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Groundsmaster® 455-D

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3. Nod 1 8 18 wells gt X WNIAWH3 L A X vtita vs _ 1 WNIWHSL vs oov 3NON 3NON 340 uem E HOLIMS NOILINDI uaawas HOLIMS V HOLIMS OA GION31OS 19 was T saSN4 HOLMS NOS RE 38 N E Y Qe Ho fox ps uo N J HOLIMS 2 NOLLINOI NYOH A Soma ON HOLIMS WOIA XY p 3 HO LIMS NHOH 4H BO N 06 QM S3HOLIMS ONIM Lie HOLM ONIM H H Ms HOLIMS Old N9 ON HOLIMS NOLLOVHL HO LN19 ONIM HA Old Avaa ANIL HO LIMS 1735 YOLIOVdVO a lt Av T3H ualuvis 28 ls 98 ualuvis up 3195103 ama A g Groundsmaster 455 D Page 5 4 Rev Wiring Schematics Special Tools NOTE Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE
4. Intake ga gb Tolerance 0 0 025 0 0 15 0 025 0 1 Production 40 161 40 6 25 8 267 40 361 40 2 6 45 8 467 Repair 1 40 461 40 3 6 45 8 467 Repair 2 40 661 40 5 6 45 8 467 Units mm Exhaust ga gb A B Tolerance 0 t 0 025 0 0 15 0 025 0 1 NN Production 34 137 34 6 05 8 15 N 34 337 34 2 6 25 8 35 4 B d d J Repair 1 34 437 34 3 6 25 8 35 Repair 2 34 637 34 5 6 25 8 35 After fitting valve seats into the cylinder head machine them according to drawings Fig 9 Figure 9 Swirl Chambers Units mm ge of g h Tolerance 0 099 0 039 0 020 0 02 0 060 0 0 025 0 04 Production 32 05 32 4 3 9 32 25 32 2 4 1 4 Repair 1 32 45 32 4 4 2 4 1 Repair 2 32 65 32 6 4 3 4 2 The protrusion j must be between 0 and 0 03 Dimension j is obtained by machining faces x and y Figure 10 Groundsmaster 455 D Page 3 7 Rev Engine Cylinder Piston Matching Units mm Identification CYLINDER PISTON eb X Tolerance Tolerance 0 018 t 0 009 0 Production None 83 82 93 Al 83 03 82 96 Repair 1 R1 83 20 83 13 Repair 2 R2 83 50 83 43 Repair 3 R3 83 80 83 73 NOTE The piston ob must be measured at dimension c c 25 00 NOTE The repair dimension is stamped on the cylinder b
5. 5 PTO Clutch 14 Engine Coupling 7 PTO System Groundsmaster 455 D 7 1 Rev A Table of Contents Specifications Item Specification PTO Clutch air gap 0 011 0 021 inches Belt adjustment Special Tools Order special tools from TORO SPECIAL TOOLS AND APPLICATIONS GUIDE Commercial Products Bearing Locknut Wrench TOR4050 Use this tool TOR4050 to remove and install the drive pulley bearing locknut Fig 6 Item 1 Bearing Locknut Wrench TOR4051 Use this tool TOR4051 to remove and install the lower driven pulley bearing locknut Fig 10 Item 30 Specifications Page7 2 Rev A 180 ft lb torque 20 inch long torque wrench in square hole of clutch plate Some tools may be listed in the Groundsmaster 455 D Parts Catalog Tools may also be available from a local supplier Groundsmaster 455 D Adjustments PTO Belt Adjustment 1 Remove 2 screws securing PTO belt cover to adapt er plate and 1 screw securing belt cover to tab on spring anchor Remove cover Figure 1 1 PTO belt cover 2 Adapter plate 2 Loosen 3 flange screws and flange nuts securing adapter plate to clutch plate Figure 2 1 PTO belt 3 Clutch plate 2 Adapter plate 4 Flange nuts 3 3 Insert end of 1 2 drive 20 long torque wrench into square hole in clutch
6. Item Description Traction Pump Variable axial piston pump Traction relief pressure 6000 100 PSI at high idle Charge pressure 100 2 _1 PSI at 3000 50 RPM Charge Auxiliary Pump Gear pump with flow divider Steering pressure 1200 100 PSI at 3000 50 RPM Traction Motor front Fixed axial piston motor Traction Motor rear w 4WD Fixed axial piston pump Lift Control Valve Spool type directional control valve Lift relief pressure 2150 2300 PSI at high idle Counterbalance pressure 600 650 PSI hot oil at 3000 50 RPM Wing Lift Counterbalance pressure 375 25 PSI hot oil at 3000 50 RPM Hydraulic Filter Spin on cartridge type Hydraulic Oil Mobil DTE 26 or equivalent Reservoir Approximately 6 5 gal U S Equivalent Hydraulic Oils interchangeable Shell Tellus 68 Amoco Rykon Oil 68 Conoco Super Hydraulic Oil 68 Exxon Nuto 68 Kendall Kenoil R amp O AW 68 Pennzoil Penreco 68 Phillips Magnus A 68 Standard Energol HLP 68 Sun Sunvis 831 WR Union Unax AW 68 Chevron AW Hydraulic Oil 68 Figure 1 1 Sight gauge 2 Hydraulic reservoir cap Specifications Page 4 2 Rev A Groundsmaster 455 D 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 ca
7. 6 Wing Pivot Arm Installation Blade Adjustment 7 and Ball Joint Service 26 Belt Tension Adjustment 8 Safety Door 27 Wing Deck Clutch Adjustment 8 Wing Cylinder Installation REPAIRS AIRE WIDE 9 and Ball Joint Service 28 Separating Cutting Unit From Traction Unit 9 Center Deck Lift Arm Ball Joint Service 29 Mounting Cutting Unit To Traction Unit 10 Idler Pulley Service 30 Drive Belt Replacement 11 Wing Deck Spring Loaded Front Castor Arm Bushing Service 13 Locking Mechanism Service 31 Castor Wheel and Bearing Service 14 Blade Removal and Installation 15 2 5 o Groundsmaster 455 D Page 8 1 Table of Contents Specifications Item Specification Cutting width 126 54 center section 36 each wing 90 with one wing up Height of cut range 1 5 Height of cut adjustment 1 2 increments Blade bolt torque 85 110 ft lb Spindle nut torque 150 170 ft lb Wing deck clutch air gap 0 016 0 005 Gearbox lubricant Fig 1 Figure 1 1 Filler plug 2 Check plug Specifications Page 8 2 SAE 80W90 API GL 5 gear lube Groundsmaster 455 D General Information Pivot Tilt Cut
8. 1 1 Chapter 2 Product Records and Manuals Product Records 2 1 Equivalents and Conversions 2 2 Torque Specifications 2 3 Maintenance Interval Charts 2 4 Equipment Operational and Service Historical Report Record Chapter 3 Peugeot XUD9 Diesel Engine Introduction 3 2 Identification and Specifications 3 3 Special Tools 3 11 Adjustments 3 17 Troubleshooting 3 18 Testing and Inspection 3 27 Fuel System Service 3 33 Timing Belt Replacement 3 36 Injection Pump Timing 3 40 Preparation for Engine Repair 3 42 Engine Removal and Installation 3 43 Engine 3 45 Chapter 4 Hydraulic System Specifications 4 2 General Information 4 3 Hydraulic Schematics 4 5 Hydraulic Flow Diagrams 4 7 Groundsmaster 455 D Special we Troubleshooting Testing Adjustments Repairs Chapter 5 Electrical System Wiring Schematics and Diagrams Special 5 Troubleshooting Testing Repairs Chapter 6 Axles and Brakes Specifications
9. eunnoi 104 J9P1O e2ueuojure y 1 51 5 q ccp Gda3lsviINSaNnou5 TORO Chapter 3 Engine Table of Contents INTRODUCTION 2 Injector Tests 29 IDENTIFICATION AND SPECIFICATIONS 3 Injection Pump Fuel Delivery Test 31 General Specifications 3 Thermostat Test 32 Cylinder Head 4 FUEL SYSTEM SERVICE 33 Cylinder Head Gasket 4 Priming the Fuel System 33 5 Injection Pump Removal 33 Valves Rc Rd Re gus 5 Injection Pump Repair 33 Valve 5 5 Injector Service 34 Valve Springs 6 TIMING BELT REPLACEMENT 36 Valve Guides 6 Timing Belt Removal 36 Valve Seats cc ind ale d oer bee pin dee dee 7 Timing Belt Installation 38 Swirl Chambers 7 INJECTION PUMP TIMING 40 Cylinder Piston Matching 8 Timing of Injection Pump 40 Piston PIN iier ne eed dee eee 8 PREPARATION FOR ENGINE REPAIR 42 Crankshaft 9 Cyli
10. 29 EP 30 Traction Neutral Switch Replacement 31 4WD Solenoid Coil Replacement 32 Axle Hi Low Switch Replacment 32 Wing Switch Replacement 33 Table of Contents Lond gt o o L d m m ICS Schemat iring W 5 66667 N S v X IWNIANY SL TWNINWYSL S IWNINWYSL 9 WNIWYSL MS IWNIWYSL NS Tava 3 MS A SS3ud YOLVNYSLIV NOILLO3 NI E T GION33OS n 4 OIA av vlad 335 aAvTad Gaui epus sasn4 m pasa ane Anon 5 ez MO15 9 a M NYOH coms somd MO15 t Es div 25v MOYIH 31Xv NS TE RN MOTI3A MFN AINO t 0s 9 SAHOLIMS ONIM 9 HO LN1D ONIM ania 8 HA Wan 27801 Od 3dO NO avaa dial aau ualuvis 9 58 bo e e udluvis BEN A3u5 aay 37191503 aay 5 1 1 Rev C Groundsmaster 455 D ICS Schemat iring 6666S TOOOS N S HOLIMS 3 3 5 JI8VIHVA N8 bia dal HOLIMS NYOH S3HOLIMS ONIM Wai GEN
11. General Information Special 5 6 4 Adjustments 6 6 Hepalrs 6 8 Chapter 7 PTO System Specifications 7 2 Adjustments 7 3 ise asia RERUM REIS qam 7 5 Chapter 8 Cutting Unit Specifications 8 2 General Information 8 3 Adjustments 8 4 Hepalrs ze ui ede Idae Ban 8 9 Rev B Product Records and Manuals Axles and Brakes Electrical System Hydraulic System PTO System 2 5 o This page is blank Table of Contents SAFETY INSTRUCTIONS 1 Before 1 While Operating 2 Safety Instructions The GROUNDSMASTER 455 D conforms to the Ameri can National Standards Institute s safety standards for riding mowers when standard rear weight ballast is installed Although hazard control and accident preven tion partially are dependent upon the design and con figuration of the machine these factors are also dependent upon the awareness concern and proper training of the personnel involved in the operation trans port maintenance and storage of the machine Im proper use or maintenance of the machine can result in injury or death To reduce the pot
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13. 3 Remove hex tapping screws Item 16 retaining trun nion seal cover Item 35 to transmission housing 4 Remove trunnion seal cover with lip seal Item 34 and o ring Item 18 5 Put seal cover in an arbor press and press out old seal Once removed the seal is not reusable 6 Inspect seal cover for damage Inspect sealing area on shaft for rust wear or contamination Polish sealing area on shaft if necessary Groundsmaster 455 D Page 4 29 7 Using an arbor press press seal into position from inside of seal cover until it bottoms out in its bore Be careful not to damage the seal 8 Install o ring onto seal cover and retain with petro leum jelly 9 Use a seal installer tool or wrap end of swashplate control shaft with thin plastic to prevent damage to seal during installation 10 Slide seal cover assembly over swashplate control shaft onto housing Install hex tapping screws and tighten to a torque of 6 to 9 ft lbs 11 Install control linkage onto transmission Check machine for creeping when engine is running with foot pedal in neutral position Do Traction Control Neutral Adjustment if necessary Repairs D gt E gt Traction Pump Check and High Pressure Relief Valves Fig 19 Figure 19 1 Park the machine on a level surface lower cutting units engage parking brake and stop the engine 2 Remove the check high pressure relief valv
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15. Groundsmaster 455 D Page 6 9 Repairs Front Axle Removal and Disassembly Install belleville washers Item 28 as shown Figure 18 Repairs Page 6 10 Groundsmaster 455 D Front Axle Removal 1 Drain oil from transaxle 2 Jack up front of machine and support chassis frame with jack stands 3 Remove front wheels Remove nuts Fig 18 Item 19 Use a puller to pull each wheel hub Item 13 off of shafts Remove belleville washers Item 28 4 Remove roll pin Fig 17 Item 42 Remove screws Item 43 44 securing shift rod support Item 10 to transaxle Remove hex flange head screws Item 12 securing transaxle support bracket Item 13 to transaxle 5 Clean all exterior surfaces of axle and transaxle 6 Remove capscrews Fig 18 Item 38 and disconnect hydraulic motor Item 37 from transaxle DO NOT disconnect hoses from hydraulic motor 7 Disconnect brake linkage rod eyes from brake link age arms NOTE Brake linkage is spring loaded 8 Disconnect and put covers on hydraulic lines that run under axle assembly or that go through bulkhead brack ets connected to axle assembly Mark hydraulic lines for proper reassembly 9 Support axle assembly then remove U bolts Fig 18 Item 23 securing axle to frame 10 Carefully lower and pull axle assembly out from under machine Front Axle Disassembly 1 Remove skid plate Fig 18 Item 25 NOTE Before r
16. SS Se PRIMARY AIRFILTER 93 9162 D SAFETY AIR FILTER E 93 9163 E FUEL 32F0 C NO2D 614 Drain and flush 800 hours lt 32F0 C 93 7213 3 5 Drain and flush 1500 hours 50 50 PEUGEOT GAL or 2 years whichever occurs ANTI FREEZE first 93 7242 Groundsmaster 455 D 2 5 Rev C Maintenance Schedules Maintenance Charts Page 2 6 Groundsmaster 455 D EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for GROUNDSMASTER 455 D TORO Model and Serial Number Engine Numbers Transaxle Numbers Rotary Deck 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 455 D Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval amp Service Type Inspect Air Filter Dust Cup and Baffle Lubricate All Grease Fittings Check Cutting Unit Gear Box Oil Level Change Engine Oil and Filter Check Battery Level and Connections Inspect Cooling System Hoses Service Air Cleaner Filter Element T Inspect PTO and Cutting Unit Belts Check Electric Deck Clutches Adjustment Check Electric PTO Clutch Adjustment T Torque Wheel Lug Nuts Replace Fuel Filter Check Front Transaxle Oil level Check
17. 4 Loosen jam nut on adjusting screw and rotate screw until the black plastic sleeve is flush even with the edge of idler support 5 When distance is attained tighten jam nut on adjust ing screw and 2 flange head nuts securing idler ad juster tube to top of cutting deck 6 Check adjustment on other adjusters and repeat procedure if required Wing Deck Clutch Adjustment The deck clutches are adjustable to ensure proper engagement and blade braking 1 To adjust clutch tighten or loosen locknuts on flange studs 2 Check adjustment by inserting feeler gauge through slots next to flange studs 3 The proper disengaged clearance between the clutch plates is 0 011 0 021 inches It will be necessary to check this clearance at each of the three slots to ensure the plates are parallel to each other Adjustments Page 8 8 Figure 11 1 Spring loaded idler 2 Idler support 3 Black plastic sleeve Figure 12 1 Clutch 2 Flange studs Groundsmaster 455 D Repairs Separating Cutting Unit From Traction Unit 1 Lower center and wing cutting units to the ground then raise center cutting unit slightly until rear deck straps hang freely on lift arm brackets Stop engine after cutting unit is raised Set parking brake 2 Remove hairpin cotters and H O C pins securing rear deck straps to H O C brackets on deck Start engine and lower center cutting unit completely to floor Make sure all lift levers
18. Check lift cylinder s for internal leakage and repair or replace if necessary Clean relief valve in lift control valve and adjust if necessary by adding required shims Inspect lift valve for internal leakage or improper operation and repair or replace if necessary Inspect steering lift pump and priority flow valve for wear or damage and repair or replace if necessary Troubleshooting Page 4 16 Groundsmaster 455 D Cutting Unit Will Not Drop or Follow Ground Contours Cause Correction Low engine RPM Adjust engine RPM use tachometer Lift arm or cylinder pivots binding Lubricate bushings Inspect for damage Repair or replace damaged parts Lift cylinder damaged Check lift cylinder s and repair or replace if necessary Counterbalance pressure to high TEST NO 2 3 Adjust counterbalance pressure or replace counterbalance relief valve if necessary Orifice in hydraulic line plugged Clean orifice Worn or damaged spool detent in lift valve Repair or replace 5 Faulty lift valve Repair or replace lift valve D 5 2 E S wad s en s 5 Cutting Unit Drops From Raised Position With Lift Valve Centered Position Correction Improperly positioned valve Instruct operator Worn detent s in lift valve Repair lift valve Internal leakage of lift cylinder s Check lift cylinder s and repair or replace if necessary Lift cylinder hydra
19. Jay 191009 IO Groundsmaster 455 D 4 10 Hydraulic Flow Diagrams Special Tools NOTE Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PRODUCTS Some tools may be listed in the Groundsmaster 455 D Parts Catalog Some tools may also be available from a local supplier Hydraulic Pressure Test Kit Used to take various pressure readings for diagnostic tests Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools A high pressure hose is provided for remote readings Contains one each 1000 5000 and 10000 PSI gauges Use gauges as recommended in Testing section of this chapter D gt 2 E gt Figure 7 Groundsmaster 455 D Page 4 11 Special Tools Hydraulic Tester With Pressure and Flow Capabilities Inlet Hose Outlet Hose High Pressure Gauge Figure 8 You must have o ring face seal ORFS adapter fittings for this tester to use it on the Groundsmaster 455 D 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
20. 1 High temperature shut down switch 2 Temperature gauge sender Figure 23 o gt 2 T 5 1 Lower the coolant level in the engine and remove the temperature gauge sender 2 Put the switch in a container of oil with a thermometer and heat the oil 3 With an Ohm meter connected as shown the follow ing resistance readings should be indicated 90 5 117 5 ohm at 160 F 70 C 21 3 26 3 ohm at 207 F 115 C A CAUTION m Figure 24 Handle hot with special to prevent personal injury or fire Groundsmaster 455 D Page 5 25 Testing Engine Oil Pressure Switch The switch is normally closed NC and opens with pressure The switch opens at approximately 8 psi 1 Turn ignition key switch ON Oil pressure lamp should be on If lamp is not on 1 Disconnect wire from switch and touch wire to a good ground such as the engine block 2 If lamp comes on replace switch Figure 25 3 If lamp does not come on check wiring between lamp and switch for continuity 1 Engine oil pressure switch If lamp is 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
21. 20 Install spacer plate Align bolt holes in spacer plate with tapped holes in housing Figure 52 Repairs Page 4 58 Groundsmaster 455 D 21 Rotate spool and sleeve assembly until pin is paral lel with port face Install drive make sure you engage drive with pin To assure proper alignment mark drive as shown ref B Note relationship between slotted end of drive to splined end of drive when marking 22 Install 3 diameter seal in meter 23 With seal side of meter toward spacer plate align star valleys ref A on drive ref B Note the parallel relationship of reference lines A B C and D Align bolt holes without disengaging meter from drive Drive Pin Parallel with Port Face Figure 53 Seal Meter Gerotor Figure 54 Meter Gerotor Star Valley Drive Marked Pin CPZ gt e Port Face Groundsmaster 455 D Page 4 59 Figure 55 Repairs bod D gt 2 3 gt lt Seal End Cap Screw 24 Install 3 diameter seal in end cap AQ 5 25 Install end cap gerotor align holes Figure 56 26 Install seven 7 DRY cap screws with new seal washers in end cap Pre tighten screws to 150 inch pounds then torque screws to 275 inch pounds in 4 sequence shown n 2 ae Figure 57 Repairs Page 4 60 Groundsmaster 455 D Table of Contents
22. Adapter bolt torque 2 5 3 0 kg m 18 22 ft lb Repairs Page 6 18 Shim 43 0 05 1 69 0 002 in Figure 31 Gauge TOR4042 Figure 32 Groundsmaster 455 D Adjusting Backlash Backlash specification 0 25 0 35 mm 0 010 0 014 in Adjust shim thickness between bearing housing of axle housing A and bearing to get specified backlash Shim stock for this adjustment is available in these thicknesses Thickness Part No Shim set 77 4000 0 1 mm 0 004 in 76 7290 0 2 mm 0 008 in 76 7300 0 4 mm 0 016 in 76 7310 Shim Between Differential and Axle Housing B After obtaining specified backlash determine amount of shims needed Axle housing A 1 Put gauge TOR4038 on axle housing A and read clearance a between ball bearing and gauge 2 Select from shim stock shown above for backlash adjustment to match clearance a Shim Figure 34 n x a o 2 x lt Groundsmaster 455 D Page 6 19 Repairs Assembling Axle Housing 1 Coat mating faces of two housings A and B with sealant and attach selected shim to face of housing B Put the two housings together and fasten them by tightening bolts to following torque value Torque specification 2 5 3 0 kg m 18 22 ft lb 2 Fit ball bearings to out end of e
23. Item 41 Tighten fasteners to a torque of 45 ft Ib Groundsmaster 455 D Page 7 11 Rev E 11 Use a press to push the lower bearing housing and bearings onto the lower pulley 17 Press on INNER race of bearing 12 Install lockwasher Item 32 and bearing locknut Item 30 to pulley shaft Use special tool TOR4051 and a torque wrench to tighten locknut Tighten to a torque of 150 200 ft lb 13 Install lower bearing housing and pulley assembly to main clutch plate Item 34 and secure with four 4 special screws Item 23 and locknuts Item 20 14 Install belts on PTO drive pulley 15 Install clutch 9 Install PTO shaft with rubber flange to clutch adapter Item 13 with new flange head screws Item 6 and and washers 7 Tighten screws to a torque of 45 ft Ib 10 Inspect rubber mounts Item 22 and replace if worn or damaged 11 Install bearing Item 4 so screws Item 1 and locknuts Item 27 are snug but not tight 12 Rotate PTO shaft by hand so self aligning bearing can find proper alignment position Tighten locknuts Item 27 13 Set bearing collar Item 2 against bearing then turn collar in direction of shaft rotation to lock Apply Loctite 242 or equivalent to setscrew Item 3 before installing 14 Lubricate bearing Item 4 with No 2 General Pur pose Lithium Base Grease Repairs PTO System Driveshaft Removal and Installation 1 To prevent possible PTO enga
24. ends melted injection pump timing out of adjustment engine overheating See Chapter 5 Electrical System Engine Page 3 24 Rev Groundsmaster 455 D Smoke During Operation Problem Possible Causes Black Defective injector Injection pump out of adjustment Injection pump timing Air intake restricted Inlet chambers clogged Not enough advance Grey Defective injector Injection pump timing Air intake restricted Not enough advance Blue Grey Defective injector Injection pump timing Too much oil Blue Too much oil Wear White Injection pump timing Cylinder head gasket Cold engine Groundsmaster 455 D Page 3 25 Rev B Engine Starting Problems Problem Engine will not start and emits black smoke Possible Causes Air intake obstructed Defective injectors Lack of compression seized rings damaged or worn valve seats or general wear Injection pump timing Engine will not start and emits white smoke Leaking cylinder head gasket Engine will not start and does not emit any smoke Frozen fuel Injection pump does not work Leaking injection pipe unions Injection valve blocked No preheating Empty fuel tank Feed pipe obstructed Air getting in pipes Tank vent plugged Injection pump needs re priming Shutdown control jammed in stop position Starter does not crank or cranks slowly Battery discharged Oil too thick En
25. 14 Install the exhaust manifold with new seals 15 Install the intake manifold 16 Remove the engine from the stand 17 Install the clutch housing centering pin 18 Install the TDC sensor Engine 3 60 Rev Groundsmaster 455 D Break in Engine After Overhaul After disassembling or overhauling the engine install the a new oil filter Replace this filter with a new filter after the first 20 to 50 hours of operation Groundsmaster 455 D Page 3 61 Rev B Engine Engine 3 62 Rev Groundsmaster 455 D Table of Contents SPECIFICATIONS GENERAL INFORMATION Hydraulic Hose and Fitting Information HYDRAULIC SCHEMATICS Two 2 Wheel Drive Four 4 Wheel HYDRAULIC FLOW DIAGRAMS General Auxiliary Pump Flow Traction Circuit Forward Lift Lower Circuit Lifting Cutting Unit Steering Circuit R H Turn SPECIAL TOOLS Hydraulic Pressure Test Hydraulic TROUBLESHOOTING System Operates Hot Machine Travels in One Direction Only Traction Response is Sluggish Machine Will Not Travel in Either Direction Four Wheel Drive Does Not Engage Four Wheel Drive Does Not Disengage Cutting Unit s Do Not Lift or Lift Too Slowly Cutting Units Will Not Drop or Follow Ground Contours Cutting Unit s Drop From Raised Position With Lift Valve in Centered P
26. 4 ar nd D Rear Deck Straps Figure 4 Groundsmaster 455 D Front Castor Wheels 1 Remove lynch pin from spindle shaft and slide spindle out of front castor arm Slide spacers onto spindle shaft to get desired height of cut 2 Push castor spindle through front castor arm install remaining spacers onto spindle and install lynch pin to secure assembly NOTE Make sure washer remains on bottom of spindle shaft Rear Castor Wheels 1 Remove hairpin cotter and H O C pin securing rear castor pivot arm to deck bracket 2 Align the pivot arm holes with selected height of cut bracket holes in the deck frame install H O C pin and secure with hairpin cotter Rear Deck Straps 1 Lower center and wing cutting units to the ground then raise center cutting unit slightly until rear deck straps hang freely on lift arm brackets Stop engine after cutting unit is raised 2 Remove hairpin cotter and H O C pin securing rear deck strap to H O C bracket on deck 3 Slide deck strap forward or backward until holes in strap are aligned with selected height of cut bracket holes in the deck frame install H O C pin and secure with hairpin cotter Groundsmaster 455 D Page 8 5 Rev A Figure 5 1 Front castor wheel 2 Lynch pin 3 Spacers 4 Washer Figure 6 1 Rear castor pivot Figure 7 1 Rear deck straps 2 Lift arm brackets 2 5 o Adjustments Safety Door
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28. COMMERCIAL PRODUCTS Some tools may be available from a local supplier Continuity Tester 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 The meter can test electrical components and circuits for current resistance or voltage draw Electrical System Figure 2 Groundsmaster 455 D 5 5 Special Tools Skin Over Grease Special non conductive grease which forms a light protective skin to help waterproof electrical switches and contacts Figure 3 Special Tools Page 5 6 Groundsmaster 455 D Troubleshooting 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 Cau
29. Item 16 off and discard gasket Item 4 3 Remove differential assembly and thrust washers Item 8A and 9 4 Remove large drive gear Item 18 from input shaft bevel gear assembly 5 Before removing shifter rod and fork the bolt Item 22 spring Item 24 and ball Item 23 should be removed at the outside of the case 6 Remove shifting rod Item 36 fork Item 35 and shifter gears Item 19 7 Remove output shaft assembly 8 Remove shifter brake shaft assembly Inspection 1 Check case and cover for leaks or cracks 2 Remove and discard all oil seals Do not replace seals until unit is reassembled 3 Inspect needle bearings and replace if necessary Use an arbor press and properly sized tool to remove and install needle bearings When installing bear ings apply pressure to bearing from stamped side Bearings should be pressed in 0 015 to 0 020 in below the thrust surface 4 Check gear teeth for wear pitting or breakage 5 Inspect bearing surfaces for smoothness 6 Inspect gears and shafts for out of round 7 Splines should allow a smooth fit Rotate meshing parts for a better fit if binding seems excessive 8 Check shift detent spring for tension and ball for wear 9 Check shifter rod grooves for wear Be sure snap ring sharp edges go away from shifter fork 10 Inspect shifter fork for straightness and wear 11 Check differential for loose or damaged parts 12 Check differential c
30. Specification Peugeot XUD9AI 4 cycle water cooled 4 cylinder vertical in line cylinders single overhead cam indirect injection naturally aspirated Compression ratio 23 5 1 Governor Mechanical centrifugal type integral with fuel injection pump Governor Adjustment 3000 50 RPM no load 1600 100 0 RPM idle speed Engine Rotation Counterclockwise when facing flywheel Crankshaft Forged steel induction hardened bearing surfaces 5 main bearing supports Cylinder Block Cast iron with integral cylinder liners Cylinder Head Cast aluminum material with single overhead camshaft Timing Drive The camshaft water pump and fuel injection pump are driven from the front end of the crankshaft through belt drive Piston and Piston Rings Pistons are aluminum alloy castings with free floating wrist pin Lubrication Full pressure feed by gear type pump Oil Filter Full flow cartridge type paper element with bypass Oil Capacity 5 liters 5 3 qt including oil filter Lubricating Oil API class CD SAE 15W 40 Oil Pressure 0 5 Bar 7 PSI minimum Fuel Requirements No 2 diesel fuel ASTM No 2 D Fuel Filter Replaceable paper element Crankcase Ventilation Connected to intake manifold with PCV valve Cooling System Water is circulated through the cylinder block and head by a centrifugal water pump mounted at the front
31. WIRING SCHEMATICS 2 Engine Crank and Start Circuit 2 Engine Run Circuit 3 Engine Run and Mowing Circuits 4 13 5 7 Starting Problems 7 General Run and Transport Problems 10 Cutting Operation Problems 12 Verify Interlock Operation 15 TESTING s iD 16 Ignition Key Switch 16 Seat Switch Relay and Time Delay Capacitor 17 Traction Neutral 18 Axle Hi Low Switch 19 PTO 5 20 Start Cutting Unit Time Delay and High Temp Relays 21 Glow Relay and Glow Plugs 22 Groundsmaster 455 D Page 5 1 Chapter 5 Electrical System Battery oe ie ae euo 23 Injection Pump ETR Solenoid 23 Gauges and Indicator Lights 24 High Temperature Shut Down Switch 25 Temperature Gauge Sender 25 Engine Oil Pressure Switch 26 Fuel Gauge 26 AWD Solenoid 27 Wing 27 PTO Clutch and Wing Cutting Unit Clutch 28 REPAIRS S ossa ia Saeed S RR ERA 29 Battery Service
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33. qt capacity Figure 1 Figure 2 1 Front axle dipstick cap 1 Rear axle check plug 2 Rear axle fill plug Specifications Page 6 2 Groundsmaster 455 D General Information Four Matic 4WD Over Running Clutch Operation There are two hydraulic drive motors on the Groundsmaster 455 D 4WD one for the front axle and one for the rear axle The drive for the rear axle incor porates OVER RUNNING ROLLER CLUTCH THAT TRANSMITS POWER ONLY IN THE FORWARD DIRECTION Fig 3 Front and rear axle gear ratios and tire sizes were carefully selected so that during normal operation the REAR AXLE SHAFT TURNS SLIGHTLY FASTER THAN THE REAR AXLE MOTOR Any time the front wheels begin to slip such as when climbing a steep hill the forward movement of the traction unit slows This causes the rear axle shaft speed to slow down As soon as the rear axle shaft is turning the same speed as the rear motor the roller clutch will engage and power will be transmitted from the rear motor to the rear wheels four wheel drive Fig 3 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 shaft are turning faster than the rear motor and the roller clutch is disengaged Fig 4 NOTE The Four Matic four wheel drive system may not operate properly ifthe tires are replaced by different size tires or if
34. 10 Install six 6 capscrews Item 1 and tighten evenly to a torque of 15 18 ft Ib Repairs D gt 2 E gt Lift Valve Repairs Fig 31 Figure 31 1 Plug 14 Lock nut 27 Spring 2 Disc 15 Washer 28 Spacer 3 Spring 16 Plug 29 Retaining ring 4 Detent plunger 17 O ring seal 30 Cap 5 O ring seal 18 Washer 31 Plunger 6 Plug 19 Washer 32 Plug 7 O ring seal 20 Washer 33 Spring 8 Body 21 Spring 34 Poppet 9 O ring seal 22 Poppet 35 Seat 10 Back up washer 23 Seat 36 O ring seal 11 Plug 24 Wiper seal 37 Plunger 12 O ring Seal 25 Bushing 13 Spool 26 Washer Disassembly of Lift Valve 1 Plug all ports and clean outside of valve thoroughly 2 Remove spool caps Item 30 Do not remove retain ing rings Item 28 from spools unless spring Item 27 is broken 3 Remove spools Item 13 from valve body Item 8 NOTE Spools and spool bores are matched sets Be sure each spool is identified with the correct body spool bore Repairs Page 4 48 4 Remove bushings Item 25 and o rings Item 12 from spools 5 Remove plugs Item 11 6 Remove plugs Item 32 springs Item 33 poppets Item 34 seats Item 35 and plungers Item 37 31 IMPORTANT Check location and positioning of plungers when removing from body to assure proper assembly Groundsmaster 455 D 7 Remove plugs Item 6 8 Remove plugs Item 1 disks Item 2 springs I
35. 150 180 ft Ib E e Clean tapered surfaces of all ball joints and mounting bosses with Solvent degreaser If more than 0 34 of ball joint stud extends through nut add washers as needed Figure 37 Repairs Page 8 26 Groundsmaster 455 D Safety Door Service When assembling safety door actuator adjust threaded After installing actuator adjust threaded rod so lower rod to get a dimension of 6 25 between center of each edge of door is even to 0 25 higher than lower edge of ball joint door guide when wing decks are in fully raised trans port position then tighten jam nuts see Safety Door Apply Loctite 242 or equivalent to threads of each ball Adjustment joint before installing in deck and safety door Safety door Door guide Figure 38 2 5 o Groundsmaster 455 D Page 8 27 Repairs Wing Cylinder Installation and Ball Joint Service When assembling wing cylinders adjust ball joint thread engagement to get a retracted length of 17 00 to elimi nate movement of wing decks in the fully raised trans port position then tighten jam nut Clean tapered surfaces of all ball joints and mounting bosses with solvent degreaser Retracted IMPORTANT Before installing wing cylinders clean tapered surfaces of ball joints and mounting bosses on deck with solvent degreaser Apply Loctite 242 or equivalent to nuts securing ball joints and tighten to a torque of 150 180 ft lb
