. Figure 32 Figure 33 12. Remove the valve plate by lifting it from the isolation manifold (Fig.
Page 246 14. Remove three springs from the isolation manifold pockets (Fig. 35). NOTE: The unit has two different length spring sets. the set you have just removed from the isolation manifold is 1/2 in. (13 mm) long. Keep this spring set separate from the set removed from the port manifold.
Page 247 18. Remove the two alignment pins that align the port manifold, valve ring and isolation manifold (Fig. 38). Figure 38 19. Remove the isolation manifold (four plates bonded together) (Fig. 39). 20. Inspect the ground surfaces of the isolation mani- fold.
Page 248 22. Remove the drive link from the unit (Fig. 41). 23. Inspect each end of the drive link. the four crowned contact surfaces should not be worn or scored. Replace if wear or scoring is evident. Figure 41 24. Remove the metering ring and discard the two seal rings (Fig.
Page 249 26. Remove and discard the commutator seal from the commutator cover (Fig. 44). Figure 44 27. Remove the eleven hex socket head screws, that hold the metering package together (Fig. 45). Use a 3/32 in. allen wrench. Inspect the screws for thread and socket damage and replace as necessary.
Page 250 30. Remove the commutator ring (Fig. 47). Inspect for cracks, burrs and scoring. IMPORTANT: Handle the commutator ring with care, as it is easily broken. Figure 47 31. Remove the commutator from the rotor (Fig. 48). IMPORTANT: To prevent damage, DO NOT use a screwdriver to remove the commutator.
Page 251 34. Remove the drive link spacer (Fig. 50). Replace it if it grooved or worn. 35. With the rotor set lying on the drive plate, the rotor should rotate and orbit freely within the stator. The commutator side of the stator face must be free of grooves or scoring.
Page 252 39. Inspect the thrust bearing side of the drive plate (Fig. 53) for brinelling (dents) or spalling (flaking). The flat sides of the input shaft engagement hole should not be grooved or worn. If any of these conditions in steps 38 and 39 are present, the drive plate must be replaced.
Page 253 43. Remove the upper cover plate (four plates bonded together) (Fig. 56). Inspect the upper cover plate. You should notice some polishing due to the action of the seal. The plate should be free of brinelling (dents) or spalling (flaking). If it is damaged, the upper cover plate must be replaced.
Page 254 47. Remove the washer and upper cover & jacket (Fig. 59). NOTE: The retaining plate and upper cover & jacket are a matched set. If either part is worn or damaged, both must be replaced. Figure 59 48. Inspect the bushing at the top of the cover & jacket for wear or damage.
Page 255 50. Remove the nuts holding the four bolts to the fixture, and remove the bolts (Fig. 62). Check the bolt threads for wear or damage. Figure 62 ® Groundsmaster 300 Series Page 8 - 35 Repairs...
Page 256 Assembly of Steering Valve Replace all seals and o-rings with new ones. Make sure the seals and o-rings remain seated correctly when components are assembled. Before assembling the steering valve, wash all parts in clean solvent. Dry the parts with compressed air. DO NOT wipe them dry with a cloth or paper as lint and dirt may remain.
Page 257 3. Put the upper cover and jacket on the four bolts with the jacket tube pointing down through the hole in fixture (Fig. 66). Make sure the square shoulder of the bolts engage the square holes in the upper cover. 4.
Page 258 8. Apply clean multi-purpose grease to the face of the upper cover plate, input shaft and face seal (Fig. 70). Figure 70 9. Assemble the seal back-up ring and face seal onto the seal spacer (Fig. 71). Figure 71 10. Install the face seal, back-up ring and spacer assem- bly over the end of the input shaft and onto the upper cover plate (Fig.
Page 259 11. Put the drive plate on a clean lint-free surface with the eleven tapped holes facing up. Put the rotor set on top of the drive plate with the five pin holes facing up. Rotate the stator until the eleven hex socket head screw relief slots are aligned with the tapped holes in the drive plate (Fig.
Page 260 14. Align the five holes and press the five alignment pins in place (Fig. 76). IMPORTANT: Make sure the five alignment pins are pressed below the surface of the commutator. Figure 76 15. Put a few drops of oil into each recess in the commutator (Fig.
Page 261 17. Put the commutator cover on top of the commutator ring with the flat surface towards the commutator (Fig. 79). Align the screw holes in the cover, with the screw holes in the drive plate. Figure 79 18. Screw the eleven hex socket head cap screws loosely into the metering package (Fig.
Page 262 20. Put another piece of the 0.007 in. (0.18 mm) shim stock between the drive plate and each of the three pieces of shim stock already in place. Lift the metering ring and metering package and remove the wood block. Push the metering package and shims into the metering ring until the drive plate and shims are at least flush with the metering ring (Fig.
Page 263 22. Insert the LARGE tang of the drive link into the slot in the rotor (Fig. 85). IMPORTANT: An incorrect (reversed) assembly of the drive link will prevent the assembly of the hex drive. Figure 85 23. Grasp the drive link and rotate the metering package by hand to make sure the parts do not bind (Fig.
Page 264 25. Put the bearing spacer onto the face of the upper cover plate (Fig. 88). Figure 88 26. Lightly grease the roller thrust bearing and put it on the upper cover plate, inside the bearing spacer (Fig. 89). Figure 89 27.
Page 265 28. Put the metering package, drive plate side first, into the metering ring (Fig. 91). Revolve the input shaft or metering package until the hole in the drive plate en- gages the end of the input shaft and the drive plate is seated on the thrust bearing.
Page 266 31. Put two alignment pins into the metering ring (Fig. 94). Figure 94 32. Stack the isolation manifold (4 plates bonded to- gether) onto the metering ring, aligning the grooves on the side of the manifold with the grooves on the side of the upper cover plate (Fig.
