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Groundsmaster® 300 Series

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2. arbon build up in muffler Decarbon muffler Refer to starting failure low compression Adjust the injection timing Repair or replace pump Inspect the injection nozzle adjust pressure Inspect fuel line connections Clean replace filters Clean the fuel tank Clean the air cleaner replace the element if unserviceable Check coolant Adjust belt tension Replace water pump Clean repair the radiator inspect hoses and cap Adjust the injecting timing Add engine oil Replace thermostat Troubleshooting Page 4 16 Groundsmaster 300 Series 3 Excessive Oil Consumption Problem Probable Cause Possible Remedy Oil leaks 1 Oil seals worn Gaskets leaking Loose fasteners Drain plug is loose Pipe plugs at oil pump loose e Burning Oil Ring end gaps positioned wrong Connecting rod bent or twisted Piston rings worn Piston and cylinder are worn Faulty valve stem seal Valves or valve guides worn Oc RON Doak Check for wear and replace if worn Replace the gasket Retighten fasteners Tighten the plug Tighten the plugs Stagger end gaps properly Overhaul engine Replace the rings Overhaul engine Overhaul engine Replace valve stem seal Replace the valves or valve guides 4 Abnormal Engine Noises Problem Probable Cause Possible Remedy C
3. 11 8 Chapter 12 Triflex 88 Cutting Unit Specifications 12 2 General 12 3 12 4 12 5 REDAS S iss et Seb 12 13 Chapter 13 Guardian 72 Recycler Cutting Unit Specifications 13 2 13 3 13 4 iu eben ies EM 13 7 Groundsmaster 300 Series TORO SAFETY 1 Before Operating 1 While 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 Al though hazard control and accident prevention partially are dependent upon the design and configuration of the machine these factors are also dependent upon the awareness concern and proper training of the person nel involved in the operation transport maintenance and storage of the machine Before Operating 1 Read and understand the Operator s Manual before starting and operating the machine Become familiar with all controls and know how to stop quickly A replace ment manual is available by se
4. T Check diesel glow plug and injector nozzles if hard starting excess smoke or rough running is noted Immediately after every washing regardless of the intervals specified Notation for areas of concern Inspection performed by Item Date Information 1 2 3 4 5 6 7 See Operator s and Service Manual for specifications and procedures suia jeuonippy peuinbaJ earAJ8g g pue y SINN 6n7 jeeuM enbijo Duueeis pue 99UM y x99u5 JOIN 401seuy eds 29114 JI V 9M 29114 1 uoissiuisueJ eoejdeu uoissiusueJ sinou ooz eoiues 2 LI LJ L1 L1 L1 DL D LI LI 1S GG8 S6 ON W104 seunpeooud pue suoneouioeds enuey eoiues pue sJojeuedo ees peuinbaJ earAJ8g 2 pue 19949 SeA eA 1sn py anbioL uoissiuusueJ amp 1u amp 9uqn eixy amz sBuueeq 1681 Y d O xog 1299 suonoeuuo pue Y29490 usnjj ureaq and pinj4 eoejdeu usn J 1 1uej o02 eoejdeu Joyi4 jany oujoe 3 eoejdeu LI L1 L L1 L1 L1 L1 LI LI sesoH uino eoejdeu 93IAJO9S Jenuuy sinou oor 2 q J8y4 1042 Jedes 1o ewleseiq eoejdeu
5. 13 Engine Speed Adjustments 14 Throttle Linkage Adjustment 15 15 TESTING emet Dans 18 Glow Plug Test 18 Compression 19 Nozzle 20 Injection Pump Test 22 Injection Timing 23 Fuel Pump 24 Thermostat Test 24 PREPARATION FOR ENGINE REPAIR 25 Cylinder and Cylinder Block Overhaul 25 EXTERNAL ENGINE COMPONENT REPAIR 26 Crankcase Breather System 26 Alternator Belt Service 27 Fan Belt Service 27 Fan Fan Pulley and Fan Shaft Service 28 Glow Plug Replacement 29 Oil Pressure Switch Replacement 29 Oil Pump 30 Groundsmaster 300 Series Page 4 1 Rev Chapter 4 For Groundsmaster 322 D 325 D only Mitsubishi K3D Diesel Engine For Groundsmaster 328 D use the Toro Operator s Manual and Parts Catalog along with the Kubota 05 Series Workshop Manual Toro Part No 01090SL Stop Solenoid Replacement 32 Water Pump 33 FUEL SYSTEM REPAIRS 34 Bleeding the Fuel 5 34
6. 8 3 FORD VSG 411 413 ENGINE SERVICE MANUAL Item Specification Make Designation Ford Model VSG 411 Firing order 1 2 4 3 Ignition timing Distributorless Ignition System DIS Timing controlled by Universal Electronic Spark Control UESC Spark plug Motorcraft AGSF22C or AGRF22 or equivalent Spark plug gap 0 040 in 1 0 mm Crankcase oil capacity 3 5 U S qt 3 25 liter including filter Oil service classification API SG SG CC SG CD Oil viscosity Ambient temperature single viscosity oil 10 to 60 F SAE 10 10 to 90 F SAE 20 Above 32 F SAE 30 Above 50 F SAE 40 Ambient temperature multi viscosity oil Below 60 F SAE 5W 30 10 to 90 F SAE 10W 30 Above 10 F SAE 10W 40 or 10W50 Above 10 SAE 20W40 or 20W50 Fuel Unleaded gasoline 87 octane or higher Coolant 50 50 ethylene glocol anti freeze and water Cooling system capacity 6 U S qt 5 7 liter Carburetor idle speed setting throttle arm against stop 1350 50 RPM Governor idle speed setting 1500 50 RPM Governor high speed setting 3200 100 RPM Groundsmaster 300 Series Page 3 1 Rev C Specifications 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 electrode
7. 2 REPAIRS penr unio net s euge ae 13 GENERAL INFORMATION 3 Blade Service 13 Grass Belt Replacement 15 5 4 Caster Arm Bushing Replacement 17 5 Rear Caster Wheel Bearing Service 18 Mechanical 5 Front Caster Wheel Bearing Service 19 Skid and Roller 5 Separating Cutting Unit From Traction Unit 20 Height of Cut Adjustment 6 Mounting Cutting Unit to Traction Unit 21 Mismatch Adjustments 8 Push Arm and Torsion Spring Service 23 Belt Tension Adjustment 9 Gear Case Removal and Installation 26 Wing Pulley Section Brake 11 Gear Case Service 28 Wing Shaft End 11 Blade Spindle 31 Wing Lift Cylinders 12 Wing Stop 12 Groundsmaster 300 Series Page 12 1 Table of Contents Specifications ITEM Cutting width Center section only With one wing disengaged SPECIFICATION 88 inches 54 inches 71 inches Height of cut range 1 to 4 inches Height of cut
8. 4 53 Chapter 4A Kubota Diesel Engine General Information 4 2 Specificatlonis i Sescni 1 4 3 Chapter 5 Hydraulic System lt 5 2 General 5 3 Hydraulic 5 6 Hydraulic Flow Diagrams 5 7 Special TOS Laver tee es 5 10 Troubleshooting 5 12 Testing ud edu Beare ed 5 18 5 22 c sr REDE 5 26 Groundsmaster 300 Series Chapter 6 Electrical System Wiring Schematics 6 2 Special 6 3 Troubleshooting Groundsmaster 345 6 6 Troubleshooting Groundsmaster 322 D 325 D 6 12 TSUNG tne 6 18 ROPAS hea ete hie Mace wi eu E deeds 6 30 Chapter 6A Electrical System S N 21000000 amp Up Wiring Schematics 6 1 Special Tools 6 2 Electrical System Quick ChecksT 6 3 Component Identification and Testing 6 4 Service and 6 12 Chapter 7 Differential Axle Introduction llle 7 1 lt
9. 6 Turn the steering wheel all the way to the right clockwise and hold it against the right stop Look at the flow meter There should be no flow as the steering i Transmission wheel is held against the right stop Flow should be 2 Tester approximately 3 gom when the steering wheel is re 3 Load valve leased Repeat this procedure with the steering wheel all the way to the left counterclockwise If flow does not return to approximately 3 gom when the steering wheel is released the control valve within the steering valve may be sticking Figure 7 If a Hydraulic Tester is Not Available 1 Engage the parking brake 2 Run the engine at full throttle 3 Turn the steering wheel all the way to the right clockwise and hold it against the stop Pull the lift control lever back to raise the implement while holding the steering wheel against the stop The implement should NOT raise until the steering wheel is released Repeat this procedure with the steering wheel turned all the way to the left counterclockwise If the implement raises slowly or not at all when the steering wheel is released the control valve within the steering valve may by sticking When turning the steering wheel the wheels must move from stop to stop The wheels must move smoothly in both directions Groundsmaster 300 Series Page 8 7 Testing Steering Cylinder Internal Leakage Test 1 Engage the parking brake and lower the cutting unit to
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11. pue dno 19edsul Uoisue 9g Old 49949 euiBu3 1eg SJ9 02 jeg HUN pun uee 2 peuinbeJ 8 9 1299 5 Huljooy joedsu So qe2 exeJg eyeouqn uOisue Jeg pue uey sum eyeouqn 000000000 29114 eoejdeu suonoeuuo pue pinj4 2949 001 g os V JuUI0 aoasgwv ueioiuuoe uoneuDiseq eunnoi 104 siy ereordnp tejeg J9p40 YOM e2ueuejure y JosiAJedng q sze pue q zee H31SVINSQNnOH5 Table of Contents SPECIFICATIONS GENERAL INFORMATION Spark Plug Inspection and Replacement Alternator Belt Adjustment Coolant Fan Belt Adjustment Governor Specifications Chapter 3 For Groundsmaster 345 only Ford VSG 411 Engine 1 REPAIRS urn UE pedet aee ER 6 2 Crankshaft Pulley Installation 6 2 Engine Removal and Installation 7 3 Engine Repair
12. TEM A Ll iHon 3unssaua SVIS 24 MOTISA YILIWYNOH NMO3S8 HOLIMS AYNSS3yd aay Groundsmaster 300 Series 6 3 3 Rev MOTI3A GN N WOLVOIONI oma MOTD aas 1959 TWNNVW dv LINOIO IA das aas ovi8 Qa LU E ovi8 qoe 098 4 v bug la S48 l1HVlS A X 1 9 NNN Z YW ania 3NON 330 1 NONIO NOILISOd 8 AYLINDUIO HOLIMS NOILINO Movia NYL N J MOlvn938 e a9 JOYLA YOLVNYALTV INOA H 4 ama ywovig 22 a9nvo 190 T3A31 1303 MOTTA Wiring Schematics Groundmaster 328 D 3NIDN3 3NIDN3 3NIDN3 L o 1 1 1 8 BM0 N 59119 MOD Na se YYY 98 Ja na A 1 7 g t NO 7 t g 9 S 7 T M 8 yd QNDOND 3NIDN3 3H 43413901 3 XA sY d SINIOd CNNOYS SSJNBVH N dN31HDIH quoe NO TT 0102 Q iv yg lav Au3llv8 J LlVO3N _ GIONIOS NAY 010m UJ IND Ali MS DAYS ONDIVd 1 1 NO Ti8Y3 ANTLLW JAILISOd YU e M ee c ill 04915 9 Toa Ya 58 f C
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14. Figure 3 1 Skid adjustment 2 Anti scalp roller adjustment When height of cut is set at 1 to 1 1 2 inches the center anti scalp roller and the two ball rollers on the front of the deck should be in the upper position when the height of cut is 2 to 4 inches the rollers should be in the lower position Figure 3 1 Center anti scalp roller 2 Upper and lower holes Groundsmaster 300 Series Page 12 5 Adjustments 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 Height of cut Spacers Below Caster Arms inches mm Front Rear 1 25 0 0 1 1 2 38 1 1 2 51 2 2 2 1 2 64 3 3 3 76 4 4 3 1 2 89 5 5 4 102 6 6 NOTE Amore optimum cutting appearance in the 1 inch height of cut setting can be achieved by lowering the rear of the cutting unit Do this by relocating the rear caster wheel axles in the upper holes of the caster forks Install the axles into the lower caster fork holes for settings above 1 inch IMPORTANT The rear caster wheel mounting hole in use must be towards the rear of the deck This is necessary to provide adequate clearance between the caster wheel and the mechanical door If neces sary the caster fork assembly should be removed fro
15. 12 Front Caster Wheel Bearing Service 13 Separating Cutting Unit From Traction Unit 14 Mounting Cutting Unit to Traction Unit 16 Push Arm and Torsion Spring Service 18 Gearbox Removal and Installation 21 Gearbox 23 Blade Spindle Service 26 Table of Contents Specifications ITEM Cutting width SPECIFICATION 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 Ib left hand thread Spindle nut torque 140 160 ft Ib Spindle end play 006 inch max Spindle rolling torque 10 in Ib max Gearbox lubricant SAE 80W90 API GL 5 gear lube Figure 1 1 Filler plug 2 Check plug Specifications Page 11 2 Groundsmaster 300 Series General Information Grass Deflector A 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 ARAISED POSITION SINCE THE BLADES COULD THEN THROW DEBRIS A CONSIDERABLE DIS TANCE WITH SUFFICIENT FORCE TO CAUSE PER Figure 2 SONAL INJURY OR DAMAGE TO PROPERTY If the grass deflector is
16. 25 Do nottouch engine muffler or radiator while engine is running or soon after it has stopped These areas could be hot enough to cause a burn 26 Lower the cutting unit or other attached implement to the ground and remove key from switch whenever machine is left unattended Groundsmaster 300 Series 27 Before getting off the seat A Move traction pedal to neutral position and re move foot from pedal B Set the parking brake and disengage the PTO C Shut the engine off and remove key from ignition switch Wait for all movement to stop before getting off the seat While Doing Maintenance Troubleshooting Testing Adjustments or Repairs 28 Remove key from ignition switch to prevent acciden tal starting of the engine when servicing adjusting or storing the machine 29 Make sure you understand a service procedure before working on the machine Unauthorized modifica tions to the machine may impair the function safety and life of the machine If major repairs are ever needed or assistance is desired contact an Authorized TORO Distributor 30 To reduce potential fire hazard keep the engine free of excessive grease grass leaves and accumulations of dirt Clean protective screen on front of engine fre quently When cleaning parts do not use flammable solvents such as diesel fuel kerosene or gasoline 31 THE ASBESTOS BRAKE LININGS CONTAIN ASBES TOS FIBERS BREATHING ASBESTOS DUST MAY BE HAZ ARDO
17. 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 Tighten the idler pulley flange nut Recommended tension is 3 8 inch deflection when an eight 8 pound load is applied to the center of the 25 inch span between pulleys Deflection is meas Figure 6 ured at the position on the belt where the load is applied 1 Lower belt idler 2 Flange nut Groundsmaster 300 Series Page 11 7 Adjustments Repairs Blade Service Fig 7 8 9 The blade must be replaced if a solid object is hit the blade is out of balance worn or bent Always use genuine TORO replacement blades to ensure safety and optimum performance Never use blades made by other manufacturers because they could be dangerous 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 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 Grasp end of blade using a rag or thickly padded glove Remove special screw belleville washer and blade from spindle assembly NOTE The special screw has left hand thread 3 To install the blade assemble parts in reverse order and make sure the blade sail is facing up Tighten special screw to 75 to 100 ft lb SPINDLE ASSEMBL
18. Figure 78 Repairs Page 8 40 Groundsmaster 300 Series 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 18 Screw the eleven hex socket head cap screws loosely into the metering package Fig 80 NOTE The commutator ring must be concentric with the drive plate within 0 005 in 0 127 mm total indicator reading AFTER tightening the eleven hex socket head cap screws The next two procedures are a method of achieving the concentricity 19 Put the metering ring on a hard flat surface Put the assembled metering package into the metering ring with the commutator cover down so the drive plate is par tially out of the metering ring Fig 81 A suitable wood block under the metering package will hold it in this position Put one piece of 0 007 in 0 18 mm shim stock approximately 0 5 in 12 mm wide and 1 5 in 38 mm long between the metering ring and drive plate in three places approximately equal distance around the outside diameter of the drive plate Groundsmaster 300 Series Page 8 41 Figure 79 Figure 80 Figure 81 Repairs 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 p
19. 8 Connect a continuity tester or ohm meter to switch connector With seat in down position and no one on seat the switch circuit should have no continuity If there is continuity check switch installation If there is no continuity go to next step 9 Set on the seat The seat switch should have conti nuity If there is no continuity check switch installation If there is continuity go to next step 10 Push switch connectors together 11 AWD units only Install sealing plate to frame above fuel tank 12 Connect battery cable and install instrument cover Repairs Page 6 36 Groundsmaster 300 Series TORO Table of Contents Chapter 6A For GM 345 Serial Number above 21000000 and GM 328 D Electrical System ELECTRICAL SCHEMATICS 1 Diode Assembly 7 SPEGIAL TOOLS iue TID Rhet Leber 2 Control Ignition Delay Module ELECTRICAL SYSTEM QUICK CHECKS 3 Groundsmaster 345 8 Battery Test Open Circuit Test 3 Glow Relay Groundsmaster 328 D 8 Charging System 3 Glow Controller Groundsmaster 328 D 9 Glow Plug System Test Groundsmaster 328 D 3 Run Solenoid Groundsmaster 328 D Solenoid COMPONENT IDENTIFICATION AND TESTING 4 with 3 Wire Connector 10 Seat Switch 4 Run Solenoid Groundsmaster 328 D Solenoi
20. A transmission that is too high at the drive coupling end may be lowered by installing a 1 16 inch 1 6 mm spacer between the rear of the mounting pad and the bottom of the frame A transmission that is too low is corrected by installing a 1 16 inch 1 6 mm spacer between the front of the mounting pad and the bottom of the frame To install the spacers remove the appropriate two cap screws and loosen the other two If the spacers must be added to the front of the mounting pad remove the front cap screws and loosen the back ones Do just the Figure 3 opposite to add spacers at the rear of the mounting pads After adding the spacers install the two cap screws and tighten all of the cap screws to secure the axle in place Check the alignment again Continue to check the align ment and add shims as required When the alignment is correct tighten the axle support nuts Tighten the rear nut with the fingers until it contacts the frame then tighten the front nut securely Secure the rear nut last Figure 4 Adjustments Page9 4 Groundsmaster 300 Series 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 4 To adjust hold head of adjusting screw with wrench un
21. Front left 11th link Front right 8th link Rear 7th link 11 Check operation to make sure chains lift deck tight against stops when lift arm is raised Figure 17 Front left lift chain 2 Front right lift chain 3 Rear lift chain Repairs 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 x 4 block of wood between the chassis and the top of the push arm and across the full width of the machine 3 Loosen the large jam nut on the left hand ball joint at the end of the push arm Remove the ball joint mount attached from the push arm 4 Remove the self tapping screws holding the floor plate to the main frame Raise the floor plate and set it aside 5 Disconnect the right hand brake cable from the brake strut Remove the jam nut holding the brake cabled in the mount on the frame and slide the cable through the hole in the push arm bracket 6 Remove the cotter pin from the end of the parking brake rod Slide the rod out of the latch Repairs Page 13 14 n BALL JOINT MOUNT REMOVED Wr EIL PARKING BRAKE R D 217 Figure 20 Groundsmaster 300 Series 7 Remove the cap screws locknuts carriage bolts lo
22. Loss Of Power Or Unit Will Not Operate In Either Direction Check Check Check Inspect Inspect Ok engine to hydraulic by pass inlet rpm transmission oil level valve filter coupler Disconnected Inspect traction control linkage Check charge pump pressure flow Ok Low or damaged Low Open or defective Loose or clogged Loose or defective i l i Adjust Fill to Close Tighten Adjust use Repair proper or or or tachometer level repair replace repair Inspect charge pump Inspect implement relief valve Defective Defective Repair or replace charge pump implement relief valve Repair or replace transmission pump amp motor Inspect valves Defective l Repair or shim acceleration Inspect charge relief valve Defective Repair or shim charge relief valve Check traction pressure Ok l Repair or replace Differential or other non hydraulic Troubleshooting Page 5 14 problem Groundsmaster 300 Series Check Inspect engine underside of rpm cutting unit Low Excess debris Adjust use Clean tachometer Repair or replace transmission pump amp motor Inspect charge pump Defective l Check Inspect lift Inspect hydraulic valve control lift arm oil level linkage pivots Bindi
23. Traction Neutral Switch Replacement Fig 25 1 Remove the two wires that are connected to the traction switch TRACTION 2 Loosen two 2 screws and remove the switch SWITCH 3 Install new switch DO NOT over tighten screws as the switch case could break NOTE Apply Loctite 271 or equivalent to threads of Switch screws before installing BEARING 4 Reconnectthe two wires to the new switch Make sure LEAF that one wire is connected to the COMMON terminal SPRINGS and one wire is connected to the NORMALLY OPEN N O terminal PUMP LEVER IMPORTANT The traction switch has three 3 ter minals If the two 2 wires are not connected to the Figure 25 COMMON and NORMALLY OPEN N O termi nals the engine will be unable to start and the safety interlock circuit will not function properly A CAUTION If the wires are not correctly installed to the switch the engine could start with the trac tion pedal in forward or reverse 5 Coat the switch terminals and wires with skin over grease 6 Check traction control neutral adjustment See Trac tion Control Neutral Adjustment in the Adjustments sec tion of Chapter 4 HYDRAULIC SYSTEM 7 Actuate the pump lever to insure all parts are operat ing freely and seated properly 8 Loosen jam nut Rotate switch adjusting screw until there is a gap between head of screw and switch button 9 Rotate adjusting screw until it contacts the switch
24. 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 Install thicker or additional bearing case shim s to move pinion shaft toward ring gear Figure 32 B Install thinner or remove differential bearing shim s to move ring gear backward E Toe Contact Tip Contact C Repeat until proper tooth contact and pinion gear to ring gear backlash are correct Ss Ser 2 If contact is toward the toe or tip of the gear Fig 33 A Install thinner or remove bearing case shim s to move pinion shaft away from ring gear B Install thicker or additional differential bearing shim s to move ring gear forward Figure 33 C Repeat until proper tooth contact and pinion gear to ring gear backlash are correct 4WD Rear Axle Rev G Page 10 1 18 Groundsmaster 328 D Dae Dong Axle Bidirectional Clutch Loctite 242 Anti seize Lubricant 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 Lock washer 11 Drive shaft assembly 4 Bidirectional clutch 8 Cap screw 12 Rear axle assembly Removal Fig 34 1 Park machine on a level surface lower cutting deck or implement stop engine engage parking brake and remove key from the ignition switch 2 Dr
25. Figure 19 1 Cutting blade 2 Mounting screw and washer 3 Anti scalp cup 4 Flange bolts 6 5 Spindle housing Repairs 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 If any wear is noticed replace the blade refer to Removing Cutter Blade A WARNING If the blade is allowed to wear a slot will form between the sail and flat part of the blade Eventually a piece of the blade may break off and be thrown from under the housing pos sibly resulting in serious injury to yourself or bystander 3 Examine cutting edges of all blades Sharpen the cutting edges if they are dull or nicked Sharpen only the top side of the cutting edge and maintain the original cutting angle to assure sharpness The blade will remain balanced if same amount of metal is removed from both cutting edges 4 To check blade for being straight and parallel lay blade on level surface and check its ends Ends of blade must be slightly lower than the center and cutting edge must be lower than heel of the blade This blade will produce good quality of cut
26. INTRODUCTION TROUBLESHOOTING Engine to Transmission Coupler PTO System ADJUSTMENTS Checking Drive Coupling Alignment Adjusting Drive Coupling Alignment Correcting PTO Belt Slippage PTO Pulley and Engine Pulley Alignment PTO Brake Adjustment Groundsmaster 300 Series Chapter 9 Transmission Coupler and PTO 2 REPAIRS ce ness cete Sede tate pisa 7 3 Drive Coupling Removal and Installation 7 3 Engine Pulley Yoke Bearing Replacement 8 3 PTO Brake 8 4 PTO Belt 9 4 Removing PTO Control Lever and Linkage 10 4 PTO Shaft and Bearing Service 11 5 PTO Drive Shaft Removal and Installation 12 5 PTO Drive Shaft Universal Joint Replacement 13 6 Installing the PTO Drive Shaft 14 Page 9 1 Table of Contents Introduction Engine to Transmission Coupler Fig 1 Engine power is transmitted from the engine through a flexible coupling and drive link to the hydrostatic trans mission With this Toro design there is no clutch used between the engine and the transmission The drive coupling consists of three main components a metal drive coupling shaft a rubber coupling bolted to each end of the shaft and the pump hub PTO System Fig 1 The power take off PTO system transmits power from the engine to the cutting deck or other implement at tached to the from of the machine The PTO leve
27. NOTE Idler arm assembly is shimmed to center the brake pad vertically in the pulley groove Add washers under the idler arm pivot hub as necessary Figure 14 1 Brake pad capscrews 2 per wing 3 Allen wrench 2 Brake pad 4 15 angle Wing Shaft End Play Fig 15 Slotted holes in the hinge bracket allow for adjustment of wing shaft end play End play should be no more than 1 16 inch Figure 15 1 Slotted wing shaft bracket holes 2 Slotted lift cylinder bracket holes Groundsmaster 300 Series Page 12 11 Adjustments 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 Tighten the bolts to a torque of 65 ft Ib Once the cylinder is in the correct position adjust the wing vertical stop on the top of the deck NOTE If the wings do not raise all the way perpendicu lar to the deck the wing lift cylinders may need adjust ment Adjust the wing stops after adjusting the wing lift cylinders Figure 16 1 Slotted wing shaft bracket holes 2 Slotted lift cylinder bracket holes Figure 17 1 Wing lift cylinder 3 Designed gap 2 Manually pull pin forward Wing Stop Adjustment Fig 18 1 Lower deck to floor remove wing cover and raise wings to 90 perpendicul
28. Part No 9280151 Rev I Service Manual Groundsmaster 300 Series Preface Groundsmaster 328 D 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 information for troubleshooting testing and repair of major systems and components on the Groundsmaster 345 322 D and 325 D Model 30788 and 30795 REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR S MANUALS FOR OPERATION MAINTENANCE AND ADJUSTMENT INSTRUC TIONS Space is provided in Chapter 2 of this book to insert the Operator s Manuals and Parts Catalogs for your machine Replacement Operator s Manuals are available by sending complete Model and Serial Num ber of traction unit and cutting unit to The Toro Company 8111 Lyndale Avenue South Minneapolis MN 55420 The Toro Company reserves the rightto change product specifications or this publication without notice A This safety symbol means DANGER WARN ING or CAUTION PERSONAL SAFETY IN STRUCTION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE A NOTE will give general information about the correct operation maintenance service testing or re pair of the machine IMPORTANT The IMPORTANT notice will give im portant instructi
29. 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 3 Measure the spring free length The standard dimen sion is 1 69 inches 43 mm Springs which measure 1 64 inches 41 7 mm or shorter must be replaced 4 Over time valve springs can lose some of their tension Test the springs to make sure that the spring pressure is within the following limits 23 5 28 5 Ibs 11 2 12 4 Kg with the installed length of 1 46 inches 37 1 mm When the spring pressure at the length given is 20 lbs 9 5 Kg or less the spring must be replaced NOTE Valve springs are inexpensive compared to the cost of repairing engine damage due to weak valve springs Rocker Arm and Rocker Shaft Service Fig 1 Disassemble the rocker shaft by removing the outside retaining rings on each end and by removing the two rocker arms stay bolts and seats from the rocker shaft 2 Inspect each rocker arm for signs of wear where they contact the valve tip and push rod contact surfaces Rocker arms which are worn should be replaced 3 Examine the rocker shaft for excessive wear or damage Replace it if it is defective 4 Measure the rocker arm inside diameter and the shaft outside diameter The maximum clearance be
30. 0 0039 inch 0 10 mm Exhaust 0 0059 inch 0 15 mm Cylinder Head Overhaul Page 4 48 Groundsmaster 300 Series 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 2 To install the new guide press it in from the top of the cylinder head using the valve guide mandrel Valve guides should be installed so that their installed height is as shown NOTE Placing the valve guide in a refrigerator or freezer for several minutes before installation will aid in assembly 3 After installing the valve guide again check the guide to stem clearance If the clearance is smaller than the standard size it will be necessary to ream the valve guide bore to obtain the proper clearance Valves Fig 56 1 Carefully clean each valve with a wire wheel to remove all carbon deposits 2 Check the valve face and the valve stem for excessive wear damage cracks or deformation If any of these conditions exist the valve must be replaced It is possi ble to reface the valve as long as the margin or valve lip thickness is not less than the surface limit 3 Check the tip of the valve stem for wear or pitting If pitted or worn the valve stem tip may be resurfaced by placing the valve stem in a V block and dressing the tip
31. 15 3rri8 NMOH8 Uu NMOHS S SIAM _ __ 1VOH TA 13n4 36vno 13n4 mim m IVHLO 3N NI TvO3d NOILOVYL HLIM GASVONASIC Old HLIM 038019 HOLIMS aa L 035019 HOLIMS MS ama Movid MS Old TWHLNAN eame lt LINN 9NIGN3S ies oO 2 2 Pom z z amp IL 9 m m 1v3sNO e z HOIVH3dO 3 o ow ON HLIM 5 E SYA N3dO HOLIMS m 5 YNOH MS 1V3S 3ONVHO 3ovia 123 eee gt WHO 02 09 V9 vl MOVIE vO 1 ana QNI We T AV T3H 390 1H31NI YALYVLS qaad AV I3H dWAL MOTT3A AVH MS 39vn9 dIWAL qaad agy Groundsmaster 300 Series Page6 2 1 Rev Wiring Schematics Groundmaster 345 incon IOH1NOO NOILINSI 82 Ws v WOO 9 v9LMuVdS 81 AWIL INVIOOO 6 WOO HOSN3S YOSNAS dV 8 vds 4 v Quvids lt WOSN3S NOILISOd MNVHO GION310S 1915 Trona 84 a 3aoia NOILOSLOYd en gt za a 8 3doia 21901 LYVLS puc 98 98 1 1 o 97128 A i ok Lag OT 7 BIS ull 1 SS3NMHVH AN 3 18IS0H OL 9 Serial Number higher than 21000000 HOLIMS JAVY ONDISIV T 3NION3 5 HD LIMS 55 Tand 3Hn3dWal AO
32. 16 17 1 Remove the P T O drive shaft 2 Separate the two sections of the P T O shaft 3 Mount the section to be repaired in a vise so that the U joint is pointing upward NOTE If the splined portion is to be repaired protect the splines from vise damage with wooden blocks vise jaw cushions etc 4 Use two thin screwdrivers to remove the C shaped snap ring from each of the U joint rollers located inside of each yoke Remove the shaft from the vise 5 The vise may now be used as a press by placing a small socket against one roller and a large socket against the yoke on the opposite side As the vise is closed the small socket will force the cross to push the opposite roller partway into the large socket 6 When the roller is forced partway out grasp the roller and strike the yoke to complete removal Do not spill the needle bearings 7 Follow steps 5 and 6 to complete the removal of the U joint from the P T O shaft 8 When replacing the U joint pack the roller bearings with the recommended lubricant multi purpose grease Pack carefully to eliminate trapped air Install seals 9 Start one of the rollers in the yoke Insert from the bottom with the open side of the roller up to prevent loss of the needles Make sure that each roller contains all of the needles 10 Insert one of the cross trunnions into the roller Start the other roller making certain it slips over the trunnion 11 When partially se
33. 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 6 Install the plunger valve side out plunger spring valve o ring washer and spring retainer Make sure the plunger operates freely 7 Install the filter and cover gaskets magnet filter and cover Tighten the cover to prevent air leaks 8 Install the fuel pump to the frame Connect the fuel lines and electrical wires 9 Bleedthe fuel system See Bleeding the Fuel System in this section of the book Fuel System Service Page 4 36 1 Spring retainer 2 Washer 3 O ring 4 Valve Figure 39 5 Plunger spring 6 Plunger 7 Plunger tube 8 Body Groundsmaster 300 Series Governor Mechanism Operation Operation of the governor keeps the engine speed constant as the centrifugal force acting on the governor weights balances with the tension of the governor spring Asthe engine speed increases the governor weights will open forcing the end of the sliding shaft against the governor lever The governor lever then moves against the governor spring tension and moves the control rack through the tie rod in the direction that decreases the amount of fuel delivered by the injectio
34. 5 Slide the flat washer onto the shaft and install the snap ring into the groove at the end of the shaft Do not use a flat washer that is bent 6 Install the control lever and the interlock switch as sembly on the right side of the transmission Adjust the traction pedal control rod and linkage for neutral refer to Traction Control Neutral Adjustment 7 Since some oil drained out of the transmission when the seals were replaced check the oil level in the axle housing Start the engine and let it run for about one or two minutes Then turn the engine off and check the oil level in the axle housing again Also check the seals in the transmission for oil leaks Repairs Page 5 26 Groundsmaster 300 Series 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 4 Check the O ring and back up ring for damage If the parts are damaged replace them 5 If the O ring or back up ring was removed because of damage slide the new back up ring into the groove at the center of the valve then install the O ring into the same groove 6 To install the by pass valve screw it into the center section Tighten the valve to 5 8 ft lb 7 Since some oil drained out of the transmission
35. 6 Alarge snap ring is still inside the spindle housing and it should remain there because it cannot be easily removed IMPORTANT If new bearings will be installed into a used spindle housing that has the original snap ring installed discard the large snap ring that came with the bearings because it is not needed However new bearings with their matched spacer and snap ring must always be installed when the spindle housing is being replaced Replacement bearings are sold only with a matched snap ring and spacer set These parts cannot be purchased separately Groundsmaster 300 Series Page 12 31 O N O Or d Grease fitting Jam nut Washer Wave seal Carriage bolt Flat washer Spindle housing Flange nut Figure 45 9 Spindle shaft 10 Spindle spacer 11 Blade 12 Anti scalp cup 13 Flat washer 14 Capscrew 15 Bearing assembly 16 Spacer matched set Repairs 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 not the large snap ring because it is not required see step 2 below 1 Install large snap ring into groove in bore of spindle housing Make sure snap ring is sea
36. Finish Undersize Journal U S 0 25 mm 0 01 in Journal U S 0 50 mm 0 02 in Journal U S 0 75 mm 0 03 in Pin U S 0 25 mm 0 01 in Pin U S 0 50 mm 0 02 in Pin U S 0 75 mm 0 03 in 51 735 51 750 mm 2 0368 2 0374in 51 485 51 500 mm 2 0270 2 0276 in 51 235 51 250 mm 2 0171 2 0177 in 41 700 to 41 715 mm 1 6417 1 6423 in 41 450 41 465 mm 1 6319 1 6325 in 41 200 41 215 mm 1 6220 1 6226 in 0 95 mm 0 037 in Specifications Page4 6 Groundsmaster 300 Series 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 1 0 mm 0 039 in both intake and exhaust Pump Camshaft Drive System Gear Bearing Front Ball bearing Rear Oylinder block hole Cam Lobe Height 44 mm 1 732 in 1 0 mm 0 039 in Tappets Outside Diameter 23 mm 0 906 in Tappet to Cylinder Block Hole Clearance 0 15 mm 0 006 in Push Rod Bend 0 3 mm 0 012 in max Lubrication System Item Standard Specification Repair Limit Service Limit Oil Capacity 3 5 liter 3 7 qt including oil filter API Service Class CD Viscosity Above 68 F 20 C SAE 30 or 10W 30 41 F to 6
37. Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Equivalents and Conversions 2 2 Groundsmaster 300 Series 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 5 8 Capscrew Head Markings i 2 5 Nam Q Capsc 3rade 5 Caps rque Grade 8 Capscrew Body Size Cast Iron Aluminum Cast Iron Aluminum ft lb Nm ft lb Nm ft lb Nm ft lb Nm 1 4 20 7
38. Lock nut 10 Spindle shaft 3 Spindle pulley 11 Spindle shaft spacer 4 Wave seal 12 Blade 5 Bearing assembly 13 Anti scalp cup 6 Carriage bolt 14 Lock washer 7 Flat washer 15 Blade screw 8 Spindle housing Groundsmaster 300 Series 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 not the large snap ring because it is not required see step 2 below 1 Install large snap ring into groove in bore of spindle housing Make sure snap ring is seated in groove 2 Using an arbor press push large spacer into top of spindle housing tightly against snap ring The spacer must contact the snap ring to be sure of the correct assembly of the parts Ly 2 t R N 3 Thoroughly oil the bearing cups and using an arbor press push the bearing cups smallest inside diameter first into the top and bottom of the spindle housing The top bearing cup must contact the spacer that was in stalled in step 2 and the bottom bearing cup must contact the snap ring to be sure of the correct assembly of parts Insure that the assembly is correct by support ing the first cup and pressing t
39. N31H9I1 N3J0u8 N340u8 Y0 3 001 TOU 35001 A311fd Old 194dSNI LAVHS 018 123dSNI LAVHS 1 41 0 3NI9N3 NO A311fd 1234SNI 0 39V14d3u N31H9IL SONNOd 1004 001 01 SL 3nD9u011uU 39V 1439 N3dU VHS N3X0uU8 35001 325001 1110 1N38 Groundsmaster 300 Series Page 12 4 Troubleshooting 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 To adjust mechanical door disconnect threaded rod from the door by removing cotter pin Loosen the jam nut and turn the rod in or out so that the bottom of the door is 1 4 inch up from the bottom of the deck side panel when the wing is fully raised Tighten jam nut and install the cotter pin Figure 3 1 Threaded rod 4 Jam nut 2 Mechanical door 5 1 4 6 mm gap 3 Cotter pin Skid and Roller Adjustment Fig 4 5 When height of cut is set or changed skids and anti scalp rollers should also be adjusted adjust on a hard level surface 1 inch height of cut skids all the way up 1 1 2 inch height of cut skids 3 8 inch to 1 2 inch off the ground 2 1 2 inch height of cut skids all the way down
40. NOTE To ease reassembly tag each of the hoses to show their correct position on the steering cylinder 3 Remove the lock nut and cap screw securing the rod end of the cylinder to the steering pivot 4 Remove the lock nut cap screw and spacer securing the barrel end of the cylinder to the rear axle 5 Remove the cylinder 6 Reverse steps 2 5 to install the steering cylinder Tighten the cap screw and nut securing the rod end of the cylinder to the steering pivot to 130 150 ft Ib 7 After installing the cylinder bleed the hydraulic system Repairs Page 8 18 Groundsmaster 300 Series Steering Cylinder Service IMPORTANT To prevent damage to rod or barrel clamp vise on pivot ends only DO NOT clamp against smooth rod surface 1 After removing the cylinder pump oil out of cylinder into a drain pan by SLOWLY moving piston in and out of cylinder bore 2 Plug the ports and clean the outside of the cylinder 3 Mount cylinder in a vise so rod end of cylinder is tilted up slightly Do not close the vise so firmly that the cylinder barrel could become distorted 4 Use aspanner wrench to unscrew counterclockwise head Fig 21 Item 2 from barrel Item 1 5 Grasp large end of piston rod Item 4 and use a twisting and pulling motion to carefully extract piston rod and head from cylinder tube 6 Securely mount piston rod and head into vise so large nut Item 6 is easily accessible for removal R
41. adjustment DO NOT over tighten the nut or the solenoid may become distorted causing it to malfunction 11 Connect the solenoid wires install the cover External Engine Component Repair Page 4 32 CONTROL RACK INJECTION PUMP PLUNGER END HOLD IN PLUNGER Figure 34 Groundsmaster 300 Series Water Pump Servicing The water pump is a centrifugal impeller type pump which is mounted on the front upper part of the cylinder block The pump bearings and seals are not service able Water Pump Removal 1 Drain the coolant from the radiator and cylinder block drain plug on the left hand side of the block 2 Disconnect the water hoses 3 Remove the V belt which drives the water pump 4 Disconnect the water bypass hose 5 Remove the six bolts fastening the water pump to the cylinder block Groundsmaster 300 Series Page 4 33 Water Pump Inspection 1 Inspect all hoses for cracks or leaks 2 Rotate the water pump impeller and shaft If the bearings do not rotate smoothly or are noisy the water pump must be replaced the water pump has no replace able components Water Pump Reassembly Reassemble in reverse order of disassembly Use a new water pump gasket to avoid leaks now move freely when operated by hand If it does not difficulty with the injection pump should be suspected External Engine Component Repair Fuel System Service When cleaning the engine DO NOT spray water onto a hot
42. against a grinding wheel Groundsmaster 300 Series Page 4 49 e E E 12 0 5mm 0 49 0 02 in VALVE GUIDE Figure 55 Installing valve guide 6 6mm 0 26 in 3 5mm 0 14 in IN 27 2mm 1 07 in EX 25 2mm 0 99 in Figure 56 Dimensions of valve Cylinder Head Overhaul 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 After lapping thoroughly clean the valve seat and valve areas to remove any traces of lapping compound To verify that the valve face is making proper contact to the valve seat lightly coat the valve seat area with Prussion blue install the valve rotate the valve 1 4 turn while holding it down and then bring it back to the original position Remove the valve and examine the valve seat The valve seat should show an even wear pattern from contact with the valve Ex amine the valve The dye should be evenly distributed around the valve and in the center of the valve face Cylinder Head Overhaul Page 4 50 26 2mm 24 2mm 1 03 in 10 95 in INTAKE EXHAUST Figure 57 Dimension of valve seat 1 to 1 5mm 0 039 to 0 059 in EXHAUST 24 2 mm 0 95 in Figure 58 Correction of valve seat Groundsmaster 300 Series
43. button Continue to rotate the screw until the circuit is completed switch clicks After the switch clicks ro tate the adjusting screw an additional 1 2 turn Tighten jam nut Repairs Page 6 32 Groundsmaster 300 Series 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 4 Install new switch with capscrew and locknut Move PTO lever to OFF position When lever is in its normal released position the switch arm must bend about 1 2 inch 13 mm If switch arm does not bend 1 2 inch 13 mm bend the mounting bracket to get the correct adjustment 5 Connect a continuity tester or ohm meter to switch connector With PTO lever in forward ON position the Switch circuit should have no continuity If there is con tinuity check switch installation If there is no continuity go to next step 6 Move PTO lever to OFF position When PTO lever is in its normal released position the PTO switch should have continuity If there is no continuity check switch installation If there is continuity go to next step 7 Liberally coat inside of wiring connectors with skin over grease Push wire harness connectors together Connect negative battery cable to
44. contamination NOTE To ease reassembly tag all lines as to their proper location Groundsmaster 300 Series Page 5 33 7 Loosen and remove the engine to transmission coupler refer to Removing Drive Coupling of Chapter 10 8 Disconnect and remove the traction pedal rod where it fastens to the transmission 9 Support the transmission to prevent it from failing while removing the two cap screws that secure the transmission to the differential 10 Carefully pull the transmission out of the differential and guide it down and out from under the machine 11 Remove the gasket that fits between the transmis sion and differential 12 Thoroughly clean the area of the differential where the new or rebuilt transmission will be installed 13 Reverse steps 1 10 to reinstall the transmission and use Loctite 271 on the two cap screws that hold the hydrostat to the differential 14 Replace the hydraulic oil filter and fill the system with oil Repairs Transmission Overhaul As the transmission components are removed for ser vice and inspection it should be noted that nominal wear to the components is acceptable Critical contact surfaces i e charge pump gerotor piston slippers etc must be in good condition or the system will be inefficient When components have circumferential scratches or grooves noted on the running surfaces it is an indication of foreign material in the hydraulic oil If upon inspec
45. cylinder block and muffler bracket 8 Remove fan assembly from machine 9 Remove cotter pins slotted nuts woodruff keys and washers from ends of the fan shaft Note number and placement of washers 10 Remove pulley from end of shaft it may be neces sary to use a puller 11 Remove cap screws and lock washers which retain fan to fan hub Remove fan hub and woodruff key from shaft NOTE If bearings or mating tube and shaft surfaces are not worn or damaged do not disassemble 12 Press shaft and fan side bearing from tube by pressing on belt pulley end of shaft Inner races of bearings are pressed onto shaft and fit against shoul ders on shaft both bearings are also pressed into tube ends 13 Press remaining bearing from tube by applying pressure to bearing outer race External Engine Component Repair Page 4 28 Rev D Fan Assembly Inspection 1 Inspect fan for cracks replace fan if damaged 2 Inspect shaft and tube for signs of wear in bearing areas replace if bearings are loose and a press fit is not possible 3 Rotate bearings replace them if they do not rotate smoothly or if there is noticeable play in them Groundsmaster 300 Series Fan Assembly Installation 1 Clean inside of pulley end of tube and outside diame ter of pulley end bearing Apply Loctite 609 or equiva lent to outside diameter of bearing and press bearing into pulley end of tube 2 Insert shaft through tube and in
46. dissipate Since the gases are explosive keep open flame and electrical spark away from the battery do not smoke Nausea may result if the gases are inhaled Unplug the charger from the electrical outlet before connecting or disconnecting the charger leads from the bat tery posts Repairs Page 6 30 Groundsmaster 300 Series 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 Groundsmaster 322 D 325 D An engine temperature reset relay fuse SFE 14 AMP is located behind reset relay An inline fuse AGC 10 protects the engine control module Access to the fuses can be gained by removing the instrument panel cover A 40 AMP circuit breaker protects the entire electrical system Areset button is located on the lower side of the Figure 23 instrument panel which can be reached after removal of Groundsmaster 322 D shown the battery cover The button should be depressed if a total loss of all electrical functions should occur 1 SFE 14 AMP fuse engine temp reset relay 2 In line fuse 3 Starter interlock relay GLOW PUG PEU INDICATOR Tm SHUT GFP Figure 24 1 Circuit breaker reset button Groundsmaster 300 Series Page 6 31 Repairs
47. repack and adjust the rear wheel bearings after each 500 hours of operation or once a year Use No 2 general purpose lithium base grease containing E P additive If operating conditions are ex tremely dusty and dirty it may be necessary to perform this maintenance more often 1 Jack up the rear of the machine until the tire is off the floor Support the machine with jack stands or blocks to prevent it from falling 2 Remove the dust cap from the end of the wheel spindle Fig 18 3 Remove the cotter pin slotted nut and washer Slide the wheel off spindle shaft 4 Pull the seal out of the wheel hub 5 Remove the bearings from both sides of the wheel hub Clean the bearings in solvent Make sure the bearings are in good operating condition Clean the inside of the wheel hub Check the bearing cups for wear pitting or other noticeable damage Replace worn or damaged parts 6 If bearing cups were removed from the wheel hub press them into the hub until they seat against the shoulder 7 Pack both bearings with grease Install one bearing into the cup on inboard side of the wheel hub Lubricate the inside of the new lip seal and press it into the wheel hub IMPORTANT The lip seal must be pressed in so it is flush with the end of the hub The lip of the seal must be toward the bearing 8 Pack inside of wheel hub with some grease not full Install remaining bearing into the bearing cup 9 Slide the wheel ont
48. shown in Fig 34 the lip of the upper seal faces out ward After noting orientation of seals remove seals from the spindle housing 10 Allow the bearings and small thick spacer to fall out of the spindle housing 11 Using a punch and hammer drive both ofthe bearing cups out of the spindle housing Also drive the large spacer out of the housing 12 A large snap ring is still inside the spindle housing and it should remain there because it cannot be easily removed IMPORTANT If new bearings will be installed into a used spindle housing that has the original snap ring installed discard the large snap ring that came with the bearings because it is not needed However new bearings with their matched spacer set and snap ring must always be installed when the spindle housing is being replaced Replacement bearings are sold only with a matched snap ring and spacer set These parts cannot be purchased separately Groundsmaster 300 Series 11 27 Rev Repairs Figure 35 1 Left hand spindle 4 Left hand pulleu 2 Right hand spindle 5 Spacer 3 Right hand pulley LOCK NUT FLAT WASHER CENTER SPINDLE PULLEY UPPER OIL SEAL GREASE FITTING BEARING LOWER OIL SEAL CENTER L4 SPINDLE pee BELLEVILLE WASHER SPECIAL SCREW LEFT HAND THREAD Figure 36 Installing Spindle Bearings and Seals Into Spindle Housing IMPORTANT If a new spindle housing is being used new beari
49. sults Figure 12 5 After control rod is adjusted correctly secure tapered 6 mm E am nu riction whee socket and traction pedal together with slotted nut and 3 Cotter pin amp slotted nut cotter pin Also tighten jam nut against front of control rod Traction Control Rod Adjustment Serial Numbers Above 50000 Fig 12A 1 Check traction drive neutral position to assure front 120 8 05 mm wheels do not creep refer to Traction Drive Neutral Ad INE a justment 2 Loosen lock nuts and adjust traction pedal stop screw to a length of 3 76 2 mm 3 Rotate traction pump lever on transmission to full for ward speed location a 4 Adjust traction control rod end until there is a 120 8 05 mm gap between top of traction pedal stop screw and pedal Figure 12A 5 Make sure that all nuts are properly secured after ad 1 Traction pedal 2 Stop screw justment 76 2 mm Traction Pedal Friction Wheel Adjustment Fig 12 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 Page5 23 Rev G Adjustments Traction Control Neutral Adjustment Fig 13 1 Park vehicle on a level surface and turn engine off Apply the parking brake tip seat forward and actuate pump lever Fig 1
50. this engine 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 Distribu tor with the TORO model number and serial number Groundsmaster 300 Series Page 4A 1 Chapter 4A For Groundsmaster 328 D only Kubota Diesel Engine General maintenance procedures are described in your Operator s Manual Information regarding engine trou bleshooting testing disassembly and assembly is iden tified in the Kubota 05 Series Service Manual Toro part 0109051 Note Refer to Chapter 4 Mitsubishi K3D Diesel En gine for Groundsmaster 328 D engine removal and installation procedure Rev G Table of Contents Specifications Item Description Make Designation Kubota Model 1105 4 Cycle 3 Cylinder Diesel Engine Number of Cylinders Bore 3 07 in 78 0 mm Stroke 3 09 in 78 4 mm Total Displacement 68 53 cu in 1123 cc Firing Order 1 2 3 Combustion Chamber Spherical Type Fuel No 2 Diesel Fuel ASTM D975 Fuel Capacity 6 5 U S gallon 24 6 liter Fuel Injection Pump Bosch MD Type Mini Pump Injection Nozzles Mini Nozzle DNOPD Governor Centrifugal Mechanical Idle Speed no load 1500 1650 RPM High Idle no load 3100 3250 RPM Coolant Capacity 6 U S quart 5 7 liter Engine Oil See Operator s Manual
51. upper cover plate input shaft and face seal Fig 70 9 Assemble the seal back up ring and face seal onto the seal spacer Fig 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 72 Figure 72 Repairs Page 8 38 Groundsmaster 300 Series 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 73 12 Apply a small amount of clean multi purpose grease to the spacer and insert it into the drive slot in the rotor Fig 74 The grease will aid in retaining the spacer during other assembly procedures Figure 74 13 Put the commutator on top of the rotor Be sure the correct surface Fig 75 is towards the rotor Figure 75 Groundsmaster 300 Series Page 8 39 Repairs 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 15 Put a few drops of oil into each recess in the commutator Fig 77 Figure 77 16 Put the commutator ring either side up on top of the stator Fig 78 Align the commutator ring screw recesses with the stator screw slots
52. 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 Put the case in a vise Drive the lock pin out of the pinion shaft Fig 24 Use a small drift punch as shown A WARNING To prevent personal injury always wear a face shield or safety goggles when siriking a drift punch with a hammer 7 While supporting the differential in a vise drive the pinion mate shaft from the differential with a long drift punch Fig 25 Figure 25 Repairs Page 7 10 Groundsmaster 300 Series 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 9 Remove the eight side cover capscrews Remove the the side cover from the carrier assembly Fig 27 Clean the gasket material from the mating surfaces before reassembly 10 If unit has an expansion plug remove it by driving a pointed punch through the plug about 3 8 inch 10 mm from the outer edge When the hole is large enough insert a large screwdriver through it and pry the plug outward Fig 28 Groundsmaster 300 Series Page 7 11 Figure 27 Figure 28 Repairs 11 Before pressing pinion out of housing If unit was equipped with an expansion plug re moved in step 10 re
53. 10 Push switch connectors together 11 Install instrument cover and lock the latches Repairs Page 6 34 Groundsmaster 300 Series 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 AWD units only Remove 4 flange screws and 2 locknuts securing sealing plate to frame above fuel tank Remove sealing plate 4 Disconnect electrical connectors for seat switch Re move capscrew and locknut securing switch to mount ing bracket 5 To install new seat switch set it on mounting bracket a and make sure locating pin on bottom of switch fits hole Figure 28 in bracket Secure switch in place with capscrew and S N Below 30001 locknut 1 Connectors 3 Switch 6 Carefully lower seat but do not sit on or apply 2 Capscrew amp locknut 4 Mounting bracket pressure to the seat There should be a slight gap between the switch and seat plate 7 Connect a continuity tester or ohm meter to switch connector With seat in down position and no one on seat the switch circuit should have no continuity If there is continuity check switch installation If there is no continuity go to next step 8 Set on the seat The seat switch should have conti nuity If there is no continuity check switch installation If there is c
54. 13 Needle bearing 4 Governor lever 9 Pump gear 14 Governor spring 5 Governor weight 10 Pump camshaft Fuel System Service 15 Speed control lever 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 A key operated stop system is pro vided Fuel Injection Control The fuel injection rate is controlled by changing the effective stroke of the plunger within the barrel The plunger is rotated by the control pinion which meshes with the plunger lower collar to directly turn the plunger Asthe engine turns the injection pump camshaft rotates to move the control rack by way of the governor weights governor sleeve and lever The control rack slides to turn the control pinions Movement of the control rack to the right decreases the fuel injection rate and movement to the left increases the rate Fuel System Service Page 4 38 11 Spring Delivery valve Valve seat Plunger barrel Adjusting plate Control pinion Upper seat Plunger spring Pump housing Groundsmaster 300 Series Control Rack Smoke Set and Ungleich Device Fig 42 43 44 The injection pump on the is equipped with a mecha nism tha
55. 5 Press shafts Item 17 19 back through bearing cones Item 9 When bearing cone is free gears Item 10 18 keys Item 8 and shims Item 11 may be removed from the shaft Groundsmaster 300 Series Page 13 19 6 Remove bearing cups Item 14 from cap by putting a punch through the shaft bore and through the seal and then tapping against the back of the bearing cup until driven out of the cap 7 If the oil seal Item 13 is removed it will be destroyed To remove the oil seal cut it out of the bore with a screw driver or chisel 8 To remove the bearing cups Item 3 from the housing a slide hammer puller may be used or if this is not available the bearing cups may be knocked out with a punch by coming down through the opposite cap bore and tapping against the back side of the bearing cup until it comes out 9 Remove the plugs Item 2 from the housing Repairs ST HNSSW LARS Ae GY 7 WUC Figure 28 Gear Box Pre Assembly 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 towards the turned end of the shaft Align the keyway in the gear with the keyway in the shaft and install one of the keys Item 8 in the keyway 2 Install one set of shims Item 11 onto the turned end of the shaft Press one of the bearing cones Item 9 over the turned end of the shaft Be sure the bearing cone is installed as shown in the illustration
56. 5 used per wheel Wheel 2 used Slotted hex nut 2 used Cylinder support bracket Jam nut 2 used per ball joint Thrust washer 0 0179 thick Thrust washer 0 0329 thick Steering cylinder O ring Retaining ring 2 used Steering cylinder ball joint 2 used Oscillation stop 2 used Groundsmaster 328 D Removal Fig 2 1 Park machine on a level surface lower cutting deck or implement stop engine engage parking brake and remove key from the ignition switch 2 Drain oil from rear axle see Traction Unit Operator s Manual When changing attachments tires or perform ing other service use correct blocks hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor Prior to raising machine remove any attach ments that may interfere with the safe and proper raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the ma chine is not properly supported by blocks or jack stands the machine may move or fall which may result in personal injury 3 Chock front wheels and jack up rear of machine Support machine with jack stands or solid wood blocks 4 Remove wheels from rear axle 5 Remove six 6 socket head screws item 8 and lock washers item 7 that secure driveshaft to bidirectional clutch on rear axle Position end of driveshaft away from clutch 6 Thoroughly clea
57. 8 x 3 4 in Adjust chain length so both become tight at the same time when lifting lift arm 11 Connect ends of tension spring between fourth link of rear chain and eye of cotter pin that holds cylinder pin Figure 20 in place Adjust length of chain so rear caster wheels are off the ground in transport position 1 PTO yoke 3 Roll pin 2 Yokes in phase 4 Capscrews amp locknuts Figure 21 1 PTO shield 4 Spring in 4th link 2 Self tapping screws 5 Spring in cotter pin 3 Lift chain Groundsmaster 300 Series Page 11 17 Repairs 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 x 4 block of wood between the chassis and the top of the push arm and across the full width of the REMOVED machine ar nar WOODEN Dm AME n 3 Loosen the large jam nut on the left hand ball joint at the end of the push arm Remove the ball joint mount attached from the push arm 4 Remove the self tapping screws holding the floor plate to the main frame Raise the floor plate and set it aside Figure 22 5 Disconnect the right hand brake cable from the brake strut Remove the jam nut holding the brake cabled in the mount on the frame and slide the cable through the hole in t