36. 2 6000 2 6155 0 038 82 5390 2 6156 2 6225 0 045 82 5380 2 6226 2 6400 0 052 82 5400 After Assembly 1 Fill transaxle with approximately 144 oz 4 5 U S qt of SAE 80 90W EP gear lube 2 Check for hydraulic oil leaks 3 Check adjustment of transaxle shift linkage 4 Check brake free play adjustment Repairs n x a x lt Transaxle Service UNE HYDROSTATIC DRIVE MOUNTING SURFACE TRANSSI DRIVE GEAR DRIVE GEAR ose SE SPACER OR SHOULDER BEAR D A E INPUT SHAFT THRUST ay E 5 BEARING i THRUST THRUST 7 WASHER WASHER SHIFTER AND BRAKE SHAFT BEVELED OIL SEAL m SIDES OF RITE omms OUTPUT SHAFT THRUST WASHER THRUST EN f BSE WASHER EA N A CORN NNNY F ON 2 LASS OIL SEAL NOTE NO BEARING AT THESE POINTS BALL BEARINGS 2 NOTE This illustration shows a differ ent hydrostatic drive mounting surface and differential than what is used on the Toro Groundsmaster 455 D Figure 19 Repairs Figure 20 Page 6 12 Groundsmaster 455 D Transaxle Disassembly 1 Clean all exterior surfaces of transaxle 2 Put the transaxle on a work bench with cover side up Remove screws Lift cover Fig 20
37. 23 O ring 37 Thrust plate 9 Spring 24 Washer 38 Cylinder block 10 Shim 25 Capscrew 39 Valve plate 11 O ring 26 Pump shaft 40 Pin 12 Charge relief plug 27 Ball bearing 41 Coupling 13 Needle bearing 28 Retaining ring 42 Plug 14 End cap gasket 29 Lip seal 43 Pin 15 Pin 30 Seal carrier 1 Clean and lightly oil parts before assembly Tighten all threaded parts to recommended torque value IMPORTANT Most parts have critical high toler ance surfaces Use caution to prevent damage to these surfaces during assembly Protect exposed surfaces openings and ports from damage and foreign material 2 Install swashplate Item 36 into housing Make sure swashplate control shaft is located on correct side of housing note marks made during disassembly Install Repairs Page 4 34 swashplate roller bearings Item 21 into housing and onto swashplate trunnions Install shims Item 20 and trunnion spacers Item 19 3 Install trunnion cover Item 17 with o ring Item 18 onto housing and over swashplate trunnion 4 Use an arbor press to press a new seal Item 34 into trunnion seal cover Item 35 Outer face of seal should be pressed flush with outer surface of seal cover Be careful not to damage the seal Groundsmaster 455 D 5 Install trunnion seal cover Item 35 with o ring 18 seal Item 34 and trunnion bearing into hous ing and over swashplate trunnion see Trunnion Seal Replacement Wrap end
38. 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 Commercial Steel Class 8 8 10 9 12 9 Capscrew Head Markings s e SS 7 Capscrew Torque Class 8 8 Capscrew Torque Class 10 9 Capscrew Torque Class 12 9 Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum mm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm 6 5 9 4 7 9 14 7 11 9 14 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 455 D Page 2 3 Torque Specifications Maintenance Schedules QUICK REFERENCE AID v gnam gt 52 CHECK SERVICE 1 ENGINE OIL LEVEL FILL 7 GREASE POINTS 23 emm 2 HYDRAULIC OIL LEVEL FILL 8 RADIATOR SCREEN 3 FRONT AXLE OIL LEVEL FILL 9 AIR FILTER SERVICE INDICATOR Mz 4 FAN BELT 10 WATER SEPARATOR FUEL FILTER 5 COOLANT LEVEL FILL 11 BATTERY 6 FUEL DIESEL ONLY 12 TIRE PRESSURE 1 1 5 BAR 15 20 PSI FLUID CHANGE INTERVALS FILTER for initial 08 FLUID FILTER PARTN
39. ACC 5A 2 RELAY 5A 3 DECK 30A 4 RUN 15A Repairs 5 30 Rev Groundsmaster 455 D Traction Neutral Switch Replacement 1 Remove the two wires that are connected to the traction switch 2 Have a helper push the traction pedal down into either the FORWARD or REVERSE position this will take the switch arm tension off of the switch Loosen two 2 screws and remove the switch 3 Install new switch DO NOT over tighten screws as the switch case could break NOTE Have a helper hold the traction pedal down while installing the switch 4 Reconnect the two wires to the new switch Make sure that one wire is connected to the COMMON terminal and one wire is connected to the NORMALLY OPEN N O terminal Q O 0 CQ IMPORTANT The traction switch has three 3 ter minals If the two 2 wires are not connected to the COMMON and NORMALLY OPEN N O termi nals the engine will be unable to start and the safety interlock circuit will not function properly 2609000 Loctite 271 NOTE Apply Loctite 271 or equivalent to threads of switch screws before installing Figure 35 1 Traction neutral switch CAUTION If the wires are not correctly installed to the switch the engine could start with the trac tion pedal in forward or reverse 2 a gt o o 5 E 5 Coat the switch terminals and wires with skin
40. Adjustment On each side of the center deck is a safety door that opens and closes as the wing decks are lowered and raised The doors open to provide overlap of the cutting blades when the wing units are down The doors close to provide safety and protection when the wing units are raised Check to make sure the forward lower edge of door is even or 1 4 higher then lower edge of door guide when wing decks are in the fully raised transport posi tion If an adjustment to the door is required proceed as follows 1 Loosen am nuts securing ball joints to threaded rod 2 Rotate threaded rod to raise or lower edge of door until is even or 1 4 higher then lower edge of door guide when wing decks are in the fully raised transport posi tion 3 Tighten jams nuts to lock adjustment Figure 8 A CAUTION 1 Safety door Check for proper operation of the safety 2 Door guide doors each time the deck is cleaned and re 3 Ball joint h 4 Threaded rod pair as needed Adjustments Page 8 6 Groundsmaster 455 D Blade Adjustment To assure proper operation of the cutting unit there must be 0 25 0 12 clearance between the tips of the wing and center cutting unit blades 1 Raise cutting unit so blades are visible and block center deck section so it cannot fall accidentally Wing S es 254 12 decks must be horizontal to center cutting unit 2 Rotate a center and adjoining wing blade so there blade tips are aligned Measu
41. CONTINUITY OTHER AMONG CIRCUITS TERMINALS MADE 1 OFF NONE NONE 2 RUN B l A X Y 3 START 7 B l S NONE Figure 5 Testing Page 5 16 Groundsmaster 455 D Seat Switch Relay and Time Delay Capacitor The seat switch is a normally open N O switch that closes when the operator is on the seat With no opera tor on the seat there is an open circuit to the time delay capacitor and relay coil If the PTO switch or traction switch is open and the operator raises off the seat the engine will stop after a delay of 1 to 2 seconds Seat Switch Test 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 Figure 6 3 Lower the seat The continuity tester should show no 1 Seat switch continuity 2 Time delay capacitor 3 Seat switch relay NOTE Make sure the compression spring and pin holds the seat 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 Relay Test To test the relay disconnect the relay wire connector and install a continuity tester between the relay termi nals terminals 30 and 87 The relay should make and break continuity at terminals 30 and 87 as
42. Engine or fuel system problem Correction Clean and tighten or repair as necessary Test solenoid Replace if faulty Test glow relay Replace if faulty Check wiring and connections Clean tighten or repair as necessary Test glow plugs and replace if faulty See Troubleshooting section of Chapter 3 Engine Engine cranks but should not with traction pedal out of neutral Traction switch out of adjustment or faulty Adjust or replace traction switch Engine cranks but should not with PTO switch ON PTO switch faulty Replace PTO switch Groundsmaster 455 D Page 5 9 Troubleshooting 2 a gt o o 5 E General and Transport Problems Condition Engine continues to run but should not when traction pedal is depressed with no operator on seat Possible Cause Seat switch plunger depressed with no operator on seat Seat switch faulty or out of adjustment Time delay relay faulty Correction 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 Test relay Replace if faulty Engine kills when traction pedal is depressed or PTO switch is turned ON Operator sitting too far forward on seat seat switch not depressed Seat hinge support pin or spring binding
43. Item 15 and install new gasket Item 14 onto end cap 15 Assemble end cap with valve plate installed onto pump housing When properly assembled cylinder block spring will hold end cap away from housing ap proximately 1 8 in 16 Install the four 4 screws Item 25 and washers Item 24 that retain housing to end cap and evenly tighten to a torque of 45 to 54 ft lb IMPORTANT Be sure all parts are properly aligned Do not force end cap into position on housing 17 Rotate the pump shaft to make sure pump is assem bled correctly When properly assembled a maximum torque of 7 ft lb should be required to turn shaft 18 Install coupling Item 41 to output end of pump shaft and secure in place with the pin Item 43 19 Assemble the following components as described in previous procedures Charge Check High Pressure Relief Valves Charge Relief Valve Repairs D D gt 2 c gt Auxiliary Steering Pump No 92 7761 S N 69999 and Below Fig 23 Figure 23 1 Dowel pin 11 Bearing seal 21 Spring 2 Idler gear assembly 12 Backup gasket 22 Back plate assembly 3 Drive gear assembly 13 Wear plate 23 Spool assembly 4 Capscrew 14 Body assembly 24 Plug assembly 5 Shaft seal 15 O ring seal 25 O ring 6 Washer 16 O ring seal 27 Coupling 7 Front plate assembly 17 Relief valve assembly 28 Hex capscrew 8 Needle bearing 18 Plug assembly 9 O ring seal 19 O ring 10 O ring
44. Lower Pulley and Bearing Service NOTE Always use new coupler flange head screws Items 2 and 6 when repairing PTO systems 150 200 ft Ib Apply Never Seez to bore 45 ft lb Apply Never Seez to spline and bearing mount Loctite 242 4 Rotate in direction of shaft rotation before tightening setscrew Loctite 242 30 35 ft lb Figure 10 1 Socket head screw 16 Ball bearing 30 Bearing locknut 2 Bearing collar 17 Lower pulley 31 Main wire harness 3 Set screw 18 Key 32 Lockwasher 4 Bearing 19 Belt set 33 Clutch spacer 5 PTO shaft 20 Locknut 34 Clutch plate 6 Flange head screw 21 Spacer 35 Belt cover 7 Flat washer 22 Rubber mount 36 Hat washer 8 Hex washer head screw 23 Special screw 37 Clutch 9 Wire harness 24 Hange head screw 38 Washer 10 J clamp 25 Wire cover 39 Flange head screw 11 Hex head bolt 26 Thrust washer 40 Rubber flange 12 Screw 27 Locknut 41 Locknut 13 Clutch adapter 28 Flange head nut 42 Washer 14 Lower bearing housing 29 Hex head capscrew 43 Grease fitting 15 Lower bearing spacer NOTE Aspecial tool TOR4051 is required remove and 3 Remove four 4 locknuts Fig 10 Item 20 and install the bearing locknut Fig 10 Item 30 special screws Item 23 securing lower bearing housing Item 14 to clutch plate Item 34 1 Remove PTO clutch see PTO Clutch Removal and Installation 4 Remove lower bearing housing and pulley assembly 2 Loosen belt tens
45. Make sure two 2 flat washers are installed under each nut Loctite 242 g 150 180 ft Ib E c _ If more than 0 34 of ball joint stud extends through nut add washers as needed Figure 39 Repairs Page 8 28 Groundsmaster 455 D Clean tapered surfaces of all ball joints and mounting bosses with solvent degreaser If more than 0 34 Clean tapered surfaces gt of ball joint stud extends of all ball joints and m through nut add mounting bosses with washers as needed solvent degreaser Figure 40 Center Deck Lift Arm Ball Joint Service When installing center deck lift arm ball joints Fig 40 IMPORTANT Before install ball joints to deck clean adjust ball joint thread engagement to get a dimension tapered surfaces of ball joints and mounting bosses of 2 50 0 12 from the lift arm end to center of ball joint on deck with solvent degreaser Tighten jam nut after ball joint is fastened to deck 2 5 o Groundsmaster 455 D Page 8 29 Repairs Idler Pulley Service Apply Loctite 242 or equivalent to threads of bolt secur ing idler pulley to deck Tighten bolt to a torque of 35 to 40 ft lb When installing V groove idler pulleys make sure bolt heads are facing down Make sure center idler pulley on center deck is installed in hole closest to edge of pulley support Install in adjacent hole if using optional high speed larger diame ter gearbox pulley Loc
46. 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 455 D Torque Specifications Use these torque values when specific torque values The torque values listed below are for lubricated are not given DO NOT use these values in place of threads Plated threads are considered to be lubricated specified values Capscrew Markings and Torque Values U S Customary o SAE Grade Number 5 8 5 Capscrew Head Markings 5 lt V oc L4 Capscrew Torque Grade 5 Capscrew Torque 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 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
47. Tighten nut to a torque of 75 100 in Ib Install spring and boot m a gt 2 5 E m Figure 39 1 Wire assembly 4 Nut 2 Wing switch 5 Spring 3 Washer 6 Boot Groundsmaster 455 D Page 5 33 Repairs Repairs Page 5 34 Groundsmaster 455 D Table of Contents SPECIFICATIONS GENERAL INFORMATION Four Matic 4WD Operation SPECIAL TOOLS 5 Brake Adjustment Rear Axle Toe In Transaxle Shift Linkage Adjustment Groundsmaster 455 D Chapter 6 Axles and Brakes 2 REPAIRS scene rit Gad pee pates 8 3 Wheel Bearing Service 8 3 Front Axle Removal and Disassembly 10 4 Transaxle Service 12 6 Rear 4WD Axle 14 6 6 7 Page 6 1 Table of Contents x a o 2 x lt Specifications Item Specification Tire pressure 20 PSI front and rear Wheel bolt torque 85 100 ft lb rear 45 55 ft lb front Front axle hub nut torque 300 350 ft Ib Transaxle adapter plate screw torque 65 ft Ib Front axle housing cap screw torque 100 ft lb Rear wheel toe in 0 25 in Service brake adjustment 1 5 in free travel in pedal Front axle lubricant SAE 80 90W EP gear lube 144 oz 4 5 U S qt capacity Rear 4WD axle lubricant SAE 80 90W EP gear lube 80 oz 2 5 U S
48. You note two half moon cavities in the body which must face away from the front plate or adapter plate Note The smaller half moon port cavity must be on the pressure side of the pump The side of wear plate with mid section cut out must be on suction side of pump Suction side of backplate or adapter plate is the side with larger port boss Reassembly 1 Replace the wear plates 4 seals 6 backup gas kets 5 shaft seal 10 and o rings 1 as new parts 2 Install o rings 1 in groove of front plate 7 adapter plate 16 and backplate 21 with a small amount of pe troleum jelly to hold in place 3 Tuck backup gasket 5 in front plate 7 and adapter plate 16 with open part of V section down Repairs Page4 39 3 Rev C 4 Place balance pressure seal 6 in groove in front plate 7 and adapter plate 16 5 Apply a thin coatof petroleum jelly to both milled gear pockets of front body 2 Slip body onto front plate 7 with half moon port cavities in body facing away from front plate NOTE The small half moon port cavity must be on the pressure side of pump 6 Place wear plate 4 on top of backup gasket 5 with bronze face up The side with the mid section cutaway must be on suction side of pump 7 Dip drive gear assembly 3 and idler gear assembly 13 into oil Slip both gear assemblies into gear pocket of front body 2 and into front plate bushings 8 Place wear plate 4 on top of back
49. ama aay HO LATD HA Av13a Ead X 7 Old ON HOLIMS MOYIH 27 YOSNAS 7 HOLIMS 3unss3ud NOLLO3 INI pa 105 XJ 335 4 sasn4 A ae 5 HOLIMS SLIHM NO AINO GMb t GIONTIOS UUWON MOTI3A YOLIDVdVD HOLIMS Old MONIA ON 58 A3u9 ennan 655 H2LIMS PT NOLLOVUL 98 v X IVNIIASL TIVNIWH3 L S 34 WNINYSL YOLVNYSLIV uo sonid AV I3 uadruvis 18 29v lt Aualiva 318Isn4 ICS Schemat iring 5 1 2 Groundsmaster 455 D 5 9 N S YOSNAS 55 YALVM YOSNAS NI YJ LYM
50. are in float position then stop the engine 3 Disconnect 3 hydraulic lines quick couplers and wire harness at rear of deck 4 Remove socket head screws securing drive shaft yoke gear box input shaft Slide yoke off shaft A CAUTION Do not start the engine and engage the PTO switch 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 5 Remove 4 capscrews flat washers and flange nuts securing ball joint mounts to castor arms on cutting unit 6 Roll the cutting unit away from the traction unit Alternate Method 1 Lower center and wing cutting units to the ground set parking brake and stop engine 2 Disconnect 3 hydraulic lines quick couplers and wire harness at rear of deck 3 Remove socket head screws securing drive shaft yoke gear box input shaft Slide yoke off shaft 4 Remove two 2 capscrews and locknuts securing cutting unit carrier frames to traction unit lift arms 5 Slowly back traction unit away from cutting unit Groundsmaster 455 D Page 8 9 Rev A Repairs Figure 13 1 Push arm 3 Ball joint mount 2 Castor arm 4 Capscrews amp washers Figure 14 1 Hydraulic lines quick couplers 2 Wire harness connector 3 Cutting unit carrier frame 4 Traction unit lift arm gt 5 o Mounting Cutting Unit to Traction Unit 1 With cutting unit on a lev
51. bearing Shim Figure 42 Torque wrench 3 0 22 615 approx Figure 43 Repairs Page 6 22 Rev C Groundsmaster 455 D Installing Axle on Machine 1 Support axle under machine with a jack 2 Install axle pivot pin to secure axle to frame Make sure to install thrust washers between axle pivot and frame 3 Install hydraulic motor to adaptor housing 4 Install wheels to axle Tighten wheel bolts to a torque of 85 100 ft lb 5 Fill axle with SAE 80 90W EP gear lube Lubricant capacity is approximately 80 oz 2 5 U S qt 6 Check rear wheel toe in and adjust if necessary Rear wheel toe in 0 25 in x a o 2 x lt Groundsmaster 455 D Page 6 23 Rev A Repairs Repairs Page 6 24 Groundsmaster 455 D Chapter 7 Power Take Off System Table of Contents SPECIFICATIONS 2 PTO Drive Pulley and Bearing Service 7 5 2 PTO Clutch Removal and Installation 8 ADJUSTMENTS Eten eet 3 Lower Pulley and Bearing Service 10 PTO Belt 3 PTO Shaft and Bearing Service 11 PTO Clutch 4 Driveshaft Removal and Installation 12 REPAIRS 2 2 eh Lass 5 Driveshaft Universal Joint Replacement 13 PTO Belt
52. bore and through the seal and then tapping against the back of the bearing cup until driven out of the cap Repairs Page 8 22 5 If 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 Be careful not to damage the bore 6 Remove locknut Item 23 and lockwasher Item 22 7 Press shaft Item 19 back through seal end of hub Item 17 When inner bearing cone Item 15 is free gear Item 21 and key Item 20 may be removed from the shaft Remove other bearing cone and seal Item 18 8 To remove the bearing cups Item 16 from the hub Item 17 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 hub bore and tapping against the back side of the bearing cup until it comes out 9 Remove the plugs Item 6 from the housing Groundsmaster 455 D Figure 34 Gearbox NOTE Apply coating of lubricating to bearings before assembling 1 Start with input shaft Item 8 and put gear Item 9 over shaft so tooth side is towards turned end of shaft Align keyway in gear with keyway in shaft and install one of keys Item 9 in keyway 2 Press bearing cone 4 over turned end of shaft 3 Put bearing cone Item 11 over other end of shaft and down against hub side of gear 4 Put thru cap Item 14 dow
53. dust seal in seal gland bush ing flat or smooth side of dust seal must face down towards bushing 15 Install the quad ring seal in seal gland bushing Smooth seal in place with your finger Do not use any seal that falls freely into pocket of bushing see Fig 60 16 Install seal gland bushing over the spool end with a twisting motion Tap the bushing in place with a rubber hammer Make sure the bushing is flush against the bearing race 17 Install retaining ring in housing After installing ring tap on ring end or pry with screwdriver around entire circumference of ring to properly seat ring in groove Groundsmaster 455 D Retaining _ Ring Seal Gland Bushing with seals Screwdriver Teflon Seal Dust Seal Retaining Ring Seal Gland Bushing Bushing with Ident Groove Page 4 57 Figure 50 Repairs bod D gt 2 E c gt 18 Clamp housing in vise as shown Clamp lightly on edges of mounting area Do not over tighten jaws NOTE Check to insure that the spool and sleeve are flush or slightly below the 14 hole surface of the housing IMPORTANT Clean the upper surface of the hous ing by wiping with the palm of clean hand Clean each of the flat surfaces of the meter section parts in a similar way when ready for reassembly Do not use cloth or paper to clean surfaces 19 Install 3 diameter seal in housing
54. flat washers Item 7 securing rubber flange Item 40 to clutch adapter Item 13 P T O Clutch 5 Remove clutch adapter 13 Figure 9 6 Remove flange head screw Item 39 and washer Item 38 securing clutch assembly Item 37 to shaft of lower pulley Item 17 7 Remove the clutch assembly Make sure you acount for the key Item 18 and clutch spacer Item 33 8 Before installing clutch assembly apply Never Seez or equivalent to bore of clutch Item 13 Install clutch spacer Item 33 and install key Item 18 in keyway on shaft of lower pulley Item 17 9 Align key on lower pulley with keyway in clutch bore and install clutch assembly on lower pulley shaft Make sure key engages both clutch sections NOTE Mark keyway location on end of shaft Mark keyway slot on outer clutch bearing Install clutch asssembly on shaft by lining up the marks 10 Make sure hole in clutch field rotor plate is aligned with pin on clutch plate Apply Loctite 242 or equivalent to flange head screw Item 39 then secure clutch in place with flange head screw and special washer Item 38 Tighten flange head screw to a torque lof 30 35 ft lb 11 Connect clutch electrical connector Adjust clutch air gap see Clutch Adjustment in the Adjustments section of this chapter 12 Install PTO shaft to clutch and retighten bearing collar Item 2 PTO System Groundsmaster 455 D 7 9 Rev Repairs
55. if necessary Faulty four wheel drive solenoid valve Inspect and clean solenoid valve and repair or replace if necessary Faulty roller clutch Replace roller clutch Faulty rear axle hydraulic motor Repair or replace motor Four Wheel Drive Does Not Disengage 2 5 2 Cause Correction 5 Electrical problem Check for faulty front axle HI LOW switch or wiring I and repair if necessary Four wheel drive solenoid valve sticking Inspect solenoid valve for damage or sticking in on position and clean or replace valve if necessary Faulty roller clutch Replace roller clutch Groundsmaster 455 D Page 4 15 Troubleshooting Cutting Unit Does Not Lift or Lift Too Slowly Cause Correction Hydraulic oil level too low Fill to proper level Low engine RPM Adjust engine RPM use tachometer Lift arm or cylinder pivots binding Lubricate bushings Inspect for damage Repair or replace damaged parts Wing deck break away spring mechanism binding Lubricate and inspect for damaged or worn parts Repair or replace damaged or worn parts Lift cylinder damaged Check lift cylinder s Repair or replace if necessary Low counterbalance pressure TEST NO 2 3 Adjust counterbalance pressure or replace counterbalance relief valve if necessary Low lift pressure TEST NO 5 Check for restriction in pump intake line or strainer and repair if necessary
56. in a suitable solvent Replace all o rings gaskets and seals 19 Inspect all parts for damage nicks or unusual wear patterns Replace all parts having unusual or excessive wear or discoloration 20 If scratches which can be felt with a pencil lead can be found on bronze surface of valve plates or running surface of cylinder blocks polish or replace the parts 21 Inspect needle bearings and drive coupling in center section If replacement is necessary remove shaft nee dle bearings using a suitable puller Do not damage valve plate surface of center section 22 Press new needle bearing Item 13 into end cap using a suitable press pin When installed correctly bearing cage will protrude from 0 08 to 0 10 in from surface of end cap to serve as pilot for valve plate IMPORTANT When installing the needle bearing the printed numbered end of the bearing cage must face the press pin 23 Install a new cylinder block kit if brass slippers on pistons are scored or excessively rounded at edges Repairs D gt i 2 gt Assembly of Traction Pump Fig 22 Figure 22 1 End cap 16 Screw 30 Seal carrier 2 Plug 17 Trunnion cover 31 O ring 3 18 O ring 32 Retaining ring 4 O ring 19 Trunnion spacer 33 Pump housing 5 Conical spring 20 Shim 34 Lip seal 6 Retaining ring 21 Roller bearing 35 Trunnion cover 7 Relief valve 22 O ring 36 Swash plate 8 Charge relief poppet
57. install socket head screw 3 Tighten socket head screw pulling spring support rod back until lock pivot is aligned with holes in deck then install clevis pin and cotter pin to secure spring loaded locking mechanism 4 Remove socket head screw Reverse rod cap so small end is facing spring support rod apply Never Seez or equivalent to threads of socket head screw and install screw to secure rod cap on end of spring sup port rod Spring Spring support rod Figure 43 Groundsmaster 455 D Page 8 31 Repairs 2 3 o This page is blank This page is blank TORO Commercial Products The Toro Company
58. its ends Ends of ORIGINAL ANGLE blade must be slightly lower than the center and cutting edge must be lower than the heel of the blade This bm blade will produce good quality of cut and require mini mal power from the engine By contrast a blade that is higher at the ends than the center or if cutting edge is END VIEW higher than the heel the blade is bent or warped and must be replaced 5 Install blade sail facing toward cutting unit with anti Fiaure 25 scalp cup lockwasher and blade bolt Tighten blade bolt 9 to 85 110 ft lb Repairs Page 8 16 Rev A Groundsmaster 455 D Blade Spindle Service 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 Release belt tension see Belt Tension Adjustment 3 Remove belt from spindle to be serviced see Belt Replacement 4 f removing spindle with clutch remove clutch rod Unplug clutch electrical connector from harness 5 Start the engine and raise the cutting unit Turn the engine OFF and remove the key from the key switch Engage locking latches to prevent cutting unit from falling accidentally Groundsmaster 455 D 8 17 Rev Figure 26 1 Clutch rod 2 Clutch electrical connector Rubber grommet Cable tie A lt th Rubber grommet amp Qo Y Hair pin cotter Clutch rod Clutch electrical connect
59. location and positioning of plungers during installation 6 Install new o rings Item 36 on seats Item 35 Install new back up washers Item 10 and o rings Item 9 on plugs Item 32 7 Install seats Item 35 new poppets Item 34 springs Item 33 and plugs Item 32 8 Install plugs Item 6 with new o rings Item 7 9 Install detent plungers Item 4 springs Item 3 discs Item 2 and plugs Item 1 with new o rings Item 5 10 If retaining ring Item 29 has been removed to replace spool spring Item 27 install washer Item 26 spring Item 27 spacer Item 28 and secure with retaining ring Item 29 11 Slide bushings Item 25 over spools Slide new o rings Item 12 over spools and position next to bush ings Dip spools in clean hydraulic oil and install spool assemblies in proper location 12 Install spool caps Item 30 and tighten to a torque of 20 25 ft lb 13 Install new wiper seals Item 24 Repairs D gt 2 E gt Steering Control Unit Repair Fig 32 2 3 4 5 6 7 8 7 Figure 32 1 Set screw 10 Control sleeve 20 Centering pin 2 Dust seal 11 Centering springs 21 Check ball retainer 3 Retaining ring 12 Control spool 22 Check ball 4 Gland seal bushing 13 Seal 23 Seal 5 Seal 14 Spacer plate 24 Check ball seat 6 Quad ring seal 15 Drive 25 Seal 7 Bearing race 16 Gerotor 8 Thrust needle bearing 17 Spacer 9 Ho
60. of swashplate control shaft with thin plastic to prevent damage to seal lip during installation 6 Install hex tapping screws Item 16 and tighten to a torque of 6 to 9 ft Ib 7 Using caution to not damage the sealing surface press ball bearing Item 27 onto drive shaft Item 26 Install bearing retaining ring Item 28 onto shaft 8 Install drive shaft and bearing into housing 9 Install input shaft seal Item 29 seal carrier Item 30 and o ring Item 31 as described in Traction Pump Shaft Seal Replacement Coat thrust plate Item 37 with petroleum jelly and install onto swashplate Item 36 The thrust plate is reversible 10 Assemble cylinder block kit Item 38 by installing piston assemblies into the slipper guide Lubricate pis tons and cylinder block bores Install assembled guide and pistons into cylinder block by inserting pistons into cylinder block bores The pistons and bores are not selectively fitted so no specific piston and bore orienta tion is required 11 Lay the pump on its side and install cylinder block kit into the housing 12 Install valve plate locating pins Item 40 into end cap Groundsmaster 455 D Page 4 35 13 Coat back steel side of valve plate Item 39 with petroleum jelly to hold itin position and install valve plate onto end cap Item 1 with the bronze face visible The notch on the valve plate must engage the locating pin 14 Install the two 2 alignment pins
61. of 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 bearing cup 9 Slide the wheel onto 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 see Adjusting Rear Wheel Bearings Figure 15 1 Wheel hub 4 Cotter pin 7 Seal 2 Wheel spindle 5 Slotted nut 8 Bearing cone 3 Dust cap 6 Washer 9 Bearing cup Repairs Page 6 8 Groundsmaster 455 D Adjusting Rear Wheel Bearings 1 Remove dust cap from end of wheel spindle Remove cotter pin retaining slotted nut in place 2 Rotate the wheel by hand and tighten the slotted nut 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 0 002 0 005 inches 3 Remove jack stands or blocks and lower machine to floor Figure 16 4 Put a coating of grease on the inside of the dust cap Install dust cap on end of wheel spindle 1 Cotter pin and slotted nut o 2 x lt
62. over grease 6 Check traction control neutral adjustment See Trac tion Control Neutral Adjustment in the Adjustments sec tion of Chapter 4 HYDRAULIC SYSTEM Groundsmaster 455 D Page 5 31 Repairs AWD Solenoid Coil Replacement 1 Park machine on a level surface engage parking brake lower the cutting units and turn engine OFF 2 Disconnect solenoid electrical connector 3 Remove coil nut 4 Remove coil assembly 5 Install new coil assembly and secure with coil nut Apply Locktite 242 or equivalent to threads on end of stem tube before installing nut Tighten nut to a torque of 15 in Ib Over tightening may damage coil nut or cause solenoid valve to malfunction 6 Connect electrical connector Axle Hi Low Switch Replacement 1 Park machine on a level surface engage parking brake lower the cutting units and turn engine OFF 2 Disconnect Hi Low switch electrical connector 3 Remove Hi Low switch with o ring spring amp ball guide spring plunger and switch pin guide 4 Before installing new switch clean spring amp ball guide spring and plunger with cleaning solvent Re place any worn or damaged parts After parts are dry coat spring amp ball guide spring plunger and inside of switch pin guide with No 2 multi purpose grease 5 Install a new o ring then install the new switch 6 Connect electrical connector NOTE For proper operation the switch must be screwed all the way in I