Page 267 34. Put the three 1/2 in. (13 mm) springs into the spring pockets of the isolation manifold (Fig. 97). NOTE: Two different length springs are used in the unit. Be sure to use the 1/2 in. (13 mm) length springs during this part of the assembly.
Page 268 37. To install the valve plate correctly, first carefully study Figures 93 and 94 for positioning of the valve plate spring slots and other cavities in relation to the spring and spring recesses on the isolation manifold. Be sure to use the alignment grooves on the side of the isolation manifold for orientation.
Page 269 39. Put the port manifold (three plates bonded together), valve side up, in a clean surface. Install three 3/4 in. springs into the spring pockets (Fig. 103). Figure 103 40. Apply a few drops of oil to the valve plate. Align the grooves on the side of the port manifold with the grooves on the side of the isolation manifold and assemble the port manifold with the springs toward the valve plate...
Page 270 42. Apply clean multi-purpose grease to the four o-rings and seal ring. Put the new o-rings and seal ring into their proper location in the port cover (Fig. 106). Figure 106 43. Align a groove on the side of the port cover with the grooves on the side of the port manifold and put the port cover into position (Fig.
Page 271 44. Install the lock nuts onto the bolts. Tighten each nut gradually until resistance is felt (Fig. 108). Tighten to a torque of 20 - 24 ft-lb (27 - 33 Nm) in the sequence shown (Fig. 109). Figure 108 Figure 109 45.
Page 272 46. Apply a small amount of clean multi-purpose grease on the lip of the seal. Install the seal onto the jacket tube and input shaft (Fig. 111). 47. Make a final inspection of the relative groove posi- tions on the side of the unit (Fig. 24). Components of the steering valve with alignment grooves, must be assem- bled so that their alignment grooves are positioned as illustrated for the valve to function correctly (Fig.
Page 273 Chapter 9 Transmission Coupler and PTO Table of Contents INTRODUCTION ......2 REPAIRS ....... . . 7 TROUBLESHOOTING .
Page 274: Introduction
The only time the PTO lever should mission. With this Toro design, there is no clutch used be in the ON position is when the implement or cutting between the engine and the transmission.
Page 275: Troubleshooting
Troubleshooting Engine to Transmission Coupler Problem Possible Cause Output shaft bearing failure. Lack of lubrication. Output shaft out of alignment. Excessive vibration of drive coupling. Drive coupling bent or deformed. Loose fasteners. Drive coupling out of alignment. Flexible (rubber) couplings wear prematurely. Drive coupling bent or deformed.
Page 276: Checking Drive Coupling Alignment
Adjustments Checking Drive Coupling Alignment (Fig. 2) When either the hydrostatic axle or the engine is re- moved and after all parts are reinstalled, the alignment of the drive coupling must be checked. In addition, any excess vibration usually indicates misalignment of the drive coupling.
Page 277: Pto Pulley And Engine Pulley Alignment
Correcting PTO Drive Belt Slippage (Fig. 5) If belt begins to slip because it has stretched or because of worn linkage: 1. Unlatch and remove instrument cover. 2. Move PTO control lever to ON position. 3. Measure length of PTO spring between flat washers. There should be a spring length of 3-3/16 inches (81 mm).
Page 278: Pto Brake Adjustment
PTO Brake Adjustment (Fig. 8) 1 . Lower the implement to the shop floor, turn the engine off, remove the key from the ignition switch, and engage the parking brake. 2. Move the P.T.O. lever to the ENGAGE position. Loosen the adjusting locknut so that the brake is free to move.
Page 279: Drive Coupling Removal And Installation
Repairs Drive Coupling Removal and Installation (Fig. 9) Removing Drive Couplings 1. Lower the cutting unit to the shop floor, turn the engine off, remove the key from the ignition switch and engage the parking brake. 2. Raise the seat and secure it in that position. 3.
Page 280: Engine Pulley Yoke Bearing Replacement
Engine Pulley Yoke Bearing Replacement (Fig. 10) 1. Position the machine on a level surface, turn the engine off, remove the key from the ignition switch, and engage the parking brake. 2. Remove the drive coupling as described in “Remov- ing Drive Couplings”.
Page 281: Pto Belt Replacement
PTO Belt Replacement (Fig. 12) The PTO belt is a special double belt referred to as a “torque team belt.” 1. To replace the belt, lower the implement to the shop floor, turn the engine off, remove the key from the ignition switch, and engage the parking brake.
Page 282: Removing Pto Control Lever And Linkage
Removing PTO Control Lever and Linkage (Fig. 13, 14) 1. Lower the implement to the shop floor and turn the engine off. Engage the parking brake. 2. Unlatch and remove the instrument panel cover. 3. With the control lever in the OFF position, the P.T.O. compression spring tension is released and the linkage can be removed or repaired.
Page 283: Pto Shaft And Bearing Service
PTO Shaft and Bearing Service (Fig. 14) 1. Remove the P.T.O. belt; refer to “Replacing the P.T.O. 6. Loosen the setscrews (Item 46) on the P.T.O. shaft Belt”. bearing collars (Item 41). Use a punch and hammer to rotate the collars in the opposite direction of shaft rota- 2.
Page 284 PTO Drive Shaft Removal (Fig. 15) DANGER Do not start the engine and engage the P.T.O. lever when the P.T.O. shaft is not connected to the gearbox on the cutting unit. If the en gine is started and the P.T.O. shaft Is allowed to rotate, serious Injury could result.
Page 285: Pto Drive Shaft Universal Joint Replacement
PTO Drive Shaft Universal Joint Replacement (Fig. 16, 17) 1 Remove the P.T.O. drive shaft. 15. Grease the fitting SLOWLY until grease starts to show at the seals. Use a low pressure hand grease gun 2. Separate the two sections of the P.T.O. shaft. or a power gun equipped with a pressure relief valve.
Page 286: Installing The Pto Drive Shaft