58. 9 6 8 11 15 9 12 28 9 12 7 9 13 18 10 14 5 16 18 15 20 12 16 22 30 18 24 24 17 23 14 19 24 33 19 25 3 8 16 30 40 20 25 40 55 30 40 24 30 40 25 35 45 60 35 45 7 16 14 45 60 35 45 65 90 50 65 20 50 65 40 55 70 95 55 75 1 2 13 70 95 55 75 95 130 75 100 20 75 100 60 80 110 150 90 120 9 16 12 100 135 80 110 140 190 110 150 18 110 150 85 115 155 210 125 170 5 8 11 135 180 110 150 190 255 150 205 18 155 210 120 160 215 290 170 230 3 4 10 240 325 190 255 340 460 270 365 16 270 365 210 285 380 515 300 410 7 8 9 360 490 280 380 550 745 440 600 14 390 530 310 420 610 825 490 660 1 8 530 720 420 570 820 1100 660 890 14 590 800 480 650 890 1200 710 960 Capscrew Markings and Torque Values Metric 10 9 12 9 7 Commercial Steel Class 8 8 am SY Capscrew Head M Thread Capsc a Capsc rque Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum mm ft Ib Nm ft Ib Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm 6 5 9 4 7 9 14 7 11 9 14 7 11 7 9 14 7 11 14 18 11 14 18 23 14 18 8 18 25 14 18 23 32 18 25 27 36 21 28 10 30 40 25 30 45 60 35 45 50 70 40 55 12 55 70 40 55 75 105 60 80 95 125 75 100 14 85 115 65 90 120 160 95 125 145 195 110 150 16 130 180 100 140 175 240 135 190 210 290 165 220 18 170 230 135 180 240 320 185 250 290 400 230 310 Groundsmaster 300 Series Page2 3 Torque Specifications Torque Specifications Page 2 4 Rev Groundsmaster 300 Seri
59. Apply Loctite 271 or equivalent to threads of Switch screws before installing PTO Switch Fig 9 10 The PTO switch is normally open and closes when the PTO lever is pushed forward to ON position Test the switch by disconnecting the wires from the Switch terminals and connecting a continuity tester across the terminals With the PTO lever pushed for ward ON there should be continuity across the termi nals With the PTO lever pulled back OFF there should be no continuity across the terminals See Replacing the PTO Switch in the Repairs section of this chapter for replacement procedures Figure 9 S N Below 30001 1 Connectors 5 Mounting bracket 2 PTO lever 6 Switch arm 3 Capscrew amp locknut 7 1 2 inch 13 mm 4 Switch Figure 10 S N 30001 and UP 1 PTO switch Testing Page 6 20 Groundsmaster 300 Series 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 is connected and disconnected to terminal 85 with terminal 86 connected to ground Figure 11 Groundsmaster 345 Figure 12 Groundsmaster 322 D 325 D Figure 13 Groundsmaster 300 Series Page 6 21 Testing Glow Plugs Groundsmaster 322 D 325 D only See C
60. Be careful while handling or testing glow plugs Glow plugs become extremely hot Ac cidental contact with the heated plug tip could cause personal injury 1 Disconnect the wire lead s to the glow plug 2 Remove the glow plug 3 Inspect the glow plug for signs of a burnt glow plug end tube Figure 16 NOTE If the metal of the glow plug end is melted it is a sign of cylinder overheating See Engine Overheats in the Troubleshooting section of this chapter 4 Connect the positive battery terminal to the glow plug terminal and the negative battery terminal to the plug body If the glow plug glows red hot the glow plug is operating correctly 5 Replace any glow plugs that do not operate correctly Testing Page 4 18 Groundsmaster 300 Series 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 F IMPORTANT DO NOT put oil into the combustion chamber before performing a compression test Damage may result because of hydraulic forces acting upon the piston and connecting rod 1 Remove the glow plug lead wires and glow plugs from all three cylinders 2 Insert the compression gauge adapter into the glow plug hole See the Special Tools section of this chapter 3 Connect the high pressure compression gauge to the adapter 4 Hold fuel shut off lever in closed pos
61. Because the steering cylinder has different dis placements when extended and retracted the steering wheel will not return to its original position after making a turn NOTE The steering system will operate with the engine off if necessary with increased effort Figure 1 Brakes The Groundsmaster 300 Series traction units are equipped with 7 inch diameter x 1 3 4 inch wide mechanical drum brakes on the front wheels Two pedals are used to control the brakes When used separately the pedals can control each wheel brake to assist steering or traction on side hills The two pedals may be locked together with the brake lock arm When the lock arm is engaged both wheels will brake equally and act as a service brake or parking brake The brake pedals operate the brakes through a cable system to a strut and lever on the brake shoes Introduction Page 8 2 Groundsmaster 300 Series Power Steering Schematics When the steering wheel is turned to the right Fig 3 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 to the steering cylinder Oil displaced by the other end of the steering cylinder returns to the steering valve through port LT and is directed out port OUT back to reservoir NOTE On 2WD units right turn pressure i
62. Fig 42B Install a retaining ring Item 7 on the turned end of the shaft 3 Put one of the bearing cones Item 12 over the other end of the shaft and down against the hub side of the gear Be sure the bearing cone is installed as shown in the illustration 4 Repeat steps 1 3 with the other set of parts to complete the assembly 5 Put one of the caps Item 16 down with the machined surface facing up Install a new seal Item 13 into the Repairs Page 13 20 cap with the open side toward the machined side of the cap 6 Install the bearing cup Item 14 into the cap Make sure the bearing cup is installed as shown in the illus tration 7 Repeat steps 5 6 with the other set of parts to complete the two cap assemblies 8 Take one of the shaft and gear assemblies and wrap the end of the shaft with a piece of shim stock to keep from cutting the oil seal on the keyway or splines Put the cap assembly down over the shaft so the bearing cone Item 12 on the shaft mates with the bearing cone Item 14 in the cap Remove the shim stock from the shaft that was used to protect the seal 9 Press the bearing cups Item 3 into both bearing bores in the housing Item 1 Make sure the cups are installed as shown in the illustration Install the plugs Item 2 into the tapped holes in the housing Groundsmaster 300 Series Gear Box Final Assembly 1 Bearing drag is adjusted by the amount of gaskets Item 4 5 6
63. Figure 103 Figure 105 Repairs 42 Apply clean multi purpose grease to the four o rings and seal ring Putthe new o rings and seal ring into their proper location in the port cover Fig 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 107 Figure 107 Repairs Page 8 50 Groundsmaster 300 Series 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 45 Tighten the plug to a torque of 8 12 ft lb 11 16 Nm Fig 110 Figure 110 Groundsmaster 300 Series Page 8 51 Repairs 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 24 Disassemble and correct the assembly if necessary 48 Remove the four nuts holding the unit to the fixture and remove the unit Fig 112 Figure 111 BL Figure 112 Repairs Page 8 52 Groundsmaster 300 Series TORO Table of Contents
64. Gear Box Oil Pack rear wheel bearings 2WD Change Rear Axle Lubricant 4WD Change Transmission Oil Torque Head Adjust Valves and Check RPM Initial break in at 10 hours Initial break in at 50 hours Replace Moving Hoses Replace Safety Switches Coolant System Flush Replace Fluid Fuel Tank Drain Flush See Operator s and Service Manual for specifications and procedures Every 100hrs A Level Service B Level Service C Level Service D Level Service Annual Recommendations Items listed are recommended every 1500 hours or 2 years whichever occurs first GROUNDSMASTER 322 D and 325 0 Daily Maintenance Check List Unit Designation Daily Maintenance duplicate this page for routine use TORO ID Daily Maintenance Check For Week Of MON TUES WED THURS FRI SAT SUN Maintenance Check Item HRS HRS HRS HRS HRS HRS HRS Y Safety Interlock Operation v Grass Deflector in Down Position v Brake Operation v Fuel Level v Engine Oil Level v Cooling System Fluid Level Drain Water Fuel Separator Y Dust Cup and Baffle Air Filter v Radiator amp Screen for Debris v Unusual Engine Noises Y Unusual Operating Noises v Transmission Oil Level Y Hydraulic Hoses for Damage v Fluid Leaks v Tire Pressure Y Instrument Operation Y Condition of Blades Lubricate All Grease Fitting Touch up damaged paint
65. IMPORTANT Hold the steering tube in a soft jaw vise Be careful not to damage the steering tube 49 Use a bearing puller to remove the bushing Fig 61 Repairs Page 8 34 Figure 61 Groundsmaster 300 Series 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 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 1 Put the four bolts into the fixture with the shortest threaded end of the bolts through the fixture holes Fig 63 Secure the bolts to the fixture with four 5 16 24 UNF nuts Tighten the nuts to secure the assembly to the fixture but loose enough to turn the bolts and facilitate stacking of components 2 If the bushing was removed from the upper cover and jacket for replacement press a new bushing into the upper end of the jacket tube with the recessed end of the bushing toward the jacket tube Use an arbor press or the wood handle end of a hammer Fig 64 Push the bushing down until it is 0 1 in 2 5 mm below the top of the jacket tube Use a pliers or punch to crimp
66. Main bearing caps reassembly NOTE Before removing the main bearing caps meas ure the crankshaft end play 16 Remove the crankshaft after removing the main bearing caps 17 Remove the crankshaft oil seal and gasket 18 Check the cylinder block for cracks or damage Replace the cylinder block if it is unserviceable Cylinder Block Overhaul Page4 54 Groundsmaster 300 Series Camshaft and Bearing Fig 65 66 1 Inspect the camshaft for evidence of severe wear FRONT OF CYLINDER BLOCK CAMSHAFT BUSHING 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 3 To remove the camshaft bushing in the cylinder block carefully drive the bushing from its location using the camshaft bushing tool refer to Special Tools PES d ER NOTE You must drive the bushing into the cylinder MERE block and then crush it to remove it Be careful not to damage the valve lifter hole when removing the cam Figure 65 shaft bushing Removing camshaft bushing 4 To install a new camshaft bushing use the camshaft bushing tool drive the bushing in from the outside f T of the cylinder block being careful to align the oil delivery hole in the cylinder block with the oil hole in the bushing 5 If the cam surface is damaged or the cam lobe is badly wo
67. NOH v 9 81 zs 3NION3 8 d N31 1NV1OOO 34nSS34d 6 HOSN3S YOSNAS 9 1 lt 2 1 5 NOILISOd MNVHO MNO SYA nnm ez SYA 01 aNnouo ve 3SN4 pA J WM ies pela SS3NHVH SNIONS 1 mm E58 440 T QNooss SQ P s Aviad NOLLINSI TOHLNOD E 77 GION310S 1304 T aniona Tuwon NO 1 l HOLIMS 3 iviia ONDYYd 98 58 1a 3a01a Tye D Eg A E NOWOSLONd c77777777 gt za Tor HOLIMS TWHLNAN ee R M SS 98v Ne 1 1 1 18 1 pA ia SS3NMHVH UNIT 3 1818013 OL 9 sunssaud o 3onvo 04 T 8 A aunivsaawal 24 440 HOLIMS 1V3S AT Pee HO 440 HOLIMS Old N9 M NOLLIQNOO dW3L H3AO NO OL Q3193NNOD HOLIMS 3GlHN3AO dial HOIH OL Q 98 1310IA 31IHM M 1 1 a3ni8 ns LHOI1 N97 MOTIJA A AVHO A9 NMONS N33HO 1 N91 39NVNO N3SYO ND 0V18 9 OL T 1 dW3L H3A
68. 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 Torque the retain ing nut to 144 180 ft Ibs 20 25 KgM 30 Install the oil screen and the oil pan using a new gasket Installing gear case 31 Reinstall the speedometer unit while rotating the speedometer shaft Make sure that the O ring is prop erly installed Apply oil to the outside surface of valve lifters and insert the lifters into the cylinder block in the order of which they were removed Install the push rods into the lifters in the order in which they were removed 32 Install the cylinder head assembly Figure 88 Inserting tappet 33 Install the fuel injection pump 34 Install the oil pump and oil filter if they have been removed 35 Install the water pump 36 Install the starter if it has been removed m 37 Install the overhauled engine onto the machine M Y X following the reverse procedure for removing the engine e EU from the machine Figure 89 Installing injection pump Cylinder Block Overhaul Page4 64 Groundsmaster 300 Series TORO Table of Contents General Information 1 Specifications 2 General Information The engine used in the Groundsmaster 328 D is manufactured by Kubota Service and repair parts for
69. Remove nut Fig 10A Item 14 and flatwasher Item 15 Remove capscrews 6 from pin Item 7 Remove the pin This will release the rear axle and washers from the support Item 9 Carefully pull the axle out from under the machine NOTE A varying number of washers Fig 10B Item 41 42 may have been installed between the axle pivot and axle support during manufacture Make sure the same number of washers are installed during reassembly 9 Reverse steps 1 8 to install axle The washers Fig 10B Item 41 42 must be positioned between the front end of the axle pivot and the axle support see the NOTE above Make sure thrust washer Fig 10B Item 14 is installed between rear end of axle pivot and the axle support Repairs Rear Axle Repair Apply Loctite 20 24 ft Ib Tighten to pre load 2 4 bearings Pinion LE should rotate with 2 0 5 5 in lb torque Measure 7 backlash here EM 0 003 0 01 Shim for bevel gear to pin ion contact adjustment Figure 12 1 Remove bolts Fig 12 Item 60 securing axle tubes 16 61 to differential case Item 24 Separate axle tubes and axles from differental case 2 Remove bolts Fig 12 Item 60 securing axle tubes Item 16 61 to gearbox housings Fig 13 Item 23 of knuckle assemblies Separate axle tubes and axles from knuckle assemblies 3 Disassemble knuckle assembly Fig 13 A Remove bolts Item 28 39
70. Retaining ring 2 Bevel gear 3 Differential shaft 4 Bearing 5 Bearing shims Groundsmaster 328 D Axle Shafts The following procedures assume the rear axle assem bly has been removed from the machine Removal 1 Remove the axle cover mounting screws Remove the axle cover from the axle case as an assembly Fig 15 2 Use a bearing puller to remove the bearing and bevel gear as shown Fig 16 3 Remove the shims spacer and retaining ring Drive the axle out of the bearing and cover Remove and dis card the axle shaft seal 4 Inspect all gears shafts bearings spacers and cases for damage and wear Replace components as necessary Installation 1 Coat new axle shaft seal with grease and install in axle cover as shown Fig 17 2 Press the axle cover and bearing assembly onto the axle shaft Press only on the inner race of the cover bearing Fig 17 3 Install retaining ring spacer and correct combina tion of bearing shims Install bevel gear and bearing 4 Coat a new O ring with grease and install the axle cover assembly Tighten axle cover screws to 17 to 20 ft lbs 23 to 27 Nm Groundsmaster 328 D Page 10 1 11 17 to 20 ft lbs 23 to 27 Nm Figure 15 3 Mounting screw 4 O ring 1 Axle case 2 Axle cover assembly Figure 16 1 Bearing 4 Spacer 2 Bevel gear 5 Retaining ring 3 Shims Figure 17 1 Axle shaft seal 3 Bearing 2 Axle cov
71. Switch 28 Fuel Gauge Sending 29 REPAIRS 4s 2s wr er MU bue Eo e 30 Battery Service 30 EUSOS Scores RERO hU ee 31 Traction Neutral Switch Replacement 32 PTO Interlock Switch Replacement 33 Seat Switch Replacement 35 Table of Contents Wiring Schematics Groundmaster 345 Serial Number less than 40000 AWLINDYID HOLIMS NOILIN9I Stiegd 1uviS A X vti d NO B 3didiS X2v18 MO 134 39015 31IHM MO1134 3NON 440 NOI 1ISOd 7102 STO N3389 1H9 038 0401 01 2 391015 30108 NMOHB 391515 3018 NMOH8 TOWHA1n3N NI 1vQ34d NOILOVYL HLIM 0350712 HOLIMS Q39V9ON 350 Old 03S0712 HOLIMS MS MS Old S10 MO123NNOO vy vy nn SNINas 19 35 NO HO1VH3dO ON HLIM N3dO HOLIMS S B x iv3s 91615 N334H9 NMCHB 3 YSLYVLS 2776 V9 vi WOVE y90 3n18 v9 vi 308 AV 38 3201831NI HALES BO1vNB3IIV dW31 39nv9 dW3l 8NV2 Groundsmaster 300 Series Page6 2 Rev Wiring Schematics Groundmaster 345 Serial Number 40001 to 200999999 AYLINDYIO HOLIMS NOILINSI AINGOW Sa HOLO3NNOO 3dlH1S 31IHWMOTI3A N3399 1HOTT1 q3H OHOL OL GHOJ HOLOANNOO
72. alignment is still correct BND SPACER tighten the lock collar setscrews T 5 Slide the spring onto the large brake mounting pin Then slide the brake onto the mounting pin and the small locating pin Figure 7 6 Move P T O lever to OFF and position brake in grooves of pulley Slide spacer onto mounting pin and secure all parts in place with the locknut Tighten locknut until spacer contacts the brake Groundsmaster 300 Series Page9 5 Adjustments PTO Brake Adjustment Fig 8 1 Lowerthe implementto the shopfloor 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 Then move the P T O lever to OFF and position M the brake in the grooves of the pulley e EX LOCKNUT AND SPACER 3 Tighten the locknut until the spacer contacts the side of the brake bracket Figure 8 Adjustments Page 9 6 Groundsmaster 300 Series Repairs Drive Coupling Removal and Installation Fig 9 Removing Drive Couplings m 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 Jack up the back end of the machine and support it with jackstands to prevent it from falling accidentally 4 Block the front and back of the traction unit s drive wheel
73. as nec essary Groundsmaster 328 D 10 1 7 4WD Rear Axle Rev Dae Dong Axle 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 the axle case cover Coat a new O ring with grease and 17 to 20 ft Ibs 23 to 27 Nm Thread Locker install the axle case cover Fig 9 Tighten cover screws to 17 to 20 ft lbs 23 to 27 Nm 3 Slide the bevel gear case over the bevel gear shaft and install the thrust washer spacer bevel gear and collar Make sure the bevel gear shaft is completely seated in the upper and lower bearings Fig 9 4 Install the knuckle pin Use medium strength Loctite thread locker and tighten the knuckle pin mounting screws to 17 to 20 ft lbs 23 to 27 Nm x 17 to 20 ft Ibs 23 to 27 Nm 4 1 Figure 9 1 Axle case cover 6 Spacer 2 Lower bevel gear 7 Upper bevel gear 3 Bevel gear shaft 8 Collar 4 Lower bearing 9 Upper bearing 5 Thrust washer 10 Knuckle pin 4WD Rear Axle Rev G Page 10 1 8 Groundsmaster 328 D Dae Dong Axle 5 Determine necessary quantity of support shims A Lubricate the axle case support bushing with a thin coat of grease and slide axle case support onto knuckle pin B Position support shims that were removed during disassembly between axle case support and ax
74. attaching 12 VDC battery leads to the solenoid terminals If the solenoid operates when battery contact is make the stopping failure is elsewhere in the electrical system refer to Chapter 6 1 Turn the engine off with emergency stop lever if necessary and remove the key from the ignition switch 2 Disconnect the solenoid wires from the main wire harness 3 Loosen the nut securing the solenoid to the engine and unscrew the solenoid Use a 36 mm wrench 4 Remove the gasket and the nut and install them on the new solenoid Thread the nut fully onto the solenoid Remove the cap from the old solenoid 5 Start to thread the solenoid into the cylinder block 6 Push the plunger on the solenoid fully in and hold it in this position 7 Rotate the emergency engine stop lever to the STOP position counterclockwise 8 Continue to hold the solenoid plunger in and thread the solenoid into the cylinder block until the inner end of the plunger contacts the control rack of injector pump Contact will be indicated when the outside end of the plunger is pushed away from the solenoid body 9 When contact is indicated discontinue threading the solenoid into the cylinder block Turn the solenoid slowly outward until the plunger again contacts the solenoid body then rotate the solenoid body one eighth turn further out 10 Hold the solenoid body to prevent it from turning and tighten the nut against the cylinder block to secure the
75. battery 8 Install instrument cover and lock the latches Groundsmaster 300 Series Page 6 33 Figure 26 S N Below 30001 1 Connectors 5 Mounting bracket 2 PTO lever 6 Switch arm 3 Capscrew amp locknut 7 1 2 inch 13 mm 4 Switch Repairs 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 Figure 27 S N 30001 and UP 6 Remove front jam nut securing switch to mounting bracket and remove switch 1 PTO switch 7 Install new switch to mounting bracket Adjust switch So it is depressed 1 2 13 mm when PTO lever is moved to OFF position Tighten jam nuts to 75 in Ib Install rubber boot on switch IMPORTANT Threads on PTO switch will be dam aged if jam nuts are over tightened 8 Connect a continuity tester or ohm meter to switch connector With PTO lever in forward ON position the Switch circuit should have no continuity If there is con tinuity check switch installation If there is no continuity go to next step 9 Move PTO lever to OFF position When PTO lever is in its normal released position the PTO switch should have continuity If there is no continuity check switch installation If there is continuity go to next step
76. charger from the electri cal outlet before connecting or disconnecting the charger leads from the battery posts Safety Instructions 43 Wear safety glasses goggles or a face shield to prevent possible eye injury when using compressed air for cleaning or drying components 44 Failure to follow proper procedures when mounting atire on a wheel or rim can produce an explosion which may result in serious injury Do not attempt to mount a tire unless you have the proper equipment and experi ence to perform the job Have it done by your Toro Distributor or a qualified tire service 45 When changing attachments or performing other Service use the correct blocks hoists and jacks Always Safety Instructions Page 1 4 use jack stands to safely support the machine when it is raised by a jack or hoist 46 At the time of manufacture the machine conformed to safety standards in effect for riding mowers To ensure optimum performance and continued safety certification of the machine use genuine TORO replacement parts and accessories Replacement parts and accessories made by other manufacturers may result in non confor mance with the safety standards and the warranty may be voided Groundsmaster 300 Series Chapter 2 TORO Product Records and Manuals Table of Contents PRODUCT RECORD 1 TORQUE 5 5 3 EQUIVALENTS AND CONVERSIONS 2 Caps
77. cover and the bolts underneath 10 Remove the camshaft and gear by carefully backing them out from the cylinder block NOTE The speedometer drive and valve lifters must be removed to remove the camshaft 11 To remove the injection pump camshaft first remove the governor sliding shaft and governor flyweight as sembly Align the hole in the injection pump camshaft gear with the retaining bolt and washer Remove the washer and carefully pull the camshaft gear and bearing from its location in the cylinder block 12 Remove the idler gear from its shaft 13 Remove the flywheel bolts and washers and remove the flywheel from the crankshaft Cylinder Block Overhaul 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 Use a wooden block to push the pistons and rods to avoid damage to the connecting rod NOTE Before removing the pistons scribe the number ofthe cylinder onto the top ofthe piston When the piston and rod assembly is removed use care to prevent damage to the piston or bearing surfaces 15 Remove the main bearing caps Arrange the re Figure 64 moved caps and bearings according to cylinder order so they may be replaced in the same position upon
78. diesel fuel to prevent corrosion Figure 35 2 Air bleed screw 1 Fuel filter water separator Figure 36 1 Fuel injection pump 2 Air bleed screw Groundsmaster 300 Series 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 2 Move the throttle control to the FAST position 3 Turn the ignition key to the START position to crank the engine and pump fuel to the nozzles Turn the ignition key to the OFF position when a steady stream of fuel flows out of the loose pipe connection 4 Tighten the pipe connector 5 Repeat steps 1 4 for the No 2 and No 3 injector nozzle and holder Fuel Pump Service Fig 38 The only serviceable parts of the fuel pump are the magnet filter and the gaskets on each end of the filter 1 Disconnect the fuel pump wires from the wiring har ness and ground connection 2 Disconnect the fuel hoses from the pump Plug the fuel lines 3 Remove the two screws which secure the pump to the frame 4 Use a 17 mm wrench to remove the cover from the fuel pump Remove the gasket magnet and filter ele ment Groundsmaster 300 Series Page 4 35 Figure 37 Figure 38 1 Cover 4 Filter 2 Cover gasket 5 Body 3 Magnet Fuel System Service
79. dirt from entering the cylinder or nozzle Do not mix components of one nozzle with another Nozzle Testing Refer to Nozzle Tests for complete instructions Nozzle Removal and Disassembly 1 Remove the fuel overflow line from the nipple on the nozzle body 2 Disconnect the fuel injection pipe from the nozzle body 3 Remove the two bolts which pass through the nozzle flange and remove the nozzle assembly from the cylin der head Remove the copper nozzle holder gasket NOTE Further disassembly of the nozzle is not required for testing purposes 4 Secure the retaining nut in a vise which is equipped with aluminum or brass jawplates and loosen the nozzle body with a wrench 5 Remove the nozzle body shim pressure spring flange pressure pin and distance piece 6 Remove the nozzle from the retaining nut If it is difficult to remove tap it lightly with a rubber or wooden mallet Be careful not to hit or damage the protruding tip of the nozzle needle valve Inspection and Cleaning 1 Clean the inside and outside of the retaining nut in clean diesel fuel to remove carbon or fuel deposits Inspect the lower seating surface for rust or damage The sealing area may be restored with emery cloth Groundsmaster 300 Series Page 4 45 2 Remove carbon or lacquer deposits from the nozzle by cleaning in clean diesel fuel Stubborn deposits may be removed with brass wired brush IMPORTANT Do not use a steel brus
80. gauge to measure the connecting rod thrust clearance between the connect ing rod and crankshaft The proper clearance is 0039 0138 inch 1 35 mm If the clearance exceeds this amount replace the connecting rod assembly 3 The connecting rod journal to crank pin oil clearance can be measured using a micrometer or Plastigauge Refer to Crankshaft Bearings for tolerances Cylinders Fig 72 1 Measure the cylinder bore size in six locations as shown The standard bore diameter is 2 8740 inches 73 mm The cylinder mustbe rebored and oversized piston and rings installed if the diameter exceeds the standard by 0079 inch 2 mm Examine the cylinder bore di ameter readings to determine the amount of taper of the cylinder If the taper exceeds 0004 inch 01 mm the cylinder must be rebored and oversized piston and rings installed Groundsmaster 300 Series 4 57 Figure 71 Measuring connecting rod thrust clearance Figure 72 Checking cylinder bore size Cylinder Block Overhaul 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 8 mm replace the piston NOTE The piston O D should be measured at the lower end of the skirt across the thrust faces or on access points perpendicular t
81. grease to the metering ring seal ring Put the seal ring into position in the metering ring seal groove opposite to the end with the alignment pin holes Stack the metering ring into place over the four bolts with the seal ring towards the upper cover plate Make sure an alignment pin hole on the metering ring is in line with and on the same side as the alignment groove on the side of the upper cover plate Fig 87 This is required so the other components can be aligned correctly IMPORTANT Make sure the seal ring does not slip from position Groundsmaster 300 Series Page 8 43 Figure 86 Figure 87 Repairs 25 Put the bearing spacer onto the face of the upper cover plate Fig 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 Inspect the exposed face of the drive plate making sure it is clean and lint free Apply a small amount of clean multi purpose grease on the drive plate Fig 90 TAM M oc an Poo m VE Bueno Figure 90 Repairs Page 8 44 Groundsmaster 300 Series 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 When properly seated the metering package will be below the surface of the metering
82. hub NOTE Only one setscrew is used to loosen the taper lock 6 Slide the gearbox pulley and taper lock off of the gearbox output shaft Account for the woodruff key that positions the pulley on the shaft and remove the set screw from the side of the taper lock Groundsmaster 300 Series Page 11 21 Repairs Installing Gearbox and Drive Pulley 1 Install four 4 isolation mounts into two 2 brackets Use water or lubricant to ease installation Install mounts from bottom of bracket 2 Install bracket on each side of gearbox with cap screws and lockwashers Tighten capscrews to a torque of 20 26 ft lb 3 To install the pulley slide the taper lock small end first into the pulley hub 4 Insert the woodruff key into the keyway in the gearbox shaft Slide the pulley with the taper lock onto the gearbox shaft while aligning the key and keyway NOTE The large hub on the pulley must face away from the gearbox and like the taper lock the pulley must contact the shoulder on the gearbox shaft 5 Rotate the pulley to get the non threaded holes in the taper lock to line up with the two threaded holes in the hub of the gearbox pulley Start threading the setscrews into the two holes and tighten them alternately and evenly until both setscrews are tight 6 Using a brass drift pin or sleeve and a hammer hit the taper lock firmly Now tighten the setscrews to 55 in Ib Continue to hit the taper lock and tighten the s
83. idler pulley s to release belt tension 48 v E E ME 3 Remove belt from spindle to be serviced 4 Start the engine and raise the cutting unit Turn the engine OFF and remove the key from the key switch Block up the cutting unit so it cannot fall accidentally 5 Remove the bolts Item 13 and flange nuts Item 8 securing spindle housing to deck Slide spindle housing assembly out the bottom of the cutting unit Figure 34 Repairs Page 11 26 Groundsmaster 300 Series 6 Remove the lock nut and flat washer retaining the spindle pulley on the spindle shaft Slide the pulley off of the shaft NOTE All three spindle housing assemblies are differ ent from one another A spacer is located beneath the right hand pulley Fig 35 7 Ifthe spindle shaft will be replaced remove the blade bolt left hand thread belleville washer and blade from the spindle shaft Otherwise the blade may be left onthe spindle shaft 8 Press the spindle shaft out of the spindle housing us ing an arbor press The small bearing spacer should re main on the spindle shaft as the shaft is being removed 9 The seals will be removed next however notice the orientation of the seal lips The lips of the lower seals face outward On spindle assemblies that have the grease fitting on the housing shown in Fig 36 the lip of the upper seal faces inward On spindle assemblies thathave the grease fitting on the top of the spindle shaft
84. ignition switch is turned off Troubleshooting Groundsmaster 322 D 325 D Engine will not restart after manual shut down 10 AMP fuse open Faulty wiring between ammeter and control unit Ignition switch faulty Faulty wiring between ignition switch and control unit Fuel shut off solenoid faulty Fuel shut off solenoid wiring faulty Control unit faulty Page 6 16 See listings under Starting Problems Replace fuse Correct cause of blown fuse Repair wiring Test ignition switch and replace if faulty Repair wiring Test fuel shut ff solenoid Adjust or replace fuel shut off solenoid if faulty Repair wiring Test control unit and replace if faulty Groundsmaster 300 Series Verify Interlock System Operation The machine has interlock switches in the electrical System These switches are designed to stop the engine when operator gets off the seat while either the PTO lever is engaged or traction pedal is depressed How ever operator may get off the seat while engine is running Although engine will continue to run if PTO lever is disengaged and traction pedal is released it is strongly recommended that the engine be stopped be fore dismounting from the seat A CAUTION Do not disconnect the interlock switches Check operation of switches daily to assure interlock system is operating correctly If a switch is malfunctioning replace it before operating the machine To ensure
85. ing Stop Bolt Adjustment in the Adjustments section 4WD Rear Axle Rev G Dae Dong Axle Bevel Gear Case and Axle Case The following procedures assume the rear axle assem bly has been removed from the machine 35 to 41 ft Ibs Pig 47 to 56 Nm i 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 3 2 Mark both right and left bevel gear case axle case assemblies F 35 to 41 ft lbs IMPORTANT Do not interchange right and left 47 to 56 Nm bevel gear case axle case assemblies Figure 3 1 Cap screw 5 Bevel gear case axle 2 Lock nut case assembly 3 Lock washer 6 O ring 4 Axle support 3 Remove the axle cover mounting screws Remove the axle cover from the axle case as an assembly Fig 4 Figure 4 1 Axle case 3 Mounting screw 2 Axle cover assembly 4 O ring 4 Remove the axle case support mounting screws the axle case support and the support shims Fig 5 Figure 5 1 Axle case 3 Mounting screw 2 Axle case support 4 Support shim 4WD Rear Axle Rev G Page 10 1 6 Groundsmaster 328 D Dae Dong Axle 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 be
86. injection pump This could cause the fuel pump to seize and be damaged When working on the fuel system ALWAYS make sure that the equipment and work area is clean The close Bleeding the Fuel System Fig 35 36 1 Stop the engine and engage the parking brake Unlatch and raise hood 2 Loosen the air bleed screw on the fuel filter water separator 3 Turn the ignition key switch to the ON position The electric fuel pump will begin to operate and force fuel out around the screw loosened in step 2 Fuel will fill the filter bowl and then flow out around the screw When a solid stream of fuel flows out around the screw tighten the screw and turn the key switch OFF 4 Open the air bleed screw on the fuel injection pump 5 Turn the ignition key switch to the ON position The electric fuel pump will begin to operate and force fuel out around the injection pump air vent screw When a solid stream of fuel flows out around the screw tighten the screw and turn the key switch OFF NOTE Normally the engine should start after this pro cedure If the engine does not start air may be trapped between the injection pump and injectors See Bleeding Air From the Injectors in this section of the book Fuel System Service Page 4 34 tolerance parts of the fuel system can be easily dam aged by dirt Wash fuel system parts in clean fresh diesel fuel If parts are removed for a period of time store them in contain ers of clean
87. loose corroded or damaged Temp gauge switch faulty Temp relay faulty Temp relay wiring loose corroded or damaged Starter interlock relay wiring loose corroded or damaged Starter interlock relay faulty Starter solenoid wires loose corroded or damaged Starter solenoid faulty Page 6 13 Charge battery Replace battery if it will not hold a charge Clean and tighten or repair as necessary Reset circuit breaker Correct cause of open circuit breaker Test ammeter and replace if faulty Repair wiring Test ignition switch Replace if faulty Repair wiring Test switch and replace if faulty Make sure wires are connected to COMMON and NORMALLY OPEN N O terminals Repair wiring Test switch and adjust or replace if faulty Repair wiring Test temp gauge switch and replace if faulty Test temp relay and replace if faulty Repair wiring Repair wiring Test relay and replaced if faulty Clean and tighten or repair as necessary Test starter solenoid Replace if faulty Troubleshooting Groundsmaster 322 D 325 D Starting Problems continued Condition Possible Cause Correction Engine cranks but does not start if engine cranks cause of problem is not in interlock system Glow plugs not used properly before starting Glow plug circuit malfunctioning Fuel shut off solenoid is IN should be OUT Engine or fuel system problem Use
88. low pressure gauge 0 1000 psi 1 Perform steps 1 7 under Charge Pressure Test 2 While observing the gauge move the lift control lever to the RAISE position While holding the lever in the RAISE position look at the pressure reading on the gauge The gauge should show 700 800 psi Stop the engine and move the lift control lever to the LOWER position to lower the implement to the ground 3 If the pressure is below 700 psi adjust the implement relief valve by adding the required amount of shims from the shim pack A CAUTION The implement relief pressure must not ex ceed 800 psi NOTE When testing the implement relief valve pres sure it may be found that the pressure is already set to the 800 psi maximum If this is so a slow or no lift condition is most likely caused by an added force being applied to the lift system and not a fault within the Testing Page 5 20 hydraulic circuit This is can be caused by parts that are binding or build up of debris under the cutting unit This adds to the amount of force that the hydraulic cylinder must overcome Repair such items before continuing with the hydraulic tests If adding shims to the relief valve does not increase the pressure inspect the condition of the charge pump gerotor and internal housing If the charge pump is in good condition no scoring scratches or excessive wear the general condition of the transmission s piston pump and piston motor might
89. make sure that the solenoid plunger moves freely and is free of dirt debris and corrosion 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 4 Touch a negative test lead from the 12 VDC source to the fuel stop solenoid frame ground Fig 13 The solenoid should engage making an audible click and the plunger should retract 5 Remove positive voltage from the pull coil termi nal The solenoid should stay engaged 6 Remove positive 4 voltage from the hold coil termi nal The solenoid should release 7 Connect the wire harness connector to the run sole noid Figure 13 3 Hold coil terminal 1 Fuel stop solenoid 2 Pull coil terminal Electrical System Rev G Service and Repairs Battery Service The battery is the heart of the electrical system With regular and proper service battery life can be extended Additionally battery and electrical component failure can be prevented Note Battery information for all Groundsmaster 322 325 machines and Groundsmaster 345 machines with serial number below 21000000 is included in Chap ter 6 Electrolyte Specific Gravity Fully charged 1 265 corrected to 80 F 26 79 C Discharged less than 1 240 Battery Specifications Groundsmaster 328 D BCI Group 24 660 Amp Cr
90. on notch in set plate 1 Control Rack travels to OFF Position 2 Over Injection for starting 3 Normal operating range Figure 44 Groundsmaster 300 Series Page 4 39 Fuel System Service 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 Second after injection into the cylinder the Delivery Valve closes reducing the pressure within the delivery pipe to nearly zero while preventing fuel from flowing from the tube During injection After injection Figure 45 Inter Cylinder Injection Control Fig 46 The amount of fuel delivered to each of the three cylin ADJUSTING PLATE PLUNGER BARREL ders is adjusted by means of adjusting plates These plates function as a cam to position the plunger barrel within the pump housing IMPORTANT Do not remove the Adjusting Plates from the pump housing If removed re calibration by a diesel shop will be necessary If it is necessary to remove the plates carefully scribe SCRIBE PLATE AND HOUSING the plate and pump body to allow for exact correct BEFORE REMOVING reassembly Figure 46 Fuel System Service Page 4 40 Groundsmaster 300 Series Injection Pump Disassembly Fig 47 The injection pump may be disassembled
91. or wear The condition of the valves can give important clues to other components which may require service example improper valve clearance worn valve guides damaged seals etc Remove the valve seals 3 Remove all of the carbon deposits from the combus tion chamber using a scraper and wire brush Figure 54 4 Clean the cylinder head thoroughly with solvent or Checking cylinder head distortion degreasing solution and dry Inspect it carefully for cracks 5 Remove all carbon deposits from the valve guide bores with a valve guide cleaner Use a valve guide bristle brush to remove loosened carbon deposits in the valve guide Push a solvent soaked cloth through the valve guides to remove all foreign materials 6 Use compressed air to ensure that the oil passage way through the head is not clogged A Wear eye protection during use of com pressed air Limit air pressure to 40 psi 280 kPa 7 Check the flatness of the cylinder head lower surface using a straight edge and feeler gauge Be sure to check the surface variation crosswise lengthwise and diago nally If a surface flatness variation greater than 0 002 inch 0 05 mm exists the cylinder head or cylinder block must be replaced or resurfaced 8 Use a micrometer and a small hole gauge to check the valve guide to valve stem clearance The valve and valve guide should be replaced if the clearance exceeds the following limits Intake Valve
92. order in which they are listed If the machine being repaired has any interlock switches by passed they must be reconnected for proper trou bleshooting and safety Condition Possible Cause Correction Starter solenoid clicks but starter will not crank If solenoid clicks problem is not in interlock system Troubleshooting Groundsmaster 322 D 325 D Low battery charge Loose or corroded battery cables Loose or corroded ground Faulty wiring at starter Loose starter mounting bolts Faulty starter Faulty starter solenoid Engine seized Page 6 12 Charge battery Replace battery if it will not hold a charge Clean and tighten or repair as necessary Repair wiring Clean mounting surface and tighten bolts Repair or replace starter Replace starter solenoid Repair engine Groundsmaster 300 Series Starting Problems continued Condition Possible Cause Correction Nothing happens when start attempt is made Groundsmaster 300 Series Battery is dead Loose or corroded battery cables Loose or corroded ground Circuit breaker open Ammeter faulty Ammeter wiring Loose corroded or damaged Ignition switch faulty Ignition switch wiring loose corroded or damaged Traction neutral switch out of adjustment or faulty Traction neutral switch wiring loose corroded or damaged PTO switch out of adjustment or faulty PTO switch wiring
93. out from below 9 Remove the components of the other two injector pumps using the same procedure 10 To remove the Control Rod remove the E rings Ungleich set spring and Ungleich set plate Slide the rack from the pump bogy 11 To remove the smoke set plate remove the cotter pin washer and return spring Groundsmaster 300 Series Page 4 41 Figure 47 E ring Ungleich set spring Ungleich set plate Pump housing E ring Return spring Smoke set plate Air breather screw Washer 10 Hollow screw 11 Pump element ass y 12 Delivery valve ass y 13 Gasket gt 14 Delivery valve spring O ring Delivery valve holder Bolt washer Adjusting plate Tappet guide pin Plate Control rack Plunger control sleeve Upper spring seat Pump plunger spring Lower spring seat Shim plate Tappet Fuel System Service 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 Replace the Pump Element Sub Assembly if defective 3 Inspect the Control Rack and Pinions for worn or damaged teeth Replace worn or damaged compo nents 4 Inspect the Tappet outside diameters rollers and shafts for wear or damage Replace damaged or worn components I
94. 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 On the button end of each pinion there is a plus or minus number or a 0 number This number indi cates the best running position for each particular gear set This dimension is controlled by the shimming be hind the inner bearing cup For example if a pinion is etched 3 this pinion would require 0 003 in less than a pinion etched 0 This means that by removing shims the mounting distance of the pinion is increased to 1 213 in which is just what 3 indicates Or if a pinion is etched 3 we would want to add 0 003 in shims the mounting distance of the the pinion was decreased to 1 207 in which is just what a 3 etching indicates If a new gear set is being used notice the or etching on both the old and new pinion and adjust the thickness of the new shim pack to compensate for the difference of these two numbers For example If the old pinion reads 2 and the new pinion is 2 add 004 in shims to the original shim pack Groundsmaster 300 Series Page 7 15 Figure 37 Repairs 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 5 Insert the pinion into the h
95. re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing 1 Disconnect the wire harness connector from the so lenoid 2 Using a digital multimeter touch one lead to the pin of the black wire and the other lead to the pin of the white wire The resistance of the pull coil should be about 0 33 ohms 3 Using a digital multimeter touch one lead to the pin of the black wire and the other lead to the pin of the red black wire The resistance of the hold coil should be about 12 2 ohms 4 Touch a negative test lead from the 12 VDC source to the pin of the black wire The solenoid should engage making an audible click 5 Remove positive voltage from the pin of the white wire The solenoid should stay engaged 6 Remove positive voltage from the pin of the red black wire The solenoid should release 7 Reconnect the wires to the solenoid Figure 12 4 Common black wire 5 Hold coil red black wire 1 Cap screw 2 Fuel stop solenoid 4 Connect solenoid to the wiring harness Bi Gasket 6 PUE Coll white wits Live testing 1 Disconnect the wire harness connector from the so lenoid Note The solenoid may be removed from the engine or tested in place 2 If the solenoid is removed from the engine make sure that the solenoid plunger moves freely and is free of dirt debris and corrosion 3 Connect a positive test lea
96. ring 29 Apply clean multi purpose grease on the new com mutator seal and put it into the commutator cover seal groove Fig 92 The rubber portion the softer side of the seal with the yellow mark must be put into the seal groove 30 Apply clean multi purpose grease to the metering ring seal ring Put the seal ring into the metering ring seal ring groove Fig 93 Groundsmaster 300 Series Page 8 45 Figure 93 Repairs 31 Put two alignment pins into the metering ring Fig 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 95 Align the alignment pin holes with the alignment pins in the metering ring The isolation manifold surface without the recessed slots must be toward the metering ring 33 Install two alignment pins into the isolation manifold Fig 96 Figure 96 Repairs Page 8 46 Groundsmaster 300 Series 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 35 Apply clean grease to a seal ring and put it in the valve ring recess that will face down when installed Install the valve ring over the bolts and alignment pins with the seal ring facing the iso
97. rods again 5 Turn the ignition switch ON so the electric fuel pump will supply fuel through the injection pump and out the number 1 delivery valve holder 6 Rotate the engine crankshaft SLOWLY in the normal direction until the flow from the number one injection pipe just stops This is the moment of actual injection timing Alarge screwdriver inserted between the trans mission drive hub and rubber coupler will provide control and leverage to slowly rotate the engine crankshaft Groundsmaster 300 Series Page 4 23 7 Standard injection timing can be confirmed by the IT marks on the crankshaft pulley and the stationary pointer on the crankcase Fig 21 The center mark on the pulley represents 23 BTDC standard fuel injection timing The outside marks repre sent 25 BTDC and 21 BTDC the acceptable range of injection timing Shims are available in different sizes from 0 2 to 1 0 mm thick Adding or removing a shim 0 1 mm thick will change injection timing by 1 Increase shim thickness if injection is too early Decrease shim thickness if injection is too late See Injection Pump Service in the Fuel System Repairs section of this chapter m 5 Figure 20 Removing the delivery valve Figure 21 Testing 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 p
98. rollers must be positioned in the upper bracket holes Groundsmaster 300 Series Page 11 5 Figure 3 3 Thrust washer 4 Large front caster spindle 1 Lynch pin 2 Spacers Figure 4 1 Lynch pin 4 Washer 2 Small rear caster 5 For 1 in H O C only 3 Spacers Adjustments Checking and Correcting Mismatch of Blades Fig 5 If there is mismatch between the blades the grass will appear streaked when it is cut This problem can be corrected by making sure the blades are straight and all blades are cutting on the same plane 1 Using a 3 foot long carpenters level find a flat surface on the shop floor 2 Set rear caster wheels in the upper hole of caster forks and adjust height of cut so all six height of cut spacers are below the caster arm 3 Lower cutting unit onto flat surface Remove covers from top of cutting unit Loosen idler pulleys to release tension against all three belts 4 Rotate blades until the ends face forward and back ward Measure from floor to front tip of cutting edge and remember this dimension Then rotate same blade so opposite end is forward and measure again The differ ence between dimensions must not exceed 1 8 inch If difference exceeds 1 8 inch replace the blade because itis bent Make sure to measure all three blades 5 Compare measurements of outer blades with the center blade Center blade must not be more than 3 8 inch lower than outer blades If center blade i
99. should be 0 volts If voltage is not present when the key switch is turned to the START position test the key switch for fault ON terminal Testing Page 6 24 Groundsmaster 300 Series Sketch of Connector Testing Procedure Connect a voltmeter to the OL terminal yellow wire of the 4P coupler 4P coupler Read the voltmeter each time the engine is stopped and operated When the engine is started the voltage at terminal OL should be 12 volts when stopped O volts If voltage is not present when the engine is started either the control unit s ground lead is not allowing current flow or the control unit assembly is at fault and must be replaced Disconnect the 4P coupler from the main wire harness and connect a lamp 3 watt or lower 12 VDO between terminals S and S 2blue wires Keep terminal OL free of any connections Turn the key switch to ON RUN and after waiting for a few seconds turn the Switch to OFF The lamp will go on and stay lit for 7 to 15 seconds OL 4p coupler If the lamp does not light or will not go out either the control unit s ground lead is not allowing current flow or the control unit is at fault and must be replaced Disconnect the 4P coupler from the main wire harness and connect an ohmmeter across terminals S and S 2 blue wires to read the resistance between the t
100. the steering cylinder is fully retracted a gap of 1 16 1 6 mm should exist between right side bevel gear case casting and stop bolt Figure 1 1 Steering stop bolt 2 Bevel gear case LH Groundsmaster 328 D Page 10 1 3 4WD Rear Axle Rev G Dae Dong Axle Repairs NOTE See Traction Unit Operator s Manual for Main tenance intervals and instructions 4WD Rear Axle 4WD rear axle Adaptor Cap screw 2 used Bidirectional clutch Flat washer Lock washer Lock washer 6 used Socket head screw 6 used Driveshaft 10 Cap screw 11 Spacer 12 Cap screw 2 used 13 Cap screw 14 R clamp 15 Washer head screw 16 Guard 17 Flange head nut 18 Rear weight 19 Jam nut 20 Thrust washer fp og oM 4WD Rear Axle Rev G Dae Dong Axle 21 22 23 24 25 26 27 28 29 1 2 34 35 Hydraulic hose 37 38 39 Figure 2 Flange head screw 4 used Frame spacer 4 used Flange nut 4 used Main frame Axle support Lock nut 2 used Rear axle pin Grease fitting Washer head screw Bumper Flat washer 2 used Lock washer 2 used Cap screw 2 used Hydraulic fitting O ring Hydraulic hose Grease fitting 2 used Cap screw 4 used Page 10 1 4 45 to 55 ft lbs 61 to 75 Nm Washer 4 used Tie rod Cap screw 2 used Cotter pin 2 used Tie rod end 2 used Grease fitting 2 used Hex nut 2 used Lug nut
101. the end of the jacket tube over the bushing in two places ap proximately 90 away from the original crimped areas Fig 65 Put clean multi purpose grease on the inside of the bushing Repairs Page 8 36 Figure 65 Groundsmaster 300 Series 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 Apply a small amount of multi purpose grease to the recessed face of the retainer plate and washer Put the retainer plate into the upper cover amp jacket with the recessed retainer face out Put the washer against the recessed face of the retainer plate 5 Install the snap ring onto the input shaft if it was removed Fig 67 6 Slide the input shaft into the upper cover end of the upper cover amp jacket and through the bushing until the retaining ring bottoms against the washer Make sure the washer bottoms against the retainer plate recessed face and the retainer plate seats against the end of the jacket tube Fig 68 7 Install the upper cover plate over the four bolts with the highly polished surface up Fig 69 IMPORTANT The alignment grooves must be all on one side of the steering valve for proper operation Groundsmaster 300 Series Page 8 37 Figure 66 Figure 69 Repairs 8 Apply clean multi purpose grease to the face of the
102. 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 3 Turn the engine OFF 4 Disconnect the hydraulic hose from the fitting on the rod end of the cylinder Put a plug in the end of the hose to prevent contamination 5 With the engine OFF continue turning the steering wheelto the left counterclockwise with the cylinder rod completely extended and observe the open fitting on the steering cylinder If oil comes out of the fitting while turning the steering wheel to the left the steering cylin der has internal leakage and must be repaired or re placed NOTE DO NOT turn the steering wheel to the right clockwise or the steering valve will meter oil out the disconnected hydraulic hose Testing 8 8 Groundsmaster 300 Series 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 1 Rotate the steering wheel so the rear wheels and steering plate are straight ahead FRONT AND REAR OF WHEELS __ 2 Loosen the jam nuts on both tie rods Adjust both tie rods until center to center distance at front o
103. the hydraulic oil to be sure it is up to the proper level Start the engine and operate the lift cylinder to remove air from the lines Turn the engine off 8 Check the level of the hydraulic oil again to be sure it is up to the proper level 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 Groundsmaster 300 Series Page 5 41 Figure 33 Repairs Lift Cylinder Repair Fig 34 Pump the oil out of the cylinder into a drain pan by moving the piston back and forth 1 Wash the lift cylinder in solvent and dry it thoroughly 2 Mount the lift cylinder vertically in a vise so the shaft end of the cylinder is facing up 3 Push the head Item 5 into the barrel Item 13 approximately 3 4 inch Remove the retaining ring Item 4 4 Grasp the large end of the shaft and use a twisting and pulling motion to carefully extract the piston Item 11 shaft Item 2 and head Item 5 from the cylinder bore 5 Remove the cylinder from the vise 6 Securely mount the piston shaft and head assembly into the vise so that the large nut Item 12 is easily assessable for removal 7 Remove the large nut from the end of the shaft 8 Remove the piston and head from the shaft 9 Inspect the head shaft and piston for exces
104. the piston slippers contact the face of the thrust plate 9 Push against the back of the cylinder block A slight spring pressure assures the correct installation of parts 10 Assemble the transmission sections if no other service work is required refer to Assembling Transmis sion Sections which follows MOTOR HOUSING CYLINDER BLOCK MOTOR HOUSING Figure 30 Groundsmaster 300 Series 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 2 Identify the motor side of the center section by locat ing the two slotted directional charge check plugs Apply transmission oil on the surfaces of the motor valve plate and install the recessed groove side of the motor valve plate against the side of the center section The slot in the valve plate must fit over the locating pin Make sure that the center of the valve plate pilots on the needle bearing extending out of the center section IMPORTANT The motor valve plate and the pump valve plate are not interchangeable Identify the motor valve plate by the four V notches in the kidney shaped grooves The pump valve plate has two V notches in the grooves 3 Apply transmission oil on the surfaces of the pump valve plate and install the rece
105. the studs Rotate the brake drum until adjusting slot is at the top and centered over star nut Fig 13 7 Use a brake adjusting tool or a screwdriver to rotate star nut until brake drum locks because of outward pressure of brake shoes Fig 14 8 Loosen star nut approximately 12 to 15 notches or until brake drum rotates freely 9 Install wheel onto studs with five 5 wheel nuts Tighten the wheel lug nuts 10 Remove jack stands or blocking and lower machine to floor Tighten wheel lug nuts to a torque of 45 to 55 ft Ib 11 Adjust brake cables see step 2 of this procedure Repairs Page 8 10 Figure 12 1 Jam nuts Figure 13 1 Brake adjusting slot Figure 14 1 Star nut 2 Brake shoe Groundsmaster 300 Series 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 IMPORTANT DO NOT hit the steering shaft with a hammer This could damage the steering valve com ponents Installing the Steering Wheel 1 Use the steering wheel to put the rear wheels in the straight ahead position 2 Slide the steering wheel onto the steering shaft 3 Secure the steering wheel in place with the jam nut Fig 10
106. 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 NOTE The steering valve will not allow oil to flow through it to the lift valve when the steering wheel is being turned Whenever the steering wheel is not moving the steering valve allows oil to flow through it Oil in the rest of the steering circuit is then trapped Pressure Return Hydraulic Flow Diagrams Page 5 8 Groundsmaster 300 Series 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 Oil displaced by the other end of the steering cylinder returns to the steering valve through port LT which directs it through the OUT port back to reservoir When the steering wheel stops turning the control valve within the steering valve shifts back to neutral allowing oil to flow through the steering valve out the AUX port to the lift control valve Oil in the rest of the steering circuit is then trapped Pressure Return 4WD Units 2WD Units Groundsmaster 300 Series Page 5 9 Hydraulic Flow Diagrams Special Tools NOTE Order special too
107. 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 If necessary scribe plates and housing carefully to ensure exact repositioning upon reinstallation Do not mix deliv ery valves delivery valve seats plungers or plunger barrels from one cylinder to another Handle these parts carefully Place these parts in clean diesel fuel to prevent rust 1 Remove the fuel pipes from the injection pump to the injector nozzles 2 Remove the fuel return hose by disconnecting the collar from the pump or by removing the hose clamp 3 Remove the tie rod cover Disconnect the Tie Rod retaining spring and Tie Rod from the Control Rack 4 Remove the four injection pump mounting bolts 5 Remove the injection pump from the cylinder block Make note of the number and thickness of the adjusting shims under the pump The shims determine the injec tion timing 6 Straighten the locking tabs on the plate which retains the Tappet Guide Pin Rotate the pin 180 push in on the Tappet slightly and remove the Guide Pin and Tap pet 7 Remove the Lower Seat Plunger Spring Upper Seat Control Pinion and Plunger 8 Remove the Delivery Valve Holder Gasket O ring Valve Spring and Delivery Valve Push the barrel as sembly
108. tubing 1 00 25 6 3 8 in 1 50 25 8 1 2 1 50 25 10 5 8 1 50 25 12 3 4 1 50 25 16 1 1 50 25 General Information 5 4 Figure 4 Lock Nut Back Up Washer O Ring Step 1 Step 3 Step 2 Step 4 Figure 5 Groundsmaster 300 Series 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 If traction unit must be moved a long distance transport it on a truck or trailer When ever traction unit is pushed or towed the by pass valve must be open 1 Raise and support seat to get access to by pass valve 2 Rotate by pass valve on transmission counterclock Figure 6 wise 1 2 to 1 turn Opening the valve opens an internal 4WD unit shown passage in the pump to by pass transmission oil Be cause fluid is by passed the machine can be pushed 1 Bypass valve slowly without damaging the transmission 3 Close by pass valve by rotating it clockwise until it is securely seated Do not exceed 5 to 8 ft lb of torque when tightening IMPORTANT Do not start engine when valve is open Running the machine with the by pass valve open will cause the transmission to overheat Groundsmaster 300 Series Page 5 5 Gene