63. port Start engine and check for 30 psi minimum at 1500 rpm If engine pressure is good replace switch If engine pressure is low DO NOT operate the engine Fuel Gauge Sender 1 Disconnect wire and remove the fuel gauge sender from the fuel tank 2 Install an ohm meter between the terminal and base 3 With arm completely down empty position resis tance should be 240 260 ohms 4 With arm completely up full position resistance should be 29 34 ohms NOTE Bend float arm if necessary to get proper gauge reading for a 1 2 full tank A CAUTION Make sure the sending unit is completely dry no fuel on it before testing Perform test away from fuel tank to prevent an explosion or fire from sparks Testing Page 5 26 Groundsmaster 455 D 4WD Solenoid 1 Disconnect the wire connector 2 Connect a 12 volt battery so the positive battery terminal is connected to colored solenoid lead Connect the negative battery terminal to black lead The valve spool should retract completely as 12 V D C is applied between leads 3 If valve spool does not operate properly check for binding or damage to valve 4 f valve moves smoothly but does not engage when 12 V D C is applied to solenoid leads replace solenoid coil 5 If valve still does not operate after replacing solenoid coil replace the valve Wing Switch The wing switch is closed with the wing cutting unit lowered and open when wing
64. proper tire pressure is not maintained Figure 4 n x a o 2 x lt Groundsmaster 455 D Page 6 3 General Information Special Tools Order special tools from the TORO SPECIALS TOOLS AND APPLICATIONS GUIDE COMMERCIAL PRODUCTS Rear 4WD Axle Tools TOR4030 Differential Case Gauge Used to determine the number of shims required between the 4WD rear axle differential housing Figure 5 TOR4039 Pilot Bushing Driver Used to install the pilot bushing into ends of 4WD rear axle Figure 6 TOR4040 Pinion Nut Tool Used to remove or install the pinion sleeve nut on the 4WD rear axle Special Tools Page6 4 Figure 7 Groundsmaster 455 D TOR4041 Bevel Gear Remover Used to separate the bevel gears from their shafts in the ends of the 4WD rear axle D Figure 5 TOR4042 Pinion Gauge Used to determine the number of shims required to properly position the 4WD rear axle pinion Figure 6 TOR4043 Oil Seal Installation Tool Used to install the oil seals in the ends of the 4WD rear axle Figure 7 x a P x lt Groundsmaster 455 D 6 5 Special Tools Adjustments Brake Adjustment Adjust service brakes when there is more than 1 5 in free travel of brake pedal or when brakes do not work effectively Free travel is the distance t
65. seal moulded 20 Disc Disassembly of Auxiliary Steering Pump 1 Thoroughly clean outside of pump 2 Use a sharp tool or marker to mark across front plate Item 7 body Item 14 and back plate Item 22 This will assure proper reassembly 3 Clamp pump in a vise with the shaft up 4 Remove capscrews 28 5 Remove pump from vise hold pump in hands and bump shaft against a wood block to separate front plate Repairs Page 4 36 Rev C Item 7 from back plate Item 22 Body Item 14 will remain with either front plate or back plate 6 If front plate was removed first remove wear plate Item 13 from body gear pockets 7 Remove drive gear assembly Item 3 and idler gear assembly Item 2 from body 8 To separate body Item 14 from plate it remains with put drive gear assembly Item 3 in a bushing and tap protruding end with a plastic hammer or soft mallet 9 Remove o ring Item 9 from front plate and back plate Groundsmaster 455 D 10 Remove backup up gasket Item 12 from front plate 11 Remove bearing seal Item 11 from front plate by prying with a sharp tool 12 Remove molded o ring Item 10 from front plate by prying with a screwdriver 13 Remove shaft seal Item 5 from front plate by prying with a screwdriver Disassembly of Back Plate Assembly Flow Divider Flow Control Relief Valve 1 Remove relief valve Item 17 from back plate NOTE Do not disassemble reli
66. seat first Push check ball seat to shoulder of hole 5 Install set screw Use a 1 4 allen wrench to torque set screw to 100 inch pounds To prevent interference make sure top of set screw is slightly below housing mounting surface 6 Assemble spool and sleeve carefully so that the spring slots line up at the same end Rotate spool while sliding parts together Some spool and sleeve sets have identification marks align these marks as shown Test for free rotation Spool should rotate smoothly in sleeve with finger tip force applied at splined end Groundsmaster 455 D Set Screw 5 8 Seal Check Ball Seat 7 16 Seal O Check Ball Check Ball Retainer Figure 44 Control Spring Sleeve Slot Spring Slot __ Identification Control Marks Spool Figure 45 Repairs Page 4 55 D gt 2 c gt 7 Bring spring slots of both parts in line and stand parts on end of bench Insert spring installation tool through spring slots of both parts Tool is available from a Eaton Hydraulics supplier as Eaton part no 600057 Position three 3 pairs of centering springs or 2 sets of 3 each on bench so that extended edge is down and arched center section is together In this position insert one end of entire spring set into spring installation tool with spring notches facing sleeve 8 Compress extended end of centering spring set and push into s
67. shaft unless unit is positioned with mounting flange UP If unit is positioned horizontally when shaft is removed the cylinder block could move out of place making shaft installation difficult 5 Remove o ring Item 31 from seal carrier Repairs Page 4 28 6 Put seal carrier in an arbor press and press out old seal Item 29 Use a properly sized pipe spacer or socket wrench for a press tool The seal cannot be used again 7 Inspect seal carrier new seal and o ring for damage Inspect sealing surface on shaft for rust wear or con tamination Polish sealing area on shaft if necessary 8 Use an arbor press to press new Seal into seal carrier Be careful not to damage seal NOTE New seals are lubricated with an assembly grease 9 Use a seal protector tool or wrap end of shaft with thin plastic to prevent damage to seal lip during installation 10 Install o ring into seal carrier and lubricate with petroleum jelly 11 Slide seal carrier assembly over shaft and into housing bore Hold inward pressure against shaft to compress cylinder block spring while pressing seal car rier into position Install retaining ring Groundsmaster 455 D Traction Pump Trunnion Seal Replacement Fig 18 Figure 18 1 Park the machine on a level surface lower cutting units engage parking brake and stop the engine 2 Remove control linkage from swashplate control shaft on transmission see Transmission Control Removal
68. 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 bearings with cups and spacer not the large snap ring because it is not required when installing bearings into a used spindle housing that still has a snap ring installed refer to step 2 below 1 Install the large retaining ring into the groove in the bore of the spindle housing Make sure the retaining ring is seated in the groove 2 Using an arbor press push the large spacer into the top of the spindle 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 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 the lips of both seals then install the bearing and the seal into the bottom of the spindle housing Remember 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 coul
69. tape and install in bottom cover 8 Turn final case around gear case by hand and check for smooth rotation Repairs Page 6 20 Ball bearing Circlip Axle housing Figure 35 Oil seal Figure 36 Holder Gear case x Pinion 14 T Final case Figure 37 Groundsmaster 455 D Installing Drag Link and Tie Rod Arm 1 Carefully insert bushing into arm 2 Put arm into position over holder fitting it to final case and secure to case with bolts 3 Check thrust clearance Proper thrust clearance is m rust Clearance 0 to 0 2 mm 0 008in If necessary reduce clearance 0 0 2mm to specification by shimming Shim stock for this adjust 0 0 008 in ment is available in the following thicknesses Shim Part No Shim Part No Nj Thickness TIE ROD ARM DRAG LINK ARM Shim set 77 4050 77 4040 Figure 38 0 8 0 03 in 76 7820 76 7700 1 0 0 04 in 76 7970 76 7760 1 2 mm 0 05 in 76 7980 76 7780 1 4 mm 0 055 in 76 7990 76 7790 4 After selecting required shim remove the arm Apply multi purpose lithium base grease to OD part of holder Install holder on arm with shim and secure to final case by tighten reamer bolts to following torque value Torque specification 8 5 9 5 kg m 61 69 ft lb Installing Gear Case Assembly to Axle Housing 1 To check backlash between pinions 14T one
70. the wing decks coun terbalance quick disconnect fitting 4 Start the engine move throttle to full speed 3000 RPM and observe gauge TESTER READING 350 400 PSI oil at normal operating temperature NOTE The wing deck counterbalance valve is not adjustable Figure 12 1 Wing deck counterbalance test port 2 Wing deck counterbalance relief valve non adjustable Testing Page 4 22 Rev A Groundsmaster 455 D TEST NO 4 Checking Steering Circuit Working Pressure or Relief Pressure WORKING Pressure Check 1 Make sure hydraulic oil is at normal operating tem perature by operating machine for approximately 10 minutes 2 Lower cutting units engage parking brake and stop the engine 3 Raise and support the seat to get access to hydraulic test fittings 4 Install a 5000 PSI gauge onto steering circuit quick disconnect fitting Figure 13 5 Operate machine while monitoring gauge 1 Steering circuit test port RANGE OF TESTER READINGS 0 1300 PSI RELIEF Pressure Check 6 With engine running turn the steering wheel until heavy resistance is felt indicating that the cylinder has reached maximum stroke 7 Momentarily hold steering wheel against resistance and read gauge D gt 2 2 c gt TESTER READING TO BE 1200 100 PSI Groundsmaster 455 D Page 4 23 Testing TEST NO 5 Checking Lift Circuit Working Pressure Relief Pressure WORKING Pres
71. water only until the plates are covered and then charge the battery After charging fill the battery to the proper level A CAUTION gt o 5 Figure 32 Do not charge a frozen battery because it can explode and cause injury Let the battery 1 Positive terminal warm to 60 F 16 C before connecting to a 2 Negative terminal charger FILLER CAPS Charge the battery a well ventilated place C WATER so that 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 the charger from the electrical outlet before connecting or disconnecting the charger leads from the bat tery posts Figure 33 Groundsmaster 455 D Page 5 29 Repairs Fuses The electrical system is protected by twelve 4 fuses located under the control panel to the operator s right NOTE It is not always possible to see if a fuse is faulty It is recommended that you check for faulty fuses with a continuity tester not visually The starter circuit is also protected by a 30A in line fuse between the start relay and starter solenoid S N 59999 and below The alternator charging circuit is protected by a 80A in line fuse S N 60001 and up Figure 34 1 ACC fuse 3 DECK fuse 2 RELAY fuse 4 RUN fuse FUSES 1
72. wear exceeds 0 0015 back plate should be replaced BODY Item 14 1 Check inside gear pockets for excessive scoring or wear 2 Body should be replaced if I D of gear pocket ex ceeds 1 713 FLOW DIVIDER FLOW CONTROL RELIEF VALVE 1 Check disk 20 for wear 2 Check spring Item 21 for weakness or breakage 3 Wash back plate in clean solvent then direct com pressed air into relief valve and flow divider cavities in back plate to remove any contamination Repairs D gt E gt Figure 23 General Auxiliary Steering Pump Information It is important that the relationship of the back plate Item 22 body Item 14 wear plate Item 13 and front plate Item 7 is correct You will note two half moon cavities in the body which must face away from the front plate NOTE The smaller half moon port cavity must be on the pressure side of the pump Side of wear plate with mid section cut out must be on suction side of pump Suction side of back plate is always side with larger port boss Repairs Page 4 38 Assembly of Back Plate Parts 1 Install relief valve Item 17 with new o rings Item 15 16 2 Install flow divider spool Item 23 plug Item 24 with new o ring Item 19 spring Item 21 disk Item 20 and other plug Item 18 with new o ring Item 19 Groundsmaster 455 D Assembly of Auxiliary Steering Pump 1 The wear plate Item 1
73. 11 0 021 inches see Chapter 7 P T O System or Chapter 8 Cutting Unit Testing Page 5 28 Figure 30 1 P T O clutch Figure 31 1 Wing clutch Groundsmaster 455 D Repairs IMPORTANT Before welding on the machine dis connect both battery cables from the battery and disconnect the terminal connector from the alter nator to prevent damage to the electrical system Battery Service IMPORTANT To prevent damage to electrical com Electrolyte Specific Gravity do not operate the engine with the battery Fully charged 1 250 1 280 cables disconnected Discharged less than 1 240 Keep the terminals and entire battery case clean To Battery Specifications ae battery wash entire ee with a Group 26 SMF 5 Battery of baking soda and water inse with clear water Do not 530 Amp Cranking Performance at 0 F 17 C get the soda solution into the battery because damage 85 min Reserve Capacity at 80 27 C to the battery will result Coat the battery posts and cable connectors with skin over grease or petroleum jelly to prevent corrosion Check for loose battery hold downs Aloose battery may crack or cause the container to wear and leak acid Check the electrolyte solution to make sure the level is 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
74. 12 V D C is connected and disconnected to terminal 85 with termi Figure 7 nal 86 connected to ground 2 a gt o T 5 E Relay Groundsmaster 455 D Page 5 17 Testing Traction Neutral Switch The traction switch is a normally closed and opens when traction pedal is depressed in either direction IMPORTANT The traction switch has three 3 ter minals Make sure the wires are connected to the COMMON and terminals Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester across the COMMON and N O terminals With the engine turned off slowly push the traction pedal in a forward and reverse direction while watching the conti nuity tester There should be indications that the traction switch is opening and closing Allow the traction pedal to return to neutral There should be continuity across the terminals See Replacing the Traction Switch in the Repairs section of this chapter for replacement and adjustment procedures NOTE Apply Loctite 271 or equivalent to threads of switch screws before installing Loctite 271 Figure 8 1 Traction neutral switch Testing Page 5 18 Groundsmaster 455 D Axle Hi Low Switch The axle hi low switch is normally open N O when the transaxle is in neutral or hi range This prevents the cutting units 4WD from engaging while the transaxle is neutral or hi
75. 20 Groundsmaster 455 D Page 6 15 Figure 25 1 Tie rod 2 Drag link 3 Hydraulic cylinder Axle housing Gear case Figure 26 a o 2 x lt Final case Figure 28 Repairs Install seal so garter spring faces hydraulic motor prs Figure 29 Disassembling Axle Housing 1 Remove axle from machine before disassembling A Jack up rear of machine and support from frame with jack stands B Remove wheels from axle C Remove hydraulic motor Do not disconnect hy draulic lines from motor D Support axle with a jack then remove axle pivot pin to separate axle from frame E Pull axle out from under machine and put on a work bench F Be sure to account for thrust washers between axle pivot and frame 2 Remove bolts Fig 29 Item 5 securing adapter to axle housing and remove adapter 3 Separate axle housing by removing bolts Repairs 6 16 Rev C 4 Pull out differential shaft Fig 23 14 from housing B 5 Remove differential gear assembly Fig 23 Items 3 11 from axle housing A 6 Pull out differential shaft from housing A Disassembling Sleeve Assembly 1 Remove sleeve 4 from adaptor case Straighten tab washer Fig 29 Item 8 and use special tool TOR4040 to remove sleeve lock nut Item 9 2 Use a press or tap lightly on shaft end to f
76. 3 bearing seal Item 11 molded o ring Item 10 back up gasket Item 12 shaft seal Item 5 and o rings Item 9 should be replaced as new parts 2 Install o ring Item 9 in groove of front plate Item 7 3 Tuck back up gasket Item 12 into groove in front plate with open part of V section down 4 Put molded o ring Item 10 in groove in front plate Put bearing seal Item 11 over molded o ring groove side down 5 Apply a thin coat of heavy grease to both milled faces of body Item 14 Slip body onto front plate half moon port cavities in body must face away from front plate NOTE The small half moon port cavity must be on the pressure side of the pump Groundsmaster 455 D Page 4 39 6 Put wear plate Item 13 on top of back up gasket with bronze face up The side with the mid section cut away must be on suction side of pump 7 Dip gear assemblies Item 2 3 into oil and slip into front plate bushings 8 Install o ring Item 9 in groove in back plate Item 22 9 Slide back plate over gear shafts until dowel pins Item 1 are engaged 10 Install bolts Item 4 and washers Item 28 Tighten evenly to a torque of 25 28 ft lb 11 Install washer Item 6 Liberally oil shaft seal Item 5 and carefully work over drive shaft being care ful not to cut rubber sealing lip 12 Put a 1 5 16 O D sleeve over the shaft and press in shaft seal until flush with front surface of front pla
77. 3 to a torque of 20 Nm 15 ft lb 5 Install the seal carrier plate and a new gasket Item 4 and tighten the bolts to a torque of 15 Nm 11 ft lb 6 Put a new oil seal on tool TOR 70153 D 7 Install the seal by tapping it fully home with a mallet 8 Apply Formetanch or Permatex No 2 sealant as shown Item a 9 Install oil pan gasket XUD9A Engine Install the oil pan gasket XUD9AI Engine Apply silicone sealant to the oil pan using the pattern shown in Figure 81a Wait 10 minutes before installing the oil pan to allow partial hardening of the gasket material 10 Install the oil pan Item 5 11 Install the bolts Item b NOTE The two shorter bolts are installed into the main bearing cap 12 Tighten the bolts Item b to a torque of 20 Nm 15 ft Ib 13 Wait a minimum of 1 hour for the oil pan gasket to harden before filling with oil Figure 81a Flywheel Installation 1 Install the flywheel Put Locket thread lock on the flywheel mounting bolts 2 Install a TORFD86 flywheel locking tool 3 Tighten the flywheel bolts to a torque of 50 Nm 37 ft Ib 4 Remove the flywheel locking tool Groundsmaster 455 D Page 3 55 Rev B Engine Cylinder Head Gasket Selection 1 Install the dial indicator on support TOR 80110 H and zero it on a surface plate 2 Turn the crankshaft and measure the protrusion of each piston at TDC 3 Note the maximum protrusion Fig 82 Item d 4 Sele
78. 38 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 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 32 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 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
79. 3914140 trao I dvd SET TS 5 10053201 es 1540002 Hydraulic Schematics Page4 5 Rev Groundsmaster 455 D ic Schematic Four 4 Wheel Drive Hydraul 1496 2 1304 1531 OT 17 dali isase A 31005 uva 2 12 9 154 007 002 D M L4 1304 1591 ava 9 15 Z 154 OTT OOT NIW Sua1r 99 s ID dv 6 9 ae S T 158 OOT SN avd Es 15 0009 ne OAA CY 31xv A3u 22 6 28 uv3u A34 2280 S 0069 N dY 009 000 ABW TOC CEST c NI TE YOLOW uv3u g 1 ANN A39 22 0 52 8 uva 8 154 0021 T 6 S6 IGNI M L Hot GV ey 7 E ZA q A3u 22 vL A LINN IOWLNOO 5NIU3als YAGNITAD 9 3331 f my OU X901 OL AION dvd 9T 8 _ 31 154 NIW SYALIT 6 1 30 AVM 3NO 6
80. 7 Ball bearing 41 Coupling 13 Needle bearing 28 Retaining ring 42 Plug 14 End cap gasket 29 Lip seal 43 Pin 15 Pin 30 Seal carrier Clean parts by using a clean solvent wash and air drying Keep parts free of foreign materials and chemi cals Protect all sealing surfaces and open cavities from damage and foreign material During assembly of the pump all surfaces which have relative motion between two parts should be coated with a film of clean hydraulic oil This will assure that these surfaces will be lubricated during start up It is recommended that all gaskets o rings and seals be replaced Lightly lubricate all o rings with clean petro Repairs Page 4 32 leum jelly before assembly All gasket sealing surfaces must be cleaned before installing new gaskets 1 Before performing major repairs on the pump remove external components as described in previous proce dures These include the Charge Check High Pressure Relief Valves and Charge Relief Valve 2 Remove pin Item 43 from coupling Item 41 on output end of pump shaft Remove the coupling 3 Remove four 4 screws 25 which retain end cap to pump housing Groundsmaster 455 D 4 Remove end cap Item 1 pump housing IMPORTANT The valve plate Item 39 may stick to the end cap Do not allow valve plate to fall from end cap 5 Remove gasket Item 14 and alignment pins Item 15 from end cap IMPORTANT Be careful not to dama
81. E0 cT 1447 LINN F 020 SNYNLO S 32l4l dO 80 14M LINN H31N3D 513 30 AVM 3NO 6E0 447 LINN 1997 4 020 YAONN 1d 10051201 3ATVA TOYULNOD TWNOILDAYIG 10051201 S6 1304 1531 uva 15 0002 SES N NI ETS YOLOW ___408 1534 A39 22 0 SD Y 3IXV INOU3 LEsustl NIW SYALIT T9 QuvMuod ES uod 1531 Groundsmaster 455 D Page4 6 Rev C Hydraulic Schematics IIOAIOSOI 0 4oeq pue ui SSe9X3 doo pesojo 20 y y 0 pue eui Udy yl OU 0 5906 dund 94 pue 191009
82. Fluid Level Drain Water Fuel Separator Optional Air Filter Precleaner v Radiator amp Screen for Debris v Unusual Engine Y Unusual Operating Noises v Hydraulic System Oil Level Y Hydraulic Hoses for Damage Y Fluid Leaks Y Tire Pressure Y Instrument Operation Y Cutting Unit Safety Doors v Height of Cut Adjustment Clean Deck Belt area Y Condition of Blades Lubricate All Grease Fittings Touch up damaged paint 1 Use only low pressure compressed air for debris removal Do not use water Check Glow Plugs and Injector Nozzles if hard starting excess smoke or rough running is noted Immediately after every washing regardless of the interval listed Notation for areas of concern Inspection performed by Item Date Information 1 See Operator s Service Manual for specifications and procedures 15 98 66 ON W104 Sijeg oeq Jenn Old pinj4 eoejdeu usnjJ 1 1 1009 SOYOUMS 000000000 eoejdeu 1219 4 pue 1 10 peuinbaJ pue y SINN jeeuM enbijo 9ui99 3 Y09490 jueunsn py seupini oui e 3 49949 sijeg pue Old P
83. I gauge onto the charge pressure quick disconnect fitting 4 Start the engine and position throttle at high idle 3000 RPM TESTER READING TO BE 100 5 4o PSI Figure 15 5 If pressure is low inspect charge relief valve and valve seat 1 Charge pressure test port 6 Also take a gauge reading while operating the ma chine in forward and reverse Start the engine and put the throttle at full engine RPM Apply the brakes and push the traction pedal forward then reverse If pres sure is good under no load but drops below specifica tion when under traction load the piston pump and or motor should be suspected of wear and inefficiency When the pump and or motor is worn or damaged the charge pump may not able to keep up with the internal leakage 2 gt 2 2 E gt Groundsmaster 455 D 4 25 Rev C Testing Adjustments Traction Pump Neutral Adjustment The machine must not creep when traction pedal is released If it does creep an adjustment is required 1 Park machine on a level surface and shut engine off Make sure transaxle is engaged in HI position Depress only the left brake pedal and engage the parking brake 2 Jack up right side of machine until front tire is off the shop floor Support machine with jack stands to prevent it from falling accidentally 3 Under left side of machine loosen locknut on traction adjustment cam Figure 16 A WARNING 1 T
84. ION OF THE SWITCHES DAILY TO ASSURE IN TERLOCK SYSTEM IS OPERATING IF A SWITCH IS DEFECTIVE REPLACE IT BE FORE OPERATING REGARDLESS IF SWITCHES ARE OPERATING PROPERLY OR NOT REPLACE THEM EVERY TWO YEARS TO ASSURE MAXIMUM SAFETY DO NOT RELY ENTIRELY ON SAFETY SWITCHES USE COMMON SENSE Troubleshooting 2 a gt o 2 E TT 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 trically 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 The ignition key switch has three positions OFF RUN and START The terminals are marked as shown The circuitry of the ignition switch is shown in the chart 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 X Figure 4 POSITION
85. Identification Identification b Thickness No notch 2 notches 1 61 3 notches 1 73 Identification and Specifications Page3 4 Rev C Figure 2 Figure 3 Groundsmaster 455 D Camshaft Camshafts with 0 5 mm oversize bearings are iden tified by a yellow paint ring d between the cams of No 1 cylinder NOTE These camshafts are installed only on ex change engines and can be obtained on special order Figure 4 Valves Units mm Intake Exhaust Min Length I 112 2 0 0 015 8 005 7 985 gb 0 1 38 5 33 a 90 90 Intake Faces x and y can machined a maximum of 0 2 mm Exhaust No machining is permissible Figure 5 Valve Recess Units mm Intake Exhaust c 0 5 to 1 05 0 9 to 1 45 te Figure 6 Groundsmaster 455 D Page 3 5 Rev Engine Valve Springs Figure 7 Units mm Spring od 29 P1 daN 18 1 42 4 Valve Guides Units mm of eg h j ok Tolerance 0 0 032 0 25 0 50 0 0 011 0 0 2 Production 14 02 13 981 14 13 14 051 Repair 1 14 29 14 211 52 00 36 50 8 02 Repair 2 14 59 14 511 gk is obtained by machining after fitting in the cylinder head Engine Page3 6 Rev B Groundsmaster 455 D Valve Seats Units mm
86. Item 18 Repairs PTO System PTO Clutch Removal and Installation NOTE Always use new coupler flange head screws Items 2 and 6 when repairing PTO systems 150 200 ft Ib Apply Never Seez to bore 45 ft lb Apply Never Seez to spline and bearing mount pM 5 Loctite 242 4 Rotate in direction of shaft rotation before lt tightening setscrew 3 45 ft lb Loctite 242 30 35 ft lb Figure 8 1 Socket head screw 16 Ball bearing 30 Bearing locknut 2 Bearing collar 17 Lower pulley 31 Main wire harness 3 Set screw 18 Key 32 Lockwasher 4 Bearing 19 Belt set 33 Clutch spacer 5 PTO shaft 20 Locknut 34 Clutch plate 6 Flange head screw 21 Spacer 35 Belt cover 7 Flat washer 22 Rubber mount 36 Flat washer 8 Hex washer head screw 23 Special screw 37 Clutch 9 Wire harness 24 Flange head screw 38 Washer 10 J clamp 25 Wire cover 39 Flange head screw 11 Hex head bolt 26 Thrust washer 40 Rubber flange 12 Screw 27 Locknut 41 Locknut 13 Clutch adapter 28 Flange head nut 42 Washer 14 Lower bearing housing 29 Hex head capscrew 43 Grease fitting 15 Lower bearing spacer Repairs 7 8 Groundsmaster 455 D 1 Disconnect clutch electrical connector 2 Loosen PTO shaft bearing collar Fig 8 Item 2 to allow shaft movement 3 Remove three 3 bolts Item 11 securing clutch adapter Item 13 to clutch 4 Remove three 3 flange head screws Item 6 and
87. Item B Camshaft gear Item C Tensioner roller Item 17 Coolant pump gear Item 10 2 Loosen the bolt Fig 47 Item 18 and nut Item 19 to release the tensioner roller DO NOT use Item to set tension Tension on is only to be set by the spring Fig 46 Item 15 when tensioner plate is free to rotate 3 Re tighten the bolt Item 18 then the nut Item 19 when the belt is tensioned Engine Page 3 38 Rev Groundsmaster 455 D 4 Remove the three gear locking bolts and TDC Lock Pin tool 5 Turn the crankshaft two revolutions clockwise 6 Re install the TDC Lock Pin tool TOR 70153 N and the three gear locking bolts IMPORTANT If you can not install any one of the locking devices repeat the Timing Belt Installation procedures from the beginning 7 Loosen the bolt Fig 48 Item 18 and nut Item 19 to release the tensioner roller Figure 48 8 Re tighten the bolt Item 18 then the nut Item 19 to ne a torque of 17 5 Nm 13 ft Ib 9 Remove the three gear locking bolts 10 Install the covers Fig 49 Item 2 3 and 4 cover clips and cover attachment nut Item 5 Figure 49 11 Install the pulley A Clean with a brush and de grease the threads of the bolt Fig 50 Item 1 the bearing faces of the washer Item 2 and the head of the bolt Item 1 B Coat the threads of the bolt Item 1 with thre
88. JEA YOSYD sJepur Ao YI 95 1 1004 4223 01 pue 121009 eui y 5906 sdf y jo yod IO 5 yr3 29609 10 eouejeg eouejeg Jejuno2 Jejuno2 Q Pd Jepul Ao yr unod 5 JepuiAo 5 JepuiKo yun Page 4 9 Hydraulic Flow Diagrams Groundsmaster 455 D IIOAJOSOI YOR Sj28JIp YOIUM Duueeis BU xoeq QU JO pue SU JNO 10 59210 JOPUIJAD eysoddo eui sey eui Buueeijs eui uum 10 Buueels 991 aui 1004 esiwyoojJo eu oi Buueeis eui 959 4oeq pue 0 009 y amod eui 0 ed y jo uod Ajuoud y SMO IO H H Una uonons ejnssaJg
89. O ENGINE OIL SAE15W 0CD 5 5 3 100HRS 100 HRS 74 7970 HYD CIRCUIT OIL Mobil DTE 26 24 6 6 56 800HRS 800 HRS 86 3010 AXLE 80 90 800HRS ELMO PRIMARY AIRFILTER eese 93 9162 0 SAFETY AIR FILTER 93 9163 FUEL gt 32 F0 C NO2D 14 Drain and flush 800 hours lt 32 F0 C NO 1 D GAL 93 7213 3 5 Drain and flush 1500 hours 50 50 PEUGEOT GAL or 2 years whichever occurs ANTI FREEZE first 93 7243 Maintenance Schedules 2 4 Rev Groundsmaster 455 D QUICK REFERENCE AID FN N xo tc m 5 xo CHECK SERVICE 1 ENGINE OIL LEVEL FILL 7 GREASE POINTS 23 emm 2 HYDRAULIC OIL LEVEL FILL 8 RADIATOR SCREEN 3 FRONT AXLE OIL LEVEL FILL 9 AIR FILTER SERVICE INDICATOR 4 REAR AXLE OIL 10 WATER SEPARATOR FUEL FILTER A FILL 11 BATTERY B CHECK 2 12 FAN BELT 5 COOLANT LEVEL FILL 13 TIRE PRESSURE 1 1 5 BAR 15 20 PSI 6 FUEL DIESEL ONLY FLUID SPECIFICATIONS CHANGE INTERVALS for initial changes L USA FLUID FILTER PART NO ENGINE OIL SAE15W 0CD 5 5 3 100 HRS 100 HRS 74 7970 4 HYD CIRCUIT OIL Mobil DTE26 246 6 5G 800HRS 800HRS 86 3010 AXLEOIL 8090 800HRS
90. O position C After engine is started release parking brake and keep foot off traction pedal Machine must not move If movement is evident the neutral return mecha nism is adjusted incorrectly therefore shut engine off and adjust until machine does not move when traction pedal is released Refer to Adjusting Trac tion Drive for Neutral in Chapter 4 Hydraulic System 11 Seating capacity is one person Therefore never carry passengers 12 Do not run engine in a confined area without ade quate ventilation Exhaust fumes are hazardous and could possibly be deadly 13 Check interlock switches daily for proper operation Do not rely entirely on safety switches use common sense If a switch fails replace it before operating the machine The interlock system is for your protection so do not bypass it Replace all interlock switches every two years 14 Using the machine demands attention and to pre vent loss of control A Operate only in daylight or when there is good artificial light B Drive slowly Avoid sudden stops and starts C Watch for holes or other hidden hazards D Look behind machine before backing up E Do not drive close to a sand trap ditch creek or other hazard Safety Instructions Page 1 2 8 Since diesel fuel is highly flammable handle it carefully A Use an approved fuel container B Do not remove fuel tank cap while engine is hot or running C Do not smoke while handlin
91. Rear Axle Oil level 4wd Inspect Fuel Lines and Connections Check Engine RPM idle and full throttle Inspect Engine Fan Belt Inspect Engine Timing Belt see note below Drain and Clean Fuel Tank Change Hydraulic Oil Replace Hydraulic Oil Filter Change Front Transaxle Oil Pack Rear Axle Bearings 2wd Change Rear Axle Oil 4wd Check Rear Wheel Toe in Initial break in at 10 hours Initial break in at 50 hours Replace Moving Hydraulic Hoses Replace Safety Switches Cooling System Flush Replace Fluid Replace PTO Belts Cutter Deck Belts Every Every 100hrs 200hrs Every 50hrs A Level Service B Level Service C Level Service D Level Service E Level Service Annual Recommendations Items listed are recommended every 1500 hours or 2 years whichever occurs first See Operator s and Service Manual for specifications and procedures NOTE Replace Timing Belt if worn cracked or oil soaked A new Timing Belt should be installed any time the Belt is removed or loosened Daily Maintenance this page for routine use Unit Designation TORO 10 GROUNDSMASTER 455 D Daily Maintenance Check List Maintenance Check Item Daily Maintenance Check For Week Of MON HRS TUES HRS WED HRS THURS HRS FRI HRS SAT HRS SUN HRS Safety Interlock Operation v Brake Operation v Engine Oil Level Y Fuel Level Y Cooling System