Installing the PTO Drive Shaft (Fig. 18, 19) DANGER Do not start the engine and engage the P.T.O. lever when the P.T.O. shaft is not connected to the gearbox on the cutting unit. If the en gine is started and the P.T.O. shaft Is allowed to rotate, serious Injury could result.
Page 287 Chapter 10 GM322-D or GM325-D with Inasaka axle 4WD Rear Axle Table of Contents SPECIFICATIONS ......2 REPAIRS .
Page 288 Specifications Item Specification __________________________________________________________________________________________ Lubricant (Fig. 1, 2) SAE 80W90 gear lube ________________________________________________________________________________________________________________________________________________________ Rear wheel toe-in 1/8 inch ________________________________________________________________________________________________________________________________________________________ Rear wheel bolt torque 45 - 55 ft-lb Figure 1 Figure 2 1. Check plugs (2) 2. Mounting bolts 1. Drain plugs ®...
Page 289 General Information Over-Running Clutch Operation A drive shaft connected to the front axle provides power for the rear 4WD drive axle. The drive shaft tor the rear Locked 49 RPM ax l e incorporates an OVER-RUNNING (ROLLER) Unlocked CLUTCH THAT TRANSMITS POWER ONLY IN THE FOR- 50 RPM (Fig.
Page 290 Adjustments Rear Wheel Toe-in (Fig. 6) 1. Measure center–to–center distance (at axle height) at front and rear of steering tires. Front measurement must be 0 to 1/8 in. less than rear measurement. 2. Remove cotter pin and nut securing one tie rod ball joint to mounting bracket on axle and disconnect ball joint from axle (Fig.
Page 291 Repairs Drive Shaft Service 0.34 ± ″ Arrow end of roller 0.03 utches must face 6-bolt f ange end of ″ 0.040 MAX utch housing toward rear axle) Apply Never-seeze Detail A Detail B Figure 8 Removing Drive Shaft Clutch Service 1.
Page 292 0.34 ± 0.03″ Arrow end of roller clutches must face 6-bolt flange end of ″ 0.040 MAX utch housing toward rear ax e) Apply Never-seeze Detail A Detail B Figure 9 5. Put thrust washer (Item 14) in housing adjacent to Installing Drive Shaft.
Page 293 Rear Axle Removal and Installation 45 - 55 ft-lb Figure 10A Figure 10B 1. Remove drain plugs from axle and allow oil to drain 8. Remove nut (Fig. 10A, Item 14) and flatwasher into a container (Fig. 2). (Item 15). Remove capscrews (Item 6) from pin (Item 7).
Page 294 Rear Axle Repair Apply Loctite 16 - 20 ft-lb 20 - 24 ft-lb Shim for backlash adjustment Measure backlash here: 0.003 - 0.01″ 16 - 20 ft-lb Tighten to pre-load Shim for bevel gear to pin- bearings. Pinion shaft ion contact adjustment should rotate with 2.0 - 5.5 in-lb torque Figure 12...
Page 295 6 - 8 ft-lb 12 - 20 ft-lb Apply Loctite 12 - 20 ft-lb Figure 13 Assembly E. Tighten bolts (Item 1, 40) to a torque of 16 - 20 ft-lb (220-280 Kg-Cm). 1. Use new gaskets and seals when reassembling axle. F.
Page 296 3. Assemble knuckle assembly (Fig. 13): (Item 38). Note that top two (2) capscrews (Item 39), securing cover (Item 30) are a shorter length. A. Insert needle bearing (Item 22), washer (Item 21), knuckle pin (Item 20), spacer (Item 19) and bevel E.
Page 297 Chapter 10.1 GM 325–D or GM 328–D with Dae Dong Axle 4WD Rear Axle Table of Contents NOTE : For GM322–D or GM325–D with Inasaka axle, see Chapter 10 – 4WD Rear Axle in this manual. SPECIFICATIONS ......2 Axle Shafts .
Page 298 Specifications Item Specification Wheel lug nut torque (rear) 45 to 55 ft-lbs. (61 to 75 Nm) Rear wheel toe-in 0.000 in. (0.0 mm) Tire pressure (front and rear) 21 psi (145 kPa) Rear axle lubricant SAE 80W90, API GL-5 gear lube Bidirectional clutch lubricant Mobil 424 hydraulic fluid 4WD Rear Axle (Rev.
Page 299 Adjustments Steering Stop Bolt Adjustment The rear axle steering stop bolts help prevent over–trav- el of the steering cylinder in case of impacts on rear wheels. When the steering cylinder is fully extended, a gap of 1/16” (1.6 mm) should exist between left side bev- el gear case casting and stop bolt (Fig.
Page 300 Repairs NOTE: See Traction Unit Operator’s Manual for Main- tenance intervals and instructions. 4WD Rear Axle 40 41 RIGHT FRONT 45 to 55 ft–lbs. (61 to 75 Nm) Figure 2 4WD rear axle 21. Flange head screw (4 used) 40. Washer (4 used) Adaptor 22.
Page 301 Removal (Fig. 2) Installation (Fig. 2) 1. Park machine on a level surface, lower cutting deck 1. Position rear axle support to axle. Install thrust wash- (or implement), stop engine, engage parking brake and ers (items 52 and 53) between axle boss and axle sup- remove key from the ignition switch.
Page 302: Bevel Gear/Axle Case Removal
Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- 35 to 41 ft–lbs. bly has been removed from the machine. (47 to 56 Nm) Removal 1. Remove the mounting screws, nuts, and lock wash- ers. Remove the bevel gear case/axle case assembly and O-ring from the axle support (Fig.
Page 303 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gas- 17 to 20 ft–lb (23 to 27 N–m) ket material from either mating surface (Fig. 6). 6. While holding the bevel gear case, lightly tap the up- Threadlocking per end of the bevel gear shaft out of the upper bearing Compound...
Page 304 Installation 1. Coat new shaft seals with grease and install in axle case and bevel gear case as shown (Fig. 8). Figure 8 1. Axle case 3. Shaft seal 2. Bevel gear case 2. Install the lower bevel gear, and bevel gear shaft in 17 to 20 ft–lbs.
Page 305 5. Determine necessary quantity of support shims. 57 to 67 ft–lbs. A. Lubricate the axle case support bushing with a (77 to 91 Nm) thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during VERTICAL disassembly between axle case support and axle ENDPLAY...
Page 306: Differential Shafts
9. Remove the bevel gear case/axle case assembly NOTE: Axle bearing shims are available in 0.008 in. from the axle support. Coat a new O-ring with grease (0.2 mm), 0.012 in. (0.3 mm), and 0.020 in. (0.5 mm) and temporarily install the axle cover assembly. Position thickness.
Page 307: Axle Shafts
Axle Shafts The following procedures assume the rear axle assem- 17 to 20 ft–lbs. bly has been removed from the machine. (23 to 27 Nm) Removal 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig.