109. used between the cap and housing ma chined surfaces 2 Puttwo 0 015 in gaskets on the machined surface of the housing then install the shaft and cap assembly in the housing so the bearing cone Item 9 on the shaft assembly and bearing cup Item 3 in the housing are mating Align the holes in the cap with the holes in the gaskets and housing 3 Install capscrews and tighten Groundsmaster 300 Series Page 13 21 4 The shaft should have a very slight amount of bearing drag If the shaft turns hard the cap must be removed and gasket s need to be added If the shaft has no bearing drag or has end play the cap must be removed and gasket s taken out The cap must be adjusted to where the shaft has no end play and only a slight amount of bearing drag 5 Repeat steps 1 4 with the other shaft and cap assembly 6 After installing the gear box on the cutting unit fill it with SAE 80W90 API GL 5 lubricant to the level of the check plug see Maintenance section in this chapter Repairs 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 Start the engine and raise the cutting unit Turn the engine OFF and remove the key from the key switch Block up the cutting unit so it cannot fall accidentally
110. way forward 4 Tighten the cap screw and nut securing the throttle cable to the governor lever 5 Make sure the throttle cable conduit does not interfere with the full range of motion of the throttle lever or governor lever Troubleshooting Giving Immediate attention to any indication of a prob lem can prevent major failures and increase the life of the engine 1 Engine Fails to Start k SPEED L SET BODIES Figure 15 4 Throttle cable 5 Throttle cable conduit 1 Governor lever 2 Cap screw and nut 3 Throttle lever Never make more that one adjustment at a time then locate the trouble by a process of elimination Remem ber the cause is usually SIMPLE rather than mysterious and complicated Problem Probable Cause Possible Remedy Slow Cranking Speed 1 Engine oil viscosity is too high 2 Battery is discharged 3 Battery plates sulfated 4 Battery terminal dirty or poor connection 5 Starter failure Use correct oil Charge the battery Replace the battery Clean the terminals repair or tighten cables Repair or replace starter Groundsmaster 300 Series Page 4 15 Troubleshooting 1 Engine Fails to Start continued Problem Probable Cause Possible Remedy Injection system 1 Air in fuel line Purge air from the fuel system Glow plug is burnt out Glow plug does not glow red hot Gove
111. with a fine wire screen 200 mesh Make sure funnel and oil are very clean to prevent accidental contamination of hydraulic system 3 Screw dipstick filler cap finger tight onto filler neck It is not necessary to tighten cap with a wrench 4 Lower the implement Figure 1 1 Dipstick cap 2 Groove Groundsmaster 300 Series 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 tions or mishandling during operation or maintenance These conditions can cause damage or premature deterioration Some hoses are more susceptible to these conditions than others Inspect the hoses fre quently for signs of deterioration or damage When replacing a hydraulic hose be sure that the hose is straight not twisted before tightening the fittings This can be done by observing the imprint on the hose Use two wrenches one to hold the hose straight and one to tighten the hose swivel nut onto the fitting Hydraulic Fitting Installation O Ring Face Seal 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material Fig 3 2 Make sure the O ring is installed and properly seated in the groove It is recommended that the O ring be replaced any time the connection is opened 3 Lubricate the O ring with a light coating of oil 4 Putthe
112. 0 D Assemble gear Item 5 to wheel shaft and install cover and wheel shaft assembly to knuckle case Item 38 Note that top two 2 capscrews Item 39 securing cover Item 30 are a shorter length E Install bevel gear Item 5 to knuckle pin and install cover Item 26 to knuckle case Item 38 Use medium strenght Loctite on capscrews Item 28 securing cover Item 26 F Evenly tighten capscrews Item 28 39 securing covers to a torque of 12 20 ft lb 170 280 Kg Cm 4 Install axle on machine see Rear Axle Removal and Installation 5 Fill axle with proper lubricant to level of check plugs see Specifications Page 10 10 Groundsmaster 300 Series Chapter 10 1 GM 325 D 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 iis it ue ug fino 11 ADJUSTMENTS 3 Removal 2e Mel ceed ea eae pip 11 Steering Stop Bolt Adjustment 3 Installation 2 2 0 eee 11 REPAIRS nue e dd dau 4 Input Shaft Pinion 12 4WD Rear 4 Removal zi EIS LIS 12 Removal 223 thee RE Ice IR d 5 Installation ve hi cedi 12 Installation 5 Differential
113. 0 Amp Cranking Performance at 0 F 17 C Keep the terminals and entire battery case clean To 45 min Reserve Capacity at 80 F 27 C clean the battery wash the entire case with a solution Reelmaster 322 D 325 D of baking soda and water Rinse with clear water Do not Battery Specifications get the soda solution into the battery because damage to the battery will result Coat the battery posts and cable BCI Group 24 Battery 550 Amp Cranking Performance at 0 F 17 C connectors with skin over grease or petroleum jelly to 140 min Reserve Capacity at 80 F 27 C prevent corrosion Checkfor loose battery hold downs Aloose battery may crack or cause the container to wear and leak acid V 3 Check the electrolyte solution to make sure the level is FEVER above the plates If the level is low but above the plates inside the battery add water so the level is to the bottom of the cap tubes If the level is below the plates add water only until the plates are covered and then charge the battery After charging fill the battery to the proper level Electrolyte Specific Gravity Fully charged 1 250 1 280 Discharged less than 1 240 Figure 22 A CAUTION Do not charge a frozen battery because it can explode and cause injury Let the battery warm to 60 F 16 C before connecting to a charger Charge the battery in a well ventilated place so that gases produced while charging can
114. 1 1 Filler plug 2 Check plug 3 Drain plug Specifications Page 13 2 SAE 80W90 API GL 5 gear lube Groundsmaster 300 Series Troubleshooting 39V 1d3U NINOS 1138 0 14 1234dSNI 39v 1939 SLIVHS X08 uv39 1234SNI 32211435 Ad1Ti1fid X08 dV19 1234SNI 35001 3330 u311n2 32V 1d3U 32v 1d3u 32V 143u N31H9I1 N3X0u8 3 001 35001 A3T11fd 01 123dSNI LAVHS 01 123dSNI LAVHS 1 41 0 3NI9N3 NO A311fd LI3dSNI 40 39V143u N31H9IL SONNOd 1004 001 015 3nDuo1iu 39V 1939 N3dUVHS NINOS 35001 35001 1100 1N38 1108 31 NIdS 1234SNI 1138 5307718 531109 123dSNI 1234SNI Troubleshooting Page 13 3 Groundsmaster 300 Series 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 Height of Cut Spacers Below Caster Arms inches mm Front Rear 2 50 0 0 24 2 64 1 1 3 76 2 2 3 1 2 89 3 3 4 102 4 4 4 1 2 114 5 5 5 127 6 6 1 Startthe engine and raise cutting unit so height of c
115. 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 16 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 322 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 322 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 16 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By
116. 12 volt battery so the positive battery terminal is connected to the positive terminal on the hourmeter Connect the nega tive battery terminal to the negative terminal on the alternator The hourmeter should operate as 12 V D C is applied between the terminals Engine Temperature Gauge and Fuel Level Gauge To test a gauge use a commercial gauge tester If a commercial gauge tester is not available substitute a new gauge or test the sending unit Groundsmaster 300 Series 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 amp C terminals of the temperature relay have a normally closed connection between them If there is no continuity between terminals B amp C check the SFE 14 fuse inside the relay box Acoil resistance may be read on the ohmmeter between terminals B amp S No resistance indicates an open coil If the coil is open replace the temperature relay device Figure 18 Temperature Gauge Sending Unit Fig 19 The temperature gauge sending unit is located on the top of the cylinder head near the thermostat 1 Lower the coolant level in the engine and remove the temperature gauge sending unit located near engine thermostat 2 Put the sending unit in a container of oil wit
117. 3 to ensure assembly is properly seated and operating freely Correct any discrepancy 2 Jack up frame so left front wheel is off the ground On four wheel drive machines jack up frame so at least one rear wheelis also offthe ground Use jack stands to sup port the raised machine 3 Block wheels that are on the ground so vehicle cannot roll forward or backward 4 Start engine and allow it to idle for 5 minutes to heat oil in transmission to operating temperatures 5 Release parking brake then check that wheel s that are off the ground are NOT rotating Check for wheel rotation with throttle in both SLOW and FAST position If wheel s that are off the ground NOT rotating pro ceed to step 8 as no adjustment is necessary 6 If the wheel s that are off the ground ARE rotating the pump plate must be adjusted as follows A Move throttle to SLOW B Loosen three 3 capscrews that secure pump plate to transmission C If wheel is rotating forward lightly tap bottom of pump plate counterclockwise By contrast tap pump plate clockwise if wheel is rotating backward When wheel stops rotating tighten capscrews to secure pump plate D Check that wheel s that are off the ground are NOT rotating with throttle in both SLOW and FAST position If necessary repeat pump plate adjustment until wheels do not rotate 7 Should wheel s that are offthe ground continue to ro tate after adjustment procedure check for the
118. 300 Series 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 13 Install the front plate Remember to use a new gasket 14 Turn the crankshaft until the No 1 piston is a top dead center TDC 15 Drive the key into the crankshaft and install the crankshaft gear onto the shaft if it has been disassem bled 16 With the idler gear mating mark 1 properly aligned with the crankshaft mating mark 1 install the idler gear on to the idler shaft 17 Insert the camshaft and gear assembly into the cylinder block and align the idler gear mark 2 with the camshaft gear mating mark 2 18 Install the injection pump camshaft assembly into the cylinder block and align the idler gear mating mark 9 with the pump gear mark 3 Remember to install the bolt and washer which retain the injection pump camshaft bearing 19 Install the governor weight assembly and sliding shaft to the injection pump cam gear Groundsmaster 300 Series Page 4 63 Figure 85 Installing piston and rod assembly Figure 86 Mating marks of gears Cylinder Block Overhaul 29 Install the front gear case and gasket using PER MATEX
119. 4 Using a rag or thickly padded glove grasp end of blade Remove blade screw flat washer anti scalp cup and blade from spindle assembly 5 Remove flange nuts and carriage bolts securing spindle housing to deck Slide spindle housing assem bly out the bottom of the cutting unit Disassembly 1 Remove lock nut retaining the spindle pulley on spindle shaft Slide pulley off of shaft 2 Press the spindle shaft out of the spindle housing using an arbor press The bearing spacer remains on the spindle shaft as the shaft is being removed 3 Remove seals from spindle housing 4 Allow the bearings and small thick spacer to fall out of the spindle housing 5 Using a punch and hammer drive both of the bearing cups out of the spindle housing Also drive the large spacer out of the housing 6 Alarge snap ring is still inside the spindle housing and it should remain there because it cannot be easily removed IMPORTANT If new bearings will be installed into a used spindle housing that has the original snap ring installed discard the large snap ring that came with the bearings because it is not needed However new bearings with their matched spacer and snap ring must always be installed when the spindle housing is being replaced Replacement bearings are sold only with a matched snap ring and spacer set These parts cannot be purchased separately Repairs Page 13 22 Figure 29 1 Grease fitting 9 Flange nut 2
120. 4 06 mm 2 Measure the differential pinion shaft O D and the pinion gear I D to determine the pinion shaft to pinion gear clearance Fig 26 Replace components as nec essary PINION SHAFT TO PINION GEAR CLEARANCE 0 001 to 0 010 in 0 03 to 0 25 mm PINION SHAFT O D Factory Spec 0 550 to 0 551 in 13 97 to 13 10 mm PINION GEAR I D Factory Spec 0 551 to 0 552 in 13 10 to 14 02 mm 3 Inspect all gears shafts bearings cases and cov ers for damage and wear Replace components as nec essary 1 1 Side gear Pinion shaft Groundsmaster 328 D Page 10 1 15 Figure 25 2 Differential case Figure 26 2 Pinion gear 4WD Rear Axle Rev G Dae Dong Axle 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 3 Install the side gear shims and side gears in their original location in the differential case 4 Place the differential pinion gears and pinion wash ers in their original location in the differential case Tem porarily install the differential pinion shaft 5 Secure the differential case in a soft jawed vise Posi tion a dial indicator on a tooth of the differential p
121. 54 55 A Assemble differential Use medium strength Loc tite on bolts Item 7 and tighten evenly to a torque of 20 24 ft lb 270 330 Kg Cm B Assemble pinion gear Item 30 and bearing case 6 Item 38 Tighten bearing nut Item 34 to pre load tapered roller bearings Tighten so pinion shaft will EP rotate with 2 5 5 in Ib 2 0 6 5 Kg Cm of torque Bend washer Item 33 to prevent nut from loosen ing Tooth contact between bevel gear and pinion with light load C Adjust tooth contact of bevel gear Item 6 to pinion Item 30 Use shims Item 29 to make good contact with light load between bevel gear and pinion Figure 14 Fig 13 D After adjusting tooth contact use shims Item 5 to make backlash 0 003 0 01 in 0 08 0 25 mm Check backlash through plug hole Item 26 with a dial indicator Groundsmaster 300 Series Page 10 9 Repairs Repairs 3 Assemble knuckle assembly Fig 13 A Insert needle bearing Item 22 washer Item 21 knuckle pin Item 20 spacer Item 19 and bevel gear Item 18 into axle gear box Item 23 Fasten bearing retainer Item 15 with bolts Item 13 and tighten bolts evenly to a torque of 6 8 ft lb 80 120 Kg Cm B Assemble knuckle pin Item 20 and knuckle case Item 38 to match knuckle arm Item 8 with knuckle pin Fasten capscrew Item 10 temporarily will be removed to fill with lubricant C Assemble wheel shaft Item 35 to cover Item 3
122. 7 2 ecu m Feu a UR 7 3 Chapter 8 Steering and Brakes 8 1 Schematics 8 3 lt 8 4 Special 8 4 Troubleshooting 8 5 Testing iu Sis ea hee ie 8 7 Adjustments 8 9 E 8 11 Chapter 9 Transmission Coupler and PTO Introduction oeri a eee 9 2 Troubleshooting 9 3 Adjustments 9 4 ueni v eh oe oe 9 7 Chapter 10 AWD Rear Axle GM322 D or GM325 D with Inasaka axle 10 2 General Information 10 3 Adjustments 10 4 EG REY NE 10 5 Chapter 10 1 AWD Rear Axle GM325 D or GM328 D with Dae Dong axle 10 2 Adjustments 10 3 Fed Sale techs Ee be ebbe ans 10 4 Chapter 11 72 Cutting Units Specifications 11 2 General 11 3 11 4 Adjustments eee 11 5 Repairs
123. 8 F 5 to 20 SAE 20 or 10W 30 Below 41 F 5 C SAE 10W 30 Oil Pump Type Gear type Check Valve Opening Pressure 4 kg cm 56 9 psi at 1000 rom Outer Rotor to Housing Clearance Outer Roto to Inner Rotor Clearance Rotor to Cover Clearance 0 15 0 20 mm 0 006 0 008 in 0 05 0 12 mm 0 002 0 005 in 0 03 0 07 mm 0 001 0 003 in 0 3 mm 0 012 in 0 25 mm 0 01 in 0 2 mm 0 008 in Oil Pressure Switch Indicator Lamp Lighting Pressure 0 5 kg cm 7 1 psi Groundsmaster 300 Series Page 4 7 Specifications 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 Injection Timing B T D C 23 B T D C at smoke set position 2 Nozzles Type Throttle type Model ND DN4SD24 Injection Start Pressure 120 kg cm 1707 psi 120 10 kg cm 1707 142 psi Cooling System Item Standard Specification Repair Limit Service Limit Coolant Capacity 5 7 liter 6 U S qt Thermostat Type Valve Cracking Temperature Full Opening Valve Temperature Valve Lift Wax type 76 5 1 5 C 177 3 90 1 5 C 194 3 F 8 mm 0 314 in Specifications Page 4 8 Groundsmaster 300 Series Electrical System Item Standard Specification Repair Limit Service Limit Starter Type Solenoid shift ty
124. 9 Remove the jackstands and lower the machine to the floor 10 Install the hydraulic hoses to the steering cylinder 11 Lubricate the rear axle bushings through the grease fitting on the rear axle 4 Use a drift punch and hammer to drive both bushings Item 41 out of the steering pivot Clean the inside of the steering pivot tube to remove dirt and foreign mate rial Also clean the mounting pin on the bottom of the rear axle 5 Apply grease to the inside and outside of the new bushings Use an arbor press to install the bushings into the top and bottom of the steering pivot tube Bushings must be flush with the end of the tube 6 Slide the steering pivot onto the mounting pin Secure the plate in place with the thrust washer washer and retaining ring Groundsmaster 300 Series 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 secure tie rod end 9 Lubricate the bushings through the grease fitting on the steering pivot Figure 16 Groundsmaster 300 Series Page 8 13 Repairs Rear Wheel Spindle Bushing Service 2WD Units The rear wheel spindles must fit snugly in the rear axle Excessive movement of the spindle in the axle indicates that the bushings are p
125. Bleeding Air From the Injectors 35 Fuel Pump Service 35 Governor Mechanism Operation 37 Governor Inspection 37 Injection Pump 38 Nozzle 45 REMOVING AND INSTALLING THE ENGINE 46 Removing the Engine 46 Installing the Engine 46 CYLINDER HEAD OVERHAUL 47 Cylinder Head 47 Cylinder Head Servicing 48 Valve 49 VAIVOS a c eese Rel eere R e t 49 Valve Seats 50 Valve 51 Rocker Arm and Rocker Shaft Service 51 Cylinder Head Reassembly and Installation 52 CYLINDER BLOCK OVERHAUL 53 Cylinder Block Disassembly 53 Camshaft and 55 Fuel Injection Pump Camshaft 55 Crankshaft Bearings 56 Timing Gears x sheesh 56 Connecting Rod and Connecting Rod Bearings 57 etre eR 57 Oversized Pistons Cylinder Bore and Rings 58 Piston and Pin Replacement 59 Engine 59 Table of Contents Introduction This chapter gives information about specifications maintenance troubleshooting testing and repair of the die
126. C TIE gt ar a ZUM p m SSINAYH YNI NAISNA yard E A na Y TIENI LVLS ren 8 Ac NO NO o i na cc OIA SS3NNYH NIT 3191514 01 8 5 NOILIONO2 NO ONONE CI C3 3302 na Yd 108 O dh 98 Y 58 OL G No VN Wiring Schematics Rev E Page 6 3 4 Groundsmaster 300 Series Special Tools NOTE Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PRODUCTS Some tools may be available from a local supplier Continuity Tester Fig 1 Battery powered test lamp which is helpful in testing for continuity of circuits and electrical components when the current is off Figure 1 Volt Ohm Amp Meter Fig 2 The meter can test electrical components and circuits for current resistance or voltage draw Figure 2 Special Tools Page6 4 Groundsmaster 300 Series 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 Page6 5 Special Tools Troubleshooting Groundsmaster 345 A CAUTION Remove all jewelry especially rings and watches before doing any electrical trou bleshooting or testing Disconnect the bat tery cables unless the test requires battery voltage For effective troubleshooting and repairs
127. D diesel engine is located under the instrument panel Note Refer to Groundsmaster 328 D electrical sche matic in Chapter 6 Electrical System when trouble shooting the glow controller circuit Controller Operation 1 When the ignition switch is placed in the RUN posi tion the controller energizes the glow plugs and lights up the glow lamp for approximately 6 seconds 2 When the ignition switch is held in the START posi tion the glow plugs will energize while the switch is held in START and the glow lamp will not light 3 When the ignition switch is released from START to RUN the glow plugs will de energize and the glow lamp will remain off Controller Checks 1 Make sure there is power from the battery 2 Disconnect electrical connector to the fuel stop sole noid to prevent the engine from starting 3 Place ignition switch in the RUN position Verify the following while in the RUN position A Glow indicator lamp is on B Glow relay is energized C Glow plugs are energized D Glow indicator lamp goes out and glow plugs de energize after approximately 6 seconds 4 Place ignition switch in the START position Verify the following while in the START position A Glow indicator lamp is out B Glow relay is energized C Glow plugs are energized D Power exists at terminal 1 of the glow controller Note If there is no power to terminal 1 of the glow con troller verify continuity of the circu
128. EL PUMP ce MEASURING db EE O Figure 22 Figure 23 Groundsmaster 300 Series Preparation for Engine Repair 1 Before cleaning and disassembly carefully check for problems that cannot be found after the engine has been cleaned or disassembled e g oil leaks from cracked components gaskets or loose fittings dam aged air cleaner or breather hoses that could cause cylinder wear etc Make a note of any problems that you find 2 Clean or wash the engine exterior thoroughly before disassembly IMPORTANT Do not spray water on a hot engine Injection pump seizure or other failures could result 3 Do not disassemble or remove parts that do not require disassembly 4 Disassemble the engine in proper order arranging the parts the disassembled parts neatly Apply clean Cylinder and Cylinder Block Overhaul Before removing any parts disassembly or overhaul of the Mitsubishi engine it is very important to understand the nature and probable cause of the problem that made an overhaul necessary When the engine trouble is caused by worn cylinders rings or valves one or more of the following symptoms will occur 1 Low engine power and a decrease in compression pressure 2 Increased fuel consumption 3 Increased lubricating oil consumption 4 Poor engine starting 5 Loud noises in the engine It is important to find the cause of the engine failure before beginning repair Symptoms 2 and 3 in
129. Gear 14 Bevel Gear Case and Axle Case 6 Removal 14 REMOVAL en 6 Inspection 15 InSpectlonis caes n terne ran 7 Installation 2 0 0 eee 16 Installation 2 0 eee eee 8 Pinion Gear to Ring Gear Engagement 17 Differential Shafts 10 Gear Pattern Movement Summary 18 Removal 0 000 c eee 10 Bidirectional Clutch 19 Installation Senes Het Os Bettis 10 Bidirectional Clutch Service 20 Groundsmaster 328 D Page 10 1 1 4WD Rear Axle Rev G Dae Dong Axle 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 G Page 10 1 2 Groundsmaster 328 0 Dae Dong Axle 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 1 When
130. Groundsmaster 345 Starting Problems continued Condition Possible Cause Correction Engine cranks but does not start Engine wiring connector or wires loose corroded or damaged Temp gauge switch faulty Temp relay faulty Temp relay wiring faulty Engine engine ignition or fuel system problem Repair wiring Test temp gauge switch and replace if faulty Test temp relay and replace if faulty Repair wiring See Ford VSG 411 413 Engine Service Manual Engine cranks but should not with traction pedal out of neutral Traction neutral switch out of adjustment or faulty Test switch and replace if faulty Make sure wires are connected to COMMON and NORMALLY OPEN N O terminals Engine cranks but should not with PTO ON Troubleshooting Groundsmaster 345 PTO switch out of adjustment or faulty Page6 8 Test switch and adjust or replace if faulty Groundsmaster 300 Series Operation Problems Condition Possible Cause Correction Engine continues to run but should not when traction pedal is depressed with no operator on seat Seat switch plunger depressed with no operator on seat Seat switch faulty or out of adjustment Traction neutral switch faulty or out of adjustment Check for seat support spring that is broken missing or stuck in down position Check for binding seat pivot hinge Check for waterlogged seat T
131. Mount the gear box and loop the belts around the gear box pulley 6 Feed the right and left spindle belts over the pulleys by rotating the cutter blades Tighten the gear box mounting fasteners 7 Tension idler pulleys against both belts Install covers on top of cutting unit Repairs Page 11 10 Groundsmaster 300 Series 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 If caster spindle is loose inside the bushings bushings are worn and must be replaced 1 Raise cutting unit and block it so it cannot fall acci dentally 2 Remove lynch pin and spacers from top of caster spindle 3 Pull caster spindle out of mounting tube Allow spacer s and thrust washer to remain on bottom of Figure 11 spindle to assure same height of cut when caster spin dle is reinstalled 4 Insert pin punch into top or bottom of mounting tube and drive bushing out of tube Also drive other bushing out of tube Clean inside of tubes to remove dirt 5 Apply grease to inside and outside of new bushings Using a hammer and flat plate drive bushings into mounting tube 6 Inspect caster spindle for wear and replace it if damaged 7 Push caster spindle through bushings and mounting tube Slide spacers onto spindle Install lynch p
132. NVS 915119 woe A S3Hd NO 330 HOLIMS LVS rr OvslnaN 440 HOLIMS TWHLNAN HOLIMS Old rie lo xo NMOG 10HS dW3L H3AO dW3L H3AO NO OL Q3193NNOO HOLIMS 3GlHN3AO dW3l H9IH OL Q 3 J3AO 3NION3 ITs Y L LATOIA OIA SLIHM M LH911 N91 Hd MOTISA A N33H9 HO 1 anig N3JHO NO MOVI8 58 SYO109 OL A33 T 1 0 YONNYSLIV 440 ANVLNAWOW dWALHOIH ANION JHL OL ANY YSHLS9OL Q3103NNOO 3HIM SV SLNIOd SS3NMVH NIV aNnONo aNnou9 LAM YALYVLS NO lNIOd 3IL 9 NMOGLNHS OL 5 4 ng LHOM TWNOLLdO Groundsmaster 300 Series Rev E Page 6 2 2 Wiring Schematics Groundmaster 322 D 325 D Serial Number less than 20000000
133. O SNIDNA Na o YOMWNYALIV 1 330 Y ANVLNAWOW 3GIHH3AO dW31H9IH ANIONS JHL OL ANY 43H13901 Q3103NNOO MOV T8 SV Q3 SHVIAL SLNIOd SS3NHVH T1V aNnONO aves ANIONS AN TH3H NMOGLNHS dA31 H3AO OL SNO W3lHVlS NO lNIOd3lL d avo AH3IIVg 9 3 0018 5 4 amp 1HOl1VNOLLdO NMOG H3AO Groundsmaster 300 Series Page6 3 1 Rev Wiring Schematics Groundmaster 322 D 325 D Serial Number less than 20000000 AlaWassv sonid MO19 LINN TONLNOO _ rt 1 f LL xovi8 mE GIONTIOS NOLLOGPNI ama ania h MOTT3A RA hs Bi N AN HOLIMS YOLVOIGNI 29 any OL 9nd MOTO 3snd bc EET T iuwaasu 1HW3H VA 1 _ Malay cmi N33H5 N33H5 AH3llv8 1399 TwANWW diia dW OF x amavis _ 348 as OY 3 aoe dau N3349 1H917 WM ov1i8 LY lt 40 98 SLIHM 5 31IHM 31IHM Y e CIV n3N NI a39VONASIC uvas A V bug S48 1MVIS IVd3d NOILOVH L
134. OTE There is an additional spring hook Fig 13 used in conjunction with the tension spring Be certain that this hook is replaced as during reassembly or the spring itself will soon break due to excessive tension 7 Remove the four cap screws from the P T O lever clamp Item 54 Lift the P T O interlock switch bracket Item 6 off and set aside Remove the clamp and P T O lever assembly 8 Reverse steps 2 7 to reinstall the assembly 9 Adjust the compression spring refer to Correcting P T O Drive Belt Slippage 10 See Chapter 6 Electrical System for P T O inter lock switch repair and replacement Repairs Page 9 10 Groundsmaster 300 Series PTO Shaft and Bearing Service Fig 14 1 Remove the P T O belt refer to Replacing the P T O Belt 2 Remove the clevis pin Item 7 from the P T O lever and compression spring yoke 3 Remove the tension spring Item 50 using a locking pliers refer to instructions and note of step 6 in Remov ing Control Lever and Linkage 4 Remove the roll pins Item 49 from the pivot shaft Item 9 5 Remove the pivot shaft and lower the P T O pivot assembly down and out of the traction frame 42 4 40 39 29 6 Loosen the setscrews Item 46 on the P T O shaft bearing collars Item 41 Use a punch and hammer to rotate the collars in the opposite direction of shaft rota tion Remove the shaft Item 43 and bearings Item 40 7
135. OTE the rotor and stator are a matched set You must replace them as a matched set if either is worn or damaged 36 Check the rotor lobe tip to stator lobe tip clear ance with a feeler gauge Fig 51 The rotor lobe directly across from the rotor lobe tip being measured see pointer in Fig 51 must be centered between stator lobes during the measurement A rotor and stator that exceeds the maximum allowable tip clearance must be replaced Max rotor to stator tip clearance 0 003 in 0 08 mm 37 Remove the rotor set from the drive plate The drive plate side of the rotor set also must be free of grooves or scoring NOTE Handle the rotor set carefully to avoid nicks and scratches 38 The rotor side of the drive plate Fig 52 should show the normal spiral pattern due to rotor movement Groundsmaster 300 Series Page 8 31 Figure 50 Figure 51 Figure 52 Repairs 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 Figure 53 40 Remove the face seal back up ring and face seal spacer from the upper cover plate Fig 54 Discard the face seal and back up ring Keep the metal spacer 41 Remove the thrust bearing and bearing spacer from the upper co
136. 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 Specifications 4 2 Rev G 205 0 Ibs 93 0 kg Groundsmaster 300 Series TORO Table of Contents Chapter 5 Hydraulic System SPECIFICATIONS 2 REPAIRS 52 uie is de odit de 26 Hydraulic Oil 2 Transmission Trunnion Seal Replacement 26 GENERAL INFORMATION 3 Transmission By Pass Valve 27 Hydraulic Hoses 3 Transmission Acceleration Valves 28 Hydraulic Fitting Installation 3 Transmission Implement Relief Valve 29 5 Transmission Charge Relief Valve 30 HYDRAULIC SCHEMATICS 6 Transmission Charge Pump 31 HYDRAULIC FLOW DIAGRAMS 7 Transmission Removal and Installation 33 Forward Traction Operation 7 Transmission Overhaul 34 Raising the Cutting Unit 8 Separating Transmission Into Sections 34 Turning Steering Wheel to Right 9 Transmission Pump Section 35 SPECIAL TOOLS 1 cued we peer ide 10 Transmission Center Section 37 TROUBLESHOOTING 12 Transmission Motor Section 38 TESTING Pa t
137. Position axle and axle support under machine with a jack Place frame spacers item 22 on axle support Raise assembly to machine frame and align mounting holes of axle support frame spacers and machine frame 4 Secure rear axle support to frame with four 4 flange head screws item 21 and flange nuts item 23 5 Remove plugs and caps from steering cylinder hy draulic hoses and fittings Connect hoses to fittings on steering cylinder 6 Position end of driveshaft to bidirectional clutch on rear axle Secure driveshaft to clutch with six 6 socket head screws item 8 and lock washers item 7 WARNING Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury 7 Install wheels to axle Torque wheel lug nuts from 45 to 55 ft Ibs 61 to 75 Nm 8 Lower machine to ground 9 If any rear weight s were removed from machine at tach weight s to machine 10 Fill axle and input gearbox with SAE 80W 90 weight gear lube see Traction Unit Operator s Manual 11 Check bidirectional clutch lubricant level see Trac tion Unit Operator s Manual Adjust if necessary 12 Start engine and check for component interference as steering wheel is turned from lock to lock Also check for any hydraulic leaks 13 Check rear wheel toe in and adjust if necessary see Traction Unit Operator s Manual 14 Check adjustment of steering stop bolts see Steer
138. Pump Tests Steering Cylinder Internal Leakage Test ADJUSTMENTS Rear Wheel Toe In Adjustment Brake Adjustment Groundsmaster 300 Series Chapter 8 Steering and Brakes 2 REPAIRS Sic cgi mae Rd DERE UU Up 11 3 Steering Wheel Removal and Installation 11 4 Rear Axle Bushing Service 12 4 Steering Pivot Bushing Service 12 5 Rear Wheel Spindle Bushing Service 14 7 Front Wheel Bearing Service 15 y Rear Wheel Bearing Service 16 8 Steering Cylinder Removal and Installation 18 9 Steering Cylinder Service 19 9 Brake Shoe Replacement 20 10 Steering Valve Removal and Installation 21 Steering Valve Service 22 Page 8 1 Table of Contents 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 Hydraulic fluid flow for power steering is supplied by the charge pump on the hydrostatic transmission The im plement steering hydraulic circuit is designed so priority flow is provided for steering The Model HGF Hydraguide steering valve Fig 1 is manufactured by TRW Ross Gear Division NOTE
139. Repairs Engine Repair Information Ford VSG 411 Component Changes Ford VSG 411 engines with a date code of 2D21 or later have five b 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 Listed below is a summary of changes from the four 4 main bearing design to the five 5 main bearing design of the VSG 411 engine Cylinder block New five main bearing design Crankshaft Same as VSG 413 Crankshaft lower main bearing No change Crankshaft upper main bearing No change Crankshaft rear oil seal retainer Same as VSG 413 Crankshaft rear bearing oil seal gasket Same as VSG 413 Repairs Page3 8 Groundsmaster 300 Series TORO Table of Contents 2 SPECIFICATIONS 3 Generalo ei eDensrbivesdikbiek te ered nae 4 Engine sime mE 5 Lubrication System 7 Fuel System 8 Governor System 8 Cooling 8 Electrical 9 Tightening Torque 10 SPECIAL TOOLS ved 11 13 Valve Clearance
140. Replace any worn bushings bearings and shafts 8 Reassemble in reverse order and check the align ment of the P T O pulley Adjust P T O brake as neces sary refer to Aligning the P T O Pulley and Engine Pulley 9 Adjust the compression spring refer to Correcting P T O Drive Belt Slippage 12 13 1415 6 14 38 37 Figure 14 Groundsmaster 300 Series Page 9 11 Repairs PTO Drive Shaft Removal Fig 15 A 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 1 Position the machine on a level surface lower the cutting unit to the shop floor turn the engine off remove the key from the ignition switch and engage the parking brake Figure 15 2 Remove the self tapping screws securing the shield 1 PTO yoke 3 Roll pin behind the cutting unit gear box and set the shield aside 2 Yokes in phase 4 Capscrews amp locknuts 3 Drive the roll pin out of the yoke and the input shaft of the gearbox Slide the yoke off of the input shaft If the traction unit will be used without the cutting unit drive the roll pin out of the yoke at the P T O pivot shaft and remove the entire universal shaft from the traction unit Repairs Page 9 12 Groundsmaster 300 Series PTO Drive Shaft Universal Joint Replacement Fig
141. 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 Item Description Tightening Torque Cylinder head bolt M12 qty 8 11 5 12 5 kgm wet 83 90 ft lb Cylinder head bolt M10 qty 3 6 5 8 0 kgm wet 47 58 ft lb Crankshaft pulley nut M18 15 16 kgm 109 116 ft lb Main bearing cap bolt 5 5 5 kgm 36 40 ft lb Connecting rod cap nut 3 2 3 5 kgm 23 25 ft lb Flywheel mounting bolts 8T flanged bolts 13 14 kgm 94 101 ft lb 8T bolts with washers 11 5 12 5 kgm 83 90 ft lb Oil drain plug 5 6 kgm 36 43 ft lb Oil filter 1 1 1 3 kgm 8 9 ft lb Fuel injection pump Delivery valve holder 4 5 kgm 29 36 ft lb Nozzle holder Holder mounting bolt 1 5 2 kgm 11 15 ft lb Holder body and retaining nut 6 8 kgm 43 58 ft Ib Glow plug 1 5 2 kgm 11 15 ft Ib Specifications Page 4 10 Groundsmaster 300 Series Special Tools Order special tools from TORO SPECIAL TOOLS AND APPLICATIONS GUIDE Commercial Products Some tools may be available from a local supplier Filter Cleaner Fig 3 Filter cleaner Mix with water and use solution to wash the Donaldson air cleaner element Diesel Engine Compression Test Kit Fig 5 Diesel engine compression test kit 0 1000 PSI Gauge allows testing of dies
142. Tighten the nut to 100 120 ft Ib and rotate the spindle shaft to be sure that the shaft rotates freely 9 Slide pulley end of spindle assembly through hole in cutting unit Mount the spindle assembly in place with the carriage bolts and flange nuts 10 Install the belt and adjust belt tension 11 Reinstall the belt covers Repairs Page 12 32 sin XX KN N 10 ER E SNS Figure 47 Groundsmaster 300 Series Table of Contents SPECIFICATIONS TROUBLESHOOTING ADJUSTMENTS Height of Cut Adjustment Adjusting Skids Mismatch Adjustments REPAIRS Blade Service Belt Replacement Groundsmaster 300 Series Page 13 1 Chapter 13 Guardian 72 Recycler Cutting Unit Caster Arm Bushing Replacement 10 Caster Wheel Bearing Service 11 Separating Cutting Unit From Traction Unit 12 Mounting Cutting Unit to Traction Unit 13 Push Arm and Torsion Spring Service 14 Gearbox Removal and Installation 17 Gearbox 19 Blade Spindle Service 22 Table of Contents Specifications ITEM Cutting width SPECIFICATION 72 inches Height of cut range 2to 5 inches Height of cut adjustment 0 5 inch increments Blade bolt torque 85 to 110 ft lb Spindle nut torque 140 160 ft Ib Gearbox lubricant Figure
143. Tighten the nut to 20 to 26 ft Ib 4 Install cap to steering wheel with screw f f Figure 15 1 Steering wheel 4 Screw 2 Jam nut 5 Foam seal 3 Cap Groundsmaster 300 Series Page 8 11 Rev I Repairs Rear Axle Bushing Service 2WD Units The rear axle must be held in place snugly by the axle pin Excessive movement of the axle which is charac terized by erratic steering usually indicates worn bush ings To correct the problem replace the bushings 1 Disconnect the hydraulic hoses from the steering cylinder Put caps or plugs on all the fittings and hoses to prevent contamination NOTE To ease reassembly tag each of the hoses to show their correct position on the steering cylinder 2 Remove the nut Fig 16 Item 9 from the end of the rear axle pin Remove the two 2 cap screws Item 2 securing the axle pin to the frame 3 Jack up the frame just ahead of the rear wheels until pressure is taken off the axle pin Support the machine with jack stands to prevent it from falling 4 Pull the axle pin out This will release the rear axle and washer s from the frame Carefully pull the entire axle and wheel assembly out from under the machine NOTE A varying number of washers Item 45 may have been installed between the axle pivot tube and frame during manufacture Make sure the same number of washers are installed during reassembly Steering Pivot Bushing Service 2WD Units T
144. US TO YOUR HEALTH AND MAY CAUSE SERIOUS RESPIRATORY OR OTHER BODILY HARM For your pro tection A AVOID CREATING DUST B Do not remove brake drum without proper equipment C Do not work on brake linings without proper protective equipment D Do not replace brake linings without proper pro tective equipment E Do not attempt to sand grind chisel file hammer or alter brake linings in any manner without proper protective equipment F Follow O S H A standards for proper protective devices to be used when working with asbestos materials 32 If the cutting unit discharge area ever plugs disen gage PTO and shut engine off before removing the obstruction 33 Make sure machine is in safe operating condition by keeping nuts bolts and screws tight Check all cutting unit blade mounting bolts frequently to assure they are torqued to proper specifications See Cutting Unit Op erator s Manual Groundsmaster 300 Series Page 1 3 34 If machine is equipped with roll over protection ROPS periodically inspect the roll bar and roll bar mounting Repair as necessary Do not weld cut drill or modify roll bar in any manner 35 Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system 36 Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not han
145. Y NN E BELLEVILLE N WASHER SPECIAL SCREW LEFT T Figure 7 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 If any wear is noticed replace the blade refer to Removing Cutter Blade A WARNING If the blade is allowed to wear a slot will form between the sail and flat part of the blade Eventually a piece of the blade may break off and be thrown from under the housing pos sibly resulting in serious injury to yourself or bystander 3 Examine cutting edges of all blades Sharpen the cutting edges if they are dull or nicked Sharpen only the top side of the cutting edge and maintain the original cutting angle to assure sharpness The blade will remain balanced if same amount of metal is removed from both cutting edges 4 To check blade for being straight and parallel lay blade on level surface and check its ends Ends of blade must be slightly lower than the center and cutting edge must be lower than heel of the blade This blade will produce good quality of cut and require minimal power from
146. a vise Thread a M12 x 1 5 hex head capscrew into the splined end of the input shaft pinion gear 7 Slowly tighten the locknut until 4 0 to 6 0 in Ibs 0 4 to 0 7 Nm of force is required to rotate the input shaft pinion gear in the bearing case 8 Secure the lock nut with the stake washer Figure 18 1 Lock nut 7 Input shaft pinion gear 2 Stake washer 8 Bearing case shims 3 Bearing case 9 Seal collar 4 Bearing case O ring 10 O ring 5 Inner bearing 11 Oil seal 6 Outer bearing 0 040 in 1 0 mm Figure 19 1 Oil seal 2 Bearing case 4WD Rear Axle Rev G Page 10 1 12 Groundsmaster 328 D Dae Dong Axle 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 distance from mating surface of axle support to end face of pinion gear 1 870 0 002 in 47 5 0 05 mm NOTE Bearing case shims are available in 0 004 in 0 1 mm and 0 008 in 0 2 mm thickness 10 Coat a new O ring with grease Place shims on the bearing case and temporarily install input shaft pinion gear assembly into axle case Tighten mounting screws to 35 to 41 ft lbs 47 to 56 Nm 11 Insert a screwdriver through the drain plug hole to hold ring gear and measure the pinion gear to
147. aced as a set Figure 34 Groundsmaster 300 Series Page 8 25 Repairs 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 Figure 35 15 Inspect the springs for bent or distorted coils If a spring is broken or deformed all six springs in the unit must be replaced Fig 36 Figure 36 16 Remove the hex drive assembly from the drive link Fig 37 17 The pin in the hex drive assembly should not show wear and must be firmly pressed in place the sides of the hex and slot should not have grooves or scoring if the hex drive assembly shows signs of this type of wear it must be replaced Figure 37 Repairs Page 8 26 Groundsmaster 300 Series 18 Remove the two alignment pins that align the port manifold valve ring and isolation manifold Fig 38 19 Remove the isolation manifold four plates bonded together Fig 39 20 Inspect the ground surfaces of the isolation mani fold You should notice a normal polished pattern due to the rotation of the valve plate and on the opposite side a normal polished pattern due to the action of the commutator cover and commutator seal The holes and edges should be free of nicks The manifold surfaces should be free of nicks or sco
148. ackage and shims into the metering ring until the drive plate and shims are at least flush with the metering ring Fig 82 Figure 82 21 Reverse the metering ring and metering package as a unit on a flat surface Push down on the metering package until the drive plate is on the flat surface Be sure the cap screws are loose enough to allow the commutator ring and drive plate to align themselves concentrically in the metering ring bore Gradually tighten the eleven cap screws following the sequence shown in Figure 83 at least twice until a final torque of 11 13 in Ib 1 24 1 47 Nm is reached Fig 83 and 84 Remove the metering package and shims from the metering ring Discard the shims A CAUTION Use care and eye protection when adding and removing shims from the metering ring as the shims will be under spring tension and could fly into the air and cause injury Figure 84 Repairs Page 8 42 Groundsmaster 300 Series 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 23 Grasp the drive link and rotate the metering package by hand to make sure the parts do not bind Fig 86 The rotor should orbit inside the stator If they bind disassemble the metering package correct the cause and repeat the assembly and concentricity procedures 24 Apply clean multi purpose
149. adjustment 0 5 inch increments Blade bolt torque 85 to 110 ft lb Spindle nut torque 140 160 ft Ib Spindle end play 006 inch max Spindle rolling torque 10 in Ib max Gear case lubricant Figure 1 1 Filler plug 2 Check plug Specifications Page 12 2 SAE 80W90 API GL 5 gear lube Groundsmaster 300 Series General Information Grass Deflectors A WARNING The grass deflectors Fig 2 are safety de vices that divert grass and other foreign ob jects being discharged downward WE STRONGLY RECOMMEND THAT THE DEFLEC TORS BE IN THEIR NORMAL OPERATING POSI TION WHENEVER THE CUTTING UNIT IS ENGAGED NEVER OPERATE CUTTING UNIT WITH THE DEFLECTORS REMOVED FROM THE CUTTING UNIT OR TIED BLOCKED IN A RAISED POSITION SINCE THE BLADES COULD THEN THROW DEBRIS A CONSIDERABLE DISTANCE WITH SUFFICIENT FORCE TO CAUSE PERSONAL INJURY OR DAMAGE TO PROPERTY If a grass deflector is damaged repair or replace the Figure 2 affected part s 1 Grass deflector 2 Groundsmaster 300 Series Page 12 3 General Information Troubleshooting 0 39V 1d3u N3 0u8 1138 O 14 1234dSNI 39V 71939 N3 0U8 SLIVHS X08 uv39 1234SNI 321435 N31H9I1 N3 0Uu8 35001 31104 X08 uv33 12334SNI 1138 S1108 S30Vv 18 32330 u311n2 31 NIdS 931112 123dSNI 1234dSNI 1234SNI 32V 1d3U 40 30v 1d3u 329V143u
150. age 13 5 Adjustments Checking and Correcting Mismatch of Blades Fig 5 If there is mismatch between the blades the grass will appear streaked when it is cut This problem can be corrected by making sure the blades are straight and all blades are cutting on the same plane 1 Using a 3 foot long carpenters level find a flat surface on the shop floor 2 Adjust height of cut so all six height of cut spacers are below the caster arm 3 Lower cutting unit onto flat surface Remove covers from top of cutting unit Release belt tension 4 Rotate blades until the ends face forward and back ward Measure from floor to front tip of cutting edge and remember this dimension Then rotate same blade so opposite end is forward and measure again The differ ence between dimensions must not exceed 1 8 inch If difference exceeds 1 8 inch replace the blade because itis bent Make sure to measure all three blades 5 Compare measurements of outer blades with the center blade Center blade must not be more than 3 8 inch lower than outer blades If center blade is more than 3 8 inch lower than outer blades proceed to step 7 and add shims between spindle housing and bottom of cutting unit 6 Rotate blades so tips line up with one another Tips of the adjacent blades must be within 1 8 inch of each other If tips are not within 1 8 inch of each other Adjustments Page 13 6 proceed to step 7 and add shims between spindle housing and
151. ain oil from bidirectional clutch see Traction Unit Operator s Manual 3 Remove six 6 socket head screws item 10 and lock washers item 9 that secure driveshaft to bidirec tional clutch on rear axle Position end of driveshaft away from clutch 4 Remove cap screw item 8 lock washer item 7 and flat washer item 6 that secure clutch to rear axle Lo cate and retrieve spacer item 5 5 Pull bidirectional clutch from rear axle input shaft Groundsmaster 328 D Page 10 1 19 Installation Fig 34 1 Apply anti seize lubricant to splines of rear axle in put shaft 2 Slide bidirectional clutch onto rear axle input shaft Align notches in clutch housing with cap screw heads on axle clutch locator adapter 3 Apply Loctite 242 or equivalent to threads of cap Screw item 8 that secures clutch to rear axle shaft 4 Secure clutch to axle shaft with cap screw lock washer item 7 flat washer item 6 and spacer item 5 5 Position end of driveshaft to bidirectional clutch on rear axle Secure driveshaft to clutch with six 6 socket head screws item 10 and lock washers item 9 6 Fill clutch with oil to the proper level see Traction Unit Operator s Manual 4WD Rear Axle Rev G Dae Dong Axle Bidirectional Clutch Service Hylomar Jointing Compound 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 sea
152. all the spool into the valve body before inserting the cam pins balls springs and hex plugs Repairs Page 5 44 Groundsmaster 300 Series Table of Contents WIRING SCHEMATICS 2 Groundsmaster 345 2 Groundsmaster 322 D 325 D 3 4 TROUBLESHOOTING Groundsmaster 345 6 Starting 6 Operation Problems 9 Verify Interlock Operation 11 TROUBLESHOOTING Groundsmaster 322 D 325 D 12 Starting 12 Operation Problems 15 Verify Interlock Operation 17 TESTING eed eene es 18 Ignition Key Switch 18 Seat Switch 0 19 Traction Neutral Switch 20 PTO Switch 20 Starter Interlock 21 Groundsmaster 300 Series Page 6 1 Chapter 6 Electrical System Glow Plugs Groundsmaster 322 D 325 D only 22 Battery i se nein diee b yel DER 22 Fuel Stop Solenoid Groundsmaster 322 D 325 D 23 Fuel Stop Control Unit Groundsmaster 322 D 325 D 24 Indicator Lights Buzzers and Gauges 26 Temperature Relay 27 Temperature Gauge Sender 27 Engine Oil Pressure
153. all wires connected to engine and engine accessories 7 Put a drain pan under radiator loosen radiator cap loosen radiator petcock and allow radiator to drain com pletely 8 Move drain pan under lower radiator hose Discon nect hose from radiator and allow coolant to drain into pan Remove lower and upper radiator hoses 9 Move drain pan under rear of engine and remove cylinder block plug located above starter to drain cool ant from cylinder block Install cylinder block plug 10 Disconnect throttle control cable from throttle bracket 11 Remove fuel line from outlet side of fuel filter water separator Installing the Engine 1 Do steps 2 18 of Removing the Engine in reverse order 2 Fill cooling system with new coolant Install a new oil filter and fill engine with correct oil Removing and Installing the Engine Page 4 46 NOTE Be prepared to insert a plug into fuel line to prevent fuel spill 12 Remove main fuel return hose at injector nozzle connection 13 Remove capscrews attaching fan belt guard and remove fan belt guard 14 Remove capscrews securing fan shroud to radiator so fan shroud can be move during engine removal for cooling fan clearance 15 Attach a short section of chain between the two lifting shakles on the engine Attach block and tackle or hoist chain to this short section of chain approximately mid way between the two shakles NOTE Do not attach hoist chain or chain
154. als Thoroughly lubricate the spindle shaft and seal lips 6 Slide the small thick spacer into the spindle housing Then install the upper bearing and seal into the top of the spindle housing On spindle assemblies that have the grease fitting on the housing shown in Fig 36 the lip of the upper seal faces inward On spindle assem blies that have the grease fitting on the top of the spindle shaft shown in Fig 34 the lip of the upper seal faces outward 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 Repairs Page 11 28 8 Push the pulley onto the splines of the spindle shaft and retain the parts together with the large flat washer and lock nut Tighten the nut to 100 120 ft lb 136 162 N m After tightening rotate the spindle shaft to be sure that the shaft rotates freely 9 Slide the pulley end of the spindle assembly through the hole in the cutting unit Mount the spindle assembly in place with the eight 8 hex flange head bolts and flange nuts 10 Install the belt and adjust idler to get proper belt ten sion 11 Reinstall the belt covers ARBOR PRESS SNAP RING SUPPORT Figure 37 Figure 38 Rev Groundsmaster 300 Series Chapter 12 Triflex 88 Cutting Unit Table of Contents
155. and can be or dered from your Toro distributor by Toro Part No 27 1040 Quantity 8 Height of Cut Spacers Below Caster Arms inches mm Front Rear 1 25 0 0 1 1 2 38 1 1 2 51 2 2 2 1 2 64 3 3 3 76 4 4 3 1 2 89 5 5 4 102 6 6 NOTE A more optimum cutting appearance of the turf can be achieved in the lower heights of cut by lowering the rear of the cutting unit Accomplish this by relocating the rear caster wheel axles in the upper hole of the caster forks Replace the axles into the lower caster fork holes for higher height of cut settings where optimum cutting appearance is not required IMPORTANT Do not attempt to cut off more than one inch of the grass blades in the one 1 inch height of cut setting with the rear of the cutting unit lowered as this may cause the engine to labor excessively 1 Start the engine and raise cutting unit so front caster height of cut can be changed Stop engine after cutting unit is raised Rear caster height of cut can be changed with cutting unit lowered 2 Squeeze back of wire and rotate wire on lynch pin Pull pin out of caster spindle Slide spacers onto the caster spindle to get desired height of cut Then slide washer onto spindle 3 Push caster spindle through caster arm Slide any remaining spacers onto spindle Install lynch pin to retain parts in place NOTE When cutting unit is used in 1 inch or 1 1 2 inch height of cut setting front and rear
156. and nuts 7 16 14 Heads of cap screws and large flat washers must be on outside of caster arm 5 Slide flat washers 1 5 32 1 D x 59 64 in O D onto two cap screws 7 16 14 x in 6 Have a helper carefully push down on left hand push arm until holes in ball joint mount are in line with holes in mount bracket on cutting unit Immediately slide 4 x 4 in block of wood between top of push arm and underside of chassis A WARNING Make sure wooden block does not slip out accidentally 7 Secure ball joint mount to mount bracket with two cap screws flat washers and flange lock nuts 7 16 14 Heads of cap screws and flat washers must contact ball joint mount Repairs Page 11 16 Figure 18 1 R H push arm 5 Flange locknuts 2 Caster arm 6 Jam nut 3 Capscrews amp flatwashers 7 Ball joint 4 Ball joint mount Figure 19 1 L H push arm 5 Caster arm 2 Ball joint 6 Flange locknuts 3 Ball joint mount 7 Jam nuts 4 Capscrews amp locknuts Groundsmaster 300 Series 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 10 Attach lift chains to lift arm and cutting unit with six 6 shackles shackle pins 3 8 x 1 1 2 in and cotter pins 1
157. and require minimal power from the engine By contrast a blade that is higher at the ends than the center or cutting edge higher than the heel of the blade is warped or bent and must be re placed 5 To install the blade assemble parts in reverse order and make sure the blade sail is facing up Tighten special screw to 85 to 110 ft lb FORMED Repairs Page 12 14 FLAT PART OF BLADE Figure 20 SHARPEN AT ORIGINAL ANGLE me END VIEW Figure 21 Groundsmaster 300 Series 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 With the wing unit raised loosen nuts on capscrews holding the spring bracket from under the deck NOTE Block deck in raised position so that it cannot accidentally lower while belts belt tension is being ad justed Wings should be in lowered position 3 With spring tension relaxed lower the wings Loosen or remove the idler pulley bolt to allow the belt to pass m between the belt guide and the idler pulley Figure 22 4 Loosen or remove belt guides as necessary to allow 1 Spring bracket retaining nuts removal of belts from remaining pulleys 5 Put new belt into correct position in groove of pulley on center section and wing section of deck then tighten idler
158. anking Performance at 0 F 17 89 C 110 Minute Reserve Capacity at 80 F 26 79 C Battery Specifications Groundsmaster 345 BCI Group 24 420 Amp Cranking Performance at 0 F 17 89 C 67 Minute Reserve Capacity at 80 F 26 79 C Wear safety goggles and rubber gloves when working with electrolyte Charge the battery in a well ventilated so gases produced while charging can dissipate Since the gases are explosive keep open flame and electrical spark away from the battery do not smoke Nausea may result if the gases are inhaled Unplug charger from electrical outlet before con necting to or disconnecting charger leads from battery posts Inspection Maintenance and Testing Perform the following inspection and maintenance tasks A Check for cracks caused by overly tight or loose hold down clamp Replace battery if cracked and leaking B Check battery terminal posts for corrosion Use a terminal brush to clean corrosion from the battery terminal posts IMPORTANT Before cleaning the battery tape or block the vent holes to the filler caps and make sure the caps are on tightly FILLER CAPS CAP TUBES COVER SEAL Figure 14 C Check for signs of wetness or leakage on the top of the battery which might indicate a loose or mis sing filler cap overcharging loose terminal post or overfilling Also check the battery case for dirt and oil Clean the battery with a solution of baking soda and wa
159. ap Rocker cover Rocker arm Rocker shaft Groundsmaster 300 Series 19 20 21 22 23 24 25 Cylinder head Cylinder block Push rod Tappet Camshaft Rear oil seal case Flywheel Refer to the specifications listed in this section when performing tests on the engine or examining parts for wear Some specifications are included in the service procedures later in this chapter 1 Air breather pipe 2 Glow plug 3 Intake manifold 4 Nozzle holder 5 Cylinder head 6 Injection pump 7 Pump camshaft Page 4 3 Figure 2b 8 Cylinder block 9 Oil screen 10 Oil pan 11 Oil filler cap 12 Rocker cover 13 Rocker arm 14 Exhaust manifold 15 Piston 16 Connecting rod 17 Push rod 18 Tappet 19 Camshaft 20 Crankshaft Specifications 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 3 Bore x Stroke 73x 78 mm 2 9 x 3 1 in Total Displacement 0 979 liter 59 7 in Compression Ratio 23 1 Firing Order 1 3 2 Dry Weight approximate 124 kg 273 Ib Fuel Diesel ASTM No 2 D ASTM No 1 D in very cold weather Fuel Injection Pump Bosch M type Governor Centrifugal fly weight type Fuel Injector Nozzle Throt
160. apacity is one person Therefore never carry passengers 15 Check carefully for overhead clearances before driving under any objects 21 The grass deflector s must always be installed and in lowest position on the cutting unit This product is designed to drive objects into the ground where they lose energy quickly in grassy areas However don t take an injury risk When a person or pet appears unexpect edly in or near the mowing area STOP MOWING Careless operation combined with terrain angles rico chets or improperly positioned guards can lead to thrown object injuries Do not resume mowing until area is cleared 22 Never raise the cutting unit or other attached imple ment while the blades or other parts are rotating 23 If cutting blades or other implement components strike a solid object or the machine vibrates abnormally disengage PTO move throttle to SLOW set parking brake and shut engine off Remove key from switch to prevent possibility of accidental starting Check cutting unit or other implement and traction unit for damage and defective parts Repair any damage before restarting the engine and operating the implement or cutting unit Assure cutting unit blades are in good condition and blade bolts are torqued to proper specifications See Cutting Unit Operator s Manual 24 To stop machine remove foot from traction pedal and use brakes Gradually reversing the traction pedal can provide additional braking
161. ar 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 A wobbly caster wheel usually indicates a worn bearing 1 Remove capscrew and locknut holding caster wheel and 2 washers between caster fork 2 Pull spanner bushing out of wheel hub 3 Remove bushing from wheel hub and allow bearing to fall out Remove bushing from opposite side of wheel hub 4 Check the bearing spanner and inside of wheel hub Figure 27 for wear Replace defective parts 5 To assemble the caster wheel push bushing into wheel hub Slide bearing into wheel hub Push other bushing into open end of wheel hub to captivate the bearing inside the wheel hub 6 Carefully slide spanner through the bushings and wheel hub 7 Install caster wheel assembly and 2 washers be tween caster fork and secure all parts in place with capscrew and locknut 8 Lubricate caster wheel bearing through grease fitting using No 2 general purpose lithium grease Repairs Page 12 18 Groundsmaster 300 Series 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 wea