92. TOR80117AM Injector Pump Timing Tool Kit Fig 26 TOR80117EZ Crankshaft Rotating Wrench Fig 27 TOR80149 Injector Socket Fig 28 Groundsmaster 455 D Page 3 11 Rev B Groundsmaster 455 D Parts Catalog Some tools may also be available from a local supplier Engine TOR2437T Dial Indicator This dial indicator may be used with TOR80110H TOR80117AM and TOR80504A2 to accomplish any of the following tasks for checking the protrusion of the swirl chambers valve recess and measurement for cylinder head gasket selection adjusting the timing of the injection pump and for checking the crankshaft and float TOR4024T Valve Spring Compressor This tool is used to compress valves for removal TOR70153A1 Main Seal Installer Used to install the two side seals to the no 1 main bearing cap TOR70153A2 Shim Set Used with main seal installer TOR70153A1 Figure 18 Figure 19 Engine 3 12 Rev Groundsmaster 455 D TOR70153C Rear Seal Installer Used with a small hammer to install new rear main oil seal An es se Figure 20 TOR70153D Front Cover Seal Installer Used with a small hammer to install new front crankshaft seal Figure 21 TOR70153N Flywheel T D C Locator Pin Used to set injection pump timing Figure 22 TOR80110DZ 2mm Shim Cut Off Gauge With Cut Off Shim U
93. TORO This publication provides the service technician with information for troubleshooting testing and repair of major systems and components on the Groundsmaster 455 D REFER TO THE GROUNDSMASTER 455 D OPERA TOR S MANUAL FOR OPERATING MAINTENANCE AND ADJUSTMENT INSTRUCTIONS Space is pro vided at the end of Chapter 2 in this publication to insert the Operator s Manuals and Parts Catalogs for your machine Replacement Operator s Manuals are avail able by sending complete Model and Serial Number 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 Part No 9380451 Rev Service Manual Groundsmaster 455 D 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 instructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 1993 1996 1998 2002 2003 This page is blank Table Of Contents Chapter 1 Safety Safety Instructions
94. WB NOLLOVUL A385 BEND E 2a AWIL EI 98 78 Av3u Lx Tl N gay aay v7 d3u Old Olson 18 dau S3Sn4 10H j vos asnd E a aau NOW gau Ne 1 9 NEA gay 298d y 5 13 Groundsmaster 455 D ICS Schemat iring Groundsmaster 455 D 5 1 4 Rev C Wiring Schematics Wiring Schematics t S N 49999 and Below ircui Engine Crank and Start C __ X WNINSL _ WNIWH3L NOY Sx duis vos AVIY A X v I 8 NOH vs oov 3NON 3NON 440 Sasnd DVN m Ex HOLIMS NOLLINOI N L HOLIMS and HOLIMS ON 3unss3ud _ _ T N8 T ya ya GION310S H 1 3 Zl UN N N Pd n Cow Mur Xu 7 S E dani unoH Y Av 5 pe fe oo 1 p d Y 9 MOT x recs lA uo 24 Ls 2 gt i AR HOLIMS j NOLLINSI NHOH L v 1
95. WYSL Tans STEVIA HOLIMS OR 3unss3ud T N8 T ya ya GIONS1OS 13 de SN rdi UN N A ie sasn4 MOI 5 a uo J Qe a pos yo Ki Li n HOLIMS NOLLINSI NHOH v 43s Somd ON HOLIMS IXY b NHOH E d M EE HOLIVNH3LV 909708 4 ya WIS 7 uouovavo M B 8 b d et S3HOLIMS ONIM vs qo 3 HOLIMS Old ais L8 T A ON ON sg H3lHVIS V8 M8 4 8 98 PS Avaa V a OSS ama NO n T T SN ONIM A3HO HOLIMS 9 oe o3 5 NouOvHL A ON gg ama s 18 fed _ ga Avaa Pat aad 98 HiH ce HO1010 HA 0 98 58 ON wis 195 8 28 Old ES 44O NO SEIT AS ND d siaisna l aa Wiring Schematics 5 3 Rev C Groundsmaster 455 D ts S N 49999 and Below ircui Engine Run and Mow C
96. ach differential shaft then mount pinion 14T and retain pinion by installing circlip The ball bearings have a groove cut in the end faces of the inner and outer races Be sure to position the bearing to its grooved end is on inner side as shown 3 Install o rings to spacers Insert differential shafts through spacers then install differential shaft and spacer to each axle housings Assembling Gear Case and Final Case 1 Use tool TOR40339 to install bushing into final case 2 Grease oil seal and use tool TOR4043 to carefully fit it to final case making sure the seal is properly aligned NOTE The steel part of this oil seal is so thin that the seal can distort at the time of installation 3 Insert final drive shaft into gear case bringing its large diameter end to top side and fitting pinion 14T onto splined end Install inner race of upper tapered roller bearing as shown 4 Fit bearing out race into gear case Apply sealant to mating face of holder and secure to case by tightening bolts to following torque value Torque specification 2 5 3 0 kg m 18 22 ft lb NOTE Be sure to wrap each bolt with sealing tape before installation 5 Attach final case to gear case while fitting pinion 15T onto splined end of shaft 6 Install tapered roller bearing Apply sealant to mating face of cover and secure cover to final case Tighten bolts to above listed torque value 7 Wrap drain plug with sealing
97. ad AW lock LOCTITE Install the bolt Item 1 and washer gt 2 1 Item 2 and tighten to a torque of 40 Nm 30 ft lb C Tighten the bolt 60 further one flat Figure 50 Groundsmaster 455 D Page 3 39 Rev B Engine Injection Pump Timing Timing of Injection Pump Pump Mounted on Engine The adjustment position for start of injection varies on each pump manufacturing tolerances The adjustment position is given by measurement in one of three places on the pump Fig 51 a Tag on pump lever AYE b Bar code label Inspection NOTE PMH in French English 1 Remove the cover attachment nut cover clips and timing belt covers 2 Slowly turn the crankshaft in the operating direction clockwise as viewed from the timing belt end until the TDC Lock Pin tool TOR 70153N goes into the hole in the flywheel Fig 52 3 Verify that the camshaft and injection pump gears are properly timed Lock the camshaft gear Fig 53 Item 6 in position with a M8 x 125 x 40 bolt Tighten finger tight B Lock the injection pump gear Item 7 in position with two M8 x 125 x 35 bolts Tighten finger tight NOTE If the locking bolts cannot be installed be cause the holes in the gears and engine block do not align remove the TDC Lock Pin tool and rotate the engine clockwise one revolution Install the TDC Lock Pin then install t
98. ad capscrew Flat washer Locknut Hex flange head screw Engine gt 3 Remove three 3 flange head screws Fig 6 6 and spacers Item 12 securing rubber coupling Item 8 to PTO pulley Item 15 4 Push driveshaft into splined hub as shown in Figure 7 so belts can be removed between rubber coupling and PTO pulley 5 Remove belts 6 Install new belts in pulley grooves then connect driveshaft to rubber coupling Make sure spacers Item 12 are installed then install new flange head screws and torque to 45 45 ft Ib Figure 6 8 Rubber coupling 9 Retaining ring 10 Grease seal 11 Splined hub 12 Spacer 13 Driveshaft 14 Pulley plug shell toward spline Index to get wrench clearance for hex flange screws Item 6 45 ft Ib 15 PTO pulley 16 Bearing 17 Bearing spacer 18 Bearing housing 19 Main adapter plate 20 Lock washer ET ad Driveshaft into 7 Adjust Belt see Belt Adjustment 8 Install PTO belt cover NOTE Check belt tension and adjust if necessary after first 25 hours of operation Repairs hub to remove belts i F Flange Head Screw 3 rA Rubber Coupling 7 6 Groundsmaster 455 0 Engine Coupling Service 1 Remove three 3 flange head screws Fig 6 Item 6 securing driveshaft Item 13 to rubber coupling Item 8 Make sure you account for
99. alve clearance unless the head has been machined or val ves ground 1 Install the camshaft gear Fig 85 Item 1 2 Check the valve clearance Units mm Running Clearance Inlet 0 15 Exhaust 0 30 Tolerance 0 04 Set on the rock Inlet 4 Exhaust 4 Inlet 1 Exhaust 1 Check Inlet 1 Exhaust 1 Inlet 4 Exhaust 4 Inlet 2 Exhaust 3 Inlet 3 Exhaust 2 03690968 4 3 2 1 Figure 85 Groundsmaster 455 D Page 3 57 Rev B Engine 3 Remove the camshaft gear Fig 86 Item 1 4 Remove the camshaft bearing caps Item 2 5 Remove the camshaft Item 3 6 Remove the tappets Item 4 7 Remove the basic shims Item 5 8 Determine the shim thickness to be fitted for each valve Example Units mm No 1 Intake valve Specified clearance 0 15 Clearance measured 0 25 Difference 0 10 Shim installed 2 425 Shim to be installed Clearance obtained 0 175 Basic shim 9 Install the shims as determined in step 8 10 Install the tappets Engine Page 3 58 Rev B Groundsmaster 455 D 11 Apply thin coat of Formetanch Permatex No 2 sealant to each end of the bearing housing at Fig 87 Item a 12 Apply MOLYKOTE G RAPID to the bearing surfaces on the camshaft 13 Install the camshaft Item 3 with the DIST marking at the timing gear end 14 Insta
100. arrier ball bearings for wear and smoothness of rotation and replace if necessary Groundsmaster 455 D Page 6 13 Transaxle Assembly Reverse steps 1 8 under Transaxle Disassembly watching out for the following 1 After shift rod is in position install ball then spring and bolt Turn bolt in until head of bolt contacts case 2 Be sure that thrust washers and spacers are between every shaft and case and cover 3 Threads of differential bolts must be coated with standard stud Loctite Install differential assembly so bolt heads are facing away from gear on output shaft 4 Install new gasket It may be helpful to dampen gasket with oil to get it to lie flat 5 After installing cover install new brake shaft oil seal Item 51 shifter rod oil seal Item 25 and axle shaft oil seals Item 7 6 To install axle assemblies into transaxle case grease axle spline ends heavily Push axle through seal Use caution to prevent damage to seal when axle splines are going through seal 6 Install hi low interlock switch Fig 17 Item 17 into transaxle case if removed Thrust Washer Thrust Bearing Shims Figure 22 Repairs x a o 2 x lt Rear 4WD Axle Service Axle Housing B Figure 23 Repairs Figure 24 Page 6 14 Groundsmaster 455 D Disassembly The two gear cases right and left can be removed from the hou
101. be affected if auxiliary pump is damaged Pump or motor damaged Inspect and repair or replace traction pump or motor if necessary Machine Will Not Travel In Either Direction Cause Front axle shift lever in neutral middle position Correction Move shift lever to engage transmission Damaged front axle or rear 4wd axle Repair axle Brakes engaged Inspect brakes and adjust or repair if necessary Hydraulic oil level too low Fill to proper level Control linkage damaged or out of adjustment Repair control linkage Charge pressure low TEST NO 6 NOTE Counterbalance pressure will also be affected Inspect charge relief valve and adjust or repair if necessary Inspect auxiliary pump and repair or replace if necessary NOTE Steering and lift will also be affected if auxiliary pump is damaged Traction pressure too low TEST NO 1 Inspect traction pump check relief valves and repair or replace if necessary Check for damaged pump or motor s and repair or replace if necessary Troubleshooting Page 4 14 Groundsmaster 455 D Four Wheel Drive Does Not Engage Cause Correction Front axle shift lever in forward position Front axle shift lever must be in LOW rear position for four wheel drive to engage Electrical problem Check for faulty front axle HI LOW switch four wheel drive solenoid or wiring and repair
102. be pressed out of the motor housing Groundsmaster 455 D 17 RETAINING RING HOUSING 3 amp BEARING 10 THRUST PLATE Figure 27 Press shaft Item 3 and bearing Item 8 together then press into housing Item 9 Install retaining ring Item 17 if used Lubricate thrust plate Item 10 and insert in counterbore of housing Item 9 Assemble cylinder block parts if necessary and lubricate with clean hydraulic oil There is no special orientation of piston to bore that needs to be maintained Groundsmaster 455 D 4 43 Place the housing assembly in a horizontal position Slide cylinder block assembly Item 2 over shaft and engage spline Be certain that pistons and thrust plate remain in place When properly installed a slight spring tension can be felt when pushing on cylinder block Lubricate exposed surface of cylinder block with clean hydraulic oil Repairs D gt 2 E c gt MOTOR HOUSING HIGH POINT OF CAM ANGLE SAME SIDE AS LOCATING PIN END CAP LOCATING PIN NOTE MOTOR HOUSING CAN BE ASSEMBLED TO END CAP 180 FROM POSITION SHOWN REFER TO PREVIOUSLY SCRIBED LINES Figure 28 Repairs 4 44 Groundsmaster 455 D MOTOR 16 car SCREW 4 p HoUsING Figure 29 Properly orient the end cap Item 14 and housing Item 9 Refer to previ
103. check ball and check ball retainer Repairs Page 4 54 Figure 42 Seal 5 8 Seal Set Screw 9 NW Not used on Check Check units with Ball Check Ball integral column Seat 7 16 Seal Ball Retainer Figure 43 Groundsmaster 455 D Check all mating surfaces Replace any parts that have scratches or burrs that could cause leakage Clean all metal parts in clean solvent Blow dry with air Do not wipe dry with cloth or paper towel because lint or other matter can get into the hydraulic system and cause damage Do not use a coarse grit or try to file or grind these parts NOTE Lubricate all seals with clean petroleum jelly such as Vaseline Do not use excessive lubricant on seals for meter section Refer to parts listings covering your steering control unit when ordering replacement parts A good service policy is to replace all old seals with new seals Control End Reassembly 1 Use a needle nose pliers to lower check ball retainer into check valve hole of housing Make sure retainer is straight not tilted on edge in housing 2 Install check ball in housing 3 Lubricate 5 8 diameter seal and 7 16 diameter seal Install seals on check ball seat as shown 4 Lubricate check ball seat and seals thoroughly before installing seat in housing When installing seat do not twist or damage seals Install check ball seat in housing insert open end of
104. ct a cylinder head gasket of suitable thickness Units mm Piston protrusion d Thickness identification 0 56 to 0 71 2 notches 0 71 to 0 75 3 notches 0 75 to 0 79 4 notches 0 79 to 0 83 5 notches Cylinder Head Installation 1 Turn the crankshaft to put the pistons at mid stroke with damper pulley key Fig 83 Item 6 atthe 9 o clock position 2 Clean the tapped holes in the cylinder block 12 x 150 thread 3 Install the centralizing dowel Item 7 4 Install a new head gasket dry 5 Install the cylinder head 6 Carefully clean the threads of the cylinder head bolts with a brush 7 Coat the bolt threads and washer contact faces with MOLYKOTE G RAPID Y TOR 80110H Figure 83 Engine Page 3 56 Rev Groundsmaster 455 D Cylinder Head Tightening 1 Install new washers on the bolts 2 Pre tighten the bolts in the order shown Fig 84 to a torque of 30 Nm 22 ft lb 3 Tighten the bolts in the order shown to a torque of 70 Nm 52 ft lb 4 Tighten each bolt in the order shown an additional 120 2 NOTE The special cylinder head bolts Item B do not require re tightening The bolts can be removed and re installed 5 times before replacing with new bolts Figure 84 Valve Clearance Adjustment NOTE If all valve parts are re installed in their original location it should not be necessary to adjust v
105. cutting unit should engage When axle shift lever is moved to N or transport position the cutting unit should disengage If the cutting unit does not disengage there is a problem in the axle hi low switch circuit see Chapter 5 Electri cal System Groundsmaster 455 D Measure from end of shaft to edge of transaxle Low position 1 2 1 3 in 30 33 mm High position 2 6 2 7 in 66 69 mm Transaxle Page 6 7 Figure 14 1 Axle shift lever 2 Upper linkage Adjustments a P x lt Repairs Wheel Bearing Service 2WD Rear Axle 1 Jack up rear of machine until tire is off the floor Support machine with jack stands or blocks to prevent it from falling 2 Remove dust cap from end of wheel spindle 3 Remove cotter pin slotted nut and washer Slide wheel off of spindle shaft 4 Pull seal out of wheel hub 5 Remove bearings from both sides of 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 Use No 2 general purpose lithium base grease containing E P additive Pack both bearings with grease Install one bearing into the cup on inboard side
106. cutting unit is raised IMPORTANT The wing switches have three 3 ter minals Make sure the wires are connected to the COMMON and N O terminals Test the switch by disconnecting the wiring connector for the switch and connecting a continuity tester across the terminals With the engine running and the P T O DISENGAGED OFF raise and lower the affected wing cutting unit while watching the continuity tester With the wing raised there should be no continuity When the wing is lowered there should be continuity Groundsmaster 455 D Page 5 27 Figure 28 1 AWD solenoid 2 Indicator 2 a gt i T E E TT Figure 29 1 Wing switch Shown from below wing with wing in raised position Testing Clutch and Wing Clutch 1 Park machine on a level surface engage parking brake lower the cutting units and turn engine OFF 2 Disconnect electrical connector from affected clutch Continuity Test Connect a continuity tester or ohmmeter to the two 2 terminals of the electrical connector on the clutch If continuity is not present replace the clutch or electro magnet part of the clutch see Chapter 7 P T O System or Chapter 8 Cutting Unit Operation Check Connect a 12 volt battery to the terminals of the electri cal connector on the clutch The clutch should engage when voltage is applied to the terminals NOTE Make sure clutch air gap is adjusted to 0 0
107. d prime system before operating Disconnect fuel stop solenoid electrical connector on engine to prevent fuel delivery to engine cylinders Turn ignition switch to engage starter for ten 10 seconds to prime pumps Repeat cranking procedure again Connect injection pump fuel stop solenoid electrical connector Start engine and run at idle speed for a minimum of two 2 minutes 4 After disconnecting or replacing any hydraulic com ponents operate machine functions slowly until air is out of system 5 Check for hydraulic oil leaks Shut off engine and correct leaks if necessary Check oil level in hydraulic reservoir and add correct oil if necessary Repairs bod D gt 2 E gt Traction Pump Shaft Seal Replacement Fig 17 Figure 17 1 Park machine on a level surface lower cutting units engage parking brake and stop the engine 2 Remove pump assembly from machine 3 Remove retaining ring Item 32 from pump housing NOTE It may be necessary to hold inward pressure against shaft to compress cylinder block spring while removing retaining ring 4 After removing retaining ring seal carrier Item 30 will move out approximately 1 4 in due to cylinder block spring force on shaft Lightly tap end of shaft with a soft mallet until seal carrier can be removed from housing NOTE After seal carrier is removed the shaft and bearing assembly are free in the housing Do not re move
108. d O Ring Port Adjustable Fig 5 6 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fitting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 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 tubing 1 00 25 6 3 8 in 1 50 25 8 1 2 in 1 50 25 10 5 8 in 1 50 25 12 3 4 in 1 50 25 16 1 in 1 50 25 General Information Page4 4 Figure 4 Lock Nut lt Back Up Washer O Ring Figure 5 Step 1 Step 3 Step 4 F H Figure 6 Groundsmaster 455 D
109. d possibly cut the seals and thor oughly lubricate both the shaft and seal lips 6 Slide the small thick spacer into the spindle housing Then install the bearing and seal into the top of the spindle housing The lip of the seal must face inward 7 Slide the spacer onto the spindle shaft Carefully slide the spindle shaft through the spindle housing The bot tom seal and spacer fit together when the spindle is installed 8 Attach grease gun to grease fitting and fill cavity with grease until grease starts to come out of lower seal 9 Push the pulley or pulley spacer and clutch onto the spindle shaft and retain the parts together with the large flat washer and nut Tighten the nut to 150 170 ft Ib and rotate the spindle shaft to be sure that the shaft rotates freely Groundsmaster 455 D Page8 19 Rev C 10 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 11 Install the belt and adjust belt tension 12 Install the clutch rod and connectthe clutch electrical connector to the wire harness 13 Install the belt covers Figure 29 Bearing M Races pacer Figure 30 Bearing Inside amp Seal Inside Spacer Bearing Seal amp 98 _ Figure 30a 2 5 o Repairs Gearbox Removal and Installation Removing Gearbox and Dri
110. dy and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result 30 Before disconnecting or performing any work on the hydraulic system all pressure in system must be relieved by lowering cutting units to the ground and stopping engine 31 If major repairs are ever needed or assistance is desired contact an Authorized Toro Distributor Groundsmaster 455 D 1 3 Rev 32 To reduce potential fire hazard keep engine area free of excessive grease grass leaves and dirt Clean protective screen on back of machine frequently 33 If engine must be running to perform maintenance or an adjustment keep hands feet clothing and other parts of the body away from cutting units and other moving parts Keep all bystanders away 34 Do not overspeed the engine by changing governor setting To assure safety and accuracy have an Author ized Toro Distributor check maximum engine speed 35 Shut engine off before checking or adding oil to the crankcase 36 Disconnect battery before servicing the machine If battery voltage is required for troubleshooting or test procedures temporarily connect the battery 37 At the ti
111. e hex plug Item 2 3 Remove the valve cartridge assembly Item 7 In spect the valve and mating seat in the housing for damage or foreign material It will be necessary to replace the center section if the seat is damaged IMPORTANT The relief valves are factory set and should not be tampered with except to replace the entire valve cartridge 4 The valve cartridge is retained in the special plug by a circlip Item 6 The check valve spring Item 5 may Repairs Page 4 30 be removed from the special plug by pulling out at a slight angle When reassembling install the check valve spring into the special plug with its larger diameter toward the plug and snap the valve cartridge into posi tion in the plug 5 Reinstall the valve cartridges with o rings into the housing and tighten the plugs to a torque of 30 to 50 ft lb 6 Before starting the engine check the oil level in the differential housing and add the correct oil as necessary Start the engine and let it run for one to two minutes then turn the engine off and check the oil level again Check the transmission for leaks Rev C Groundsmaster 455 D Traction Pump Charge Pressure Relief Valve Fig 20 Figure 20 1 Park the machine on a level surface lower cutting units engage parking brake and stop the engine 2 Remove the charge relief valve hex plug Item 12 3 Remove the spring Item 9 and poppet Item 8 from the housing 4 Do not in
112. e injector body in a V type injector holder 2 Remove the injector holder nut 3 Remove the injector spacer push rod pressure setting spring adjusting shims and body 4 Dip all parts in clean diesel fuel 5 Clean nozzle and needle in clean diesel fuel 6 De carbon injector nozzle using a wooden spatula Never use metallic objects emery cloth or rags Do not attempt to grind the needle on its seat Clean each injector separately to matched parts are not mixed up The needle should slide freely and fallin the nozzle by its own weight SS a P NN 222 777 772 777 1 RS 1 AJ E ps CLL WS V LZ Engine 3 34 Rev Figure 40 Adjusting shim Pressure setting spring 2 sealing face spacer Injector nut Leak return connectors Injector holder nut Groundsmaster 455 D Assembly 1 Check all parts for condition and cleanliness Oil parts before reassembly 2 Secure the injector body in a V type injector holder 3 Install the adjusting shims spring push rod spacer and injector Fig 40 Items 2 3 4 5 6 4 Install the injector holder nut Fig 28 7 and tighten by hand 5 Tighten injector nut to a torque of 10 Nm Tighten the nut an additional 22 of rotation Installation NOTE Each time an injector is removed from the en gine new washers must be installed Fir
113. e plate tends to lift off with the end cap Item 14 hold itin place on the end cap and remove both parts together If the valve plate remains on the cylinder block remove it at this time The end cap is actually an assembly consisting of a needle bearing which is a press fit in the end cap and the valve plate locating pin Item 13 Inspect the bear ing Item 12 and remove if replacement is required Repairs D gt 2 E c gt 17 RETAINING RING HOUSING 3 Som 10 THRUST PLATE Figure 26 Lift outthe cylinder block assembly Item 2 The pistons may come out of cylinder block bores There is no special orientation of piston to bore that needs to be maintained Do not attempt to disassemble the spring and other parts from the center bore of the cylinder block The entire cylinder block assembly Item 2 should be re placed if any of its components are damaged Visually inspect wear surfaces of valve plate cylinder block and slippers for damage Check to be sure pistons are free in bores Repairs Page4 42 Remove thrust plate Item 10 from counter bore in motor housing Item 9 Visually inspect both sides for damage and flatness The retaining ring Item 17 must be removed prior to removal of shaft and bearing The output shaft seal must be removed to expose the retaining ring See Shaft Seal Replacement The motor shaft Item 3 and bearing Item 8 can
114. e ring washer is installed with convex surface up Figure 41 1 Install new fire ring washers Fig 58 Item 21 convex surface facing up 2 Install new copper washers Fig 58 20 3 Install the injectors and tighten to a torque of 90 Nm 66 ft lb 1 Install new flame arrestor steel washer and copper gasket 2 Install injector in cylinder head 3 Install injection pipe unions on pump and injectors and tighten by hand 4 Moderately tighten each union 25 Nm 18 ft lb max on pump and injector Over tightening will distort the end of the injector line 5 Connect fuel return pipe Groundsmaster 455 D Page 3 35 Rev B Engine Timing Belt Replacement Timing Belt Removal IMPORTANT Never install a used belt When the timing belt is removed a NEW timing belt must be installed SPECIAL TOOLS REQUIRED Tune Up Tool Set TOR 4035 1 ea M8 x 125 x 40 Metric Bolt 2 ea M8 x 125 x 35 Metric Bolt 1 Slowly turn the crankshaft in the operating direction clockwise as viewed from the timing belt end until the TDC Lock Pin tool TOR 70153N goes into the hole in the flywheel Fig 42 2 Remove the crankshaft pulley bolt Fig 43 Item 1 and the pulley Note The bolt is secured with thread locking compound and will be difficult to remove 3 Remove cover attachment nut Item 5 cover clips and timing belt covers Item 2 3 and 4 in the numbered order 4 Re i
115. ed keyway on drive shaft that drives the slip fit gear of the rear pump 2 Inspect both the drive gear and idler gear shafts at bushing points and seal area for rough surfaces and ex cessive wear 3 Replace gear assembly if shaft is worn in bushing area One gear assembly may be replaced separately shafts and gears are available as assemblies only The Slip fit gear is available separately 4 Inspect gear face for scoring and excessive wear 5 Assure that snap rings are in grooves on either side of drive and idler gears 6 If edge of gear teeth are sharp break edge with emery cloth Repairs Front Plate Backplate and Adapter Plates Inspection 1 Oil groove in bushings in front plate backplate and adapter plates should be in line with dowel pin holes and 180 degrees apart This positions the oil grooves closest to respective dowel pin holes 2 Replace the backplate front plate or adapter plates if bushings are worn Bushings are notavailable as sep arate items 3 Bushings in front plate and backup gasket side of adapter plates should be flush with face of plate 4 Check for scoring on face of backplate or adapter plates Body Inspection 1 Check bodies inside gear pockets for excessive scor ing or wear 2 Replace bodies if D of gear pockets is worn General Information It is important that the relationship of the backplate adapter plates bodies wear plate and front plate is cor rect
116. ef valve cartridge as sembly it must be replaced as an assembly 2 Remove hex plugs Item 24 18 flow divider spool Item 23 spring Item 21 and disk Item 20 Inspect Auxiliary Steering Pump Parts GENERAL 1 Clean and dry all parts 2 Remove all nicks and burrs from all parts with emery cloth GEAR ASSEMBLY Item 2 3 1 Check drive shaft spline for twisted or broken teeth 2 Inspect both drive gear and idler gear shafts at bushing points and seal area for rough surfaces and excessive wear 3 If shaft measures less than 0 748 in bushing area the gear assembly should be replaced one gear as sembly may be replaced separately shafts and gears are available as assemblies only 4 Inspect gear face for scoring and excessive wear Groundsmaster 455 D Page 4 37 5 If gear width is less than 0 636 the gear assembly should be replaced 6 Be sure snap rings are in grooves on either side of drive and idler gears 7 If edge of gear teeth are sharp break edge with emery cloth FRONT PLATE 7 AND BACK PLATE Item 22 1 Oil groove in bushings in both front plate and back plate should be in line with dowel pin holes and 180 apart 2 If I D of bushings in front plate or back plate exceed 0 755 front or back plate should be replaced bushings are not available separately 3 Bushings in front plate should be flush with face of front plate 4 Check for scoring on face of back plate If
117. efully 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 damaged 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 Cylinder and Cylinder Block Overhaul Before removing any parts disassembly or overhaul of the Peugeot 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 4 in the above Engine Page 3 42 Rev 4 Disassemble the engine in proper order arranging the parts the disassembled parts neatly Apply clean engine oil to all disassembled parts to prevent rust 5 Keep the work area clean dirt causes engine failures 6 Be very careful w
118. el surface move traction unit into position aligning drive shaft yoke with gear box input shaft and lift arm ball joints with mounting holes in castor arms Shut engine off 2 Secure ball joint mounts to castor arms with cap screws flat washers and flange nuts Flat washers to be positioned to outside of castor arm Tighten cap screws and flange nuts to a torque of 80 90 ft lb 3 Line up holes in yoke and input shaft of gear box Slide yoke onto shaft and secure together with socket head screws Torque screws to 20 25 ft lb 4 Start engine raise center cutting unit slightly so rear deck straps can be mounted on lift arm brackets Stop engine after cutting unit is raised 5 Secure rear deck straps to H O C brackets on deck with hair pin cotters and H O C pins Start the engine and lower center cutting unit completely to floor Make sure all lift levers are in the float position then stop the engine 6 Connect wire harness and 3 hydraulic lines couplers at rear of deck Figure 15 1 Push arm 3 Ball joint mount 2 Castor arm 4 Capscrews amp washers Figure 16 1 Hydraulic lines quick couplers 2 Wire harness connector 3 Cutting unit carrier frame 4 Traction unit lift arm Repairs 8 10 Rev A Groundsmaster 455 D Drive Belt Replacement Signs of a worn belt are squealing when belt is rotating blades slipping when cutting grass frayed edges burn marks and cracks Replace a belt
119. emoving axle housings scribe align ment marks across transaxle housing adapter plate and axle housing for proper reassembly 2 Remove remaining capscrews securing axle housing Item 11 to transaxle and carefully pull axle housing and shaft Item 27 away from transaxle 3 Remove axle housing cover Item 8 4 Remove cotter pin and clevis pin to disconnect brake clevis from brake actuator Groundsmaster 455 D Page 6 11 5 Remove brake disks Item 4 and brake actuator Item 5 6 Remove adapter plate Item 2 and transaxle spacer Item 1 7 To remove axle from housing remove retaining ring Item 21 from outboard end of housing then tap lightly with a mallet from inside out A seal ring Item 20 and a pressed on sealed ball bearing Item 22 will be on the end of the axle 8 Do steps 2 7 for axle housing on other side Front Axle Assembly Reverse steps 1 8 under Front Axle Disassembly To install axle assemblies into transaxle case grease axle spline ends heavily Push axle through seal Use caution to prevent damage to seal when axle splines are going through seal Front Axle Installation Reverse steps 1 10 under Front Axle Removal If anew transaxle is installed determine correct shim to use behind spiral bevel gear on hydraulic motor by subtracting actual motor flange face to sleeve dimen sion from dimension stamped on transaxle or attached to tag Dimensional Range Pinion Shim