Page 308: Removal
Input Shaft/Pinion Gear The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove input shaft/pinion gear assembly from the axle support. Remove the shims and bearing case O- ring. 2. Release the stake washer and remove the locknut. Remove and discard the stake washer (Fig.
Page 309 9. Use a depth gauge to measure the distance from the end face of the input shaft/pinion gear to the mating sur- face of the bearing case. Subtract the “Design Cone Center Distance” from this distance to determine initial shim thickness (Fig. 20). Design Cone Center Distance...
Page 310: Removal
Differential Gear The following procedures assume the rear axle assem- 35 to 41 ft–lbs. bly has been removed from the machine. (47 to 56 Nm) Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual).
Page 311: Inspection
Inspection 1. Measure the differential side gear O.D. and the dif- ferential case I.D. to determine the side gear to case clearance (Fig. 25). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 in. (0.05 to 0.30 mm) SIDE GEAR O.D.
Page 312: Installation
Installation 1. If the ring gear was removed from the differential case, use medium strength Loctite thread locker and tighten the mounting screws from 22 to 25 ft-lb (30 to 34 N–m). 2. Apply molybdenum disulfide lubricant (Three Bond 1901 or equivalent) to the splines and bearing surfaces of the differential pinion gears, pinion washers and side gears.
Page 313: Pinion Gear To Ring Gear Engagement
Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using PROFILE the gear contact pattern method as described in the fol- TOP LAND lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 29): Toe – the portion of the tooth surface at the end to- LENGTHWISE wards the center.
Page 314: Gear Pattern Movement Summary
Gear Pattern Movement Summary Heel Contact Base Contact Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed. 1. If contact is toward the heel or base of the gear (Fig. 32): A.
Page 315: Bidirectional Clutch
Bidirectional Clutch RIGHT FRONT Anti–seize Lubricant Loctite #242 Figure 34 1. Clutch locator adapter 5. Spacer 9. Lock washer (6 used) 2. Cap screw (2 used) 6. Flat washer 10. Socket head screw (6 used) 3. Cap screw (2 used) 7.
Page 316: Bidirectional Clutch Service
Bidirectional Clutch Service Hylomar Jointing Compound DRIVE SHAFT REAR AXLE 14 ft–lb (19 N–m) Figure 35 1. End plate 7. Phillips head screw w/o–ring 13. Oil seal 2. Socket head screw (6 used) 8. Hub 14. Bearing Housing 3. Oil seal 9.
Page 317 Chapter 11 72″ Cutting Units Table of Contents SPECIFICATIONS ......2 Caster Arm Bushing Replacement ..11 GENERAL INFORMATION .
Page 318: Specifications
Specifications ITEM SPECIFICATION __________________________________________________________________________________________ Cutting width 71.5 inch ________________________________________________________________________________________________________________________________________________________ Height of cut range 1 to 4 inch ________________________________________________________________________________________________________________________________________________________ Height of cut adjustment 0.5 inch increments ________________________________________________________________________________________________________________________________________________________ Blade bolt torque 75 to 100 ft-lb (left-hand thread) ________________________________________________________________________________________________________________________________________________________ Spindle nut torque 140 - 160 ft-lb. ________________________________________________________________________________________________________________________________________________________ Spindle end play .006 inch max.
Page 319: General Information
General Information Grass Deflector WARNING The grass deflector (Fig. 2) is a safety device that diverts grass and other foreign objects being discharged downward. WE STRONGLY RECOMMEND THAT THE DEFLECTOR BE IN ITS NORMAL OPERATING POSITION WHENEVER THE CUTTING UNIT IS ENGAGED. NEVER OPERATE CUTTING UNIT WITH THE DEFLECTOR REMOVED FROM THE CUTTING UNIT OR TIED BLOCKED IN A RAISED POSITION, SINCE THE BLADES COULD...
Page 320: Troubleshooting
Troubleshooting ® Troubleshooting Page 11 - 4 Groundsmaster 300 Series...
Page 321: Adjustments
The height of cut chart below gives the combinations of spacers to use for all height of cut settings. NOTE: 1/4 inch spacers are available and can be or- dered from your Toro distributor by Toro Part No. 27-1040. (Quantity - 8). Height of Cut...
Page 322 Checking and Correcting Mismatch of Blades (Fig. 5) If there is mismatch between the blades, the grass will 7. Remove cap screws, flat washers, lock washers and appear streaked when it is cut. This problem can be nuts from outer spindle, in the area where shims must corrected by making sure the blades are straight and all be added.
Page 323: Belt Tension Adjustment
Belt Tension Adjustment (Fig. 6) 1. Lower the cutting unit to the floor and shut off the engine. Engage the parking brake. 2. Remove the deck covers from the top of the cutting unit. 3. Loosen the idler pulley for the belt being adjusted and move idler into belt using a pry bar, until you get the proper tension.
Page 324: Repairs
Do not try to straighten a blade that is bent, and never weld a broken or cracked blade. Always use a new TORO blade to assure continued safety certification of the product. Figure 7 1 .
Page 325 Inspecting and Sharpening Blade 1. Raise cutting unit to highest position, shut the engine off and engage parking brake. Block cutting unit to prevent it from falling accidentally. 2. Examine cutting ends of the blade carefully, espe- cially where the flat and curved parts of the blade meet. Since sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check the blade before using the machine.
Page 326: Belt Replacement
Belt Replacement (Fig. 10) 1. Lower cutting unit to the shop floor, shut off the engine and engage the parking brake. Remove covers on top of cutting unit and set covers aside. Loosen idler pulleys to release tension of belts. 2.