162. ar to deck Block mechanical door in fully raised position Loosen jam nuts 2 Pull up on mechanical door lift lever Tighten the wing bolt jam nuts by hand so that there is no gap between the bolt head and the main deck surface 3 Tighten jam nuts lower wings and install covers Adjust mechanical door height if necessary Figure 18 1 Wing stop bolt 3 Jam nuts 2 Mechanical door lift lever 4 Main deck surface Adjustments Page 12 12 Groundsmaster 300 Series Repairs Blade Service Fig 19 20 21 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 A 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 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 Grasp end of blade using a rag or thickly padded glove Remove special screw washer anti scalp cup and blade from spindle assembly 3 To install the blade assemble parts in reverse order and make sure the blade sail is facing up Tighten special screw to 85 to 110 ft lb Groundsmaster 300 Series Page 12 13
163. arance Oversize 73 mm 2 874 in 0 25 0 50 0 75 mm 0 01 0 02 0 03 in 0 3 mm 0 012 in Piston Pin Type Outside Diameter Pin to Piston Clearance Pin to Connecting Rod Clearance Semi floating 19 mm 0 748 in Press fit load 1000 500 kg 2200 1100 Ib 0 08 mm 0 003 in Piston Rings Number of Rings 3 Compression 1 Oil Compression Ring Width Oil Ring Width Compression Ring Side Clearance No 1 No 2 Oil Ring Side Clearance Ring Gap No 1 Chrome plated semi keystone type No 2 and No 3 Tapered Chrome plated ring with coil expander 2 mm 0 079 in 3 mm 0 118 in 0 06 0 12 mm 0 05 0 09 mm 0 03 0 07 mm 0 15 0 40 mm 0 0024 0 005 in 0 002 0 004 in 0 001 0 003 in 0 006 0 016 in p 0 3 mm 0 012 in 0 2 mm 0 008 in 0 2 mm 0 008 in 1 5 mm 060 in Connecting Rod Type Bend and Twist Big End Thrust Clearance Forged l beam 0 05 mm 0 002 in max 0 1 0 35 mm 0 004 0 014 in 0 15 mm 0 006 in max 0 5 mm 0 02 in Connecting Rod Bearings Oil Clearance 0 15 mm 0 006 in Undersize 0 25 0 50 0 75 mm 0 01 0 02 0 03 in Crankshaft Type Fully counterbalanced Bend Within 0 03 mm 0 001 in 0 05 mm 0 002 in End Play 0 05 0 205 mm 0 002 0 008 in Journal O D 52 mm 2 047 in 0 15 mm 0 006 in 0 95 mm 0 037 in Pin O D 42 mm 1 654 in 0 15 mm 0 006 in
164. arting Problems continued Condition Possible Cause Correction Nothing happens when start attempt is made Groundsmaster 300 Series Battery is dead Loose or corroded battery cables Loose or corroded ground Fuse open Ammeter faulty Ammeter wiring loose corroded or damaged Ignition switch faulty Ignition switch wiring loose corroded or damaged Traction neutral switch out of adjustment or faulty Traction neutral switch wiring loose corroded or damaged PTO switch out of adjustment or faulty PTO switch wiring loose corroded or damaged Starter interlock relay wiring loose corroded or damaged Starter interlock relay faulty Starter solenoid wires loose corroded or damaged Starter solenoid faulty Page 6 7 Charge battery Replace battery if it will not hold a charge Clean and tighten or repair as necessary Check fuse and replace if fuse is open If fuse burns out often find and correct cause Test ammeter and replace if faulty Repair wiring Test ignition switch Replace if faulty Repair wiring Test switch and replace if faulty Make sure wires are connected to COMMON and NORMALLY OPEN N O terminals Repair wiring Test switch and adjust or replace if faulty Repair wiring Repair wiring Test relay and replaced if faulty Clean and tighten or repair as necessary Test starter solenoid Replace if faulty Troubleshooting
165. ated place the two rollers between the vise jaws Squeeze until FLUSH with the yoke Stop when flush do not over tighten 12 Tap one of the rollers use a brass punch the full width of the roller through the yoke until the snap ring can be inserted Insert the snap ring Use new snap rings Make certain the snap ring is seated to full depth 13 Support the cross and strike the yoke to force the snap ring againstthe inner face of the yoke Always seat the roller in this fashion to prevent improper centering of the cross 14 Install the other snap ring or rings and seatthe rollers against the rings Groundsmaster 300 Series Page 9 13 15 Grease the fitting SLOWLY until grease starts to show at the seals Use a low pressure hand grease gun or a power gun equipped with a pressure relief valve Never use a high pressure gun without this adapter as it is possible to blow the rollers out of the yokes with the tremendous pressure seals may also be damaged 16 Test the action of the assembled joint It should move throughout its range without binding If a slight bind exists rap the yoke lugs with a soft hammer This will usually free the joint If it does not disassemble and check for the source of the bind IMPORTANT When clamping in the vise clamp the solid portion of the U joint If the yoke must be clamped clamp lightly Use jaw covers Avoid clamping the tube portion of the propeller shaft as it is thin and easily cr
166. auses 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 Restricted oil cooler Restricted recentering of steering valve control valve plate Troubleshooting Page 8 6 Groundsmaster 300 Series 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 Disconnect the hydraulic hose at the charge pump outlet pressure fitting 3 Connect the inlet hose of the tester to the hydraulic fitting on the transmission and the outlet hose of the tester to hose that was disconnected in step 2 IMPORTANT Make sure that the oil flow indicator arrow on the flow gauge is showing that the oil will flow through the tester from the charge pump to the steering valve 4 Make sure that the tester load valve is fully open counterclockwise Start the engine and allow it to run for approximately 5 minutes so that the hydraulic oil reaches normal operating temperature 5 With the tester load valve fully open counterclock wise run the engine at full throttle
167. be suspected of wear and inefficiency A lack of sufficient implement pressure could be due to the fact that the charge pump is having to direct most of its flow to the main traction circuit piston pump and piston motor When this occurs oil pressure may not increase to the 700 800 psi pressure necessary to raise the heavy implement At this point a traction pressure test could be used to determine whether the hydrostatic transmission has excessive piston group leakage and needs to be repaired See Traction Pressure Test Groundsmaster 300 Series TEST NO 3 Traction Pressure Fig 10 Using a high pressure gauge 0 5000 psi A 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 injury due to leaking hot oil 1 Before beginning the traction test drive the machine to an open area lower the cutting unit turn the engine OFF and engage the parking brake Connect a chain to the rear axle Connect the other end of the chain to an immovable object and remove all slack from the chain 2 Place a drain pan on the floor beneath the transmis sion Remove the hex head plug from the transmission 3 Connect the high pressure hydraulic gauge hose to the gauge port 4 Start the engine and allow it to run for approximately 5 minutes so that the hydraulic oil reaches normal operating temperature 5 Increa
168. bearing saddles with a strip of wood if the press bed is rough Insert a press plate of the proper size and press the bearing cup toward the inside of the housing Retain the shims located under the bearing cup Fig 34 If the shims are damaged replace with new shims of the same thickness Groundsmaster 300 Series Page 7 13 Figure 32 Figure 33 Figure 34 Repairs Differential and Housing Reassembly 1 Inspect the differential parts for damage before assembling If any bearings are damaged they must be re placed with new ones B Checkthe ring pinion and spur gear for abnormal wear and damage replace worn components C Inspect the housings for cracks and external damage that could affect the operation of the axle assembly D Inspect the differential case for wear in the side gear and pinion mate area Replace the case if its machined areas are scored or if the pinion mate shaft Figure 35 fits loosely in the bore 2 Press the inner pinion bearing onto the pinion drive gear Support the bearing on the inner cup of the bearing ONLY WHEN INSTALLING Fig 35 3 Putthe front housing on a press Using a press plate push the outer pinion bearing cup into the housing until it bottoms in the housing Fig 36 Figure 36 Repairs Page 7 14 Groundsmaster 300 Series Ring and Pinion Set Rings gears and pinions are supplied in matched sets only Matching numbers are etched on both the
169. bottom of cutting unit 7 Remove cap screws flat washers lock washers and nuts from outer spindle in the area where shims must be added To raise or lower the blade add a shim Part No 3256 24 between spindle housing and bottom of cutting unit Continue to check alignment of blade and add shims until tips of blades are within the required dimension IMPORTANT Do not use more than three shims at any one hole location Use decreasing numbers of shims in adjacent holes if more than one shim is added to any one hole location 8 Adjust belt tension and install covers Figure 5 Groundsmaster 300 Series Repairs Blade Service Fig 6 7 8 The blade must be replaced if a solid object is hit or if the blade is out of balance worn or bent Always use genuine TORO replacement blades to ensure safety and optimum performance Never use blades made by other manufacturers because they could be dangerous A 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 Block cutting unit to 1 Blade bolt prevent it from falling accidentally 2 Lockwasher 3 Anti scalp cup 2 Grasp end of blade using a rag or thickly padded glove Remove blade bolt lockwasher anti scalp cup and blade from
170. bushings and wheel hub 7 Install caster wheel assembly between caster fork and secure all parts in place with capscrew and locknut 8 Lubricate caster wheel bearing through grease fitting using No 2 general purpose lithium grease Groundsmaster 300 Series Page 13 11 Figure 13 1 Caster wheel 4 Spanner bushing 2 Capscrew and locknut 5 Roller bearing 3 Bushing 2 Repairs 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 Drive roll pin out of yoke and input shaft of gear box Also loosen cap screws and lock nuts Slide yoke off the input shaft If traction unit will be used without the cutting unit drive roll pin out of yoke at PTO pivot shaft and remove entire universal shaft from traction unit A DANGER Figure 14 Do not start the engine and engage the PTO 1 Drive shaft yokes 3 Roll pin lever when PTO shaft is not connected to gear 2 Yokes phiese box on cutting unit If engine is started and PTO shaft is allowed to rotate serious injury could result gt 4 Disconnect cotter pins clevis pins securing lift chains to lift arms A WARNING Since the right hand push arm is spring loaded to about 100 pounds and left hand push arm is spring load
171. c tion when operating the nozzle tester IMPORTANT Always use fresh filtered fuel in the nozzle tester Use of dirty fuel can damage the precision parts of the injector nozzle It is a good practice to 1 Bolt the tester securely to the test bench 2 Use a drain pan to catch fuel 3 Flush the adapter by pumping the handle of the tester slowly several times before attaching the nozzle to be tested Injection Pressure Test The diesel engine requires that fuel be sprayed into the combustion chamber at a precise point in the compres sion stroke The point at which this fuel injection occurs is determined by the injection timing If the nozzle is defective damaged or adjusted incorrectly starting fail ures low power output or engine knocking can occur 1 Securely fasten the nozzle to the adapter 2 Pump the handle several times to purge air from the nozzle mechanism Testing Page 4 20 3 Allow pressure to dissipate before performing the test 4 Operate the pump handle slowly and observe the gauge to determine the pressure at which the nozzle opens and the fuel is sprayed 5 Verify that starting pressure is within the following limits 120 kg cm 1700 psi 2 Minimum starting pressure Maximum starting pressure 130 kg cm 1850 psi 6 Starting pressure can be adjusted by adding or re moving shims from the nozzle See Nozzle Service in the Fuel System Repairs section of t
172. ces 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 4 Install the fitting into the port and tighten it down full length until finger tight Fig 4 5 Tighten the fitting to the correct flats from finger tight F F F T Size F F F T 4 1 4 in nominal hose or tubing 1 00 25 6 3 8 1 50 25 8 1 2 1 50 25 10 5 8 1 50 25 12 3 4 1 50 25 16 1 1 50 25 SAE Straight Thread O Ring Port Adjustable 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material Fig 5 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 4 Turn back the jam nut as far as possible Make sure the back up washer is not loose and is pushed up as far as possible Step 1 5 Install the fitting into the port and tighten finger tight until the washer contacts the face of the port Step 2 6 To put the fitting in the desired position unscrew it by the required amount but no more than one full turn Step 3 7 Hold the fitting in the desired position with a wrench and turn the jam nut with another wrench to the correct flats from finger tight F F F T Step 4 Size F F F T 4 1 4 in nominal hose or
173. ch as when climbing a steep hill the forward movement of the traction unit slows This causes the rear axle pinion speed to slow down As soon as the rear axle pinion is turning the same speed as the drive shaft the roller clutch will engage and power will be transmitted from the drive shaft to the rear wheels four wheel drive Fig 4 When the traction unit is turning the rear wheels swing out in a larger arc and must travel faster than the front wheels In this condition the rear wheels and axle pinion shaft are turning faster than the drive shaft and the roller clutch is disengaged Fig 5 NOTE The four wheel drive system may not operate properly if the tires are replaced by different size tires or if proper tire pressure is not maintained Rear axle drive shaft Rear axle pinion shaft Figure 4 Groundsmaster 300 Series Page 10 3 Figure 5 General Information 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 7 3 Loosen screw on tie rod clamp Rotate ball joint in or out to adjust length of tie rod 4 Reinstall ball joint ot mounting bracket and check wheel toe in 5 After getting co
174. ck washers and nuts holding the brake mount and pedal assembly in place Lay the brake mount and the pedal assembly on the wheel PUSH ARM AND SPRING LOAD FULLY RELEASED 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 Slowly and carefully allow the push arm to move upward until all spring load is released 9 Remove the cap screws locknuts support plate and push arm bracket holding the left side of the push arm and pivot shaft to the main frame 10 Remove the cap screws locknuts reinforcement and push arm bracket holding the right side of the push die arm and pivot shaft to the main frame The entire push MQUNT AND arm and pivot shaft assembly should now be free of the main frame 11 Drive the roll pins out of the pivot shaft and slide the push arm assemblies off of the shaft 12 Drive the pushing out of both push arm pivot tubes 5 Clean the inside of the pivot tubes to remove all dirt and SUPPORT other material THRUST WASHER BUSHING THRUST LEFT PUSH WASHER ARM Figure 23 Groundsmaster 300 Series Page 13 15 Repairs 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 Inspect the torsion s
175. ck switches to allow the engine to run when the traction pedal is in neutral and the PTO switch is off The diodes plug directly into the wiring harness Testing The diodes can be individually tested using a digital multimeter diode test or ohms setting and the table be low Multimeter Black Lead on Terminal Multimeter Red Lead on Terminal Continuity Groundsmaster 300 Series 7 TO MAIN STARTER B HARNESS FUSIBLE LINK Figure 7 Figure 8 3 Female terminal 1 Diode 2 Male terminal Electrical System Rev G Control Ignition Delay Module Groundsmaster 345 The control ignition delay module on the Groundsmas ter 345 is one of the components in the interlock system Whenever the run enable relay is energized the control ignition delay module is energized and allows current to the engine ignition control module If the run enable relay is de energized e g operator gets off the seat the control ignition delay module will de energize after 5 second and will cause the engine to stop running as power to the engine ignition control module is shut off The module is attached to a bracket under the instru ment panel next to the battery Testing 1 Locate control ignition delay module Unplug wire harness connectors from module 2 Connect multimeter DC volts setti
176. complete revolution Ideal tooth contact observed on the ring gear should cover more than 3596 of each tooth surface The contact area should be in the center of each tooth and extend 1 3 1 3 to 1 2 of entire width to 1 2 way across each tooth from the toe end Fig 30 Adjustments to the gear contact position are made by moving the input shaft pinion gear bearing case shims or by moving the differential gear case differential bear ing shims Fig 31 NOTE Bearing case shims are available in 0 004 in 0 10 mm and 0 008 in 0 20 mm thickness NOTE Differential bearing shims are available in 0 004 in 0 10 mm 0 008 in 0 20 mm and 0 016 in 0 40 mm thickness Study the different contact patterns Figs 32 and 33 and correct gear engagement as necessary NOTE When making changes note that two variables are involved see Gear Pattern Movement Summary in this section of this manual Example If the pinion gear to ring gear backlash is set Sade id Figure 31 correctly to specifications and the bearing case shim is 1 Input shaft pinion gear 4 Differential bearing changed to adjust tooth contact it may be necessary to 2 Bearing case shims shims readjust backlash to the correct specification before 3 Differential gear case checking the contact pattern Groundsmaster 328 D Page 10 1 17 4WD Rear Axle Rev G Dae Dong Axle Gear Pattern Movement Summary Heel Contact Base Contact
177. correc tions are made by switching shims from one side of the differential case to the other To check the ring gear and pinion pattern 1 Paint the teeth of the ring gear both drive and coast side with a gear marking compound such as DyKem Steel Blue 2 While applying a light load to the ring gear rotate the pinion gear until the ring gear has made one complete revolution Study the patterns in the following illustra tions and correct as necessary The preferred pattern is shown in Figure 54A The drive side pattern should be located at the toe portion of the tooth The coast pattern should also be at the toe portion of the tooth Groundsmaster 300 Series Page 7 21 LENGTHWISE BEARING ARC Figure 54 Drive Side Coast Side Heel Toe Heel Toe Figure 54A NOTE When making changes note that two variables are involved Example If you have the backlash set correctly to specifications and you change the pinion position shim you may have to readjust backlash to the correct specification before checking the pattern Repairs Drive Side Coast Side Heel Toe Heel Toe Backlash correct Thicker pinion position shims required Figure 55 Drive Side Coast Side Heel Toe Heel Toe Backlash correct Thinner pinion position shims required Figure 56 Drive Side Coast Side Heel Toe Heel Toe Backlash incorrect Thinner pinion position shim re quired Adjust backlash to matc
178. crew Markings and Torque Values U S 3 Decimal and Millimeter Equivalents 2 Capscrew Markings and Torque Values Metric 3 U S to Metric Conversions 2 EQUIPMENT OPERATION AND SERVICE HISTORY REPORT FORM Product Records Record information about your Groundsmaster 345 Insert Operator s Manuals and Parts Manuals for your 322 D or 325 D on the Equipment Operation and Serv Groundsmaster 345 322 D or 325 D at the end of this ice History Report Form Use this information when section referring to your machine Groundsmaster 300 Series 2 1 Rev Product Records Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals mm Fractions Decimals mm 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 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 9375 2 381 19 322 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762
179. d High Temperature Override Switch 4 with 2 Wire Connector 11 Start Enable Run Enable Over Temperature SERVICE AND REPAIRS 12 and Seat Delay GM 328 D Relays 5 Battery Service 12 Fuel Sender 6 Fusible Link 5 7 Note Only new information for Groundsmaster 345 machines with serial numbers above 21000000 and Groundsmaster 328 D machines is provided in this 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 Special Tools Digital Multimeter The Digital Multimeter can test electrical components and circuits for current resistance or voltage drop 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 Ex cess current can cause damage to a circuit that is not de signed to carry it Skin Over Grease Special non conductive grease which forms a light pro tective skin to help waterproof electrical switc
180. d a helmet is advisable and required by some local ordinances and insurance regulations 7 Be sure interlock switches are adjusted correctly so engine cannot be started unless traction pedal is re leased to neutral position and PTO lever is in OFF position 8 Grass deflectors must be installed in lowest position on side discharge cutting units and properly attached to Triflex cutting unit wings 9 Fill fuel tank with the proper fuel before starting the engine Avoid spilling any fuel Since fuel is very flam mable handle it carefully A Use an approved fuel container B Do not fill fuel tank when engine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and up to about one inch 25 mm from the top of the tank not the filler neck E Wipe up any spilled fuel Safety Instructions 10 Sit on the seat when starting the engine and oper ating the machine 11 On machines equipped with roll over protection ROPS always use seat belt and ROPS together Make sure seat pivot retaining pin is installed 12 Before starting the engine A Engage parking brake B Make sure traction pedal is in neutral and PTO is in OFF disengage position C After engine is started release parking brake and keep foot off traction pedal Machine must not move While Operating 16 Using the machine demands the operator s com plete attention To prevent loss of control A Operate only in daylight o
181. d as described above 2 Use a micrometer and bore gauge to measure the clearance between the piston and pin If the clearance exceeds 0 0031 inch 0 08 mm the piston and or pin must be replaced Engine Reassembly The engine should be reassembled in the order given in this section The following general precautions should be observed when reassembling the engine 1 Clean each part carefully Pay particular attention to oil holes bearing surfaces and rotating parts 2 Before assembly apply engine oil to all sliding and rotating parts such as bearings and cylinder inner walls Groundsmaster 300 Series Page 4 59 Figure 76 Piston pin removal tool 3 Replace all gaskets packings and oil seals with new ones Reuse of these parts is not acceptable 4 Apply sealant to gaskets and threads 5 Tighten all fasteners to the proper torque as outlined in the torque specifications 6 Check clearances and end plays when installing Cylinder Block Overhaul Engine Reassembly Procedures Cylinder block oit hole Cylinder block Follow the procedures listed below in reassembling the engine 1 Install the camshaft bushing Bushing Installer With bushing oil hole properly aligned with cylinder block oil hole press in the 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 3 Install t
182. d be normal If the fuel accumulates and drips down during the test about ten seconds the nozzle assembly is defective and must be replaced Spray Test For proper combustion the nozzle must effectively at omize the injected fuel 1 Operate the pump handle at a rate of 20 30 strokes per minute Figure 18 2 Observe the injector nozzle spray The spray pattern should be finely atomized in a broad straight stream Fig 19 3 If the nozzle fails to spray properly it must be cleaned repaired or replaced See Nozzle Service in the Fuel System Repairs section of this chapter li Good Replace Replace broad spray narrow spray angled spray fine mist streaky mist straight Figure 19 Groundsmaster 300 Series Page 4 21 Testing Injection Pump Test Calibration of fuel delivery volumes pressure and dis tribution between pump barrels should be performed by a professional diesel engine service shop Special test fixtures and equipment are required It is possible to determine if the fuel injection pump requires service through a process of elimination using other fuel system tests The following test procedure will help isolate fuel system difficulties 1 Make sure that fuel is being supplied to the injector pump See Fuel Pump Testin this section and Bleeding Air From the Fuel System in the Fuel System Repairs section of this section 2 Check the operating condition of th
183. d bearing into the pump housing from the large open side Install the large snap ring into the pump housing 12 Slide the swash plate onto the pump shaft and into the pump housing The counterbore side of the swash plate must face up 13 Align the holes on both sides of the swash plate with the holes on both sides of the pump housing Next slide the control and trunnion shafts into the housing and swash plate Make sure the control shaft is on the implement relief side of the housing see alignment marks on the shaft and housing Secure the shafts and swash plate together with the spring pins IMPORTANT Use only new spring pins when as sembling the swash plate and shafts two pins through the control shaft and one pin through the trunnion shaft When installing two pins through the swash plate and control shaft drive the first pin flush with the swash plate and install the other pin onto the top of the first pin Drive both pins in until the top pin is 1 4 inch below the surface of the swash plate The pin holding the trunnion shaft must also Repairs Page 5 36 be 1 4 inch below the surface of the swash plate Make sure the swash plate swings freely 15 degrees to each side of center 14 Lubricate the thrust plate with transmission oil Slide the thrust plate onto the pump shaft and into the counter bore of the swash plate 15 Lubricate the pump cylinder block parts with oil Assemble the cylinder block parts and slid
184. d from a 12 VDC source to the pins of the red black and white wires Electrical System Rev G Page 6A 10 Groundsmaster 300 Series Run Solenoid Groundsmaster 328 D Solenoid With 2 Wire Connector The run ETR solenoid must be energized for the en gine to run The solenoid is mounted on the engine block near the injection pump In Place Testing Note Prior to taking small resistance readings with a digital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing 1 Disconnect machine wire harness connector from solenoid 2 Using a digital multimeter touch one test lead to the pull coil terminal and the other test lead to the fuel stop solenoid frame ground Fig 13 The resistance of the pull coil should be less than 1 ohm but not zero 3 Using a digital multimeter touch one test lead to the hold coil terminal and the other test lead to the fuel stop solenoid frame ground Fig 13 The resistance of the hold coil should be approximately 15 ohms 4 Connect solenoid to the machine wire harness Live testing 1 Disconnect wire harness connector from run sole noid Note The solenoid may be removed from the engine or tested in place 2 If the solenoid is removed from the engine
185. d washers Install the air breather hose on the rocker cover Groundsmaster 300 Series Page 4 13 Adjustments Engine Speed Adjustments Fig 13 14 Adjustments to the engine speed settings are not nor mally necessary unless the throttle linkage injection pump or governor mechanism have been repaired rebuilt replaced or are not operating correctly Since there is no ignition system from which to power an electronic tachometer a vibration type tachometer must be used to set engine speed NOTE This engine is equipped with a special damper spring Fig 14 which is designed to prevent engine stalling when the throttle decelerated quickly Adjust ment of this spring is required when adjusting the engine rpm High Speed Adjustment NOTE Specified rpm is with no load on engine The high speed set bolt has been set properly and sealed at the factory Never tamper with the seal unless necessary Idle rpm 1500 50 rpm Setting A 3120 3160 rpm Setting B 3145 3200 rpm No load governed rpm 1 The engine should be at operating temperature Make sure the parking brake is engaged 2 Open and support the hood 3 Remove sealing cap from damper spring adjusting bolt Fig 14 and loosen adjusting bolt to remove damper spring tension NOTE If tie rod cover was removed make sure governor tie rod has been pushed to the high speed position before cover is installed 4 Loosen the lock nut on the hig
186. damaged repair or re 1 Deflector in lowest position place the affected part s NOTE The deflector is spring loaded into its downward normal operating position but the operator can temporarily swing it out of the way to facilitate loading in a trailer or when otherwise necessary Groundsmaster 300 Series Page 11 3 General Information Troubleshooting 0 39V 1d3u N3 0u8 1138 O 14 1234dSNI 39V 71939 N3 0U8 SLIVHS X08 uv39 1234SNI 321435 N31H9I1 N3 0Uu8 35001 31104 X08 uv33 12334SNI 1138 S1108 S30Vv 18 32330 u311n2 31 NIdS 931112 123dSNI 1234dSNI 1234SNI 32V 1d3U 40 30v 1d3u 329V143u N31H9I1 N3J0u8 N340u8 Y0 3 001 TOU 35001 A311fd Old 194dSNI LAVHS 018 123dSNI LAVHS 1 41 0 3NI9N3 NO A311fd 1234SNI 0 39V14d3u N31H9IL SONNOd 1004 001 01 SL 3nD9u011uU 39V 1439 N3dU VHS N3X0uU8 35001 325001 1110 1N38 Groundsmaster 300 Series Page 11 4 Troubleshooting Adjustments Height of Cut Adjustment Fig 3 4 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 NOTE 1 4 inch spacers are available
187. de 3 Drive roll pin out of yoke and input shaft of gear box Also loosen cap screws and lock nuts Slide yoke off the input shaft If traction unit will be used without the cutting unit drive roll pin out of yoke at PTO pivot shaft and remove entire universal shaft from traction unit A DANGER Figure 14 Do not start the engine and engage the PTO 1 PTO yoke 3 Roll pin 2 Yokes in phase 4 Capscrews amp locknuts lever when PTO shaft is not connected to gear box on cutting unit If engine is started and PTO shaft is allowed to rotate serious injury could result 4 Disconnect spring from lift cylinder cotter pin Re move cotter pins and clevis pins securing lift chains to lift arm Figure 15 1 PTO shield 4 Spring in 4th link 2 Self tapping screws 5 Spring in cotter pin 3 Lift chain Repairs Page 11 14 Groundsmaster 300 Series A 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 5 Have a helper push down on the right push arm while you remove the cap screws flat washers lock washers and nuts securing ball joint mount to caster arm on cutting unit Now the helper can carefully allow push arm to move upward which will gradually release the 100 pounds of spring load 6 Have a helper push down on t
188. defective by failing the glow plug test it should be replaced 1 Remove the nut and lead wire 2 Clean the area around the glow plug to prevent dirt or grit from falling into the glow plug hole and the cylinder during replacement Oil Pressure Switch Replacement Fig 28 The engine is equipped with an oil pressure switch which activates a lamp and buzzer on the control panel if the oil pressure drops below safe levels during opera tion The switch is located on the oil pump at the rear of the right hand side of the cylinder block The switch and lamp circuit can be tested with a 12 VDC battery With the switch removed the warning lamp should light and buzzer sound when it is connected in series with the switch and battery Removing the switch from the circuit will test the lamp and buzzer only If the switch is defective it should be replaced Use a small amount of LOCTITE 567 Thread Sealant or equivalent on the switch threads Be careful to install the switch carefully so that the sealant will not block the oil hole in the switch Groundsmaster 300 Series Page 4 29 3 Remove the defective glow plug from its mounting hole 4 Install the replacement glow plug Torque the glow plug to 11 14 5 ft lb 1 5 2 5 Reinstall the lead wires and nuts Oil pressure Figure 28 External Engine Component Repair Oil Pump Servicing The oil pump is a trochoid gear type pump mounted to the rear o
189. der PTO actuating arm and turn locknut 5 Move PTO lever to OFF position and install instru Figure 5 ment cover 1 3 3 16 in 81 mm 3 Locknut 2 PTO actuating arm PTO Pulley and Engine Pulley Alignment Fig 6 7 1 Lowerthe implement to the shop floor turn the engine off remove the key from the ignition switch and engage STRAIGHT EDGE the parking brake 2 Move the P T O lever to the ON position to move the BN NORMAL pulley away from the brake Remove the locknut holding B WRX ROTATION the brake onto the mounting pin and slide the spacer brake and spring off of the pins 3 Loosen the setscrews in the lock collars at the front e and back of the P T O shaft Using a punch and ham LOCK COLLAR mer loosen the collars by driving them in the opposite SET SCREW direction of the normal shaft rotation The P T O shaft and P T O pulley assembly should now be free to slide 4 Using a straight edge line up the top of the engine pulley with the top of the P T O pulley When the top of the pulleys are aligned the bottom of the pulleys are misaligned by three degrees Move the P T O pulley 0 emee until its top is in line with the top of the engine pulley Then lock the pivot shaft and pulley place by tighten ing the lock collars in the normal direction of shaft rotation Check the alignment of the pulleys again to assure that the alignment did not change when the collars were tightened If
190. ds to search for leaks Hydraulic fluid escaping under pressure can have suffi cient force to penetrate skin and do serious damage If fluid is ejected into the skin it must be surgically re moved within a few hours by a doctor familiar with this form of injury or gangrene may result 37 Before disconnecting or performing any work on the hydraulic system all pressure in system must be re lieved by stopping engine and lowering implement to the ground 38 If the engine must be running to perform mainte nance or an adjustment keep clear of PTO shaft cutting unit blades and other moving parts 39 Do not over speed the engine by changing the governor settings To ensure safety and accuracy have an Authorized TORO Distributor check maximum en gine speed with a tachometer 40 Engine must be shut off before checking oil or adding oil to the crankcase 41 Disconnect the cables from the battery before serv icing the machine If battery voltage is required for troubleshooting or test procedures temporarily connect the battery 42 Do not charge a frozen battery because it can explode and cause injury Let the battery warm to 60 F 15 5 C before connecting to a charger Charge the battery in a well ventilated place so that gases produced while charging can dissipate Since the gasses are explosive keep open flame and electrical spark away from the battery do not smoke Nausea may result if the gases are inhaled Unplug the
191. e can cause high steering valve steering effort in one direction This is usually caused by excessive heat in the system Defective Defective Replace Repair or hydraulic replace valve cylinder Troubleshooting Page 5 16 Groundsmaster 300 Series 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 Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks See the Special Tools section in this Chapter A CAUTION Failure to use gauges with the recommended pressure psi rating as listed in the test pro cedures could result in damage to the gauge and possible personal injury from leaking hot oil Before Performing Hydraulic Tests All obvious areas such as oil supply filter binding linkage loose fasteners or improper adjustments must be checked before assuming that a hydraulic com ponent is the source of the problem being experienced Do electrical diagnostics before performaing hydraulic tests to make sure the electrical system is operating properly If the electrical syst
192. e commutator If the cover has nicks burrs or scoring it must be replaced Figure 46 Groundsmaster 300 Series Page 8 29 Repairs 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 31 Remove the commutator from the rotor Fig 48 IMPORTANT To prevent damage DO NOT use a screwdriver to remove the commutator Use a wood dowel if necessary 32 The commutator is made up of two round plates pinned and bonded together as a permanent assembly that cannot be disassembled Inspect the ground sur faces of the commutator The holes and edges should be free of nicks The ground surfaces should be free of scoring The edges should be sharp NOTE The commutator and commutator ring are a matched set If either is worn or damaged the set must be replaced IMPORTANT Five alignment pins connect the com mutator to the rotor with a slip fit Care and minimum force should be used to separate the two compo nents 33 Remove the five alignment pins Fig 49 Repairs Page 8 30 Figure 47 Figure 48 A Figure 49 Groundsmaster 300 Series 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 N
193. e injection nozzles to make sure that the injection pressure is correct See Injection Pressure Test in this section of the book 3 Make sure that the injection pump is providing suffi cient fuel pressure to operate the nozzle by performing the following procedures A Loosenthe fuel delivery pipe from the number one nozzle B Remove the nozzle from the cylinder head C Connect the fuel delivery pipe to the nozzle as sembly so the tip of the nozzle is pointed away from the engine Tighten the fitting securely Testing Page 4 22 D Put the throttle control in the FAST position Turn the ignition key to the START position to crank the engine Observe the nozzle A The injection pump forces fuel from the noz zle under extremely high pressure Always point the nozzle tip away from yourself and any other personnel Contact with the fuel stream even though it appears to be a mist can cause fuel to penetrate clothing and skin If fuel is injected into the skin get proper medical attention from a doctor immediately A serious infection or other reaction can de velop if the injury is not properly treated Tighten all adapter fittings to prevent leaks If a leak is suspected use a piece of cardboard not your hands to search for a leak If the nozzle produces an atomized mist of fuel the injector pump for that cylinder is operating properly Failure of the nozzle to inject fuel can indicate a injection pump cylinder
194. e it as instructed See Steering Valve Service in the Repairs section of this chapter DIMENSIONS SHOWN IN INCHES 45 FOUR HOLES 3 8 375 DIA EQUALLY SPACED ON A 3 25 DIA CIRCLE 2 00 DIA Figure 6 Special Tools Page 8 4 Groundsmaster 300 Series Troubleshooting Problem Steering Wander Possible Causes 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 toe in Steering linkage binding Low tire pressure Steering column binding or out of alignment Shimmy Steering linkage loose worn or out of adjustment Wheel bearings out of adjustment Air in hydraulic system Internal leakage of steering cylinder High Steering Effort in One Direction Low hydraulic system pressure Excessive heat causing steering valve plate valve to stick See Excessive Heat in this section High Steering Effort in Both Directions Cold hydraulic oil or oil viscosity not correct for ambinent temperature Low hydraulic fluid level Low flow or pressure from hydraulic pump Steering linkage binding Restriction in hydraulic return line Groundsmaster 300 Series Page8 5 Troubleshooting Problem Possible C
195. e the cylinder block assembly onto the pump shaft The cylinder block must slide onto the splines near center of the shaft Assure that the thrust plate remains seated in the counterbore and that the piston slippers contact the face of the thrust plate 16 Push against the back of the cylinder block A slight spring pressure assures correct installation of the parts 17 Assemble the transmission sections if no other service work is required refer to Assembling Transmis sion Section THRUST CYLINDER BLOCK PORT FACE PUMP SHAFT KEYED END CONTROL SHAFT TRUNNION SHAFT Figure 27 Groundsmaster 300 Series Transmission Center Section Fig 28 1 Separate the center section from the motor and pump housings refer to Separating Transmission Into Sections 2 Wrap the pump side of the center section with a clean rag to protect its face Set the center section on a clean work bench so that the motor side faces up The rag will protect the pump side of the center section from direct contact with the top of the work bench 3 Remove the two slotted directional charge check plugs from the motor side of the center section Invert the center section and allow the two valve springs and check balls to fall into your cupped hand Also remove the two O rings from the pump side of the center section 4 If the needle bearings must be serviced press them out of the center section 5 Clean and inspect the followi
196. earing cones Item 12 from shafts Item 17 19 NOTE Mark each gear Item 10 and 18 so they are installed on the proper shaft Item 17 or 19 when re assembled 4 Remove retaining rings Item 7 5 Press shafts Item 17 19 back through bearing cones Item 9 When bearing cone is free gears Item 10 18 keys Item 8 and shims Item 11 may be removed from the shaft Groundsmaster 300 Series Page 11 23 6 Remove bearing cups Item 14 from cap by putting a punch through the shaft bore and through the seal and then tapping against the back of the bearing cup until driven out of the cap 7 Ifthe oil seal Item 13 is removed it will be destroyed To remove the oil seal cut it out of the bore with a screw driver or chisel 8 To remove the bearing cups Item from the housing a slide hammer puller may be used or if this is not available the bearing cups may be knocked out with a punch by coming down through the opposite cap bore and tapping against the back side of the bearing cup until it comes out 9 Remove the plugs Item 2 from the housing Repairs LM GY 7 WUC ELA LESS E Figure 32 Gear Box Pre Assembly 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 towards the turned end of the shaft Align the keyway in the gear with the keyway in the shaft and install one of the keys Item 8 in the keyway 2 Install o
197. eat up off the seat switch when there is no operator on the seat 4 Have the operator sit on the seat slowly depressing the seat switch The continuity tester should show con tinuity as the seat approaches the bottom of its travel See Replacing Seat Switch in Repairs section of this chapter for replacement and adjustment procedures Groundsmaster 300 Series Page 6 19 Figure 6 S N Below 30001 1 Connectors 3 Switch 2 Capscrew amp locknut 4 Mounting bracket Figure 7 S N 30001 and UP 1 Seat switch 4 Spring 2 Seat support bracket 5 Pin 3 Connector Testing Traction Neutral Switch Fig 8 The traction switch is normally open and closes when traction pedal is in neutral TRACTION IMPORTANT The traction switch has three 3 ter SWITCH minals Make sure the wires are connected to the COMMON and terminals Test switch by disconnecting wires from switch termi nals and connecting a continuity tester across COM MON and N O terminals With engine off slowly push traction pedal in forward and reverse direction while BEARING watching continuity tester There should be indications LEAF that traction switch is opening and closing Allow traction SPRINGS pedal to return to neutral There should be continuity across the terminals See Replacing Traction Switch in PUMP Repairs section of this chapter for replacement and LEVER adjustment procedures Figure 8 NOTE
198. ecessary BLADE DRIVE BELT ROUTING IMPORTANT Too much tension on the belt will cause early belt failure Figure 25B Repairs Page 12 16 Groundsmaster 300 Series 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 If caster spindle is loose inside the bushings bushings are worn and must be replaced 1 Raise cutting unit and block it so it cannot fall acci dentally 2 Remove lynch pin and spacers from top of caster spindle 3 Pull caster spindle out of mounting tube Allow spacer s and thrust washer to remain on bottom of Figure 26 spindle to assure same height of cut when caster spin dle is reinstalled 4 Insert pin punch into top or bottom of mounting tube and drive bushing out of tube Also drive other bushing out of tube Clean inside of tubes to remove dirt 5 Apply grease to inside and outside of new bushings Using a hammer and flat plate drive bushings into mounting tube 6 Inspect caster spindle for wear and replace it if damaged 7 Push caster spindle through bushings and mounting tube Slide spacers onto spindle Install lynch pin through caster spindle to retain all parts in place Groundsmaster 300 Series Page 12 17 Repairs Rear Caster Wheel Bearing Service Fig 27 The re
199. ed to about 150 pounds a helper is needed to release push arms from cutting unit Sudden release of the Figure 15 push arms could cause injury 1 R H push arm 4 Capscrews and washers 2 Caster arm 5 Ball joint 5 Have a helper push down on the right push arm while 3 Ball joint mount 6 Jam nut you remove the cap screws flat washers lock washers and nuts securing ball joint mount to caster arm on cutting unit Now the helper can carefully allow push arm to move upward which will gradually release the 100 pounds of spring load 6 Have a helper push down on the left push arm while you remove the cap screws flat washers lock washers and nuts securing ball joint mount to mount bracket on cutting unit Now the helper can carefully allow push arm to move upward which will gradually release the 150 pounds of spring load 7 Roll the cutting unit away from the traction unit Figure 16 1 L H push arm 5 Capscrews and washers 2 Caster arm 6 Ball joint 3 Ball joint mount 7 Jam nut 4 Chain mount Repairs Page 13 12 Groundsmaster 300 Series Mounting Cutting Unit to Traction Unit Fig 14 15 16 17 1 Position machine on level surface and shut engine off 2 Move cutting unit into position in front of traction unit A 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 push the push arm down Sudd
200. ee belt guides 8 Install the P T O fork onto the P T O arm and secure it with the clevis pin and a new cotter pin 9 Install the P T O brake between the pulleys and adjust it refer to Adjusting The P T O Brake 10 Install the drive coupling between the engine pulley and transmission hub refer to Installing Drive Cou plings Groundsmaster 300 Series Page 9 9 Repairs 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 SPRING ANCHOR 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 2 CHECK FOR 4 Remove the long cap screw Fig 14 Item 35 that OSION passes through the P T O compression spring THESE ENDS Item 48 Have a helper hold the nuts Item 33 34 on the top of the compression spring using the appropriate wrench Then remove the spring washers and cap Screw P T O 5 Remove the cotter pin Item 8 from the clevis pin ARM UH Item 7 that secures the P T O lever to the P T O compression spring yoke Item 51 Remove the clevis pin and yoke Fi 13 6 Use locking pliers to grasp the tension spring 9576 Item 50 which is attached to the frame just forward and left of the P T O lever Unhook and remove the tension spring from the P T O assembly N
201. ee eere 18 Assembling Transmission Sections 39 Test No 1 Charge Pressure 19 Priming After Transmission Overhaul Test No 2 Implement Relief Pressure 20 or Replacement 40 Test No 3 Traction Pressure 21 Lift Cylinder Removal and Installation 41 Test No 4 Charge Pump Flow and Lift Cylinder Repair 42 Implement Relief Pressure 22 Lift Valve Removal and Installation 43 ADJUSTMENTS peed sede Pel 23 Lift Valve Repair 44 Traction Control Rod Adjustment 23 Traction Pedal Friction Wheel Adjustment 23 Traction Control Neutral Adjustment 24 Lift Lever Latch Adjustment 25 Groundsmaster 300 Series Page 5 1 Table of Contents Specifications Item Description Standard Transmission Sauer Sundstrand 15 Series In line Operating Pressure Charge pressure Implement relief pressure Forward traction relief pressure 4WD only 500 to 5200 PSI 70 150 PSI 700 to 900 PSI 5200 PSI Oil filter 25 micron rated screw on type Hydraulic oil Fig 1 Extreme over 90 F Normal 40 100 F Cool Spring Fall 30 50 F Winter Below 30 F SAE 30 SF CC or CD SAE 10W30 or 10W40 SF CC or CD SAE 5W30 SF CC or CD Type F or FA ATF Automatic Transmission Fluid Hydraulic resevoir Front axle differe
202. eed for trial and error shimming pro cedures to establish the correct contact pattern between ring and pinion gears Repairs Socket Hd Screw 94 6934 Nut 94 6935 Washer 94 6936 Hold socket head screw and tighten nutto 16 20 ft Ib 2 3 Kgm Page 7 8 Rev A Figure 18 Figure 19 Groundsmaster 300 Series 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 When reassembling place them back in the same position 3 To remove the differential assembly place two wooden devices i e hammer handles under the differ ential case and pry firmly upward The bearing cups must be kept with their mating cones Fig 21 4 Remove the ring gear cap screws Using a hard wooden block and a hammer drive the ring gear off of the differential case Be prepared to protect the ring gear when removing it from the differential case this will avoid damage of the ring gear teeth Fig 22 NOTE It is recommended that whenever the ring gear screws are removed they are to be replaced with new Screws Groundsmaster 300 Series Page7 9 Figure 20 Figure 21 Figure 22 Repairs 5 Do not remove the bearings from the differential case unless bearing failure is evident It is recommended that
203. el engines to check general oper ating condition of engine Includes case guage with hose glow plug hole adapters and instructions Piston Pin Tool Fig 6 Piston pin tool is used to remove and install the wrist pin without distorting the piston Inludes an adapter for use with Mitsubishi and most other engines Figure 6 Groundsmaster 300 Series Page 4 11 Special Tools 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 engine Figure 9 Special Tools Page 4 12 Groundsmaster 300 Series 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 Remove the rocker cover nuts and washers Remove the rocker cover 4 Tighten the cylinder head bolts to the proper torque The rocker assembly must be removed before tighten ing the cylinder head bolts When tightening the cylinder head bolts lower the coolant level in the engine loose
204. em is not operating properly the hydraulic system may appear to malfunction A WARNING Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved by lowering the cut ting unit to the ground and shutting the en gine OFF Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and do serious damage If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result Testing Page 5 18 1 Thoroughly clean the machine before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hydraulic equipment 2 Put caps or plugs on any hydraulic lines left open or exposed during testing or removal of components 3 The engine must be in good operating condition Use a tachometer when making a hydraulic test Engine speed can affect the accuracy of the tester readings 4 To prevent damage to tester or components the inlet and the outlet hoses must be properly connected and not reversed tester with pressure and flow capabilities 5 To minimize the possibility of damaging components completely open the load valve by turning it countercloc
205. emove nut by turning it counterclockwise 7 Remove piston Item 5 Slide head off of piston rod 8 Remove all seals and O rings Item 2 9 Wash parts in a safe solvent Dry parts with com pressed air DO NOT wipe them dry with a cloth or paper as lint and dirt may remain 10 Carefully inspect internal surface of barrel for dam age deep scratches out of round etc Replace entire cylinder if barrel is damaged Inspect head rod and piston for evidence of excessive scoring pitting or wear Replace any damaged parts 11 Putalight coating of oil on all new seals and O rings Install new seals and O rings 12 Install head onto piston rod 13 Install piston onto rod and tighten hex nut to 30 34 ft Ib 14 Put a light coating of oil on all cylinder parts 15 Slide piston rod assembly into cylinder tube 16 Install head into tube and tighten by hand to properly engage threads Tighten head with a spanner wrench Figure 21 Groundsmaster 300 Series Page 8 19 Repairs Brake Shoe Replacement A CAUTION The brake linings contain asbestos fibers Breathing dust containing asbestos fibers may be hazardous to your health and may cause serious respiratory or other bodily harm When servicing wheel brake parts do not create dust by grinding sanding or filing brake linings or by cleaning wheel brake parts with a dry brush or compressed air Use a water dampened cloth Use proper protec
206. en release of the push arm could cause injury 3 Have a helper carefully push down on right hand push arm until holes in ball joint mount line up with holes in caster arm 4 Secure ball joint mount to caster arm with capscrews flat washers and flange nuts Flat washers must be installed to outside of caster arm 5 Have a helper carefully push down on left hand push arm until holes in ball joint mount are in line with holes in mount bracket on cutting unit Immediately slide 4 x 4 in block of wood between top of push arm and under side of chassis A WARNING Make sure wooden block does not slip out accidentally 6 Secure ball joint mount and chain bracket to caster arm with capscrews flat washers and flange nuts Flat washers must be installed to outside of caster arm Chain bracket must be installed using forward set of holes 7 Carefully remove wood block holding push arm down Groundsmaster 300 Series Page 13 13 8 Line up holes in yoke and input shaft of gear box Slide yoke onto shaft and secure parts together with roll pin 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 10 Connect lift chains to lift arm and cutting unit chain brackets with 6 shackles shackle pins and cotter pins To make sure cutting unit lifts properly secure chains to the following links when connecting
207. er 4 Axle shaft 4WD Rear Axle Rev G Dae Dong Axle 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 18 3 Drive the input shaft pinion gear out from the outer bearing cone and bearing case Remove and discard the oil seal and O ring 4 Inspect all gears shafts bearings spacers and cases for damage and wear Replace components as necessary NOTE Replacement input shaft pinion gears are only available in matched ring and pinion sets Installation NOTE When installing new bearing cones press only on the inner race of the bearing cone 1 If the inner bearing cone was removed press a new bearing cone all the way onto the input shaft pinion gear 2 Place the shaft and bearing assembly in the bearing case and install the outer bearing cone NOTE The bearings must be completely seated There should be no input shaft pinion gear end play 3 Coat a new oil seal with grease and install as shown Fig 19 4 Coat a new O ring with grease Install O ring in the oil seal collar and install the collar 5 Install a new stake washer Install the lock nut finger tight 6 Set the bearing preload be securing the bearing case in
208. er measures actual oil flow in the operation circuit with a gauge rated at 15 GPM 6 OUTLET HOSE Hose from the outlet side of the hydraulic tester to be connected to the hydraulic system circuit Special Tools Troubleshooting The cause of an improperly functioning hydraulic sys tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com plete hydraulic system A hydraulic system with an excessive increase in heat or noise is a potential failure Should either of these conditions be noticed immediately stop the machine turn off the engine locate the cause of the trouble and correct it before allowing the machine to be used again Continued use of an improperly functioning hydraulic system could lead to extensive internal component damage The charts that follow contain detailed information to assist in troubleshooting There may possibly be more than one cause for a machine malfunction All causes should be checked in the order in which they are listed on the charts Refer to the Testing section of this Chapter for precau tions and specific test procedures System Operates in Only One Direction Inspect traction control linkage Inspect acceleration valves Defective Repair linkage Defective Repair acceleration valves System Jerky When Starting Inspect friction Inspect wheel on traction control traction pedal linkage Inspect accelera
209. erential shaft assembly from the axle support 3 Remove the retaining ring and bevel gear Fig 14 4 Drive the differential shaft out of the bearings Re move the bearings and bearing shims 5 Inspect all gears shafts bearings and cases for damage and wear Replace components as necessary Installation 1 Press bearings onto differential shaft Place correct combination of bearing shims in axle support and drive differential shaft and bearing assembly into axle sup port 2 Install bevel gear and retaining ring 3 Align differential shaft splines with differential gear assembly and slide differential shaft assembly onto axle support 4 Coat new O ring with grease Install bevel gear case axle case assembly see Bevel Gear Case Axle Case Assembly in this section of this manual 4WD Rear Axle Rev G Dae Dong Axle Page 10 1 10 NOTE Axle bearing shims are available in 0 008 in 0 2 mm 0 012 in 0 3 mm and 0 020 in 0 5 mm thickness 11 Tighten axle cover screws from 17 to 20 ft lbs 23 to 27 Nm 12 Coat a new O ring with grease and install the bevel gear case axle case assembly on the axle support Tighten mounting screws and nuts from 35 to 41 ft lbs 47 to 56 Nm Fig 13 35 to 41 ft Ibs Aa 47 to 56 Nm 35 to 41 ft lbs 47 to 56 Nm Figure 13 1 Cap screw 5 Bevel gear case axle 2 Locknut case assembly 3 Lock washer 6 O ring 4 Axle support Figure 14 1
210. erminals IMPORTANT Be sure to disconnect the coupler or the control unit may be damaged Then measure the resistance between ground black wire and each terminal S and S with the ohmmeter The ohmmeter readings between the two S terminals should be approximately 1 7 ohms of resistance The ohmmeter readings between each S terminal and the ground lead should be infinity ohms If these tests are failed replace the control unit assembly Groundsmaster 300 Series Page 6 25 Testing Indicator Lights Buzzers and Gauges Cil Pressure Light and Buzzer Oil pressure lamp and buzzer should come on when the ignition key switch is in the RUN position with the engine not running or if the oil pressure switch closes during operation oil pressure below 7 psi 0 5 kg cm Test the light and buzzer by disconnecting the wire from oil pressure switch and grounding it against the engine The light and buzzer should come on when the wire is grounded with the ignition switch in the ON position Ammeter Check the ammeter by comparing it to another amme ter Replace it if it registers incorrectly Glow Indicator Groundsmaster 322 D 325 D only The glow indicator should glow red after holding the glow plug switch on for approximately 20 seconds Testing Page 6 26 Testthe indicator by disconnecting the wires and check ing for continuity across the terminals Hourmeter Test the hourmeter by connecting a
211. ers from top of cutting unit A DANGER Do not start the engine and engage the P T O when the P T O shaft is not connected to the gear case If engine is started and the P T O shaft is allowed to rotate serious injury could result 3 Loosen belt tension and remove belt from gear case pulley 4 Remove flange nuts and carriage bolts securing gear case mount plate Item 22 to cutting unit and remove plate and gear case 5 Remove the set screws Item 28 from the taper lock bushing Item 27 Install one setscrew into the hole that is threaded on the side of taper lock Tighten the set screw until the taper lock is loose from the inside of the pulley hub NOTE Only one setscrew is used to loosen the taper lock 6 Slide the gear case pulley Item 26 and taper lock Item 27 off of the gear case output shaft Account for the woodruff key Item 24 that positions the pulley on the shaft and remove the setscrew from the side of the taper lock 7 Remove gear case from mount plate and remove brackets Item 18 from gear case Figure 41 Repairs Page 12 26 Groundsmaster 300 Series Installing Gear Case and Drive Pulley 1 Install bracket Item 18 on each side of gear case with capscrews and lockwashers Tighten capscrews to a torque of 20 26 ft Ib Install gear case and bracket assembly to mount plate Item 22 with carriage bolts and flange nuts 2 To install pulley Item 26 and slide taper loc