120. ential for injury or death comply with the following safety Instructions WARNING Engine exhaust contains carbon monoxide which is an odorless deadly poison Carbon monoxide is also known by the State of California to cause birth defects Do not run engine indoors or in an enclosed area Before Operating 1 Read and understand the Operator s Manual before starting operating maintaining or repairing the ma chine Become familiar with the controls and know how to stop the machine and engine quickly Replacement Operator s Manuals are available by sending complete Model and Serial Number of traction unit and cutting units to The Toro Company 8111 Lyndale Avenue South Minneapolis MN 55420 Use the Model and Serial Number when referring to your machine If you have questions about this Service Man ual please contact The Toro Company Commercial Service Department 8111 Lyndale Avenue South Minneapolis MN 55420 Groundsmaster 455 D Page 1 1 Chapter 1 Safety While Doing Maintenance Troubleshooting Testing Adjustments or Repairs 3 A CAUTION Obey the following safety instructions Read and understand these instructions before op erating the Groundsmaster 455 D or doing maintenance troubleshooting testing ad justments or repairs Failure to comply with the safety instructions may result in personal injury 2 Never allow children to operate the machine Do not allow adults to ope
121. er to remove front body 2 from the front plate 7 or adaptor plate 16 6 Remove adapter plate 16 from body 2 by tapping on the adapter plate with a plastic hammer or rawhide mallet 7 Remove backplate 21 from body 2 by tapping on backplate with plastic hammer or rawhide mallet 8 Remove rear idler gear 13 slip fit gear 14 and key 15 9 Remove drive gear assembly 3 from adapter plate 16 10 Place rear idler gear 13 back into gear pocket and tap protruding end with softface hammerto remove rear body 2 from the backplate assembly 21 or adaptor plate 16 Groundsmaster 455 D Page 4 39 2 Rev C 11 Remove the wear plates 4 from front plate 7 and adapter plate 16 12 Remove o rings 1 from front plate 7 adapter plate 16 and backplate 21 13 Remove backup gaskets 5 and balance pressure seals 6 from front plate 7 and adapter plate 16 by prying out with a sharp tool 14 Remove shaft seal 10 and washer 11 from front plate 7 by prying with a screw driver Be careful not to damage Seal bore 15 Remove relief valve 20 from backplate assembly 21 16 Remove O ring 17 backup washer 18 and O ring 19 from relief valve 20 Inspect Parts for Wear General 1 Clean and dry all parts 2 Remove nicks and burrs from all parts with emery cloth Gear Assembly Inspection 1 Check spline drive shaft for twisted or broken teeth Also check for damag
122. flat washer securing the blade Units with S N 30001 amp up will have a hex flange bolt securing the blade 3 Install blade sail facing toward cutting unit with anti scalp cup lockwasher and blade bolt Tighten blade bolt to 85 110 ft lb Groundsmaster 455 D Page 8 15 Rev A Repairs P3 A 1 85 110 ft lb Figure 23 1 Blade bolt 2 Flat washer S N below 30001 3 Anti scalp cup 2 5 o Inspecting and Sharpening Blade 1 Raise cuffing unit to highest position shut the engine off and engage the parking brake Engage locking FLAT PART latches to prevent cutting unit from falling accidentally OF BLADE 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 wear is noticed replace the blade see Cutting Blade Re moval and Installation 3 Inspect cutting edges of all blades Sharpen the cutting edges if they are dull or nicked Sharpen only the top of the cutting edge and maintain the original cutting Figure 24 angle to make sure of sharpness The blade will remain balanced if same amount of metal is removed from both cutting edges FORMED 4 To check blade for being straight and parallel lay SHARPEN AT blade on a level surface and check
123. g 57 Injection Pump Timing 27 Valve Clearance Adjustment 57 Glow Plug Test 27 Assembly of External Components 60 Compression Test 28 Groundsmaster 455 D 3 1 Rev Engine Introduction The following pages give information about specifica tions maintenance troubleshooting testing and repair of the diesel engine used in the Groundsmaster 455 D mowers 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 Engine Page3 2 Rev B Service and repair parts for the Peugeot engine used in the Groundsmaster 455 D 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 A plate riveted to the left hand side of the engine block carries the Engine Serial Number Always include the engine serial number with parts orders and warranty claims Groundsmaster 455 D Identification and Specifications General Specifications Item Engine Type
124. g Page 5 24 Test the lamp by disconnecting the wires and applying 12 V D C between the lamp wiring terminals Temperature Light The temperature light should come on only if the high temperature shut down switch and relay has stopped the engine coolant temperature above 221 F 105 C Test the lamp and relay by disconnecting the wire from high temperature shut down switch and grounding it against the engine The light should come on when the wire is grounded with the ignition switch in the ON position Hourmeter Test the hourmeter by connecting a 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 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 455 D High Temperature Shut Down Switch 1 Lower the coolant level in the engine and remove the high temperature shut down switch 2 Put the switch in a container of oil with a thermometer and heat the oil 3 The switch is normally open N O and should close at approximately 221 F 105 C A CAUTION Handle hot oil with special care to prevent personal injury or fire Figure 22
125. g fuel D Fill fuel tank outdoors and only to within an inch from the top of the tank not the filler neck Do not overfill E Wipe up any spilled fuel F Reduce speed when making sharp turns and turning on a hillside 15 Traverse slopes carefully Do not start or stop sud denly when traveling uphill or downhill Never shift axle when moving Machine must be on a flat surface and or brakes must be engaged to prevent freewheeling 16 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 17 When operating 4 wheel drive machine always use the seat belt and ROPS together and have seat pivot retaining pin installed 18 If engine stalls or loses headway and cannot make it to the top of a slope do not turn machine around Always back slowly straight down the slope 19 Raise cutting decks and latch securely in transport position before driving from one work area to another 20 DON T TAKE AN INJURY RISK When a person or pet appears unexpectedly in or near the mowing area STOP MOWING Careless operation combined with terrain angles ricochets or improperly positioned guards can lead to thrown object injuries Do not resume mowing until area is cleared 21 Do not touch engine muffler or exhaust pipe while engine is running or soon after itis stopped These areas co
126. gap and adjust if necessary Test clutch Repair or replace if faulty Repair wiring Test relay Replace relay if faulty Repair wiring Check linkage and adjust if necessary Test switch Check for proper installation and operation of plunger assembly Replace Switch or repair plunger if faulty Repair wiring Test switch Replace if faulty Repair wiring See Chapter 7 PTO System Groundsmaster 455 D Page 5 13 Troubleshooting 2 a gt o 2 5 E Cutting Unit Operation Problems continued Condition One wing cutting unit does not operate Possible Cause Wing switch faulty Wing switch wiring loose corroded or damaged Wing clutch air gap out of adjustment Wing clutch faulty Wing clutch wiring loose corroded or damaged Correction Test switch Replace if faulty Repair wiring Check air gap and adjust if necessary Test clutch Repair or replace if faulty Repair wiring Center cutting unit operates but neither wing cutting unit operates Time delay relay faulty Time delay relay wiring loose corroded or damaged Timer faulty Timer wiring loose corroded or damaged Test relay Replace relay if faulty Repair wiring Test timer Replace timer if faulty Repair wiring Troubleshooting Page 5 14 Groundsmaster 455 D Verify Interlock System Operation The purpose of the
127. ge valve plate and end cap surfaces 6 Carefully remove valve plate Item 39 from end cap It may be necessary to pry valve plate off with a small screwdriver 7 Remove valve plate pins Item 40 from end cap 8 Lay pump housing on its side and remove cylinder block assembly Item 38 from housing 9 Remove the slipper guide and piston assemblies from cylinder block 10 Use an o ring pick or wire to remove thrust plate Item 37 from swashplate and housing 11 Remove shaft seal carrier See Tandem Pump Shaft Seal Replacement 12 Slide drive shaft 26 and bearing assembly Item 27 from housing 13 Remove retaining ring Item 28 and press shaft out of bearing 14 Remove hex tapping screws Item 16 retaining trunnion seal cover Item 35 and trunnion cover Item 17 to housing Mark position of covers for reas sembly 15 The trunnion seal cover assembly includes an o ring Item 18 and lip seal Item 34 on the control side and Groundsmaster 455 D Page 4 33 an o ring Item 18 on the side opposite the control Remove these parts from the housing See Trunnion Seal Replacement 16 Remove the trunnion spacers Item 19 shims Item 20 and roller bearings Item 21 from housing and swashplate The bearing assemblies are a slip fit in the housing 17 Tilt and lift swashplate Item 36 from housing Inspection and Replacement of Parts 18 After disassembly thoroughly clean all parts
128. gement disconnect wire harness connector Figure 11 1 Wire harness connector 2 Remove socket head capscrews securing driveshaft yoke to gearbox input shaft 3 Slide yoke off of gearbox input shaft Figure 12 1 Socket head capscrew 4 Remove socket head capscrews securing driveshaft yoke to PTO shaft 5 Slide yoke off of PTO shaft A DANGER DO NOT start the engine and engage the PTO switch when PTO shaft is not connected to gearbox on cutting unit If engine is started and PTO shaft is allowed to rotate serious injury could result Figure 13 2 1 Socket head capscrew 6 To install the driveshaft apply Never seez or equiva lent to splines of gearbox input shaft and PTO shaft then reverse steps 1 5 of above instructions Tighten socket head capscrews at each end of driveshaft to a torque of 20 25 ft Ib Repairs Page 7 12 Groundsmaster 455 D Driveshaft Universal Joint Replacement 1 Remove the driveshaft See Driveshaft Removal and SMALL LARGE SOCKET Installation in this section of the book SOCKET 2 Separate the two sections of the driveshaft 3 Use a press or large vise to remove the cross and bearings by putting 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 part way into the large socket 4 When the roller is forced part way out grasp the rol
129. gine seized Faulty starter Faulty wiring Engine Page 3 26 Rev Groundsmaster 455 D Testing and Inspection Injection Pump Timing See Timing of Injection Pump in the Engine Overhaul section Glow Plug Test A CAUTION 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 Battery 2 Remove the glow plug 3 Inspect the glow plug for signs of a burnt glow plug Figure 34 end tube NOTE If the metal of the glow plug end is melted it is a sign of cylinder overheating 4 Connect the positive battery terminal to the glow plug terminal and the negative battery terminal to the plug body Fig 34 If the glow plug glows red hot in 9 to 12 seconds the glow plug is operating correctly DO NOT leave on more than 20 seconds 5 Replace any glow plugs that do not operate correctly Groundsmaster 455 D Page 3 27 Rev B Engine Compression Test Minimum cylinder compression is 20 bar 290 psi at 200 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
130. glow plugs from all four cylinders 2 Insert a compression gauge adapter into the glow plug hole 3 Connect a high pressure compression gauge to the adapter 4 Disconnect the fuel stop solenoid electrical connector or hold the fuel stop lever in the stop position to prevent fuel delivery during the compression test This will prevent wash down of the 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 20 bar 290 psi it will be necessary to find the cause of low compression 7 Repeat the test for the other three cylinders Dif ference between cylinders should be no more than 5 bar 70 psi 8 Connect the fuel stop solenoid electrical connector 9 Install the glow plugs Engine Page 3 28 Rev Groundsmaster 455 D Injector Tests 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 A CAUTION 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
131. gs are worn and must be replaced 1 Raise cutting unit so wheels are off floor and block it so it cannot fall accidentally 2 Remove lynch pin and spacer s from top of castor spindle 3 Pull castor spindle out of mounting tube Allow spacer s to remain on bottom of spindle 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 castor spindle for wear and replace it if damaged 7 Push castor spindle through bushings and mounting tube Slide spacer s onto spindle Install lynch pin on castor spindle to retain all parts in place Groundsmaster 455 D Page 8 13 Figure 21 1 Bushing 2 Front castor arm tube 2 5 o Repairs Castor Wheel and Bearing Service Awobbly castor wheel usually indicates a worn bearing 1 Remove locknut from capscrew holding castor wheel assembly between front castor fork or rear castor pivot arm Grasp castor wheel and slide capscrew out of fork or pivot arm 2 Remove bearing from wheel hub and allow bearing spacer to fall out Remove bearing from opposite side of wheel hub 3 Check the bearings spacer and inside of wheel hub for wear Replace defective parts 4 To assemble the castor wheel push bearing into
132. haft and into hub so open side is facing towards inside of hub 15 Install plugs Item 6 into tapped holes in housing Repairs 2 5 o 13 11 12 23 22 Figure 35 Gearbox Final Assembly 1 Bearing drag for input shaft Item 8 is adjusted by amount of gaskets 7 used between thru cap Item 14 and housing machined surfaces 2 Put two 0 015 in gaskets on machined surface of housing then install shaft and thru cap assembly in housing so bearing cone Item 4 on shaft assembly and bearing cup Item 3 in blank cap Item 2 are mating Align holes in caps with holes in gaskets and housing 3 Install capscrews and tighten 4 shaft 8 should have a very slight amount of bearing drag when turned If shaft turns hard cap must be removed and gasket s need to be added If shaft has no bearing drag or has end play thru cap Item 14 must be removed and gasket s taken out thru cap must be adjusted to where shaft has no end play and only a slight amount of bearing drag Repairs Page 8 24 5 Gear lash is adjusted by amount of gaskets Item 7 used between hub Item 17 and housing machined surfaces 6 Put two 0 015 in gaskets on machined surface of housing then install shaft and hub assembly in housing Align holes in hub with holes in gaskets and housing 7 Install capscrews and tighten 8 output shaft Item 19 should turn freely with a slight amount of bea
133. he bolts as instructed IMPORTANT To prevent damage to the face of the injector pump housing and future timing problems the camshaft gear and injection pump gear locking bolts must be tightened ONLY FINGER TIGHT 4 Remove the three locking bolts Fig 53 5 Remove the TDC Lock Pin tool TOR 70153N then turn the crankshaft 1 4 to 1 3 turn in the opposite direc tion of running counterclockwise as viewed from the timing belt end Figure 53 Engine Page 3 40 Rev B Groundsmaster 455 D 6 Clean the area around the pump timing plug Fig 54 Item Remove the pump timing plug 7 Use Timing Tool Assembly TOR 80117 AM Lubricate the timing rod Fig 55 Item 1 with Diesel fuel then install the timing rod in the pump timing hole Item d Check to see that the rod moves freely in the bore 8 Install the dial indicator metric on the indicator bracket Item 2 9 Install the indicator bracket with dial indicator on the plug boss Set the dial indicator to 0 00 mm 10 Slowly turn the crankshaft in the operating direction clockwise as viewed from the timing belt end until the TDC Lock Pin tool TOR 70153N goes into the hole in the flywheel Fig 56 11 The dial indicator should show the reading 0 04 mm engraved on the injection pump If adjustment is required loosen the three bolts at the pump flange one bolt at the rear and the injection lines Rotate the pump awa
134. he brake pedal moves before braking resistance is felt To reduce free travel of brake pedals tighten nut on brake rod adjuster 1 2 turn at a time until you get desired free travel in pedal Rear Axle Toe in Adjustment 1 Measure center to center distance at axle height at front and rear of steering tires Front measurement must be 1 4 in less than rear measurement 2 To adjust loosen clamps at both ends of tie rods 3 Rotate tie rod to move front of tire inward or outward 4 Tighten tie rod clamps when adjustment is correct Adjustments Page 6 6 Figure 11 1 Brake rod adjuster Figure 12 1 Tie rod clamps Groundsmaster 455 D Transaxle Shift Linkage Adjustment 1 Remove steering tower cover 2 Move axle shift lever forward to transport high speed position Measure shaft dimension from side of transaxle case to end of shaft Fig 13 Adjust upper linkage length at top eye rod if necessary to get proper dimension Fig 14 3 Move axle shift lever rearward to mow low speed position Measure shaft dimension from side of transaxle case to end of shaft Adjust linkage length at top eye rod if necessary to get proper dimension 4 Move axle shift lever forward to transport high speed position and verify that the dimension is correct 5 Move axle shift lever rearward to mow low speed position Start the engine and with decks in down posi tion turn on PTO engagement switch The
135. hen working on fuel system com ponents 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 IMPORTANT Apply clean engine oil to all surfaces when engine is assembled to prevent marking when engine is first started 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 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 150 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 chapter unnecessary disassembly and inspection can be eliminated Groundsmaster 455 D Engine Removal and Installation 1 Put machine on a level surface and engage parking brake Turn engine OFF and remove key from ignition switch Allow engine and radiator to cool 2 Open the hood Disconnect hood stop cable fr
136. hing machine can be the result of thermal shock Normal functions will return after steering control unit temperature stabilizes To prevent damage to steering control unit DO NOT attempt to turn steering wheel until temperature stabilizes when thermal shock is noted Troubleshooting Page 4 18 Groundsmaster 455 D 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 compo nent is the source of the problem being experienced A WARNING Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved by stopping the en gine and lowering the cutting units Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid un der high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to pe
137. ices if necessary NOTE Swirl chambers do not need to be removed unless cylinder head is to be machined or replaced 5 Clean the cylinder head Use a wooden scraper and gasket stripping solvent to clean the gasket face DO NOT use a metal scraper 6 Check the gasket face for bow flatness Check corner to corner and side to side Fig 67 Maximum bow 0 7 mm 7 Check the condition of the valve seats and guides valve valve springs swirl chambers camshaft cam shaft bearings and all tapped holes See Identification and Specifications section Groundsmaster 455 D Page 3 49 Rev B Figure 67 Engine 8 Check the protrusion of the swirl chambers Fig 68 A Protrusion 0 to 0 03 mm Achieve this dimension by machining faces a and b 9 Check the valve recess B Exhaust 0 9 to 1 45 mm Inlet 0 5 to 1 05 mm Achieve this dimension by machining the valve seats 10 Lap in the valves 11 Re install the valves IMPORTANT If the cylinder head has been machined fit compensating washers under the valve springs See Identification and Specifications section 12 Install the shims as removed in step 2 If replacing cylinder head or if cylinder head has been machined install a basic shim Fig 69 6 2 425 mm thick to each valve stem and check that each shim is higher than the spring cup Item c If a shim is not higher than the cup grind the to
138. ide and outside race of new bearing is on a flat surface and press collar into bearing E Put armature and pulley assembly in arbor press pulley side up Put spacers in three 3 locations between pulley and armature plate to prevent dam age to springs Three 3 stacks of flat washers can be used for spacers Make sure extended part of collar is facing down and press on outer bearing race to install bearing and collar F Install retaining ring 5 Assemble clutch halves install on spindle shaft and adjust air gap see Clutch Adjustment and Clutch Re placement Groundsmaster 455 D Page 8 25 Figure 36 1 Field rotor ass y Items 1 4 2 Field bearing 3 Retaining ring 4 Field coil ass y 5 Armature amp pulley ass y Items 5 8 6 Bearing collar 7 Pulley bearing 8 Retaining ring 9 Locknut 10 Spring 11 Brake plate 2 5 o Repairs Wing Pivot Arm Installation and Ball Joint Service When assembling wing pivot arms adjust ball joint IMPORTANT Before installing wing pivot arms thread engagement to get a length of 8 06 for proper clean tapered surfaces of ball joints and mounting blade plane setting then tighten jam nut also see Blade bosses on deck with solvent degreaser Adjustment Apply Loctite 242 or equivalent to nut securing ball joint and tighten to a torque of 150 180 ft lb Make sure two 2 flat washers are installed under nut Loctite 242
139. if any of these condi tions are evident IMPORTANT When installing new belts do not force over pulleys or kink belt in place This could fracture cords in belt resulting in reduced belt life NOTE Check tension of new belts after first 25 hours of operation 1 Lower cutting unit to the shop floor Remove belt covers from center and wing cutting units To Remove Wing Deck Belts 2 To relieve tension on wing belt pull back on idler pulley until holes in idler adjuster tube and tube sleeve are aligned Thread a 5 16 18 capscrew into holes retaining parts 3 Remove hairpin cotter securing clutch rod to front of cutting deck and disconnect rod from deck Unplug clutch wire from harness 4 To ease right wing belt removal loosen or remove stationary idler pulley next to right wing s inner spindle pulley 5 To relieve tension on center deck belt pull back on idler pulley until holes in idler adjuster tube and tube sleeve are aligned Thread a 5 16 18 capscrew into holes retaining parts Groundsmaster 455 D Page 8 11 Rev A Figure 17 Left wing shown 1 Spring loaded idler pulley 2 Stationary idler pulley T Figure 18 1 Clutch 2 Clutch wire 2 5 o Repairs To Remove Center Deck Belt 6 Wing deck belts must be removed before center deck belt can be removed repeat steps 1 3 on previous page 7 Remove 2 flange head screws securing drive shaft cove
140. ing assembly Item 14 from housing assembly Repairs Page 4 46 10 Thrust bearing DO NOT attempt to disassemble the spring and other parts from the center bore of the cylinder block The entire rotating assembly Item 14 should be replaced if any of its components are damaged 7 Remove camplate insert Item 5 from housing 8 Remove retaining ring Item 13 from housing 9 Remove spacer Item 11 from housing 10 Remove drive shaft Item 12 with thrust bearing from housing 11 Remove retaining rings Item 8 from shaft and remove thrust races Item 9 and thrust bearing Item 10 Groundsmaster 455 D Inspection of Rear Axle 4WD Motor Parts 1 Wash all parts thoroughly in a suitable solvent 2 Examine needle bearings Item 4 and Item 7 in housing and back plate Make sure they are free of excessive play and remain in the bearing cage If needle bearings are damaged housing Item 6 or back plate Item 2 should be replaced bearings are not available separately 3 Inspect thrust races Item 9 and thrust bearing Item 10 All surfaces should be free of any signs of wear or fretting 4 Inspect spider and pivot of rotating assembly Conical surfaces should be free of wear and score marks 5 Inspect the pistons The O D surface should be smooth and free of scoring the shoes should be snug fit to the piston The face of the shoes should be flat and free of scoring or flaking DO NOT LAP SHOES o
141. interlock system is to prevent the engine from cranking or starting unless the traction pedal is in NEUTRAL and the cutting unit engagement switch is DISENGAGED In addition the engine will stop when the cutting unit engagement switch is engaged or traction pedal is depressed with operator off the seat 1 In a wide open area free of debris and bystanders lower cutting unit to the ground Stop engine 2 Move cutting unit engagement switch to DISEN GAGED position and remove foot from traction pedal so it is fully released 3 Rotate the ignition key to START Engine should start If engine starts proceed to step 4 If engine does not start there may be a malfunction in the interlock system 4 Raise off the seat and engage the cutting unit engage ment switch while the engine is running The engine should stop within 2 seconds If engine stops the switch is operating correctly proceed to step 5 If engine does not stop there is a malfunction in the interlock system Groundsmaster 455 D Page 5 15 5 Raise off the seat and depress the traction pedal while engine is running and the cutting unit engagement switch is DISENGAGED The engine should stop within 2 seconds If engine stops the switch is operating correctly continue operation If engine does not stop there is a malfunction in the interlock system A CAUTION THE INTERLOCK SWITCHES ARE FOR THE OPERATOR S PROTECTION SO DO NOT DISCONNECT THEM CHECK OPERAT
142. ion Check gaskets and pipes Check filter cartridge Correct timing Check clean and adjust injectors Have pump repaired Have pump repaired Check hoses and air cleaner Engine Page 3 20 Rev Groundsmaster 455 D Problem Engine will not start Possible Cause No preheating No fuel supply Defective solenoid valve Seized pump plunger Discharge valve blocked in stop position Seized feed pump Correction Check glow plugs and relay Make sure tank is not empty Check filter element and pipes Check system bleeding Check electric stop solenoid Have pump repaired Have pump repaired Drain water from tank pipes and filter repair pump Irregular engine speed Defective fuel supply Carbon fouled injectors Unequal discharge rates Faulty governor Check filter cartridge and pipes Check clean and adjust injectors Have pump repaired Have pump repaired Noisy engine Incorrect pump timing Blocked automatic advance Automatic advance to far advanced Correct timing Have pump repaired Have pump repaired Engine stalls at idling Air getting into fuel system Idling stop out of adjustment Jammed discharge rate Check gaskets and pipes Adjust idling stop Have pump repaired Vibrating engine Unequal discharge rate Air in fuel system Defective fuel injector Jammed discharge valve Have pump repaired Check fuel lines and clamps Check injectors Have p
143. ion and remove PTO belts see PTO 5 Remove bearing locknut Item 30 and lockwasher Belt Replacement Item 32 Repairs 7 10 Rev E Groundsmaster 455 D 6 Use a press to remove pulley Item 17 7 Use a puller to remove bearings Item 16 Remove bearing spacer Item 15 8 Inspect bearings and pulley Replace parts if worn or damaged 9 Use a press to install one bearing Item 16 into lower bearing housing Item 14 When installing bearing press on OUTER race of bearing 10 Install lower bearing spacer Item 15 and press other bearing Item 16 into bearing housing until bear ings contact the spacer When installing bearing press on OUTER race of bearing PTO Shaft and Bearing Service 1 Remove driveshaft between cutting unit and tractor 2 Loosen setscrew Fig 10 Item 3 and turn bearing collar Item 2 in opposite direction of shaft rotation to remove 3 Remove socket head screws Item 1 and locknuts Item 27 securing bearing Item 4 to rubber mounts Item 22 4 Remove bearing Item 4 5 To remove PTO shaft remove three 3 flange head screws 6 and flat washers Item 7 securing rubber flange Item 40 to clutch adapter Item 13 6 Remove PTO shaft Item 5 with rubber flange Item 40 attached 7 Replace PTO shaft if bent or if splines are damaged 8 Install rubber flange Item 40 to PTO shaft with new flange head screws Item 6 flat washers Item 7 and locknuts
144. itch faulty Ignition switch wiring loose corroded or damaged Start relay faulty Start relay wires loose corroded or damaged In line 30 amp starter solenoid fuse open Starter solenoid wiring loose corroded or damaged Starter solenoid faulty Correction 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 Replace fusible link Test temp switch and relay Replace if faulty Repair wiring Test traction switch Adjust or replace traction switch if faulty Repair wiring Make sure PTO switch is OFF Test switch and replace if faulty Repair wiring Test ignition switch Replace if faulty Repair wiring Test start relay Replace if faulty Clean and tighten or repair as necessary Check fuse and replace if fuse is open If fuse burns out often find and correct cause Clean and tighten or repair as necessary Replace starter Troubleshooting Page 5 8 Groundsmaster 455 D Starting Problems continued Condition Engine cranks but does not start if engine cranks cause of problem is not in interlock system Possible Cause Injection pump ETR solenoid wiring loose or corroded Injection pump ETR solenoid faulty Glow relay faulty Glow relay glow plug wiring loose corroded or damaged Glow plugs faulty
145. ld and inlet manifold 5 Remove the coolant manifold 6 Remove the alternator and belt 7 Remove the oil filter Fig 57 Item 10 8 Remove the injector pipes Item 12 9 Remove the glow plug leads 10 Remove the crankcase breather pipes oil filter filter pipe assembly Item 13 11 Remove the oil pressure switch Item 14 Figure 57 Groundsmaster 455 D Page 3 45 Rev B Engine 12 Remove the thermostat housing cover Fig 58 Item 17 13 Remove the thermostat housing Item 18 14 Remove the injectors Item 19 and retrieve the copper washer Item 20 and flame trap washer Item 21 15 Remove the glow plugs Item 22 Injection Pump Removal 1 Remove the timing belt 2 Use injector pump gear puller TOR70153H 10 remove injector pump gear Fig 58a 5 3 Remove the injection pump Fig 58b Item 19 4 Remove bracket Item 20 NOTE If the pump needs to be inspected or repaired it is recommended that is be done by an authorized CAV Lucas ROTO DIESEL service dealer especially during the warranty period Repairs by non authorized dealers WILL void the pump warranty IMPORTANT Clean the injection pump and the area around the injection pump before removing or ser vicing it DO NOT spray water onto a hot injection pump TOR 80149 Figure 58 lt WU 52 3 woo Bass NS aA Ee AN T AU Figu
146. ler and strike the yoke to complete removal DO NOT spill the needle bearings Figure 13 5 When replacing the U joint pack the roller bearings with multi purpose grease Pack carefully to eliminate trapped air Install seals 6 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 7 Insert one of the cross trunnions into the roller Start the other roller making certain it slips over the trunnion 8 When partially seated put the two rollers between the vise jaws Squeeze until FLUSH with the yoke Stop when flush DO NOT OVER TIGHTEN Figure 14 9 Tap on each roller until fully seated use a brass drift or socket that is the full width of the roller 10 Grease the fitting SLOWLY until it starts to show at the seals Use a low pressure hand grease gun or a power gun equipped with a pressure relief valve A high pressure grease gun can blow the rollers out of the yokes with the tremendous pressure seals may also be damaged 11 Test the action of the assembled joint It should move throughout its range without binding If a slight bind exists hit the yoke lugs with a soft hammer this will usually free the joint If it does not disassemble and check for the source of binding PTO System Groundsmaster 455 D Page 7 13 Repairs PTO Clutch Service Figure 15 1 Retai