Page 327 Caster Arm Bushing Service (Fig. 11) The caster arms have bushings pressed into the top and bottom portion of the tube and after many hours of operation, the bushings will wear. To check the bush- ings, move caster fork back and forth and from side-to- side.
Page 328: Rear Caster Wheel Bearing Service
Rear Caster Wheel Bearing Service (Fig. 12) The rear caster wheels rotate on high quality roller bearings which are supported by spanner bushings. Even after many hours of use, provided that the bearing was kept well-lubricated, bearing wear will be minimal. However, failure to keep bearings lubricated will cause rapid wear.
Page 329: Front Caster Wheel Bearing Service
Front Caster Wheel Bearing Service (Fig. 13) The front caster wheels rotate on high-quality roller bearings which are supported by spanner bushings. Even after many hours of use, provided that the bearing was kept well-lubricated, bearing wear will be minimal. However, failure to keep bearings lubricated will cause rapid wear.
Page 330: Separating Cutting Unit From Traction Unit
Separating Cutting Unit From Traction Unit (Fig. 14, 15, 16, 17) 1. Position machine on level surface, lower cutting unit to the shop floor, shut engine off and engage parking brake. 2. Remove self-tapping screws securing shield to top of cutting unit and set shield aside.
Page 331 WARNING Since the right hand push arm is spring loaded to about 100 pounds and left hand push arm is spring-loaded to about 150 pounds, a helper is needed to release push arms from cutting unit. Sudden release of the push arms could cause injury.
Page 332: Mounting Cutting Unit To Traction Unit
Mounting Cutting Unit to Traction Unit (Fig. 18, 19, 20, 21) 1. Position machine on level surface and shut engine off. 2. Move cutting unit into position in front of traction unit. WARNING Since the right hand push arm is spring loaded to about 100 pounds and left hand push is spring-loaded to about 150...
Page 333 8. Line up holes in yoke and input shaft of gear box. Slide yoke onto shaft and secure parts together with roll pin (3/16 x 1-1/2 in.). Tighten (2) capscrews and locknuts securing yoke to input shaft. 9. Mount PTO shield over input shaft and onto gear box mounting plate with two self-tapping screws.
Page 334: Push Arm And Torsion Spring Service
Push Arm and Torsion Spring Service (Fig. 22, 23, 24, 25, 26, 27, 28) Removing Push Arms, Torsion Springs and Bushings 1. Separate cutting unit from traction unit and roll cutting unit away from traction unit. 2. Have a helper push down on the left push arm while you put a 4"...
Page 335 7. Remove the cap screws, locknuts, carriage bolts, lock washers and nuts holding the brake mount and pedal assembly in place. Lay the brake mount and the pedal assembly on the wheel. 8. Have a helper push down slightly on the left push arm while you remove the block of wood between the push arm and the chassis.
Page 336 Installing Push Arms, Torsion Springs and Bushings 1. Apply grease to inside and outside of new bushings. Using a hammer and flat plate, carefully drive the bush- ings into the push arm pivot tubes. The bushings must be flush with the end of the tube. 2.
Page 337: Gearbox Removal And Installation
Gearbox Removal and Installation (Fig. 29, 30) Removing Gearbox and Drive Pulley 1. Lower the cutting unit, shut engine off and engage the parking brake. 2. Remove shroud covering universal drive shaft. Dis- connect drive shaft from gearbox. Remove belt covers from top of cutting unit.
Page 338 Installing Gearbox and Drive Pulley 10. Mount gearbox with brackets onto top of cutting unit. Insert four (4) carriage bolts up from bottom of cutting 1. Install four (4) isolation mounts into two (2) brackets. unit and install flatwasher and nut on each bolt to secure Use water or lubricant to ease installation.
Page 339 Gear Box Repair (Fig. 31, 32, 33) Figure 31 Gear Box Disassembly 6. Remove bearing cups (Item 14) from cap by putting a punch through the shaft bore and through the seal and 1. Drain lubricant from gear box. then tapping against the back of the bearing cup until driven out of the cap.
Page 340 4, 5, 6 Figure 32 Gear Box Pre-Assembly cap with the open side toward the machined side of the cap. 1. Start with one of the shafts (Item 17) and put one of the gears (Item 10) over the shaft so the tooth side is 6.
Page 341 Gear Box Final Assembly 4. The shaft should have a very slight amount of bearing drag. If the shaft turns hard, the cap must be removed 1. Bearing drag is adjusted by the amount of gaskets and gasket(s) need to be added. If the shaft has no (Item 4, 5, 6) used between the cap and housing ma- bearing drag, or has end play, the cap must be removed chined surfaces.
Page 342: Blade Spindle Service
Blade Spindle Service (Fig. 34, 35, 36, 37, 38) Removing Spindle and 3. Remove belt from spindle to be serviced. Bearings From Spindle Housing 4. Start the engine and raise the cutting unit. Turn the 1. Lower the cutting unit, shut the engine off and engage engine OFF and remove the key from the key switch.
Page 343 OIL SEAL are sold only with a matched snap ring and spacer set. These parts cannot be purchased separately. CENTER SPINDLE BELLEVILLE WASHER SPECIAL SCREW (LEFT HAND THREAD) Figure 36 Groundsmaster 300 Series Page 11 - - 27 Rev. I Repairs...
Page 344 7. Slide the bearing spacer onto the spindle shaft. Care- fully slide the spindle shaft up through the spindle hous- ing. The bottom seal and bearing spacer should fit together when the spindle is installed. Page 11 - - 28 Repairs Rev. I Groundsmaster 300 Series...
Page 345 Chapter 12 ® Triflex 88″ Cutting Unit Table of Contents SPECIFICATIONS ......2 REPAIRS ....... . 13 GENERAL INFORMATION .
Page 346: Specifications