212. ervice 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 Components of the steering valve are stacked on four bolts and held in alignment with alignment pins The alignment pins are designed to be a slip fit into the components Use the minimum force necessary and maximum care when separating or assembling the com ponents The steering valve has several components that are of brazed laminate construction These components have plates and parts bonded together permanently to form an integral component that cannot be disassembled Disassemble the steering valve only to the extent shown in this book IMPORTANT Do not force or abuse closely fitted parts or you may damage them Components of the steering valve with alignment grooves must be assembled so that their alignment grooves are positioned as illustrated for the valve to function correctly Fig 24 Repairs Page 8 22 Figure 24 Groundsmaster 300 Series 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 va
213. es EQUIPMENT OPERATION AND SERVICE HISTORY REPORT BRGUNDSMASTERS 345 Unit Model and Serial Number Deck Model and Serial Number Engine Numbers Transmission Numbers 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 GROUNDSMASTER 345 Maintenance Schedule i Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval amp Service Check Battery Fluid Level a o Ans 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 A Level Inspect Air Filter Dust Cup and Baffle t Change Engine Cil and Filter T Check Fan and Alternator Belt Tension B Level Inspect Cooling System Hoses T Replace Transmission Oil Filter Service Air Filter Check Governor Oil Level Decarbon Spark Arrestor Muffler Check Rear Wheel Toe In and Steering Linkage C Level Service T Torque Wheel Lug Nuts Replace Fuel Filter Change Transmission Oil Change Cutting Unit Gear Box Oil Replace Spark Plugs Pack Rear Wheel Bearings D Level Torque Head Adjust Valves Check Engine RPM Service T Initial break in at 10 hours t Initial break in at 50 hours Re
214. est seat switch Adjust or replace if faulty Test switch Adjust or replace if faulty Check for correct terminal connections Engine kills when traction pedal is depressed or PTO is engaged Operator sitting too far forward on seat seat switch not depressed Seat hinge support pin or spring binding preventing seat switch from closing Seat switch is faulty or out of adjustment Seat switch wiring loose corroded or damaged Instruct operator Repair seat pivot and support Test seat switch Adjust or replace if faulty Repair wiring Battery does not charge Loose corroded or broken wire s Faulty alternator Dead battery Repair wiring Test alternator and replace if faulty Charge battery Replace battery if it will not hold a charge Battery continuously charges at high rate Groundsmaster 300 Series Regulator rectifier faulty Page6 9 Replace regulator rectifier Troubleshooting Groundsmaster 345 Operation Problems continued Condition Possible Cause Correction Engine continues to run but should not when PTO is ON with no operator on the seat Troubleshooting Groundsmaster 345 Seat switch plunger depressed with no operator on seat Seat switch faulty or out of adjustment Page 6 10 Check for seat support spring that is broken missing or stuck in down position Check for binding seat pivot hinge Check
215. et screws until the 55 in Ib of torque will not turn the setscrews 7 Check the alignment of the gearbox with a spindle pulley Loosen and relocate the taper lock to adjust if necessary 8 Fill the recessed socket head in each setscrew and the other taper lock holes with grease to prevent dirt from packing into the holes 9 Align holes in thin metal strip with the two front gearbox mounting holes on base plate Repairs Page 11 22 10 Mount gearbox with brackets onto top of cutting unit Insert four 4 carriage bolts up from bottom of cutting unit and install flatwasher and nut on each bolt to secure the gearbox Tighten nuts to 20 26 ft Ib 11 Install drive belts onto gear box pulley and adjust idlers to tension belts 12 Install cutting unit covers 13 Install drive shaft to gear box and secure with a new roll pin 14 Remove the gear box fill plug and check plug Add SAE 80W90 API GL 5 gear lube until level is to the bottom of the check plug hole Install plugs in gear box Figure 30 1 Isolation mounts 6 Pulley assembly 2 Brackets 7 Metal straps 3 Capscrews amp lockwashers 8 Carriage bolts 4 Gear box 9 Flatwashers amp nuts 5 Woodruff key 10 Taper lock Groundsmaster 300 Series Gear Box Repair Fig 31 32 33 Figure 31 Gear Box Disassembly 1 Drain lubricant from gear box 2 Remove capscrews and lift out shaft and cap assem blies 3 Remove cap assemblies and b
216. et screws 8 Check alignment of gearbox with a spindle pulley Loosen and relocate taper lock to adjust if necessary 9 Fill recessed socket head in each setscrew and other taper lock holes with grease to prevent dirt from packing into holes 10 Install gear box plate on deck channels while routing belt around gear box pulley Mount gear box plate to deck channels with capscrews and nuts 11 Install idler arm bracket to idler arm with cotter pin and clevis pin Hook spring onto idler arm bracket To make sure there is proper belt tension on drive belt spring should be extended to a length of approximately 7 00 inches If spring is not extended to this length move spring rod to other mounting holes further away from belt 12 Install belt covers Install drive shaft to gear box and secure with a new roll pin 13 Remove gear box fill plug and check plug Add SAE 80W90 API GL 5 gear lube until level is to bottom of check plug hole Install plugs in gear box Figure 26 Repairs Page 13 18 Groundsmaster 300 Series Gear Box Repair Fig 27 28 Figure 27 Gear Box Disassembly 1 Drain lubricant from gear box 2 Remove capscrews and lift out shaft and cap assem blies 3 Remove cap assemblies and bearing cones Item 12 from shafts Item 17 19 NOTE Mark each gear Item 10 and 18 so they are installed on the proper shaft Item 17 or 19 when re assembled 4 Remove retaining rings Item 7
217. f rear wheels is 0 1 8 of an inch less than at the rear of the wheels Fig 9 Figure 9 3 When toe in is correct tighten jam nuts against tie 1 Steering plate rods Groundsmaster 300 Series Page8 9 Adjustments 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 When cable is no longer adjustable star nut on inside of the brake drum must be adjusted to move brake shoes outward Brake cables must be adjusted again after star nut is adjusted 1 Disengage lock arm from left brake pedal so both pedals work independently of each other 2 To reduce free travel of brake pedals A Loosen front nut on threaded end of brake cable Fig 12 B Tighten rear nut to move cable toward the rear until brake pedals have 1 2 to 1 in of free travel C Tighten front nut after adjusting 3 When brake cables cannot be adjusted to get free travel within 1 2 to 1 in star nut inside brake drum must be adjusted Before adjusting the star nut loosen brake cable nuts to prevent unnecessary strain on the cables 4 Loosen do not remove the five 5 wheel lug nuts 5 Jack up machine until front wheel is off the floor Use jack stands or block machine to prevent it from falling accidentally 6 Remove wheel nuts and slide wheel off
218. f 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 Disassembly of Oil Pump Fig 29 1 Drain the engine oil 2 Remove the oil filter The use of a filter wrench may be necessary 3 Remove the four bolts which hold the pump cover in place and attach the pump to the cylinder block 4 Remove the pump cover body and rotors and gasket Oil Pump Inspection Fig 30 31 32 The oil pump or its worn components should be re placed when internal pump clearances exceed those shown in the table above 1 Outer Rotor to body clearance should be checked with a feeler gauge If clearance exceeds the service limit replace the rotor assembly 2 Outer rotor to Inner Rotor clearance should be checked with a feeler gauge If clearance exceeds the service limit replace the rotor assembly Check the coupling end of the Inner Rotor shaft for cracks or damage 3 Rotor to cover clearance should be check with a feeler gauge by placing the rotor assembly in the pump body and using the cover as a straight edge In case of excessive clearance replace either the Rotor Assembly or the Oil Pump Body 4 Inspect the Pump Body O ring for cuts cracks or other damage 5 The Pump Relief Valve can be disassembled by removing the plug gasket spring and plunger Ens
219. floor 4 Lower the seat and start the engine to test for proper operation of the coupling components Groundsmaster 300 Series Page 9 7 Repairs 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 3 Remove the engine hub from the crankshaft pulley after loosening the two setscrews that secure it in place Remove the woodruff key 4 Use a thin screwdriver to remove the external retain ing ring that secures the bearing onto the crankshaft pulley shaft 5 Remove the two cap screws and spacers that secure the large yoke to the bearing collar 6 Use a pry bar to carefully remove the bearing and bearing collar from the crankshaft pulley shaft 7 Remove the bearing from the bearing collar after removing the large internal snap ring from the bearing collar An arbor press should be used to press the bearing out of the collar 8 After bearing service reinstall the components in reverse order 9 Lubricate the bearing with No 2 general purpose lithium base grease PTO Brake Replacement Fig 11 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 to move the pulley away from the b
220. following A Ball bearing is loose or worn B Plunger on interlock switch is sticking C Fasteners on pump control assembly are loose or missing Adjustments Page 5 24 Rev D Weak or damaged leaf springs E Pump lever loose on transmission control shaft Make sure that fasteners are tight bolts or spring pin If necessary remove pump lever from control shaft apply Loctite 680 or equivalent to shaft and reat tach pump lever F Internal transmission component malfunction see Repairs section of this chapter 8 Shut engine off 9 Adjust traction control rod refer to Traction Control Rod Adjustment in this section 10 Check operation of neutral switch and adjust if nec essary SWITCH BEARING LEAF SPRINGS Figure 13 Groundsmaster 300 Series 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 1 Unscrew ball from lift lever 2 Remove self tapping screws and lift cover off lift lever to expose the latch 3 Loosen two capscrews on top of the lift lever latch Place lever on rounded tip of latch and slide latch w lever forward until stoppi
221. for waterlogged seat Test seat switch Adjust or replace if faulty Groundsmaster 300 Series Verify Interlock System Operation The machine has interlock switches in the electrical System These switches are designed to stop the engine when operator gets off the seat while either the PTO lever is engaged or traction pedal is depressed How ever operator may get off the seat while engine is running Although engine will continue to run if PTO lever is disengaged and traction pedal is released it is strongly recommended that the engine be stopped be fore dismounting from the seat A CAUTION Do not disconnect the interlock switches Check operation of switches daily to assure interlock system is operating correctly If a switch is malfunctioning replace it before operating the machine To ensure maximum safety replace all switches after every two years or 1000 hours whichever comes first To check operation of interlock switches 1 Drive the machine slowly to a large relatively open area Lower cutting unit stop the engine and apply parking brake Groundsmaster 300 Series Page 6 11 2 Sit on seat Move PTO lever to ON position With the traction pedal in neutral position try to start the engine The engine should not crank If the engine cranks there is a malfunction in the interlock system that should be corrected before beginning operation 3 Sit on seat Move PTO lever to OFF and depress the
222. from the housing Groundsmaster 300 Series aid 4 b poe Dac N N a ZZ Kx A 2 GY 9 SS A LFESSSW Figure 44 Gear Case Pre Assembly 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 towards the turned end of the shaft Align the keyway in the gear with the keyway in the shaft and install one of the keys Item 8 in the keyway 2 Install one set of shims Item 11 onto the turned end of the shaft Press one of the bearing cones Item 9 over the turned end of the shaft Be sure the bearing cone is installed as shown in the illustration Fig 42B Install a retaining ring Item 7 on the turned end of the shaft 3 Put one of the bearing cones Item 12 over the other end of the shaft and down against the hub side of the gear Be sure the bearing cone is installed as shown in the illustration 4 Repeat steps 1 3 with the other set of parts to complete the assembly 5 Putone ofthe caps Item 16 down with the machined surface facing up Install a new seal Item 13 into the Groundsmaster 300 Series Page 12 29 cap with the open side toward the machined side of the cap 6 Install the bearing cup Item 14 into the cap Make sure the bearing cup is installed as shown in the illus tration 7 Repeat steps 5 6 with the other set of parts to complete the two cap assemblies 8 Take
223. g seat Pump plunger spring Lower spring seat Shim plate Tappet Fuel System Service 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 Injection Pump Timing and Adjustment Adjusting the shim thicknesses as explained on Injec tion Timing Test will adjust the injection timing NOTE If timing requires adjustment and the engine has not been worked on or the shim thickness changed the injection pump components and camshaft should be inspected for wear or damage Fuel System Service Page 4 44 Groundsmaster 300 Series Nozzle Servicing Fig 51 The fuel from the injection pump flows through the injection pipes to the nozzle During the injection stroke of the pump pressurized fuel builds up in the nozzle When the pressure becomes sufficiently high the noz zle valve opens and a spray of fuel is injected into the combustion chamber where it is ignited due to the heat produced by the cylinder compression If the nozzle does not function properly starting failure low power output or engine knocking can occur IMPORTANT When servicing the injection nozzles make certain that the engine and fuel delivery pipes are clean in order to prevent
224. ge 8 20 5 Star wheel assembly Groundsmaster 300 Series 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 Remove the six 6 self tapping screws securing the steering tower cover Fig 23A Slide the steering tower cover off of steering column and parking brake rod 5 Clean outside of the steering valve and the area around the hydraulic fittings Disconnect hydraulic hoses from steering valve Put caps or plugs on all fittings and hoses to prevent contamination NOTE To ease reassembly tag each hose and tube line to show their correct position on the steering valve 6 Remove two 2 capscrews to remove clamp half securing steering column to column support Fig 23B 7 Remove four 4 locknuts and flat washers securing steering valve to mounting bracket 8 Carefully move hydraulic lines to the side and pull steering valve and column out through bottom of steer ing tower 9 Reverse steps 2 8 to install the steering valve Groundsmaster 300 Series Page 8 21 Figure 23A 1 Steering column cover 3 Self tapping screws 2 Steering column 4 Parking brake knob Figure 23B 1 Column support 4 Steering column 2 Clamp half 5 Valve 3 Mounting bracket 6 Pivot plate Repairs Steering Valve S
225. ges of governor More than two surges of governor usually indicates that the anti surge screw must be turned in slightly more than it is When adjustment is correct lock jam nut against governor body 10 Check low and high idle speed to be sure there is no change from initial setting If high idle speed has increased anti surge screw has been turned into gov ernor too far and it must be backed out Then repeat the entire adjustment procedure NOTE If the throttle control on instrument panel will not stay in FAST position during operation remove panel cover and tighten nut and capscrew at base of throttle lever assembly Groundsmaster 300 Series Page3 5 Figure 4 1 High idle stop screw 5 Oil check plug 2 Speed control lever 6 Low idle stop screw 3 Jam nut 7 Oil fill plug 4 Anti surge screw Adjustments Repairs Crankshaft Pulley Installation 1 Insert three of four locking rings into crankshaft pulley NOTE Outside locking rings have tapered 1 0 and flat O D Inside locking rings have flat I D and tapered O D CRANKSHAFT A Install first outside ring seated against small inter nal shoulder of pulley flat edge of ring touching small pulley shoulder B Install second inside ring mating taper to taper with first ring C Install third outside ring with flat edge against previous inside ring D Align ring end gaps with key slot in pulley 2 Align pulley key slot with crankshaft key Install pu
226. gh grease fitting Item 32 with No 2 General Purpose Lithium Grease Installing Drive Shaft 1 Apply never seize to splines of traction shaft and axle input shaft 2 Slide clutch end of drive shaft onto rear axle shaft spline aligning roll pin hole in shaft with hole in axle coupling Item 37 Install roll pin Item 35 through coupling and shaft 3 Tighten two 2 capscrews Item 44 and locknuts Item 43 to secure coupling to shaft 4 Secure drive shaft yoke flange to flange on front axle differential with six 6 socket head capscrews and lockwashers not shown Repairs Page 10 6 Groundsmaster 300 Series Rear Axle Removal and Installation Figure 10A 1 Remove drain plugs from axle and allow oil to drain into a container Fig 2 2 Remove drive shaft see Drive Shaft Service 3 Disconnect clutch engagement cable from rear axle 4 Thoroughly clean around hydraulic hoses connec tions to steering cylinder Mark hoses so they will be installed correctly during reassembly Disconnect hoses from fittings on steering cylinder Put plugs or caps on open hoses and fittings to prevent contamination of hydraulic system 5 Loosen rear wheel capscrews Fig 10A Item 23 6 Block front tires and jack up rear of machine until there is approximately one inch clearance between rear tires and the ground SECURELY BLOCK FRAME 7 Remove rear wheels Groundsmaster 300 Series Page 10 7 Figure 10B 8
227. glow plugs to pre heat engine cylinders before and during cold starting Hold glow plug switch in ON position until indicator glows red or as specified in Operator s Manual for ambient temperature DO NOT exceed 2 minutes of continuous use Test glow switch glow plug indicator and glow plugs and replace if faulty Check glow plug circuit wiring and repair if loose corroded or damaged Check for voltage at solenoid connector while cranking If no voltage but solenoid is IN solenoid is faulty If there is voltage control unit is faulty See Troubleshooting section of Chapter 4 Mitsubishi Diesel Engine Engine cranks but should not with traction pedal out of neutral Traction neutral switch out of adjustment or faulty Test switch and replace if faulty Make sure wires are connected to COMMON and NORMALLY OPEN N O terminals Engine cranks but should not with PTO ON Troubleshooting Groundsmaster 322 D 325 D PTO switch out of adjustment or faulty Page 6 14 Test PTO switch and adjust or replace if faulty Groundsmaster 300 Series Operation Problems Condition Possible Cause Correction Engine continues to run but should not when traction pedal is depressed with no operator on seat Seat switch plunger depressed with no operator on seat Seat switch faulty or out of adjustment Check for seat support spring that is broken missing or stuck i
228. gned PTO drive shaft does not telescope Worn bearings or U joints Lack of lubrication to splines and tube Galling of U joint journal cross ends Drive shaft RPM to high Lack of lubrication Abrasive corosion on PTO drive shaft Extreme low angle operation Broken U joint journal Excessive shock loading to PTO shaft Groundsmaster 300 Series 9 3 Troubleshooting 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 The drive coupling will be damaged when misalignment is more than 1 8 inch 3 mm To check the alignment of the drive couplings place the square end of a ruler or scale against the face of the drive pulley and the bottom of the coupling retainer If there is more than 1 8 inch 3 mm between the ruler or scale and the opposite coupling retainer or the scale is more than 1 8 inch 3 mm higher than the bottom of the coupling an adjustment is required To correct for a misaligned drive coupling proceed to Adjusting Drive Figure 2 Coupling Alignment which follows Adjusting Drive Coupling Alignment Fig 3 4 To correct drive coupling misalignment first loosen the axle support nuts at the rear of the floor plate
229. h Figure 57 Repairs Page 7 22 Groundsmaster 300 Series 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 Increasing backlash moves the ring gear away from the pinion Drive pattern moves higher and toward the heel Coast pattern moves slightely lower and toward the toe 3 Thicker pinion position shim with the backlash con stant moves the pinion closer to the ring gear Drive pattern moves deeper on the tooth flank contact and slightly toward the toe Coast pattern moves deeper on the tooth and to ward the heel 4 Thinner pinion position shim with backlash constant moves the pinion further from the ring gear Drive pattern moves toward the top of the tooth face contact and toward the heel Coast pattern moves toward the top of the tooth face contact and toward the heel Apply silicone sealant between the front and rear axle housings and install the eight housing cap screws Tighten the cap screws to a torque of 18 23 ft lb 2 5 3 2 KgM Fig 58 Groundsmaster 300 Series Page 7 23 Figure 58 Repairs Repairs Page 7 24 Groundsmaster 300 Series TORO Table of Contents INTRODUCTION SCHEMATICS SPECIFICATIONS SPECIAL TOOLS TROUBLESHOOTING TESTING Steering Valve and
230. h steel wool etc or the nozzle hole or pin tip may become dam aged and need to be replaced 3 Clean the flange body shim spring pin and distance piece in clean diesel fuel Replace any worn or damaged parts Reassembly and Test 1 Install the nozzle assembly distance piece and pres sure pin into the retaining nut 2 Install the shim pressure spring and flange in the body Assemble the body to the retaining nut Torque the body and nut to 43 58 ft lb 6 8 3 Test the reassembled nozzle for proper operation Refer to Nozzle Tests Installation 1 Install a new nozzle holder gasket onto the nozzle 2 Position the nozzle assembly on the head and install the bolts through the flange Alternate tightening the bolts to ensure even pressure on both sides of the flange Torque the bolts to 11 15 ft lb 1 5 2 OVERFLOW NIPPLE SHIM WASHER FLANGE SPRING PIN DISTANCE PIECE RETAINING NUT NOZZLE Figure 51 Fuel System Service Removing and Installing the Engine Removing the Engine 1 Put machine on a level surface stop engine remove key from ignition switch and engage parking brake 2 Remove intake hose from air cleaner and carburetor 3 Remove transmission drive coupling see Chapter 10 Transmission Coupler and PTO 4 Remove PTO belt see Chapter 10 Transmission Coupler and PTO 5 Disconnect battery cables from battery terminals 6 Disconnect and tag
231. h a thermometer and heat the oil 3 With an Ohm meter connected as shown the resis tance readings should changed as the temperature increases resistance should get lower as temperature gets higher Figure 19 CAUTION Handle hot oil with special care to prevent personal injury or fire Groundsmaster 300 Series Page 6 27 Testing 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 HOUR METER buzzer should be on If lamp and buzzer are not on OIL PRESSURE LIGHT 1 Disconnect wire from oil pressure switch and touch wire to a good ground such as the engine block SWITCH IS OPEN WIT H NO OPERATOR ON SEAT 2 If lamp and buzzer come on replace switch SEAT SWITCH 3 If lamp and buzzer do not come on check wiring Figure 20 between switch lamp and buzzer for continuity If lamp and buzzer are on with engine running 1 Shut off engine immediately 2 Check switch by disconnecting wire with ignition switch in ON position Light should go out 3 If light is still on check for short circuit in wiring 4 Install test gauge in engine oil pressure switch port Start engine and check oil pressure If engine oil pres sure is good replace switch If engine pressure is low DO NOT operate the engine Te
232. h 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 A wobbly caster wheel usually indicates a worn bearing 1 Remove capscrew and locknut holding caster wheel and 2 washers between caster fork 2 Pull spanner bushing out of wheel hub 3 Remove bushing from wheel hub and allow bearing to fall out Remove bushing from opposite side of wheel hub 4 Check the bearing spanner and inside of wheel hub Figure 13 for wear Replace defective parts 5 To assemble the caster wheel push bushing into wheel hub Slide bearing into wheel hub Push other bushing into open end of wheel hub to captivate the bearing inside the wheel hub 6 Carefully slide spanner through the bushings and wheel hub 7 Install caster wheel assembly and 2 washers be tween caster fork and secure all parts in place with capscrew and locknut 8 Lubricate caster wheel bearing through grease fitting using No 2 general purpose lithium grease Groundsmaster 300 Series Page 11 13 Repairs 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 asi
233. h speed set bolt Fig 13 and adjust maximum engine speed to setting A by rotating the high speed set bolt Tighten lock nut after adjusting 5 Tighten damper spring adjusting bolt to adjust maxi mum engine speed to setting B then tighten locknut to secure adjusting bolt apply Loctite 242 or equivalent to threads of adjusting bolt 5 Install a wire and lead seal on high speed set bolt Adjustments 4 14 Idle Speed Adjustment NOTE Specified engine rpm is with no load on engine 1 The engine should be at operating temperature Make sure the parking brake is engaged 2 Move the throttle control lever to the idle position against the stop plate Open the hood 3 Make sure throttle cable is mounted correctly to allow complete travel of throttle control 4 Loosen the lock nut on the low speed set bolt Fig 13 and adjust idle speed to 1500 rpm by rotating the low speed set bolt Tighten the lock nut a HROTTLE x IDLE SFEES C ABI CABLE Or A wend Men SPEED p SET Bani Mite Damper spring Tie rod cover Lock nut Adjusting boit Sealing cap Figure 14 Groundsmaster 300 Series 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
234. hapter 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 Wing nuts 3 Positive terminal 2 Hold down strap 4 Negative terminal Figure 15 Groundsmaster 322 D 325 D 1 Wing nuts 3 Positive terminal 2 Hold down strap 4 Negative terminal Testing Page 6 22 Groundsmaster 300 Series Fuel Stop Solenoid Groundsmaster 322 D 325 D only Fig 16 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 Solenoid Figure 16 Groundsmaster 300 Series Page 6 23 Testing Fuel Stop Control Unit Groundsmaster 322 D 325 D only Fig 17 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 when the key is turnedto the OFF position after having been in the RUN position and then once again approximately 7 to 15 seconds after the key switch has been turned off The clicking should is made by the
235. hassis Also install the cable into the mount on the frame Repairs Page 13 16 Figure 24 1 L H push arm 5 Capscrews and washers 2 Caster arm 6 Ball joint 3 Ball joint mount 7 Jam nut 4 Chain mount Groundsmaster 300 Series Gearbox Removal and Installation Fig 25 26 Removing Gearbox and Drive Pulley 1 Lower cutting unit to shop floor stop the engine and engage the parking brake Remove belt covers from top of cutting unit 2 Remove shroud Item 9 covering universal drive shaft Disconnect drive shaft from gearbox A DANGER Do not start the engine and engage the P T O when the P T O shaft is not connected to the gearbox If engine is started and the P T O shaft is allowed to rotate serious injury could result 3 Disconnect spring from idler arm bracket to release belt tension Remove cotter pin and clevis pin securing idler arm bracket to idler arm 4 Remove capscrews and nuts securing gear box plate Item 10 to deck channels 5 Remove the set screws Item 19 from the taper lock bushing Item 18 Install one setscrew into the hole that is threaded on the side of taper lock Tighten the set screw until the taper lock is loose from the inside of the pulley hub NOTE Only one setscrew is used to loosen the taper lock 6 Slide the gearbox pulley Item 17 and taper lock off of the gearbox output shaft Account for the woodruff key that positions the pulley on the shaft and remo
236. he crankshaft 4 Install the main bearing caps then tighten the cap bolts to the specified torque Each cap carries an em bossed arrow mark and letter or numeral to indicate its position in the cylinder block When installing the no 1 and no 4 bearing caps apply sealant to the upper surface that meets with the cylinder block Figure 78 Installed direction of main bearing caps 5 With the bolts torqued use a dial indicator on the end of the crankshaft to measure the crankshaft end play If the end play exceeds 0197 inch 0 5 mm replace the No 3 main bearing Figure 79 Measuring crankshaft end play Cylinder Block Overhaul Page 4 60 Groundsmaster 300 Series 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 Insert the oil seal into the crankshaft rear oil seal case Apply a light coat of oil to the oil seal lip and install the seal case to the cylinder block NOTE Use a new gasket 8 Install the rear engine plate if it has been removed 9 Install the flywheel onto the crankshaft using the bolts and special washers Torque the flywheel bolts to 83 90 ft lbs 11 5 12 5 Figure 82 Installing oil seal case Groundsmaster 300 Series Page 4 61 Cylinder Block Overhaul NOTE Before i
237. he following steps to remove the parts A Remove the snap ring from the housing B Slide the pump shaft and bearing out of the housing toward the large open end C Remove the snap ring from the shaft D Press the bearing off of the pump shaft toward the keyed end Groundsmaster 300 Series Page 5 35 Repairs 10 Clean and inspect the following parts A Thrust Plate Check both sides for damage and flatness B Oylinder Block Assembly Check surfaces for wear scratches and scoring Also check the slip pers for damage and make sure the pistons are free in the bores C Ball Bearing Check for free rotation and notice able damage D Pump Shaft Check for scratches scoring damaged splines and burrs near keyway E Control and Trunnion Shafts Check for wear scratches and burrs F Needle Bearings Check needle bearings in the pump housing for free rotation and any noticeable damage G Swash Plate Inspectthe swash plate for damage and any noticeable imperfections NOTE Replace any defective part Remember that the cylinder block assemblies must be replaced as a com plete component not individual parts Interchanging parts between the pump cylinder block assembly and the motor cylinder block assembly will cause the trans mission to malfunction 11 Lubricate the bearing with transmission oil and press the bearing onto the shaft Install the snap ring onto the shaft Then slide the shaft an
238. he left push arm while you remove the cap screws flat washers lock washers and nuts securing ball joint mount to mount bracket on cutting unit Now the helper can carefully allow push arm to move upward which will gradually release the 150 pounds of spring load 7 Roll the cutting unit away from the traction unit Groundsmaster 300 Series Page 11 15 Figure 16 1 R H push arm 5 Flange locknuts 2 Caster arm 6 Jam nut 3 Capscrews amp flatwashers 7 Ball joint 4 Ball joint mount Figure 17 1 L H push arm 5 Caster arm 2 Ball joint 6 Flange locknuts 3 Ball joint mount 7 Jam nuts 4 Capscrews amp locknuts Repairs 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 A 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 push the push arm down Sudden release of the push arm could cause injury 3 Slide a large flat washer 1 2 I D x 1 1 4 in O D onto both cap screws 7 16 14 x 3 in 4 Have a helper carefully push down on right hand push arm until holes in ball joint mount line up with holes in caster arm Secure ball joint mount to caster arm with two cap screws w large flat washers one flat washer 15 32 I D x 59 64 in O D two lock washers
239. he push arm bracket 6 Remove the cotter pin from the end of the parking brake rod Slide the rod out of the latch PARKING BRAKE R D m Figure 24 Repairs Page 11 18 Groundsmaster 300 Series 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 PUSH ARM AND SPRING LOAD FULLY RELEASED 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 Slowly and carefully allow the push arm to move upward until all spring load is released 9 Remove the cap screws locknuts support plate and push arm bracket holding the left side of the push arm and pivot shaft to the main frame 10 Remove the cap screws locknuts reinforcement and push arm bracket holding the right side of the push dif arm and pivot shaft to the main frame The entire push MOUNT AND arm and pivot shaft assembly should now be free of the te i main frame 11 Drive the roll pins out of the pivot shaft and slide the push arm assemblies off of the shaft 12 Drive the pushing out of both push arm pivot tubes 5 Clean the inside of the pivot tubes to remove all dirt and SUPPORT other material THRUST WASHER BUSHING THRUST LEFT PUSH WASHER ARM Figure 27 Groundsmaster 300 Series Page 11 19 Repairs Installing Push Arms Torsio
240. he second against it ISN 2 VIEW RPE D D 2227 4 Apply a film of grease on lips of both seals then install bearing and seal into bottom of spindle housing Re member the BOTTOM SEAL MUST HAVE THELIP FACING OUTWARD not toward the inside of the spindle housing Figure 31 5 Check the spindle shaft to make sure it is free of burrs and nicks that could possibly cut the seals and thor oughly lubricate both the shaft and seal lips 6 Slide small thick spacer into spindle housing then install bearing and seal into top of spindle housing LIP OF UPPER SEAL MUST FACE INWARD 7 Slide bearing spacer onto spindle shaft Carefully slide spindle shaft through spindle housing The bottom seal and bearing spacer fit together when the spindle is installed 8 Push pulley onto splines of spindle shaft and retain the parts together with the large flat washer and nut Tighten the nut to 100 120 ft lb and rotate the spindle shaft to be sure that the shaft rotates freely 9 Slide pulley end of spindle assembly through hole in cutting unit Mount the spindle assembly in place with the carriage bolts and flange nuts 10 Install the belt and adjust belt tension 11 Reinstall the belt covers Groundsmaster 300 Series Page 13 23 Repairs This page is blank This page is blank TORO Commercial Products The Toro Company
241. he steering pivot Fig 16 Item 38 must fit snugly onto the mounting pin Excessive movement of the steering pivot may indicate worn bushings or tie rod ball joints 1 Remove the lock nut Item 37 and cap screw Item 11 securing the steering cylinder rod end to the steering pivot Fig 16 2 Remove two 2 nuts Item 43 to disconnect the tie rod end Item 39 from the spindle arm Item 1 33 Inspect all tie rod end ball joints for wear or damage and replace as necessary 3 Remove the retaining ring Item 12 washer Item 17 and thrust washer Item 18 Slide the steering pivot off of the mounting pin on the bottom of the axle Repairs Page 8 12 5 Use a drift punch and hammer to drive both bushings Item 4 out of the axle pivot tube Clean the inside of the axle pivot tube to remove dirt and foreign material 6 Apply grease to the inside and outside of the new bushing Use an arbor press to install the bushings into the top and bottom of the axle pivot tube Bushings must be flush with the axle tube 7 Wipe the rear axle pin with a rag to remove dirt and grease Inspect the pin for wear or damage and replace as necessary 8 Mount the axle to the frame with the axle pin The washer s Item 45 must be positioned between the front end of the pivot tube and the frame see the NOTE after step 4 Secure the axle pin in place with the two 2 cap screws Item 2 Install the washer Item 8 and nut Item 9
242. he unit has two different length spring sets The set you have just removed from the port manifold are 3 4 in 19 mm long Keep this set of three springs separate from the next set of three springs to be re moved 9 Inspect the springs for bent or distorted coils If a spring is broken or deformed all six springs in the unit should be replaced 10 Inspectthe ground surfaces of the port manifold You should notice a normal polished pattern due to the rotation of the valve plate and hex drive assembly All edges should be sharp and free of nicks and burrs The surfaces ofthe port manifold should be free of scratches or scoring NOTE Scoring is indicated by fine scratches or grooves If these scratches can be detected by feel finger nail or lead pencil the manifold should be re placed IMPORTANT Many components in the unit have finely ground surfaces Be careful not nick or scratch these surfaces Repairs Page 8 24 Figure 29 Figure 31 Groundsmaster 300 Series 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 33 12 Remove the valve plate by lifting it from the isolation manifold Fig 34 13 Inspect the slot edges and ground surfaces If the valve plate shows nicks or scoring or the edges are not sharp it must be replaced NOTE The valve ring and valve plate are a matched set and must be repl
243. heck the continuity of the switch by connecting a multimeter ohms setting across the switch connector terminals 4 With no pressure on the seat cushion there should be no continuity between the switch terminals 5 Press directly onto the seat switch through the seat cushion There should be continuity as the seat cushion approaches the bottom of its travel 6 Connect machine wire harness connector to seat Figure 3 Switch 1 Seat 4 Seat switch 2 Seat plate 5 Switch harness If switch removal is necessary remove seat with sliders 3 Screw 2 used from seat plate Remove switch from bottom of seat High Temperature Override Switch The high temperature override switch is located on the control console The switch terminals are marked as shown in Figure 4 The circuitry of the switch is shown in the chart below With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each position Verify continuity between switch terminals BACK OF SWITCH SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS o 23 5 Figure 4 ON Electrical System Rev G Page 6A 4 Groundsmaster 300 Series Start Enable Run Enable Over Temperature and Seat Delay GM 328 D Relays Three 8 relays start enable run enable and over tem perature are used on the Groundsmaster 328 D and Groundsmaster 345 to control engine o
244. heck the surfaces for wear scratches and scoring Also check the slip pers for damage and make sure the pistons are free in the bores of the cylinder block D Ball Bearing Check for free rotation and any noticeable damage E Motor Shaft Check for scratches scoring or damaged splines NOTE Replace any defective part Remember that the cylinder block assemblies must be replaced as a com plete component not individual parts Do not inter change parts between the motor cylinder block assembly and the pump cylinder block assembly be cause the transmission will not operate at its optimum capacity 6 Lubricate the bearing with transmission oil Press the bearing onto the motor shaft Slide the motor shaft and bearing into the motor housing from the flange side Install the snap ring into the groove at the flange end of the motor housing Repairs Page 5 38 NOTE Make sure the splines at the end of the motor shaft are toward the flange side of the motor housing 7 Lubricate the thrust plate with transmission oil Slide the thrust plate onto the motor shaft and into the counterbore of the motor housing 8 Lubricate the motor cylinder block parts with trans mission oil Assemble the cylinder block parts and slide the cylinder block assembly onto the motor shaft The cylinder block must slide onto the splines near the center of the shaft NOTE Assure that the thrust plate remains seated in the counterbore and that
245. hes and contacts Toro P N 505 47 8 oz 24 L can Inductive Ammeter AC DC Current Transducer Hall Effect Use this tool connected to a Digital multimeter for doing current draw tests This tool can be useful when check ing glow plug and starter circuits Obtain the Inductive Ammeter from a local supplier Electrical System Rev G 6A 2 Figure 1 Figure 2 Groundsmaster 300 Series Electrical System Quick Checks Battery Test Open Circuit Test Use a multimeter to measure the voltage between the battery terminals Set the multimeter to the DC volts setting The battery should be at a temperature of 60 to 1009 F 16 to 389 C The ignition key should be in the OFF position and all accessories turned off Connect the positive me ter lead to the positive battery post and the negative meter lead to the negative battery post Use the table to the right to determine charge level of the battery Note This test provides a relative condition of the bat tery Load testing of the battery will provide additional and more accurate information Charging System Test This is a simple test used to determine if the charging system is functioning It will tell you if the charging sys tem has an output but not its capacity Use a multimeter set to the DC volts position Connect the positive meter lead to the positive battery post and the negative meter lead to the negative battery po
246. his chapter A 0 1 mm shim will cause a 10 kg cm 140 psi starting pressure difference 7 Repeat the test after installing shim to verify that a correct starting pressure has been obtained Chattering Test Proper and free operation of the nozzle valve can be determined by the chattering test 1 Securely fasten the nozzle to be tested to the adapter 2 Operate the pump handle slowly ten strokes per minute As the pump pressure reaches the starting pressure the nozzle valve will chatter as it opens and closes rapidly A nozzle which does not chatter may be the result of a binding or bent nozzle valve Nozzle Leakage Test A nozzle that leaks fuel from the nozzle orifice must be replaced 1 Securely fasten the nozzle to the adapter 2 Wipe all fuel from the nozzle 3 Operate the pump until the pressure is approximately 108 kg cm 1500 psi Maintain this pressure to the nozzle 4 Watch for leaks where the threaded nozzle body threads into the retaining nut Leaks in this area would indicate a bad seat between the distance piece and or the body or nozzle assembly 5 If leakage occurs verify that the body is tightly fas tened in the retaining nut If the leak continues replace the nozzle Groundsmaster 300 Series 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 woul
247. ht side axle support half 13 Coat a new o ring with grease and install left side axle support half Tighten axle support case screws from 35 to 41 ft lb 47 to 56 14 Install input shaft pinion gear assembly see Input Shaft Pinion Gear in this section of this manual 15 Coat new o rings with grease align differential shaft splines with differential gear assembly and slide differ ential shaft assemblies onto axle support see Differen tial Shafts in this section of this manual 16 Install bevel gear case axle case assemblies see Bevel Gear Case Axle Case Assembly in this section of this manual Groundsmaster 328 D Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using the gear contact pattern method as described in the fol PROFILE TOP LAND lowing procedure RM GEAR TOOTH DEFINITIONS Fig 29 Toe the portion of the tooth surface at the end to wards the center LENGTHWISE Heel the portion of the gear tooth at the outer end HEEL T Top Land top surface of tooth xL T T EE 1 Paint the teeth of the ring gear both drive and coast side with a gear marking compound such as DyKem Steel Blue Figure 29 2 Install the input shaft pinion gear assembly into axle case More than 35 total tooth contact 3 While applying a light load to the ring gear rotate the pinion gear in the direction of forward travel until the ring gear has made one
248. ide pin Rotate the guide pin to lock its edge under the lip on the pump housing and lock the pin by bending the plate tab 9 Torque the Delivery Valve Holder to 28 9 36 2 ft lb 4 5 KgM Ensure that the control rack slides smoothly with little resistance Sliding force should be 1 75 oz 50 g or less If the rack binds it is assembled incorrectly or parts are dirty and it must be reassembled or cleaned 10 Repeat the procedure for the other remaining cylin ders 11 Install the injection pump to the cylinder block Make certain that the same number and size shims that were under the pump when removed are replaced correctly 12 Connect the Tie Rod and Tie Rod Retaining Spring to the Control Rack 13 Push the control rack to the high speed position left and reinstall the tie rod cover using a new cover gasket 14 Reassemble the fuel return line and delivery pipes 15 Bleedthe air fromthe fuel system Referto Bleeding Air From Fuel System Groundsmaster 300 Series Page 4 43 Figure 50 E ring Ungleich set spring Ungleich set plate Pump housing E ring Return spring Smoke set plate Air breather screw Washer 10 Hollow screw 11 Pump element ass y 12 Delivery valve ass y 13 Gasket WONOAPON gt 14 Delivery valve spring O ring Delivery valve holder Bolt washer Adjusting plate Tappet guide pin Plate Control rack Plunger control sleeve Upper sprin
249. ide 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 SHIM PACK NOTE Count the shims when they are removed The same number of shims must be installed when assem bling the parts Do not interchange charge relief shims with implement relief shims CHARGE RELIEF 3 Remove the O ring from the plug 4 Inspect the plug and pump housing for stripped Figure 19 threads Replace any part that is damaged Also check the seat inside the pump housing for damage and foreign material 5 Check the spring for damage and correct specifica tions Replace the spring if is condition is doubtful Spring specifications are listed in the table below Charge Relief Spring Specifications Free Length eer 1 051 in Number of Coils 14 Outside Diameter 0 249 0 251 in Pounds per Inch 13 8 6 To install the charge relief valve slide a new O ring onto the charge relief plug 7 In sequence insert the check ball or cone spring and shim pack into the pump housing Install the plug to retain the parts in place 8 Since some oil drained out of the transmission when the charge relief valve was removed check the oil level in the axle housing Start the engine and let it run for about one or two minutes Then turn the engine off and check the oil level in axle housing again Also i
250. in through caster spindle to retain all parts in place Groundsmaster 300 Series Page 11 11 Repairs 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 wobbly caster wheel usually indicates a worn bearing 1 Remove capscrew and locknut holding caster wheel and 2 washers between caster fork 2 Pull spanner bushing out of wheel hub 3 Remove bushing from wheel hub and allow bearing to fall out Remove bushing from opposite side of wheel hub 4 Check the bearing spanner and inside of wheel hub Figure 12 for wear Replace defective parts 5 To assemble the caster wheel push bushing into wheel hub Slide bearing into wheel hub Push other bushing into open end of wheel hub to captivate the bearing inside the wheel hub 6 Carefully slide spanner through the bushings and wheel hub 7 Install caster wheel assembly and 2 washers be tween caster fork and secure all parts in place with capscrew and locknut 8 Lubricate caster wheel bearing through grease fitting using No 2 general purpose lithium grease Repairs Page 11 12 Groundsmaster 300 Series Front Caster Wheel Bearing Service Fig 13 The front caster wheels rotate on hig
251. in 0 004 in 0 1 mm 0 008 in 0 2 mm and 0 020 in 0 5 mm thickness Groundsmaster 328 D Page 10 1 9 57 to 67 ft lbs 77 to 91 Nm VERTICAL ENDPLAY Figure 10 4 Dial indicator 5 Knuckle pin 6 Support shim location 1 Axle case support 2 Axle case 3 Bevel gearcase Figure 11 4 Dial indicator 5 Axle bearing shims 1 Axle support 2 Upper bevel gear 3 Differential shaft gear Figure 12 4 Dial indicator 5 Axle bearing shims 1 Axle cover assembly 2 Lower bevel gear 3 Axle gear 4WD Rear Axle Rev G Dae Dong Axle 9 Remove the bevel gear case axle case assembly from the axle support Coat a new O ring with grease and temporarily install the axle cover assembly Position a dial indicator at the tooths center Prevent the axle from turning and measure the lower bevel gear to axle gear backlash Fig 12 LOWER BEVEL GEAR BACKLASH 0 004 to 0 016 in 0 10 to 0 40 mm 10 Adjust backlash by increasing or reducing axle bear ing shim thickness see Axle Shafts in this section of this manual Differential Shafts The following procedures assume the rear axle assem bly has been removed from the machine Removal IMPORTANT Do not interchange right and left dif ferential shafts assemblies 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 13 2 Mark and pull the diff
252. ing Rods and Bearings Cylinders Oversized Pistons Cylinder Bore and Rings Piston and Pin Replacement Cylinder Block Disassembly NOTE It is assumed that the engine has been removed from the mower placed on an engine stand and the cylinder head removed 1 Place a drain pan under the engine Remove the oil pan drain plug and drain the oil from the engine Re move the oil filter from the oil pump body Discard the oil filter Dispose of the oil in the proper manner 2 Remove the water pump 3 Remove the fuel injection pump from the cylinder block body and the fuel filter NOTE It is necessary to remove the tie rod cover the control rod and retaining spring from the control rack before removing the injection pump 4 Lift the push rods out of the cylinder block 5 Remove the valve lifters from their positions in the cylinder block 6 Remove the speedometer drive assembly from the left hand side of the engine by removing the cap screw and clamp and pulling the gear out 7 Turn the engine upside down on the stand and remove the oil drain pan and filter screen spring like screen Groundsmaster 300 Series Page 4 53 8 Remove the crankshaft pulley nut washer lock washer and key 9 Remove the gear case from the front of the motor NOTE The front plate is retained to the cylinder block by bolts that are underneath the cover Do not attempt to remove the plate without first removing the gear case
253. ing from the plug 4 Inspect the plug and the pump housing for stripped Figure 18 threads Replace any part that is damaged Also check the seat inside the pump housing for damage and foreign material 5 Inspect the relief valve cone for noticeable damage If cone is damaged replace it 6 Check the spring for damage and correct specifica tions Replace the spring if its condition is doubtful Spring specifications are listed in the table below Implement Relief Spring Specifications Free Length 0 804 in Number of Coils 10 Outside Diameter 0 260 0 262 in Pounds per Inch 339 7 To install the implement relief valve slide the new O ring onto the implement relief plug 8 In sequence install the cone spring and shim pack into the pump housing Install the plug to retain the parts in place 9 Since some oil drained out of the transmission when the implement relief valve was removed check the oil level in the axle housing Start the engine and let it run for about one or two minutes Then turn the engine off and check the oil level in the axle housing again Also inspect implement relief plug area for oil leaks Groundsmaster 300 Series Page 5 29 Repairs 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 s
254. ining ring Personal injury could result from flying metal particles Keep all personnel away during this procedure Figure 11 8 Inspect the shaft for possible damage Fig 12 Inspect the sealing surface of the hub and shaft Re place it if the seal has grooved the surface more that 1 64 inch 0 4 mm 9 Put a new grease seal brake assembly and a new grease packed bearing in that order onto the axle shaft Figure 12 10 Press the assembly until the bearing is firmly seated against the axle shaft shoulder Fig 13 Figure 13 Repairs Page 7 6 Groundsmaster 300 Series 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 Puta light coating of No 1 Permatex on the outside diameter of a new grease seal surface that contacts the axle housing Install the new seal to a depth of 1 218 in into the housing Fig 15 16 After the seal has been assembled put grease on the lip of the seal Figure 15 1 218 seal installation depth Figure 16 Groundsmaster 300 Series Page 7 7 Repairs 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 h
255. inion gear Press the pinion and side gear against the differen tial case and measure the pinion gear to side gear back lash Fig 27 PINION GEAR TO SIDE GEAR BACKLASH 0 004 to 0 016 in 0 10 to 0 40 mm 6 Adjust backlash by increasing or reducing side gear shim thickness NOTE Side gear shims are available in 0 043 in 1 10 mm 0 047 in 1 20 mm and 0 051 in 1 30 mm thick ness 7 Apply gear marking compound such as DyKem Steel Blue lightly over several gear teeth 8 While applying a light load to either side gear rotate either pinion gear until the side gears have made one complete revolution 9 Ideal tooth contact should cover more than 35 of each tooth surface The contact area should be in the center of each tooth and extend 1 3 to 1 2 way across each tooth from the toe small end Fig 28 10 Adjust side gear shims if necessary to correct tooth contact Recheck differential pinion gear to side gear backlash if any changes are made 11 After backlash and tooth contact have been ad justed align the hole in the differential pinion shaft with the hole in the differential case and install a new spring pin 4WD Rear Axle Rev G Dae Dong Axle Page 10 1 16 Figure 27 1 Vise 3 Dial indicator 2 Differential gear case More than 35 total tooth contact SS 72 1 8 to 1 2 of entire width from small end of tooth Figure 28 12 Install differential gear assembly in rig
256. injection pump to noz zles 4 Remove the rocker cover and breather tube 5 Loosen the two bolts and the cap screw which retain the rocker shaft assembly and remove the rocker shaft 6 Remove the push rods Place each push rod into a marked holder so that it can be replaced in the original position 7 Loosen and remove the cylinder head bolts in the sequence shown Lift the cylinder head from the cylinder block It may be necessary to tap the cylinder head with a wooden mallet to break the seal of the head gasket Place the cylinder head on a flat clean surface 9 Remove the thermostat housing and the thermostat 10 Remove the glow plug lead wires and glow plugs 11 Remove the nozzle holder bolts and nozzles 12 Remove the used cylinder head gasket Use a scraper to remove all traces of gasket material Pay particular attention not to damage or scratch the cylinder head or cylinder block surface Groundsmaster 300 Series Page 4 47 CYLINDER HEAD BOLT LOOSENING SEQUENCE FRONT RR Figure 53 Cylinder Head Overhaul 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 Remove the valves and place them in position in the rack Examine each valve for indications of burning pitting heavy carbon deposits
257. ission 4 Connect the inlet hose of the tester to the fitting on the transmission Connect the tester outlet hose to the hose that was disconnected in step 3 IMPORTANT Make sure that the oil flow indicator arrow on the flow gauge is showing that the oil will flow through the tester from the pump to the steer ing valve 5 Make sure that the tester load valve is fully open counterclockwise Start the engine and allow it to run for approximately 5 minutes so that the hydraulic oil reaches normal operating temperature 6 Increase the engine speed to the FULL throttle setting and use a tachometer to verify that the engine is running at 3200 50 rpm 7 While watching the flow and pressure gauges slowly close the flow control valve load valve until the flow gauge reads 1 0 GPM 8 If the pressure is below 700 psi or 1 0 GPM could not be achieved adjust the implement relief valve by adding the required amount of shims from the shim pack A CAUTION The implement relief pressure must not ex ceed 800 psi Testing Page 5 22 If adding shims to the relief valve does not increase the pressure inspect the condition of the charge pump gerotor and internal housing If the charge pump is in good condition no scoring scratches or excessive wear the general condition of the transmission s piston pump and piston motor might be suspected of wear and inefficiency A lack of sufficient implement pressure could be d
258. it and set shield aside 4 Drive roll pin out of yoke and input shaft of gear case Loosen capscrews and nuts securing yoke to shaft Slide yoke off the input shaft If traction unit will be used without the cutting unit drive roll pin out of yoke at PTO pivot shaft and remove entire universal shaft from trac tion unit A DANGER Do not start the engine and engage the PTO lever when PTO shaft is not connected to gear case on cutting unit If engine is started and PTO shaft is allowed to rotate serious injury could result 5 Disconnect spring from lift cylinder cotter pin Re move cotter pins and clevis pins securing lift chains to lift arm A WARNING Since the right hand push arm is spring loaded to approximately 100 pounds and left hand push arm is spring loaded to approxi mately 150 pounds another person is needed to help release push arms from cutting unit Sudden release of the push arm could cause injury Repairs Page 12 20 6 Have another person help push down on the right push arm while you remove the capscrews flat washers and nuts securing ball joint mount to caster arm on cutting unit Now the person helping can carefully allow push arm to move upward which gradually releases the 100 pounds of spring load 7 Have another person help push down on the left push arm while you remove the capscrews flat washers and nuts securing ball joint mount to carrier frame on cutting unit Now the person hel
259. ition to prevent fuel delivery during compression test This will prevent wash down of cylinders and inaccurate readings 5 Crank the engine with the starter motor until you get a stable gauge reading 6 If the pressure is less than 26 kg cm 370 psi it will be necessary to find the cause of low compression See Engine Fails to Start Low Compression in the Trou bleshooting section of this chapter 7 Repeat the test for the other two cylinders Difference between cylinders should be no more than 2 5 kg cm 36 psi Groundsmaster 300 Series Page 4 19 Figure 17 Testing Nozzle Tests Fig 18 19 There are several tests to examine the condition of the injection nozzles These tests require the use of a nozzle tester and nozzle tester adapter See the Spe cial Tools section of this chapter A The nozzle tester forces fuel from the nozzle under extremely high pressure Always point the nozzle tip away from yourself and any other personnel Contact with the fuel stream even though it appears to be a mist can cause fuel to penetrate clothing and skin If fuel is injected into the skin get proper medical at tention from a doctor immediately A serious infection or other reaction can develop if the injury is not properly treated Tighten all adapter fittings to prevent leaks If a leak is suspected use a piece of cardboard not your hands to search for a leak A To prevent possible injury wear eye prote
260. itry from the ignition Switch to the glow controller and perform Step 4 again see Groundsmaster 328 D electrical schematic in Chapter 6 Electrical System Groundsmaster 300 Series 6A 9 5 If any of the conditions in Step 3 are not met or power to terminal 1 exists and any of the other conditions in Step 4 are not met A Verify continuity of the circuitry from the battery to the glow relay and glow plugs see Groundsmaster 328 D electrical schematic in Chapter 6 Electrical System B Verify continuity of the circuitry from the battery to ignition switch glow controller glow lamp glow relay and ground see Groundsmaster 328 D electrical schematic in Chapter 6 Electrical System C Replace parts as necessary 6 Connect electrical connector to the fuel stop sole noid LI 7 om Oo oe 5 o Ce o o s 2 Figure 11 1 Glow controller end view 3 Side view 2 Top view Electrical System Rev G Run Solenoid Groundsmaster 328 D Solenoid With 3 Wire Connector The run ETR solenoid must be energized for the en gine to run The solenoid is mounted on the engine block near the injection pump In Place Testing Note Prior to taking small resistance readings with a digital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal
261. k Item 27 small end first into pulley hub 3 Insert woodruff key Item 24 into keyway in gear case shaft Slide pulley with taper lock onto gear case shaft while aligning key and keyway NOTE Large hub on pulley must face away from gear case and like the taper lock the pulley must contact the shoulder on the gear case shaft 4 Rotate pulley to get non threaded holes in taper lock toline up with the two threaded holes in hub of gear case pulley Start threading setscrews Item 28 into the two holes and tighten setscrews alternately and evenly until both setscrews are tight 5 Using a brass drift pin or a sleeve and hammer hit taper lock firmly Now tighten setscrews to 55 in lb Continue to hit taper lock and tighten set screws until 55 in Ib of torque will not turn the setscrews 6 Check alignment of gear case with a spindle pulley Loosen and relocate taper lock to adjust if necessary 7 Fill recessed socket head in each setscrew and the other taper lock holes with grease to prevent dirt from packing into the holes 8 Mount gear case with brackets onto top of gear case mount plate Item 22 with carriage bolts and flange nuts 9 Mount gear case mount plate to cutting unit with carriage bolts and flange nuts 10 Install drive belt onto gear case pulley and adjust belt tension 11 Install belt covers 12 Install drive shaft to gear box and secure with a new roll pin 13 Remove gear case fill p
262. k washer and nuts Route the right hand brake cable through the hole in the right hand push arm bracket Connect the cable to the brake strut with the clevis pin and the tension spring Hook the opposite end of the tension spring into the hole in the side of the chassis Also install the cable into the mount on the frame Repairs Page 11 20 Groundsmaster 300 Series 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 A DANGER Do not start the engine and engage the P T O when the P T O shaft is not connected to the gearbox If engine is started and the P T O shaft is allowed to rotate serious injury could result 3 Loosen idler pulleys for cutting unit drive belts and Figure 29 remove belts from gearbox pulley 9 1 Isolation mounts 6 Pulley assembly 4 Disassemble fasteners securing gearbox to cutting 2 Brackets 7 Metal straps unit and remove gearbox 3 Capscrews amp lockwashers 8 Carriage bolts 4 Gear box 9 Flatwashers amp nuts 5 Remove the set screws from the taper lock bushing 5 Woodruff key 10 Taper lock Install one setscrew into the hole that is threaded on the side of taper lock Tighten the setscrew until the taper lock is loose from the inside of the pulley
263. kwise tester with pressure and flow capabilities 6 Install fittings finger tight far enough to insure that they are not cross threaded before tightening with a wrench 7 Position the tester hoses so that rotating machine parts will not make contact with them and result in hose or tester damage 8 Check the oil level in the reservoir 9 Check the control linkage for improper adjustment binding or broken parts 10 All hydraulic tests should be made with the hydraulic oil at normal operating temperature Groundsmaster 300 Series TEST NO 1 Charge Pressure Fig 9 Using a low pressure gauge 0 1000 psi 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 Raise and support the seat 3 Place a drain pan under the transmission Use a 3 16 inch Allen wrench to remove the 1 8 inch pipe plug located next the implement pressure port on top of the transmission 4 Connect the 0 1000 psi hydraulic gauge hose into the 1 8 inch pipe opening 5 Start the engine and move the throttle to SLOW so that the engine idles Use a tachometer to verify that the engine is running at 1500 50 rpm The engine must idle at this speed to provide sufficent charge pump flow and pressure to lubricate the internal parts of the trans mission 6 Allow the engine to run for approximately 5 minutes so that the hydraulic
264. l 9 Needle bearing 15 Bearing 4 Snapring 10 Thrust washer 16 Snap ring 5 Bearing 11 Wave spring 17 Retaining ring 6 Housing 12 Roller cage assembly 18 Oil seal Disassembly Fig 35 1 Thoroughly clean exterior of clutch before disassem bly 2 Disassemble clutch using Figure 35 as a guide Assembly Fig 35 1 Lightly lubricate clutch components with clean Mobil Fluid 424 before assembly 2 Assemble clutch using Figure 35 as a guide 4WD Rear Axle Rev G Dae Dong Axle Page 10 1 20 3 When installing oil seals make sure that seal lips are facing in 4 Apply Hylomar Jointing Compound or equivalent to end plate item 1 mating surface before installing end plate 5 Secure end plate with six 6 socket head cap screws Torque screws 14 ft lb 19 Groundsmaster 328 D Chapter 11 72 Cutting Units Table of Contents SPECIFICATIONS GENERAL INFORMATION Grass Deflector esr b Rd ix ADJUSTMENTS Height of Cut Adjustment Mismatch Adjustments Belt Tension Adjustment REPAIRS Blade Service Belt Groundsmaster 300 Series Page 11 1 Caster Arm Bushing Replacement 11 Rear Caster Wheel Bearing Service
265. lame and electrical spark away from the battery Do not smoke Nausea may result if the gases are in haled Unplug the charger from the elec trical outlet before connecting or discon necting the charger leads from the battery posts 3 Following the manufacturer s battery charger instructions connect the charger cables to the battery Make sure a good connection is made 4 Charge the battery following the manufacturer s battery charger instructions 5 Occasionally check the temperature of the battery electrolyte If the temperature exceeds 125 F 51 6 C or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 6 Three hours prior to the end of the charging mea sure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 003 change in specific gravity for three consecutive readings Groundsmaster 300 Series Table of Contents INTRODUCTION 1 TORQUE SPECIFICATIONS 2 REPAIRS eeu utaz existat lod sated 3 Axle Removal and Installation 3 Introduction Groundsmaster 300 Series traction units are equipped with a Dana Hydrostatic Axle model GT 20 The differ ential and axle form the final drive of the power train Fig 1A The differential has a heavy duty case with automotive type cut gea
266. lation manifold Fig 98 IMPORTANT Be sure the seal ring is seated cor rectly after the valve ring is assembled 36 Put the hex drive assembly pin side up through the hole in the isolation manifold Fig 99 the slot in the hex drive must be engaged with the SMALL tang of the drive link Turn the input shaft to assist the engagement NOTE If the hex drive does not readily assemble on the drive link the drive link was assembled incorrectly See step 22 of this procedure Groundsmaster 300 Series Page 8 47 Figure 97 Figure 98 Figure 99 Repairs 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 Put the valve plate with the surface that reads shaft side down over the hex drive assembly Align the three spring slots centrally over the three springs installed in the spring recesses of the isolation manifold The valve plate spring slot with the small cavity and the words port side centrally below it Fig 100 must be placed over the spring and spring recess in the isolation manifold at the top 12 o clock position as shown Fig 100 and 101 Adjust the valve plate position radially to centralize the spring slots over the springs and the spring
267. le case Install mounting screws into axle case Slowly tighten screws while frequently checking for clear ance vertical endplay between axle case support and knuckle pin If binding of components is noted before screws are fully tightened add additional sup port shims Torque screws from 57 to 67 ft lbs 77 to 91 Nm C Use dial indicator to measure vertical endplay of axle case Fig 10 AXLE CASE ASSEMBLY ENDPLAY 0 001 to 0 008 in 0 02 to 0 20 mm D Adjust endplay by increasing or reducing number of axle case support shims NOTE Axle case support shims are available in 0 004 in 0 1 mm 0 008 in 0 2 mm and 0 016 in 0 4 mm thickness 6 After correct support shims have been determined remove mounting screws apply heavy strength Loctite thread locker to screw threads reinstall screws and torque from 57 to 67 ft lbs 77 to 91 Nm IMPORTANT Correct engagement between bevel gears is critical to axle performance and durability 7 Temporarily install the bevel gear case axle case as sembly on the axle support Position a dial indicator at the tooths center Prevent the axle from turning and measure the upper bevel gear to differential shaft gear backlash Fig 11 UPPER BEVEL GEAR BACKLASH 0 004 to 0 016 in 0 10 to 0 40 mm 8 Adjust backlash by increasing or reducing axle bear ing shim thickness see Differential Shafts in this section of this manual NOTE Axle bearing shims are available
268. ll out of the housing because damage may result NOTE The motor valve plate will probably adhere to the side of the center section Do not let it fall when separat ing the motor housing from the center section 4 Remove the motor valve plate and gasket 5 Set the motor housing and motor valve plate aside Keep the motor valve plate separate from the pump valve plate because these parts are not interchangeable Repairs Page 5 34 6 Pull the pump housing away from the center section Do not let the internal parts fall out of the housing because damage may result NOTE The pump valve plate will probably adhere to the side of the center section Do not let it fall when separat ing the pump housing from the center section 7 Remove the pump valve plate and gasket 8 Set the pump housing and pump valve plate aside Keep the pump valve plate separate from the motor valve plate because these parts are not interchangeable CAP SCREWS GASKET BEARING PUMP HOUSING CENTER SECTION ory AND PUMP VALVE PLATE Figure 23 Groundsmaster 300 Series Transmission Pump Section Fig 24 25 26 27 1 Separate the pump housing from the center section refer to Separating Transmission Into Sections 1 THRUST 2 Lift the cylinder block assembly out of the pump housing Do not be concerned if the pistons come out ofthe cylinder block because they do not have a special order in the cylinder block NOTE Si
269. lley Figure 5 approximately 1 4 onto crankshaft 1 Woodruff key 4 Special washer 3 Insert fourth locking ring taper to taper with third ring 2 Pulley 5 Metric bolt 3 Locking rings 4 Insert bolt through special washer Shoulder on washer contacts shoulder of fourth locking ring 5 Draw pulley onto crankshaft by tightening crankshaft bolt Resistance will be felt as crankshaft passes through locking rings 6 Tighten crankshaft bolt to a torque of 40 44 ft lb Check pulley alignment between crankshaft and water pump Repairs Page 3 6 Groundsmaster 300 Series Engine Removal and Installation Removing the Engine 1 Put machine on a level surface stop engine remove key from ignition switch and engage parking brake 2 Remove intake hose from air cleaner and carburetor 3 Remove transmission drive coupling see Chapter 10 Transmission Coupler and PTO 4 Remove PTO belt see Chapter 10 Transmission Coupler and PTO 5 Disconnect battery cables from battery terminals 6 Disconnect and tag all wires connected to engine and engine accessories 7 Put a drain pan under radiator loosen radiator cap loosen radiator petcock and allow radiator to drain com pletely 8 Move drain pan under lower radiator hose Discon nect hose from radiator and allow coolant to drain into pan Remove lower and upper radiator hoses 9 Move drain pan under rear of engine and remove cylinder block plug located above star
270. lleys and through idler pulley assembly 6 Install gear box plate on deck channels while routing belt around gear box pulley Mount gear box plate to deck channels with capscrews and nuts 7 Install idler arm bracket to idler arm with cotter pin and clevis pin Hook spring onto idler arm bracket To make sure there is proper belt tension on drive belt spring should be extended to a length of approximately 7 00 inches If spring is not extended to this length move spring rod to other mounting holes further away from belt 8 Install belt covers Groundsmaster 300 Series Page 13 9 Figure 9 1 Spring 2 Idler arm 3 Idler arm bracket Figure 10 1 Gear box plate 2 Capscrews and nuts BELT ROUTING Figure 11 Repairs 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 If caster spindle is loose inside the bushings bushings are worn and must be replaced 1 Raise cutting unit and block it so it cannot fall acci dentally 2 Remove lynch pin and spacers from top of caster spindle 3 Pull caster spindle out of mounting tube Allow spacer s and thrust washer to remain on bottom of Figure 12 spindle to assure same height of cut when caster spin dle is reinstalled 4 Insert pin punch into top
271. ls 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 7 Used to take various hydraulic pressure readings for diagnostic tests Low pressure gauge 0 1000 psi high pressure gauge 0 5000 psi and associated hoses and fittings Figure 7 Special Tools Page 5 10 Groundsmaster 300 Series Hydraulic Tester With Pressure and Flow Capabilities Fig 8 9 Gauge Protector Vaive Low Pressure Gauge T Inlet Hose 2 Load Valve Figure 8 You must have o ring face seal ORFS adapter fittings for this tester to use it on current models of the Groundsmaster 300 Series 1 INLET HOSE Hose connected from the system circuit to the inlet side of the hydraulic tester 2 LOAD VALVE If required upon turning the valve to restrict flow a simulated working load is created in the circuit 3 LOW PRESSURE GAUGE Low range gauge to provide accurate reading at low pressure 0 1000 psi This gauge has a protector valve which cuts out when pressure is about to exceed the normal range for the gauge The cutout pressure is adjustable Groundsmaster 300 Series Page 5 11 4 HIGH PRESSURE GAUGE High range gauge to accommodate pressure beyond the capacity of the low pressure gauge 0 5000 5 FLOW METER This met
272. lug and check plug Add SAE 80W90 API GL 5 gear lube until level is to the bottom of check plug hole Install plugs in gear case Figure 42 Groundsmaster 300 Series Page 12 27 Repairs Gear Case Repair Fig 43 44 Figure 43 Gear Case Disassembly 1 Drain lubricant from gear case 2 Remove capscrews and lift out shaft and cap assemblies 3 Remove cap assemblies and bearing cones Item 12 from shafts Item 17 19 NOTE Mark each gear Item 10 and 18 so they are installed on the proper shaft Item 17 or 19 when re assembled 4 Remove retaining rings Item 7 5 Press shafts Item 17 19 back through bearing cones Item 9 When bearing cone is free gears Item 10 18 keys Item 8 and shims Item 11 may be removed from the shaft Repairs Page 12 28 6 Remove bearing cups Item 14 from cap by putting a punch through the shaft bore and through the seal and then tapping against the back of the bearing cup until driven out of the cap 7 If the oil seal Item 13 is removed it will be destroyed To remove the oil seal cut it out of the bore with a screw driver or chisel 8 To remove the bearing cups Item 3 from the housing a slide hammer puller may be used or if this is not available the bearing cups may be knocked out with a punch by coming down through the opposite cap bore and tapping against the back side of the bearing cup until it comes out 9 Remove the plugs Item 2
273. lve Head Dia EX Overall Length Valve Stem O D Stem to Guide Clearance IN Stem to Guide Clearance EX Valve Seat Face Angle Valve Head Thickness margin width Valve Head Sinkage from cyl head bottom face 27 2 mm 1 079 in 25 2 mm 0 992 in 114 5 4 508 in 6 6 mm 0 260 in 459 1 mm 0 039 in 0 5 mm 0 020 in 0 10 mm 0 004 in 0 15 mm 0 006 in 0 5 mm 0 020 in 1 5 mm 0 06 in Valve Spring Free Length 43 mm 1 693 in 1mm 0 039 in Installed Load Height 14 0 7kg 36 mm 1596 30 9 1 5 Ib 1 417 in 29 75 1 5 kg 28 mm 1096 65 6 3 3 Ib 1 102 in Squareness 2 3 Rocker Arm I D 18 9 mm 0 744 in Rocker Arm to Shaft Clearance 0 2 mm 0 008 in Oylinder Block Camshoft hole I D Front Bush Oil Clearance Center Rear Oylinder Bore Oversize finish tolerance Oylindricity of cylinder bore Warpage of head gasket mating surface 45 mm 1 772 in 0 15 mm 0 006 in 44 mm 1 732 in 34 mm 1 339 in 73 mm 2 874 in 0 to 0 03 mm 0 to 0 001 in 0 01 mm 0 0004 in max 0 05 mm 0 0020 in max 40 2 mm 0 008 in 0 1 mm 0 004 in 0 95 mm 0 037 in Groundsmaster 300 Series Page4 5 Specifications Engine cont Item Standard Specification Repair Limit Service Limit Piston Type Solid Material Aluminum alloy Piston Outside Diameter skirt end Piston to Cylinder Wall Cle
274. lve to the fixture with four 4 5 16 24 UNF nuts Fig 26 NOTE Before beginning the disassembly of the steer ing valve study the relative positions of the alignment grooves on the side of the components in the assembly The relative alignment groove positions on the compo nents must be maintained at reassembly Fig 24 2 Use a slot type screwdriver or screwdriver socket to loosen the plug assembly one turn counterclockwise Fig 27 Do not remove the plug assembly 3 Remove the four nuts from the port cover assembly Be careful not to damage the ports Fig 28 IMPORTANT The nuts are a special self locking type Do not substitute any other type Groundsmaster 300 Series Page 8 23 Figure 25 Figure 28 Repairs 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 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 30 Discard the o ring 6 Inspect the port cover for port fitting sealing surface scratches and thread damage Replace the port cover if itis damaged NOTE Be prepared to catch three springs which may become disengaged when removing the port manifold 7 Carefully lift the port manifold 3 plates bonded to gether from the unit Fig 31 8 Remove the three springs from the port manifold NOTE T
275. m the square tube and turned around so that the mounting hole with the axle through it is toward the rear The caster wheel grease fittings should always face outward IMPORTANT Do not attempt to cut off more than one inch of the grass blades in the one 1 inch height of cut setting with the rear of the cutting unit lowered as this may cause the engine to labor excessively 1 Start the engine and raise cutting unit so height of cut can be changed Stop engine after cutting unit is raised 2 Squeeze back of wire and rotate wire on lynch pin Pull pin out of caster spindle Slide spacers onto the caster spindle to get desired height of cut Then slide washer onto caster shaft front only 3 Push caster shaft through caster arm Slide any remaining spacers onto spindle Install lynch pin to retain parts in place Always have the same number of spacers on each caster when adjusting height of cut Adjustments Page 12 6 Figure 6 1 U spacers 6 3 Caster wheel axle holes 2 Spacer opening 4 Mechanical door Figure 7 1 Thrust washer 3 Spacers 6 2 Lynch pin 4 Wire spring Groundsmaster 300 Series 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 Never install with the spacer facing the side or middle
276. main bearing and connect ing rod bearing oil clearances may be measured with a micrometer or Plastigauge Crankshaft oil clearances are Journal 0 0039 inch 0 10 mm Crank pin 0 0059 inch 0 15 mm NOTE When using Plastigauge to measure the clear ance between the crankshaft and its bearings install the crankshaft into the cylinder block place a piece of Plastigauge onto the crank pin or journal and torque the bearing cap with bearing in place DO NOT TURN THE CRANKSHAFT WHEN PLASTIGAUGE IS IN PLACE SINCE THE PLASTIGAUGE WOULD BE DESTROYED Remove the bearing cap and measure the width of the Plasti gauge to determine the clearance If the oil clearances exceed these amounts attempt to install a new bearing to reduce the clearance If installing a replacement bearing does not reduce the clearance to within toler ance the crankshaft must be reground and an oversized bearing installed Timing Gears Fig 70 1 Inspect the idler gear fuel injection pump gear cam shaft gear and crankshaft gear for wear or damage Replace these gears if defective Cylinder Block Overhaul Page 4 56 A Figure 68 Figure 69 Figure 70 Groundsmaster 300 Series 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
277. maximum safety replace all switches after every two years or 1000 hours whichever comes first To check operation of interlock switches 1 Drive the machine slowly to a large relatively open area Lower cutting unit stop the engine and apply parking brake Groundsmaster 300 Series Page 6 17 2 Sit on seat Move PTO lever to ON position With the traction pedal in neutral position try to start the engine The engine should not crank If the engine cranks there is a malfunction in the interlock system that should be corrected before beginning operation 3 Sit on seat Move PTO lever to OFF and depress the traction pedal Try to start the engine The engine should not crank If the engine cranks there is a malfunction in the interlock system that should be corrected before beginning operation A CAUTION Do not operate machine without implement unless the PTO drive shaft is also removed 4 Sit on seat and start the engine Raise off the seat and move the PTO lever to ON The engine should stop within 2 3 seconds If the engine does not stop there is a malfunction in the interlock system that should be corrected before beginning operation Troubleshooting Groundsmaster 322 D 325 D 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 For accurate resistance and or continuity checks elec t
278. me stop 1 16 to 3 8 inch Half chain link adjustments 2 Roll pin 7 Right push arm can be made by switching mounting holes in push arm 3 Gear case input shaft 8 Carrier frame brackets Tie up extra chain links if additional length may 4 Tension spring 9 Left push arm be needed in the future 5 Rear lift chain IMPORTANT Improper chain adjustment could re sult in main deck lift arm damage if deck contacts traction unit NOTE As starting points use the following settings Right front chain 10 links lower bracket hole Left front chain 14 links lower hole Rear chain 10 links upper and front holes 11 Adjust length of rear chain so rear caster wheels are as far as possible from the ground but carrier frame does not contact right push arm when deck is lifted A CAUTION Improper chain adjustment may result in the deck contacting the traction pedal and forc ing it into reverse 12 To check adjustment stay in the driver s seat raise the deck all the way and turn the key OFF Set the parking brake and then walk to the front of the traction unit to see if the deck is contacting the linkage 13 Connect ends of tension spring between fourth link of rear chain and eye of cotter pin that holds cylinder pin in place Repairs Page 12 22 Groundsmaster 300 Series Push Arm and Torsion Spring Service Fig 34 35 36 37 38 39 40 Removing Push Arms Torsion Springs and Bushings 1 Separate cutting u
279. move 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 3C must be removed before pressing pinion out of housing Figure 29 12 Position the housing assembly on a suitable press Place a 1 8 inch 3 mm piece of steel or a screwdriver blade under the edge of the spur gear This will prevent the spur gear from cocking and possibly cracking the housing Fig 30 When the pinion is close to being pressed completely out of the bearing reach under the housing and catch the pinion in your hand to prevent any damage to the pinion Figure 30 Removing the drive pinion releases the spur gear spacer and outer pinion bearing for removal Fig 31 If unit was equipped with a flange for 4WD no expan sion plug remove oil seal from housing Fig 3C Figure 31 Repairs Page 7 12 Groundsmaster 300 Series 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 14 To remove the outer pinion bearing cup position the housing in a press Place a press plate of the proper size against the cup Press the cup out of the housing Fig 33 15 Position the front housing on a press bed with the bearing saddles resting on the press bed Protect the
280. n down position Check for binding seat pivot hinge Check for waterlogged seat Test seat switch Adjust or replace if faulty Engine kills when traction pedal is depressed or PTO is engaged Operator sitting too far forward on seat seat switch not depressed Seat hinge support pin or spring binding preventing seat switch from closing Seat switch is faulty or out of adjustment Seat switch wiring loose corroded or damaged Instruct operator Repair seat pivot and support Test seat switch Adjust or replace if faulty Repair wiring Battery does not charge Groundsmaster 300 Series Loose corroded or damaged wire s Faulty alternator Dead battery Page 6 15 Repair wiring Check alternator belt tension Test alternator and replace if faulty Charge battery Replace battery if it will not hold a charge Troubleshooting Groundsmaster 322 D 325 D Operation Problems continued Condition Possible Cause Correction Engine continues to run but should not when PTO is ON with no operator on the seat Seat switch plunger depressed with no operator on seat Seat switch faulty or out of adjustment Check for seat support spring that is broken missing or stuck in down position Check for binding seat pivot hinge Check for waterlogged seat Test seat switch Adjust or replace if faulty Engine continues to run but should not when
281. n the bolts slightly and then re tighten in the sequence shown M12 bolt torque wet 1 5 12 5 kgm 83 90 ft Ib M10 bolt torque wet 6 5 8 0 kgm 47 58 ft lb Rocker stay bolt torque 1 5 2 2 KgM 11 16 ft Ib 5 Rotate the crankshaft until the TDC mark located next to the injection timing mark s on the pulley lines up with the registration mark on the gear case This will be TDC on cylinder No 1 NOTE There are two TDC positions compression and intake strokes At compression TDC the rocker arms will not move when the crankshaft pulley is rotated a small distance each way Compression TDC is where the valves are to be adjusted 6 Measure the valve clearance by using a thickness gauge inserted between the valve stem and rocker arm The correct valve clearance for both the intake and exhaust valves is 0 25 mm 0 01 in 7 To adjust the valve clearance loosen the adjusting lock nut and turn the rocker arm adjusting screw clock wise or counterclockwise until you get the correct clear ance Tighten the locknut securely Check to make sure that the clearance was not changed while tightening the locknut 8 Perform steps 6 and 7 of this procedure for cylinder Figure 12 No 2 and 3 while at their TDC position Turn the crankshaft 240 clockwise to get No 3 cylinder TDC Turn the crankshaft an additional 240 clockwise to get No 2 cylinder TDC 9 Install the rocker cover Install the rocker cover nuts an
282. n to keep the pin in place during reassembly Then slide the gerotor wheel onto the pump shaft and drive pin so positive engagement results 11 Using a seal protector for the lip seal slide the charge pump housing onto the pump shaft and against the side of the adjacent pump housing Align the scribe marks in both housings to assure proper assembly and to prevent damage to the transmission CAP SCREW Figure 21 Most Sundstrand charge pump housings are marked 9 with the letters RH and LH These are used to denote which side of the charge pump is mounted towards the top of the transmission for a given direction of engine rotation i e clockwise The GROUNDSMASTER mower application requires that the LH markings be toward the top of the transmission Having LH toward the bottom of the transmission will result in a complete loss of hydraulic functions NOTE In place of a seal protector use plastic wrap or a similar material to wrap the pump shaft This protects the seal from possible damage when sliding it onto the pump shaft Apply transmission oil on the plastic wrap to make the seal slide freely 12 Secure the charge pump housing against the ad jacent housing with four cap screws Tighten the cap screws to 12 15 ftlb IMPORTANT Excessive pressure on the pump shaft will shear the pin that propels the gerotor wheel If the pin should shear the transmission will not operate 13 Install the drive coupling and tran
283. n 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 Inspect the torsion springs If the springs are dam aged use new springs when assembling the parts 3 Slide the torsion springs onto the inside of the push arm pivot tubes Install the washers push arms with springs and push arm brackets onto the pivot shaft Install the roll pins to secure the parts in place Figure 28 4 Raise the push arm and pivot shaft assembly into position and secure it in place with cap screws support plate reinforcement support and locknuts Make sure the springs contact the retainer plate on the push arms and the underside of the frame 5 Have a helper push down on the left push arm while you place a 3ft long block of wood between the chassis and to top of the push arms across the full width of the machine NOTE After the wood block is installed there should be enough clearance for installing the ball joint into the front of the push arm 6 Thread jam nut fully onto the left hand ball joint Screw the ball joint into the left hand push arm until the center of the ball joint is 2 3 8 inches away from the front ofthe push arm Do nottighten the jam nut until the deck is mounted 7 Install the brake mount and pedal assembly with cap screws locknuts carriage bolts loc
284. n around hydraulic hose connec tions to steering cylinder Label hoses for assembly pur poses Disconnect hoses from fittings on steering cylinder Put plugs or caps on open hoses and fittings to prevent contamination of hydraulic system 7 If machine has rear weight s attached to frame re move weight s 8 Support rear axle to prevent it from falling Remove four 4 flange head screws item 21 and flange nuts item 23 that secure rear axle support to equipment frame Lower rear axle and rear axle support from ma chine 9 Locate and retrieve frame spacers item 22 10 Remove jam nut item 19 and thrust washer item 20 from rear axle pin item 27 that attaches rear axle to rear axle support Remove washer head screw item 29 that secures flange of axle pin to rear axle support 11 Remove rear axle pin Separate rear axle support from rear axle Note location and quantity of thrust washers items 52 and 53 between axle boss and axle support Groundsmaster 328 D 10 1 5 Installation Fig 2 1 Position rear axle support to axle Install thrust wash ers items 52 and 53 between axle boss and axle sup port to minimize clearance 2 Install rear axle pin item 27 to secure axle to rear axle support Install thrust washer item 20 and jam nut item 19 onto pivot pin Torque jam nut from 90 to 120 ftHb 122 to 163 Secure pivot pin to axle support with washer head screw item 29 3
285. n gear end play 0 00 to 0 005 in Special Tools NOTE Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PRODUCTS Some tools may be listed in the Parts Differential Gear Holder Remove gear cover from right hand side of differential and bolt this tool in place to lock spur gear in position when removing nut that secures drive shaft flange for 4WD drive shaft Special Tools 7 2 Rev A Catalog for your Toro equipment Some tools may also be available from a local supplier Figure 2 Groundsmaster 300 Series 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 If unit is equipped with 4WD remove rear axle drive shaft see Chapter 9 4WD Rear Axle 4 Remove hydrostatic transmission See Repairs sec tion of Chapter 5 Hydraulic System 5 Slightly loosen all front wheel lug nuts Jack both front wheels off the ground and install jackstands or blocks under traction unit frame not axle tubes to prevent machine from falling Remove both front wheels 6 Remove extension spring and clevis pin to disconnect brake cable from brake actuating lever on each brake 7 Remove capscrew securing axle support bracket to top of differen
286. n phase 4 Capscrews amp locknuts Repairs Page 9 14 Groundsmaster 300 Series Chapter 10 TORO GM322 D or GM325 D with Inasaka axle 4WD Rear Axle Table of Contents SPECIFICATIONS 2 REPAIRS tese Bae Ee ca ie a ds 5 GENERAL INFORMATION 3 Drive Shaft 5 Over Running Clutch Operation 3 Rear Axle Removal and Installation 7 4 Axle Repair 8 Rear Wheel 4 Groundsmaster 300 Series 10 1 Rev C Table of Contents 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 Specifications Page 10 2 Groundsmaster 300 Series 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 axle incorporates an OVER RUNNING ROLLER CLUTCH THAT TRANSMITS POWER ONLY IN THE FOR WARD DIRECTION Fig 4 Front and rear axle gear ratios and tire sizes were carefully selected so that during normal operation the REAR AXLE PINION SHAFT TURNS SLIGHTLY FASTER THAN THE REAR AXLE DRIVE SHAFT Any time the front wheels begin to slip su
287. n pump A leaf spring on the tie rod cover is used to prevent stalling during rapid deceleration by limiting the travel of the tie rod Servicing the governor requires removal of the gear case on the front of the engine and there for engine removal Governor Inspection Engine Not Removed Fig 40 A governor failure can result in a starting failure loss of engine speed control or engine surging hunting Be fore removal and disassembly of the engine the follow ing inspections are recommended 1 Remove the tie rod cover and operate the speed control lever The injection pump control rack should move as the lever is operated 2 If the control rack does not move remove the tie rod retaining spring and tie rod from the control rack The control rack should now move freely when operated by hand If it does not difficulty with the injection pump should be suspected 3 With the tie rod removed from the control rack operate the speed control lever and watch for tie rod travel Failure of the tie rod to move would indicate difficulty with the governor spring governor lever or other internal parts Refer to Removing and Replacing the Engine for engine removal instructions Groundsmaster 300 Series Page 4 37 al AF ir d Cc d si Lf Figure 40 1 Injection pump 6 Sliding shaft 11 Idle gear 2 Stopper spring 7 Gear case 12 Needle bearing 3 Tie rod 8 Governor shaft
288. nce the entire cylinder block assembly must ORE be replaced if it is defective do not disassemble the spring and other parts from the center bore of the cylinder block Cylinder block components are not inter changeable 3 Remove the thrust plate from the counterbore in the variable position swash plate PORT FACE 4 Wrap the port side of the pump housing with a clean rag to protect the face of the housing Set the pump housing on to a clean work bench 5 Drive the spring pins through the swash plate and out AN PUMP SHAFT of the trunnion and control shafts KEYED END CONTROL NOTE There are two spring pins on the control shaft SPATT side of the pump housing and one pin on the trunnion shaft side The control shaft must have two pins be cause of the continuous applied force from the traction pedal during operation 6 Mark the control shaft and housing so the shaft can be installed correctly when the parts are reassembled TRUNNION Slide a long punch through the hole at the end of the SHAFT control shaft and pull the shaft out of the bore in the swash plate and pump housing PUMP HOUSING Figure 25 7 Slide a 3 8 x 7 inch wooden dowel into the bore at the control shaft side of the housing Place the dowel against the end of the trunnion shaft and drive it out of the housing 8 Lift the swash plate out of the pump housing and off of the pump shaft 9 If the pump shaft or bearing must be serviced use t
289. nding complete Model and Serial Numbers to The Toro Company 8111 Lyndale Avenue South Minneapolis Minnesota 55420 2 Never allow children to operate the machine Do not allow adults to operate the machine without proper instruction Only trained operators skilled in slope op eration and who have read the Operator s Manual should operate this machine 3 Never operate machine when under the influence of drugs or alcohol 4 Remove all debris or other objects that might be picked up and thrown by cutter blades or fast moving components from other attached implements Keep all bystanders away from the operating area 5 Keep all shields and safety devices in place If a shield safety device or decal is defective or damaged repair or replace it before operating the machine Also tighten any loose nuts bolts and screws to make sure machine is in safe operating condition Groundsmaster 300 Series Page 1 1 Chapter 1 Safety While Doing Maintenance Troubleshooting Testing Adjustments or Repairs 3 A CAUTION Improper operation maintenance trou bleshooting testing adjustments or repairs of the machine can result in injury or death To reduce the potential for injury or death comply with the following safety instructions 6 Do not wear loose fitting clothing because it could get caught in moving parts Always wear long pants and substantial shoes Wearing safety glasses safety shoes an
290. ne set of shims Item 11 onto the turned end of the shaft Press one of the bearing cones Item 9 over the turned end of the shaft Be sure the bearing cone is installed as shown in the illustration Fig 42B Install a retaining ring Item 7 on the turned end of the shaft 3 Put one of the bearing cones Item 12 over the other end of the shaft and down against the hub side of the gear Be sure the bearing cone is installed as shown in the illustration 4 Repeat steps 1 3 with the other set of parts to complete the assembly 5 Put one of the caps Item 16 down with the machined surface facing up Install a new seal Item 13 into the Repairs Page 11 24 cap with the open side toward the machined side of the cap 6 Install the bearing cup Item 14 into the cap Make sure the bearing cup is installed as shown in the illus tration 7 Repeat steps 5 6 with the other set of parts to complete the two cap assemblies 8 Take one of the shaft and gear assemblies and wrap the end of the shaft with a piece of shim stock to keep from cutting the oil seal on the keyway or splines Put the cap assembly down over the shaft so the bearing cone Item 12 on the shaft mates with the bearing cone Item 14 in the cap Remove the shim stock from the shaft that was used to protect the seal 9 Press the bearing cups Item 3 into both bearing bores in the housing Item 1 Make sure the cups are installed as shown in the illu
291. ng broken or out of adjustment Y Low Binding Fill to Lubricate Lubricate proper or or level repair repair Check charge pump pressure flow Inspect inlet filter Loose or clogged Inspect Test Tighten implement steering or relief valve valve replace Control valve Defective sticking l l Repair charge pump Test lift cylinders for internal leakage Inspect lift valve Defective Defective Replace Repair hydraulic lift valve cylinder Groundsmaster 300 Series Repair or shim Repair or replace implement steering relief valve valve Cutting Unit Will Not Lift or Lifts Slowly Page 5 15 Troubleshooting Checksteering Ok Check Ok High Steering Effort linkage for binding hydraulic or damage oil level Defective Low Fill to Repair proper level Check charge Inspect pump transmission I pressure flow inlet filter Loose or clogged Repair or replace transmission pump amp motor Inspect charge pump Inspect Test Tighten implement steering or relief valve valve replace Control valve Defective Defective sticking Repair charge pump Repair or shim Repair or replace implement steering relief valve valve Check for restric tion in return line OUT port Inspect NOTE Sticking steering valve plat
292. ng leads to mod ule terminals P1 2 meter lead and P1 1 meter lead Fig 9 3 Connect a jumper lead from module terminal P1 4 to module wire connector J1 4 Using a 12 VDC power source apply 12 VDC to ter minal P1 3 and ground terminal P1 1 Glow Relay Groundsmaster 328 D The Groundsmaster 328 D diesel engine uses a relay to energize the engine glow plugs This glow relay is at tached to the frame below the radiator assembly Testing 1 Verify coil resistance between terminals 86 and 85 with a multimeter ohms setting Fig 10 Resistance should be from 41 to 51 ohms 2 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 412 VDC is applied and removed from terminal 85 3 Disconnect voltage and leads from the terminals Electrical System Rev G 8 5 Connect second jumper lead to module terminal P1 3 and touch terminal P1 4 The multimeter display should show 12 VDC as long as the jumper is connected to P1 4 6 Disconnect the jumper wire from module wire con nector J1 while watching the multimeter display The meter should show 0 VDC after 5 seconds Figure 9 Figure 10 Groundsmaster 300 Series Glow Controller Groundsmaster 328 0 The glow controller used on the Groundsmaster 328
293. ng Specifications Free Length i e s ain eee 2 25 in Number of Coils 23 1 2 Outside Diameter 0 297 0 303 in Pounds per Inch 17 8 To install acceleration valves place a new O ring onto both acceleration valve plugs 9 Slide one acceleration valve into the center section then install plug Then slide the spring and remaining acceleration valve into the opposite side of the center section Install the remaining plug to retain the parts in place 10 Since some oil has drained out of transmission when the acceleration valves were removed check the oil level in the axle housing Start the engine and let it run for about one or two minutes Then turn the engine off and check the oil level in the axle housing again Also inspect the acceleration valve areas for oil leaks Repairs Page 5 28 Groundsmaster 300 Series Transmission Implement Relief Valve Fig 18 1 Place a drain pan below the implement relief valve IMPLEMENT SHIM 2 Removethe implement relief plug and O ring from the RELIEF mm 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 SPRING NOTE Count the shims when they are removed The same number of shims must be installed when assem bling the parts Do not interchange implement relief shims with charge relief shims 3 Remove the O r
294. ng parts A Slotted plugs and O rings Check the slotted plugs for damaged threads and burrs Also check the O ring for tears It is a good practice to install new O rings whenever the slotted plugs are removed B Valve Springs and Check Balls Check the valve springs and check balls for damage Spring specifications are listed in the table below Check Valve Spring Specifications Free Length E heme 0 550 in Number of Coils 10 Outside Diameter 0 217 0 219 in Pounds Per Inch 3 67 C Needle Bearings Check for free rotation and any noticeable damage D Dowel Pins Check the dowel pin on the motor side and the pump side of the center section for wear and damage Groundsmaster 300 Series Page 5 37 NOTE Replace any defective parts The slotted plugs valve springs and check balls are interchangeable 6 If the needle bearings were removed press new bearings into the center section Allow 3 32 1 8 inch of the bearing to extend beyond the face of the center section because the motor valve plate and pump valve plate pilot on the two bearings 7 Press the locating pins into the holes in the motor side and pump side of the center section 8 Insert the check balls and valve springs into the two holes in the motor side of the center section Slide the O rings onto the slotted plugs and install the plugs into the two h
295. ng resistance is felt Then tighten capscrews to lock the latch in place Check for free operation of the lift lever by moving lever from RAISE or TRANSPORT to FLOAT position Lift lever should just clear rounded position of latch as lever is moved into FLOAT position 4 Slide cover into place and install it with self tapping screws Screw ball onto lift lever Groundsmaster 300 Series Page 5 25 Figure 14 1 Capscrews 3 Lift lever 2 Rounded tab Adjustments 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 FLAT WASHER SEAL 2 Remove the snap ring from the end of trunnion shaft and slide the flat washer off of the shaft Using a seal puller pull the seal out of the housing Do not scratch the shaft NOTE Since oil drains out of the transmission when the seal is removed use a drain pan to catch the oil however do not use this oil again 3 Examine the trunnion shaft and remove all burrs sharp edges and residue p eag FLAT WASHER 4 Using a seal protector press a new seal into the transmission housing and assure that it is seated Figure 15 properly NOTE In place of a seal protector use plastic wrap or a similar material to wrap the shaft This protects the lip of the seal from possible damage when sliding it onto the shaft and pressing it onto the housing
296. ngs and the matched snap ring set must be installed refer to step 1 below Never use the old bearings spacer and snap ring with a new spindle housing By contrast use only new bear ings with cups and spacer not the large snap ring because it is not required when installing bearings into a used spindle housing that has the large snap ring installed refer to step 2 below 1 Install the large snap ring into the groove in the bore of the spindle housing Assure the snap ring is seated in the groove 2 Using an arbor press push the large spacer into the top of the spidle housing tightly against the snap ring The spacer must contact the snap ring to be sure of the correct assembly of the parts 3 Thoroughly oil the bearing cups and using an arbor press push the bearing cups smallest inside diameter first into the top and bottom of the spindle housing The top bearing cup must contact the spacer that was installed in step 2 and the bottom bearing cup must con tact the large snap ring to be sure of the correct assem bly of parts Insure that the assembly is correct be supporting the first cup and pressing the second against it 4 Install the lower bearing and the lower oil seals into the bottom of the spindle housing Remember the bot tom seals must have the lip facing outward not toward the inside of the spindle housing 5 Check the spindle shaft to make sure it is free of burrs and nicks that could possibly cut the se
297. nit 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 x 4 block of wood between the chassis and the top of the push arm and across the full width of the machine 3 Loosen the large jam nut on the left hand ball joint at the end of the push arm Remove the ball joint mount attached from the push arm 4 Remove the self tapping screws holding the floor plate to the main frame Raise the floor plate and set it aside 5 Disconnect the right hand brake cable from the brake strut Remove the jam nut holding the brake cabled in the mount on the frame and slide the cable through the hole in the push arm bracket 6 Remove the cotter pin from the end of the parking brake rod Slide the rod out of the latch Groundsmaster 300 Series Page 12 23 BALL JOINT MOUNT COP SCRE PARKING BRAKE R D Figure 36 Repairs 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 3 assembly on the wheel ib B PUSH ARM AND SPRING LOAD FULLY RELEASED 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 Slowly and carefully allow the push arm to move upward until all spring load is released 9 Remove the cap screws locknuts support plate and push arm bracket holding
298. njection Pump Reassembly Fig 49 50 NOTE Wash each part thoroughly in clean diesel fuel as it is reassembled 1 Install the Control Rack Smoke Set and Ungleich plates retainer springs and fasteners 2 If the adjusting plate assemblies have been removed reinstall them paying careful attention to install them according to the marks scribed on the pump housing and plates 3 Install the Plunger Barrel into the bore in the top of the Pump Housing Make sure that the groove in the barrel aligns with the pin in the side of the bore 4 Install the delivery valve and seat gasket spring O ring and Valve Holder and hand tighten the assembly Be careful not to damage the O ring when installing it onto the valve holder 5 Install the control pinion by positioning it so that the deeply cut tooth is aligned with the grooves in the Control Rack Fuel System Service Page 4 42 Figure 48 Figure 49 Alignment of pinions and control rack Groundsmaster 300 Series 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 8 Insert the tappet carefully to avoid dropping the shim Align the tappet guide hole with the hole for the tappet guide pin Install the guide pin locking plate and gu
299. nsertion 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 Make sure the identification mark of the rod and and the arrow mark on the piston head are di rected up Pin press fitting force 500 1500 kg 1100 3300 Ib NOTE The piston and piston pin are matched parts and should not be mixed After assembling the piston and connecting rod make certain that the connecting rod small end is properly positioned at the center of the piston pin 11 Install the piston rings IMPORTANT The piston rings differ in shape from one another Be careful to install them in proper position and with the ring gaps in the directions as illustrated In the case of the oil ring with the coil expander the gap clearance of the ring should be positioned 180 away from the joint of the expander NOTE Install the piston rings with the stamped manu facturer mark facing up Arrow mark indicates the front of engine Identification mark Bearing mating grooves Figure 83 Installing piston rod K3D 2 x 3 v 1 A US di Compression ront of 4 ring engine Be i e Compression ring J ms ES 22 ring d Oil ring Figure 84 Ring gap positions Piston ring shapes Cylinder Block Overhaul Page 4 62 Groundsmaster
300. nspect the charge relief plug area for oil leaks Repairs Page 5 30 Groundsmaster 300 Series 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 Examine the transmission pump shaft and remove all burrs sharp edges and residue to prevent possible damage to the lip seal NOTE Disassembly of the charge pump is not neces sary when the seal is the only part that must be replaced see step four Servicing any other part of the charge pump requires disassembly see step 5 4 f the charge pump seal is the only part being ser viced pull the seal out of the charge pump housing CAP SCREW using the oil seal puller or similar tool Do not scratch the pump shaft Since oil flows out of the transmission when the seal is removed use a drain pan to catch the Figure 20 oil however do not use this oil again 5 If the charge pump must be disassembled scribe a mark on charge pump housing and adjacent pump housing to assure correct installation when parts are assembled NOTE Charge pump housings that have the letters LH and RH on the external surface must be installed with the letters LH positioned closest to the top of the transmission 6 Remove the cap screws holding the charge pump housing against the adjacent pump ho
301. ntegrity and operation of the Groundsmaster 328 D glow plug system The test should be run anytime hard starting cold engine is encountered on a diesel engine equipped with a glow plug system Use a digital multimeter and or inductive Ammeter AC DC Current Transducer set to the correct scale With the ignition switch in the OFF position place the amme Groundsmaster 300 Series 6A 3 ter pickup around the main glow plug power supply wire Adjust the meter to read zero if applicable Cycle the glow plug system at least two times per instructions in Traction Unit Operator s Manual and record the final re sults The Groundsmaster 328 D glow plug system should have a reading of approximately 27 Amps If low current reading is observed one or more glow plugs is faulty Electrical System Rev G Component Testing Note See Chapter 6 Electrical System for additional component identification and testing information Only new information for Groundsmaster 345 machines with serial numbers above 21000000 and Groundsmaster 328 D machines is provided in this Chapter Seat Switch The seat switch is normally open and closes when the operator is on the seat The switch is located directly un der the seat Fig 3 1 Make sure the engine and ignition switch are Off Re move key from ignition switch 2 Tilt operator seat up Disconnect machine wire har ness connector from seat switch 3 C
302. ntial housing 5 U S qt 4 7 liter approx capacity Lift control valve Four way three position open center Hydraulic Oil The hydraulic system is designed to operate on any high quality detergent oil having the American Petroleum Institute API service classification SF CC or CD Oil viscosity weight must be selected according to anticipated ambient temperature See Hydraulic oil specifications in above chart IMPORTANT DO NOT mix engine oil and automatic transmission fluid or hydraulic system component damage may result When changing fluids also change transmission filter DO NOT USE DEX RON II ATF NOTE Fluid to operate the power steering is supplied by the hydraulic system transmission charge pump Cold weather start up may result in stiff operation of the steering until the hydraulic system has warmed up Using proper weight hydraulic oil in system minimizes this condition To check oil level 1 Put machine on a level surface raise the implement and stop the engine 2 Unscrew dipstick cap from filler neck and wipe it with a clean rag Screw dipstick cap finger tight onto filler neck Unscrew dipstick and check level of oil If level is not within 1 2 inch 13 mm from groove in dipstick add enough oil to raise level to groove mark DO NOT OVER FILL by more than 1 2 inch 13 mm above groove Specifications Page 5 2 IMPORTANT When adding oil to hydraulic system use a funnel
303. nto the top and bottom of the axle tube The bushings must be flush with ends of the axle tube 8 Wipe the spindle shaft with a rag to remove any dirt and grease Inspect the spindles for wear and replace as necessary 9 Install the thrust bushing Item 34 onto the spindle shaft and push the shaft through the axle tube Hold the wheel and spindle shaft assembly in place and install the thrust washer Item 18 washer Item 17 and retaining ring Item 12 onto the end of the spindle shaft 10 Connect the tie rod end to the spindle bracket with one 1 nut Tighten the nut to a torque of 25 33 ft Ib Install the jam nut and tighten against the other nut to secure tie rod end 11 Mount the axle to the frame with the axle pin The washer s Item 45 must be positioned between the front end of the pivot tube and the frame see the NOTE after step 4 Secure the axle pin in place with the two 2 cap screws Item 2 Install the washer Item 8 and nut Item 9 12 Remove the jackstands and lower the machine to the shop floor 13 Install the hydraulic hoses to the steering cylinder 14 Lubricate the steering spindle and rear axle pivot Groundsmaster 300 Series 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 Rear Wheel Bearing Service 2WD Units Disassemble clean
304. nuts 94 6935 See Figure 18 1 After the wheel has been removed slide the brake drum off of the axle flange Fig 5 NOTE It may be necessary to loosen the brake shoes by turning the star wheel inside the brake drum assemb ly See Chapter 7 Steering and Brakes Figure 5 2 Line up the hole in the axle shaft flange and remove the backing plate nuts which hold the axle shaft assemb ly to the axle housing Use a 1 2 inch socket wrench Fig 6 3 Pull out the axle shaft and brake assembly Fig 7 NOTE Bearing races and retainer ring are cemented together with an epoxy adhesive If the bearing and race come apart remove the bearing cup from the housing with a puller Figure 7 Repairs 7 4 Rev A Groundsmaster 300 Series 4 Remove the inner axle shaft seal Fig 8 Discard the seal and replace with a new one at the time of assembly 5 Center punch the outside of the retaining ring Fig 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 10 IMPORTANT Drilling completely through the re tainer ring could damage the shaft Figure 10 Groundsmaster 300 Series Page7 5 Repairs 7 After drilling put a chisel in position across the hole and strike sharply to break the ring Replace with a new ring at time of reassembly Fig 11 A WARNING Wear protective safety goggles when break ing the reta
305. o the piston pin direction 3 Thoroughly clean the carbon deposits from the piston and ring grooves A ring groove cleaner or piece of a discarded ring may be used to clean the ring grooves 4 Measure the piston ring side clearances using a thickness gauge If the piston ring side clearance exceeds the service limit in the chart below the ring must be replaced NOTE In the case of a tapered ring No 1 measure the clearance on the bottom or widest area of the ring 5 Measure the piston ring gap clearance Insert the ring into the least worn area of the cylinder by pushing it into place with the piston The standard gap is 0 0059 0 0157 inch 0 15 0 4 mm If the gap exceeds 0 0590 inch 1 5 mm the ring must be replaced Cylinder Block Overhaul Page 4 58 Figure 73 Measuring piston outside diameter Figure 74 Measuring piston ring side clearance Figure 75 Measuring piston ring gap clearance Groundsmaster 300 Series 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 1100 3300 Ibs 500 1500 Kg pressure is standard force needed to remove the piston pin 1 Press the piston pin from the connecting ro
306. o the spindle shaft and secure it in place with the flat washer and slotted nut DO NOT tighten the nut or install the cotter pin 10 Adjust preload on the wheel bearings 2 Figure 18 1 Wheel hub 5 Slotted nut 9 Bearing cup 2 Wheel spindle 6 Washer 10 Stud 3 Dust cap 7 Seal 11 Wheel 4 Cotter pin 8 Bearing cone 12 Wheel nut Repairs Page 8 16 Groundsmaster 300 Series 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 Reinstall the cotter pin to retain the slotted nut in place NOTE The correct end play of the adjusted assembly is 002 005 inches 3 Remove jack stands or blocks and lower machine to floor 4 Put a coating of grease on the inside of the dust cap Install dust cap on the end of the wheel spindle Fig 18 Figure 19 1 Cotter pin and slotted nut Groundsmaster 300 Series Page 8 17 Repairs 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
307. of the deck the arrow on the spacer should be in the same direction as the pin NOTE On front caster shafts insert lynch pin in front side of shaft with caster wheels in position as if deck were traveling in forward direction When inserted from the front the wire loop is less likely to be flipped up during operation causing the pin to fall out IMPORTANT The thrust washer not the spacers must contact bottom of front carrier frame tube Figure 8 1 Rear caster spacers 2 Hooked over plate Groundsmaster 300 Series Page 12 7 Adjustments Checking and Correcting Mismatch of Blades Fig 9 10 If there is mismatch between the blades the grass will appear streaked when it is cut This problem can be corrected by making sure the blades are straight and all blades are cutting on the same plane 1 Put the deck into position on a flat 4 x 8 foot sheet of plywood that is at least 3 4 inch thick IMPORTANT If the rear caster wheel axle is in the lower hole put a 3 4 inch block under each front caster wheel to level the deck This is not necessary if the rear caster wheel axle is in the upper hole 2 Adjust height of cut so all six 6 height of cut spacers are below the caster arm highest height of cut 3 Lower cutting unit onto flat surface 4 Rotate blades until the ends face forward and back ward Measure from floor to front tip of cutting edge and record this dimension Then rotate same blade so op
308. oil reaches normal operating temperature 7 Increase the engine speed to the FULL throttle setting and use a tachometer to verify that the engine is running at 3200 50 rpm 8 Observe the pressure measurement on the low pres sure gauge The reading should be 70 150 psi NOTE A higher reading may be obtained due to the back pressure in the system This is acceptable 9 If the pressure is below 70 psi adjust the charge relief valve by adding the required amount of shims from the shim pack Groundsmaster 300 Series Page 5 19 NOTE If adding shims to the relief valve does not increase the pressure inspect the condition of the charge pump gerotor and internal housing If the charge pump is in good condition no scoring Scratches or excessive wear the general condition of the transmission s piston pump and piston motor might be suspected of wear and inefficiency A lack of minimum charge pressure or low flow could be due to the fact that the charge pump is having to direct all of its flow to the main traction circuit piston pump and piston motor When this occurs oil pressure may not increase to the 70 150 psi pressure necessary to open the charge relief valve therefore no oil can flow into the steering and implement circuit 2 i a s adn AS Figure 9 1 Low pressure gauge 0 1000 psi Testing TEST NO 2 Implement Relief Pressure Fig 9 Using a