147. lic oil is at normal operating tem perature by operating machine for approximately 10 minutes 2 Lower cutting units engage parking brake and stop the engine 3 Raise and support seat to get access to hydraulic test fittings 4 Install a 1000 PSI gauge into the counterbalance lift circuit quick disconnect fitting 5 Start the engine move throttle to full speed EVI 8000 RPM and observe gauge Figure 10 TESTER READING 600 650 PSI oil at normal 1 Counterbalance lift circuit test port operating temperature Counterbalance Relief Valve Adjustment 6 If necessary adjust the relief valve screw until the desired pressure is attained Adjust nearer the high end of the range for improved hill climbing or nearer the low end for improved quality of cut A CAUTION When adjusting counterbalance relief valve 2 a gt 2 gt do not unscrew relief valve adjuster too far Watch pressure gauge while adjusting valve Figure 11 Stop unscrewing valve adjuster when pres sure no longer decreases 1 Counterbalance relief valve Groundsmaster 455 D Page 4 21 Rev A Testing TEST NO 3 Checking Wing Deck Counterbalance Pressure Wing Deck Counterbalance Pressure 1 Make sure hydraulic oil is at normal operating tem perature by operating machine for approximately 10 minutes 2 Lower cutting units engage parking brake and stop the engine 3 Install a 1000 PSI gauge into
148. linder Head 90 9 66 Main bearing caps 70 7 52 Oil pump 20 2 15 Oil seal carrier timing gear end 15 1 5 11 Sump to block 20 2 15 Timing belt tensioner 15 1 5 11 Water drain plug 25 2 5 18 Oil drain plug 37 3 7 27 Tension roller pin nut 17 1 7 12 Manifold screws 22 2 2 16 Alternator bracket 17 1 7 12 NOTE 40 60 is tighten to 40 Nm then an additional 60 60 degrees of rotation one flat of bolt head Engine Page 3 10 Rev Groundsmaster 455 D Special Tools NOTE Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PRODUCTS Some tools may be listed in the TOR4033 Overhaul Tool Set This tool kit includes tools required for overhauling the engine TOR4035 Tune Up Set will also be required if overhauling the engine TOR80504A1 Extension Fig 24 TOR801 10H Indicator Holder Fig 25 TOR80110DZ 2mm Shim Cutoff Gauge Fig 23 TOR80504A2 Indicator Holder Fig 30 TOR80110GY Extension Rod Adapter Fig 24 TOR70153A1 Main Seal Installer Fig 18 TOR70153A2 Main Seal Installer Shims Fig 19 TOR70153C Rear Main Seal Installer Fig 20 TOR70153D Front Cover Seal Installer Fig 21 TOR4035 Tune Up Set This tool kit includes tools required for doing timing belt replacement injection pump timing injector removal and camshaft seal replacement TOR976697 Camshaft Seal Installer Fig 31 TOR2437T Dial Indicator Fig 16 TOR70153N Flywheel TDC Locator Pin Fig 22
149. line secure seal in place with retaining ring Item 9 NOTE Seal Item 10 is retained with Loctite on units with Serial Number 20001 29999 6 When assembling parts index driveshaft and splined hub to get clearance for hex flange screws that secure driveshaft to rubber coupling 7 Install new fasteners Item 6 and torque to 45 ft lb 8 Lubricate slip joint with No 2 General Purpose Lith ium Base Grease at grease fitting on coupling 10 Install bearing spacer Item 17 and press other bearing Item 16 into bearing housing until bearings contact the spacer When installing bearing press on OUTER race of bearing 11 Make sure plug Item 14 is installed in pulley Item 15 12 Use a press to push the bearing housing and bear ings onto the pulley Item 15 Press on INNER race of bearing 13 Install lockwasher Item 2 and bearing locknut Item 1 to pulley shaft Use special tool TOR4050 and a torque wrench to tighten locknut Tighten to a torque of 150 200 ft lb 14 Install bearing housing and pulley assembly to main adapter plate Item 19 and secure with four 4 flange screws Item 2 15 Install belts on PTO drive pulley 16 Apply Never Seez or equivalent to spline of hydrau lic pump shaft then install hydraulic pump assembly 17 Install engine coupling assembly see Engine Cou pling Service 18 Add No 2 General Purpose Lithium Base Grease at grease fitting on bearing housing Fig 6
150. ll the camshaft bearing caps Item 2 as shown by cast in markings 15 Progressively tighten the bearing caps to 17 5 Nm 13 ft lb 16 Install a new oil seal on tool TOR 976697 on the side where the inner flange is the farthest away Fig 88 17 Use a camshaft gear or pulley bolt to install the two camshaft oil seals Groundsmaster 455 D TOR 976697 oo J ay E EET Figure 88 Page 3 59 Rev Engine Assembly of External Components 1 Install new fire ring washers Fig 89 Item 1 convex surface facing up 2 Install new copper washers Item 2 3 Install the injectors and tighten to a torque of 90 Nm 66 ft lb 4 Install the pre heat plugs Item 4 and tighten to a torque of 22 Nm 16 ft lb 5 Install the thermostat housing Item 5 and cover Item 6 fitted with a new thermostat and gasket 6 Install the cylinder head cover Item 7 and tighten to a torque of 10 Nm 7 ft lb 7 Install the pre heat plug wires 8 Install the breather pipe assembly with oil filler pipes and filler orifice Fig 90 Item 13 9 Install the injector pipes Item 12 10 Install the oil pressure switch Item 14 and tighten to a torque of 27 5 Nm 20 ft lb 11 Install a new oil filter Item 10 See Break in Engine After Overhaul 12 Install the alternator and alternator belt 13 Install the water inlet housing
151. lled with the lip facing in the proper direction Now remove the seals Figure 28 from spindle housing 1 Grease fitting 11 Spindle shaft 2 Lock nut 12 Spindle spacer 11 Allow the bearings and small spacer to fall out of the 3 Clutch 13 Blade spindle housing 4 Square key 14 Anti scalp cup 5 Spacer 15 Flat washer 12 Using a punch and hammer drive both of the 5 Pulley S N below 20001 bearing cups out of the spindle housing Also drive the i Wave seal 18 Blade 8 Hex flange head screw 17 Bearing assembly large spacer out of the housing 9 Spindle housing 18 Washer 10 Flange nut 13 A large retaining ring is inside the spindle housing The retaining ring is difficult to remove and it is recom T mended that it be left in place unless damaged IMPORTANT If new bearings will be installed into a used spindle housing that has the original snap ring n TI installed discard the large snap ring that came with E r the bearings because itis 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 Figure 28a Repairs 8 18 Rev Groundsmaster 455 D Installing Spindle Bearings and Seals Into Spindle Housing IMPORTANT If a new spindle housing is being used new bearings and the matched
152. lock and pistons Piston Pin Units mm external 24 994 to 25 internal 13 8 to 14 1 Engine Figure 11 Page 3 8 Rev Groundsmaster 455 D Crankshaft Units mm Crank Pins and Journals ga b gc d Tolerance 0 0 003 0 0 003 0 016 0 019 Production 50 00 1 827 60 00 1 842 Repair 1 49 70 1 977 59 70 1 992 NOTE Repair 1 size connecting rod and main bearing shells can be identified by white paint 1 on the edge of the shell Units mm End Float No 2 Journal Half Shell Thickness e f Tolerance 0 05 0 025 0 Production 26 60 2 305 Repair 1 26 80 2 405 Repair 2 26 90 2 455 Repair 3 27 00 2 505 Units mm Oil Seal Contact Surface og Tolerance 0 0 087 Production 90 00 Repair 1 89 80 Groundsmaster 455 D Page 3 9 Rev B Figure 13 Engine Tightening Torques Part Nm Kgm ft lb Connecting rod end caps 50 5 37 Camshaft bearing caps 17 5 1 8 13 Camshaft gear 40 4 30 Coolant pump 15 1 5 11 Crankshaft pulley 40 60 4 60 30 60 Cylinder head bolts pre tightening 30 3 22 tightening 70 120 7 120 52 120 Cylinder head cover 10 1 7 Flywheel 50 5 36 Glow plugs 22 2 2 16 Injector pump gear 47 4 7 33 Injector into Cy
153. m for re installation 3 Remove the flywheel 4 Remove the main bearing caps Item 9 marks are cast in 5 Retrieve end float washers with No 2 cap 5 Remove the oil seal Fig 63 Item 10 6 Remove the end float washers Item 11 7 Remove the crankshaft 8 Remove the main bearing shells 9 Remove the piston connecting rod assemblies mark ing each piston and connecting rod for re installation in the same location NOTE Connecting rods and end caps are not num bered Once they are removed there is no way of knowing the correct location for installation unless you mark them for re installation 10 Remove the piston pin circlips and separate the pistons from the connecting rods 11 Remove the plugs Fig 63 and 64 Item 12 from the oil galleries Engine 3 48 Rev Figure 64 Groundsmaster 455 D Cylinder Head Overhaul 1 Progressively slacken the camshaft bearing caps Fig 65 Item 1 2 Remove the bearing caps Item 1 oil seals Item 2 camshaft Item 3 tappets 4 and adjustment shims Item 5 Mark adjustment shims and tappets so they will be re installed in the same location 1 intake 1 exhaust 2 intake 2 exhaust etc NOTE The shims are small and can stick to the tappets 3 Use a valve compressor to remove the eight valves Fig 66 4 Use hammer and drift to remove the swirl chambers from the injector orif
154. me of manufacture the machine conformed to the safety standards for riding mowers Ballast weight mounted to rear of traction unit is required for machine to conform to safety standard DO NOT re move ballast weight at any time To assure optimum performance and continued safety certification of the machine use genuine Toro replacement parts and ac cessories Replacement parts and accessories made by other manufacturers may result in non conformance with the safety standards and the warranty may be voided Safety Instructions Safety Instructions Page 1 4 Groundsmaster 455 D Table of Contents PRODUCT RECORDS EQUIVALENTS AND CONVERSIONS Decimal and Millimeter Equivalents U S to Metric Conversions TORQUE SPECIFICATIONS Capscrew Markings and Torque Values U S Capscrew Markings and Torque Values Metric WWWNNN Product Records Record information about your Groundsmaster 455 D on the Equipment Operation and Service History Report Form Use this information when referring to your ma chine Chapter 2 Product Records and Manuals 4 Wheel Drive Quick Reference Aid 6 EQUIPMENT OPERATION AND SERVICE HISTORY REPORT 7 OG 3 MAINTENANCE CHARTS 4 rae 2 Wheel Drive Quick Reference Aid 4 5 Insert the Operator s Manuals and Parts Catalogs for your Groundsma
155. ming plunger Wipe up any spilled fuel NOTE The high pressure fuel system is self bleeding It is not necessary to open the high pressure lines Injection Pump Removal See Injection Pump Removal in the Engine Overhaul section Injection Pump Repair NOTE If the pump needs to be inspected or repaired it is recommended that it be done by an authorized CAV Lucas ROTO DIESEL service dealer especially during the warranty period Repairs by non authorized dealers WILL void the pump warranty Groundsmaster 455 D Page 3 33 Rev B Figure 38 1 Primer plunger 2 Bleed screw Figure 39 1 Injection pump fitting IMPORTANT Clean the injection pump and the area around the injection pump before removing or ser vicing it DO NOT spray water onto a hot injection pump Engine Injector Service NOTE If injectors need to be inspected or repaired it is recommended that it be done by an authorized CAV Lucas ROTO DIESEL service dealer especially during the warranty period Repairs by non authorized dealers WILL void the warranty on the injectors Removal 1 Clean top of cylinder head and injection pipes 2 Remove injection pipes Fig 57 Item 12 3 Disconnect injector leakage pipe 4 Remove the injectors Fig 58 Item 19 and retrieve the copper washer 20 and flame trap washer Item 21 NOTE Never disassemble injector before checking its operation Disassembly and Cleaning 1 Secure th
156. mproper lubrication or debris in the switch could cause the switch to not open and close properly Shift linkage that is out of adjustment can also cause improper switch operation Repairs Page 5 32 Figure 36 1 4WD solenoid Figure 37 1 Hi Low Switch 4 Spring 2 O ring 5 Plunger 3 Spring amp ball guide 6 Switch pin guide Groundsmaster 455 D Wing Switch Replacement 1 Park machine on a level surface engage parking brake lower the cutting units and turn engine OFF 2 Remove deck covers 3 Disconnect wing switch electrical connector 4 Remove boot spring nut and washer then remove the wing switch Disconnect wiring assembly from switch terminals 5 Install wire assembly on new wing switch Make sure that one wire is connected to the COMMON terminal and one wire is connected to the NORMALLY OPEN N O terminal Figure 38 IMPORTANT The wing switch has three 3 termi 1 Wing switch nals the two 2 wires are not connected to the Shown from below wing with wing in raised position COMMON and NORMALLY OPEN N O termi nals the safety interlock circuit will not function properly A CAUTION If the wires are not correctly installed to the switch the wing deck could operate when in the raised position 6 Coat switch terminals and wires with skin over grease 7 Install new switch Apply Loctite 242 or equivalent switch threads before installing nut
157. n pistons 6 Inspect piston block The bores should be free of scoring The surface that contacts the back plate should be smooth and free of grooves or metal buildup DO NOT LAP PISTON BLOCK 7 Inspect the camplate insert Item 5 The surface should show no signs of scoring or grooves 8 Inspect the flat surface of the back plate Item 2 The surface should be free of excessive scoring or metal build up DO NOT LAP BACK PLATE 9 Inspect the drive shaft Item 12 for fretting in the bearing areas Groundsmaster 455 D Page 4 47 Assembly of Rear Axle 4WD Motor Parts 1 Lubricate all moving parts with clean hydraulic oil before assembly 2 Install one retaining ring Item 8 in rear groove of drive shaft Item 12 Install one thrust race Item 9 thrust bearing Item 10 and second thrust race Item 9 on drive shaft Install second retaining ring 8 in front groove on drive shaft 3 Install shaft assembly in housing Item 6 and install spacer Item 11 4 Install retaining ring Item 13 5 Assemble rotating assembly Item 14 by installing pivot spider and pistons in cylinder block 6 Lubricate camplate insert Item 5 and install in housing 7 Install rotating assembly 14 in housing The piston shoes must contact the camplate insert Item 5 Make sure all parts in the proper position 8 Install new o ring Item 3 on back plate Item 2 9 Install back plate on housing
158. n with machined surface facing up Install a new seal Item 13 into thru cap with open side toward machined side of thru cap 5 Install bearing cup Item 12 into cap Item 2 6 Take input shaft and gear assembly and wrap end of shaft with a piece of shim stock to keep from cutting oil seal on splines Put cap assembly down over shaft so bearing cone Item 11 on shaft mates with bearing cup 12 in cap Remove shim stock from shaft that was used to protect seal 7 Press a bearing cone 15 onto splined end of output shaft Item 19 Groundsmaster 455 D Page 8 23 8 Press a bearing cup Item 16 into outer end of hub Item 17 9 Install shaft through outer end of hub so bearing cone on shaft mates with bearing cone in hub 10 Press a bearing cup Item 16 into inner end of hub Item 17 11 Press a bearing cone Item 15 onto threaded end of shaft so it mates with bearing cone in hub 12 Install gear Item 21 over shaft so tooth side is towards threaded end of shaft Align keyway in gear with keyway in shaft and install a key in keyway 13 Install lockwasher Item 22 and locknut Item 23 Tighten locknut while turning shaft until there is no end play in shaft Do not over tighten shaft should have a very slight amount of bearing drag when turned 14 Wrap splined end of output shaft Item 19 with a piece of shim stock to prevent damage to oil seal Install a new oil seal Item 18 over s
159. nder and Cylinder Block 42 Tightening Torques 10 ENGINE REMOVAL AND INSTALLATION 43 SPECIAL TOOLS 11 ENGINE OVERHAUL 45 ADJUSTMENTS 17 Disassembly of External Components 45 Valve Clearance Adjustment 17 Injection Pump Removal 46 Engine Speed Adjustments 17 Cylinder Head 47 Throttle Cable Adjustments 17 Oil Pump 47 TROUBLESHOOTING 18 Crankshaft and Piston Removal 48 ee eee 18 Cylinder Head Overhaul 49 Fuel Injectors 19 Crankshaft Installation 51 Fuel Injection 20 Pistons and Connecting Rod Assembly 53 Low ee 22 Oil Seal Installation 54 Noisy Engine 23 Oil Pump Installation 54 Pre heatirigi ocootcsece leve heenicbeneebve 24 Flywheel Installation 55 Smoke During Operation 25 Cylinder Head Gasket Selection 56 Starting Problems 26 Cylinder Head Installation 56 TESTING AND INSPECTION 27 Cylinder Head Tightenin
160. netrate skin and do serious dam age 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 gan grene may result Groundsmaster 455 D Page 4 19 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 load valve in hydraulic tester if using 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
161. ng Leave bolts lightly tightened NOTE Inner ball bearing is left out at this time 5 Check backlash between bevel gear 29T and pinion 15T by installing dial indicator on tip of wheel shaft Adjust shim between bevel gear 29T and ball bearing if reading is outside of specification Bevel gear 29T backlash 0 2 0 4mm 0 008 0 016 in Shim stock for this adjustment is available in the follow ing thicknesses Thickness Part no Shim set 77 4030 0 1 mm 0 004 in 76 7890 0 2 mm 0 008 in 76 7900 0 4 mm 0 016 in 76 7910 6 After obtaining proper backlash remove bearing holder Apply Loctite 680 or equivalent to inner race bore of bearing Press inner race of bearing onto wheel shaft and clean off excess Loctite Install outer portion of bearing Apply sealant to mating face of final case and attach holder Tighten bolts to following torque value Torque specification 2 5 3 0 kg m 18 22 ft lb 7 Use a torque wrench as shown to check final case for torque required to turn it around gear case and make sure that no more than 0 03 kg m 0 22 ft lb is required Adjusting shim 9 o a 2 2 piece inner wheel bearing Flange of inner race faces bevel gear Add Loctite to inner race bore M va SS HSS TS PL al oce Ball
162. ning ring 2 Bearing 3 Brake plate 4 Bearing collar NOTE Individual parts such as bearings in the field rotor assembly or armature assembly are not service able and must be replaced as an assembly 1 Remove the clutch assembly see Clutch Removal and Installation in this section of the book 2 Remove the three 3 lock nuts Fig 15 10 Remove the brake plate Item 3 and three 3 springs Item 9 Repairs 5 Armature ass y Items 1 2 4 5 6 Field coil assembly 7 Field bearing Page 7 14 8 Field rotor ass y Items 6 7 8 9 Spring 10 Locknut 3 Separate the armature assembly Item 5 from the field rotor assembly Item 8 4 Reassemble the two clutch halves armature assem bly and field rotor assembly 5 Install the three 3 springs Item 9 over the studs Install the brake plate Item 3 and the three 3 locknuts Item 10 Groundsmaster 455 D Chapter 8 Cutting Unit Table of Contents SPECIFICATIONS 2 Inspecting and Sharpening Blade 16 GENERAL INFORMATION 3 Blade Spindle Service 17 Pivot Cutting Cutting Unit Upright 3 Gearbox Removal and Installation 20 5 4 Gearbox 22 Height of Cut Adjustment 4 Deck Clutch Service 25 Safety Door Adjustment
163. njectors 130 5 bar or kg cm 1885 70 psi 6 Starting pressure can be adjusted by adding or removing shims from the nozzle 0 10 mm shim thick ness will cause a 10 bar or kg cm 140 psi starting pressure difference 7 Repeat the test after installing shim to verify that a correct opening 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 1 2 strokes per second As the pump pressure reaches the starting pressure the nozzle valve will chatter or buzz as it opens and closes rapidly A nozzle which does not chatter or buzz may be the result of a binding or bent nozzle valve Engine Nozzle Leakage Test 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 20 bar or kg cm 280 psi below opening pressure 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 6 While pressure is being ap
164. nstall the crankshaft bolt Fig 44 Item 1 and the washer 5 Lock the camshaft gear Item 6 in position by install ing an M8 x 125 x 40 bolt Tighten finger tight 6 Lock the injection pump gear Item 7 in position with two M8 x 125 x 35 bolts Tighten finger tight IMPORTANT To prevent damage to the face of the injector pump housing and future timing problems the camshaft gear and injection pump gear locking bolts must be tightened ONLY FINGER TIGHT NOTE If the bolts in steps 5 and 6 cannot be installed because the holes in the gears and engine block do not align remove the TDC Lock Pin tool and rotate the engine clockwise one revolution Install the TDC Lock Pin then install the bolts as instructed in steps 5 and 6 Figure 44 Engine Page 3 36 Rev Groundsmaster 455 D 7 Loosen the nut Fig 45 Item 8 and the bolt Item 9 securing the roller tensioner bracket Item 10 8 Rotate the roller tensioner bracket square Item A to compress the spring Item 11 9 Re tighten the bolt Item 9 10 Remove the timing belt Figure 45 Groundsmaster 455 D Page 3 37 Rev B Engine Timing Belt Installation IMPORTANT Never install a used belt When the timing belt is removed a NEW timing belt must be installed 1 Install the new timing belt with the runs taut in the following order Fig 46 Crankshaft gear Item 13 Fixed roller 11 Injection pump gear
165. oad 0 04 0 06 kg m 0 29 0 43 ft lb NOTE Make sure pinion shaft has no end play when checking bearing preload 6 After obtaining specified preload secure lock nut by bending tab washer Groundsmaster 455 D 6 17 Rev C Figure 30 Repairs x E lt Adjusting Pinion Shaft Cone Center Cone Center is the distance from the mating face of axle housing to end face of pinion This distance can be increased or decreased by installing removing shims Cone center specification 43 0 05 1 69 0 002 in Shim stock for this adjustment is available in the follow ing thicknesses Thickness Part No Shim set 77 4010 0 1 mm 0 004 in 76 7410 0 2 mm 0 008 in 76 7420 0 4 mm 0 016 in 77 7430 Using gauge TOR4042 for cone center adjustment determine the required thickness of shim by proceeding as follows 1 Apply grease to o rings Install o rings to sleeve then install sleeve assembly into adapter case 2 Put gauge alternately on pinion shaft and select the shim so that with the short gauge a clearance will occur between the gauge end and case face but with the long gauge a similar clearance will occur between the gauge and pinion end face 3 Apply grease to o ring and fitto mating face of sleeve Attach adapter case to axle housing A and secure by tightening bolts to proper torque
166. ocedures Cause Cooling system not operating properly Correction Clean screen oil cooler amp radiator Repair fan or belt Check coolant level and add coolant if necessary Make sure radiator screen is properly sealed Low engine RPM Adjust use tachometer Hydraulic oil level too low Fill to proper level Kinked or severely bent hose or tubing Replace kinked or bent hose or tubing Traction circuit working pressure too high TEST NO 1 Check for other cause of excessive machine load and correct Inspect brakes for binding and adjust or repair if necessary Damaged pump or motor s Repair or replace pump or motor s Machine Travels In One Direction Only Cause Traction control linkage damaged or out of adjustment Correction Repair control linkage Pump charge check relief valves defective valves Inspect and clean or replace pump check relief Groundsmaster 455 D Page 4 13 Troubleshooting D gt i gt Traction Response Is Sluggish Cause Brakes dragging Correction Inspect brakes and adjust or repair if necessary Charge pressure low TEST NO 6 NOTE Counterbalance pressure will also be affected Inspect charge relief valve and adjust or repair if necessary Inspect auxiliary pump and repair or replace if necessary NOTE Steering and lift will also
167. of the cylinder block The water pump operates at 1 05 times engine speed Water flow is 92 liters min at 2500 engine RPM Firing Order NO 1 CYL IS ON FLYWHEEL END 1 3 4 2 Electrical System 12 volt negative ground 55 AMP alternator with integral regulator 12 volt 1 4 Kw starter motor with integral solenoid pinion shaft type Groundsmaster 455 D Page 3 3 Rev B Engine Cylinder Head Cylinder head height h is measured with the camshaft in place fitted with two bearing caps h is measured on the oil seal lip contact diameter the largest diameter h nominal 157 40 to 157 75 mm Maximum permissible bow on bottom of cylinder head 0 07 mm camshaft must turn freely Maximum permissible gasket face machining 14 mm in rela tion to the measured h nominal Cylinder heads machined undersize are stamped R in the area a After machining gasket face the following operations must be done 1 Valve seat machining to re establish correct re cess see Valve Recess in this section 2 Replacement of swirl chambers by repair dimen sion and correction of their protrusion see Swirl Chambers in this section 3 Fitting of 0 4 mm thick compensation washers under the valve springs to match cylinder head machining Cylinder heads manufactured with oversize camshaft bearings 0 5 are stamped 1 in the area a Cylinder Head Gasket Thickness identification Units mm
168. om engine Lower the hood Remove left and right hinge plates Lift hood off chassis 3 Disconnect positive and negative battery ca bles from battery Loosen battery securing bolt and remove battery 4 Open the radiator cap Open radiator drain valve or remove lower radiator hose and allow coolant to drain into a pan A CAUTION DO NOT open radiator cap or drain coolant if engine or radiator is hot Pressurized hot coolant can escape and cause burns 5 Loosen hose clamps and disconnect upper and lower radiator hoses from engine and radiator 6 Loosen hose clamp and remove fuel hose from injector pump Plug end of fuel line to prevent fuel leakage Disconnect injector return hose 7 Loosen hose clamp and disconnect PCV hose from engine Groundsmaster 455 D Page 3 43 Rev B 8 Disconnect and tag electrical wires that attach to the engine or engine components alternator starter motor and solenoid ground cable oil pressure switch tem perature gauge sender thermoswitch fuel stop ETR solenoid glow plugs 9 Disconnect drive coupling from flywheel end of en gine 10 Remove upper fan shroud from radiator 11 Disconnect throttle cable from speed control lever on fuel injection pump Loosen clamp and remove throt tle cable and from engine bracket 12 Remove fasteners securing engine to engine mounts 13 Attach a short section of chain between the two lifting brackets on the engine C
169. on final drive shaft and one on differential shaft tempo rarily fit gear case to axle housing and tighten two bolts diametrically opposite DO NOT use black reamer bolt for this temporary assembly 2 Install a dial indicator to final case putting gauge 9 spindle to tooth pinion 15T pinion on bottom end of final drive shaft Take a backlash reading a Pinion 14T backlash 0 2 0 4mm S 0 008 0 016 in Figure 39 z lt 3 If reading is outside of specified range remove gear case and adjust shim between pinion 14T on differen tial shaft and ball bearing Shim stock for this adjustment is available in the following thicknesses Thickness Part No Shim set 77 4020 0 1 mm 0 004 in 76 7520 0 2 mm 0 008 in 76 7530 0 4 mm 0 016 in 76 7540 Groundsmaster 455 D Page 6 21 Repairs 4 After obtaining proper pinion backlash grease o ring and fit it to mating face of axle housing Secure gear case to housing by tightening bolts to the following torque value Torque specification 5 0 6 0 kg m 36 43 ft lb Reassembling Wheel Shaft 1 Grease oil seal and fit it to bearing holder 2 Insert shaft into holder Install ball bearing and retain bearing by installing circlip 3 Mount bevel gear 29T on splined end of shaft 4 Fit bearing holder complete with shaft and bevel gear to final case and temporarily secure it bolti
170. onnect hoist or block and tackle chain at center of the short section of chain One person should operate hoist or block and tackle and other person should help guide engine out of chassis Remove engine from chassis Be careful when remov ing engine to prevent damage to engine radiator or other parts Mount engine in an engine rebuilding stand 14 Remove muffler brackets coolant expansion tank and accessories from engine as necessary Drain oil from engine and remove engine oil filter Engine Installing the Engine 1 To install the engine perform steps 2 14 of Removing the Engine in reverse order 2 After disassembling or overhauling the engine install a new oil filter Replace this filter after the first 20 to 50 hours of operation 3 Fill the engine with the correct oil Fill the cooling system with a 50 50 solution of ethylene glycol anti freeze and clean soft water Check for oil and coolant leaks and repair as necessary Peugeot recommended Coolant Antifreeze is available in 1 U S Gallon containers under Toro Part No 93 7213 IMPORTANT The anti freeze should contain no Borate and have a Ph of 7 to 8 5 4 Adjust the throttle linkage Engine Page 3 44 Rev B Groundsmaster 455 D Engine Overhaul Disassembly of External Components 1 Remove TDC sensor and clutch housing center ing pin 2 Mount the engine on a stand 3 Lock the flywheel with TOR FD86 tool 4 Remove exhaust manifo
171. operating temperature Testing D gt 2 E c gt TEST NO 1 Checking Traction Circuit Working Pressure or Relief Pressure WORKING Pressure Check 1 Make sure hydraulic oil is at normal operating tem perature by operating machine for approximately 10 minutes 2 Lower cutting units engage parking brake and stop the engine 3 Raise seat to get access to hydraulic test fittings Remove access cover from in front of auxiliary pump 4 Install a 10 000 PSI gauge with extension hose onto the traction circuit quick disconnect fitting for the func tion to be checked Install gauge and hose so gauge can be observed while sitting on seat BUT WILL NOT CONTACT CUTTING UNIT WHEN RAISED Figure 9 5 Operate machine while monitoring gauge 1 Traction FORWARD test port RANGE OF TESTER READINGS 100 6100 PSI RELIEF Pressure Check A CAUTION Move machine to an open area away from people and obstructions 6 Set traction pedal stop for minimum ground speed 1 MPH 7 Start the engine and move throttle to full speed 3000 RPM 8 Release parking brake 9 Engage the traction pedal to start machine in motion 10 Maintain traction pedal engagement while momen tarily engaging the brakes to bring the unit to a halt and read gauge TESTER READING TO BE 6000 100 PSI Testing Page 4 20 Groundsmaster 455 D TEST NO 2 Checking Counterbalance Pressure 1 Make sure hydrau
172. or 2 5 o Repairs 6 Remove the hex flange head screws Item 8 and lock nuts Item 10 securing spindle housing to deck Slide spindle housing assembly out the bottom of the cut ting unit 150 170 ft lb 18 7 Remove the nut Item 2 and washer 18 retaining the spindle pulley or clutch on the spindle shaft Slide the pulley or clutch Item 3 spacer Item 5 and pulley Item 6 off of the shaft Make sure you account for the key Item 4 NOTE There are three 3 different types of spindle housing assemblies The type with the clutch is shown Small spacer LX Large spacer 8 If the spindle shaft Item 11 will be replaced remove J Retaining ring the blade bolt Item 16 and blade Item 13 from the Ince spindle shaft Otherwise the blade may be left on the spindle shaft EE n 22 NOTE Units with S N below 30001 will have a hex bolt and flat washer securing the blade Units with S N 30001 amp up will have a hex flange bolt securing the blade 9 Press the spindle shaft Item 11 out of the spindle housing 9 using an arbor press The spacer Item 12 remains on the spindle shaft as the shaft is being removed 10 The seals Item 7 will be removed next however notice the lip of the seal The lip of the upper seal faces inward and the lip of the lower seal faces outward 85 110 ft lb Therefore new seals must always be insta