Specifications ITEM SPECIFICATION __________________________________________________________________________________________ Cutting width 88 inches Center section only 54 inches With one wing disengaged 71 inches ________________________________________________________________________________________________________________________________________________________ Height of cut range 1 to 4 inches ________________________________________________________________________________________________________________________________________________________ Height of cut adjustment 0.5 inch increments ________________________________________________________________________________________________________________________________________________________ Blade bolt torque 85 to 110 ft-lb ________________________________________________________________________________________________________________________________________________________ Spindle nut torque...
Page 347: General Information
General Information Grass Deflectors WARNING The grass deflectors (Fig. 2) are safety de vices that divert grass and other foreign ob jects being discharged downward. STRONGLY RECOMMEND THAT THE DEFLEC- TORS BE IN THEIR NORMAL OPERATING POSI- TION WH ENEVER THE CUTTING UNIT IS ENGAGED.
Page 348: Troubleshooting
Troubleshooting ® Troubleshooting Page 12 - 4 Groundsmaster 300 Series...
Page 349: Adjustments
Adjustments Mechanical Door (Fig. 3) On each side of the deck center section is a mechanical door that opens and closes as the wing sections are lowered and raised. The doors open to provide overlap of the cutter blades when the wing units are down. The doors close to provide safety and protection when the wing units are raised.
Page 350: Height Of Cut Adjustment
Height of Cut Adjustment (Fig. 6, 7, 8) The height of cut is adjustable from 1 to 4 inches in 1/2 inch increments, by adding or removing an equal number of spacers on the front and rear caster forks. The height of cut chart below gives the combinations of spacers to use for all height of cut settings.
Page 351 IMPORTANT: All six “U” shaped spacers must be on rear square caster shafts – if one is left off, remaining spacers will not stay in position during operation. Always install spacers on caster shafts with the spacer opening facing forward or to the rear.
Page 352 Checking and Correcting Mismatch of Blades (Fig. 9, 10) If there is mismatch between the blades, the grass will Center Section: appear streaked when it is cut. This problem can be corrected by making sure the blades are straight and all 7.
Page 353: Belt Tension Adjustment
Belt Tension Adjustment (Fig. 11, 12, 13) NOTE: Check that belts are in good condition and positioned correctly in the sheaves of the pulleys on the center section and wing sections of the deck. IMPORTANT: Check tension on new belts after 10 hours of use.
Page 354 Center Section: NOTE: Spring tension is only 10 to 15 lbs. on the wing section, but is 80 to 90 lbs. on the center section, requiring the use of a threaded rod for adjustments. 1. Loosen nuts securing the spring bracket to the deck. Loosen the jam nut on the threaded rod.
Page 355: Wing Shaft End Play
Wing Pulley Brake (Fig. 14) Raise wing to be adjusted, 15 degrees (use a magneti- cally mounted compass) and loosen brake pad cap- screws with an Allen wrench. Push brake pad against pulley with one hand and tighten capscrews with the other hand.
Page 356: Wing Lift Cylinders
Wing Lift Cylinders (Fig. 16, 17) Slotted holes in the lift cylinder bracket allow for adjust- ment of the wing lift cylinders. With the cylinder fully extended manually pull the pivot pin outward. The pivot pin should rest up against the outer edge of the pivot hole on each wing section.
Page 357: Repairs
The blade must be replaced if a solid object is hit, the blade is out-of-balance, worn or bent. Always use genu- ine TORO replacement blades to ensure safety and optimum performance. Never use blades made by other manufacturers because they could be dangerous.
Page 358 Inspecting and Sharpening Blade 1. Raise cutting unit to highest position, shut the engine off and engage parking brake. Block cutting unit to prevent it from falling accidentally. 2. Examine cutting ends of the blade carefully, espe- cially where the flat and curved parts of the blade meet. Since sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check the blade before using the machine.
Page 359: Belt Replacement
Belt Replacement (Fig. 22, 23, 24, 25) Wing Sections: 1. Lower cutting unit to shop floor, turn off engine and remove key. Remove belt covers. NOTE: To remove center section belt, the wing section belts have to be removed first. 2.
Page 360 Center Section: NOTE: Wing belts must be removed first. 1. Loosen capscrew nuts holding the spring bracket to the deck. Loosen the threaded rod jam nut, then gradu- ally loosen the tension nut to release the spring tension. CAUTION Loosen capscrew nuts holding the spring bracket to the deck before loosening threaded rod to avoid sudden movement of the spring bracket.
Page 361 Caster Arm Bushing Service (Fig. 26) The caster arms have bushings pressed into the top and bottom portion of the tube and after many hours of operation, the bushings will wear. To check the bush- ings, move caster fork back and forth and from side-to- side.
Page 362: Rear Caster Wheel Bearing Service
Rear Caster Wheel Bearing Service (Fig. 27) The rear caster wheels rotate on high quality roller bearings which are supported by spanner bushings. Even after many hours of use, provided that the bearing was kept well-lubricated, bearing wear will be minimal. However, failure to keep bearings lubricated will cause rapid wear.
Page 363: Front Caster Wheel Bearing Service
Front Caster Wheel Bearing Service (Fig. 28) The front caster wheels rotate on high-quality roller bearings which are supported by spanner bushings. Even after many hours of use, provided that the bearing was kept well-lubricated, bearing wear will be minimal. However, failure to keep bearings lubricated will cause rapid wear.
Page 364: Separating Cutting Unit From Traction Unit
Separating Cutting Unit From Traction Unit (Fig. 29) 1. Position machine on level surface, lower cutting unit 6. Have another person help push down on the right to the shop floor, shut engine off and engage parking push arm while you remove the capscrews, flat washers brake.