309. oles in the motor side of center section Insert the two new O rings into the holes in the pump side of the center section 9 Assemble the transmission sections if no other ser vice work is required refer to Assembling Transmission Sections PUMP VALVE s SLOTTED PLUG O RING SPRING AND CHECK BALL BEARING MOTOR VALVE PLATE Figure 28 Repairs Transmission Motor Section Fig 29 30 1 Separate the motor housing from the center section refer to Separating Transmission Into Sections 2 Lift the cylinder block assembly out of the motor housing The pistons may come out of the cylinder block but do not be concerned they do not have a special order in the cylinder block NOTE Since the entire cylinder block assembly must be replaced if it is defective do not disassemble the spring and other parts from center bore of the cylinder block Cylinder block components are not interchangeable 3 Remove the thrust plate from the counterbore in the motor housing 4 If the motor shaft or bearing must be serviced remove the snap ring from the motor housing Slide the motor shaft and bearing out of the housing toward the flange end If the shaft sticks in the housing tap it lightly with a rubber hammer to remove it 5 Clean and inspect the following parts A Motor Valve Plate Check for wear scratches and scoring B Thrust Plate Check both sides for damage and flatness C Cylinder Block Assembly C
310. oles of the brake assembly and oil seal Push the axle shaft as far as possible into the axle housing Fig 17 Wheel end gasket material P N 92 8775 Liquid Gasket Kit Kit contains Loctite Ultra Gray gasket eliminator and instructions Make sure surface is flat File off any high spots Make sure capscrews are flat against flange Grind off any material rd from tube that interferes SEALANT 0625 BEAD 14 Start the nuts by hand Tighten the nuts so the bearing assembly is drawn evenly into the axle housing Fig 18 NOTE It is recommended that you replace hex head screws and flange nuts with socket head Screws washers and nuts Fig 18 If installing socket head screws tighten the nuts to a torque of 16 20 ft Ib 2 3 If reinstalling hex head screws tighten the nuts to a torque of 37 45 ft Ib 5 6 IMPORTANT Hold the socket head screw or hex head screw when tightening the nut to prevent the head from turning into the tube radius Differential and Housing Disassembly 1 Remove the right and left hand axle assemblies See Axle Shaft Disassembly and Wheel Bearing Service in this section of the book Remove the eight 8 housing cap screws and separate the upper and lower axle housings Fig 19 Clean the gasket material from the mating surfaces before reas sembly NOTE A complete Upper Housing Assembly for Dif ferential repairs is available Using this assembly eliminates the n
311. one of the shaft and gear assemblies and wrap the end of the shaft with a piece of shim stock to keep from cutting the oil seal on the keyway or splines Put the cap assembly down over the shaft so the bearing cone Item 12 on the shaft mates with the bearing cone Item 14 in the cap Remove the shim stock from the shaft that was used to protect the seal 9 Press the bearing cups Item 3 into both bearing bores in the housing Item 1 Make sure the cups are installed as shown in the illustration Install the plugs Item 2 into the tapped holes in the housing Repairs Gear Case Final Assembly 1 Bearing drag is adjusted by the amount of gaskets Item 4 5 6 used between the cap and housing ma chined surfaces 2 Puttwo 0 015 in gaskets on the machined surface of the housing then install the shaft and cap assembly in the housing so the bearing cone Item 9 on the shaft assembly and bearing cup Item 3 in the housing are mating Align the holes in the cap with the holes in the gaskets and housing 3 Install capscrews and tighten Repairs Page 12 30 4 The shaft should have a very slight amount of bearing drag If the shaft turns hard the cap must be removed and gasket s need to be added If the shaft has no bearing drag or has end play the cap must be removed and gasket s taken out The cap must be adjusted to where the shaft has no end play and only a slight amount of bearing drag 5 Repeat steps 1 4 wi
312. ons which must be followed to pre vent damage to systems or components on the machine The Toro Company 1992 1996 1998 2001 2003 2004 2005 2007 Table Of Contents Chapter 1 Safety Safety Instructions 1 1 Chapter 2 Product Records and Manuals Product 2 1 Equivalents and Conversions 2 2 Torque 2 3 Maintenance Interval Charts 2 4 Equipment Operational and Service Historical Report Record Chapter 3 Ford VSG 411 Gasoline Engine 3 1 General Information 3 2 Adjustments 3 3 p aea DERE ESSE 3 6 FORD VSG 411 413 ENGINE SERVICE MANUAL Chapter 4 Mitsubishi K3D Diesel Engine IntrodU ction ci epe sei pb Ter 4 2 4 3 Special Tools 4 11 Adjustments 4 13 Troubleshooting 4 15 Testing oio LR Vda ihe ne 4 18 Preparation for Engine Repair 4 25 External Engine Component Repair 4 26 Fuel System 4 34 Removing and Installing the Engine 4 46 Cylinder Head 4 47 Cylinder Block
313. ontinuity go to next step 9 Liberally coat inside of wiring connectors with skin over grease and push wire harness connectors to gether 10 AWD units only Install sealing plate to frame above fuel tank 11 Disengage support rod lower the seat Install lynch pin through rod to hold seat in place Connect negative battery cable to battery Groundsmaster 300 Series Page 6 35 Repairs 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 AWD units only Remove 4 flange screws and 2 locknuts securing sealing plate to frame above fuel tank Remove sealing plate 4 Remove boot from button end of seat switch Keep boot for installation later Disconnect seat switch wiring connector 5 Remove top jam nut securing seat switch to mounting bracket and remove switch Figure 29 S N 30001 and UP 6 Install new seat switch to support bracket Adjust Switch height so it is 3 32 2 4 mm below top of spring 1 Seat switch 4 Spring pin Tighten jam nuts to 75 in Ib Install rubber boot 2 Seat support bracket 5 Pin 3 Connector IMPORTANT Threads on seat switch will be dam aged if jam nuts are over tightened 7 Carefully lower seat but do not sit on or apply pressure to the seat There should be a slight gap between the switch and seat plate
314. or 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 Checking Ring Gear Pattern Final position of pinion is verified by using the gear contact pattern method as described in the following procedure Gear tooth Toe the portion of the tooth surface at the end towards the center Gear tooth Heel the portion of the gear tooth at the outer end Gear tooth Top Land top surface of tooth Every gear has a characterisitc pattern The illustrations show typical patterns only and explaing how patterns shift as gear location is changed When making pinion position changes shims should be changed in the range of 002 inch to 004 inch until a correct pattern has been obtained When a change in backlash is required backlash shims should be changed in the range of 1 1 2 times the amount of backlash required to bring the gears into specification For example if the backlash needed to be changed by 004 inch the shim pack should be changed by 006 inch as a starting point High backlash is corrected by moving the ring gear closer to the pinion Low backlash is corrected by mov ing the ring gear away from the pinion These
315. or bottom of mounting tube and drive bushing out of tube Also drive other bushing out of tube Clean inside of tubes to remove dirt 5 Apply grease to inside and outside of new bushings Using a hammer and flat plate drive bushings into mounting tube 6 Inspect caster spindle for wear and replace it if damaged 7 Push caster spindle through bushings and mounting tube Slide spacers onto spindle Install lynch pin through caster spindle to retain all parts in place Repairs Page 13 10 Groundsmaster 300 Series 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 wobbly caster wheel usually indicates a worn bearing 1 Remove capscrew and locknut holding caster wheel between caster fork 2 Pull spanner bushing out of wheel hub 3 Remove bushing from wheel hub and allow bearing to fall out Remove bushing from opposite side of wheel hub 4 Check the bearing spanner and inside of wheel hub for wear Replace defective parts 5 To assemble the caster wheel push bushing into wheel hub Slide bearing into wheel hub Push other bushing into open end of wheel hub to captivate the bearing inside the wheel hub 6 Carefully slide spanner through the
316. or greater with the difference in specific gravity between the highest and lowest cell less than 0 050 If these charging conditions can not be met replace the battery 3 Perform a high discharge test with an adjustable load tester This is one of the most reliable means of testing a battery as it simulates the cold cranking test A commercial bat tery load tester is required to perform this test Groundsmaster 300 Series Page 6A 13 A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 0 VDC recharge the battery B If the battery has been charged apply a 150 amp load for 15 seconds to remove the surface charge Use a battery load tester following the manufactur er s instructions C Make sure the battery terminals are free of corro sion D Measure the temperature of the center cell E Connect a battery load tester to the battery ter minals following the manufacturer s instruc tions Connect a digital multimeter to the battery terminals F Apply a test load of one half the Cranking Perfor mance rating of the battery for 15 seconds G Take a voltage reading at 15 seconds then re move the load H Using the table below determine the minimum voltage for the cell temperature reading Minimum Voltage Battery Electrolyte Temperature 709 F and 21 19 C and up 1 If the test voltage is below the minimum replace the bat
317. ounting hardware 2 Carrier frame holes 6 Have a helper carefully push down on right hand push arm until holes in bracket line up with holes in caster arm Immediately slide a 4 x 4 inch block of wood between top of push arm and under side of chassis 7 Secure mounting bracket to caster arm with mounting hardware Bolts should be tighten to 45 ft lbs Tighten lock nut where ball joint connects to lift arm Figure 32 1 Right push arm ball joint 3 Mounting hardware 2 Mounting bracket Groundsmaster 300 Series Page 12 21 Repairs 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 8 Line up holes in yoke and input shaft of gear case Slide yoke onto shaft and secure parts together with roll pin capscrews and nuts 9 Mount PTO shield over input shaft and onto gear case mounting plate with two self tapping screws 10 Attach three 3 lift chains to lift arm and cutting unit with six 6 shackles shackle pins and cotter pins Adjust chain length so that the front of the deck raises Figure 33 level side to side When main lift cylinder is fully extended the left push arm should be just below the 1 PTO shaft yokes in phase 6 Front lift chains fra
318. ousing NOTE A number marked on the new ring and pinion set is used to establish the proper amount of shims required prior to installing the pinion gear see page 15 The final pinion position will be verified by using the gear contact pattern method as described on page 210f this chapter Figure 39 6 Insert the spur gear into the front housing with the chamfered area of the center spline toward the drive pinion Install the drive pinion with a soft mallet to engage the splines in the spur gear Fig 40 Figure 40 Repairs Page 7 16 Groundsmaster 300 Series 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 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 Ib torque to rotate Fig 43 If the drag is to severe tap the pinion shaft with a soft mallet until the drag is reduced Figure 43 Groundsmaster 300 Series Page 7 17 Repairs 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 Apply a small bead of Permate
319. ow plugs should be torqued to 10 8 14 5 ft Ibs 1 5 2 0 KgM 6 Install the nozzle holder and tighten the bolts evenly to 10 8 14 5 ft lbs 1 5 2 0 7 Ensure that the cylinder head and cylinder block surfaces are clean Position a new head gasket on the head and insert some dowel pins into two cylinder head bolt holes in the cylinder to assist with mounting the cylinder head Carefully position the cylinder head over the dowels onto the cylinder block and remove the dowel pins Insert the head bolts IMPORTANT Do not coat the cylinder head gasket with any sealant 8 Tighten the cylinder head bolts to their specified torque as in the order shown A good practice is to tighten the head bolts in proper order first to one third of their specified torque then to two thirds of theirtorque and finally to the specified torque 9 Adjust the valve clearance Cylinder Head Overhaul Page4 52 STEM SEAL VALVE GUIDE EE Figure 61 Valve stem seal IDENTIFICATION MARK FRONT Figure 62 Rocker arm and shaft assembly Figure 63 Cylinder head bolt tightening sequence Groundsmaster 300 Series 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 Connect
320. pe Nominal Output Direction of Rotation No load Characteristics Cold Terminal Voltage Current Speed Height of Brush Spring Pressure Commutator O D Depth of Commutator Undercut 2 0 kW 12V Clockwise as viewed from pinion side 11V 130A max at 20 C 68 F 3850 rpm min 11 5 mm 0 45 in 3 kg 6 6 Ib 38 7 mm 1 52 in 0 5 0 8 mm 0 02 0 03 in 1 7 mm 0 07 in 1 8 kg 4 Ib 1 0 mm 0 4 in 0 2 mm 0 008 in Pinion Gap 0 5 2 0 mm 0 02 0 08 in Thrust Gap 0 5 0 02 in max Alternator Nominal Output Direction of Rotation No Load Output Characteristics Cold Terminal Voltage Current Speed Load Output Characteristics Cold Terminal Voltage Current 12V 35A Clockwise as viewed from pulley side 14V 0A at 20 C 68 F 1300 rpm or less 14V 30A or more at 20 C 68 F Speed 2500 rpm Regulator separate type Regulated Voltage 14 8 0 3V Glow Plugs Rated Voltage 10 5V DC Rated Current when rated voltage is applied for 30 seconds 9 7A 1 0A Resistance 0 16 ohm at room temperature Glow Plug Indicator Rated Current Voltage Across Terminals at 29A 29A 1 7V 0 2V Groundsmaster 300 Series Page4 9 Specifications 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
321. peration The Groundsmaster 328 D uses an additional relay seat delay to allow the engine to continue to run when the operator lifts from the seat momentarily The relays are attached to a bracket under the instrument panel next to the battery These relays are identical Refer to electrical schematics in Chapter 6 Electrical System for relay identification Testing Figure 5 Note Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from the measured value of the component you are testing 1 Locate relay to be tested Disconnect the machine wire harness connector from the relay 2 Using a multimeter ohms setting measure coil re sistance between terminals 85 and 86 Fig 5 Resist ance should be between 70 and 90 ohms 3 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 412 VDC is applied and removed from terminal 85 4 Disconnect voltage from terminal 85 and multimeter lead from terminal 87 5 Connect multimeter ohms setting leads to relay ter minals 30 and 87A Apply 12 VDC to terminal 85 The relay should make and break continuit
322. ping can carefully allow push arm to move upward which will gradually release the 150 pounds of spring load 8 Roll the cutting unit away from the traction unit Figure 29 1 Hose plugs 3 Yoke 2 Quick disconnects 4 Roll pin Groundsmaster 300 Series 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 A 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 push the push arm down Sudden release of the push arm could cause injury 2 8 inch 60 mm Figure 30 3 To assure correct alignment measure from the end 1 Lock nut 3 Push arm of each push arm to the center line of the ball joint Adjust 2 Ball joint to 2 3 8 inches If adjustment is required leave the lock nut loose 4 Have a helper carefully push down on left hand push arm until holes in bracket line up with holes in caster arm Immediately slide a 4 x 4 inch block of wood between top of push arm and under side of chassis 5 Secure mounting bracket to caster arm with mounting hardware Tighten bolts to a torque of 45 ft Ibs Tighten lock nut where ball joint connects to lift arm A WARNING Figure 31 Make sure wooden block does not slip out accidentally 1 Mounting bracket holes 3 M
323. place Moving Hoses Annual Recommendations Items listed are recommended every 1500 hours or 2 years whichever occurs Coolant System Flush Replace Fluid first Replace Safety Switches See Operator s and Service Manual for specifications and procedures GROUNDSMASTER 345 Daily Maintenance Check List Unit Designation Daily Maintenance duplicate this page for routine use TORO ID Daily Maintenance Check For Week Of MON TUES WED THURS FRI SAT SUN Maintenance Check Item HRS HRS HRS HRS HRS HRS HRS Y Safety Interlock Operation Y Grass Deflector in Down Position v Brake Operation v Fuel Level v Engine Oil Level Y Cooling System Fluid Level Y Dust Cup and Baffle Air Filter v Radiator amp Screen for Debris v Unusual Engine Noises Y Unusual Operating Noises v Transmission Oil Level v Hydraulic Hoses for Damage Y Fluid Leaks v Tire Pressure Y Instrument Operation v Condition of Blades Lubricate All Grease Fittings Touch up damaged paint E Immediately after every washing regardless of the intervals specified Notation for areas of concern Inspection performed by Item Date Information 1 2 3 4 5 6 7 See Operator s and Service Manual for specifications and procedures S vv8 S6 ON W104 senpeooud pue suoneouioeds enuey eoiues pue
324. posite end is forward and measure again The difference between dimensions must not exceed 1 8 inch If differ ence exceeds 1 8 inch replace the blade because it is bent Make sure to measure all five 5 blades 5 Rotate blades until the ends face forward and back ward Measure and record the dimensions from floor to tips of blades at the front and the rear Rotate blades until ends face side to side Measure and record dimen sions from floor to tips of blades at each end of blades Compare measurements of all five blades the maxi mum difference between any two adjacent blades should not exceed 1 4 inch the maximum difference between the highest and lowest blade should not ex ceed 3 8 inch The three center section blades can be adjusted with shims see Step 7 The wing blades can be adjusted by repositioning the hinge bushing brackets and or the wing stops see Step 8 6 Rotate blades so tips line up with on another Tips of adjacent blades must be within 1 8 inch of each other If tips are not within 1 8 inch of each other proceed to step 7 and add shims between spindle housing and bottom of cutting unit or Step 8 to adjust wing sections Adjustments Page 12 8 Center Section 7 Remove locknuts from spindle in the area where shims must be added To lower a blade add a shim Part No 3256 24 between spindle housing and bottom of cutting unit Continue to check alignment of blade and add shims until tips of blades are
325. prings If the springs are dam aged use new springs when assembling the parts 3 Slide the torsion springs onto the inside of the push arm pivot tubes Install the washers push arms with springs and push arm brackets onto the pivot shaft Install the roll pins to secure the parts in place 4 Raise the push arm and pivot shaft assembly into position and secure it in place with cap screws support plate reinforcement support and locknuts Make sure the springs contact the retainer plate on the push arms and the underside of the frame 5 Have a helper push down on the left push arm while you place a 3 ft long block of wood between the chassis and to top of the push arms across the full width of the machine NOTE After the wood block is installed there should be enough clearance for installing the ball joint into the front of the push arm 6 Thread jam nut fully onto the left hand ball joint Screw the ball joint into the left hand push arm until the center of the ball joint is 2 25 inches away from the front of the push arm Do not tighten the jam nut until the deck is mounted 7 Install the brake mount and pedal assembly with cap Screws locknuts carriage bolts lock washer and nuts Route the right hand brake cable through the hole in the right hand push arm bracket Connect the cable to the brake strut with the clevis pin and the tension spring Hook the opposite end ofthe tension spring into the hole in the side of the c
326. pter unnecessary disassembly and inspection can be eliminated Preparation for Engine Repair External Engine Component Repair In this section repairs to the external engine compo nents will be outlined These are repairs which can be accomplished without removing the engine from the mower frame They are Crankcase Breather System Fig 24 The crankcase breather system is shown in the illustra tion Blow by fumes are recirculated for recombustion without being discharged into the atmosphere The fumes within the cylinder block flow into the rocker cover through holes in the valve tappets and the push rod clearance holes They are carried through a rubber air breather pipe from the rocker cover to the inlet pipe and then to the combustion chamber The air breather pipe rubber hose should be replaced if it is damaged or shows any sign of deterioration Failure to periodically inspect this hose or to replace a faulty hose will allow dirt to enter directly into the engine cylinder and can cause premature engine wear or damage External Engine Component Repair Page 4 26 Crankcase Breather Fan Pulley Bearing and Shaft Repair or Replacement Oil Pressure Switch Replacement Oil Pump Stop Solenoid Replacement Water Pump Replacement AIR BREATHER PIPE INLET PIPE Figure 24 Crankcase breather system Groundsmaster 300 Series Alternator Belt Service Fig 25 1 Unlatch and open hood 2 Check ten
327. pulley boot 6 Replace or reposition all belt guides and adjust belt tension 7 Adjust wing pulley brake then install covers IMPORTANT Check new belt tension and brake adjustment after initial 10 hours of operation Figure 23 1 Rubber bumper 3 Idler pulley bolt 2 Spring bracket SMALL GUIDE SHOULD CONTACT LARGE GUIDE 08 APPROX Figure 24 Groundsmaster 300 Series Page 12 15 Repairs 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 A CAUTION Loosen capscrew nuts holding the spring bracket to the deck before loosening threaded rod to avoid sudden movement of the spring bracket 2 With belt tension released remove idler arm and belt Figure 25A guides as necessary and remove the belt 1 Threaded rod 4 Tension nut 3 Position new belt correctly in the center section 2 Spring bracket nuts 5 Jam nut pulleys Replace and tighten the idler arm and guide 3 Rubber stop 4 Be sure all belt guides are in the correct position and secured to the deck and adjust belt tension by following the procedure described above IMPORTANT Check tension of new belts after initial 10 hours of operation FRONT IMPORTANT If there is a gap of more than 3 16 inch between the rubber stop and the idler arm a belt adjustment is n
328. r has two positions ON engage and OFF disengage To engage the PTO shaft slowly push the PTO lever fully forward to the ON position this will start the implement or cutting unit blades Slowly pull the lever backward to the OFF position to stop the imple ment s operation The only time the PTO lever should be in the ON position is when the implement or cutting unit is down in the operating position and the operator is in the seat A 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 or other implement If the engine is started and the P T O shaft Is allowed to rotate serious Injury could result Figure 1 Introduction Page 9 2 Groundsmaster 300 Series Troubleshooting Engine to Transmission Coupler Problem Output shaft bearing failure Possible Cause 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 Loose fasteners Drive coupling out of alignment Pump hub damaged Drive coupling bent or deformed Loose fasteners Drive coupling out of alignment PTO System Problem Possible Cause Machine vibrates excessively PTO shaft not properly ali
329. r to the main frame 5 Lift out the control valve 6 Reverse order to install a new or reconditioned con trol valve Groundsmaster 300 Series 5 43 Figure 35 Repairs 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 The control valve spool snap ring Item 15 should be facing up 3 Remove the hex cap plug Item 1 from the side of the valve body Within the valve body beneath each hex cap plug there is a spring Item 3 ball Item 4 and cam pin Item 6 withdraw these parts 4 Remove the snap ring Item 15 from the spool Item 8 Carefully push and twist the spool to remove the spool from the valve bogy 5 Use a hooked scribe or thin screwdriver to remove the O rings from the inside bore of the valve body be careful not to scratch valve bore finish These O rings are the seals for the spool itself Inspect all components for wear paying special attention to the spool itself Signs of wear on one side of the spool may indicate a bent spool Inspect the spool for flatness and replace if necessary 6 After completing reassembly by reversing these pro cedures and after having installed new O rings and seals Figure 36 7 Priorto reassembly coat all the O rings with oil to ease assembly Inst
330. r when there is good artificial light B Drive slowly C Avoid sudden stops and starts D Look behind machine before backing up E Watch for holes or other hidden hazards F Do not drive close to a sand trap ditch creek or hazard G Reduce speed when making sharp turns and when turning on a hillside H The cutting deck must be lowered when going down slopes for steering control 17 To maintain machine control 35 Ib of weight must be mounted on rear of traction unit before using the Triflex 88 cutting unit More weight may be required in some steeper slope conditions 18 Operator must be skilled and trained in how to drive on hillsides Failure to use caution on slopes or hills may cause loss of control and vehicle to tip or roll possibly resulting in personal injury or death 19 Traverse slopes carefully Do not start or stop sud denly when traversing slopes or when traveling uphill or downhill 20 If engine stalls or machine loses headway and cannot make it to the top of a slope do notturn machine around Always back slowly straight down the slope Safety Instructions Page 1 2 If movement is evident the neutral return mecha nism is adjusted incorrectly Shut engine off and adjust until machine does not move when traction pedal is released 13 Do not run the engine in a confined area without adequate ventilation Exhaustfumes are hazardous and could possibly be deadly 14 Maximum seating c
331. r will be minimal However failure to keep bearings lubricated will cause rapid wear wobbly caster wheel usually indicates a worn bearing 1 Remove capscrew and locknut holding caster wheel and 2 washers between caster fork 2 Pull spanner bushing out of wheel hub 3 Remove bushing from wheel hub and allow bearing to fall out Remove bushing from opposite side of wheel hub 4 Check the bearing spanner and inside of wheel hub Figure 28 for wear Replace defective parts 5 To assemble the caster wheel push bushing into wheel hub Slide bearing into wheel hub Push other bushing into open end of wheel hub to captivate the bearing inside the wheel hub 6 Carefully slide spanner through the bushings and wheel hub 7 Install caster wheel assembly and 2 washers be tween caster fork and secure all parts in place with capscrew and locknut 8 Lubricate caster wheel bearing through grease fitting using No 2 general purpose lithium grease Groundsmaster 300 Series Page 12 19 Repairs Separating Cutting Unit From Traction Unit Fig 29 1 Position machine on level surface lower cutting unit to the shop floor shut engine off and engage parking brake 2 Disconnect three 3 hydraulic lines at mounting bracket located next to traction pedal using quick disconnects Immediately put attached rubber plugs in disconnects on both the traction unit and deck hoses 3 Remove PTO shield from top of cutting un
332. rake 3 Remove the locknut holding the brake onto the mounting pin Slide the spacer brake and spring off of the pins 4 Reverse procedures to install the brake 5 Adjust the brake as described in Adjusting the P T O Brake Repairs Page9 8 a SX X amp 99 LOCKNUT i PTO Figure 10 iA ta e PTO BRAKE _ h l rm AND SPACER Figure 11 Groundsmaster 300 Series 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 2 Remove the drive coupling from between the engine pulley and transmission hub refer to Hemoving Drive Couplings 3 Move the P T O lever to the ON position and remove the P T O brake refer to Replacing The P T O Brake 4 Move the P T O lever to the OFF position to release the tension on the belt 5 Remove the cotter pin and clevis pin from the P T O fork and pivot the P T O fork forward off of the P T O arm Figure 12 6 Roll the old belt off of the engine pulley and P T O pulley by carefully turning the P T O pulley by hand and moving the belt across the pulley grooves 7 To install the new belt roll the belt onto the P T O pulley and engine pulley making sure the belt is to the inside of the thr
333. ral Information Hydraulic Schematics 2 Wheel Drive Traction Unit STEER CYLINDER 2 00 DIA BORE 4 00 STROKE STEER VALVE LIFT CYLINDER pz 4 95 CU IN DISP TRANSMISSION IMPLEMENT 2 50 DIA BORE RELIEF 700 900 PSI 3 25 STROKE CHARGE PUMP 33 IN REV Ahe IBS rie aral NE Se CASE DRAIN THRU BEARING AT OUTPUT SHAFT OF TRANSMISSION i i i STEER CYLINDER 4 Wheel Drive Traction Unit PDA Bore 715 STROKE STEER VALVE LIFT CYLINDER 4 95 CU IN DISP TRANSMISSION IMPLEMENT 2 50 DIA BORE RELIEF 700 900 PSI 3 25 STROKE CHARGE PUMP 33 IN REV CASE DRAIN THRU BEARING AT OUTPUT SHAFT OF TRANSMISSION L 2 15200 PSI Hydraulic Schematics Page 5 6 Groundsmaster 300 Series 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 HOUSING Relief ammo vm om i Charge a i TUARUM ENGINE C F Groundsmaster 300 Series Page 5 7 Hydraulic Flow Diagrams 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
334. rankshaft and main bearing 1 Worn crankshaft 2 Worn or damaged bearings Connecting rod and bearings 1 Connecting rod bearing worn 2 Worn crankpin 3 Twisted connecting rod Piston piston pin and piston rings 1 Oylinder is worn 2 Piston pin is worn Rocker arm mechanism and relative parts 1 Camshaft is worn 2 Excessive valve clearance 3 Worn timing gear 4 Worn fan shaft bearings Repair or replace crankshaft inspect bearings Replace bearings inspect crankshaft Replace bearing inspect crankshaft Repair or replace crankshaft inspect bearing Replace connecting rod Overhaul engine Replace piston and pin inspect cylinder rod and rings Replace camshaft Adjust the valve clearance Replace the timing gear inspect mating gears Replace the bearing shaft b Engine Runs Rough Problem Probable Cause Possible Remedy injection pump mechanism 1 Irregular injection pump volume 2 Faulty control rack function 3 Worn delivery valve 4 Faulty injection nozzle Governor mechanism 1 Governor lever sticking 2 Stretched or weak governor spring Repair or replace injection pump Repair or replace injection pump Replace the delivery valve Repair or replace nozzle Inspect repair governor Replace the spring Groundsmaster 300 Series Page 4 17 Troubleshooting Testing Glow Plug Test Fig 16 A
335. recesses in the isolation manifold IMPORTANT The unit will not function if the valve plate is not positioned on the isolation manifold exactly as shown in Figure 101 If the valve plate spring slots isolation manifold spring recesses and springs are not centrally aligned in this step the springs could be damaged when the port manifold is installed onto the assembly 38 Apply clean multi purpose grease to the valve ring seal ring Install the seal ring in the valve ring Fig 102 Repairs Page 8 48 Figure 102 Groundsmaster 300 Series 39 Putthe 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 40 Apply a few drops of oil to the valve plate Align the grooves onthe 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 Fig 104 Be careful not to pinch a spring during installation The two alignment pins in the valve plate will engage the holes in the port manifold The pin on the hex drive assembly must engage the center hole in the port manifold 41 Install a new o ring on the plug Insert the check ball hole in the port cover Be sure the ball is seated in the bottom of the check ball hole Turn the plug assembly into the port cover until the ball is retained Fig 105 Groundsmaster 300 Series Page 8 49
336. rically disconnect the component being tested from the circuit e g unplug the seat switch connector before doing a continuity check NOTE Electrical troubleshooting of any 12 Volt power connection can also be performed through voltage drop tests without disconnection of the component Ignition Key Switch Fig 5 The circuitry of the ignition switch is shown in the charts With the use of a continuity tester the switch functions may be tested to determine whether all circuits are being completed while the key is moved to each position A CAUTION When testing electrical components for con tinuity with a volt ohm meter or continuity tester make sure that power to the circuit has been disconnected POSITION CONTINUITY AMONG TERMINALS 1 OFF NONE 2 ON B l A 3 START 1 5 Testing Page 6 18 Figure 5 Groundsmaster 300 Series 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 Raise the seat to get access to the seat switch wiring connector 2 Disconnect the seat switch wiring connector and install a continuity tester or ohm meter between the two leads of the seat switch 3 Lower the seat The continuity tester should show no continuity NOTE Make sure the compression spring and pin holds the s
337. ring If the manifold has developed any of these conditions it must be replaced 21 Remove the two isolation manifold metering ring alignment pins Fig 40 Groundsmaster 300 Series Page 8 27 Figure 38 Figure 40 Repairs 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 42 If the metering ring bore is scored it should be replaced Figure 42 25 The metering package components are held to gether with eleven hex socket head screws Lift the metering package from the assembly and put it on a clean surface Fig 43 IMPORTANT Do not clamp the metering package in a vise as this could damage the components Figure 43 Repairs Page 8 28 Groundsmaster 300 Series 26 Remove and discard the commutator seal from the commutator cover Fig 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 N Figure 45 28 Lift the commutator cover from the metering pack age Fig 46 29 Inspect the ground surfaces of the commutator cover You should notice a normal polished pattern due to the rotation of th
338. ring gear backlash Fig 21 PINION GEAR TO RING GEAR BACKLASH 0 004 to 0 016 in 0 10 to 0 40 mm 12 Adjust backlash by increasing or reducing bearing case shim thickness 13 Check pinion gear to ring gear engagement see Pin ion Gear to Ring Gear Engagement in this section of this manual 14 Place the correct combination of shims on the bear ing case Tighten mounting screws to 35 to 41 ft Ibs 47 to 56 Nm Groundsmaster 328 D Page 10 1 13 Design Cone Center Distance Figure 20 1 Input shaft pinion gear 2 Bearing case 35 to 41 ft lbs 47 to 56 Nm Figure 21 1 Axle case 3 Dial indicator 2 Screwdriver 4 Input shaft pinion gear 4WD Rear Axle Rev G Dae Dong Axle Differential Gear The following procedures assume the rear axle assem bly has been removed from the machine Removal 1 Remove bevel gear case axle case assemblies see Bevel Gear Case Axle Case Assembly in this section of this manual IMPORTANT Do not interchange right and left dif ferential shafts assemblies 2 Mark and pull the differential shaft assemblies from the axle support see Differential Shafts in this section of this manual 3 Remove input shaft pinion gear assembly shims and O ring from the axle support Fig 22 4 Remove the axle support case screws Separate the axle support halves and remove the O ring 5 Remove the differential gear assembly bearings and adjusting
339. rn it must be replaced Cam lobe height should be measured using a micrometer The standard cam lobe height for both intake and exhaust valves is 1 4079 inches 35 75 mm The maximum allowable wear on cam surface is 0 0394 inch 1 0 mm Replace the camshaft if wear exceeds this amount Figure 66 Measuring camshaft cam lobe height Fuel Injection Pump Camshaft Fig 67 1 Inspect the camshaft bearing replace if defective 2 Examine the oil pump coupling The camshaft must be replaced if this coupling is worn 3 Examine the cam lobe surfaces Replace the cam if they are damaged 4 Measure the cam lobe height in the same manner as measuring the valve camshaft lobe height The standard lobe height for each cylinder of the injection pump is 1 7323 inches 44 mm The camshaft must be replaced if the cam lobe has been worn by 0 0394 inch 1 mm or more Figure 67 Fuel injection pump camshaft Groundsmaster 300 Series Page 4 55 Cylinder Block Overhaul 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 2 Check the crank journals and crank pins for damage such as galling seizure etc If journals or pins are seriously damaged they may be reground and over sized bearings installed The
340. rnor lever position incorrect Governor spring broken or disconnected 2 Fuel filter is clogged Clean replace filters 3 Injection pressure is low Adjust injection pressure of nozzle 4 Poor nozzle spray Clean or repiace the nozzle 5 Poor injection pump pressure Repair or replace injection pump 6 Incorrect fuel Use recommended fuel 7 Injection timing is advanced Adjust injection timing Low Compression 1 Valve clearance is incorrect Adjust valve clearance 2 Valve seat surface is rough or burnt Finish surface by lapping Replace valve and guide 3 Valve spring is broken Replace the spring 4 Leaking cylinder head gasket Replace the gasket 5 Piston rings are seized Overhaul the engine 6 Piston rings and cylinder are worn Overhaul the engine Replace the glow plug Poor wiring connection Adjust governor lever Repair governor spring 2 Low Power Problem Probable Cause Possible Remedy Low Compression Injection system faulty 1 Injection timing is incorrect 2 Injection volume is insufficient 3 Injection pressure is low Lack of fuel 1 Air in fuel system 2 Filter is clogged 3 Fuel tank is contaminated Air cleaner is clogged Engine overheats 1 Low or incorrect coolant level Improper belt tension Defective water pump Radiator clogged or leaks pressure Injection timing is incorrect Engine oil is low Defective thermostat
341. robably worn and must be re placed 1 Disconnect the hydraulic hoses from the steering cylinder Put caps or plugs on all the fittings and hoses to prevent contamination NOTE To ease reassembly tag each of the hoses to show their correct position on the steering cylinder 2 Remove nut Fig 16 Item 9 and washer Item 8 from end of rear axle pin Remove the two 2 cap screws Item 2 securing the axle pin to the frame 3 Jack up the frame just ahead of the rear wheels until pressure is taken off the axle pin Support the machine with jack stands to prevent it from falling 4 Pull the axle pin out This will release the rear axle and washer s from the frame Carefully pull the entire axle and wheel assembly out from under the machine NOTE A varying number of washers Item 45 may have been installed between the axle pivot tube and frame during manufacture Make sure the same number of washers are installed during reassembly 5 Remove the retaining ring Item 12 and washers Item 17 18 that secure the wheel spindle Item 1 33 into the axle tube Slide the spindle and wheel assembly out of the axle tube to expose the bushings 6 Use a punch and hammer to drive both bushings Item 4 out of the axle tube Clean the inside of the axle tube to remove any dirt and foreign material Repairs Page 8 14 7 Apply grease to the inside and outside of the new bushings Use an arbor press to install the bushings i
342. rom the pipe nipple in the differential assembly and add oil to the proper level Repairs Page 5 40 4 Start the engine and operate the traction and lift system controls for approximately five minutes Then turn the engine off 5 Allow the machine to stand idle for approximately two minutes remove the dipstick and check the oil level If the oil level is too high drain the system until it is at the correct level Add oil if the fluid level is too low Groundsmaster 300 Series Lift Cylinder Removal and Installation Fig 33 1 Lower the cutting unit to the shop floor and turn the engine off Jack up the right front side of the traction unit and support it with a jack stank Remove the wheel nuts and slide the wheel off of the mounting studs 2 Remove the hoses from the lift cylinder and cap the hoses to prevent contamination 3 Remove the hair pin cotters and spring from the cotter pin Remove the mounting pins and slide the cylinder from between the lift arm and the stationary mounting bracket 4 Install the new or rebuilt cylinder with the pins and assure the cotter pin which secures the moveable end of the cylinder is to the outside Hook the chain tension spring through the eye of the cotter pin 5 Connect the hydraulic hoses from the control valve to the cylinder 6 Install the wheel and tighten the nuts to 45 55 ft Ib Remove the jack stank and lower the deck to the shop floor 7 Check the level of
343. rrect adjustment tighten screw on tie rod clamp and connect ball joint to mounting bracket with nut and cotter pin Steering Stop Adjustment Fig 7 The rear axle steering stops help prevent over travel of the steering cylinder in case of impact on rear wheels The stops should be adjusted so there is 0 090 in clearance between bolt head and knuckle on axle when steering wheel is completely turned left or right 1 Thread bolt in out out unitl 0 090 in clearance is attained Fig 7 Adjustments Page 10 4 Figure 6 1 Ball joint 3 Tie rod clamp 2 Tie rod Figure 7 1 Steering stops Groundsmaster 300 Series Repairs Drive Shaft Service 0 34 0 03 ATON end of yon clutches must face 31 bolt flange end o sow max h 220 Sol fange ena o 7 2 toward rear axle Apply Yr NA apply 7 22 lever seeze N f ISSN Detail A Detail B A A Figure 8 Removing Drive Shaft 1 Put machine on a level surface lower cutting unit stop the engine and remove the key from the ignition Switch Block the rear wheels to prevent the machine from moving 2 Use a hammer and punch to drive roll pin Fig 8 Item 35 out of axle coupling Item 37 and rear axle shaft Loosen two 2 capscrews and locknuts securing coupling to axle shaft Slide coupling off of shaft 3 Remove six 6 socket head capscrews and lock washers securing drive shaft yoke flange
344. rs that rotate on tapered roller bearings Single row pre set tapered roller bearings are used on the outside ends of the axle shafts The entire drive line of the axle assembly is made of alloy steel The axle has a die cast aluminum housing that also serves as the hydraulic oil reservoir Power is transmitted from the transmission output gear to the pinion spur gear The pinion spur gear transmits power directly to the differential drive gears to turn the axles and the wheels The differential axle has a one piece axle shaft with the flange being part of the axle stem Fig 1B Groundsmaster 300 Series Page 7 1 Chapter 7 Differential Axle Axle Shaft Disassembly and Wheel Bearing 4 Differential and Housing Disassembly 8 Differential and Housing Reassembly 14 Figure 1B Introduction Specifications Item Specification Front wheel lug nut torque 45 to 55 ft lb Front to rear housing torque 18 to 28 ft lb Transmission to axle torque 25 to 30 ft lb Differential bearing caps torque 30 to 45 ft lb Ring gear to differential case torque 45 to 65 ft lb Fill pipe torque 20 to 30 ft lb Side plate gear cover torque 25 to 40 in lb Axle shaft bearing retainer nut torque With hex head screw 37 to 45 ft lb With socket head screw newer models 16 to 20 ft lb Ring gear to pinion gear backlash 0 003 to 0 007 in Pinio
345. rt 2 Ball joint plate reinforcement support and locknuts Make sure the springs contact the retainer plate on the push arms and the underside of the frame 5 Have a helper push down on the left push arm while you place a 3 ft long block of wood between the chassis and to top of the push arms across the full width of the machine NOTE After the wood block is installed there should be enough clearance for installing the ball joint into the front of the push arm 6 Thread jam nut fully onto the left hand ball joint Screw the ball joint into the left hand push arm until the center of the ball joint is 2 3 8 inches away from the front ofthe push arm Do nottighten the jam nut until the deck is mounted 7 Install the brake mount and pedal assembly with cap screws locknuts carriage bolts lock washer and nuts Route the right hand brake cable through the hole in the right hand push arm bracket Connect the cable to the brake strut with the clevis pin and the tension spring Hook the opposite end ofthe tension spring into the hole in the side of the chassis Also install the cable into the mount on the frame Groundsmaster 300 Series Page 12 25 Repairs Gear Case Removal and Installation Fig 41 42 Removing Gear Case and Drive Pulley 1 Lower the cutting unit shut engine off and engage the parking brake 2 Remove shroud Item 20 covering universal drive shaft Disconnect drive shaft from gear case Remove belt cov
346. s at 100 hour intervals The correct spark plugs to use in the engine are Motor craft AGSF22C or AGRF22 or equivalent Set air gap at 0 040 in 1 0 mm 1 Clean area around spark plugs so dirt does not fall into cylinder when plugs are removed 2 Pull wire off spark plugs and remove plugs from cylinder head 3 Check condition of center and side electrodes to determine operating temperature of engine A Light brown insulator tip indicates correct spark plug and heat range B Black or oily insulator tip indicates an excessively rich fuel mixture possibly caused by a dirty air cleaner element or a carburetor that is set too rich C Light gray or blistered white insulator indicates overheating caused by a lean carburetor setting or incorrect spark plug heat range too high IMPORTANT A cracked fouled or dirty spark plug must be replaced Do not sandblast scrape or clean electrodes by using a wire brush because grit may release from the plug and enter combustion cham ber resulting in engine damage 4 After setting air gap at 0 040 in 1 0 mm install spark plug in cylinder head Tighten the plug to 11 15 ft lb Push wire onto spark plug General Information Page 3 2 Groundsmaster 300 Series 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 Ibs 1 To adjustable tension loosen bolt securing brace to engine bol
347. s directly to shackles on engine as this may cause damage to fan shaft tube or muffler when the engine weight is sup ported by chains 16 Remove four bolts securing rear engine mount to frame 17 Remove slack from lifting chain and carefully re move two capscrews which pass through the two rubber front engine mounts 18 Lift and guide engine from engine compartment Be careful not to damage the radiator cooling fan or other components during removal 3 Inspect for oil and coolant leaks 4 Check engine idle speed and maximum governed speed settings Groundsmaster 300 Series Cylinder Head Overhaul This section explains disassembly inspection repair and reassembly of the cylinder head and its compo nents as outlined below Cylinder Head Removal Cylinder Head Servicing Valve Guides Valves Valve Seats Valve Springs Rocker Arms Bearings Shaft Cylinder Head Reassembly and Installation IMPORTANT When overhauling the cylinder head and cylinder block it is important that many of the components be reinstalled in the exact location from where they were removed These items are noted in the text It is useful to construct a rack where these components can be stored in order until reassembly Cylinder Head Removal Engine Removed Fig 52 53 1 Remove the fan shaft bracket muffler and rear motor mount 2 Disconnect the water bypass hose from the cylinder head 3 Remove the injection pipes
348. s more than 3 8 inch lower than outer blades proceed to step 7 and add shims between spindle housing and bottom of cutting unit 6 Rotate blades so tips line up with one another Tips of the adjacent blades must be within 1 8 inch of each other If tips are not within 1 8 inch of each other proceed to step 7 and add shims between spindle housing and bottom of cutting unit Adjustments Page 11 6 7 Remove cap screws flat washers lock washers and nuts from outer spindle in the area where shims must be added To raise or lower the blade add a shim Part No 3256 24 between spindle housing and bottom of cutting unit Continue to check alignment of blade and add shims until tips of blades are within the required dimension IMPORTANT Do not use more than three shims at any one hole location Use decreasing numbers of shims in adjacent holes if more than one shim is added to any one hole location 8 Tension idler pulleys against all three belts Also install covers to top of cutting unit 9 Set rear caster wheels in lower holes in caster forks if height of cut is above one 1 inch and adjust height of cut 10 Mount cutting unit to traction unit refer to Mounting Cutting Unit To Traction Unit Figure 5 Groundsmaster 300 Series 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
349. s supplied to the rod end of the steering cylinder and left turn pressure to the barrel end as shown On 4WD units these hydraulic lines are reversed right turn pres sure to barrel end and left turn pressure to rod end When the steering wheel is stationary the control valve within the steering valve shifts back to neutral Fig 4 allowing system oil to flow through the steering valve and out the AUX port back to reservoir Oil in the rest of the steering circuit is then trapped When the steering valve is turned to the left Fig 5 oil is metered out port LT to the steering cylinder Oil displaced by the other end of the cylinder returns to the steering valve through port RT and is directed out port OUT back to reservoir Groundsmaster 300 Series Figure 3 FROM PUMP xt 4 5 E STEERING VALVE 24 gums Page 8 3 Figure 5 Power Steering Schematics 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 Brake pedal free travel 1 2 to 1 in Special Tools Steering Valve Service Fixture To avoid distorting or damaging the steering valve when repairing do not clamp it directly into a vise Fabricate a service fixture Fig 6 and us
350. s to prevent the machine from rolling 5 Remove the two cap screws lock washers flat wash ers and spacers securing the drive coupling assembly Figure 9 to the engine hub Remove the two cap screws flat washers and locknuts securing the coupler to the trans mission hub Slide the assembly out after the cap screws have been removed 6 If the drive coupling assembly must be disassembled separate the rubber couplings Item 17 from the drive coupling Item 18 by removing the nuts flatwashers and cap screws Installing Drive Couplings 1 Assemble the rubber couplings and drive coupling with the cap screws flat washers and nuts 2 Position the drive coupling assembly between the engine hub and transmission hub align the holes Se cure the drive coupling to the hubs with cap screws lock washers flat washers and nuts Tighten the cap screws alternately and evenly to prevent distortion of the rubber couplings NOTE After installing the drive coupling assembly the rubber coupling must not be deformed more than 125 in 8 mm in either direction If the rubber coupling is deformed correct by loosening the transmission hub hub setscrews and changing the position of the hub The end of the pump hub must be positioned 0 60 250 in 1 5 6 mm away from the transmission face Tighten the setscrews on the hub s to a torque of 12 ft Ib 1 7 Kgm 3 Remove the wheel blocks and jackstands Lower the machine to the shop
351. screws Close and latch hood NOTE Check fan belt tension after first days of opera tion Readjust tension if necessary Groundsmaster 300 Series Page 4 27 Figure 25 1 Alternator 4 Brace 2 Engine brace bolt 5 Fan belt guard 3 Alternator brace bolt Figure 26 1 1 4 in 6 mm deflection 2 Idler pulley locknut External Engine Component Repair Fan Fan Pulley and Fan Shaft Service Fig 27 Fan Assembly Removal 1 Park the machine on a level surface turn engine off remove key from switch and apply the parking brake 2 Remove five capscrews which secure fan belt guard and remove guard 3 Loosen locknut securing idler pulley Slide pulley to right to remove tension from fan V belt and slip belt off of flywheel and fan pulleys 4 Use a hoist connected to the two engine hangers to support the rear of the engine IMPORTANT Position lift chain underneath fan shaft tube to prevent damage to tube NOTE An alternate method is to put a sturdy board beneath oil pan and use a floor jack to support engine 5 Remove two cap screws which pass through rubber engine mounts If shims are used between rubber mounts and metal engine mount bar be sure to note their locations and reinstall them correctly 6 Remove two cap screws which fasten fan mount to the rear of engine block These are located just above edge of flywheel 7 Remove four cap screws which secure fan mount to front of cylinder head
352. se and start the new capscrews into the gear with your fingers Tighten the screws alternating back and forth across the gear to allow the gear to be pulled evenly into place Tighten the cap screws to a torque of 45 65 ft lb 6 2 9 0 Fig 50 17 When installing new differential bearings reuse the original shims or use new shims of the same thickness Press the bearing onto the differential case If a new differential case is being installed start with a 020 inch pack of shims under each differential bearing Shims are available in 003 005 010 and 030 inch sizes Fig 51 18 Assemble new differential bearing cups to differen tial bearing cones Seat differential assembly with drive gear on proper side of carrier into carrier bearing cra dles NOTE Groundsmaster 300 Series S N 90001 amp up require that the ring gear teeth face toward the spur gear cover The bearing cradles are designed to apply a slight preload to the bearings It is important to push both of the bearing assemblies simultaneously into their saddles Bearing caps must be installed with indexing marks P adjacent to indexing marks P in case Install the bear ing caps into their original position as previously marked Tighten the cap screws to a torque of 30 45 ft lb 4 1 6 2 Fig 52 Repairs Page 7 20 Figure 50 3 Figure 51 Figure 52 Groundsmaster 300 Series 19 Using a dial indicat
353. se the engine speed to the FULL throttle setting Figure 10 and use a tachometer to achieve 3200 50 rpm A CAUTION 1 High pressure gauge 0 5000 psi To prevent damage to gauge and possible personal injury due to leaking hot oil do not exceed 5000 psi during traction pressure test 6 Sit on the seat and with the brakes locked slowly depress the top of the traction pedal While pushing the top of the traction pedal down look at the pressure reading on the gauge The gauge should show 4000 4500 psi DO NOT exceed 5000 psi 7 If the traction pressure is lower than 4000 psi check the acceleration valves If the acceleration valves are in good condition and there is no foreign material in the ports of the transmission inspect the charge check valves If the charge check valves are in good condition overhaul the transmission because either the pump motor or both piston groups are at fault Groundsmaster 300 Series Page 5 21 Testing TEST NO 4 Charge Pump Flow and Implement Relief Pressure Fig 11 Using a 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 Raise and support the seat or remove the seat and seat mounting plate 3 Put a drain pan below the transmission Disconnect the hydraulic hose from the charge pump outlet pres sure fitting on the transm
354. securing covers Item 30 26 to knuckle case Item 28 B Pull out outer axle shaft Irem 35 and bevel gear Item 5 C Remove capscrews Item 10 securing knuckle arm Item 8 to knuckle case Item 28 Pull off knuckle arm toward upper side and pull off case toward bottom D Remove capscrews Item 13 and remove bear ing retainer Item 15 Remove bevel gear Item 18 and knuckle pin Item 20 Repairs Page 10 8 4 Disassemble differential case Fig 12 A Remove bolts Item 53 56 and remove clutch cover Item 53 B Remove bolts Item 40 and remove bearing case Item 38 and pinion gear Item 30 from differential case Item 24 C Remove bolts Item 1 and remove cover Item 2 Remove differential assembly from differential case C Remove bolts Item 7 to disassemble differential Inspection Inspect shaft splines gears and bearings for wear and damage Replace parts as necessary Use suitable bearing pullers and an arbor press when replacing bearings NOTE Ring gear Item 6 and pinion Item 30 are a matched set that must be replaced together Groundsmaster 300 Series 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 Assemble clutch parts and install clutch cover 2 Assemble differential case Fig 12 Item 53 Install new oil seals Item
355. sel engine used in the Groundsmaster 322 D and 325 D mower Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the Special Tools section The use of some specialized test equipment is explained how ever the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at a qualified diesel engine repair facility The engine used in the Groundsmaster 322 D 325 D mower is manufactured by Mitsubishi Heavy Industries Figure 1 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 The engine model number is embossed on the pump mounting side of the crankcase The serial number is stamped on the injection pump mounting surface of the crankcase Fig 1 Introduction Page4 2 Groundsmaster 300 Series Specifications The illustrations Figs 2a and 2b give information about the general construction of the engine COANODARWHND Cooling fan 10 Water oulet fitting 11 Intake valve 12 Exhaust valve 13 Water pump pulley 14 Water pump 15 Piston 16 Connecting rod 17 Fan belt 18 Figure 2a Crank pulley Crankshaft Gear case Oil pan Oil screen Oil filler c
356. sg v ueiouuoe j0119 uuoped S4IeuleH uoneuBiseq Hun asn eunnoi 104 eDed ereordnp J9p40 YOM e2ueuejure y JosiAJedng Gye YALSVINSGNNOYD EQUIPMENT OPERATION AND SERVICE HISTORY REPORT 322 0 325 0 Unit Model and Serial Number Deck Model and Serial Number Engine Numbers Transmission Numbers 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 GROUNDSMASTER 322 D and 325 D Maintenance Schedule i Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval amp Service Check Battery Fluid and Cable Connections 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 Check PTO Belt Tension Inspect Air Filter Dust Cup and Baffle Replace Engine Oil Filter Check Fan and Alternator Belt Tension Inspect Cooling System Hoses Replace Transmission Oil Filter Service Air Filter Decarbon Spark Arrestor Muffler Check Rear Wheel Toe In and Steering Linkage T Torque Wheel Lug Nuts Replace Diesel Water Separator Filter Replace Electric Fuel Pump Filter Check Fuel Lines and Connections Change Cutting Unit
357. shims from the axle case 6 Drive the spring pin from the differential case with a punch and hammer Discard the spring pin Fig 23 NOTE Mark and arrange all components so they can be reassembled in their original position 7 Remove the differential pinion shaft pinion gears and pinion washers Remove the differential side gears and side gear shims Remove the ring gear from the dif ferential case only if the ring gear will be replaced Fig 24 NOTE Replacement ring gears are only available in matched ring and pinion sets 35 to 41 ft lbs 5 47to56Nm M Figure 22 1 Pinion gear 5 Case screws 2 O ring 6 Differential gear 3 Axle support right 7 O ring 4 Axle support left Figure 23 1 Differential case 2 Spring pin 22 to 25 ft lbs 30 to 34 Nm Thread Locker Figure 24 1 Differential pinion shaft 5 Side gear shims 2 Pinion gear 6 Ring gear 3 Pinion washer 7 Differential case 4 Side gear 4WD Rear Axle Rev G Page 10 1 14 Groundsmaster 328 D Dae Dong Axle Inspection 1 Measure the differential side gear O D and the dif ferential case 1 0 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 Factory Spec 1 335 to 1 337 in 83 91 to 33 95 mm DIFFERENTIAL CASE I D Factory Spec 1 339 to 1 341 in 34 00 to 3