173. orce pinion shaft out of case 3 Remove oil seal Item 6 and bearings Item 1 and 11 as necessary Groundsmaster 455 D Inspection Clean the disassembled parts by washing in cleaning solvent Inspect gears and pinions to be sure their teeth are in good condition Check to be sure that each bearing rotates smoothly Examine housings for cracks Reassembly Replace damaged or worn parts as necessary Oil or grease the surfaces of rotating or sliding parts before assembling Grease oil seals and o rings before installing Assembling Pinion Shaft 1 Fit two outer races of tapered roller bearings into sleeve positioning each race as shown 2 Fit inner race of tapered roller bearing to gear side of pinion shaft pushing it all the way against the pinion shoulder 3 Insert pinion shaft into sleeve Fit other inner race to shaft and install o ring and bushing Pinion shaft is now securely installed inside the sleeve 4 Grease oil seal and install it between sleeve and bushing making outer end face flush with mating face of sleeve Install seal with garter spring facing toward hydraulic motor 5 Grease o ring Install o ring tab washer and lock nut Tighten lock nut with special tool TOR4040 to specified preload on bearings Oil seal flush with case face Sleeve Tapered roller Bearings gt lt Pinion shaft Oil seal garter spring facing toward hyd motor Pinion shaft bearing prel
174. osition Cutting Unit s Lower or Raise Too Quickly Steering Loss Groundsmaster 455 D Chapter 4 Hydraulic System 2 TESTING der e hee 19 3 Test No 1 Checking Traction Circuit 3 Working Pressure or Relief Pressure 20 5 Test No 2 Checking Counterbalance Pressure 21 5 Test No 3 Checking Wing Deck 6 Counterbalance Pressure 22 7 Test No 4 Checking Steering Circuit 7 Working Pressure or Relief Pressure 23 8 Test No 5 Checking Lift Circuit 9 Working Pressure or Relief Pressure 24 10 Test No 6 Checking Charge Pressure 11 For Traction 11 5 12 Traction Pump Neutral Adjustment 13 REPAIRS ecrit e aic eu n ATE MS 13 Removing Hydraulic System Components 13 Traction Pump Shaft Seal Replacement 14 Traction Pump Trunnion Seal Replacement 14 Traction Pump Check and 15 High Pressure Relief Valves 15 Traction Pump Charge Pressure Relief Valve 16 Disassembly of Traction Pump Assembly of Traction 17 Auxiliary Steering Pump Repairs Front Traction Motor Repairs 17 Rear Axle 4wd Motor Repairs 18 Lift Valve 18 Steering Control Unit Repairs Page 4 1 Table of Contents Hydraulic System Specifications
175. other cylinders Engine Thermostat Test If the engine overheats or runs too cool and a faulty thermostat is suspected the thermostat should be tested 1 Remove the thermostat 2 Put the thermostat in a container of water with a thermometer and heat the water Starts to open at 81 C 178 7 mm 0 28 in full open at 88 C 190 F 3 If the thermostat fails to open only partially opens or sticks it should be replaced Engine Page 3 32 Rev 0090 090 Figure 37 Groundsmaster 455 D Fuel System Service Priming Fuel System 1 Stop the engine Unlatch and raise the hood 2 Fill the fuel tank 3 Install a 3 16 hose over bleed screw Put other end of hose into a container to catch fuel Fig 38 4 Pump priming plunger until resistance is felt Try to start engine If engine does not start go to step 5 5 Loosen bleed screw a few turns Pump priming plunger until a steady stream of fuel comes out of hole in bleed screw When fuel stops foaming tighten bleed screw during down stroke of priming plunger Wipe up any spilled fuel NOTE It may be necessary to bleed air out of the fuel line between the fuel filter water separator and the injection pump To do this loosen the fitting on the injection pump Fig 39 and pump priming plunger until a steady stream of fuel comes out of fitting When fuel stops foaming tighten the fitting during the down stroke of the pri
176. ously scribed lines for assembly guide Press the bearing Item 11 into end cap Item 14 leaving 3 32 to 1 8 inch of bearing protruding beyond face The valve plate Item 1 pilots on this bearing Insert locating pin Item 13 into end cap Lubricate the slotted side of the motor valve plate Item 1 and slip it over the locating pin and protruding bearing Groundsmaster 455 D Page 4 45 Place gasket Item 11 on housing Item 9 then install end cap and valve plate Hold the valve plate so it does not drop off during assembly Install four Item 4 screws Item 16 and tighten alter nately until the end cap and housing are pulled com pletely together Torque to 27 37 ft lbs Check for proper internal assembly by slowly rotating motors shaft while tightening these screws Repairs D gt gt Rear Axle 4WD Motor Repairs Fig 30 Figure 30 1 Capscrew 6 Housing 11 Spacer 2 Back plate 7 Bearing 12 Drive shaft 3 O ring 8 Retaining ring 13 Retaining ring 4 Bearing 9 Thrust race 14 Rotating assembly 5 Cam plate insert Disassembly of Rear Axle 4WD Motor 1 Clean outside of motor thoroughly 2 Clamp shaft in a protected jaw vise with back plate end up 3 Remove six capscrews Item 1 from back plate Item 2 4 Use a plastic mallet and tap the back plate Item 2 to loosen it 5 Remove o ring Item 3 from back plate 6 Remove complete rotat
177. p of the cup Item c 13 Re install the tappets 14 Oil the camshaft bearings 15 Install the camshaft with the DIST mark at the timing gear end 16 Progressively tighten the bearing caps to a torque of 17 5 Nm 13 ft lb The bearing caps have cast in markings for correct installation Figure 70 Engine Page 3 50 Rev Groundsmaster 455 D Crankshaft Installation 1 Put thread lock Loctite on the oil gallery plugs and install them in the cylinder block 2 Install the grooved main bearing shells See Crankshaft in the Inspection and Specifications section for main bearing shell thickness 3 Install the crankshaft 4 Install the no 3 4 and 5 main bearing caps 5 Install the two end float half washers Fig 72 1 with the anti friction faces towards the crankshaft 6 Install the no 2 main bearing cap Fig 73 Item 2 with its two end float half washers with the anti friction faces towards the crankshaft Groundsmaster 455 D Page 3 51 Rev B Engine 7 Check crankshaft end float Fig 74 A Install the dial indicator using tools TOR 80110G1 TOR 80504 A1 and A2 B End float must be between 0 07 and 0 32 mm NOTE For choice of half washer thickness see Crankshaft in the Identification and Specifications section 8 Apply a thin coat of Formetanch or Permatex No 2 sealant to surface of block whe
178. partially short circuited Rectifier diode short circuited Battery voltage too high In line diode defective Regulator defective Poor connections Alternator noisy Belt worn Alternator mounting loose Alternator pulley loose Worn bearings Rectifier diode short circuited Engine Page 3 18 Rev Groundsmaster 455 D Fuel Injectors Problem Bad spray pattern Possible Cause Carbon deposit around the orifice Scored nozzle seat Needle damaged Correction Clean Replace injector Replace injector Leaking injector Foreign matter jammed between nozzle seat and needle Nozzle seat out of true Clean Replace injector Needle seized or showing seizing marks Water in fuel Copper gasket not replaced Injector nut too tight on injector body Drain water and flush fuel feed system 1 Replace gasket at each repair Tighten injector nut 1 Leakage collector fills too quickly Leak between upper bearing face of nozzle and bearing face of injector body Foreign matter between bearing faces Unevenness Clean Replace injector Blue needle point Incorrect injection pump timing Replace injector and adjust pump timing again End of injector body corroded Running temperature of engine too low Intermittent operation Check thermostat Run machine longer Do not start and stop engine 1 In these cases re
179. performing any work on the hydraulic system all pressure in the system must be relieved by stopping the en gine and opening the bypass valve Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid un der 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 Figure 2 Final Initial Mark Nut Position Position and Body Extend Line Finger Tight After Proper Tightening Page4 3 Figure 3 General Information Hydraulic System SAE Straight Thread O Ring Port Non adjustable Fig 4 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fitting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 4 Install the fitting into the port and tighten it down full length until finger tight 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 in 1 50 25 8 1 2 in 1 50 25 10 5 8 in 1 50 25 12 3 4 in 1 50 25 16 1 in 1 50 25 SAE Straight Threa
180. place the injector Groundsmaster 455 D Page 3 19 Rev B Engine Fuel Injection Pump Problem Engine has no power Possible Cause Defective fuel supply Incorrect pump timing Incorrect spray or injector pressure out of adjustment Air intake restriction Insufficient automatic advance Discharge rates too low Correction Check filter cartridge and pipes Correct timing Check clean and adjust injectors Check hoses and air cleaner Have pump repaired Have pump repaired Idling too fast Idling stop out of adjustment Throttle cable out of adjustment Governor out of adjustment Adjust stop and fast idling control Adjust throttle cable Have pump repaired Maximum speed too high Max speed stop out of adjustment Jammed discharged valve Blocked pump governor Have pump repaired Have pump repaired Have pump repaired Engine will not accelerate Defective fuel supply Seized pump plunger Broken pump plunger spring Hard discharge valve Seized feed pump Accelerator linkage defective Check filter cartridge and pipes Have pump repaired Have pump repaired Have pump repaired Drain water from tank pipes and filter have pump repaired Repair linkage Engine emits smoke Air getting into feed system Defective fuel supply Incorrect pump timing Incorrect spray or injectors out of adjustment Insufficient automatic advance Discharge rates too high Air intake restrict
181. plate With wrench handle parallel to ground pull wrench upward until 180 ft Ibs of torque is applied to tension belt 4 Tighten flange screws and flange nuts locking adjustment 5 Install PTO belt cover E 2 a gt o Figure 3 1 Square hole Groundsmaster 455 D 7 3 Adjustments PTO Clutch Adjustment 1 To adjust clutch tighten or loosen locknuts on flange studs 2 Check adjustment by inserting feeler gauge through slots next to flange studs 3 The proper disengaged clearance between the clutch plates is 0 011 0 021 inches It will be necessary to check this clearance at each of the three slots to ensure the plates are parallel to each other Figure 3 1 PTO clutch 2 Flange studs Adjustments Page 7 4 Groundsmaster 455 D Repairs PTO Belt Replacement 1 Remove 2 screws securing PTO belt cover to adapt er plate and 1 screw securing belt cover to tab on spring anchor Remove cover Figure 4 1 PTO belt cover 2 Adapter plate 2 Remove tension on belt by loosening three 3 flange screws and flange nuts securing adapter plate to clutch plate Figure 5 1 PTO belt 3 Clutch plate 2 Adapter plate 4 Flange nuts 3 PTO System Groundsmaster 455 D 7 5 Repairs NOTE Always use new coupler flange head screws Items 2 and 6 when repairing PTO systems 150 200 ft Ib Bearing locknut Hex flange head screw Hex he
182. plied watch for an ac cumulation of fuel at the tip of the nozzle Fig 35 A small amount of fuel may be present due to a previous chattering test this would be normal If the fuel accumu lates 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 atomize the injected fuel 1 Operate the pump handle quickly 4 6 strokes per second 2 Observe the injector nozzle spray The spray pattern should be finely atomized in a broad straight stream Fig 36 3 If the nozzle fails to spray properly it must be cleaned repaired or replaced Engine Good Bad Bad Figure 35 Good broad spray fine mist straight Bad narrow spray streaky mist Bad angled spray Page 3 30 Rev Figure 36 Groundsmaster 455 D Injection Pump Testing 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 2 Check the operating condition of the injection nozzles to make
183. polish the shaft exten sion wrap it in thin plastic and lubricate with hydraulic The lip type shaft seal Item 6 can be replaced without oil to insure that the seal is not damaged during assem disassembly of the motor however replacement of the bly Slide the seal over the shaft and press it into the seal requires removal of the motor from the transaxle housing bore Pry the seal carefully out of the housing bore using care not to distort the housing or damage the bore or shaft Once removed the seal is not reusable Repairs Page 4 40 Groundsmaster 455 D Major Repair MOTOR 16 SCREW 4 2 Housino o pt b 1 oN SE bct PLATE 11 GASKET Figure 25 When the four 4 cap screws Item 16 are loosened the internal spring loading will cause the end cap Item 14 to separate slightly Loosen these screws evenly to prevent distortion of parts If separation does not occur as screws are loosened tap end cap with soft hammer until parts separate IMPORTANT All surfaces exposed are critical and caution must be used to avoid damage Note the orientation of housing Item 9 to end cap Item 14 To insure proper assembly scribe a line across housing and end cap for an assembly guide Groundsmaster 455 D Page 4 41 The end cap Item 14 can now be removed from the motor however be certain that the valve plate Item 1 does not fall and become damaged If the valv
184. pool sleeve assembly withdrawing installa tion tool at the same time 9 Center the spring set in the parts so that they push down evenly and flush with the upper surface of the spool and sleeve 10 Install pin through spool and sleeve assembly until pin becomes flush at both sides of sleeve 11 Position the spool and sleeve assembly so that the splined end of the spool enters the fourteen 14 hole end of housing first IMPORTANT Be extremely careful that the parts do not tilt out of position while inserting Push parts gently into place with slight rotating action keep pin nearly horizontal Bring the spool assembly entirely within the housing bore until the parts are flush at the meter end or 14 hole end of housing Do not pull the spool assembly beyond this point to prevent the cross pin from dropping into the discharge groove ofthe housing With the spool assembly in this flush position check for free rotation within the housing by turning with light finger tip force at the splined end 12 Place housing on clean lint free cloth Install 2 1 8 diameter seal in housing 13 Install two 2 bearing races and the needle thrust bearing in the order shown Repairs Page 4 56 Figure 46 Figure 47 Needle Thrust Bearing ee Bearing Soke Race 2 SA SI Seal ____ Figure 48 Groundsmaster 455 D 14 Install 1 1 4 diameter
185. preventing seat switch from closing Seat switch is faulty or out of adjustment Seat switch wiring loose corroded or damaged Time delay relay faulty Time delay wiring loose corroded or damaged Relay fuse open Ignition switch faulty Ignition switch or fuse wiring loose corroded or damaged Instruct operator Repair seat pivot and support Test seat switch Adjust or replace if faulty Repair wiring Test relay Replace if faulty Repair wiring Check fuse and replace if fuse is open If fuse burns out often find and correct cause Test ignition switch Replace if faulty Repair wiring AWD is engaged but should not be with axle in HI range Axle HI LOW switch faulty 4WD solenoid valve faulty Test HI LOW switch Replace switch if faulty Test 4WD solenoid valve Replace if faulty Troubleshooting Page 5 10 Groundsmaster 455 D General and Transport Problems continued Condition 4WD does not engage Possible Cause Axle in HI range Axle HI LOW switch or plunger faulty Axle HI LOW switch wiring loose corroded or damaged 4WD solenoid valve faulty 4WD solenoid wiring loose corroded or damaged Problem is not electrical Correction Axle must be in Low range for 4WD to engage Test HI LOW switch Check for proper installation and operation of plunger assembly Replace Switch or repair plunger if fault
186. r pump gear then use this tool to loosen the pulley from the tapered shaft on the injector pump Figure 33 Engine 3 16 Rev Groundsmaster 455 D Adjustments Valve Clearance Adjustment See Valve Clearance Adjustment in the Engine Over haul Section Engine Speed Adjustments Maximum fuel flow and speed adjustments are sealed and should only be unsealed by a CAV Lucas ROTO DIESEL service dealer Throttle Cable Adjustments The throttle control lever at the operator s station must not touch the end of the slot during full range of motion from idle SLOW to full engine RPM FAST Adjust throttle cable at injection pump so throttle lever on injection pump operates at full range of motion without throttle control lever at operator s station touch ing end of slot at either FAST or SLOW position Groundsmaster 455 D Page 3 17 Rev B Engine Troubleshooting Alternator Problem Alternator is not charging Possible Causes Alternator belt loose Charging circuit defective Energizing circuit defective Brushes worn or seized Rotor winding defective Stator winding defective Regulator defective Output low or irregular Alternator belt loose Charging circuit defective Energizing circuit defective Brushes worn or seized Rotor winding defective Stator winding defective Regulator defective Rotor partially short circuited Rectifier diode defective Stator
187. r to gear box support and remove cover 8 Remove capscrews and nuts securing front of gear box support to deck channels and loosen capscrews securing rear of gear box support to deck channels 9 Raise front of gearbox support and remove old belt from around gear box pulley and remaining pulleys 10 Route new belts around appropriate pulleys as shown IMPORTANT When installing new belts do not force over pulleys or kink belt in place This could fracture cords in belt resulting in reduced belt life 11 Remount gear box support to deck channels with capscrews and nuts previously removed 12 Reinstall drive shaft cover to gear box support with 2 flange head screws previously removed 13 Remount clutch rod to deck with hairpin cotter and plug clutch connector into harness 14 While holding idler pulley adjuster in position care fully remove capscrew securing idler adjust or tube to tube sleeve Allow idler pulley to release tensioning belt 15 Check idler pulley adjustment see Belt Tension Adjustment 16 Reinstall belt covers NOTE Check tension of new belts after first 25 hours of operation Figure 19 1 Gearbox support 2 Capscrews amp nuts Belt Routing Figure 20 Repairs 8 12 Rev A Groundsmaster 455 D Front Castor Arm Bushing Service To check the bushings move castor fork back and forth and from side to side If castor spindle is loose inside the bushings bushin
188. raction adjustment cam 2 Locknut Engine must be running so final adjustment of traction adjustment cam can be performed To guard against possible personal injury keep hands feet face and other parts of body away from rotating parts 4 Start engine and run at low idle 5 Rotate cam hex in either direction until raised wheel is not rotating 6 Tighten locknut to secure adjustment 7 Stop the engine Remove jack stands and lower machine to ground Release parking brake and test drive machine to make sure it does not creep in neutral Adjustments Page 4 2 Rev E Groundsmaster 455 D Repairs Removing Hydraulic System Components 1 Thoroughly clean the machine before disconnecting removing 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 or fittings left open or exposed 3 Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed After Repair or Replacement of Components 1 Check oil level in hydraulic reservoir and add correct oil if necessary Drain and refill hydraulic system reser voir and change oil filter if component failure was severe or system is contaminated 2 After repairs check control linkage for proper adjust ment binding or broken parts Groundsmaster 455 D Page 4 27 3 If a pump was disconnected or remove
189. range The switch closes when the axle shift rod is moved to low range which pushes the switch button in 1 Disconnect the switch wire connector and install a continuity tester or ohm meter between the two leads of the switch 2 With the axle in neutral or hi range the switch should show no continuity With the axle in low range the switch should show continuity NOTE For proper operation the switch must be screwed all the way in Debris in the switch could cause 1 Axle Hi Low switch the switch to not open and close properly Shift linkage that is out of adjustment can also cause improper switch operation D a gt 2 5 E TT Groundsmaster 455 D Page 5 19 Testing PTO Switch To test the PTO switch independent of wiring harness disconnect wire connector from the switch terminals When the switch is ON there should be continuity between terminals only When the switch is OFF terminals C D and B E should show continuity Figure 14 1 PTO switch terminals Testing Page 5 20 Groundsmaster 455 D Start Cutting Unit Time Delay and High Temp Relays To test the relay disconnect the relay wire connector and install a continuity tester between the relay termi nals 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 termi nal 86 connected to ground Fig
190. rate machine without proper instruc tion Only trained operators who have read this manual should operate this machine 3 Never operate the machine when under the influence of drugs or alcohol 4 Keep all shields safety devices and decals in place If a shield safety device or decal is defective illegible or damaged repair or replace it before operating the machine Also tighten any loose nuts bolts or screws to ensure machine is in safe operating condition 5 Always wear substantial shoes Do not operate ma chine while wearing sandals tennis shoes sneakers or when barefoot Do not wear loose fitting clothing that could get caught in moving parts and possibly cause personal injury Wearing safety glasses safety shoes Safety Instructions long pants and helmet is advisable and required by some local ordinances and insurance regulations 6 Assure interlock switches are adjusted correctly so engine cannot be started unless traction pedal is in NEUTRAL and cutting unit is DISENGAGED 7 Remove all debris or other objects that might be picked up and thrown by the blades or fast moving components from other attached implements Keep all bystanders away from operating area While Operating 9 Sit on the seat when starting and operating the machine 10 Before starting the engine A Engage the parking brake B Make sure traction pedal is in NEUTRAL and cutting decks are DISENGAGED Move axle shift to HI or L
191. re 58b Engine Page 3 46 Rev B Groundsmaster 455 D Cylinder Head Removal 1 Remove the cylinder head cover 2 Use a Torx head T55 tool to loosen the cylinder head bolts working in a spiral from the outside Remove the cylinder head bolts IMPORTANT DO NOT pry at gasket surface to loosen cylinder head from block 3 Use levers 0 0149 to release the cylinder head from the block 4 Remove the cylinder head and gasket Oil Pump Removal 1 Remove the oil pan and gasket IMPORTANT Use solvent and a wood or plastic scraper to remove the silicone gasket material Be careful not to damage the sealing face of the block 2 Remove the bolts Fig 60 1 2 and 3 3 Remove the seal carrier plate Item 4 IMPORTANT The bolt Item 1 is a special bolt that centers the pump in the correct location 4 Remove the pump Fig 61 5 drive chain crankshaft sprocket 7 assembly NOTE 6 spacer is not used on engines used in TORO machines Figure 59 Figure 61 Groundsmaster 455 D Page 3 47 Rev B Engine Crankshaft and Piston Removal 1 Remove flywheel locking tool 2 Remove the connecting rod end caps Fig 62 Item 8 marking each cap for re installation in the same location NOTE Connecting rods and end caps are not num bered Once they are removed there is no way of knowing the correct location for installation unless you mark the
192. re bearing cap will mate Fig 73 Item a 9 Install the two new side seals Fig 75 Item 3 to no 1 main bearing cap 10 Using a bolt and washer Item 5 attach tool 80153 fitted with shims A2 to no 1 main bearing cap Item 4 11 Adjust the height x of the shims X 0 5 mm above flat on side of rear main cap 12 Oil the shims and the housing IMPORTANT To avoid stretching the side seals fit the cap as follows A Engage it in its housing at 45 B Straighten it C Lower it slowly D Tighten the two bearing cap bolts Item 6 finger tight E Remove the capscrew securing the tool to the main bearing cap and withdraw the tool horizontally Engine E e L TOR80110G1 LT 4 BS TOR 80153A1 aN EST Page 3 52 Rev B Figure 75 Groundsmaster 455 D 13 Tighten the bearing cap bolts to a torque of 70 Nm 52 ft lb 14 Using shim TOR 8011007 cut off the side seals so that they protrude 2 mm 15 Check that the crankshaft rotates without tight spots eRe WIS 000 2 3 TOR 801100 IN NS NS 3 I Dy Pistons and Connecting Rod Assembly 1 Assemble the connecting rods and pistons with the bearing shell tab recess Fig 77 Item a on the same side as the piston crown recess Item b 2 Use a piston rings pliers to install the piston rings NOTE The marked face of
193. re distance between blade tips distance should be approximately 0 25 0 12 3 To adjust distance locate adjuster bolt on rear outside corner of center cutting unit Loosen jam nut on adjuster bolt Loosen or tighten adjuster bolts until 0 25 0 12 Figure 9 clearance is attained then tighten jam nut 4 Repeat procedure on opposite side of cutting deck IMPORTANT Blade plane is adjusted at the factory and should not need further adjustment Figure 10 1 Adjuster bolt 2 Jam nut 2 5 o Groundsmaster 455 D Page8 7 Adjustments Belt Tension Adjustment Each cutting unit drive belt is individually tensioned by a self tensioning spring loaded idler When the idlers are properly adjusted the black plastic sleeve should be flush even with the edge of the idler support When 1 2 of the plastic sleeve is exposed an adjustment is required To assure proper operation of the cutting unit check adjustment of spring loaded idler after first 10 hours of operation and every time maintenance on the belt is required 1 Lower cutting unit to the shop floor Remove belt covers from center and wing cutting units 2 Measure the length of the exposed black plastic sleeve If distance is 0 to 1 2 spring loaded idler is properly adjusted and belt tension is correct If dimen sion is not correct proceed to next step 3 Loosen 2 flange head nuts securing idler adjust or tube to top of cutting deck
194. ring drag and no sticking or binding If shaft turns hard hub Item 17 must be removed and gasket s need to be added If shaft has free play backlash cap must be removed and gasket s taken out hub must be adjusted to where shaft has minimal backlash and only a slight amount of bearing drag assembly must turn freely without sticking or binding 9 After installing gear box on cutting unit fill it with SAE 80W90 API GL 5 lubricant to level of check plug Groundsmaster 455 D Deck Clutch Service Failure to get clutch engagement would likely be caused by aclutch air gap that is too large see Clutch Adjust ment a circuit fault in clutch electromagnet or other electrical problem see Troubleshooting section of Chapter 5 Electrical System NOTE It is recommended that clutch be serviced in sub assemblies however some individual parts of clutch can be replaced 1 Follow steps 1 7 under Blade Spindle Service to remove clutch 2 Remove three 3 locknuts Item 9 and springs Item 10 3 Separate clutch into two halves field rotor assembly Items 1 4 and armature and pulley assembly Items 5 8 4 To replace pulley bearing Item 7 A Remove retaining ring Item 8 B Put armature and pulley assembly pulley side down in an arbor press Press on bearing collar Item 6 to remove bearing and collar If bearing is removed it MUST be replaced C Press collar out of bearing D Make sure both ins
195. sed to gage and gut off new side seals to 2mm height Figure 23 Groundsmaster 455 D Page 3 13 Rev B Engine TOR80110GY Extension Rod and Adapter Used with TOR 80504A1 and TOR80504A2 to check crankshaft end float TOR80110H Indicator Holder Block used to hold dial indicator to check protrusion of swirl chambers valve recess and measurement for cylinder head gasket selection TOR80117AM Timing Tool Kit For Roto Diesel DPC Pump Used with dial indicator to adjust timing of injection pump TOR80117EZ Crankshaft Rotating Wrench Used with a 1 2 drive ratchet wrench to turn the crankshaft a Figure 24 Figure 25 Figure 26 0 Figure 27 Engine Page 3 14 Rev Groundsmaster 455 D TOR80149 Injector Socket Used to remove and install fuel injectors Figure 28 TOR80504A1 Extension Used with TOR 80110GY and TOR 80504A2 to check crankshaft end float Figure 29 TOR 80504A2 Indicator Holder Used with TOR80110GY and TOR 80504A1 to check crankshaft end float TOR976697 Camshaft Seal Installer Used to install camshaft seal Groundsmaster 455 D Page 3 15 Rev B Figure 31 Engine 0149 Cylinder Head Separating Levers Make Locally Used to remove cylinder head qty 2 required Units mm Figure 32 TOR70153H Injector Pump Gear Puller Loosen the nut on the injecto
196. ses 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 Starter solenoid clicks but starter will not crank If solenoid clicks problem is not in interlock system Possible Cause 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 Correction 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 Groundsmaster 455 D 5 7 Troubleshooting 2 a gt o o 5 E Starting Problems continued Condition Nothing happens when start attempt is made Possible Cause Battery is dead Loose or corroded battery cables Loose or corroded ground Run fuse open Fusible link open Temp switch or relay faulty Temp relay wiring loose corroded or damaged Traction switch out of adjustment or faulty Traction switch wiring loose corroded or damaged PTO switch engaged or faulty PTO switch wiring loose corroded or damaged Ignition sw
197. shut off with PTO switch Cutting unit relay faulty PTO switch faulty Test relay Replace if faulty Test switch Replace if faulty Cutting units run but should not with axle in range Axle HI LOW switch or plunger faulty Cutting unit relay faulty Test HI LOW switch Check for proper installation and operation of plunger assembly Replace switch or repair plunger if faulty Test cutting unit relay Replace if faulty Troubleshooting Page 5 12 Groundsmaster 455 D Cutting Unit Operation Problems continued Condition No cutting units Operate Possible Cause Axle in HI range Deck fuse open Relay fuse open PTO clutch air gap out of adjustment PTO clutch faulty PTO clutch wiring loose corroded or damaged Cutting unit relay faulty Cutting unit relay wiring loose corroded or damaged Transaxle shift linkage out of adjustment not closing Hi Low switch in Low range Axle HI LOW switch or plunger faulty Axle HI LOW switch wiring loose corroded or damaged PTO switch faulty PTO switch wiring loose corroded or damaged Problem not electrical Correction Axle must be in Low range for cutting units to operate Check fuse and replace if fuse is open If fuse burns out often find and correct cause Check fuse and replace if fuse is open If fuse burns out often find and correct cause Check air
198. sing without requiring the entire axle to be dis assembled 1 Remove tie rod by disconnecting rod end ball joint on each end Disconnect hydraulic cylinder rod end from drag link arm 2 Remove bolts Fig 23 Item 23 and 21 securing gear case to axle housing and pull gear case complete with final drive case NOTE Of four 4 bolts securing the gear case the one on the bottom right side viewed from center of axle is reamer bolt Item 21 Disassembling Final Drive Case 1 Remove bearing holder Fig 24 19 from final drive case The holder will come out together with the wheel shaft Item 21 2 Pull draglink arm or tie rod arm off final drive case Be sure to recover the thrust washer 3 Remove the bolts securing top cover Item 4 to gear case and remove the cover to expose the top end of final drive shaft Item 2 Use special tool TOR4041 to drive lightly on the exposed shaft end so that the final drive case will slide off the gear case 4 Remove bottom cover Item 9 from final drive case to expose bottom end of shaft Use special tool TOR4041 to drive the shaft out and take out the 15T bevel pinion Item 11 Disassembling Wheel Shaft 1 Use a gear puller to draw the bevel gear Item 13 and ball bearing Item 12 off wheel shaft 2 Remove shaft from bearing holder by lightly tapping on the shaft 3 Remove retaining ring Item 17 from holder and remove bearing outer race and oil seal Item