Page 365: Mounting Cutting Unit To Traction Unit
Mounting Cutting Unit to Traction Unit (Fig. 30, 31, 32, 33) 1. Position machine on level surface and shut engine off. 2. Move cutting unit into position in front of traction unit. WARNING Since the right hand push arm is spring loaded to about 100 pounds and left hand push arm is spring-loaded to about 150 pounds, another person is needed to help...
Page 366 IMPORTANT: The PTO shaft yokes must be exactly in line with each other when outer PTO is installed on splined shaft. Remove sleeve and change yoke position if alignment is not correct. Misalignment of the two yokes will shorten life of PTO shaft assem bly and cause unnecessary vibration when cutting unit is operated.
Page 367: Push Arm And Torsion Spring Service
Push Arm and Torsion Spring Service (Fig. 34, 35, 36, 37, 38, 39, 40) Removing Push Arms, Torsion Springs and Bushings 1. Separate cutting unit from traction unit and roll cutting unit away from traction unit. 2. Have a helper push down on the left push arm while you put a 4"...
Page 368 7. Remove the cap screws locknuts, carriage bolts, lock washers and nuts holding the brake mount and pedal assembly in place. Lay the brake mount and the pedal assembly on the wheel. 8. Have a helper push down slightly on the left push arm while you remove the block of wood between the push arm and the chassis.
Page 369 Installing Push Arms, Torsion Springs and Bushings 1. Apply grease to inside and outside of new bushings. Using a hammer and flat plate, carefully drive the bush- ings into the push arm pivot tubes. The bushings must be flush with the end of the tube. 2.
Page 370: Gear Case Removal And Installation
Gear Case Removal and Installation (Fig. 41, 42) 4. Remove flange nuts and carriage bolts securing gear Removing Gear Case and Drive Pulley case mount plate (Item 22) to cutting unit and remove 1. Lower the cutting unit, shut engine off and engage the plate and gear case.
Page 371 Continue to hit taper lock and tighten set screws until Installing Gear Case and Drive Pulley 55 in-lb of torque will not turn the setscrews. 1. Install bracket (Item 18) on each side of gear case with capscrews and lockwashers. Tighten capscrews to 6.
Page 372 Gear Case Repair (Fig. 43, 44) Figure 43 6. Remove bearing cups (Item 14) from cap by putting Gear Case Disassembly a punch through the shaft bore and through the seal and 1. Drain lubricant from gear case. then tapping against the back of the bearing cup until driven out of the cap.
Page 373 4, 5, 6 Figure 44 cap with the open side toward the machined side of the Gear Case Pre-Assembly cap. 1. Start with one of the shafts (Item 17) and put one of the gears (Item 10) over the shaft so the tooth side is 6.
Page 374 4. The shaft should have a very slight amount of bearing Gear Case Final Assembly drag. If the shaft turns hard, the cap must be removed 1. Bearing drag is adjusted by the amount of gaskets and gasket(s) need to be added. If the shaft has no (Item 4, 5, 6) used between the cap and housing ma- bearing drag, or has end play, the cap must be removed chined surfaces.
Page 375: Blade Spindle Service
Blade Spindle Service (Fig. 45, 46, 47) Removing Spindle Housing Assembly 1. Lower the cutting unit, shut the engine off and engage the parking brake. 2. Remove deck covers from top of cutting unit. Release belt tension. Remove belt from spindle to be serviced. 3.
Page 376 Assembly and Installation of Spindle IMPORTANT: If a new spindle housing is being used, new bearings and matched snap ring set must be installed; see step 1 below. Never use old bearings, spacer, and snap ring with a new spindle housing. If installing bearings into a used spindle housing that still has a snap ring installed, use only new bearings with cups and spacer –...
Page 377 Chapter 13 ® ® Guardian 72″ Recycler Cutting Unit Table of Contents SPECIFICATIONS ......2 Caster Arm Bushing Replacement .
Page 378: Specifications
Specifications ITEM SPECIFICATION __________________________________________________________________________________________ Cutting width 72 inches ________________________________________________________________________________________________________________________________________________________ Height of cut range 2 to 5 inches ________________________________________________________________________________________________________________________________________________________ Height of cut adjustment 0.5 inch increments ________________________________________________________________________________________________________________________________________________________ Blade bolt torque 85 to 110 ft-lb ________________________________________________________________________________________________________________________________________________________ Spindle nut torque 140 - 160 ft-lb. ________________________________________________________________________________________________________________________________________________________ Gearbox lubricant SAE 80W90, API GL-5 gear lube...
Page 379: Troubleshooting
Troubleshooting ® Groundsmaster 300 Series Page 13 - 3 Troubleshooting...
Page 380: Adjustments
Adjustments Height of Cut Adjustment (Fig. 2, 3) The height of cut is adjustable from 2 to 5 inches in 1/2 inch increments, by adding or removing an equal num- ber of spacers on the front and rear caster forks. The height of cut chart below gives the combinations of spacers to use for all height of cut settings.
Page 381: Adjusting Skids
Adjusting Skids (Fig. 4) 1. Adjust each skid by loosening the three (3) flange nuts and moving the skid to the desired position. Tighten the flange nuts to secure the skid in position. Figure 4 1. Skid 2. Flange nuts ®...
Page 382 Checking and Correcting Mismatch of Blades (Fig. 5) If there is mismatch between the blades, the grass will proceed to step 7 and add shims between spindle appear streaked when it is cut. This problem can be housing and bottom of cutting unit. corrected by making sure the blades are straight and all blades are cutting on the same plane.
Page 383: Repairs