358. sion 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 Loosen bolt securing brace to engine and bolt secur ing alternator to brace 4 Insert pry bar between alternator and engine and pry out alternator 5 Hold alternator in position after proper belt tension setting is achieved and tighten alternator and brace bolts to secure adjustment Fan Belt Service Fig 25 26 1 Unlatch and open hood 2 Remove capscrews 5 securing fan belt guard and remove guard 3 Belt should deflect 1 4 in 6 mm midway between pulleys with 5 Ibf 22 N of force applied If deflection is incorrect proceed to step 4 If correct proceed to step 5 4 Loosen locknut securing idler pulley Push idler pulley against belt until proper deflection is achieved and tighten idler pulley locknut 5 Install fan belt guard and secure with capscrews Close and latch hood To replace belt 1 Do steps 1 and 2 above 2 Loosen locknut securing idler pulley slide pulley away from belt and remove belt from top and bottom pulleys 3 Install new belt and adjust for proper tension Push idler pulley against belt until belt deflects 1 4 in 6 mm with 5 Ibf 22 N of force applied midway between top and bottom pulleys Tighten idler pulley locknut to se cure adjustment 4 Install fan belt guard and secure with cap
359. sive scoring pitting or wear Replace any defective parts 10 Use a new seal kit Items 3 6 10 to replace all O rings seals and back up rings IMPORTANT The dust seal lips must point outward the seal must have the O ring portion facing towards the inside of the cylinder 11 The rod end is retained with 75 90 ft Ibs torque and with Loctite Retaining Compound very strong 12 Tighten the piston head locknut to 75 90 ft Ib Remove the piston head and shaft assembly from the vise NOTE Coat all O rings seals wiper rings and the interior bore of the cylinder with a light coating of hydraulic oil to ease assembly 13 Install the barrel into the vise in the vertical position described in step 3 14 Slide the shaft piston and head assembly into the barrel aligning the ports for the hydaulic lines as needed 15 Install the retaining ring to secure the head in the barrel Pull up on the piston to make sure the retaining ring is in place Figure 34 Repairs Page 5 42 Groundsmaster 300 Series 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 di n of the lift lever to expose the valve 3 Loosen and remove the hydraulic lines that are attached to the valve Cap or plug all of the fittings and hoses to prevent contamination P 4 Remove the five cap screws and locknuts that secure the valve and leve
360. smission hub to the engine pulley refer to Installing Drive Couplings in Chapter 10 14 Since some oil has drained out of the transmission when the charge pump was serviced check the oil level in axle housing Start the engine and let it run for about one or two minutes Then turn the engine off and check oil level in the axle housing again Also check the seal in the charge pump for oil leaks Repairs Page 5 32 Groundsmaster 300 Series Transmission Removal and Installation 1 Position the machine on a level surface in a clean area of the workshop Block all four wheels of the unit to prevent it from moving 2 Lower the cutting unit or implement to the shop floor Turn the engine off and remove the key from the ignition switch 3 Disconnect the positive battery terminal from the battery Place the cable out of the way and in such a position that it cannot spring back and make contact with the positive battery terminal 4 Raise the seat of the machine and secure it in that position 5 Place a drain pan underneath the differential Remove any loose sand grass or debris from the top of the transmission Place a drain pan underneath the differential and hydrostat Remove the oil line that con nects the differential to the transmission or hydraulic filter Allow oil to drain Cap or plug the lines and fittings 6 Remove the hydraulic lines that connect to the trans mission Cap or plug all hoses and fittings to prevent
361. solenoid on back of injection pump These sounds signify that the system is functioning properly electrically Detailed testing of the control unit alone is provided in the chart that follows These tests must be performed with the control unit installed in the machine and con nected to the electrical system Figure 17 IMPORTANT Testing the control unit by any other method especially when using a battery powered meter or tester may cause damage to the solid state circuitry in the control unit Testing Procedure Connect a voltmeter to the B terminal red wire of the 3P coupler Voltmeter reading should be approximately 12 volts D C If no voltage is present check the 40 amp circuit breaker manual reset the 10 amp fuse in line holder or the battery for fauit Connect a voltmeter to the green wire of the 3P coupler Read the voltmeter each time the key switch is turned to ON RUN and OFF When ON voltage should be 12 volts when OFF voltage should be 0 volts If voltage is not present when the key switch is turned to the ON position test the key switch for fault the fuse in the temperature relay box or the safety interlock switches for proper operation Connect a voltmeter to the ST terminal red white wire of the coupler Read the voltmeter each time the key switch is turned to START and ON RUN When switch is turned to START voltage should be 12 volts when turned to ON RUN voltage
362. spindle shaft 3 Install the blade anti scalp cup lockwasher and blade bolt Make sure blade sail is facing up toward cutting unit Tighten blade bolt to a torque of 85 to 110 ft lb Groundsmaster 300 Series Page 13 7 Repairs Inspecting and Sharpening Blade FLAT PART OF 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 If any wear is noticed replace the blade refer to Removing Cutter Blade A WARNING If the blade is allowed to wear a slot will form Figure 7 between the sail and flat part of the blade Eventually a piece of the blade may break off and be thrown from under the housing pos sibly resulting in serious injury to yourself or bystander SHARPEN AT ORIGINAL ANGLE b3 3 Examine cutting edges of all blades Sharpen the END VIEW cutting edges if they are dull or nicked Sharpen only the top side of the cutting edge and maintain the original cutting angle to assure sharpness The blade will remain balanced if same amount of metal is removed from both cutting edges Figure 8 4 To check blade for being s
363. ssed groove side of the pump valve plate against the pump side of center sec tion The slot in the valve plate must fit over the locating pin Assure that the center of the valve plate pilots on the needle bearing extending out of the center section 4 Assemble the center section between the motor housing and the pump housing The line scribed or painted on the motor housing center section and pump housing must line up to assure the correct assembly of the parts NOTE When assembling the three main sections make sure the gaskets valve plates and cylinder block assemblies remain in place 5 Use new capscrews and special flat washer when assembling the transmission sections Lubricate the four cap screws with oil and secure the three main sections together Alternately and in gradual incre ments tighten the cap screws to 34 37 ft Ib Groundsmaster 300 Series Page 5 39 CAP SCREWS GASKET BEARING PUMP HOUSING GASKET AND PUMP VALVE PLATE SECTION Figure 31 MOTOR VALVE PUMP VALVE PLATE Figure 32 Repairs Priming After Transmission Overhaul Or Replacement Use the following procedures to prime the hydraulic system whenever the Sundstrand Transmission is over hauled or replaced 1 Pour a quantity of transmission oil into the transmis sion before mounting it to the machine 2 Fill a new filter with fresh clean oil and install it onto the transmission 3 Remove the dipstick f
364. st Leave the multimeter test leads connected to the battery and record the battery voltage Note Upon starting the engine the battery voltage will drop and then should increase once the engine is running Note Depending upon the condition of the battery charge and battery temperature the charging system voltage will increase at different rates as the battery charges Start the engine and run at high idle speed Allow the battery to charge for at least three 3 minutes Record the battery voltage Voltage Measured Battery Charge Level Fully charged 10096 75 charged 12 68 v or higher 12 45 v 12 24 v 5096 charged 12 06 v 2596 charged 11 89 v 096 charged After allowing the engine to run for at least three 3 min utes battery voltage should be at least 0 5 volts higher than initial battery voltage see example in table to the right Note While engine is running if battery voltage ex ceeds 16 volts the regulator in the charging system should be inspected After allowing the engine to run for at least three 3 min utes if battery voltage does not increase at least 0 5 volts additional testing of the battery and or charging system should be performed Acceptable voltage increase 12 25 12 80 v 0 55 Initial Battery Voltage Battery Voltage after 3 Minute Charge Difference Glow Plug System Test Groundsmaster 328 D This is a fast simple test that can help to determine the i
365. sting Page 6 28 Groundsmaster 300 Series 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 A 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 Prevent sparks and DO NOT smoke while working on the fuel system to avoid the possibility of an explosion and personal injury 3 Carefully remove sending unit from fuel tank Figure 21 4 Connect an ohmmeter set on the R x 1 scale across the two terminals of the sending unit As the float is moved up and down the resistance in Ohms will be registered on the meter The resistance should vary between 90 and 0 Ohms 5 If not change in the resistance is measured as the float is moved up and down the sending unit is faulty and must be replaced 6 Reverse steps 1 4 to install the sending unit Groundsmaster 300 Series Page 6 29 Testing 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 ponents do not operate the engine with the battery Battery Specifications cables disconnected BCI Group 24 Battery 37
366. stration Install the plugs Item 2 into the tapped holes in the housing Groundsmaster 300 Series Gear Box Final Assembly 1 Bearing drag is adjusted by the amount of gaskets Item 4 5 6 used between the cap and housing ma chined surfaces 2 Put two 0 015 in gaskets on the machined surface of the housing then install the shaft and cap assembly in the housing so the bearing cone Item 9 on the shaft assembly and bearing cup Item 3 in the housing are mating Align the holes in the cap with the holes in the gaskets and housing 3 Install capscrews and tighten Groundsmaster 300 Series Page 11 25 4 The shaft should have a very slight amount of bearing drag If the shaft turns hard the cap must be removed and gasket s need to be added If the shaft has no bearing drag or has end play the cap must be removed and gasket s taken out The cap must be adjusted to where the shafthas no end play and only a slight amount of bearing drag 5 Repeat steps 1 4 with the other shaft and cap assembly 6 After installing the gear box on the cutting unit fill it with SAE 80W90 API GL 5 lubricant to the level of the check plug see Maintenance section in this chapter Repairs Blade Spindle Service Fig 34 35 36 37 38 Removing Spindle and Bearings From Spindle Housing 1 Lower the cutting unit shut the engine off and engage the parking brake 2 Remove deck covers from top of cutting unit Loosen
367. t allows for over injection of fuel during starting and thereafter limits the amount of fuel delivered during operation to reduce excessive exhaust smoke These SMOKE SET devices the smoke set plate and Ungleich set plate are PLATE located on the side of the injection pump and operate by limiting the travel of the control rack SPRING SET PLATE UNGLEICH The Ungleich device requires that the engine be OFF SET SPRING either with the key switch or emergency stop lever in order for the control rack to travel completely to the left over injection Once started the action of the governor Figure 42 causes the control rack to move to the right less fuel until the corner of the smoke set plate engages the shoulder of the Ungleich set plate The amount of control rack movement is now restricted by the locations of the smoke set plate and the Ungleich set plate During extreme loading the control rack will overcome the tension on the smoke set spring and slightly in crease the amount of fuel delivered to the cylinders This fuel increase is determined by the Ungleich set plate and is referred to as Ungleich Effect L length Ungleich Effect L Figure 43 c Function 1 prevents engagement of stop plate corner to d Stop plate now b Corner of set plate Ungleich plate limits rack travel q removed from shoulder P P shoulder during q to smoke set of Ungleich Plate starting position a Ungleich Plate catches
368. t retaining nuts position the belt is properly tensioned Figure 12 1 Rubber bumper 3 Idler pulley bolt 2 Spring bracket Groundsmaster 300 Series Page 12 9 Adjustments Center Section NOTE Spring tension is only 10 to 15 Ibs on the wing section but is 80 to 90 165 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 2 Adjust the spring bracket so that the lip on the spring bracket just contacts the rubber stop on the idler arm Use the threaded rod to make belt adjustments Tighten the capscrews and nuts securing the spring bracket in position and tighten the jam nut on the threaded rod 3 Be sure all belt guides are in the correct position and secured to the deck before operating the cutting unit IMPORTANT If there is a gap of more than 3 16 inch between the rubber stop and the idler arm a belt adjustment is necessary IMPORTANT Too much tension on the belt will cause early belt failure Adjustments Page 12 10 Figure 13 1 Threaded rod 4 Tensioning nut 2 Spring bracket nuts 5 Jam nut 3 Rubber stop Groundsmaster 300 Series 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
369. t securing alternator to brace and alternator mounting bolts 2 Insert pry bar between alternator and engine and pry out on alternator 3 Hold alternator in position after proper tension is achieved and tighten alternator and brace bolts to se cure adjustment Coolant Fan Belt Adjustment Fig 2 A new fan belt is to be tensioned to 45 Ibs A used belt is to be re tensioned to 28 lbs 1 To adjust belt tension loosen upper and lower nuts securing idler arm to front engine mount 2 Pull out on idler arm until desired belt tension is achieved 3 Tighten mounting nuts to secure adjustment Groundsmaster 300 Series 3 3 Figure 1 1 Alternator 2 Brace Figure 2 1 Edler arm 2 Engine mount Adjustments Governor Adjustment Fig 3 4 1 With engine shut off move throttle control 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 gapis not correct adjust throttle rod by turning ball joint ends until gap is 1 32 in 0 8 mm If gap is correct to to step 2 A WARNING Engine must be running so final adjustment of governor can be performed To guard against possible personal injury engage parking brake and keep hands feet face and other parts of body away from fan and other moving parts Figure 3 2 Start engine and move throttle to SLOW position Allow engine to warm up to normal operating
370. ted in groove 2 Using an arbor press push large spacer into top of spindle housing tightly against snap ring The spacer must contact the snap ring to be sure of the correct assembly of the parts 3 Thoroughly oil the bearing cups and using an arbor press push the bearing cups smallest inside diameter first into the top and bottom of the spindle housing The top bearing cup must contact the spacer that was in stalled in step 2 and the bottom bearing cup must contact the snap ring to be sure of the correct assembly of parts Insure that the assembly is correct by support ing the first cup and pressing the second against it 4 Apply a film of grease on lips of both seals then install bearing and seal into bottom of spindle housing Re member the BOTTOM SEAL MUST HAVE THE LIP FACING OUTWARD not toward the inside of the spindle housing 5 Check the spindle shaft to make sure it is free of burrs and nicks that could possibly cut the seals and thor oughly lubricate both the shaft and seal lips 6 Slide small thick spacer into spindle housing then install bearing and seal into top of spindle housing LIP OF UPPER SEAL MUST FACE INWARD 7 Slide bearing spacer onto spindle shaft Carefully slide spindle shaft through spindle housing The bottom seal and bearing spacer fit together when the spindle is installed 8 Push pulley onto splines of spindle shaft and retain the parts together with the large flat washer and nut
371. tely dry no fuel on it before testing Perform test away from the tank to prevent an explosion or fire from sparks 5 Check resistance of the sender with a multimeter Fig 6 A Resistance with the float in the full position should be 27 5 to 39 5 ohms B Resistance with the float in the empty position should be 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 Electrical System Rev G 6A 6 Groundsmaster 300 Series Fusible Link Harness The Groundsmaster 328 D and Groundsmaster 345 use three 3 fusible links for circuit protection These fusible links are located in a harness that connects the starter B terminal to the main wire harness If any of these links should fail current to the protected circuit will cease Refer to wire harness drawings in Chapter 6 Electrical System for additional fusible link information Use a multimeter to make sure that continuity exists be tween each terminal pin in connector P1 and connector J1 at the starter Fig 7 If any of the fusible links are open replace the complete harness Diode Assembly Two 2 diode assemblies Fig 8 are used in the ma chine wire harness Diode D1 is used for circuit protec tion from inductive voltage spikes that occur when the starter motor is shut off Diode D2 provides logic for the interlo
372. tempera 1 1 32 0 8 mm 4 Stop ture 2 Throttle rod 5 Throttle arm 3 Carbruetor idle speed screw 3 Rotate throttle arm closed until it contacts stop 4 Check idle speed and adjust carburetor idle speed screw if necessary to attain 1350 50 rpm Adjustments Page 3 4 Groundsmaster 300 Series 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 IMPORTANT Do not over speed the engine because the transmission could be damaged 7 Move throttle rapidly from SLOW to FAST The engine should not surge If engine surges go to step 8 8 Check V belts from engine to governor pulley and make sure they are tight If belts are loose engine will surge If belts are tensioned properly loosen jam nut that retains anti surge screw Rotate screw clockwise 1 8 turn at a time until surging stops Should governor continue to surge check the following A Carburetor too rich or too lean B Binding in throttle linkage C Governor worn internally IMPORTANT Never rotate anti surge screw in too far so that speed of engine increases 9 Bump throttle lever with your hand so engine speeds up momentarily If governor is working properly engine speed should return to normal within one or two sur
373. ter then rinse it with clean water D Check that the cover seal is not broken away Replace the battery if the seal is broken or leaking E Check the electrolyte level in each cell If the lev el is below the tops of the plates in any cell fill all cells with distilled water to the bottom of the cap tubes Charge at 15 to 25 amps for 15 minutes to al low sufficient mixing of the electrolyte Electrical System Rev G Page 6A 12 Groundsmaster 300 Series 2 Conduct a hydrometer test of the battery electrolyte IMPORTANT Make sure the area around the cells is clean before opening the battery caps A Measure the specific gravity of each cell with a hydrometer Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm up the hydrometer At the same time take the tem perature of the cell B Temperature correct each cell reading For each 10 F 5 5 C above 80 F 26 79 C add 0 004 to the specific gravity reading For each 109 F 5 59 C be low 809 F 26 79 C subtract 0 004 from the specific gravity reading Example Cell Temperature 1009 F Cell Gravity 1 245 ADD 20 above 80 F 0 008 Correction to 809 F 1 253 C If the difference between the highest and lowest cell specific gravity is 0 050 or greater or the lowest cell specific gravity is less than 1 225 charge the battery Charge at the recommended rate and time given in Charging or until specific gravity of all cells is 1 225
374. ter to drain cool ant from cylinder block Install cylinder block plug 10 Remove cable tie securing control cables and vacuum sensor hose near caburetor 11 Disconnect vacuum sensor hose from fuel trap on carbruetor 12 Disconnect choke control cable from carburetor 13 Disconnect throttle control cable from governor Groundsmaster 300 Series Page 3 7 14 Remove fuel line from inlet side of fuel pump NOTE Be prepared to insert a plug into fuel line to prevent fuel spill 15 Remove capscrews securing fan shroud to radiator so fan shroud can be move during engine removal for cooling fan clearance 16 Attach a short section of chain between the two lifting shakles on the engine Attach block and tackle or hoist chain to this short section of chain approximately mid way between the two shakles 17 Remove four bolts securing rear engine mount to frame 18 Remove slack from lifting chain and carefully re move two capscrews which pass through the two rubber front engine mounts 19 Lift and guide engine from engine compartment Be careful not to damage the radiator cooling fan or other components during removal Installing the Engine 1 Do steps 2 19 of Removing the Engine in reverse order 2 Fill cooling system with new coolant Install a new oil filter and fill engine with correct oil 3 Inspect for oil and coolant leaks 4 Check engine idle speed and maximum governed speed settings
375. tery If the test voltage is at or above the mini mum return the battery to service Electrical System Rev G Charging To minimize possible damage to the battery and allow the battery to be fully charged the slow charging meth od is presented here This charging method can be ac complished with a constant current battery charger which is available in most shops Follow the manufacturer s instructions when using a battery charger 1 Determine the battery charge level from either its open circuit voltage or specific gravity Level Voltage Gravity 2 Determine the charging time and rate using the manufacturer s battery charger instructions or the following table Reserve Battery Charge Level Capacity Percent of Fully Charged iine 80 or less 3 8hrs 7 5 hrs 11 3hrs 15 hrs at at at at 3 amps 3 amps 3 amps 3 amps 81 to 125 5 3hrs 10 5 hrs 15 8 hrs 21 hrs at at at at 4 amps 4amps 4 amps 4 amps 126 to 3 16 5 hrs 22 hrs 170 at at 5 amps 5 amps 171 to 11 5 hrs 17 3 hrs 23 hrs 250 at at at 6 amps 6 amps 6 amps above 24 hrs 250 at 10 amps Electrical System Rev G Page 14 Do not charge a frozen battery because it can explode and cause injury Let the bat tery warm to 60 F 15 5 C before con necting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are explosive keep open f
376. th the other shaft and cap assembly 6 After installing the gear box on the cutting unit fill it with SAE 80W90 API GL 5 lubricant to the level of the check plug Groundsmaster 300 Series 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 Start the engine and raise the cutting unit Turn the engine OFF and remove the key from the key switch Block up the cutting unit so it cannot fall accidentally 4 Using a rag or thickly padded glove grasp end of blade Remove blade bolt flat washer anti scalp cup and blade from spindle assembly 5 Remove flange nuts and carriage bolts securing spindle housing to deck Slide spindle housing assem bly out the bottom of the cutting unit Disassembly 1 Remove the nut and flat washer retaining the spindle pulley on the spindle shaft Slide pulley off of shaft 2 Press the spindle shaft out of the spindle housing using an arbor press The bearing spacer remains on the spindle shaft as the shaft is being removed 3 Remove seals from spindle housing 4 Allow the bearings and small thick spacer to fall out of the spindle housing 5 Using a punch and hammer drive both of the bearing cups out of the spindle housing Also drive the large spacer out of the housing
377. that is not operating correctly 5 Repeat the test for the other cylinders Groundsmaster 300 Series Injection Timing Test Fig 20 21 Injection timing can be adjusted by installing shims under the pump body The timing is important because it determines when the fuel enters the combustion chamber The most accurate method of timing is done with an electronic diesel timing tester available from major tool supply companies The following method is an initial setting for starting the machine 1 Remove the number one injection pipe from both the pump and nozzle The number 1 cylinder is opposite from the flywheel end of the engine 2 Set up the injection pump for the test A Remove the delivery valve holder Fig 20 Re move the delivery valve assembly and spring B Replace the valve holder and tighten it in place 3 Put the throttle control in the middle of its range of travel 4 Slowly rotate the crankshaft counterclockwise from the flywheel end normal rotation until the IT marks injection timing marks on the crankshaft pulley are approximately 1 2 in 21 mm from alignment with the stationary pointer on the engine gear case Fig 21 Make sure the number 1 cylinder compression stroke is approaching by checking the push rods Both push rods on the number 1 cylinder should be loose and the valves closed If either push rod is tight rotate the engine crankshaft one full revolution and inspect the push
378. the above Groundsmaster 300 Series Page 4 25 engine oil to disassembled parts as necessary to pre vent rust 5 Keep the work area clean dirt causes engine failures 6 Be very careful when working on fuel system compo nents Cover the work area with clean paper Store components of the nozzles or injector pump in clean fuel oil Do not allow components to strike each other or other objects Wet hands with clean diesel fuel before handling these parts Engine Compression The time interval to overhaul the engine can most accurately be determined by regular and systematic cylinder compression measurement See Compres sion Test in the Testing section of this chapter list can be a result of excessive fuel injection improper injection timing or nozzle and injection pump wear Poor starting may be a result of electrical problems Noises may be associated with a mechanical part outside the engine Excess fuel or oil consumption may be the result of leaks See the Troubleshooting section of this chap ter Another indicator of the need for an overhaul is oil consumption Make sure the engine does not leak oil when the oil consumption between the oil change main tenance interval is approximately 1 1 2 times normal 15096 engine overhaul should be considered With a good knowledge of how the engine operates access to maintenance and compression test records and information in the Troubleshooting section of this cha
379. the engine By contrast a blade that is higher at the ends than the center or cutting edge higher than the heel of the blade is warped or bent and must be re placed 5 To install the blade assemble parts in reverse order and make sure the blade sail is facing up Tighten special screw to 75 to 100 ft lb Groundsmaster 300 Series Page 11 9 FLAT PART OF BLADE SAIL E SLO FORMED Figure 8 SHARPEN AT ORIGINAL ANGLE a END VIEW Figure 9 Repairs Belt Replacement Fig 10 1 Lower cutting unitto 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 Remove carriage bolts lock washers and nuts hold ing gear box in place Lift gear box off mounting plate and lay it on top of cutting unit 3 Remove belts from spindle pulleys 4 Mount a belt on lower pulley groove of left spindle slide belt under belt idler mount plate and install around center spindle pulley Tension belt by levering idler pulley against belt and tighten idler pulley flange nut 1 Lower belt idler 2 Flange nut Figure 10 5 Place the right spindle belt under the gear box mount plate and the opposite end on top of the right spindle pulley Place the left spindle belt under the gear box mount plate and the opposite end on top of the left spindle pulley
380. the left side of the push arm and pivot shaft to the main frame 10 Remove the cap screws locknuts reinforcement and push arm bracket holding the right side of the push dift arm and pivot shaft to the main frame The entire push MQUNT AND arm and pivot shaft assembly should now be free of the 277 main frame 11 Drive the roll pins out of the pivot shaft and slide the push arm assemblies off of the shaft 12 Drive the pushing out of both push arm pivot tubes 1 Clean the inside of the pivot tubes to remove all dirt and SUPPORT other material THRUST WASHER PUSH ARM BUSHING THRUST LEFT PUSH WASHER ARM Figure 39 Repairs Page 12 24 Groundsmaster 300 Series 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 Inspect the torsion springs If the springs are dam aged use new springs when assembling the parts 3 Slide the torsion springs onto the inside of the push 2 inch arm pivot tubes Install the washers push arms with 60 mm springs and push arm brackets onto the pivot shaft Install the roll pins to secure the parts in place Figure 40 4 Raise the push arm and pivot shaft assembly into 1 Lock nut 3 Push arm position and secure it in place with cap screws suppo
381. tial Loosen nuts securing axle support bracket to frame Fig 3A 8 Put a jack or blocking under differential to hold it in place Remove capscrews and locknuts securing axle mounting pads to frame Note number of shims between frame and axle mounting pad which are used to get correct engine to transmission alignment Fig 3B Carefully lower axle and pull it out from under trac tion unit 9 If unit is equipped with 4WD remove nut Fig 3C Item 20 washer Item 21 and flange Item 22 from differential axle pinion Item 8 Use Differential Gear Holder tool to gears when removing nut NOTE Before installing flange for 4WD drive shaft apply Permatex No 2 to external splines of pinion and internal splines of flange Tighten lock nut to secure pinion coupler 75 90 ft Ib 102 122 N m 10 To install axle reverse steps 1 9 Leave axle mounting pad nuts loose Install shims P N 42 6080 between axle mounting pads and frame to get correct engine to transmission alignment then tighten axle mounting nuts Groundsmaster 300 Series Figure 3A EDM AXLE PAD TRANSMISSION SIDE BN x 2 d ann He i amp j 10 E M Figure 3C Page 7 3 Rev F Repairs Axle Shaft Disassembly and Wheel Bearing Service NOTE When servicing the bearing and seal area of the axle shaft itis recommended that you replace hex head screws and flange nuts with socket head screws 94 6934 washers 94 6936 and
382. tion valves No contact Worn with pedal Rotate or Repair replace linkage wheel Defective Defective Repair acceleration valves Troubleshooting Page 5 12 Groundsmaster 300 Series Check Check engine hydraulic rpm oil level Low Low Adjust Fill to use proper tachometer level Groundsmaster 300 Series Check radiator Inspect Ok cooling system Open or defective Clean radiator amp Close or screen Repair fan or repair belt Add coolant Reduce load on Check Repair or replace transmission pump amp motor System Operates Hot Check for kinked or severely bent hose or tubing Inspect lift lever latch position Inspect acceleration valves screen fan by pass IL fan belt and valve coolant level Defective Kinked or bent Defective Adjust Replace kinked Repair lever or bent hose acceleration or tubing valves Incorrect flow Inspect transmission inlet filter transmission traction non hydraulic pressure problem Low Loose or clogged Inspect charge pump Inspect Test Tighten implement steering or relief valve valve replace Control valve Defective Defective sticking Repair or replace Repair or shim Repair or replace charge pump implement steering relief valve valve Page 5 13 Troubleshooting
383. tion of the critical contact surfaces you notice circumferential scratches that might be removed by a minimum amount of polishing or touch lapping rework and use them again When scratches or grooves can be detected by feel with a fingernail or lead pencil the part should be replaced Polishing or touch lapping can be ac complished using 4 0 grit sandpaper on a flat lapping table table must be kept flat Polish parts using polish ing solvent or equivalent Do not polish parts dry IMPORTANT Lapping plate must be flat within 0 00005 inch Separating Transmission Into Sections Fig 23 The transmission must be separated into three main sections to perform major overhaul The three sections are pump section center section and motor section NOTE The following procedures are for major overhaul of the in line transmission Servicing the charge pump seals and valves is covered on previous pages 1 Before separating the transmission scribe or paint an alignment mark on each housing to assure correct reassembly of the sections 2 Remove the four cap screws in small increments so the three main sections separate evenly As the cap screws are loosened oil will drain from the housings NOTE When the cap screws are first loosened an internal spring load causes the sections to separate slightly 3 Whenthe four cap screws are removed pull the motor housing away from the center section Do not let the internal parts fa
384. tive equipment when working with asbestos materials 1 Loosen wheel lug nuts Jack up machine until front wheel is off of floor Use jackstands to prevent machine from falling accidentally Remove wheel lug nuts and slide wheel and tire assembly off of studs 2 Remove brake drum If drum will not come off easily brake shoes may have to be retracted with star nut see Brake Adjustment 3 Remove brake shoe return spring Fig 22 by prying the end of the spring up and over its retaining boss Use a brake spring pliers or flat blade screwdriver A CAUTION Wear a face shield when removing brake re turn spring Fig 22 The spring is under ten sion and could possibly slip during removal 4 Remove brake lever retainers cotter pins with a slip joint pliers 5 Pull strut and lever from brake shoes Remove brake shoes by sliding them both on one motion straight down off cast iron spider 6 Remove adjusting screw spring and star wheel as sembly 7 Install new brake shoes reverse steps 2 7 Install new brake drum if it is severely scored 8 Install wheel and tire assembly on studs with five 5 wheel nuts Tighten wheel lug nuts Remove jack stands or blocking and lower machine to the floor Tighten wheel lug nuts to a torque of 45 55 ft lb 9 Adjust brakes see Brake Adjustment Figure 22 1 Return spring 2 Cotter pins Repairs 3 Strut and lever 4 Adjusting screw spring Pa
385. tle type Fuel Injection Pressure 120 130 kg cm 1700 1850 psi Lubrication System Forced lubrication Oil Pump Gear type Oil Filter Paper element filter full flow type Crankcase Oil Capacity 3 5 liter 3 7 U S qt including filter Cooling System Forced circulation water cooling Water Pump Centrifugal type Cooling System Capacity 5 7 liter 6 U S qt Starter Solenoid shift type 2 0 kW 12 volt Alternator AC type 12 volt 35A Glow Plug Sheathed type Specifications Page4 4 Groundsmaster 300 Series Engine Item Standard Specification Repair Limit Service Limit Governor Mechanical Centrifugal Operating Speed no load 3200 rpm 50 rpm Idle Speed no load 1500 rpm 50 rpm Compression 32 kg cm 455 psi at 280 rpm 26 kg cm 370 psi 22 kg cm 313 psi Pressure Difference Between Oylinders 2 5 kg cm 36 psi max Cylinder Injection Order 1 3 2 Injection Timing 23 B T D C at smoke set position Cylinder Head Bottom Surface Flatness distortion Valve Guide 1 0 Valve Seat Angle Valve Seat Width Valve Seat Sinkage 0 05 mm 0 002 in max 6 6 mm 0 26 in 45 1 3 1 8 mm 0 051 0 071 in 0 1 mm 0 004 in 2 5 mm 0 1 in 1 mm 0 039 in Valve Clearance cold both intake and exhaust 0 25 mm 0 01 in Valves Valve Head Dia IN Va
386. to flange on front axle differential not shown Groundsmaster 300 Series Page 10 5 Clutch Service 1 To disassemble clutch remove six 6 capscrews Item 17 and lockwashers Item 16 Remove axle coupling Item 15 from clutch housing Item 23 2 Remove retaining ring Item 21 Clutch housing Item 23 along with thrust washers Item 14 roller clutches Item 22 and seals Item 13 can now be removed from yoke shaft Item 12 3 Inspect parts and replace as necessary 4 Roller clutches Item 22 must be installed into hous ing Item 23 so end is flush to 0 040 in inset with shoulder at each end of housing bore Both roller clutches must be installed with arrow end toward 6 bolt flange end of housing as shown in view B B Repairs Arrow end of roller clutches must face 6 bolt flange end of clutch housing toward rear axle Apply Never seeze NI JANE E gt SN E Mapan Er WEISS AIRES KAS Figure 9 5 Put thrust washer Item 14 in housing adjacent to roller clutch as shown Press both seals Item 13 into end of housing to dimensions shown Seals must be installed with lip facing out 6 Install clutch assembly onto yoke shaft then install other thrust washer Install retaining ring Item 29 to secure clutch assembly to shaft Install axle coupling Item 37 to clutch housing with six 6 capscrews and lockwashers then tighten capscrews evenly 7 Lubricate clutch throu
387. to installed bearing Support inner race of bearing as shaft is being installed into bearing 3 Position second bearing no Loctite on this bearing onto fan end of shaft Press bearing into tube 4 Position woodruff key in fan shaft and slide pulley onto shaft Fit flat washer and shim washer s to shaft and install slotted hex nut Torque nut from 50 to 70 ft lb 68 to 94 N m 5 Position woodruff key in fan shaft and slide fan hub onto shaft Install fan to fan hub with cap screws and lock washers Fit flat washer and shim washer s to shaft and install slotted hex nut Torque nut from 50 to 70 ft lb 68 to 94 IMPORTANT If hex nut slot and cotter pin shaft hole do not align after applying correct torque to slotted hex nut remove nut and add shim washers until alignment is correct DO NOT loosen nut to align the slot and hole 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 BON Slotted hex nut Cotter pin Flat washer Fan shaft Figure 1 5 6 7 8 Woodruff key Fan hub Bearing Shim washer Page 4 28 1 Rev D External Engine Component Repair This page is intentionally blank External Engine Components Repair Page 4 28 2 Rev D Groundsmaster 300 Series Glow Plug Replacement If a glow plug has been determined to be
388. traction pedal Try to start the engine The engine should not crank If the engine cranks there is a malfunction in the interlock system that should be corrected before beginning operation A CAUTION Do not operate machine without implement unless the PTO drive shaft is also removed 4 Sit on seat and start the engine Raise off the seat and move the PTO lever to ON The engine should stop within 2 3 seconds If the engine does not stop there is a malfunction in the interlock system that should be corrected before beginning operation Troubleshooting Groundsmaster 345 Troubleshooting Groundsmaster 322 D 325 D A CAUTION Remove all jewelry especially rings and watches before doing any electrical trou bleshooting or testing Disconnect the bat tery cables unless the test requires battery voltage For effective troubleshooting and repairs you MUST have a good understanding of the electrical circuits and components used on this machine See Electrical Schematics and Diagrams section of this chapter Starting Problems 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 check that area repairing one component at a time Attempting to repair more than one system at one time will lead to confusion Possible Causes and Corrections in the troubleshooting charts should be checked in the
389. traight and parallel lay blade on level surface and check its ends Ends of blade must be slightly lower than the center and cutting edge must be lower than heel of the blade This blade will produce good quality of cut and require minimal power from the engine By contrast a blade that is higher at the ends than the center or cutting edge higher than the heel of the blade is warped or bent and must be re placed 5 To install the blade assemble parts in reverse order and make sure the blade sail is facing up Tighten blade bolt to a torque of 85 to 110 ft lb Repairs Page 13 8 Groundsmaster 300 Series 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 1 Lower cutting unit to shop floor stop the engine and engage the parking brake Remove belt covers from top of cutting unit 2 Disconnect spring from idler arm bracket to release belt tension Remove cotter pin and clevis pin securing idler arm bracket to idler arm 3 Remove capscrews and nuts securing gear box plate to deck channels Lift gear box plate and gear box off deck channels and lay it on top of deck 4 Remove belt from around spindle pulleys and through idler pulley assembly 5 Install belt around spindle pu
390. tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight 5 Mark the nut and fitting body Hold the body with a wrench Use another wrench to tighten the nut to the correct flats from finger tight F F F T The markings on the nut and fitting body will verify that the connection has been tightened Size F F F T 4 1 4 in nominal hose or tubing 75 25 6 3 8 75 25 8 1 2 75 25 10 5 8 1 00 25 12 3 4 75 25 16 1 75 25 Groundsmaster 300 Series A WARNING Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved by lowering the cut ting unit to the ground and stopping the engine Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and do serious damage If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result Page 5 3 Final Mark Nut Position Initial and Body Position Extend Line Finger Tight After Proper Tightening Figure 3 General Information SAE Straight Thread O Ring Port Non adjustable 1 Make sure both threads and sealing surfa
391. tween the rocker arm and the rocker arm shaft should be 0079 inches 0 2 mm Replace the shaft if clearance is in excess of this dimension 5 Inspectthe oil passages in the rocker shaft and rocker arms to make sure that they are clear of obstruction Clean if necessary Figure 59 Checking valve spring length 60 Figure 60 Rocker arm and shaft Groundsmaster 300 Series Page 4 51 Cylinder Head Overhaul 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 Install the valve springs valve retainers and retainer locks 4 Assemble the rocker arms to the rocker shaft in the following order First attach the front rocker arm stay to the cylinder head with the bolt hole toward the right valve side of the cylinder head Next install the rocker shaft so that the identification mark small drilled hole near the end of the shaft is located near the front water pump and to the right side of the engine Install the cap screw and washer through the stay and into the shaft Install the front rocker arm and retaining ring Next install the remaining rocker arms springs and rocker shaft stays and bolt them to the cylinder head 5 Install the glow plugs and glow plug lead wires The gl
392. ue to the fact that the charge pump is having to direct most of its flow to the main traction circuit piston pump and piston motor When this occurs oil pressure may not increase to the 700 800 psi pressure necessary to raise the heavy implement At this point a traction pressure test could be used to determine whether the hydrostatic transmission has excessive piston group leakage and needs to be repaired See Traction Pressure Test Figure 11 1 Transmission 2 Tester 3 Load valve Groundsmaster 300 Series Adjustments Traction Control Rod Adjustment Serial Numbers Below 50000 Fig 12 1 Check traction drive neutral position to assure front wheels do not creep refer to Traction Drive Neutral Ad justment 2 Depress traction pedal fully There must be 1 16 inch 1 6 mm between inside front edge of pedal and trian gular support brace If distance is as specified the con trol rod is adjusted correctly If distance is not as specified proceed to step 3 for an adjustment 3 Loosen jam nut away from front of control rod Re move cotter pin and slotted nut retaining tapered socket in pivot mount on bottom of traction pedal 4 Adjust tapered socket as required Slide end of ta pered socket through traction pedal pivot mount Then depress pedal and check for 1 16 inch 1 6 mm clear ance between front edge of pedal and top of support brace Adjust tapered socket until correct adjustment re
393. ump 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 22 If the pump now operates check for an electrical failure of the pump circuit eg fuses connec tions wires etc 3 The delivery of the fuel pump may be checked by disconnecting the fuel lines from the water separator and fuel filter and routing them to a can of filtered diesel fuel and a drain pan Fig 22 Activate the pump and measure the amount of fuel pumped in during a 15 second time interval The standard pump rate is approxi mately 8 ounces 225 cc in 15 seconds 4 If the fuel delivery rate is below the standard value the pump should be disassembled and checked See Fuel Pump Service in the Fuel System Repairs section of this chapter Thermostat Test Fig 23 If the engine overheats and a faulty thermostat is sus pected the thermostat should be tested 1 Remove the thermostat see Thermostat Removal and Installation in the External Engine Component Re pair section of this chapter 2 Put the thermostat in a container of water with a thermometer and heat the water Fig 23 Valve cracking temperature 76 5 C 177 F Full open temperature 90 C 194 F Valve lift 8 mm 0 314 in 3 If the thermostat fails to open only partially opens or Sticks it should be replaced Testing Page 4 24 500 MM 19 7 IN 07 SUCTION HEAD APPROX FU
394. ure that the Relief Plunger travels freely and that the drain holes in the Plunger are not blocked External Engine Component Repair Page 4 30 9 gt Oil pressure switch Check valve A 5 Figure 29 Figure 32 Groundsmaster 300 Series 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 O ring in the pump body if replaced or removed 3 Place the Rotor Assembly into the Pump Body Apply oil to the rotating parts NOTE The Inner and Outer Rotors have a dimple which faces outward from the Pump Body 4 Place the Pump Body along with a new oil Pump Body Gasket in position and rotate the rotor assembly until the inner rotor shaft couples with the slot in the injector pump cam shaft 5 Position the Pump Cover on the dowel pins and secure the pump into positions with the four bolts washers and lock washers Torque the bolts to 12 13 ft Ib 1 7 KgM Groundsmaster 300 Series Page 4 31 9 gt Oil pressure switch Check valve Figure 33 External Engine Component Repair 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
395. ushed Never clamp the tube portion even lightly when it is necessary to ham mer on the yoke Support the free end of the propel ler shaft to remove some of the strain from the clamped end LARGE SOCKET SMALL SOCKET Figure 16 Figure 17 Repairs Installing the PTO Drive Shaft Fig 18 19 A DANGER Do not start the engine and engage the P T O TO CUTTING UNIT 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 The P T O Drive Shaft has two major components When replacing it on the machine the spline shaft portion attaches to the traction unit and the tube portion attaches to the cutting unit gearbox IMPORTANT The P T O shaft yokes must be exactly in line with each other when the outer P T O sleeve is installed on the splined shaft Remove the sleeve and change the yoke position if alignment is not correct Misalignment of the yokes will shorten the life of the P T O Drive Shaft assembly and cause unnecessary vibration when the cutting unit is op erated 1 Line up the holes in the yoke and the input shaft of the gearbox Slide the yoke onto the shaft and secure the parts together with the roll pin 2 Mount the P T O shield over the input shaft and onto the gearbox mounting plate with the two self tapping Screws Figure 19 1 PTO yoke 3 Roll pin 2 Yokes i
396. using Using a seal protector slide the charge pump housing and gerotor wheel off of the pump shaft The O ring will probably stay in the groove on the inside of the pump housing NOTE If a seal protector is not used wrap the pump shaft with plastic wrap to protect the seal When sliding the housing and gerotor wheel off of the pump shaft the drive pin may drop out of the pump shaft Do not lose the pin because it is the only part that drives the gerotor wheel Without the pin the gerotor wheel will not rotate thus no charge pressure and no hydraulic functions 7 Examine the gerotor wheel and the inside of the charge pump housing for excessive wear patterns scratches or score marks If a part is damaged beyond repair replace it IMPORTANT If either the gerotor wheel or the charge pump housing is damaged replace both parts Never replace only one part because the charge pump housing and gerotor wheel have a definite wear in characteristic Groundsmaster 300 Series Page 5 31 Repairs 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 Apply transmission oil on the gerotor wheel and the inside of the charge pump housing Slide the drive pin through the hole in the pump shaft It is helpful to have this hole positioned horizontally as show
397. ut can be changed Stop engine after cutting unit is raised Front Caster Wheels 1 Squeeze back of wire and rotate wire on lynch pin Pull pin out of caster spindle and slide spindle out of front caster arm Slide spacers onto the caster spindle to get desired height of cut Then slide washer onto spindle 2 Push caster spindle through caster arm Install other thrust washer and remaining spacers onto spindle In stall lynch pin to retain parts in place Rear Caster Wheels 1 Squeeze back of wire and rotate wire on lynch pin Pull pin out caster spindle NOTE Rear caster fork assembly does not need to be removed from caster arm to change height of cut 2 Remove or add C shaped spacers at narrow part of spindle shaft below caster arm to get desired height of cut Make sure thrust washers not spacers contact top and bottom of caster arm 3 Install lynch pin to secure caster wheel assembly 4 Make sure all four caster wheels are set at same height of cut Adjustments Page 13 4 Figure 2 1 Front caster wheel 3 Spacers 2 Lynch pin 4 Thrust washer Figure 3 1 Rear caster wheel 3 Spacers 2 Lynch pin 4 Thrust washer Groundsmaster 300 Series 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 Groundsmaster 300 Series P
398. ve the setscrew from the side of the taper lock 7 Disassemble fasteners securing gear box to gear box mount plate and remove gearbox Remove brackets Items 6 13 from gear box Figure 25 Groundsmaster 300 Series Page 13 17 Repairs Installing Gearbox and Drive Pulley 1 Install isolation mounts Item 3 into brackets Item 7 13 Use water or lubricant to ease installation Install mounts from bottom of bracket 2 Install bracket on each side of gearbox with cap screws and lockwashers Tighten capscrews to a torque of 20 26 ft Ib 3 Install gearbox with brackets to gear box mount plate Item 10 4 To install pulley Item 17 slide taper lock Item 18 small end first into pulley hub 5 Insert woodruff key into keyway in gearbox shaft Slide pulley with taper lock onto gearbox shaft while aligning key and keyway NOTE Large hub on pulley must face away from gear box and like the taper lock the pulley must contact shoulder on the gearbox shaft 6 Rotate pulley to get non threaded holes in taper lock to line up with the two threaded holes in hub of gearbox pulley Start threading set screws Item 19 into the two holes and tighten them alternately and evenly until both set screws are tight 7 Using a brass drift pin or sleeve and a hammer hit taper lock firmly Now tighten set screws to 55 in lb Continue to hit taper lock and tighten set screws until 55 in Ib of torque will not turn the s
399. vel gear shaft out of the upper bearing Compound and upper bevel gear 7 Pull the bevel gear case from the axle case and re move the upper bevel gear collar spacer and thrust washer from the gear case 8 Remove the axle case cover screws cover and the O ring from the axle case 9 Remove the plug and sealing washer from the center of the axle case cover While holding the axle case cov er lightly tap the lower end of the bevel gear shaft out of the lower bearing and lower bevel gear 10 Remove and discard bevel gear shaft seals from bevel gear case and axle case Fig 6 17 to 20 ft lb 23 to 27 N m Figure 6 1 Knuckle pin 9 Upper bevel gear 2 Shaft seals 10 Thrust washer 3 O ring 11 Lower bevel gear 4 Bevel gear case 12 Lower bearing 5 Upper bearing 13 Axle case 6 Bevel gear shaft 14 Axle case cover 7 Collar 15 O ring 8 Spacer Inspection 1 Measure the knuckle pin O D and the axle case sup port bushing I D to determine the bushing to pin clear ance Fig 7 Replace components as necessary BUSHING TO PIN CLEARANCE 0 002 to 0 016 in 0 05 to 0 40 mm KNUCKLE PIN O D Factory Spec 0 982 to 0 983 in 24 95 to 24 98 mm AXLE CASE SUPPORT BUSHING I D Factory Spec 0 984 to 0 987 in 25 00 to 25 08 mm Figure 7 2 Inspect all gears shafts bearings cases and cov 1 Knuckle pin 2 PRIS Case support ers for damage and wear Replace components
400. ver plate Fig 55 42 Inspect the thrust bearing for brinelling dents or spalling flaking if either exists or if one or more of the rolls are lost or broken replace the bearing assembly Replace the seal spacer or bearing spacer if worn or broken Figure 55 Repairs Page 8 32 Groundsmaster 300 Series 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 itis damaged the upper cover plate must be replaced 44 Slide the seal from the jacket tube Fig 57 If the seal is worn or damaged it must be replaced 45 Remove the input shaft and snap ring sliding it out of the upper cover end of the assembly Fig 58 46 Inspect the input shaft serrations threads and flats for grooves wear or damage Figure 58 Groundsmaster 300 Series Page 8 33 Repairs 47 Remove the washer and upper cover amp jacket Fig 59 NOTE The retaining plate and upper cover amp jacket are a matched set If either part is worn or damaged both must be replaced 48 Inspect the bushing at the top of the cover amp jacket for wear or damage If bushing replacement is neces sary put the upper cover amp jacket in a vise Use a pliers or punch to straighten the crimped areas on the bushing end of the jacket tube Fig 60
401. when the by pass valve was removed check the oil level in the axle housing Start the engine and let it run for about one or two minutes Then turn the engine off and check the oil level in the axle housing again Also inspect the by pass valve area for oil leaks Groundsmaster 300 Series Page 5 27 Rev H Figure 16 1 Transmission by pass valve Repairs 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 Also slide the other acceleration valve out of the opposite side of the center section ACCELERATION NOTE There are two acceleration valves in the center A VALVE PLUG ACCELERATION section but only one spring 4 Remove the O rings from the plugs Figure 17 5 Inspect the plugs valves and center section for damage or stripped threads Replace any damaged part 6 Inspect the bore of the acceleration valve for damage and foreign material If the valve is damaged replace it however clean the valve with cleaning fluid and use it again if foreign material is in its bore 7 Check the spring for damage and correct specifica tions Replace the spring if its condition is doubtful Spring specifications are listed in the table below Acceleration Valve Spri
402. within the required dimension IMPORTANT Do not use more than three 3 shims at any one hole location Use decreasing numbers of shims in adjacent holes of more than one shim is added to any one hole location Wing Sections 8 Raise or lower hinge bushing brackets and or adjust front and rear stops to achieve proper blade match and height of cut Each wing section should rest against the front and back stops A 1 2 inch gap between the wing section and the center section should be maintained Torque fasteners to 65 ft Ib Adjust wing lift cylinders and belt tension after making wing adjustments Install cov ers on top of cutting unit Figure 10 1 Adjustable stop 2 1 2 gap Groundsmaster 300 Series 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 Wing Section NOTE Block deck in raised position so that it cannot accidentally lower while belts are being adjusted Wings should be in lowered position Loosen two 2 capscrews securing spring bracket nuts are located under the deck Slide the spring bracket so that the rubber bumper at one end just contacts the edge Figure 11 of the idler arm and tighten the nuts under the deck to secure the spring bracket With the spring bracket in this 1 Spring bracke
403. x No 2 or silicone sealant to the outer edge of the carrier bore Install the expansion plug or seal if equipped with flange for 4WD into carrier until plug or seal seats firmly in carrier bore Fig 45 12 Install the spur gear cover Use Permatex No 2 or silicone sealant when installing the cover Tighten the capscrews to a torque of 25 40 in Ib Fig 46 Figure 46 Repairs Page 7 18 Groundsmaster 300 Series 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 Rotate the side gears until the holes of the washers and pinion gears line up with the holes of the case If the gears cannot be rotated by hand install one of the axle shafts into the side gear spline and use a pipe wrench to turn the shafts 14 Install the pinion shaft Grease the shaft to aid assembly Be sure the hole in the pinion shaft lines up with the hole in the differential case Fig 48 15 Assemble the lock pin Drive the pin to the approxi mate center location of the pinion mate shaft Peen the metal of the case to lock the pin in place Fig 49 Groundsmaster 300 Series Page 7 19 Figure 48 Figure 49 Repairs 16 Put the ring gear onto the differential ca
404. y between termi nals 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 5 Electrical System Rev Fuel Sender The fuel sender is located on top of the fuel tank Testing 1 Remove blue wire and black ground wire from the Yor FIT sender f FULL POSITION If testing circuit wiring and fuel gauge make sure wire connections are secure before turning igni tion switch ON to prevent an explosion or fire from sparks 2 To test the circuit wiring and fuel gauge connect blue and black wires and turn ignition switch to ON Fuel gauge needle should point to the right edge of the green area full Turn ignition switch OFF and continue testing fuel sender if circuit wiring and gauge are acceptable Q A E lt LLLTLZZL LZ ZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZ 3 Remove five 5 screws that secure the sender to the Figure 6 fuel tank 4 Remove sender and gasket from the fuel tank Clean any fuel from the sender Note Before taking small resistance readings with a digital multimeter short meter test leads together The meter will display a small resistance value This internal resistance of the meter and test leads should be sub tracted from the measured value of the component Make sure sending unit is comple
405. you MUST have a good understanding of the electrical circuits and components used on this machine See Electrical Schematics and Diagrams section of this chapter Engine Starting Problems 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 check that area repairing one component at a time Attempting to repair more than one system at one time will lead to confusion Possible Causes and Corrections in the troubleshooting charts should be checked in the order in which they are listed If the machine being repaired has any interlock switches by passed they must be reconnected for proper trou bleshooting and safety Condition Possible Cause Correction Starter solenoid clicks but engine will not crank If solenoid clicks problem is not in interlock system Troubleshooting Groundsmaster 345 Low battery charge Loose or corroded battery cables Loose or corroded ground Faulty wiring at starter Loose starter mounting bolts Faulty starter Faulty starter solenoid Engine seized Page 6 6 Charge battery Replace battery if it will not hold a charge Clean and tighten or repair as necessary Repair wiring Clean mounting surface and tighten bolts Repair or replace starter Replace starter solenoid Repair engine Groundsmaster 300 Series St

Groundsmaster® 300 Series

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Groundsmaster&reg; 300 Series

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Groundsmaster® 300 Series