199. spacers Item 12 2 Remove three 3 flange head screws Item 6 secur ing rubber coupling to engine Be sure you account for flat washers Item 4 3 Push driveshaft into splined hub Item 11 and remove coupling assembly 4 Inspect rubber couplings driveshaft and splined hub and replace as necessary PTO Drive Pulley and Bearing Service NOTE Aspecial tool TOR4050 is required remove and install the bearing locknut Fig 6 Item 1 1 Remove engine coupling assembly see Engine Cou pling Service 2 Disconnect hydraulic pump assembly from bearing housing Item 18 NOTE To prevent contamination of hydraulic system do not disconnect hydraulic lines from pump assembly 3 Loosen belt tension and remove PTO belts see PTO Belt Replacement 4 Remove four 4 flange screws Item 2 securing bearing housing Item 18 to main adapter plate Item 19 then remove bearing housing and PTO drive pulley assembly 5 Remove bearing locknut Item 1 and lockwasher Item 20 6 Use a press to remove pulley Item 15 7 Use a suitable puller to remove bearings Item 16 Remove bearing spacer Item 17 8 Inspect bearings and pulley Replace parts if worn or damaged 9 Use a press to install one bearing 16 into bearing housing Item 18 When installing bearing press on OUTER race of bearing Groundsmaster 455 D 7 7 Rev E 5 Install grease seal Item 10 so steel shell is towards sp
200. spool and sleeve assembly forward with your thumbs just far enough to free gland bushing from housing Remove bushing Repairs Spacer Drive Plate Page 4 52 Figure 38 Groundsmaster 455 D 12 Remove quad ring seal from seal gland bushing 13 Use a thin blade screwdriver to pry dust seal from seal gland bushing Do not damage bushing 14 Remove 2 bearing races and the needle thrust bearing from spool and sleeve assembly 15 Remove spool and sleeve assembly from 14 hole end of housing IMPORTANT Do not bind spool and sleeve in hous ing Rotate spool and sleeve assembly slowly when removing from housing 16 Push pin from spool and sleeve assembly Quad Ring 7 Seal Seal Dust Seal Gland Bushing Figure 39 Needle Bearing Thrust Race Bearing Figure 41 Groundsmaster 455 D Page 4 53 Repairs Hydraulic System 17 Push spool partially from control end of sleeve then remove six 6 centering springs from spool carefully by hand 18 Push spool back through and out of sleeve Rotate spool slowly when removing from sleeve 19 Remove seal from housing 20 Remove set screw from housing 21 Screw a 10 24 machine screw into end of check ball seat Then by pulling on screw with a pliers lift seat out of housing 22 Remove two 2 seals from check valve seat 23 Tip housing to remove
201. ster 455 D at the end of this section Groundsmaster 455 D Page2 1 Rev B 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 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 7 541 13 16 0 8125 20 6
202. sure Check 1 Make sure hydraulic oil is at normal operating tem perature by operating machine for approximately 10 minutes 2 Lower cutting units engage parking brake and stop the engine 3 Raise and support seat to get access to hydraulic test fittings Remove access cover from in front of auxiliary pump 4 Install a 5000 PSI gauge onto lift circuit quick discon nect fitting Put gauge and hose through opening below seat in front of auxiliary pump so gauge can be observed while sitting on seat 5 Raise center cutting unit while monitoring gauge RANGE OF TESTER READINGS 600 2800 PSI when counterbalance setting is 600 PSI NOTE Changes in counterbalance setting will affect the lift circuit relief pressure RELIEF Pressure Check 6 With engine running at full speed engage control lever into the LIFT position 7 Momentarily hold the lever in the engaged position after full cylinder extension and read gauge TESTER READING TO BE 2600 2800 PSI when counterbalance setting is 600 PSI NOTE Changes in counterbalance setting will affect the lift circuit relief pressure Testing Page 4 24 Figure 14 1 Lift circuit test port Groundsmaster 455 D TEST 6 Checking Charge Pressure 1 Make sure hydraulic oil is at normal operating tem perature by operating machine for approximately 10 minutes 2 Lower cutting units engage parking brake and stop the engine 3 Install a 1 000 PS
203. sure that the injection pressure is correct 3 Make sure that the injection pump is providing suffi cient fuel pressure to operate the nozzle by performing the following procedures A Loosen the 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 Groundsmaster 455 D Page 3 31 Rev B 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 CAUTION 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 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 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 that is not operating correctly 5 Repeat the test for the
204. te Repairs D gt i 2 c gt Gear Pump No 94 8297 S N 70001 amp Up Fig 23a Figure 23a 1 O ring 8 Washer 15 Key 2 Body asm 9 Cap screw 16 Adaptor plate 3 Drive gear asm 10 Shaft seal 17 O ring 4 Wear plate 11 Washer 18 Washer 5 Backup gasket 12 Plug 19 O ring 6 Seal 13 Idler gear 20 Valve 7 Front plate 14 Gear 21 Back plate asm Repairs Page 4 39 1 Rev C Groundsmaster 455 D Repair Information Work ina clean area cleanliness is extremely important when repairing hydraulic pumps Before disconnecting the lines clean portarea of pump Disconnect hydraulic lines removing pump assembly from vehicle and plug ports Thoroughly clean the outside of pump After cleaning then remove port plugs and drain oil Disassembly 1 Scribe a line atan angle across front plate 7 bo dies 2 adapter plate 16 and backplate 21 This will assure proper reassembly NOTE To maintain maximum pump efficiency keep body gears and wear plates for each section together DO NOT mix parts between different sections 2 Clamp pump in vise shaft end up 3 Remove the eight cap screws 9 4 Remove pump from vise hold pump in hands and bump shaft against wooden block to separate pump sections F rontbody 2 will remain with either front plate 7 or adapter plate 16 5 Place front idler gear 13 back into gear pocket and tap protruding end with soft face hamm
205. tem 3 and detent plungers Item 4 9 Remove locknut Item 14 washer Item 15 plug Item 16 washers Item 18 19 20 spring Item 21 and poppet Item 22 IMPORTANT Do not remove seat Item 23 Seat has been set to a predetermined depth and locked in place 10 Remove all o rings and back up rings from all plugs and seats Inspection of Lift Valve 1 Remove all nicks and burrs from parts and inspect for excessive wear 2 Inspect all plungers and poppet seats for burrs or roughness 3 Inspect spool springs Item 27 Relief valve spring Item 21 lockout springs Item 33 and detent springs Item 3 for breakage 4 If spools have excessive wear the valve becomes non serviceable as the spools and spool bores are matched and damaged spools cannot be replaced 5 Inspect relief valve poppet Item 22 for breakage or wear Assembly of Lift Valve 1 Thoroughly clean and dry all parts Apply a light coating of clean hydraulic oil to parts prior to assembly NOTE All o rings back up washers wiper seals and nylon poppets should be replaced as new items Groundsmaster 455 D Page 4 49 2 Install new o rings Item 12 in proper grooves in spool bores 3 Install relief valve components Items 22 21 20 19 18 with new o ring Item 17 on plug 16 4 Install plugs Item 11 with new back up washers Item 10 and o rings Item 9 5 Install plungers Item 37 31 IMPORTANT Check
206. terchange parts with another valve NOTE The shim s Item 10 which may be installed between the spring and plug may remain inside the plug being held by an oil film Make sure the same number and thickness of shims is installed when reassembling Groundsmaster 455 D Page 4 31 the parts unless shims need to be added or removed to adjust the pressure setting 5 Inspect the poppet and mating seat in the end cap for damage or foreign material 6 Reinstall the poppet spring and plug with shims and o ring into the housing Tighten the plug to a torque of 30 to 70 ft lb 7 Before starting the engine check the oil level in the differential housing and add the correct oil as necessary Start the engine and let it run for one to two minutes then turn the engine off and check the oil level again Check the transmission for leaks Repairs D gt E gt Disassembly of Traction Pump Fig 21 Figure 21 1 End cap 16 Screw 30 Seal carrier 2 Plug 17 Trunnion cover 31 O ring 3 18 O ring 32 Retaining ring 4 O ring 19 Trunnion spacer 33 Pump housing 5 Conical spring 20 Shim 34 Lip seal 6 Retaining ring 21 Roller bearing 35 Trunnion cover 7 Relief valve 22 O ring 36 Swash plate 8 Charge relief poppet 23 O ring 37 Thrust plate 9 Spring 24 Washer 38 Cylinder block 10 Shim 25 Capscrew 39 Valve plate 11 O ring 26 Pump shaft 40 Pin 12 Charge relief plug 2
207. the tapered ring must be towards the combustion chamber 1 scraper ring 2 tapered ring 3 domed chrome ring Space the ring gaps at 120 in relation to the scraper ring gap Item c Figure 77 Groundsmaster 455 D Page 3 53 Rev B Engine 3 Oil the piston and tighten the piston ring clamp Fig 78 4 4 Remove the connecting rod end caps 5 Install the pistons in the bores matching the markings made when removed and aligning the crown recess Item a on the oil filter side of the block 6 Install the connecting rod end caps Tighten the nuts to a torque of 50 Nm 37 ft lb NOTE For choice of bearing shell thickness see Crankcase in Identification and Specifications section Oil Seal Installation 1 Put a new oil seal on tool TOR 70153 C 2 Install seal with lip toward the inside of the engine block to keep the oil in Fit the seal by tapping fully home with a mallet 3 Withdraw the tool with a twisting movement Oil Pump Installation 1 Install the key Fig 80 6 2 Install the pump Item 7 drive chain and sprocket Item 8 assembly WEE E Lo 4 VA EL AR Figure 79 Figure 80 Engine Page 3 54 Rev D Groundsmaster 455 D 3 Install the special shoulder bolt Fig 81 1 to center the pump in the proper location 4 Install the other bolts and tighten the bolts Item 1 2
208. then two 2 are faulty if draw is 12 amps then three 3 are faulty if draw is 0 amps then all are faulty if draw is more than 48 amps 60 to 100 amps there is a short in one or more of the glow plugs see Glow Plugs in Testing section of Chapter 3 Engine NOTE The glow relay has a built in temperature sensor and timer Battery voltage is always available at termi nal 1 When voltage is sensed at terminal 3 ignition switch turned to ON power is directed to terminals 5 glow plugs and 6 glow indicator light At 68 F 20 C the glow indicator light will turn off after 5 seconds then the glow plugs will turn off after 12 seconds At 32 F 0 the glow indicator light will turn off after 10 seconds then the glow plugs will turn off after 18 seconds Testing Page 5 22 Groundsmaster 455 D Battery 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 Injection Pump ETR Solenoid The Groundsmaster 455 D has energize to run ETR fuel stop solenoid The solenoid will stop injector pump fuel delivery with any electrical failure in the RUN circuit 1 Disconnect the wire from the solenoid 2 Remove the solenoid from the injector pump 3 Connect a 12 volt battery so that a wire from positive battery terminal is connected to switch terminal Touch a wire from the nega
209. ting Unit Upright NOTE Drive front wheels onto ramps before doing this procedure so there is room for cutting unit to pivot tilt upright 1 Lower center and wing cutting units to the ground then raise center cutting unit slightly until rear deck straps hang freely on lift arm brackets Stop engine after cutting unit is raised Set parking brake 2 Disconnect 3 hydraulic lines quick couplers and wire harness at rear of deck 3 Remove hairpin cotters and H O C pins securing rear deck straps to H O C brackets on deck Start engine and lower center deck to ground Figure 2 4 Remove socket head screws securing drive shaft 1 Hydraulic line couplers yoke gear box input shaft Slide yoke off shaft 2 Wire harness A CAUTION Do not start the engine and engage the PTO 3 Rear deck straps switch 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 5 Sit on seat start the engine and slowly raise the center cutting unit allowing cutting unit to pivot upright Stop the engine and remove the key from the ignition switch Figure 3 Pivot Cutting Unit Down into Operating Position 1 Drive shaft yoke 1 Sit on seat start the engine and slowly lower the 2 Gearbox input shaft cutting units to the ground then raise center cutting unit slightly so rear deck straps can be mounted to lift arm brackets Stop engine after cu
210. tite 242 35 40 ft Ib Install idler pulley Mets in hole closest to edge of pulley support With optional high speed larger diameter gearbox pulley install idler pulley in this hole Loctite 242 35 40 ft Ib idler pulleys so bolt heads are facing down Loctite 242 35 40 ft lb Install V groove idler pulleys so bolt heads are facing down Loctite 242 35 40 ft Ib Figure 42 Repairs Page 8 30 Groundsmaster 455 D Wing Deck Spring Loaded Locking Mechanism Service A WARNING This mechanism is spring loaded Use proper disassembly procedures to prevent possible personal injury NOTE Some early production units were not equipped with rod caps and socket head screws These parts must be used for the following procedure Order Toro Parts 92 4036 Cap Rod and 92 4037 Screw Hex Socket Hd To disassemble 1 Remove socket head screw 2 Reverse rod cap so large diameter end is facing spring support rod then re install socket head screw 3 Remove cotter pin from large clevis pin in center of lock Tighten socket head screw pulling spring support Large clevis pin rod back until large clevis pin is loose then remove clevis pin 4 Remove socket head screw to relieve spring tension and remove locking mechanism To install locking mechanism 1 Replace worn or damaged parts in mechanism 2 Place rod cap on bracket so large end is facing spring support rod and
211. tive battery terminal to solenoid body The plunger should retract NOTE You can also test operation without removing the Figure 21 solenoid from the injector pump Listen for an audible click as the solenoid extends and retracts while doing 1 Injection pump ETR solenoid step 3 of the above procedure This will not show if the solenoid is fully extending and retracting o gt 2 T 5 Groundsmaster 455 D Page 5 23 Testing Gauges and Indicator Lights Oil Pressure Light Oil pressure lamp 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 lamp by disconnecting the wire from oil pres sure switch and grounding it against the engine The light should come on when the wire is grounded with the ignition switch in the ON position Amp Light The amp light should come on when the ignition key switch is in the RUN position with the engine not running or if the charging circuit is not operating properly during operation NOTE If amp light or amp is faulty or lamp is burnt out the alternator will not charge properly Test the lamp by disconnecting the wires and applying 12 V D C between the lamp wiring terminals Glow Light The glow light should come on for 5 to 12 seconds after the ignition key switch is turned ON Testin
212. 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 To prevent possible injury wear eye protec 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 Groundsmaster 455 D Page 3 29 Rev B defective damaged or adjusted incorrectly starting failures 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 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 C injectors 115 5 bar or kg cm 1668 70 psi D i
213. tting unit is raised Set parking brake 2 Line up holes in yoke and input shaft of gear box Slide yoke onto shaft and secure together with socket head screws Torque screws to 20 25 ft lb 3 Secure rear deck straps to H O C brackets on deck with hair pin cotters and H O C pins Start engine and lower center cutting unit completely to floor Make sure all lift levers are in the float position then stop the engine 4 Connect wire harness and 3 hydraulic lines couplers at rear of deck 2 5 o Groundsmaster 455 D Page8 3 Rev A General Information Adjustments Height of Cut Adjustment The height of cut is adjustable from 1 to 5 inches in 1 2 inch increments Positioning the castor wheel axles in the top holes of the castor forks or pivots see Chart below allows low range height of cut settings from 1 to 3 1 2 inches Positioning the castor wheel axles in the lower holes of the front castor forks or rear castor pivots allows see Chart below high range height of cut set tings from 2 1 2 to 5 inches 1 Start the engine and raise the cutting unit so height of cut can be changed Stop engine after cutting unit is in raised position 2 Position all castor wheel axles in the same holes in the castor forks or pivots Adjustments SPACERS m 5 2 25 HIGH 0 25 3 35 45 RANGE Front Castor Wheels 099 Rear Castor Wheels Page 8
214. uld be hot enough to cause burns 22 f cutting deck strikes a solid object or vibrates abnormally stop immediately turn engine off set park ing brake and wait for all motion to stop Inspect for damage If damaged repair or replace any components before operating Groundsmaster 455 D 23 Before getting off the seat A Set parking brake B Move traction pedal to neutral and axle shift to Hi or LO position C Disengage cutting decks and wait for blades to stop D Stop engine and remove key from switch E Do not park on slopes unless wheels are chocked or blocked 24 Use only a rigid tow bar if it becomes necessary to tow machine Use trailer for normal transport While Doing Maintenance Troubleshooting Testing Adjustments or Repairs 25 Before servicing or making adjustments stop en gine and remove key from the switch 26 When changing attachments tires or performing other service use the correct blocks hoists and jacks Always chock or block the wheels and use jack stands or solid wood blocks to support the raised machine If the traction unit is not properly supported by blocks or jack stands the unit may move or fall resulting in injury 27 Make sure machine is in safe operating condition by keeping all nuts bolts and screws tight 28 Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system 29 Keep bo
215. ulic lines or fittings leaking Check for leaks Correct any leaks by replacing o rings and tightening connection properly Replace lines or fittings if necessary Faulty lift valve lockout assembly Check for damaged o rings on lockout plugs or seats and repair if necessary Check for damaged or worn lockout poppet assembly and replace if necessary Check for broken lockout spring and replace if necessary Groundsmaster 455 D Page 4 17 Troubleshooting Cutting Unit Lowers Raises Too Quickly Cause Missing or improperly installed orifice in hydraulic line Correction Properly install orifice between left valve and hydraulic hose to hydraulic lift cylinder s NOTE Orifice must be installed to avoid interference with adapter fitting Steering Loss Cause Steering linkage or cylinder pivots damaged worn or binding Correction Lubricate bushings Inspect for damage Repair or replace damaged parts Low steering pressure TEST NO 4 Check for restriction in pump intake line or strainer and repair if necessary Check steering cylinder for internal leakage and repair or replace if necessary Clean relief valve in steering pump and adjust or replace if necessary Inspect steering lift pump for wear or damage and repair or replace if necessary Steering control unit faulty Repair or replace steering control unit NOTE Steering loss after was
216. ulley with adjacent spindle pulleys Loosen and relocate the gear box pulley if necessary 5 Mount rear end of gearbox support to deck channels Leave capscrews and nuts loose Lift front of gearbox support and install belt around gearbox pulley Groundsmaster 455 D Page 8 21 6 Secure front of gear box support to deck channels with capscrews and nuts Tighten capscrews and nuts securing rear of gearbox support to deck channels 7 Install drive shaft cover to gear box support with 4 flange head screws 8 While holding idler pulley adjuster in position care fully remove capscrew securing idler adjuster tube to tube sleeve Allow idler pulley to release tensioning belt 9 Check idler pulley adjustment see Belt Tension justment 10 Install belt covers 11 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 Repairs 2 5 o Gearbox Repair Figure 33 Gear Box Disassembly 1 Drain lubricant from gear box 2 Remove capscrews Item 1 and lift out shaft and cap assemblies NOTE Mark each gear Item 10 and 21 so they are installed on the proper shaft 8 or 19 when reassembled 3 Remove thru cap Item 14 and bearing cones Item 4 11 from shaft Item 8 4 Remove bearing cup Item 12 from thru cap Item 14 by putting a punch through the shaft
217. ump repaired Engine will not stop Key switch defective Defective electric stop solenoid Replace key switch Check electric stop solenoid Groundsmaster 455 D Page 3 21 Rev B Engine Low Power Problem Possible Causes Engine does not give full power Injection pump timing Seized piston rings Defective injector s Air intake restricted Valve leaks Clogged fuel filter Injection pipe restriction due to excessive tightening of unions Defective injection pump Irregular idling Defective injection pump Air getting into fuel system Idling stop out of adjustment Leaky injection pipe unions Speed fall Off Clogged fuel filter Defective injection pump Engine speed rises to maximum Defective injection pump Throttle cable jammed Engine Page 3 22 Rev Groundsmaster 455 D Noisy Engine Problem Possible Causes Knocking Loose main bearings Broken part Leakage return collector clogged Lifters out of adjustment Foreign matter in a cylinder Seized injector Injection pump timing Sheared glow plug Timing out of adjustment Whistling blowing Leaking cylinder head gasket Leaky glow plug Valve seats Leaky injector Groundsmaster 455 D Page 3 23 Rev B Engine Pre heating Problem Possible Causes Glow plug does not glow red hot Faulty glow plug Faulty glow plug relay Damaged wiring or connector All four glow plugs burnt out
218. up gasket 5 with bronze face up The side with the mid section cutaway must be on suction side of pump 9 Install adapter plate 16 in place on front body 2 Check positioning marks 10 Install rear body 2 onto adapter plate 16 11 Install key 15 in slot of drive gear shaft 3 Dip slip fit gear 13 in oil and slip on shaft and into gear pocket of rear body 2 Check key for proper alignment 12 Dip idler gear 13 in oil and install in gear pocket of rear body 2 13 Position backplate 21 over shafts until dowel pins in body are engaged 14 Secure with cap screws 9 and washers 8 Tighten cap screws evenly in a crisscross pattern to 25 to 28 ft 165 34 to 38 Nm torque 15 Place washer 11 over drive shaft into housing Lib erally oil shaftseal 10 and install over drive shaft care fully so that rubber sealing lips are not cut 16 Placeasleeve overshaftand press in shaftseal 10 20 in 5 08mm below front surface of front plate Groundsmaster 455 D This page is blank Groundsmaster 455 D 4 39 4 Rev C Repairs Front Traction Motor Repairs Fig 24 Figure 24 1 Valve plate 7 Sleeve 13 Straight 2 Cylinder block kit 8 Roller bearing 14 End cap assembly 3 Shaft assembly 9 Housing 15 Flat washer 4 Plug 10 Thrust plate 16 Capscrew 5 O ring seal 11 Gasket 17 Retaining ring 6 Lip seal 12 Bearing Shaft Seal Replacement Prior to installing the new seal
219. ure 15 1 Start relay Figure 16 1 Cutting unit relay 2 High temp relay 3 Wing deck time delay relay 2 a gt i 5 E TT Figure 17 Groundsmaster 455 D Page 5 21 Testing Glow Relay and Glow Plugs 1 Attach an amp meter to glow plug circuit Turn ignition switch to ON Meter may have an initial reading as high as 100 amps A If amp meter shows a reading for 5 to 12 seconds the glow relay is operating If there is no reading go to step 2 B Turn ignition switch OFF then ON again A read ing of 48 amps should be observed Go to step 3 2 To test the circuit A Check with a test light at buss bar connection for glow plugs at cylinder head Turn the ignition switch Figure 19 ON If the light glows power is being supplied from glow relay If light does not glow check wiring or 1 Glow relay relay B Check relay with a test light connected at termi nal 5 on relay glow plugs connection Turn ignition switch ON If the light glows the power relay is working If the light does not glow check for power to relay by moving to terminal 1 power from bat tery If the light glows check for power from ignition Switch by moving to terminal 3 4 Glow plug test A Warm up the glow plugs then check for total draw of all four 4 glow plugs if draw is 48 amps all four 4 are OK if draw is 36 amps then one 1 is faulty if draw is 24 amps
220. use damage or premature de terioration Some hoses such as reel motor hoses are more susceptible to these conditions than others In spect the hoses frequently 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 Fig 2 3 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 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 Put the 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 in 75 25 8 1 2 in 75 25 10 5 8 in 1 00 25 12 3 4 in 75 25 16 1 in 75 25 Groundsmaster 455 D A WARNING Before disconnecting or
221. using 18 End cap Disassembly Although not all drawings show the unit in a vise it is recommended that you keep the unit in the vise during disassembly Follow the clamping procedures explained in the instructions Cleanliness is extremely important when repairing a steering control unit Work in a clean area Before disconnecting lines clean port area of unit thoroughly Use a wire brush to remove foreign material and debris from around exterior joints of the unit Repairs Page 4 50 Groundsmaster 455 D Meter Gerotor End Disassembly 1 Clamp unit in vise meter end up Clamp lightly on edges of mounting area Use protective material on vise jaws Housing distortion could result if jaws are over tightened Figure 33 Seal Washer 2 Remove 5 16 cap screws 3 Remove end cap 4 Remove seal from end cap End Cap Seal Cap Screw Figure 34 bod D gt 2 3 c gt 5 Remove meter Be careful not to drop star 6 Remove seal from meter Meter Gerotor Spacer s Figure 35 Groundsmaster 455 D Page 4 51 Repairs 7 Remove drive 8 Remove spacer plate 9 Remove seal from housing Control End Disassembly 10 Remove housing from vise Place housing on a clean soft cloth to protect surface finish Use a thin blade screwdriver to pry retaining ring from housing 11 Rotate spool and sleeve until pin is horizontal Push
222. ve Pulley 1 To relieve tension on center deck belt pull back on idler pulley until holes in idler adjuster tube and tube sleeve are aligned Thread a 5 16 18 capscrew into holes retaining parts 2 Disconnect drive shaft from gearbox input shaft A CAUTION 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 Figure 31 shaft is allowed to rotate serious injury could result 1 Gearbox support 2 Capscrews amp nuts 4 Remove 2 flange head screws securing drive shaft cover to gearbox support and remove cover 5 Remove four 4 sets of capscrews and nuts securing gearbox support to deck channels 6 Remove gearbox support with gearbox attached 7 Loosen two 2 capscrews securing pulley to gearbox output shaft and slide pulley off of gearbox output shaft 8 Remove four 4 capscrews securing gearbox to gearbox support and remove gearbox Figure 32 Repairs Page 8 20 Groundsmaster 455 D Installing Gearbox and Drive Pulley 1 If replacing rubber mounts for gearbox support use soapy water or lubricant to ease installation Install left hand mounts from top and right hand mounts from bottom of bracket as shown 2 Install gearbox to support bracket with with four 4 capscrews 3 Slide pulley onto gearbox output shaft and secure by tightening two 2 capscrews 4 Check the alignment of the gearbox p
223. wheel hub Slide bearing spacer into wheel hub Push other bearing into open end of wheel hub to captivate the bearing spacer inside the wheel hub 5 Install castor wheel assembly between castor fork and secure in place with capscrew and locknut 6 Lubricate castor wheel bearing through grease fitting using No 2 general purpose lithium base grease Repairs Page 8 14 Figure 22 1 Castor wheel 3 Bearing 2 2 Front castor fork 4 Bearing spacer Figure 22 1 Castor wheel 3 Bearing 2 2 Rear castor pivot arm 4 Bearing spacer Groundsmaster 455 D Blade Removal and Installation The blade must be replaced if a solid object is hit the blade is out of balance or if the blade is bent Always use genuine TORO replacement blades to be sure of safety and optimum performance Never use replace ment 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 now blade to assure continued safety certification of the product 1 Raise cutting unit to highest position shut the engine off and engage the parking brake Engage locking latches to prevent cutting unit from falling accidentally 2 Grasp end of blade using a rag or thickly padded glove Remove blade bolt washer if equipped anti scalp cup and blade from spindle shaft NOTE Units with S N below 30001 will have a hex bolt and
224. which cuts out when pressure is about to exceed the normal range for the gauge The cutout pressure is adjustable Special Tools Page 4 12 4 HIGH PRESSURE GAUGE High range gauge to accommodate pressure beyond the capacity of the low pressure gauge 0 10 000 PSI 5 FLOW METER This meter 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 Groundsmaster 455 D 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 Operates Hot 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 pr
225. y Repair wiring Test 4WD solenoid valve Replace if faulty Repair wiring See Troubleshooting section of Chapter 4 Hydraulic System Battery does not charge Loose or broken wire s Faulty alternator Dead battery Alternator warning lamp is faulty or burnt out Alternator waring lamp wiring loose corroded or damaged Repair wiring Check alternator belt tension Test alternator and replace if faulty Charge battery Replace battery if it will not hold a charge Replace lamp Repair wiring Groundsmaster 455 D Page 5 11 Troubleshooting 2 a gt o o 5 E TT Cutting Unit Operation Problems Condition Engine continues to run but should not when PTO switch is ON with no operator on the seat Possible Cause Seat switch plunger depressed with no operator on seat Seat switch faulty or out of adjustment Time delay relay faulty Correction 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 Test relay Replace if faulty Wing cutting unit runs but should not when raised but shuts off with PTO switch Wing switch faulty Test switch Replace if faulty Make sure switch is properly installed Wing cutting units shut off when raised but cutting units do not
226. y from the engine then slowly rotate the pump toward the engine in one smooth motion to obtain the reading If you go to far and the reading is passed stop Again rotate the pump away from the engine then rotate the pump toward the engine in one smooth motion Dial Indicator 12 After obtaining the correct reading be careful to keep the pump in position and tighten the pump bolts 13 Remove the TDC Lock Pin tool TOR 70153 N 14 Turn the crankshaft 1 4 to 1 3 turn in the opposite direction of running counterclockwise as viewed from timing belt end Check that the indicator reads 0 00 15 Slowly turn the crankshaft in the operating direction clockwise as viewed from the timing belt end until the TDC Lock Pin tool TOR 70153N goes into the hole in the flywheel Fig 56 16 In this position the dial indicator mounted on the pump should read the value shown on the pump 0 04 mm 17 Check to make sure the three lock bolts fit in the cam pulley and injection pump pulley Fig 53 18 Repeat steps 11 and 12 if necessary 19 Remove TDC Lock Pin tool three lock bolts in dicator and indicator bracket Install pump cover plug 2 TOR 70153N 20 Tighten injector lines Figure 56 21 Install timing belt covers clips and attachment nut Groundsmaster 455 D Page 3 41 Rev B Engine Preparation For Engine Repair 1 Before cleaning and disassembly car

Groundsmaster® 455-D

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Groundsmaster® 455-D