CAUTION Do not try to straighten a blade that is bent, and never weld a broken or cracked blade. Always use a new TORO blade to assure continued safety certification of the product. Figure 6 1 . Raise cutting unit to highest position, shut the engine off and engage parking brake.
Page 384 Inspecting and Sharpening Blade 1. Raise cutting unit to highest position, shut the engine off and engage parking brake. Block cutting unit to prevent it from falling accidentally. 2. Examine cutting ends of the blade carefully, espe- cially where the flat and curved parts of the blade meet. Since sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check the blade before using the machine.
Page 385: Belt Replacement
Belt Replacement (Fig. 9, 10, 11) Signs of a worn belt are: squealing when belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks. Replace the belt if any of these conditions are evident. The blade drive belt is held under tension by a spring loaded idler.
Page 386 Caster Arm Bushing Service (Fig. 12) The caster arms have bushings pressed into the top and bottom portion of the tube and after many hours of operation, the bushings will wear. To check the bush- ings, move caster fork back and forth and from side-to- side.
Page 387: Caster Wheel Bearing Service
Caster Wheel Bearing Service (Fig. 13) The rear caster wheels rotate on high quality roller bearings which are supported by spanner bushings. Even after many hours of use, provided that the bearing was kept well-lubricated, bearing wear will be minimal. However, failure to keep bearings lubricated will cause rapid wear.
Page 388: Separating Cutting Unit From Traction Unit
Separating Cutting Unit From Traction Unit (Fig. 14, 15, 16) 1. Position machine on level surface, lower cutting unit to the shop floor, shut engine off and engage parking brake. 2. Remove self-tapping screws securing shield to top of cutting unit and set shield aside. 3.
Page 389: Mounting Cutting Unit To Traction Unit
Mounting Cutting Unit to Traction Unit (Fig. 14, 15, 16, 17) 1. Position machine on level surface and shut 8. Line up holes in yoke and input shaft of gear box. engine off. Slide yoke onto shaft and secure parts together with roll pin.
Page 390: Push Arm And Torsion Spring Service
Push Arm and Torsion Spring Service (Fig. 18, 19, 20, 21, 22, 23, 24) Removing Push Arms, Torsion Springs and Bushings 1. Separate cutting unit from traction unit and roll cutting unit away from traction unit. 2. Have a helper push down on the left push arm while you put a 4"...
Page 391 7. Remove the cap screws, locknuts, carriage bolts, lock washers and nuts holding the brake mount and pedal assembly in place. Lay the brake mount and the pedal assembly on the wheel. 8. Have a helper push down slightly on the left push arm while you remove the block of wood between the push arm and the chassis.
Page 392 Installing Push Arms, Torsion Springs and Bushings 1. Apply grease to inside and outside of new bushings. Using a hammer and flat plate, carefully drive the bush- ings into the push arm pivot tubes. The bushings must be flush with the end of the tube. 2.
Page 393: Gearbox Removal And Installation
Gearbox Removal and Installation (Fig. 25, 26) 4. Remove capscrews and nuts securing gear box plate Removing Gearbox and Drive Pulley (Item 10) to deck channels. 1. Lower cutting unit to shop floor, stop the engine and engage the parking brake. Remove belt covers from top 5.
Page 394 7. Using a brass drift pin or sleeve and a hammer, hit Installing Gearbox and Drive Pulley taper lock firmly. Now tighten set screws to 55 in-lb. 1. Install isolation mounts (Item 3) into brackets (Item 7, Continue to hit taper lock and tighten set screws until 13).
Page 395 Gear Box Repair (Fig. 27, 28) Figure 27 6. Remove bearing cups (Item 14) from cap by putting Gear Box Disassembly a punch through the shaft bore and through the seal and 1. Drain lubricant from gear box. then tapping against the back of the bearing cup until driven out of the cap.
Page 396 4, 5, 6 Figure 28 cap with the open side toward the machined side of the Gear Box Pre-Assembly cap. 1. Start with one of the shafts (Item 17) and put one of the gears (Item 10) over the shaft so the tooth side is 6.
Page 397 4. The shaft should have a very slight amount of bearing Gear Box Final Assembly drag. If the shaft turns hard, the cap must be removed 1. Bearing drag is adjusted by the amount of gaskets and gasket(s) need to be added. If the shaft has no (Item 4, 5, 6) used between the cap and housing ma- bearing drag, or has end play, the cap must be removed chined surfaces.
Page 398: Blade Spindle Service
Blade Spindle Service (Fig. 29, 30, 31) Removing Spindle Housing Assembly 1. Lower the cutting unit, shut the engine off and engage the parking brake. 2. Remove deck covers from top of cutting unit. Release belt tension. Remove belt from spindle to be serviced. 3.
Page 399 Installing Spindle, Bearings and Seals Into Spindle Housing IMPORTANT: If a new spindle housing is being used, new bearings and matched snap ring set must be installed; see step 1 below. Never use old bearings, spacer, and snap ring with a new spindle housing. If installing bearings into a used spindle housing that still has a snap ring installed, use only new bearings with cups and spacer –...
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This manual is also suitable for:

Groundsmaster 328-d Groundsmaster 345 Groundsmaster 322-d Groundsmaster 325-d

Toro Groundsmaster 300 Series Service Manual

Ford Vsg-411 Engine

Chapter 3

Table of Contents

Chapter 4 Stop Solenoid Replacement

Chapter 5 Hydraulic System

Chapter 11 - 72″Cutting Units

Chapter 12 - Triflex 88″Cutting Unit

Chapter 6 Electrical System

Electrical System

Chapter 7 Differential Axle

Chapter 8 Steering and Brakes

Chapter 9 Transmission Coupler and Pto

4Wd Rear Axle

Chapter 10 .1

72" Cutting Units

Triflex 88" Cutting Unit

72" Recycler

Quick Links

Service Manual

Chapters

Troubleshooting

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Summary of Contents for Toro Groundsmaster 300 Series